PRODUCT SUPPORT FOR REPLACING THE CYLINDER HEAD GASKET AFTER A FAILURE HAS OCCURRED ON CERTAIN C-10 AND C-12 TRUCK ENGINES Caterpillar

PRODUCT SUPPORT FOR REPLACING THE CYLINDER HEAD GASKET AFTER A FAILURE HAS OCCURRED ON CERTAIN C-10 AND C-12 TRUCK ENGINES

Usage:

SEBE7398-07

August 26, 2000
(Revised January 2004)
U-240
A-176
AU-141
S-106
O-200
TT-4

Show/hide table

*After failure only*	PRODUCT SUPPORT FOR REPLACING THE CYLINDER HEAD GASKET AFTER A FAILURE HAS OCCURRED ON CERTAIN C-10 AND C-12 TRUCK ENGINES
1100		PS50041

NOTE: This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS50041" as the Part number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

NOTE: The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.

NOTE: If the cylinder head has been removed for another reason claim ONLY THE NEW HEAD BOLTS AND STUDS (if equipped with a Compression Brake) under PS50041.

NOTE: This Revised Service Letter replaces the August 26, 2000 (Revised July 2003) Service Letter. Changes have been made to the Termination Date.

TERMINATION DATE

May 31, 2004

PROBLEM

The cylinder head gasket may allow coolant to leak into the lubrication oil on certain C-10 and C-12 Truck Engines.

NOTE: If PS50041 has been applied to an engine after September 2001, that specific engine will no longer be eligible for a second claim against PS50041 or any head gasket repair with out Service Representative Authorization.

NOTE: A Service Rep. Authorization will have to be submitted in the claim story on any repeat claims to PS50041 after September 2001.

PARTS NEEDED

Parts Group A - ALL ENGINES

NOTE: Individual parts MUST BE USED. If gasket kit is claimed it will be paid at 70%. 4 - 1182797 Gasket (water manifold to cylinder head).

6 - 4G4972 O-Ring Seal (cylinder block to cylinder head).

1 ? 7E5555 Gasket (water pump tube adapter to regulator housing)

2 - 7L6580 O-Ring Seal (seals for water pump tube)

1 - 1013125 Air Inlet Gasket

1 - 9Y1758 Breather-Gasket

6 - 9X7557 Injector Seal

6 - 1198784 Injector Seal

6 - 9X7317 Injector Seal

PARTS REQUIRED FOR THE TURBO SUPPLY AND DRAIN LINES FOR MOST ENGINES (FLAT FLANGES)

1 ? 8H9788 Gasket (turbo supply line)

1 ? 1886126 Gasket (turbo drain line)

4 ? 6V5218 Bolt (turbo supply and drain lines)(See Diagram)

4 ? 6H7127 Spacer (turbo supply and drain lines)(See Diagram)

PARTS REQUIRED FOR TURBO SUPPLY AND DRAIN LINES FOR ALL OTHER ENGINES (STEPPED FLANGE)

1 ? 8H9788 Gasket (turbo supply line)

1 ? 1886126 Gasket (turbo drain line)

4 ? 8T0276 Bolt (turbo supply and drain lines)(See Diagram)

1 ? 4K5824 Spacer (turbo supply and drain line)(See Diagram)

3 ? 9G8661 Spacer (turbo supply and drain lines)(See Diagram)

CYLINDER HEAD GASKET INDENTIFICATION

CHART 1

Show/hide table

Cylinder Block Configuration	Cylinder Head Configuration	Use Head Gasket Part Number
Straight	Straight	1873307/">187-3307
Straight	Scalloped	1873306/">187-3306
Scalloped	Scalloped	1873306/">187-3306
Scalloped	Straight	1873306/">187-3306

Block View

Head View

Parts Group B - for use on C-10 and C-12 engine serial numbers
1YN1?up, 9NS1?16227, 2KS1-388, 2PN1-up,
8YS1-5388, 3CS1-718

1 - 1873306 Cylinder Head Gasket (MUST BE USED WHEN YOU HAVE A SCALLOPED HEAD AND BLOCK OR STRAIGHT-SCALLOPED HEAD AND BLOCK COMBINATION. SEE CHART 1.) Parts Group C - for use on C-10 and C-12 engine serial numbers
9NS16228-20095, 2KS389-57687, 8YS5389-7578,
3CS719-17568 1 - 1873307 Cylinder Head Gasket (MUST BE USED WHEN YOU HAVE A STRAIGHT HEAD AND BLOCK ONLY. SEE CHART 1.) Parts Group D - for all engine serial numbers without compression brake

26 ? 1293184 Bolt

Parts Group E - for all engine serial numbers with compression brake

23 ? 1293184 Bolt

3 - 1787508 Stud

ACTION REQUIRED

NOTE: PRIOR TO MAKING A HEAD GASKET REPAIR THE TECHNICIAN MUST
BE TRAINED BY USING THE C-10/C-12 HEAD GASKET REPAIR
PROCEDURE VIDEO LEVN5101 OR LEVP5101.

Confirm the engine has coolant in the oil using an Oil Sample to identify a failure. Sodium (Na) or Potassium (K), and Soot readings must also be included. Use the following limits from the Chart 2 below:

NOTE: A complete copy of the actual oil sample results will be required, and must exceed the published limits for this service letter to apply.

CHART 2

If SOS results show Positive for Antifreeze or Glycol, continue to step 2.

NOTE: If extended oil drain intervals are being used beyond Caterpillar recommendations indicated with chart 2, the oil sample is not valid and this service letter does not apply. It is required to change the oil and resample within the chart limits.

Must test for Na (Sodium) if using Standard coolant.
Must test for K (Potassium) if using ELC coolant.
Use chart below to determine whether to investigate a coolant leak into oil.
Only if your reading is in the investigation range for either Sodium (Na) or Potassium (K), continue to step 2.

NOTE: The engine must meet one of the three criteria, 1. Sodium (Na) 2. Potassium (K) 3. Positive for Antifreeze or Glycol.

Inspection of Engine connecting rod & main bearings should only be done if lead (Pb) exceeds 25 PPM and Sodium (Na) or Potassium (K) exceeds 1000 PPM for a normal oil change period as shown in chart below. Thrust plates should not be replaced.

NOTE: The oil sample threshold outlined above does not imply any standard to be used outside of this service letter. Maximum Extended Oil Change Interval is 25,000 miles or 500 hours or 4,170 gallons of fuel for light duty applications only.

Verify the engine has not exceeded the service letter mileage or hour limitations using Cat Electronic Technician, and print a copy of the ECM Life Time Totals.

NOTE: A copy of the ecm life time totals is required and should not exceed the published limits in this service letter. Examples:

You have 20,000 miles on oil and you have 235 PPM Sodium or Potassium the source of the coolant leak SHOULD BE investigated.
You have 20,000 miles on oil and you have 135 PPM Sodium or Potassium DO NOT investigate.

Verify that it is the head gasket and not the water pump that is leaking.
Remove the oil and oil pan. The 1095308 Oil Pan Gasket Should be reused.
Use the 9S8140 Radiator Pressure kit, or equivalent, to pressurize the cooling system.

If coolant drips into the crankcase from the water pump the PUMP MUST BE REPLACED. DO NOT REPLACE THE HEAD GASKET.

STOP: AT THIS POINT THE SERVICE LETTER DOES NOT APPLY.

If no coolant is detected proceed to replace the cylinder head gasket.

It is necessary to determine the correct head gasket part number. There are two head gasket designs, scalloped or straight. Refer to the Chart 1 under "Parts Required" to select the correct head gasket part number for the engine you are repairing.
Replace the cylinder head gasket following the Disassembly and Assembly Procedure from one of the following Service Manual Modules:

Show/hide table

Serial Number Prefix	D&A Module Form Number	Revision Date
1YN	SENR1002-03*	JANUARY 2000
9NS	RENR1318-02**	JANUARY 2000
2KS	RENR2236-02***	JANUARY 2000

* Part of the complete Service Manual Form Number SENR6590.

** Part of the complete Service Manual Form Number RENR1320.

*** Part of the complete Service Manual Form Number RENR2240.

Clean the cylinder block bolt threads by running an 8T3096 (M16x2) tap down into all 26 cylinder block bolt holes. Clean the tap after each hole. This will prevent additional debris from being deposited in the next hole. Some holes may have more debris then others.

NOTE: Do not use a bottoming tap because the block threads are tapped 12.5mm (.5") deeper than the grip length of the bolt.

Vacuum any remaining debris from each hole.
After you have cleaned the holes, inspect them for thread damage. If you find missing or stripped threads, a heli-coil must be installed.

Drill the cylinder bolt hole using a 1U5686 (21/32") drill.

Tap hole using 4C9732 tap. (For a M16X2 Heli-Coil insert).
Using the 8T2799 installation tool to install a 9U5604 Heil-Coil insert.

NOTE: The 9U5604 insert is a Special M16x2 32mm Grip Length HELI-COIL 1084-16CN-32.

DO NOT use any of the following Heli-Coil inserts ? MAJOR BLOCK DAMGE WILL OCCURR. The standard 4C8405 M16x2 24mm Grip Length HELI-COIL 5403-16 or the 4C8455 M16x2 24mm Grip Length HELI-COIL R1084-14.

Check the bottom deck of the cylinder head for flatness. The reusability specifications are:

Refer to the Specifications Module of the Service Manual or the Guidelines for Reusability SEBF8162 for additional information.

Check the overall flatness using the 600mm (24.0") straight edge. The flatness should be within 0.15mm (.006") over the 600mm (24.0"span).
Also, The flatness should be within 0.05mm (.002") for any 150mm (6.0") span.

If the head you are working on exceeds the flatness specifications, machine the bottom deck of the cylinder head.

Check the top deck of the cylinder block for flatness. The reusability specifications are:

Refer to the Specifications Module of the Service Manual or the Guidelines for Reusability SEBF8076 for additional information.

The flatness should be within 0.05mm (.002") for any 150mm (6.0") span.

Once the head gasket has been installed and the head placed back on the block, install new head bolts.

If the engine IS NOT equipped with a COMPRESSION BRAKE:

Lubricate 26 129-3184 head bolts using 6V4876 Molycote paste and cover the threads, washer and underside of the bolt head of each bolt.

If the engine IS equipped with a COMPRESSION BRAKE:

Lubricate 23 129-3184 head bolts and 3 178-7508 studs using 6V4876 Molycote and cover the threads, washer and underside of the bolt head of each bolt.

Tighten bolt (1) through (26) in a numerical sequence to the following torque?.. 160 ± 15 N·m (120 ± 11 FT LB). (As shown in Illustration 1).
Tighten bolt (1) through (26) again in a numerical sequence to the following torque?.. 160 ± 15 N·m (120 ± 11 FT). (As shown in Illustration 1).
Place an index mark on bolt (1) through (26).
Rotate the bolt (1) through (26) in numerical sequence, an additional 90 degrees (1/4 turn). (As shown in Illustration 1).
LOOSEN ALL 26 BOLTS UNTIL THE WASHER ROTATES FREELY UNDER THE HEAD OF EACH BOLT.
Again, Tighten bolt (1) through (26) in a numerical sequence to the following torque?.. 160 ± 15 N·m (120 ± 11 FT LB). (As shown in Illustration 1).
Again, Tighten bolt (1) through (26) in a numerical sequence to the following torque?. 160 ± 15 N·m (120 ± 11 FT LB). (As shown in Illustration 1).
Place a mark on bolt (1) through (26).
Rotate the bolt (1) through (26) in numerical sequence, an additional 90 degrees (1/4 turn). (As shown in Illustration 1).
Torque bolts 27-33 to 28 ±7 N·m(21 ± 5 LB-FT). (As shown in Illustration 1).

Illustration 1

Install the new 8H9788 turbo supply gasket, 188-6126 turbo drain gasket with the longer bolts and spacers per diagrams below.
Fax a complete copy of the actual Oil Sample and a copy of ECM Life time Totals, which were used to determine the eligibility for this service letter. Fax to the Attention of PS50041, before the claim is submitted to allow time for processing. Retain the documentation for later reference.

NOTE: This is not an authorization fax line. The dealer still has the decision whether to apply the Program or not.
ASSEMBLE PARTS FOR FLAT FLANGES PER DIAGRAM:

ASSEMBLE PARTS FOR STEPPED FLANGE PER DIAGRAM:

SERVICE CLAIM ALLOWANCES

Show/hide table

Product smu/age whichever comes first *	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first *	Parts (Sell)	Labor Hrs (Sell)	Parts	Labor Hrs	Parts (C/L)	Labor Hrs (Sell)
0-500,000 Mi * 0-805,000 Km * 0-13,000 Hrs * 5 Years *	100%	** 100%	0	0	0	0
* Whichever occurs first

**Labor Hour/Supplement Breakdown by Cab Type

Show/hide table

SMCS Code	SC	MC	CV	CO	Description
1100-000*	19.2	18.8	16.7	16.9	Remove And Install Cylinder Head
1201-064-TP-S	1.0	1.0	1.0	1.0	Tap Cylinder Head Bolt Holes
1302-010	1.1	1.1	1.1	1.3	Remove and Install Oil Pan
	$20	$20	$20	$20	Sublet for Oil Sample (up to $20 US)
Add if required:
1119-010-ES-S	1.0	1.0	1.0	1.0	R&I Jake Brake (Set)
1051-010	0.5	0.5	0.5	0.5	R&I Air Filter Housing
1353-010-BK	0.3	0.3	0.3	0.3	R&I Radiator Support
1318-010	0.1	0.1	0.1	0.1	R&I Oil Filter
1201-007-BH	1.0	1.0	1.0	1.0	Drill Cylinder Block Hole, Tap for Insert and Install Heil-Coil Insert into Cylinder Block Hole (1^st)
1201-007-BH-A	0.5	0.5	0.5	0.5	Each Additional Hole

NOTE: *The special torque time of .7 hours, 1350-034 of .3 hours leak test the cooling system, and the time to inspect parts for reuseability is already included in labor code 1100-000.

NOTE: One hour of Trouble Shooting is included in the 1100-000 labor code which accounts for pulling the Oil Sample and performing an ECM Download.

NOTE: For Recreational Vehicle (RV), Bus & Fire Truck applications ONLY: RV, Bus and Fire Truck Engines may require additional labor time (reasonable/actual) for difficult engine access. Claim the total time for rework using 1100-500-BC and include in the claim story why the additional time is required.