PRODUCT SUPPORT PROGRAM FOR REPLACING THE CYLINDER PACKS ON CERTAIN 793C AND 792D OFF-HIGHWAY TRUCKS EQUIPPED WITH 3516HD LONG STROKE ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE CYLINDER PACKS ON CERTAIN 793C AND 792D OFF-HIGHWAY TRUCKS EQUIPPED WITH 3516HD LONG STROKE ENGINES

Usage:

TEBE0857-00

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20May2014

T070
T080
T130
T183

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Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING THE CYLINDER PACKS ON CERTAIN 793C AND 792D OFF-HIGHWAY TRUCKS EQUIPPED WITH 3516HD LONG STROKE ENGINES
1225 1239 1290 1920		PS90384

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NOTE:

This Containment Program can be administered either before or after a failure occurs. In either case the decision whether to apply the Program is made by the dealer and service rep. Obtain the service reps Goodwill Approver Code before completing the repair. EAME dealers should use their standard Industry Group specific goodwill approval codes. The Goodwill Approver Code must be included when submitting the claim.

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NOTE:	When reporting the repair, use "PS90384" as the Part Number and "7777" as the Group Number. If administered before failure, use "56" as Warranty Claim Description and "T" as the SIMS Description Code. If administered after failure, use "96" as 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.

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TERMINATION DATE

30Nov2015

PROBLEM

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Certain 793C, and 792D Off-Highway Trucks equipped with 3516HD Long Stroke Engines with single piece forged steel pistons can fail top compression rings due to excessive carbon build up.

AFFECTED PRODUCT

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Model	Identification Number
793C	4AR00316-00317, 331, 334 4GZ00132-00133 ATY00534-00536, 538-539, 550-556, 569-572, 638-640
793D	FDB00170-00173, 184-187, 189, 213-218, 236, 239-240, 324-326, 388, 393, 439, 463-468, 478-483, 507-509, 519-522, 539-544, 581, 617, 620, 622, 624, 628, 630, 780, 796-797, 842, 899-900, 967, 984, 994, 1024-1025, 1410, 1438, 1477, 1635, 1638-1639, 1642-1644

PARTS NEEDED

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Qty	Part Number	Description
16	2W0752	GASKET
16	4S5898	SEAL-O RING
32	5P0840	SEAL-O-RING
16	5P7530	SEAL-O-RING
8	5P9890	SEAL-O-RING
16	6J2245	SEAL-O-RING
8	6V5066	SEAL-O RING
16	6V5101	SEAL-O-RING
48	6V6228	SEAL-O-RING
32	6V9769	SEAL-O-RING
1	7E2632	GASKET-OIL PAN
16	7N5080	GASKET-MANIFOLD
32	7N6806	SEAL-RECTANGULAR
16	10R4029	CYLINDER PACK AS
4	1092332	SEAL-O-RING
16	1213558	RETAINER AS
16	1228856	GASKET AS
32	1272176	SEAL-INTEGRAL
16	1445692	GASKET-PLATE
16	1623898	TUBE AS
16	2302520	BEARING-CONN ROD
2	2377623	SEAL-O-RING
16	2407032	SEAL-PIP
16	2415928	GASKET AS
6	2432288	GASKET AS
16	2720759	SEAL-PIP
16	2720760	SEAL
3	2733967	GASKET
1	2986387	SEAL-O-RING
16	3208974	GASKET AS
3	3388603	RING-RETAINER
16	3628264	GASKET-CYL HEAD
64	4200652	SEAL AS-WATER
64	4200653	SEAL AS-WATER
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 20% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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This Service Letter provides support for replacing all 16 cylinder single piece forged pistons with articulated two piece pistons. Supporting documentation of the following conditions should be attached to the claim.

Condition 1: Air Intake System Cleanliness
Customer must demonstrate silicon levels have been maintained at or below 9 PPM by producing archived SOS reports. This program WILL NOT support engines that have had ring failures as a result of dust, dirt or debris ingress due to a faulty air intake system.

Condition 2: Increased Nitration and Oxidation levels
Customer must demonstrate an increasing trend of Nitration and Oxidation by producing archived SOS reports. A trend will be defined as at least 3 consecutive samples with Nitration and Oxidation levels above the proposed guidelines listed below.

- Nitration levels maintained at or below 12 UFM
- Oxidation levels maintained at or below 24 UFM

Condition 3: Oil filter plugging alarm history
Customer must demonstrate a worsening oil filter plugging alarms history by providing the VIMS downloads clearly showing the oil filter differential warnings.

Condition 4: Troubleshooting Documentation
Customer must demonstrate the Blowby test has been performed and results must be included in the claim story. Inspection should be completed as per Special Instruction REHS7857.

Where commercially justified the repair may be performed before failure in conjunction with the midlife service.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-9500 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
9501-9900 hrs, 25-28 mo	27.0%	50.0%	0.0%	0.0%	55.0%	50.0%
9901-10800 hrs, 29-32 mo	20.0%	50.0%	0.0%	0.0%	60.0%	50.0%
10801-11700 hrs, 33-36 mo	13.0%	50.0%	0.0%	0.0%	65.0%	50.0%
11701-12600 hrs, 37-40 mo	7.0%	50.0%	0.0%	0.0%	70.0%	50.0%
12601-13500 hrs, 41-44 mo	0.0%	50.0%	0.0%	0.0%	75.0%	50.0%

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NOTE: This is a 345.0-hour job If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
Repair hours are to support removal and installation of the engine, replacing the cylinder packs, dyno and paint touch up. This program supports replacement of all 16 cylinder packs. All of the parts listed in Parts Needed must be installed during the repair. Partial replacement of cylinder packs will not be supported by this Service Letter.

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