PRODUCT SUPPORT PROGRAM FOR UPDATING THE ENGINE AT THE CRC WITH CUFFED CYLINDER SYSTEM COMPONENTS ON CERTAIN 793D OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR UPDATING THE ENGINE AT THE CRC WITH CUFFED CYLINDER SYSTEM COMPONENTS ON CERTAIN 793D OFF-HIGHWAY TRUCKS

Usage:

TEBE4437-00

Show/hide table

04Nov2016

V27E

Show/hide table

Containment - After Failure Only (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR UPDATING THE ENGINE AT THE CRC WITH CUFFED CYLINDER SYSTEM COMPONENTS ON CERTAIN 793D OFF-HIGHWAY TRUCKS
1203 1213 1207 1162 1151 1206 1307 1052 1201 1306 1308 1304 1315 1000 1225 1218 1123 1121 1102 1302		PS61335

Show/hide table

NOTE:	Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.
NOTE:	This Containment Program can only be administered after a failure occurs. 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.

Show/hide table

NOTE:

When reporting the repair, use "PS61335" as the Part Number and "7777" as the Group Number. Use "96" as Warranty Claim Description Code and use "Z" as the SIMS Description Code.

Show/hide table

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.

Show/hide table

TERMINATION DATE

30Nov2017

PROBLEM

Show/hide table

The engine may have top piston ring breaking, excessive carboning and liner polishing on certain 793D Off-Highway Trucks.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
793D	FDB01364, 1366, 1435, 1492, 1496-1497, 1505, 1558-1559, 1573-1574, 1582, 1630-1632

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
64	1H9696	SEAL-O-RING
1	1R0750	FILTER AS-FUEL
2	1R0755	FILTER-FUEL
1	1U5514	ROLL-CUT/POLISH
2	1V6341	SEAL
1	1W4954	GASKET-COVER
10	1W6005	BEARING-SLEEVE
4	2A3435	DOWEL-BEARING
64	2A4429	LOCK-RETAINER
1	2H3928	SEAL-O RING
1	2J6274	SEAL-O RING
4	2K8198	SEAL-O RING
1	2M9189	GASKET
4	2M9780	SEAL-O-RING-STOR
4	2N0931	GASKET
72	2N2766	LOCKNUT
1	3D2824	SEAL-O-RING-STOR
1	3E6735	SEAL-0 RING
3	3J1907	SEAL-O-RING-STOR
3	3J7354	SEAL-O-RING-STOR
32	3J9196	NUT-JAM
2	3K0360	SEAL-O-RING
2	3P0654	SEAL-O-RING
1	3P0655	SEAL-O-RING
4	3S9643	SEAL-LIP TYPE
2	4B8407	GASKET-COPPER
3	4F3765	GASKET-IDLER SFT
2	4J5477	SEAL-O-RING-ORFS
1	4N1320	GASKET-ADAPTER
1	4N3841	GASKET
4	4P4460	GASKET-TURBO
1	4P5460	BEARING-SLEEVE
1	4W3100	GASKET
1	5B4399	SEAL-O RING
4	5D5957	SEAL-O-RING
4	5F9657	SEAL-O RING
1	5H6734	SEAL-O-RING
1	5H8848	SEAL-O RING
56	5P3345	BOLT-HEX HEAD
60	5P3875	BOLT-HEX HEAD
4	5P3961	BOLT
1	5P4892	SEAL-O-RING
4	5P5700	SEAL-O-RING
1	5P5846	SEAL-O-RING
16	5P7128	BOLT-HEX HEAD
1	5P7701	SEAL-O-RING
2	5P8068	SEAL-O-RING
3	5P8210	SEAL-O-RING
3	5P8940	SEAL-O-RING
8	5P9890	SEAL-O-RING
1	6D7128	SEAL-O-RING
1	6F4868	GASKET
1	6J2244	SEAL-O-RING
16	6J2245	SEAL-O-RING
3	6J2680	SEAL-O-RING
1	6L1883	GASKET-GOVERNOR
1	6V0973	SEAL-O-RING
2	6V1454	SEAL-O-RING
3	6V3348	SEAL-O-RING
1	6V3908	SEAL-O-RING
16	6V3917	SEAL-O-RING
2	6V4314	SEAL-O-RING
2	6V4315	SEAL-O-RING
4	6V4368	SEAL-O-RING
2	6V5043	SEAL-O-RING
3	6V5048	SEAL-O-RING
3	6V5066	SEAL-O-RING
1	6V5101	SEAL-O-RING
9	6V6609	SEAL-O-RING
2	6V6809	SEAL-O-RING
3	6V8397	SEAL-O-RING-ORFS
10	6V8398	SEAL-O-RING-ORFS
2	6V9027	SEAL-O-RING
2	6V9746	SEAL-O-RING-ORFS
1	7C3258	WASHER AS-THRUST
2	7C6209	PLATE-THRUST
1	7E2632	GASKET-OIL PAN
4	7E6016	GASKET AS
1	7E7209	RING-RETAINER
100	7K1181	STRAP-CABLE
2	7M8485	SEAL-O-RING-STOR
2	7N3006	WASHER-THRUST
1	7N3049	GASKET
2	7N3368	GASKET
2	7N4320	GASKET
1	7N4927	GASKET-HSG COVER
1	7N4932	GASKET
5	7N4945	GASKET
1	7N5057	GASKET
2	7N5246	WASHER-THRUST
2	7N7539	WASHER-THRUST
4	7N7559	GASKET
3	7X4805	SEAL-O-RING
2	8C0624	SEAL-O-RING
1	8C3107	SEAL-O-RING
4	8L2786	SEAL-O-RING
1	8M7065	GASKET-AIR INLET
2	8N9885	GASKET-ACCESSORY
2	8T1919	SEAL-O-RING
4	8T2928	SEAL-O-RING
4	8T2929	SEAL-O-RING
4	8T9527	SEAL-O-RING
16	9F7707	RING-RETAINER
1	9L2662	GASKET
2	9M2092	SEAL-O-RING
1	9X7371	SEAL-O-RING
4	9Y8387	GASKET
3	9Y8388	GASKET
1	9Y8389	GASKET
16	20R2296	INJECTOR GP-FUEL
16	20R5616	CYLINDER PACK AS
6	0336031	SEAL-O-RING
18	1011198	BEARING-CAMSHAFT
1	1011365	PLATE-THRUST
2	1011368	WASHER-THRUST
1	1026299	BEARING-SLEEVE
2	1058901	GASKET
8	1090075	SEAL-O-RING
4	1092332	SEAL-O-RING
1	1095724	SEAL GP-LIP TYPE
4	1097411	SEAL-O-RING
16	1106991	GASKET-HEAD
1	1111349	GASKET
8	1123540	SEAL-O-RING
1	1138432	SEAL-CRANKSHAFT
1	1138433	SEAL-CRANKSHAFT
2	1199443	SEAL-O-RING
16	1213558	RETAINER AS
4	1215736	GASKET-TURBO
2	1215746	GASKET
2	1259751	BEARING-SLEEVE
1	1274422	GASKET
4	1275400	BEARING-SLEEVE
12	1278269	SEAL-EXHAUST
32	1302607	INSERT-V SEAT
32	1302608	INSERT-V SEAT
16	1326469	HARNESS AS-WRG
32	1339306	GUIDE-VALVE
1	1378298	BEARING-SLEEVE
1	1409597	BEARING-SLEEVE
1	1424159	SEAL-INTEGRAL
9	1496031	BEARING AS-MAIN
16	1623898	TUBE AS
4	1942971	SEAL-O-RING
32	1976995	GUIDE-VALVE
64	1977055	LOCK-RETAINER
3	2056612	COOLANT
32	2102542	VALVE-INLET
64	2147566	SEAL-O-RING-STOR
1	2287089	SEAL-O-RING-ORFS
20	2287090	SEAL-O-RING-ORFS
1	2287097	SEAL-O-RING-STOR
4	2287098	SEAL-O-RING
2	2301072	GASKET
16	2302520	BEARING-CONN ROD
6	2348937	SEAL-INTEGRAL
1	2352484	SEAL-LIP TYPE
3	2353546	SEAL-O-RING
2	2377623	SEAL-O-RING
4	2385080	SEAL-O-RING-STOR
2	2385081	SEAL-O-RING-STOR
4	2485513	REGULATOR-TEMP
1	2594596	SEAL-O-RING
5	2594598	SEAL-O-RING
6	2676535	TOWEL
3	2701820	SEAL-O-RING
16	2720759	SEAL-PIP
2	2733967	GASKET
4	2752604	FILTER AS-LUBE
1	2986387	SEAL-O-RING
1	3008567	SLEEVE
1	3079926	ABSORBENT-ROLL
2	3150741	WASHER-THRUST
1	3151409	BEARING-SLEEVE
64	3165976	SPRING
64	3165977	SPRING-VALVE
32	3165978	ROTOCOIL AS
32	3165979	ROTOCOIL AS
32	3165980	SEAL
32	3165981	WASHER
16	3171121	NUT-JAM
16	3419211	GASKET
32	3580768	SCREW-ADJUSTING
16	3804843	SCREW-ADJUSTING
16	4421340	KIT-GASKET (SCH)
32	4432712	VALVE-EXHAUST
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

Show/hide table

This program provides support for replacing all 16 cylinder single piece forged pistons with articulated two piece piston cylinder packs. Supporting documentation of the following conditions must be attached to the claim.

Condition 1: Prior to removing the engine for shipment to the CRC approval must be gained from the CIS engine group SR Engineer.

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 10 UFM
- Oxidation levels maintained at or below 24 UFM

Condition 3: Troubleshooting Documentation customer must demonstrate a blowby test has been performed and results must be must be included in the claim story. Blowby Testing and Inspection should be completed as per Special Instruction, REHS7857.

Show/hide table

SERVICE CLAIM ALLOWANCES

Show/hide table

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%
0-9000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
9001-16000 hrs, 61-96 mo	33.0%	100.0%	0.0%	0.0%	50.0%	0.0%

Show/hide table

NOTE: This is a 464.0-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.
120 hours will be allowed for removing and installing the engine. Up to 344 hours will be allowed at the CRC.

Show/hide table