PRODUCT SUPPORT PROGRAM FOR INSTALLING AIR COMPRESSOR HEAD GASKET KIT ON CERTAIN C13 ON-HIGHWAY TRUCK ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING AIR COMPRESSOR HEAD GASKET KIT ON CERTAIN C13 ON-HIGHWAY TRUCK ENGINES

Usage:

REBE1823-00

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30Mar2007

E140
E310

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Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR INSTALLING AIR COMPRESSOR HEAD GASKET KIT ON CERTAIN C13 ON-HIGHWAY TRUCK ENGINES
1803		PS42373

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NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS42373" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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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

31Mar2008

PROBLEM

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The existing air compressor head gasket may fail on certain C13 On-highway truck engines. If the existing gasket fails it may put compressed air into the cooling system.

AFFECTED PRODUCT

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Model

Identification Number

C13

KCB61033, 71712, 72203, 72207, 72218, 72226, 72230, 72262, 72266, 72312, 72533, 72639, 72660, 72666, 72678, 72813-72819, 73075-73079, 73176-73179, 73287-73290, 73402-73403, 73510-73511, 73624-73627, 73985-73986, 74252-74257, 74686, 74822, 74911-74914, 75001-75003, 75093-75095, 75343-75344, 75359, 75585, 75887-75888, 76099-76100, 76160, 76244, 77539, 77573, 77664-77665, 77803-77804, 77846, 78053, 78273-78275, 78462, 78515, 78626-78628, 78745-78748, 78942-78943, 79029, 79147, 79248-79249, 79943-79944, 80037, 80068-80069, 80093-80094, 80184, 80228, 80335-80336, 80438-80440, 80599-80600, 80758, 80760, 80994-80997, 81075-81078, 81151-81154, 81203, 81479, 89638

PARTS NEEDED

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No parts needed for this program

ACTION REQUIRED

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All repair parts will be supplied at the dealer. In case of part discrepencies contact Joshua Evans. Phone: 1-309-578-3479 E-mail: Evans_Joshua_J@cat.com

WARNING
When working on air system components the following precautions should be observed:
1.Stop engine when working under a vehicle. Always block the vehicle wheels to prevent a fore or aft roll. Bleeding off system pressure may cause the vehicle to roll. Keep hands away from brake chamber push rods and brake adjusters; they may apply as system pressure drops.
2.Never connect or disconnect a hose or line containing air pressure. It may whip as air escapes. Never remove a component or a pipe plug unless you are certain all system air pressure has been exhausted.
3.Never exceed recommended working air pressure and always wear safety glasses when working with air pressure. Never look directly into component ports or direct a pressurized air flow at anyone.
4.Never attempt to disassemble a component until you have read and understood all recommended procedures. Some components contain powerful springs and injury can result if not properly disassembled. Use only proper tools and observe all precautions pertaining to the use of those tools.

Refer to the attached Rework Procedure.

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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%
0-500000 miles, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 3.0-hour job

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PARTS DISPOSITION

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Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

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In Chassis Procedure with air compressor left in place on engine:
Parts required to complete the cylinder head replacement procedure:
1 6L-1883 Gasket (governor mounting)
2 6V-6609 Seal-O-ring (to replace the seals on the waterline fittings)
1 6V-1903 Seal-O-ring (to replace the seal on the air inlet fittings)
2 2M9780 Seal-O-ring (to replace the seals on the air outlet fitting and on the Pressure Relief Valve)
1 307-6209 Kit-Cylinder Head
Contents of kit contains:
1 Cylinder Head Assembly
1 Head Gasket
6 Head bolts

Cylinder Head Removal
1.Bleed the air system to less than 90 psig.
2.Drain the vehicle coolant system.
3.Disconnect the air and coolant lines from the mating fittings on the compressor.
4.Remove the governor, if applicable, mating fittings and pressure relief valve on the compressor head. Set aside for re-installation on new cylinder head assembly.
5.Loosen and remove the six compressor head bolts and discard.
6.Note the orientation of the cylinder head ports to the engine. Remove the cylinder head assembly from the cylinder block. If necessary, tap the head assembly lightly with a plastic mallet to assist loosening of the head assembly from the cylinder block.
7.Remove the gasket on top of the cylinder block and discard.

Cylinder Head Installation
1.Insure the top of the cylinder block is clean and dry.
2.Retrieve the new cylinder head gasket, cylinder head assembly and head bolts.
3.Oil the threads of the head bolts with 15W40.
4.Install two head bolts into the new cylinder head assembly.
5.Install the head gasket onto the two head bolts until it is flush with the bottom surface of the cylinder head assembly.
6.While holding the gasket against the cylinder head assembly and the two bolts against the cylinder head, orient the cylinder head/head gasket assembly onto the cylinder block in the same orientation as the original cylinder head. Align the two head bolts in the thread holes of the cylinder block.
7.Hand tighten the two head bolts.
8.Install the four remaining head bolts and hand tighten.
9.Torque the six head bolts (M15 socket) to the following procedure in a cross pattern. (see figure 1).
a.42 ? 5 N-m (31 ? 4 lb-ft) to burnish the threads.
b.Loosen the six head bolts
c.Tighten the six head bolts, in sequence, to 14 ? 1 N-m (10 ? 1 lb-ft)
d.Angle tighten the six head bolts, in sequence, to 120deg -2deg /+4deg.

Image1.3.1

10.Torque the Unloader bolts (M10 socket) to 12 ? 3 N-m (106 ? 27 lb-in) in the sequence shown (see figure 2).

Image1.4.1

11.Re-install the *governor, *new governor gasket, mating fittings and pressure relief valve (using new o-ring seals) to their original position on the cylinder head. * If applicable.
12.Connect the air and coolant lines to the appropriate cylinder head fittings.
13.Refill the vehicle coolant system.

Operational Checks
After repairs are completed and air lines are connected, start the engine, build-up system air pressure to cut-out pressure (audible purge of the air dryer). Shut off the engine. Check for air leaks at the governor interface to the compressor (if applicable) and outlet (port "2") of the air compressor. Check for coolant leaks at the cylinder head/cylinder block interface and fittings. Correct any leakage problems.