PRODUCT SUPPORT PROGRAM FOR REPLACING PISTON RINGS IN CAPACITY BRAND YARD JOCKEYS WITH THE C7 ENGINE Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING PISTON RINGS IN CAPACITY BRAND YARD JOCKEYS WITH THE C7 ENGINE

Usage:

REBE2095-00

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13Jun2007

B168
B170
B374
B420
D120
D250
D310
D490
E140
E149
E481
H160
H270
H335
H356
H374
H380

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After Failure Only (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING PISTON RINGS IN CAPACITY BRAND YARD JOCKEYS WITH THE C7 ENGINE
1215 1225		PS51313

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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 "PS51313" 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.

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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

30Jun2009

PROBLEM

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The existing top piston ring can break on certain Capacity brand yard jockeys that had operated with programming that prevented the transmission from going into 4th gear. This resulted in high rpm no/low load operation with subsequent piston ring damage possible. Although the transmissions have been reprogrammed, some piston rings may be damaged to the point they will fail before usefull service life.

AFFECTED PRODUCT

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Model

Identification Number

KAL34172-34173, 34256, 34276, 34351, 34384, 34388, 34414, 41817, 41891, 42604, 42620-42621, 42626, 42729, 46223, 46239, 46265, 46291, 48314, 48345, 50160, 50216, 50251, 50280, 50317, 50337, 50369, 50406, 51181, 51216, 51276, 51298, 51316, 51330, 51349, 51362, 51390, 55637, 55664, 56627, 56639, 56660-56661, 56666, 56684, 56689, 56708, 56743, 57482-57483, 57487, 57502, 57850, 66347, 66369, 66379, 66400, 66425, 66457, 66468, 67316, 67409, 67443, 67484, 67488, 67513, 67996, 68016, 68020, 68067, 68138, 68148, 68156, 68187, 68205, 68240, 68244, 68255-68256, 68290, 68308, 68361, 68422, 69848, 69926, 70037, 70051, 70070, 70078-70079, 70104, 70136-70137, 70172-70173, 70192, 70202, 70258, 70271, 74536, 74541, 74547, 74566, 74604, 74610-74611, 74639, 74643, 74700-74701, 74764, 74775, 74821, 74858-74859, 74887, 74895, 74912-74913, 74947, 74956, 75047-75048, 75077

SAP00366, 370, 456, 522, 609, 645-646, 683, 954, 1012, 1120, 2060, 2092, 2100, 2126, 2137, 2179, 2209, 2213, 2310, 2343, 2442, 2467, 2496, 2533, 2555, 2565, 2662, 2737, 2916, 2963, 2967, 2971, 2975-2976, 18976-18979, 19221-19226, 90029-90036

WAX01815, 1863, 1902, 1939, 2004, 11519, 11589, 11611, 11656, 11670, 12267, 12503, 12556, 12559, 12562, 12568, 12608, 13182-13183, 13201, 13204, 13215, 13283, 13300, 13313, 13315, 13335, 13750, 14413, 14424, 14430, 14458, 14460, 14534, 14548, 14599, 14631, 14658, 14668, 16309, 16314, 16331, 16358, 16378, 16386, 16422, 16433, 17976, 17979, 26560, 26622, 26749, 26765, 27270, 27288, 27310-27311, 27386, 27421, 27458-27459, 33831, 36175, 36329, 43810, 43998, 44012, 44211, 44213, 51366, 55352, 55451, 58547, 58574, 58630, 58771, 58811, 58834, 58870, 58936, 58939, 59220, 59235, 59262, 59286, 59327, 59373, 59424, 59430, 64591, 64604, 64615, 64637-64638, 64664, 64704, 64707, 64798, 64860, 64864, 64866, 64871, 64879, 64922, 65012, 65060, 65069, 67602, 67618, 67635, 67687, 67705, 67768, 67786, 68619, 68628, 68670, 68805, 78420, 78442

PARTS NEEDED

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Qty	Part Number	Description
1	2382743	RING-PISTON-OIL
1	2629288	BODY AS.-PISTON
1	2663110	RING-PSTN-INTMD
1	2997612	RING-PISTON

ACTION REQUIRED

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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%
0-7500 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
7501-12500 hrs, 61-72 mo	25.0%	25.0%	0.0%	0.0%	75.0%	75.0%

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NOTE: This is a 28.0-hour job
*Dealer to perform the most economical repair option* Exceptions may be considered and claimed depending on chasis type Depending on option(s) chosen in letter. After Failure: Labor for Option 1 Description___________________SMCS Code ______Hours R & I Engine__________________1000-010________13.8 R & I Cyl. BLK________________1201-010________20.4 Sleeve Cyl. First Cylinder: ___________________3.0 ____________Additional Cyl: ___________________2.0 Each Wash engine___________________1000-074_________0.5 Diagnosis_____________________1000-038_________1.0 Test After____________________1000-030_________1.0 Labor for Option 2 Description___________________SMCS Code ______Hours R & I Engine__________________1000-010________13.8 Transfer comp.________________1201-002________12.1 Wash engine___________________1000-074_________0.5 Diagnosis_____________________1000-038_________1.0 Test After____________________1000-030_________1.0

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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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AFTER FAILURE:
1. If the engine is still within the factory warranty period, use Warranty Update #0409 to troubleshoot excessive oil consumption or blow-by. Confirm the engine has excessive blow-by caused by ring failure. Then update the engine with above mentioned parts and claim per standard warranty guidelines. If the unit is out of the normal warranty period apply this Service Letter for the piston ring repair.

2. Once engine is disassembled for high blow-by and piston ring breakage is verified inspect the condition of each cylinder and determine if the cylinders can be restored with a hard honing process. If not then determine the most cost effective repair option.

3. Repair using new cylinder sleeve(s) in the block or replace with a reman bare block. Restore the engine block via the most cost effective method.

4. Re-assemble the engine using 2007 model piston and ring part numbers listed above following standard D&A practices and C7 TRG up to 20 hours.