PRODUCT SUPPORT PROGRAM FOR REPLACING CYLINDER HEAD BOLTS ON CERTAIN 794 AC OFF-HIGHWAY TRUCKS Caterpillar


PRODUCT SUPPORT PROGRAM FOR REPLACING CYLINDER HEAD BOLTS ON CERTAIN 794 AC OFF-HIGHWAY TRUCKS

Usage:

TEBE4484-01

01Apr2016
(Revised 19Oct2016)


U-162
A-124
D-146

 

After Failure Only

  
  

PRODUCT SUPPORT PROGRAM FOR REPLACING CYLINDER HEAD BOLTS ON CERTAIN 794 AC OFF-HIGHWAY TRUCKS

1100
PS53183
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 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 "PS53183" 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:

This Revised Service Letter replaces the 01Apr2016 Service Letter. Changes have been made to the Title, Problem, Parts Needed, Action Required, and Service Claim Allowances.


TERMINATION DATE

30Apr2018

PROBLEM

The existing cylinder head bolts can fail on certain 794 AC Off-Highway Trucks. If the existing bolts fail it can result in a combustion leak.

AFFECTED PRODUCT

Model Identification Number
794 AC  MT500100-00112
MT5300D AC  MN500052-00056

PARTS NEEDED

Qty

Part Number Description
4 8T2223 BOLT-SOCKET HD
1 8T9524 SEAL-O-RING
2 1520195 WASHER-HARD
1 2287100 SEAL-O-RING-STOR
1 2287108 SEAL-O-RING-STOR
1 2300940 SEAL
1 2464924 GASKET
1 2589925 GASKET-COMB
1 2589926 GASKET
1 2697852 SEAL-O-RING
2 2747701 BOLT-12 POINT
1 3170808 SEAL-O-RING
1 3708028 SEAL-INTEGRAL
2 4983113 INSERT-BOLT
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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

Ensure that the area around the cylinder head is properly cleaned prior to disassembly in order to prevent contamination of the oil system. Follow the guidance in Special Instruction, M0070538, "Best Practice for Ensuring the Oil System is Full and Free of Contamination ". Failure to thoroughly clean the area prior to head removal could result in an engine failure.

Refer to the Disassembly and Assembly, UENR5561 for the removal and installation instructions for the cylinder head.

Refer to Reuse and Salvage Guidelines, SEBF9109, "Contamination Control of the Common Rail Fuel System on C175 Engines" for additional information in handling fuel system parts.

The parts provided by this letter includes items that need to be replaced due to their one-time use requirement. Non failed cylinder head bolts can be used if they meet reuse guidelines in the C175 Engine Fasteners section in SEBF8301, however it is recommended that the bolts in the two positions (Image 1) are replaced. Prior to installing bolts in these two holes, install plastic alignment sleeves 498-3113 with the chamfer facing downward. A plastic hammer can be used to lightly tap the sleeves flush with the top of the cylinder head. Refer to Image 2.
Image1
Image2

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
0-24000 hrs,
0-60 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 6.0-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.




PARTS DISPOSITION

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

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