PRODUCT SUPPORT PROGRAM FOR REPLACING THE INJECTOR SLEEVE ON CERTAIN 793F, 797B RETROFIT AND 797F OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE INJECTOR SLEEVE ON CERTAIN 793F, 797B RETROFIT AND 797F OFF-HIGHWAY TRUCKS

Usage:

TEBE4514-02

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07Apr2016

(Revised 15Sep2016)

R120

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Containment - After Failure Only (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING THE INJECTOR SLEEVE ON CERTAIN 793F, 797B RETROFIT AND 797F OFF-HIGHWAY TRUCKS
1290 1251 1254 1713 1100 1201 1216 1059		PS61322

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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.

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NOTE:

When reporting the repair, use "PS61322" 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.

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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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NOTE:	This Revised Service Letter replaces the 07Apr2016 (Revised 15Sep2016) Service Letter. Changes have been made to the Affected Product and Action Required.

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TERMINATION DATE

30Apr2017

PROBLEM

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The existing injector sleeve can leak on certain 793F, 797B and 797F Off-Highway Trucks. If the existing injector sleeve leaks it will result in sodium contamination in the engine oil and/or exhaust stream.

AFFECTED PRODUCT

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Model	Identification Number
793F	SSP00356, 362-363, 366, 376, 378-379, 561, 685-686, 695, 720, 752, 754, 815
797B	JSM00293
797F	LAJ00148-00150, 158-182, 185-187, 216-221, 230, 233-236, 247-250, 256-261, 263, 265, 397, 406, 408, 411, 414-415, 423, 425-427, 433, 435-438, 467, 471-473, 495-501, 610-611

PARTS NEEDED

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Qty	Part Number	Description
1	8C3132	SEAL-O RING
4	8T2223	BOLT-SOCKET HD
1	20R0703	HEAD GP-CYL BSC
1	2287089	SEAL-O-RING-ORFS
1	2287100	SEAL-O-RING-STOR
1	2300940	SEAL
1	2435741	SEAL-FUEL SYSTEM
1	2435742	SEAL-FUEL SYSTEM
4	2464924	GASKET
1	2589925	GASKET-COMB
1	3708028	SEAL-INTEGRAL
1	3940295	SEAL-INTEGRAL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 6% 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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Replace cylinder head, reusing cylinder head bolts and washers after performing visual inspection. Reinstall injector, injector return line, and quill tube with new injector seals, injector return line seals, and quill tube bolts. Reference KENR6052 for removal and installation procedures and for troubleshooting guidance on diagnosing a leaking injector sleeve refer to the info below.

If the source of the sodium cannot be isolated via other normal testing of individual components (water pumps, oil coolers, etc.) then complete the following procedure:

1. Shut down the engine and allow system to cool.

2. Flip the ground level shutdown switch on the truck front bumper and leave the switch engaged. This action disables the fuel injection.

3. Verify that the engine will crank but the engine does NOT start.

4. Pull the last exhaust manifold from each bank of the engine.

5. Pressurize the truck cooling system, refer to Testing and Adjusting, KENR5397 for additional information.

6. Hold pressure on the cooling system for no more than 10 minutes for the first test. If the leak is bad, holding the pressure too long could risk hydraulic lock.

7. While cranking the engine, shine a light up into the exhaust manifolds and look for cylinders that are puffing steam and white smoke. Refer to Image 1.

8. Verify any leaks by pulling the exhaust thermocouple port from the exhaust runner on that cylinder. Check for signs of moisture/steaming in that exhaust runner.

9. Repair any leaking injector sleeve by replacing the head.

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Image1

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%
0-9000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
9001-18000 hrs, 25-48 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

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NOTE: This is a 8.0-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.
The 8 hour labor allowance consists of: 4 hours troubleshooting max per repair 4 hours repair time If more than one cylinder has failed, an additional 4 hours repair time per additional cylinder is allowed. Repairing up to 4 cylinders (793F) and 6 cylinders (797B, 797F) in chassis is allowed. No additional troubleshooting time is allowed.