PRODUCT SUPPORT PROGRAM FOR RESEALING ALL THE CYLINDER HEAD TO BLOCK JOINTS ON CERTAIN CERTAIN TH55 KRESS COAL HAULERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR RESEALING ALL THE CYLINDER HEAD TO BLOCK JOINTS ON CERTAIN CERTAIN TH55 KRESS COAL HAULERS

Usage:

REBE7239-00

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29Jun2011

U-262

D-239

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR RESEALING ALL THE CYLINDER HEAD TO BLOCK JOINTS ON CERTAIN CERTAIN TH55 KRESS COAL HAULERS
1100		PS52047

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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 "PS52047" 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

30Jun2013

PROBLEM

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The cylinder head to block joints using the 110-6991 Head Gaskets may leak combustion gas on certain TH55 Kress Coal Haulers. Combustion gas may pressurize the cooling system.

AFFECTED PRODUCT

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Model	Identification Number
TH55 OEM	KCH22001-22050

PARTS NEEDED

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Qty	Part Number	Description
48	2A4429	LOCK-RETAINER
12	2W0752	GASKET
48	3J7354	SEAL-O-RING
12	4S5898	SEAL-O RING
24	5P0840	SEAL-O-RING
12	5P7530	SEAL-O-RING
12	6J2245	SEAL-O-RING
12	6V5101	SEAL-O-RING
36	6V6228	SEAL-O-RING
24	6V9769	SEAL-O-RING
36	7N2046	SEAL-O-RING
12	7N5080	GASKET-MANIFOLD
24	7N6806	SEAL-RECTANGULAR
14	1011198	BEARING-CAMSHAFT
12	1179315	SEAL-BASE
12	1228856	GASKET
24	1272176	SEAL-INTEGRAL
12	1445692	GASKET-PLATE
12	1445695	RING-PISTON
7	1496031	BEARING AS-MAIN
12	1656668	RING-PISTON
48	1977055	LOCK-RETAINER
12	2117826	LINER-CYLINDER
24	2147568	SEAL-O-RING-STOR
12	2291632	RING-PISTON
12	2302520	BEARING-CONN ROD
12	2407032	SEAL
24	2415928	GASKET
24	2432288	GASKET
12	2688154	KIT-GASKET-SFI
12	2720758	SEAL-PIP
12	2720760	SEAL-PIP
24	3165980	SEAL
1	3192141	KIT-GASKET(ACL)
1	3192142	KIT-GASKET(AIR)
1	3192157	KIT-GASKET(CL)
1	3192160	KIT-GASKET(F)
1	3192165	KIT-GASKET(FS)
1	3192204	KIT-GASKET(MAN)
1	3193828	KIT-GASKET(OCL)
1	3193830	KIT-GASKET(OP)
1	3193839	KIT-GASKET(RS)
1	3193855	KIT-GASKET(T)
1	3193856	KIT-GASKET(WLG)
1	3193857	KIT-GASKET(WP)
12	3208974	GASKET AS
48	3251410	SEAL AS-WATER
48	3251412	SEAL AS.-WATER
12	3526061	SEAL-LINER
12	3628264	GASKET-CYL HEAD
12	3629677	PLATE-SPACER
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

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Remove all cylinder heads and reseal with 362-8264 Head Gasket. For detailed information regarding the removal and installation of components reference SENR1126, Disassembly and Assembly.

NOTE: This program does not cover single cylinder, in-chassis repairs. This program should only be applied after single cylinder, in-chassis repairs have been made on at least three cylinders of the affected engine. Refer to REBE7250 for single cylinder, in-chassis repairs.

This program provisions for the block to be inserted with stainless steel water ferrule inserts and stainless steel liner bore inserts for repair. Refer to Reuse and Salvage Guidelines: SEBF8255 and SEBF8263 for proper inserting instructions.

OPTION A: 117-9315 Seal, to be used with a 119-5654 Rocker Base.
OPTION B: 240-7032 Seal, to be used with a 247-8340 Rocker Base.

Only order the appropriate seal part number according to the rocker base in use on the engine. The rocker base part number is located under the valve cover. Example location for 119-5654 Rocker Base shown in Image1.

NOTE: The Parts Needed list contains the new 339-4950 Liner Seal. Refer to Special Instruction SEBF9203 for cylinder block liner bore chamfering instructions.

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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%
0-10000 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
10001-14000 hrs, 49-60 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

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NOTE: This is a 335.0-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.
Product hours are engine/component hours. 135 hours are allowed for Removal and Installation of engine. 200 hours are allowed for Disassembly and Assembly of the engine. The claim allowance for inserting and resurfacing the cylinder block is a flat rate of $3500. All water passages and the liner bores must be inserted to claim full amount. Please refer to SEBF8255 for the liner bore inserting procedure and SEBF8263 for the water passage inserting procedure.

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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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The new 362-9677 Spacer Plate requires the use of a new liner projection specification.

The liner projection must be 0.083mm to 0.151mm (0.003 to 0.006 inch).

The maximum acceptable difference between the high measurements and the low measurements on a single cylinder is 0.05 mm (0.002 inch).

The new 362-8264 Head Gasket requires the use of a new head bolt tightening pattern and procedure.

Tightening procedure (Refer to Image1.2.1):
1. Tighten bolts 1 through 8 in numerical sequence shown to a torque of 30+/-5Nm.

2. Tighten bolts 1 through 8 in numerical sequence shown to a torque of 100 +/- 15Nm.

3. Tighten bolts 1 through 8 in numerical sequence shown to a torque of 450 +/- 15Nm.

4. Loosen bolts 1 through 8 in numerical sequence shown to an angle of 90deg +/-5deg.

5. Tighten bolts 1 through 8 in numerical sequence shown to a torque of 490 +/- 15Nm.