Product Support Program For Replacing The Scavenge Oil Pump On Certain D11N and D11R Tractors; 776B, 776C, 776D, 777B, 777C, 777D, 784B, 784C, 785, 785B, 785C, 789, 789B, 789C, 793, 793B, 793C, 797A, 797B Trucks; 854G Tractor; 992G, 994, 994D Wheel L Caterpillar

Product Support Program For Replacing The Scavenge Oil Pump On Certain D11N and D11R Tractors; 776B, 776C, 776D, 777B, 777C, 777D, 784B, 784C, 785, 785B, 785C, 789, 789B, 789C, 793, 793B, 793C, 797A, 797B Trucks; 854G Tractor; 992G, 994, 994D Wheel L

Usage:

SEBE9275-01

July 23, 2005
(Revised August 2005)
U-246
A-180
D-191
O-202

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*Before or* *after failure* *Parts stock action needed*	Product Support Program For Replacing The Scavenge Oil Pump On Certain D11N and D11R Tractors; 776B, 776C, 776D, 777B, 777C, 777D, 784B, 784C, 785, 785B, 785C, 789, 789B, 789C, 793, 793B, 793C, 797A, 797B Trucks; 854G Tractor; 992G, 994, 994D Wheel Loaders; 5130, 5130B, 5230, 5230B Excavators
1312		PS41816

NOTE: This Program can 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 "PS41816" as the Part number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, 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 July 23, 2005 Service Letter. Changes have been made to the Problem Description and the Action Required.

TERMINATION DATE

July 31, 2006

PROBLEM

Two issues exist for all Remanufactured 3500-machine engines:

The 161-2513 Drive Gear torque may fail due to improper cleaning of the shaft and gear surfaces, and improper torque procedure. The drive gear then falls into the oil pan and the scavenge oil pump will no longer operate. For engines installed in machines equipped with VIMS a second failure mode may occur. This failure is an unexpected engine shutdown due to low oil level when the engine is at idle.
The pump housing may be machined incorrectly causing the drive gear to bind. The binding may cause the drive gear torque to loosen. The drive gear then falls into the oil pan and the scavenge oil pump will no longer operate.

AFFECTED PRODUCT

NOTE: This Service Letter only affects machines that have Remanufactured 3500 engines installed. ****Group 1****

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Model	Identification Number
776B	6JC00001-99999
776C	2TK00001-99999
776D	5ER00001-99999 AFS00001-99999
777B	4YC00001-99999
777C	4XJ00001-99999
777D	3PR00001-99999 AGC00001-99999
D11N	74Z00001-99999 4HK00001-99999
D11R	9TR00001-99999 9XR00001-99999
992G	7HR00001-99999 ADZ00001-99999
5130B	4CS00001-99999

****Group 2****

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Model	Identification Number
785	8GB00001-99999
785B	6HK00001-99999

****Group 3****

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Model	Identification Number
789	9ZC00001-99999
789B	7EK00001-99999
789C	2BW00001-99999
793	3SJ00001-99999
793B	1HL00001-99999
793C	4AR00001-99999 ATY00001-99999 4GZ00001-99999
994	9YF00001-99999
994D	3TZ00001-99999

****Group 4 (Front Engine Only)****

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Model	Identification Number
797	5YW00001-99999

PARTS NEEDED

****Group 1****

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Qty	Part Number	Description
1	0R-3860	PUMP GP-SCAV

****Group 2****

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Qty	Part Number	Description
1	0R-3233	PUMP GP-SCAV

****Group 3****

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Qty	Part Number	Description
1	0R-9250	PUMP GP-SCAV

****Group 4 (Front Engine Only)****

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Qty	Part Number	Description
1	0R-3233	PUMP GP-SCAV

ACTION REQUIRED

* Parts Stock *

0R3860, 0R3233, and 0R9250 scavenge oil pumps in dealer parts inventory check build date code of pump.

For pumps in the Date range of September 1, 2004 ? March 23, 2005 check the S/N on the pump housing. If the S/N falls into the (B4078-B4256) range then replace the entire pump with a new remanufactured scavenge oil pump of same p/n as bad pump.
If the pump build date code is September 1, 2004 ? March 23, 2005, and pump housing S/N does not fall into the specified range (B4078-B4256) then disassemble the drive gear from the pump. Utilizing alcohol clean the pump shaft and gear taper. Install and torque the 161-2513 drive gear utilizing the SENR2353-03 Specification for 3500 Industrial Engine Attachments.

*****Affected Product *****

If the engine installed in Service Letter Affected Product is a Remanufactured Engine S/N listed in Table 1 below perform the following:

Check that scavenge oil pump p/n installed on remanufactured engine is a remanufactured p/n 0R3860, 0R3233, or 0R8250.
If scavenge oil pump is a remanufactured pump then check the s/n on the pump housing. If the pump housing s/n is in range B4078-B4256 replace the entire pump with a remanufactured pump from the list in "Parts Needed" section above.
If scavenge oil pump is a remanufactured pump and pump housing s/n is not in range B4078-B4256, then disassemble the drive gear from the pump. Utilizing alcohol clean the pump shaft and gear taper. Install and torque the 161-2513 drive gear utilizing the SENR2353-03 Specification for 3500 Industrial Engine Attachments.
If drive gear has failed on remanufactured scavenge oil pump replace the entire pump with a remanufactured pump from the list in "Parts Needed" section above.

Table 1:

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Group 1
4ZL	01032 - 1084
5TL	00712 - 740
5XS	00576 - 625, 628, 630, 632, 635, 637-639, 642, 644
BTB	00042 - 48
BTR	00259 - 273
KAM	00224 - 228
BWA	00153 - 157

Group 2
5EL	00303 - 315
6FL	00761 - 774, 776
7SS	00813 - 818

Group 3
6CL	00511 ? 520, 522
7CL	01541 ? 1585, 1587-1597
7DS	00495 ? 519, 521-523, 526, 528
CPW	00554 ? 617
KNS	00315 ? 359, 361-362, 367

Group 4	(Front Engine Only)
CND	00409
NPM	00104 ? 108, 110

SERVICE CLAIM ALLOWANCES

***** Parts Stock *****

Submit one claim for all oil pumps that were reworked in dealer parts stock.

***** Affected Product *****

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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
0-999999	100%	14.0	0	0	0	0
NOTE: Action 1: Inspection and rework time for pumps in dealer inventory. This is a 1-hour Job. NOTE: Action 2: Inspection and rework of engine. This is a 14-hour job. NOTE: Action 2: If this repair is made at overhaul, Parts may only be claimed. Labor cannot be claimed at overhaul.