PSP FOR INSTALLING THERMOCOUPLES TO MONITOR EXHAUST GAS TEMPERATURES ON CERTAIN D11N TRACTORS; 776B TRACTORS; 777B, 785 , AND 789 TRUCKS - PS4399 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA
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PSP FOR INSTALLING THERMOCOUPLES TO MONITOR EXHAUST GAS TEMPERATURES ON CERTAIN D11N TRACTORS; 776B TRACTORS; 777B, 785 , AND 789 TRUCKS - PS4399 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA
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.
U-235 A-152 AU-152 E-102 O-145 1050, 1088 PS4399 NOTE: This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4399" as Part Number, "7755" as Group Number, and "96" as Description Code.
Termination Date
December 31, 1990
Problem
Troubleshooting an engine for a miss can be time consuming and difficult on certain D11N Tractors; 776B Tractors; and 777B, 785, and 789 Trucks. Exhaust thermocouples can be installed to minimize down time and help detect problems early.
Affected Product
Model Identification Number Equipped With Engines D11N 74Z1-Up 99W1-2033 776B 6JC1-Up 99W1-2033 777B 4YC1-Up 99W1-2033 3NF1-Up 99W1-2033 785 8GB1-Up 96Z1-551 789 9ZC1-Up 54Z1-403
Parts Needed
(Quantities Per Cylinder) 1 - 7E6830 Thermocouple 1 - 6K8179 Clip 1 - 5N2126 Adapter
Action Required
Remove the 5B7890 Pipe Plug from the cylinder head. See Illustration 1. ****** IMAGE: SEBE4192.00001.001 CAPTION: Illustration 1 Apply 5P3931 Anti-Seize Compound on the threads of the 5N2126 Adapter. Install the adapter in the cylinder head in the same location where the pipe plug was. Tighten the adapter to a torque of 35 +/- 4 N.m (25 +/- 2 lb ft). Put the 6K8179 Clip on the cable of the thermocouple. Insert the thermocouple into the adapter and tighten the nut to a torque of 12 +/- 2 N.m (9 +/- 1 lb ft). See Illustration 2. ****** IMAGE: SEBE4192.00001.002 CAPTION: Illustration 2 Attach the clip on the thermocouple cable to valve cover with one of the existing valve cover bolts. Until tooling is available, a cable adapter will be needed to read the 7E6830 Thermocouples. The cable adapter can be made with one standard female type K thermocouple cable connecter, one miniature male thermocouple cable connector, and 7X7481 Thermocouple Wire. Connect one of the thermocouple cable connectors to each end of the wire. Connect the ends of the yellow lead of the wire to the (+)positive terminals of the thermocouple cable connectors. Connect the ends of the red lead of the wire to the (-)negative terminals of the thermocouple cable connectors. This adapter cable will plug into the 6V9130 Temperature Probe Adapter used with the 6V7070 and 6V7800 Digital Multimeters. When troubleshooting for an engine miss, look for a cylinder exhaust temperature that is more than 200 deg.C (392 deg.F) less than the average of the remaining cylinder exhaust temperatures.
Service Claim Allowances
Product Caterpillar Dealer Suggested Customer Suggested smu/age Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs. (D/N) (Cost) (C/L) (Sell) ***** D11N Tractors ***** No Limit 33 1/3% 0 0 0 50% 2 ***** 776B Tractors and 777B Trucks ***** No Limit 33 1/3% 0 0 0 50% 2 ***** 785 Trucks ***** No Limit 33 1/3% 0 0 0 50% 3 ***** 789 Trucks ***** No Limit 33 1/3% 0 0 0 50% 4 NOTE: This is a .25-hour job per cylinder.
Parts Disposition
All parts removed (with the exception of cores used for Caterpillar Remanufactured parts) should be rendered useless and scrapped immediately upon completion of the repair.
Caterpillar Information System:
PSP FOR INCREASING THE WELD ON THE TRANSMISSION TUBE ASSEMBLIES (SLIDE TRACKS), AND INSTALLING BEVEL GEAR, BEVEL GEA R SHAFT BEARING, AND RETAINING BOLTS ON CERTAIN D10N TRACTORS - PS4390 - MAILED US AND CANADA, CACO, CFEL, COSA PSP FOR INCREASING THE WELD ON THE TRANSMISSION TUBE ASSEMBLIES (SLIDE TRACKS), AND INSTALLING BEVEL GEAR, BEVEL GEA R SHAFT BEARING, AND RETAINING BOLTS ON CERTAIN D10N TRACTORS - PS4390 - MAILED US AND CANADA, CACO, CFEL, COSA
PRIORITY - NEW FIRE SUPPRESSION CONTROL NEEDS TO BE INSTALLED ON CERTAIN D8N, D9N, D10N, AND D11N TRACTORS; AND 992C LOADERS - P I3435 - MAILED US AND CANADA, CACO, CFEL, COSA, LIMITED COFA PRIORITY - NEW FIRE SUPPRESSION CONTROL NEEDS TO BE INSTALLED ON CERTAIN D8N, D9N, D10N, AND D11N TRACTORS; AND 992C LOADERS - P I3435 - MAILED US AND CANADA, CACO, CFEL, COSA, LIMITED COFA
PSP FOR INSTALLING A NEW CAMSHAFT AND LIFTERS IN CERTAIN D11N TRACTORS; 776B TRACTORS; AND 777B, 785 AND 789 TRUCKS - PS0423 - M AILED US AND CANADA, CACO, COFA, BRAZIL, COSA, LIMITED CFEL - NOTE:THIS PROGRAM CANCELED AND REPLACED BY JULY 31, 1990 SL PSP FOR INSTALLING A NEW CAMSHAFT AND LIFTERS IN CERTAIN D11N TRACTORS; 776B TRACTORS; AND 777B, 785 AND 789 TRUCKS - PS0423 - M AILED US AND CANADA, CACO, COFA, BRAZIL, COSA, LIMITED CFEL - NOTE:THIS PROGRAM CANCELED AND REPLACED BY JULY 31, 1990 SL
PRIORITY - THE LEFT HAND AXLE SHAFT NEEDS TO BE REPLACED ON CERTAIN 651E AND 657E WHEEL TRACTORS - PI3436 - MAILED US, CAN ADA PRIORITY - THE LEFT HAND AXLE SHAFT NEEDS TO BE REPLACED ON CERTAIN 651E AND 657E WHEEL TRACTORS - PI3436 - MAILED US, CAN ADA
PSP FOR TRACK JOINT FAILURES (LEAKS) ON D4H LGP, D5H LGP, AND D6H LGP TRACTORS - PS0394 - MAILED CACO PSP FOR TRACK JOINT FAILURES (LEAKS) ON D4H LGP, D5H LGP, AND D6H LGP TRACTORS - PS0394 - MAILED CACO
PSP FOR TRACK JOINT FAILURES (LEAKS) ON D4H, D5H, AND D6H TRACTORS - PS0395 - MAILED CACO PSP FOR TRACK JOINT FAILURES (LEAKS) ON D4H, D5H, AND D6H TRACTORS - PS0395 - MAILED CACO
PSP FOR REPLACING THE REAR GEAR TRAIN ON CERTAIN D11N TRACTORS AND 3508 ENGINES (SPARE) - PS0410 - MAILED US AND CANADA, COFA COS A, LIMITED CACO - SEE SUPPLEMENT SEBE4196 DATED JANUARY 6, 1990 PSP FOR REPLACING THE REAR GEAR TRAIN ON CERTAIN D11N TRACTORS AND 3508 ENGINES (SPARE) - PS0410 - MAILED US AND CANADA, COFA COS A, LIMITED CACO - SEE SUPPLEMENT SEBE4196 DATED JANUARY 6, 1990
PSP FOR ERRATIC OR INTERMITTENT SHIFTING OF THE ICM CONTROLLED TRANSMISSIONS ON CERTAIN 621E, 623E, 627E, 631E, 637E, 651E, AND 657E SCRAPERS; 768C, 772B, AND 776B TRACTORS; AND 769C, 773B, 777B, 785, AND 789 TRUCKS - PS4402 - MAILED US AND CANADA , PSP FOR ERRATIC OR INTERMITTENT SHIFTING OF THE ICM CONTROLLED TRANSMISSIONS ON CERTAIN 621E, 623E, 627E, 631E, 637E, 651E, AND 657E SCRAPERS; 768C, 772B, AND 776B TRACTORS; AND 769C, 773B, 777B, 785, AND 789 TRUCKS - PS4402 - MAILED US AND CANADA ,
Product Support Program For Repeat Track Joint Failures (Leaks) On D11N Tractors Product Support Program For Repeat Track Joint Failures (Leaks) On D11N Tractors
PSP FOR INSTALLING A NEW DRIVE SHAFT SLIP JOINT GROUP, SPIDER, AND SHAFT ASSEMBLIES IN CERTAIN 518 SKIDDERS AND 518 GRAPPLE SKI DDERS - PS4372 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA PSP FOR INSTALLING A NEW DRIVE SHAFT SLIP JOINT GROUP, SPIDER, AND SHAFT ASSEMBLIES IN CERTAIN 518 SKIDDERS AND 518 GRAPPLE SKI DDERS - PS4372 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA
PARTS STOCK ACTION ONLY - BOLTS AND WASHERS THAT WERE USED TO HOLD THE COUNTERWEIGHT ON THE CRANKSHAFT IN SOME OF THE 3500 SER IES FAMILY OF ENGINES NEED TO BE REMOVED FROM PARTS STOCK - PI7215 - MAILED US AND CANADA, CACO, COFA, BRAZIL, CFEL, COSA, PARTS STOCK ACTION ONLY - BOLTS AND WASHERS THAT WERE USED TO HOLD THE COUNTERWEIGHT ON THE CRANKSHAFT IN SOME OF THE 3500 SER IES FAMILY OF ENGINES NEED TO BE REMOVED FROM PARTS STOCK - PI7215 - MAILED US AND CANADA, CACO, COFA, BRAZIL, CFEL, COSA,
PARTS STOCK ACTION ONLY - CERTAIN ELECTRIC STARTING MOTORS USED ON THE 3100 SERIES FAMILY OF ENGINES NEED TO BE REMOVED FRO M PARTS STOCK - PI7218 - MAILED US AND CANADA PARTS STOCK ACTION ONLY - CERTAIN ELECTRIC STARTING MOTORS USED ON THE 3100 SERIES FAMILY OF ENGINES NEED TO BE REMOVED FRO M PARTS STOCK - PI7218 - MAILED US AND CANADA
PRIORITY - THE RIGHT HAND AXLE SHAFT NEEDS TO BE REPLACED ON CERTAIN 651E AND 657E WHEEL TRACTORS - PI3445 - MAILED US AND CAN ADA PRIORITY - THE RIGHT HAND AXLE SHAFT NEEDS TO BE REPLACED ON CERTAIN 651E AND 657E WHEEL TRACTORS - PI3445 - MAILED US AND CAN ADA
PARTS STOCK ACTION ONLY:9J0942 PIN ASSEMBLIES IN PARTS STOCK NEED TO BE CHECKED FOR CORRECT LENGTH - PI7227 - MAILED US AND CAN ADA, CACO, COFA, BRAZIL, CFEL, COSA PARTS STOCK ACTION ONLY:9J0942 PIN ASSEMBLIES IN PARTS STOCK NEED TO BE CHECKED FOR CORRECT LENGTH - PI7227 - MAILED US AND CAN ADA, CACO, COFA, BRAZIL, CFEL, COSA
Supplemental Steering Flow Switch Needs To Be Replaced On Certain 992C Loaders Supplemental Steering Flow Switch Needs To Be Replaced On Certain 992C Loaders
PSP FOR INSTALLING NEW BUCKET TIP ADAPTER ON CERTAIN 235B/C EXCAVATORS AND 988B LOADERS - PS0406 - MAILED US AND CANADA, CFE L, COSA, LIMITED CACO PSP FOR INSTALLING NEW BUCKET TIP ADAPTER ON CERTAIN 235B/C EXCAVATORS AND 988B LOADERS - PS0406 - MAILED US AND CANADA, CFE L, COSA, LIMITED CACO
PSP FOR REPEAT TRACK JOINT FAILURES (LEAKS) ON D8N TRACTORS - PS0430 - MAILED COFA, CFEL, COSA PSP FOR REPEAT TRACK JOINT FAILURES (LEAKS) ON D8N TRACTORS - PS0430 - MAILED COFA, CFEL, COSA
PSP FOR PISTON FAILURES ON D11N TRACTORS; 776B TRACTORS; AND 777B, 785, AND 789 TRUCKS - PS0424 - MAILED US AND CANADA, CAC O, COFA, BRAZIL, CFEL, COSA PSP FOR PISTON FAILURES ON D11N TRACTORS; 776B TRACTORS; AND 777B, 785, AND 789 TRUCKS - PS0424 - MAILED US AND CANADA, CAC O, COFA, BRAZIL, CFEL, COSA
SERVICE LETTER SUPPLEMENT FOR DECEMBER 1, 1989 SL - PSP FOR INSTALLING A NEW CAMSHAFT & LIFTERS IN CERTAIN D11N TRACTORS; 776 B TRACTORS; & 777B, 785 & 789 TRUCKS - PS0423 - MAILED US & CANADA, CACO, COFA, BRAZIL, COSA, LIMITED CFEL SERVICE LETTER SUPPLEMENT FOR DECEMBER 1, 1989 SL - PSP FOR INSTALLING A NEW CAMSHAFT & LIFTERS IN CERTAIN D11N TRACTORS; 776 B TRACTORS; & 777B, 785 & 789 TRUCKS - PS0423 - MAILED US & CANADA, CACO, COFA, BRAZIL, COSA, LIMITED CFEL
PSP FOR CRANKSHAFTS IN CERTAIN D10 TRACTORS, D348 ENGINES, 776 TRACTORS, 777 TRUCKS, AND 992 LOADERS - PS0428 - MAILED US AND CAN ADA, CACO, COFA, CFEL, COSA PSP FOR CRANKSHAFTS IN CERTAIN D10 TRACTORS, D348 ENGINES, 776 TRACTORS, 777 TRUCKS, AND 992 LOADERS - PS0428 - MAILED US AND CAN ADA, CACO, COFA, CFEL, COSA
PARTS STOCK ACTION ONLY - NEW CYLINDER HEAD GASKETS USED ON 3408 AND 3412 ENGINES - PI7228 - MAILED US AND CANADA, CACO, COF A, BRAZIL, CFEL, COSA, MARINE TEPS PARTS STOCK ACTION ONLY - NEW CYLINDER HEAD GASKETS USED ON 3408 AND 3412 ENGINES - PI7228 - MAILED US AND CANADA, CACO, COF A, BRAZIL, CFEL, COSA, MARINE TEPS
PSP FOR INCREASING THE NUMBER OF DISCS AND PLATES IN THE STEERING CLUTCH AND BRAKE MODULES ON CERTAIN D9N AND D10N TRA CTO RS - PS0416 - MAILED CACO, COFA, CFEL, COSA - REVISED 10/90 PSP FOR INCREASING THE NUMBER OF DISCS AND PLATES IN THE STEERING CLUTCH AND BRAKE MODULES ON CERTAIN D9N AND D10N TRA CTO RS - PS0416 - MAILED CACO, COFA, CFEL, COSA - REVISED 10/90
PSP FOR INSTALLING NEW ROLLERS IN THE ONE-WAY CLUTCH OF CERTAIN 56H WINCHES - PS4418 - MAILED US, CANADA, CACO, COFA, CFE L, COSA PSP FOR INSTALLING NEW ROLLERS IN THE ONE-WAY CLUTCH OF CERTAIN 56H WINCHES - PS4418 - MAILED US, CANADA, CACO, COFA, CFE L, COSA
PSP FOR INSTALLING NEW PISTON RINGS AND CYLINDER LINERS TO REDUCE OIL CONSUMPTION ON CERTAIN CHALLENGER 65 TRACTORS; 235C E24 0, EL240, E300 AND EL300 EXCAVATORS; AND 963 AND 973 LOADERS - MAILED US, CANADA, CACO, COFA, CFEL - PS0434 PSP FOR INSTALLING NEW PISTON RINGS AND CYLINDER LINERS TO REDUCE OIL CONSUMPTION ON CERTAIN CHALLENGER 65 TRACTORS; 235C E24 0, EL240, E300 AND EL300 EXCAVATORS; AND 963 AND 973 LOADERS - MAILED US, CANADA, CACO, COFA, CFEL - PS0434