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
Usage:
@media screen {
div.divFooter {
display: none;
}
}
@media print {
div.divFooter {
position: fixed;
bottom: 0;
right: 0;
}
}
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
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-16 A-11 AU-11 B-5 E-11 O-15 1213, 1214 PS0424 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 "PS0424" as Part Number, "7755" as Group Number, and "96" as Description Code.
Termination Date
January 31, 1992
Problem
Breakage of the ring band or piston skirt scuffing may cause the pistons to fail in the engines of D11N Tractors; 776B Tractors; and 777B, 785, and 789 Trucks.
Affected Product
Model Identification Number D11N 74Z1-Up 776B 6JC1-Up 777B 4YC1-Up 3NF1-Up 785 8GB1-Up 789 9ZC1-Up
Parts Needed
***** Parts Required To Remove And Install Engine ***** 776B/ Part # Description D11N 777B 785 789 3D2824 Seal-Trans Oil Cooler 3 - - - 3F5792 Seal-Aux Rear Drive 2 - - - 2H3934 Seal-Torque Conv Lines - - 1 2 2H6338 Seal-Hyd Oil Lines 1 - - - 8H8754 Gasket-Rad Top Tank - 2 - - 9H6832 Seal-Torque Conv - 1 - - 4J0522 Seal-Hyd Oil Lines 5 6 5 2 4J0524 Seal-Tor Conv/Trans Cool Line - - 2 5 4J0524 Seal-Torque Conv Lines - 1 - - 4J0527 Seal-Tor Conv/Trans Cool Line - 2 9 10 4J0527 Seal-Tor Conv/Trans Cool Line - 6 - - 4J5267 Seal-Torque Conv Lines - - - 1 4J5267 Seal-Torque Conv/Brake Lines - 2 - - 7J9108 Seal-Fuel Lines 2 - - - 3K0360 Seal-Trans Oil Cooler 1 - - - 2M5173 Seal-Air Lines 4 - - - 7M8485 Seal-High Speed Oil Change 1* - - - 8M2888 Gasket-Radiator - 2 - - 8M4390 Seal-Torque Conv Oil Lines 1 - - - 8M4443 Seal-Torque Conv Oil Lines 2 - - - 8M4986 Seal-Torque Conv Oil Lines 2 - - - 8M5254 Seal-Torque Conv Oil Lines 1 - - - 8M5661 Seal-Torque Conv Oil Lines 3 - - - 8M8157 Seal-Torque Conv Oil Lines 2 - - - 9M2092 Seal-Torque Conv Lines - 1 - - 4N3841 Gasket-Coolant Flow Switch 1 - - - 7N3368 Gasket-Trans Oil Cooler 1 - - - 7N4945 Gasket-Jacket Water Heater 1* - - - 7N6494 Gasket-Starter 2 - - - 8N8089 Gasket-Trans Oil Cooler 1 - - - 1P3704 Seal-Hyd Fan Lines 1 - - - 1P3705 Seal-Hyd Oil Lines 1 - - - 8T2230 Seal-Acc Drive Yoke 1 - - - 6V8260 Seal-Torque Conv Oil Lines 1 - - - 6V8397 Seal-Torque Conv Lines - - - 1 6V8398 Seal-Torque Conv Lines - - - 1 6V9746 Seal-Torque Conv Lines - - - 1 7W2478 Gasket-Dust Ejector Tube 1 - - - * If Applicable ***** Parts Required To Replace All Pistons ***** NOTE: Inspect all parts and use as required. 776B/ Part # Description D11N 777B 785 789 2D1690 Seal-Oil Pan 1 1 - - 7E2630 Gasket-Oil Pan - - 1 - 7E2631 Gasket-Oil Pan 1 1 - - 7E2632 Gasket-Oil Pan - - - 1 7E3382 Injector 8 8 12 16 4F3765 Gasket-Dipstick 1 1 1 1 2H2665 Seal-Pump Scavage 2 2 - 2 2J0157 Seal-Valve Cover Base 16 16 24 32 6J2680 Seal-Oil Cooler Lines - - - 1 5L2692 Gasket-Air Cleaner - - 2 - 2M4453 Seal-Spacer Plate 16 16 24 32 7M7260 Liquid Gasket-Oil Pan 1 1 1 1 7M7273 Gasket-Turbo 2 2 2 4 7N2046 Seal-Liner 24 24 36 48 7N4904 Gasket-Exhaust Manifold 8 8 12 16 7N5080 Gasket-Air Intake 8 8 12 16 7N7628 Gasket-Turbo Water Lines 2 2 2 4 7N8875 Gasket-Turbo Oil Lines 2 2 2 4 8N1233 Ring-Piston 8 8 12 16 8N1269 Gasket-Water Lines 2 2 2 2 8N4707 Band-Cylinder Liner 8 8 12 16 8N6861 Liner-Cylinder 8 8 12 16 8N6862 Seal-Cylinder Head 32 32 48 64 8N6863 Seal-Cylinder Head 32 32 48 64 8N7640 Seal-Water Lines 8 8 12 16 8N7810 Ring-Piston 8 8 12 16 1P3709 Seal-Engine Oil Lines 1 - - - 3P0649 Seal-Engine Oil Lines 6 8 5 5 3P0657 Seal-Pump Scavage - - 2 - 5P3944 Seal-Air Cond. Lines - - 1 1 5P5700 Seal-Air Lines 4 4 - 8 1S8947 Seal-Air Cond. Lines - - 1 1 6V3908 Seal-Engine Oil Lines 1 1 1 1 6V3917 Seal-Air Lines - - 4 - 6V4314 Seal-Oil Pan - - 1 1 6V5101 Seal-Oil Pan 1 1 1 1 1W7538 Bearing-Con Rod (standard) 8 8 12 16 2W0752 Gasket-Turbo Oil Lines/Filter 3 3 3 4 4W7656 Gasket-Valve Cover Base 8 8 12 16 7W2221 Ring-Piston 8 8 12 16 7W7730 Gasket-Cylinder Head 8 8 12 16 9Y1484 Gasket-Spacer Plate 8 8 12 16 9Y2100 Piston (Except W/5Z8993 Arr#) 8 8 12 16 9Y4124 Piston (776B with 5Z8993 Arr#) - 8 - -
Action Required
Check and record the injector timing before disassembly. If the injector timing was out of tolerance and LESS than what the specifications call for, replace the piston in that cylinder. See the Fuel Setting And Related Information Microfiche (0T) for the correct specifications. Ensure that the proper injectors are installed. 7E3382 or 9Y1785 in all applications except the 776B with the 5Z8993 Engine Arrangement. If an obsolete set of injectors is in use, replace the entire set. After a failure, also visually inspect the other pistons and liners for scuffing or breakage and replace as necessary. If the vehicle is subject to cold weather starts, make certain the ether injection system is charged and operational.
Service Claim Allowances
Product Caterpillar Dealer Suggested Customer Suggested smu/age Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs. whichever (D/N) (Cost) (C/L) (Sell) comes first ***** D11N Tractors And 789 Trucks ***** 0-6000 100% 40 0 40 0 0 0-24 mo 6001-10000 33 1/3% 20 0 20 50% 40 25-36 mo NOTE: This is an 80-hour job including removal and installation of the engine. No labor will be allowed at overhaul. ***** 776B Tractors And 777B Trucks ***** 0-6000 100% 35 0 35 0 0 0-24 mo 6001-10000 33 1/3% 17.5 0 17.5 50% 35 25-36 mo NOTE: This is a 70-hour job including removal and installation of the engine. No labor will be allowed at overhaul. ***** 785 Trucks ***** 0-6000 100% 37.5 0 37.5 0 0 0-24 mo 6001-10000 33 1/3% 18.8 0 18.7 50% 37.5 25-36 mo NOTE: This is a 75-hour job including removal and installation of the engine. No labor will be allowed at overhaul.
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 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 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
Supplemental Steering Flow Switch Needs To Be Replaced On Certain 992C Loaders Supplemental Steering Flow Switch Needs To Be Replaced On Certain 992C Loaders
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
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
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 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
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
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
PSP FOR INSTALLING NEW PISTON RINGS AND CYLINDER LINERS TO REDUCE OIL CONSUMPTION ON CERTAIN CHALLENGER 65 TRACTORS; 235C EXC AVATORS; AND 963 AND 97S LOADERS - PS0434 - MAILED COSA PSP FOR INSTALLING NEW PISTON RINGS AND CYLINDER LINERS TO REDUCE OIL CONSUMPTION ON CERTAIN CHALLENGER 65 TRACTORS; 235C EXC AVATORS; AND 963 AND 97S LOADERS - PS0434 - MAILED COSA
SERVICE LETTER SUPPLEMENT FOR AUGUST 2, 1989 SL - PS4339 - PSP FOR REDUCING BEVEL GEAR AND PINION NOISE AND REDUCING THE RUST BEA RING WEAR ON CERTAIN 56 WINCHES USED ON D6H TRACTORS - MAILED US AND CANADA, CACO, COFA, CFEL, COSA SERVICE LETTER SUPPLEMENT FOR AUGUST 2, 1989 SL - PS4339 - PSP FOR REDUCING BEVEL GEAR AND PINION NOISE AND REDUCING THE RUST BEA RING WEAR ON CERTAIN 56 WINCHES USED ON D6H TRACTORS - MAILED US AND CANADA, CACO, COFA, CFEL, COSA
PSP FOR INSTALLING A NEW DIFFERENTIAL SEAL ON CERTAIN 631E AND 637E WHEEL TRACTORS - PS4413 - MAILED US, CANADA, CACO, COFA, BRA ZIL, CFEL, COSA PSP FOR INSTALLING A NEW DIFFERENTIAL SEAL ON CERTAIN 631E AND 637E WHEEL TRACTORS - PS4413 - MAILED US, CANADA, CACO, COFA, BRA ZIL, CFEL, COSA
Product Support Program For Replacing The Cylinder Block On Certain D8L Tractors And 631E Wheel Tractors Product Support Program For Replacing The Cylinder Block On Certain D8L Tractors And 631E Wheel Tractors
PSP FOR INSTALLING NEW BRAKE PLATES AND DISCS IN CERTAIN D4H, D5H, D6H, AND D7H TRACTORS - PS0432 - MAILED COFA PSP FOR INSTALLING NEW BRAKE PLATES AND DISCS IN CERTAIN D4H, D5H, D6H, AND D7H TRACTORS - PS0432 - MAILED COFA
PRIORITY - PARTS STOCK ACTION NEEDED - HOUSINGS NEED TO BE INSPECTED FOR CHIPS AND BEARINGS NEED TO BE REPLACED IN THE RET ARDER AND TRANSFER GEAR GROUP ON CERTAIN 657E SCRAPERS - PI3459 - MAILED US, CANADA, CACO, COFA, COSA - REVISED 4/90 PRIORITY - PARTS STOCK ACTION NEEDED - HOUSINGS NEED TO BE INSPECTED FOR CHIPS AND BEARINGS NEED TO BE REPLACED IN THE RET ARDER AND TRANSFER GEAR GROUP ON CERTAIN 657E SCRAPERS - PI3459 - MAILED US, CANADA, CACO, COFA, COSA - REVISED 4/90