Product Support Program For Rotated Rod Eye Bushings On Certain; 776B, 776C, And 776D Tractors; 777B, 777C, 777D, 784B, 785, 785B, 789, 789B 793, 793B And 793C Trucks; D11N And D11R Tractors; 992G, And 994 Wheel Loaders; 5130, 5130B, And 5230 Excavat Caterpillar

Product Support Program For Rotated Rod Eye Bushings On Certain; 776B, 776C, And 776D Tractors; 777B, 777C, 777D, 784B, 785, 785B, 789, 789B 793, 793B And 793C Trucks; D11N And D11R Tractors; 992G, And 994 Wheel Loaders; 5130, 5130B, And 5230 Excavat

Usage:

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Caterpillar: Confidential Yellow

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 "PS5308" 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.

NOTE: This Revised Service Letter replaces the July 9, 1997(Revised March 1999) Service Letter. Changes have been made to the TERMINATION DATE.

Termination Date

July 31, 2000

Problem

Connecting rods on 3500 Series Engines have a steel backed bronze bushing in the eye end to support the piston pin. During engine operation some rod bushings have shown a tendency to rotate. If the rod eye bushing rotates, it will interfere with the proper operation of the piston and failure could result with damage to the crank and cylinder block.

NOTE: This Program applies to rod eye bushing failures of the 7C8608, 0R3036, 0R4381 Rod Assemblies and the 1013281/">1013281, change level 00 and 01, Rod Assembly all with the 7C8609 Rod Eye Bushing. It also applies to rod eye bushing failures of the 0R3036, 0R4381, 0R9200 and change level 02 and higher of 1013281 Rod Assemblies all with the 1181655 Rod Eye Bushing.

NOTE: This program only applies to a re-used connecting rod if the connecting rod was subject to and passed the "Guideline For Reusable Parts" described in SEBF8242 "Verification of Connecting Rod Eye Bushing Using the 5P8639 Connecting Rod Bushing Press Group" before installation. Engines which have been built with re-used connecting rods that did not pass or were not subject to the "Proof Load Test" are not eligible for this program.

Affected Product
Model & Identification Number

776B (6JC1-Up)

777B (4YC1-Up)

776C (2TK1-Up)

777C (4XJ1-Up)

776D (5ER1-Up)

777D (3PR1-Up)

784B (5RK1-Up)

785 (8GB1-Up)

785B (6HK1-Up)

789 (9ZC1-Up)

789B (7EK1-Up)

793 (3SJ1-Up)

793B (1HL1-Up)

793C (4AR1-Up)

Affected Product Cont
Model & Identification Number

D11N (74Z1-Up 4HK1-Up )

D11R (8ZR1-Up)

992G (7HR1-Up)

994 (9YF1-Up)

5130 (7TJ7 5ZL1-Up )

5130B (4CS1-Up)

5230 (7LL1-Up)

Parts Needed

(For 3508 Engines)

1 - 7E3912 Crankshaft (225 mm radius)

-or-

1 - 7E4899 Crankshaft (222 mm radius)

1 - 1153503 Cylinder Block

^* - 0R9200 Connecting Rods

^*only replace those rods that are damaged.

NOTE: These crankshafts can have oil holes as indicated in Illustrations 1 or 2. Either type can be used in 3508 Engines.

(For 3508B Engines)

1 - 1004159 Crankshaft (225 mm radius)

1 - 1153503 Cylinder Block

^*- 0R9200 Connecting Rods

^*only replace those rods that are damaged.

NOTE: The 1004159 Crankshaft can only be used in a 3508B Engine and is only made with oil holes indicated in Illustration 2.

(For 3512 Engines)

1 - 7E3914 Crankshaft (225 mm radius)

-or-

1 - 7E4897 Crankshaft (222 mm radius)

1 - 1155154 Cylinder Block

^*- 0R9200 Connecting Rods

^*only replace those rods that are damaged.

NOTE: These crankshafts can have oil holes as indicated in Illustrations 1 or 2. Either type can be used in 3512 Engines.

(For 3512B Engines)

1 - 7E3914 Crankshaft (225 mm radius)

1 - 1155154 Cylinder Block

^*- 0R9200 Connecting Rods

^*only replace those rods that are damaged.

NOTE: Use a crankshaft with oil holes in the rod journals only as indicated in Illustration 2 in 3512B Engines. Do not use a crankshaft with oil holes as indicated in Illustration 1.

(For 3516 Engines)

1 - 7E3916 Crankshaft (225 mm radius)

-or-

1 - 7E5165 Crankshaft (222 mm radius)

1 - 1155160 Cylinder Block

^*- 0R9200 Connecting Rods

^*only replace those rods that are damaged.

NOTE: These crankshafts can have oil holes as indicated in Illustrations 1 or 2. Either type can be used in 3516 Engines.

(For 3516B Engines)

1 - 7E3916 Crankshaft (225 mm radius)

1 - 1155160 Cylinder Block

^*- 0R9200 Connecting Rods

^*only replace those rods that are damaged.

NOTE: Use a crankshaft with oil holes in the rod journals only as indicated in Illustration 2 in 3516B Engines. Do not use a crankshaft with oil holes as indicated in Illustration 1.

Action Required

See the attached rework procedure.

Service Claim Allowances

For Crank, block, and rods only.

Parts Disposition

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Attach.

(1-Rework Procedure)

Rework Procedure

Refer to Service Magazines dated September 16, 1991 and March 25, 1991 for use of 222 mm and 225 mm crankshafts in various cylinder blocks.

During 3500 Series Engine overhauls, whether the rods are reused, new or reman, follow the instructions in Guidelines for Reusable Parts SEBF8149-08 or higher and SEBF8242-04 or higher with regards to the proof test to verify the retention of the rod eye bushing prior to installing the rod in the engine. During the proof test the rod bushing must not move during the test at 30,000 N (6750 pounds). Be sure and calculate the required pressure for your hydraulic cylinder to reach 6750 pounds of force.

(Rod Journal)