PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE INTEGRAL SEAL ON CERTAIN 793F AND 797F OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE INTEGRAL SEAL ON CERTAIN 793F AND 797F OFF-HIGHWAY TRUCKS

Usage:

REBE6146-01

Show/hide table

13Jul2010

(Revised 27Oct2010)

U-255

A-354

D-219

Show/hide table

*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE INTEGRAL SEAL ON CERTAIN 793F AND 797F OFF-HIGHWAY TRUCKS
1100		PI31771

Show/hide table

NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31771" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. Exception: If the repair is done after failure, use "PI31771" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

Show/hide table

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.

Show/hide table


NOTE:	This Revised Service Letter replaces the 13Jul2010 Service Letter. Changes have been made to add Mail Code "A".

Show/hide table

COMPLETION DATE	TERMINATION DATE
31Jan2011	31Jul2011

PROBLEM

Show/hide table

The 295-8494 Integral Seal needs to be replaced on certain 793F and 797F Off-Highway Trucks. The existing seal can fail leading to an external oil leak at the head to block joint.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
*****Group 1*****
797F	LAJ00159-00166, 168-173

Show/hide table

*****Group 2*****
793F	SSP00128-00137, 139-140

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
*****Group 1*****
80	6V5839	WASHER-HARD
20	8C3132	SEAL-O RING
80	8T2223	BOLT-SOCKET HD
20	8T9524	SEAL-O-RING
20	9U7071	CAP/PLUG-TAPERED
20	9X7381	SEAL-O-RING
20	1234724	SEAL-O-RING
20	2287089	SEAL-O-RING-ORFS
20	2287100	SEAL-O-RING-STOR
20	2287108	SEAL-O-RING-STOR
36	2432975	CLAMP AS-V-BAND
20	2435739	SEAL-FUEL SYSTEM
20	2435741	SEAL-FUEL SYSTEM
20	2435742	SEAL-FUEL SYSTEM
20	2464924	GASKET
20	2589925	GASKET-COMB
20	2589926	GASKET
18	2915165	BELLOWS AS
40	3566939	BRIDGE
20	3625169	SEAL-INTEGRAL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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.
*****Group 2*****
64	6V5839	WASHER-HARD
16	8C3132	SEAL-O RING
64	8T2223	BOLT-SOCKET HD
16	8T9524	SEAL-O-RING
16	9U7071	CAP/PLUG-TAPERED
16	9X7381	SEAL-O-RING
16	1234724	SEAL-O-RING
16	2287089	SEAL-O-RING-ORFS
16	2287100	SEAL-O-RING-STOR
16	2287108	SEAL-O-RING-STOR
24	2432975	CLAMP AS-V-BAND
16	2435739	SEAL-FUEL SYSTEM
16	2435741	SEAL-FUEL SYSTEM
16	2435742	SEAL-FUEL SYSTEM
16	2464924	GASKET
16	2589925	GASKET-COMB
16	2589926	GASKET
12	2915165	BELLOWS AS
32	3566939	BRIDGE
16	3625169	SEAL-INTEGRAL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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

Show/hide table

Refer to the attached Rework Procedure.

Show/hide table

OWNER NOTIFICATION

Show/hide table

U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

Show/hide table

Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 80.0-hour job for Group 1

Show/hide table

Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 64.0-hour job for Group 2

PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Show/hide table

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE INTEGRAL SEAL

MODELS INVOLVED - 793F and 797F Off-Highway Trucks

Dear Caterpillar Product Owner:

The Cylinder Head Integral Seal needs to be replaced on the products listed below. The existing Cylinder Head Integral Seal can fail leading to an external oil leak at the head to block joint. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

Please refer the dealer to their Service Letter dated 13Jul2010 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 13Jul2010 Service Letter

Rework Procedure

NOTE: Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Cleanliness is an important factor. Before you begin the disassembly procedure, the exterior of the components should be thoroughly cleaned. Cleaning will help to prevent dirt from entering the internal mechanism. Precision components can be damaged by contaminants or by dirt. Perform disassembly procedures on a clean work surface.

Keep components covered and protected at all times. Refer to SEBF9109 for a list of caps available to prevent fuel system contamination.

1. Remove valve covers, rocker shafts, and push rods.

2. (Refer to Image1.1.1) Remove exhaust manifold bolts (1). Disconnect exhaust manifold section (2). Remove intake manifold bolts (9). Disconnect inlet manifold (10).

NOTE: Do not open the high pressure fuel system without allowing the fuel system to purge. After the engine has shut down, allow the fuel system to purge for ten minutes. This operating fuel system contains high pressure. Exposure to high pressure fuel can result in personal injury.

3. Remove return line bolt (7) and the washer. Remove tube assembly (5). Disconnect harness assembly (6).

4. Remove quill tube bolts (12) and (11). Remove tube assembly (8).

NOTE: Exercise care in removing the cylinder head and the gasket in order to avoid contamination of oil supply holes in the cylinder block.

5. Attach a suitable lifting device onto cylinder head. Cylinder head weighs approximately 68 kg (150 lb). Remove head bolts (4). Remove cylinder heads (3) from the engine. Position cylinder heads (3) onto suitable cribbing in order to prevent damage to the electronic unit injector

NOTE: The positioning dowels need to remain in the cylinder block. Remove the dowels if the dowels remain in the cylinder head. Install the dowels in the cylinder block before installing the cylinder head.

Image1.1.1

6. Inspect all liner cuffs for cracks (see Image1.2.2), replace as needed. Replace integral seal (13) with new part number seal and install new fire ring (14).

Image1.2.1

Image1.2.2

7. Install cylinder heads. Lubricate the head bolt threads with oil and install.

8. Tighten bolts in the numerical sequence as shown in image 1.3.1 to a torque of 30 +/- 5 N.m (22 +/- 7 lb ft). Tighten the head bolts in the numerical sequence shown to a torque of 250 +/- 20 N.m (184 +/- 15 lb ft). Tighten bolts again in the numerical sequence to a torque of 250 +/- 20 N.m (184 +/- 15 lb ft). Tighten bolts in the numerical sequence for an additional 175 to 185 degrees.

Image1.3.1

9. Apply clean engine oil to Area (X) of the quill tube collar (refer to Image1.4.1). Repeat for the opposite collar. Apply clean engine oil to the ends of tube assembly (refer to Image1.4.2). Install tube assembly (8) along with new o-ring seals. Install new quill tube bolts and washers (11 & 12) hand tight. Evenly tighten bolts (12) to a torque of 20 N.m (15 lb ft).Evenly tighten bolts (11) to a torque of 20 N.m (15 lb ft). Evenly tighten bolts (12) to a torque of 40 N.m (30 lb ft). Evenly tighten bolts (11) to a torque of 40 N.m (30 lb ft).

10. Connect harness assembly (6). Replace the O-ring seals on both ends of the tube assembly (5). Install tube assembly (5). Install the washer and bolt (7).

11. Position inlet manifold (10) with new gaskets. Install bolts (9) and tighten to proper torque. Position exhaust manifold (2) with new gaskets. Install bolts (1) and tighten to proper torque.

NOTE: Orientation of the bridge assemblies - Ensure that the cutout feature is positioned inward toward the rocker arm shaft assembly during installation. Also ensure that the pushrods are seated in the bores. Use a flashlight in order to ensure that the pushrods are in the lifter cups.

12. Replace the current valve bridges with the new 356-6939 Valve Bridges. Install pushrods and rocker shaft (use a flash light to ensure push rods are properly seated in valve lifter cup and valve stem is properly inserted in valve bridge pocket). Tighten rocker shaft bolts to a torque of 200 +/- 30 N.m (147 +/- 22 lb ft).

13. Fill the cooling system with coolant.

15. Set the valve lash to 1.0 mm on intake and 1.5mm on exhaust.