PRODUCT SUPPORT PROGRAM FOR CLEANING THE BEARING SURFACES OF THE CONNECTING ROD AND BEARING CAP FACES AND REPLACING THE CONNECTING ROD BEARINGS IN C175-16 AND C175-20 ENGINES INSTALLED IN CERTAIN 793F, 795F, 797B, AND 797F OFF-HIGHWAY TRUCKS Caterpillar
PRODUCT SUPPORT PROGRAM FOR CLEANING THE BEARING SURFACES OF THE CONNECTING ROD AND BEARING CAP FACES AND REPLACING THE CONNECTING ROD BEARINGS IN C175-16 AND C175-20 ENGINES INSTALLED IN CERTAIN 793F, 795F, 797B, AND 797F OFF-HIGHWAY TRUCKS
Usage:
REBE6365-11
Show/hide table
05Aug2010
(Revised 03Oct2013)
U-298
A-230
D-255
O-114
Show/hide table
Before/After
PRODUCT SUPPORT PROGRAM FOR CLEANING THE BEARING SURFACES OF THE CONNECTING ROD AND BEARING CAP FACES AND REPLACING THE CONNECTING ROD BEARINGS IN C175-16 AND C175-20 ENGINES INSTALLED IN CERTAIN 793F, 795F, 797B, AND 797F OFF-HIGHWAY TRUCKS
1218
PS43135
Show/hide table
NOTE:
This Program must 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 "PS43135" as the Part Number
and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code.
If administered after failure, use "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
Show/hide table
Show/hide table
NOTE:
This Revised Service Letter replaces the 05Aug2010 (Revised 15Jul2013) Service Letter. A change has been made to Service Claim Allowances.
Show/hide table
TERMINATION DATE
30Apr2017
PROBLEM
Show/hide table
The 3223030/">322-3030 and 3223031/">322-3031 connecting rod bearings in C175-16 and C175-20 engines installed in certain 793F, 795F, 797B, and 797F Off-Highway Trucks need to be replaced at 8,000 hours of engine operation. Bearing interface surfaces of the rod and rod cap must be properly cleaned prior to the installation of the new bearings. Failure to carry out the cleaning operation and bearing replacements could result in bearing failure and significant machine down time and cost to repair.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 19% 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.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 20% 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
This letter applies to all C175 engine serial numbers 999 and lower. The affected engine serial number prefixes are A4K, LLM, JTL, B7B, and B7C.
See attached rework procedure.
Show/hide table
SERVICE CLAIM ALLOWANCES
Show/hide table
Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-6000 hrs, 0-12 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
6001-9000 hrs, 13-36 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
NOTE: This is a 140.0-hour job for Group 1
If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
140.0 hours will be allowed for repair Option 1. (In chassis repair) 250.0 hours will be allowed for repair Option 2. (Out of chassis repair)
NOTE: Claims submitted for repairs performed 0 - 6,000 hours / 0 - 12 months will only be allowed for repairs performed After Failure.
Show/hide table
Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-6000 hrs, 0-12 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
6001-9000 hrs, 13-36 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
NOTE: This is a 110.0-hour job for Group 2
If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
110.0 hours will be allowed for repair Option 1. (In chassis repair) 210.0 hours will be allowed for repair Option 2. (Out of chassis repair)
NOTE: Claims submitted for repairs performed 0 - 6,000 hours / 0 - 12 months will only be allowed for repairs performed After Failure.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Return all connecting rod bearings that have been removed from the engine via the Send-It-Back system. A Send-It-Back Part Return Request (PRR) will be generated when filing the claim with this program "PS43135" as the part causing failure.
Rework Procedure
Repair option 1: In chassis repair.
Repair option 2: Out of chassis repair. Labor hours are provided for the removal and installation of the engine. Parts for the removal and installation of the engine are not provided by this program.
Replace all 3223030/">322-3030 and 3223031/">322-3031 connecting rod bearings in C175-16 and C175-20 engines installed in 793F, 795F, 797B, and 797F Off-Highway Trucks at 8,000 hours of engine operation.
Refer to KENR6052 "Connecting Rod Bearings - Remove and Install" for bearing removal and installation instructions.
NOTE: Each rod end and rod cap surface must be properly cleaned once the old bearing is removed. It is absolutely necessary that the surfaces be cleaned using only brake cleaner and a lint-free cloth. EXERCISE CARE SO AS NOT TO LEAVE ANY DIRT OR DEBRIS FROM THE CLOTH ON THE FRACTURE-FACE SURFACES OF THE ROD AND CAP! PROTECT OIL PASSAGES ON THE CRANK JOURNALS FROM CLEANING FLUID ENTRY!
This service letter includes all new 428-7386 Connecting Rod Bolts. Lubricate each bolt with 334-0519 Molylube, fully coating under the head of the connecting rod bolt (1), the elastomer rings on the center of the bolt shank (2), and the threads of the bolts (3). See image 1.2.1 below.
Note: The 428-7386 bolts should only be cleaned with a dry lint-free towel and if needed, 4C-6796 Mineral Spirits is one solvent that is compatible with the elastomer rings. Never clean the bolts in a parts washer or with solvents such as brake cleaner or carburetor cleaner. They could damage the elastomer rings.
Note: A video demonstrating the proper assembly procedure for the rod bolts is available at https://dealer.cat.com/Service-Training/Instructional-Videos
Image1.2.1
Ensure the connecting rod cap and rod end bolt holes are dry and free of debris. Install six lubed connecting rod bolts thru the washer plates and into the connecting rod cap by simultaneously rotating and pushing each bolt. It is required to slowly rotate the bolt during installation to prevent damage to the elastomer rings. Do not exceed 700 RPM with a rundown tool. This could damage the elastomer rings.
Install the connecting rod cap over the crank journal. Engage the threads of all six bolts before the joint is drawn closed on either side. The order of engaging the threads should be by bolt number 1-2-3-4-5-6 (see image 1.3.1 for bolt numbering). Engaging bolts 1 and 2 first helps center the cap with the rod such that bolts 3-4-5-6 will go in straight and not cause damage to the starting thread. The bolt should be rotated slowly (less than 700 RPM) during installation to prevent damage to the elastomer rings. Do not tap the bolt since an impact between the end of the bolt and the start of the threads could cause thread damage.
Follow the connecting rod bolt torque procedure documented below. This is the torque procedure for all type 1 connecting rods. Image 1.3.1 below shows the connecting rod bolt numbering sequence as viewed from beneath the engine. Note: Bolt (1) is always identified as the center bolt on the bearing tab side of the connecting rod.
Image1.3.1
Step 1: Tighten bolts (1) and (2) to a torque of 105 +/- 5 N.m (77 +/- 4 lb ft). Step 2: Tighten bolts (3) and (4) to a torque of 105 +/- 5 N.m (77 +/- 4 lb ft). Step 3: Tighten bolts (5) and (6) to a torque of 105 +/- 5 N.m (77 +/- 4 lb ft).
Step 4: Repeat Steps 1 through 3
Step 5: Turn bolts (3) and (4) for an additional 90 +/- 5 degrees. Step 6: Turn bolts (5) and (6) for an additional 90 +/- 5 degrees. Step 7: Turn bolts (1) and (2) for an additional 90 +/- 5 degrees.
NOTE: Claims submitted for repairs performed 0 - 6,000 hours / 0 - 12 months will only be allowed for repairs performed After Failure.
NOTE: The piston support tooling referenced in the Disassembly and Assembly guide is necessary for this procedure. The tool part number is 369-4008 Piston Support.
NOTE: This service letter may be claimed more than once if there is a need to extend the time to overhaul to meet Maintenance And Repair Contracts.
