PSP TO REPLACE CYLINDER PACKS ON CERTAIN 980G WHEEL LOADERS; 824G, 825G, AND 826G COMPACTORS TO REDUCE OIL CONSUMPTION - PS5 591 - MAILED US AND CANADA, CACO, COFA, CAPL, CCL, COSA - REVISED 03/2001
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PSP TO REPLACE CYLINDER PACKS ON CERTAIN 980G WHEEL LOADERS; 824G, 825G, AND 826G COMPACTORS TO REDUCE OIL CONSUMPTION - PS5 591 - MAILED US AND CANADA, CACO, COFA, CAPL, CCL, COSA- REVISED 04/2000
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.
March 28, 1999 (Revised March 2001) SEBE6833-04 March 28, 1999 (Revised March 2001) U-84 A-67 AU-51 S-48 H-32 O-76 After failure only PRODUCT SUPPORT PROGRAM TO REPLACE CYLINDER PACKS ON CERTAIN 980G WHEEL LOADERS; 824G, 825G, AND 826G COMPACTORS TO REDUCE OIL CONSUMPTION 1213 PS5591 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 "PS5590" 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: 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. NOTE: This Revised Service Letter replaces the March 28, 1999 (Revised April 2000) Service Letter. Changes have been made to the Termination Date, Parts Needed, and the Action Required.
Termination Date
March 31, 2002
Problem
Engines are reporting high oil consumption because of carbon packing of the ring grooves.
Affected Product
Model Identification Number ***** Group 1 ***** 980G 9CM1-Up (With Engine 41Z1-7270) 2KR1-Up (With Engine 41Z1-7270) 2SR1-Up (With Engine 41Z1-7270) 824G 4SN1-Up (With Engine 41Z1-7270) 825G 6NR1-Up (With Engine 41Z1-7270) 826G 7LN1-Up (With Engine 41Z1-7270) ***** Group 2 ***** 980G 9CM1-Up (With Engine 41Z7271-8065) 2KR1660-Up (With Engine 41Z7271-8065) 2SR432-Up (With Engine 41Z7271-8065) 824G 4SN368-Up (With Engine 41Z7271-8065) 825G 6RN329-Up (With Engine 41Z7271-8065) 826G 7LN324-Up (With Engine 41Z7271-8065) ***** Group 3***** 980G 9CM1-Up (With Engine 41Z8066-12894) 2KR1804-Up (With Engine 41Z8066-12894) 2SR447-Up (With Engine 41Z8066-12894) 824G 4SN380-Up (With Engine 41Z8066-12894) 825G 6RN334-Up (With Engine 41Z8066-12894) 826G 7LN350-Up (With Engine 41Z8066-12894)
Parts Needed
Quantit Part Number Description y ***** Group 1 ***** 6 0R9847 CYLINDER PACK 6 1663650 TUBE AS-OIL JET 6 1501156 BOLT -OIL JET 1 9Y1792 RETAINER (IF REQUIRED) 6 7W4487 WASHER 6 9Y7735 BEARING 6 9L9098 SEAL - NOZZLE CARBON DAM ***** Group 2 ***** 6 0R9847 CYLINDER PACK 6 1663650 TUBE AS-OIL JET 1 9Y1792 RETAINER 6 7W4487 WASHER 6 9Y7735 BEARING 6 9L9098 SEAL - NOZZLE CARBON DAM ***** Group 3 ***** 6 0R9847 CYLINDER PACK 6 1580449 TUBE AS-OIL JET 1 9Y1792 RETAINER 6 7W4487 WASHER 6 9Y7735 BEARING 6 9L9098 SEAL - NOZZLE CARBON DAM
Action Required
Complete documentation of the oil control concern is required prior to applying the program. This documentation is accomplished by providing units (liters, gallons) of fuel used divided by units (liters, gallons) of oil used for the last 30 days. See SERVICE WARRANTY BULLETIN SELD0552, which contains the oil consumption test report Form #01-081227, for additional details. Please indicate if the FACTORY governor seal is on the engine. If the FACTORY seal is not present, the current engine rack setting must be provided. Use the attached sheet (OIL CONSUMPTION CLAIM AUTHORIZATION SHEET) to forward this information to the 3400 Product Health group to obtain an authorization number for this single machine repair. The returned authorization number for this single machine must appear on the claims report to obtain claim payment. Claims which do not have this data attached may be denied. Remove six tube as. - oil jet and bolts, six cylinder packs, six fuel injection nozzle washers (nozzle to adapter). Inspect the oil pump bypass spring retainer for correct part number. The spring retainer should be 9Y1792. Install six 0R9847 Cylinder Packs, six Tube As-Oil Jet and Bolts (Torque 3/8 inch bolts to 25+/-6 Nm 18+/-4 lb ft) (Torque 7/16 inch bolts to 40+/-8 Nm 30+/-6 lbft), 9Y1792 Oil Pump Spring Retainer if required. Install the six 7W4487 Fuel Injection Nozzle Washers (nozzle to adapter) (black) (1.27 mm (0.050) inch thick) and 9L9098 Carbon Dam Seal if required. NOTE: Be sure to remove all carbon from bore and end of injector adapter in cylinder head as the 7W4487 Washer allows the nozzle to seat deeper into the adapter. Install related gaskets and seals.
Service Claim Allowances
Product Caterpillar Dealer Suggested Customer smu/age Suggested whicheve r comes first Parts Labor Parts Labor Parts Labor (D/N) Hrs Hrs (C/L) Hrs (Cost) (Sell) 0-4000 100% 50.0 0 0 0 0 0-48 mo 4001- 50% 35.0 0 0 37.5% 15.0 6000 0-48 mo 6001- 33.3% 20.0 0 0 50% 30.0 8000 0-48 mo NOTE: This is a 50-hour job.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. Attach. (1-Oil Consumption Claim Authorization Sheet)
Caterpillar Information System:
PSP TO REPLACE CYLINDER PACKS ON CERTAIN 980G WHEEL LOADERS; 824G, 825G, AND 826G COMPACTORS BECAUSE OF PISTON DEBONDING - PS5 592 - MAILED US AND CANADA, CACO, COFA, CAPL, CCL, COSA - REVISED 03/01 PSP TO REPLACE CYLINDER PACKS ON CERTAIN 980G WHEEL LOADERS; 824G, 825G, AND 826G COMPACTORS BECAUSE OF PISTON DEBONDING - PS5 592 - MAILED US AND CANADA, CACO, COFA, CAPL, CCL, COSA - REVISED 03/01
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Product Support Program For Replacing The Cover Group On Certain AP-650B, AP-800C, AP-1000B, AP-1050B, AP-1055B Asphalt Pavers; And On Certain Barber-Greene BG-225C, BG-230, BG-245C, BG-260C, BG-2455C Asphalt Pavers Manufactured By Caterpillar Product Support Program For Replacing The Cover Group On Certain AP-650B, AP-800C, AP-1000B, AP-1050B, AP-1055B Asphalt Pavers; And On Certain Barber-Greene BG-225C, BG-230, BG-245C, BG-260C, BG-2455C Asphalt Pavers Manufactured By Caterpillar
Product Support Program For Inspecting The Tow Point Cylinder On Certain AP-1055B Asphalt Pavers; And On Certain Barber-Greene BG-2455 Asphalt Pavers Manufactured By Caterpillar Product Support Program For Inspecting The Tow Point Cylinder On Certain AP-1055B Asphalt Pavers; And On Certain Barber-Greene BG-2455 Asphalt Pavers Manufactured By Caterpillar
Product Support Program For Improving Undercarriage Performance And Belt Tracking On Certain AP-1055B Asphalt Pavers; And On Certain Barber-Greene BG-2455C Asphalt Pavers Manufactured By Caterpillar Product Support Program For Improving Undercarriage Performance And Belt Tracking On Certain AP-1055B Asphalt Pavers; And On Certain Barber-Greene BG-2455C Asphalt Pavers Manufactured By Caterpillar
New Engine Software Needs To Be Installed On 793, 793B And 793C Off-Highway Trucks New Engine Software Needs To Be Installed On 793, 793B And 793C Off-Highway Trucks
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Product Support Program For Reworking The Air Conditioner Compressor Belts That May Loosen And/Or Come Off On Certain 928G Wheel Loaders And IT28G Integrated Tool Carriers Product Support Program For Reworking The Air Conditioner Compressor Belts That May Loosen And/Or Come Off On Certain 928G Wheel Loaders And IT28G Integrated Tool Carriers
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Product Support Program For Updating The MPC-10 Material Module Update On Certain AP-650B, AP-1000B, AP-1050B, And AP-1055B Asphalt Pavers; And On Certain Barber-Greene BG-225C, BG-245C, BG-260C, And BG-2455C Asphalt Pavers Manufactured By Caterpilla Product Support Program For Updating The MPC-10 Material Module Update On Certain AP-650B, AP-1000B, AP-1050B, And AP-1055B Asphalt Pavers; And On Certain Barber-Greene BG-225C, BG-245C, BG-260C, And BG-2455C Asphalt Pavers Manufactured By Caterpilla
Product Support Program For Replacing The Transmission Shift Control On Certain 120H, 135H, 140H, 143H, 160H, 163H, 12H, And 24H Motor Graders Product Support Program For Replacing The Transmission Shift Control On Certain 120H, 135H, 140H, 143H, 160H, 163H, 12H, And 24H Motor Graders
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Product Support Program For Replacing The Fuel Nozzles On Certain D25D, D30D, D250E, D300E, Articulated Trucks; Challenger 65D Agricultural Tractors; 970F Wheel Loaders; And 615C Scrapers Product Support Program For Replacing The Fuel Nozzles On Certain D25D, D30D, D250E, D300E, Articulated Trucks; Challenger 65D Agricultural Tractors; 970F Wheel Loaders; And 615C Scrapers
Service Letter Cancellation Service Letter Cancellation
Engine Emission Labels And An Owner Notification Letter Will Be Provided to Owners Of Certain 914G Wheel Loaders And IT14G Integrated Tool Carriers Engine Emission Labels And An Owner Notification Letter Will Be Provided to Owners Of Certain 914G Wheel Loaders And IT14G Integrated Tool Carriers
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PRODUCT SUPPORT PROGRAM FOR REPLACING FAILED INJECTORS ON CERTAIN 988F AND 990 WHEEL LOADERS; D9R TRACK-TYPE TRACTORS; 769D, 771D, 773D, AND 775D TRUCKS; 631E, 633E, 637E, 651E AND 657E WHEEL TRACTOR SCRAPERS; 834B WHEEL DOZER; 836 WHEEL TRACTOR SCRA PRODUCT SUPPORT PROGRAM FOR REPLACING FAILED INJECTORS ON CERTAIN 988F AND 990 WHEEL LOADERS; D9R TRACK-TYPE TRACTORS; 769D, 771D, 773D, AND 775D TRUCKS; 631E, 633E, 637E, 651E AND 657E WHEEL TRACTOR SCRAPERS; 834B WHEEL DOZER; 836 WHEEL TRACTOR SCRA