PSP TO REPLACE CYLINDER PACKS ON CERTAIN D8R TRACK-TYPE TRACTORS AND 583R PIPELAYERS TO REDUCE OIL CONSUMPTION - PS5 557 - MAILED US AND CANADA, CACO, COFA, CAPL, CCL, COSA - REVISED 03/01 Caterpillar

March 30, 1999
(Revised March 2001)
SEBE6835-04
March 30, 1999
(Revised March 2001)
U-86
A-69
AU-53
S-50
H-34
O-78
After failure only PRODUCT SUPPORT PROGRAM TO REPLACE CYLINDER
PACKS ON CERTAIN D8R TRACK-TYPE TRACTORS AND
583R PIPELAYERS TO REDUCE OIL CONSUMPTION
1213   PS5557
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
"PS5557" 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 30,
1999 (Revised April 2000) Service Letter. Changes
have been made to the Termination Date, Parts Needed,
and the Action Required.

March 31, 2002

Engines are reporting high oil consumption because of carbon
packing of the ring grooves.

Model Identification Number
***** Group 1 *****
D8R 7XM1-Up (With Engine 41Z1-7270)
9EM1-Up (With Engine 41Z1-7270)
***** Group 2 *****
D8R 7XM1-Up (With Engine 41Z7271-8065)
9EM1-Up (With Engine 41Z7271-8065)
***** Group 3*****
D8R 7XM1-Up (With Engine 41Z8066-12894)
9EM1-Up (With Engine 41Z8066-12894)
583 2XS1-Up (With Engine 41Z8066-12894)

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

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.

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% 30.0 0 0 0 0
0-48 mo
4001- 50% 21.0 0 0 37.5% 9.0
6000
0-48 mo
6001- 33.3% 12.0 0 0 50% 18.0
8000
0-48 mo
NOTE: This is a 30-hour job.

Handle the parts in accordance with your Warranty Bulletin on
warranty parts handling.
Attach. (1-Oil Consumption Claim Authorization Sheet)