PRODUCT SUPPORT PROGRAM FOR REPLACING CYLINDER LINERS ON CERTAIN C-15 TRUCK ENGINES

Usage:

SEBE8606-01

December 13, 2003
(Revised March 2004)
U-344
A-233
D-249
O-283
TT-27

Show/hide table

*After failure only*	PRODUCT SUPPORT PROGRAM FOR REPLACING CYLINDER LINERS ON CERTAIN C-15 TRUCK ENGINES
1216		PS50740

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 "PS50740" 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 December 13, 2003 Service Letter. Changes have been made to the Problem, Affected Product, Parts Needed, Action Required, Service Claim Allowances, and Rework Procedure.

TERMINATION DATE

December 31, 2005

PROBLEM

Cylinder Liners may need to be replaced when one fails on certain C-15 Truck Engines. A machining error can cause the cylinder liner to crack. This crack can result in the bottom of the cylinder liner separating from the liner flange. This problem applies to 1599778 and 1979322 Cylinder Liners and cylinder packs containing these liners.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
C-15	MBN12044-21022 6NZ91415-92097 C2A131-141
3406	8SB3066-3067
3406B	7XC12188-12259
3406C	2MZ562-583
3406E	4AS665-689

NOTE: In addition to the affected product listed above the engines that satisfy the following criteria are also covered:

6NZ using 0R8915 Pack

7XC all using 0R2861 Pack

4MG all using 0R2694, 0R2861 Packs

3ZJ all using 0R4281 Pack

1LW all using 0R8915 Pack

2WS all using 0R8915 Pack

5EK all using 0R4487, 0R8913 Packs

6TS all using 0R8913 Pack

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
* MBN engines *
0-5	1102220	SEAL-LINER-M
0-5	1426217	SEAL-O-RING
0-5	1427072	SEAL-LINER-C
0-5	1899771	RING-PISTON OIL CONTROL
0-5	1765749	RING PISTON INTERMEDIATE
0-5	1979322	LINER
1-6	10R1503	CYLINDER PACK
0-5	2257010	RING-PISTON TOP
* 6NZ, 1LW, 2WS engines *
Qty	Part Number	Description
0-5	1609874	Gasket kit*
0-5	1899771	RING-PISTON OIL CONTROL
0-5	1765749	RING PISTON INTERMEDIATE
0-5	1979322	LINER
1-6	0R8915	CYLINDER PACK
0-5	2257010	RING-PISTON TOP
* 5EK, 6TS *
Qty	Part Number	Description
0-5	1609874	Gasket kit*
0-5	7N-7078	RING-PISTON OIL CONTROL
0-5	144-5902	RING PISTON INTERMEDIATE
0-5	197-9322	LINER
1-6	0R-8913 OR 0R-4487	CYLINDER PACK
0-5	134-3761	RING-PISTON TOP
* 3ZJ *
Qty	Part Number	Description
0-5	1609874	Gasket kit*
0-5	7N-7078	RING-PISTON OIL CONTROL
0-5	2P-2817	RING PISTON INTERMEDIATE
0-5	197-9322	LINER
1-6	0R-4281	CYLINDER PACK
0-5	1W-9460	RING-PISTON TOP
* 4MG, 7XC *
Qty	Part Number	Description
0-5	1609874	Gasket kit*
0-5	7N-7078	RING-PISTON OIL CONTROL
0-5	2P-2817	RING PISTON INTERMEDIATE
0-5	159-9778	LINER
1-6	0R2694 OR 0R2861	CYLINDER PACK
0-5	1W-9460	RING-PISTON TOP

* This gasket kit contains all 3 liner seals.
Gaskets and seals as required in repair.

ACTION REQUIRED

See the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

Show/hide table

Product smu	Caterpillar		Dealer Suggested		Customer Suggested
	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
0-100,000 miles	100%	25.0	0	0	0	0
NOTE: This is a 25.0?hr job.
NOTE: When necessary overtime to complete repairs is covered by this service letter.

PARTS DISPOSITION

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

Attach. (1-Rework Procedure)

Rework Procedure

If one or more liners within the suspect date code are observed, complete the repair under this Service Letter. If no suspect liners are observed, repair under normal warranty guidelines.
NOTE: ONLY cylinder liners with DATE CODES of "090 3" through "106 3" and "134 3" through "200 3" should be replaced unless additional liners are damaged by failure. If a liner failure occurs: (After Failure Only) 1. Remove the oil pan and check the date code on all of the Liners.

2. If one or more liners within the suspect date code are observed, complete the repair under this Service Letter. If no suspect liners are observed, repair under normal warranty guidelines.

3. Remove the Cylinder Head.

4. Remove and replace Cylinder Liner/s or Cylinder Pack/s that have a suspect date code (90 3 ? 106 3) and 134 3 ? 200 3).

NOTE: For cylinders WITH cracked Liner(s): Use Remanufactured Cylinder Packs to repair the cylinders.

NOTE: For cylinders WITHOUT cracked Liner(s), with a suspect date code: Use new parts to replace ONLY the Liners and Piston Rings.

Replace parts as needed.
Include liner date code(s) in claim story.

Reference applicable Service Publications for making the repair.

Inspection Procedure

The liners can be inspected by removing the engine oil pan to inspect the liner date code. The liner date code is stamped on the bottom of the liner.

The DATE CODE format is as follows: The word "CAT " followed by the liner part number "1599778 or 1979322" with a space followed by a three digit code that indicate the DAY OF THE YEAR (1 through 365) then a space followed by a single digit that indicates the YEAR (1 through 9) followed by the SEQUENCE NUMBER of the cylinder liner. Some liners have been remarked with an additional "CAT" followed by a DATE CODE followed by "DD". These remarked liners are OK to use for repair.

Example, CAT 1979322 93 3 17305 the DATE CODE "93 3" indicates the 93rd day of the year 2003. (Illustration 1)

Cylinder liners with DATE CODES of "090 3" through "106 3" and "134 3" through "200 3" SHOULD NOT be used for repair.

Cylinder liners with DATE CODES of "107 3" through "133 3" are OK to use for repair.

Cylinder Liners that have been remarked with a second date code followed by "DD" are OK to use for repair. Example: CAT 1979322 93 3 1735 CAT 225 3 DD (Illustration 2)