PRODUCT SUPPORT PROGRAM FOR REPLACING CYLINDER PACKS ON CERTAIN 793D OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING CYLINDER PACKS ON CERTAIN 793D OFF-HIGHWAY TRUCKS

Usage:

TEBE2074-02

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18Dec2014

(Revised 24Feb2016)

V27E

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Containment - After Failure Only (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING CYLINDER PACKS ON CERTAIN 793D OFF-HIGHWAY TRUCKS
1225 1223 0705 0701 1000 1100 1124		PS61280

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NOTE:	Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.
NOTE:	This Containment Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer and service rep. Obtain the service reps Goodwill Approver Code before completing the repair. EAME dealers should use their standard Industry Group specific goodwill approval codes. The Goodwill Approver Code must be included when submitting the claim.

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NOTE:

When reporting the repair, use "PS61280" as the Part Number and "7777" as the Group Number. Use "96" as Warranty Claim Description Code and use "Z" as the SIMS Description Code.

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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.

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NOTE:	This Revised Service Letter replaces the 18Dec2014 (Revised 13Jul2015) Service Letter. A change has been made to the Termination Date.

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TERMINATION DATE

28Feb2017

PROBLEM

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Certain 793D Off-Highway Trucks are experiencing top and middle piston ring failures. This Containment Service Letter can be applied to the Affected Product until the true root cause for failure is determined and corrected.

AFFECTED PRODUCT

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Model	Identification Number
793D	FDB01364-01367, 1371, 1434-1437, 1492-1493, 1496-1497, 1505, 1558-1559, 1571, 1573-1574, 1582, 1586, 1626, 1628, 1630-1632, 1801-1805

PARTS NEEDED

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Qty	Part Number	Description
3	4P4460	GASKET-TURBO (As Required)
3	4S5898	SEAL-O-RING (As Required)
6	5P0840	SEAL-O-RING (As Required)
6	6V3917	SEAL-O-RING (As Required)
3	6V9769	SEAL-O-RING (As Required)
3	7E2632	GASKET-OIL PAN (As Required)
3	7N5080	GASKET-MANIFOLD (As Required)
6	7N7559	GASKET (As Required)
3	10R9224	CYLINDER PACK AS (As Required)
6	1123540	SEAL-O-RING (As Required)
3	1272176	SEAL-INTEGRAL (As Required)
3	1445692	GASKET-PLATE (As Required)
3	2302520	BEARING-CONN ROD (As Required)
3	2407032	SEAL-PIP (As Required)
3	2415928	GASKET AS (As Required)
3	2720760	SEAL (As Required)
3	3208974	GASKET AS (As Required)
3	3628264	GASKET-CYL HEAD (As Required)
12	4200652	SEAL AS-WATER (As Required)
12	4200653	SEAL AS-WATER (As Required)
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

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Refer to the troubleshooting guide in the attached Rework Procedure to determine the cylinders with suspected broken piston rings.
Proceed with replacing cylinder packs with failed piston rings once identified.

NOTES:
This program WILL support the proactive replacement of up to 3 cylinder packs that fail the troubleshooting guidelines.

This program WILL NOT support the replacement of engines that have had piston ring failures as a result of dust, dirt or debris ingress as a result of a faulty air intake system.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-9000 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
9001-16000 hrs, 49-72 mo	33.0%	100.0%	0.0%	0.0%	50.0%	0.0%

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NOTE: This is a 110.0-hour job 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.
10 hours will be allowed for troubleshooting the system in the attached procedure. 40 hours will be allowed for the replacing of the first cylinder pack with failed rings. 35 additional hours will be allowed for each additional cylinder pack with failed rings.

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PARTS DISPOSITION

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

Rework Procedure

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Checking Crankcase Pressure Changes to Detect Failed Piston Rings

Introduction:

This test can detect a single cylinder that has worn/broken piston rings and is not performing correctly.

The test kit can be assembled from common material that will be found in most shops.

This test uses the crank case breathers or T-hoses, where all venting locations are fitted with caps or plugs. One plug is drilled to 3/4 inch to provide exhaust restriction, one is fitted with a 1/8 inch hose barb fitting affixed to it, and all the others are capped off. A manometer is then used in conjunction with the cylinder cutout function in Caterpillar ET to determine the crank case pressure drop, as each cylinder is cut out during idling.

Needed for the Test Kit

3 ABS Black Plastic Caps, one 1/2 inch ID / two 1/4 inch OD used at plugs or 6 similar caps to seal off the individual breathers.

Drill a 3/4 inch hole in one plug or cap to provide restriction and amplify the signal to the manometer.

Install a threaded fitting into one cap that will allow a 1/8 inch hose barb fitting to be installed.

3 to 6 hose clamps (used to hold plugs or caps on breathers)
20 to 25 feet of 1/8" rubber hose that will not easily kink
1 digital manometer with a resolution of 0.01 inches of water

Example of part of a test kit and installation

Image1.1.1

Installation of the Test Kit

Place the plug or cap with the 3/4 inch hole on one breather or T-hose to provide restriction and amplify the signal to the manometer.

Use a different breather or T-hose with the cap or plug containing the 1/8 inch barb fitting installed. Run the 1/8 inch tube to the cab. Install the tube on the manometer and plug or cap the remaining T-hose or breathers as shown.

Examples of how to cap breathers

Image1.2.1

Testing of the Engine

At idle, with truck at operating temp of 170F or greater, take a stabilized pressure reading as indicated on the digital manometer, Record this value. This is the reference value for the whole engine. If the value exceeds 4 inched of water, there is excessive blowby. During the test you will want to verify that this reference value does not change significantly.

Perform a single cylinder cut out tests for each cylinder and allow the value to stabilize. Record the values from the manometer and list the values in the included chart.

The contribution to blowby of each cylinder is given by subtracting the stabilized value read during each cylinder cutout from the reference value as shown.

Example: Truck 550 ? FDB01150 ? 8WM02896.
Reference value (R) = 4.32 inches of water
Measured value by cutting unit 1 = 4.12 inches of water
Measured value when cutting unit 8 = 3.98 inches of water
Measured value when cutting unit 16 = 3.32 inches of water
Contribution cylinder 1 = (R) ? 4.12 = 0.20 inches of water (Cylinder is OK)
Contribution cylinder 8 = (R) ? 3.98 = 0.34 inches of water (Excessive Blowby)
Contribution cylinder 16 = (R) ? 3.32 = 1.00 inches of water (Failed Ring)

In this example, cylinder 16 is contributing 1 inches of water and should be evaluated along with cylinder 8.

Cylinder 8 does not likely have failed rings, but may have significant cylinder liner damage. Use Special Instruction, REHS7138, "New Cylinder Leak Test Procedure Available for 3500 Engines" or borescope the cylinder through the exhaust side plug or tattle tale valve cover holes. If necessary, a comparison should be made to a cylinder with a reading below 0.1 inches of water.

Evaluation Worksheet