PRODUCT SUPPORT PROGRAM FOR INSTALLING CUFFED CYLINDER SYSTEM COMPONENTS ON CERTAIN 793D OFF-HIGHWAY TRUCKS EQUIPPED WITH 3500 HIGH DISPLACEMENT ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING CUFFED CYLINDER SYSTEM COMPONENTS ON CERTAIN 793D OFF-HIGHWAY TRUCKS EQUIPPED WITH 3500 HIGH DISPLACEMENT ENGINES

Usage:

TEBE5397-00

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09Nov2016

L100

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Containment - After Failure Only (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR INSTALLING CUFFED CYLINDER SYSTEM COMPONENTS ON CERTAIN 793D OFF-HIGHWAY TRUCKS EQUIPPED WITH 3500 HIGH DISPLACEMENT ENGINES
1290 1201 1225 1239 1216 1214 1213 1331 7750		PS61336

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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 "PS61336" 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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TERMINATION DATE

30Nov2018

PROBLEM

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In high load conditions, certain single piece forged steel pistons used in the Single Piece Cylinder System may develop hard deposits at the top land of the piston.
If severe enough, deposits may wear the liner crosshatch, compromising oil control and contributing to additional deposit formation, wear, and blowby.

AFFECTED PRODUCT

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Model	Identification Number
793D	FDB01140, 1145, 1300, 76001, 76003-76004

PARTS NEEDED

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Qty	Part Number	Description
3	10R9224	CYLINDER PACK AS
16	20R5616	CYLINDER PACK AS
16	4421340	KIT-GASKET (SCH)
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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This Service Letter provides support for replacing Single Piece Cylinder System components provided both of the following conditions are met AND supporting documentation is attached to the claim.

Condition 1: Air Intake System Cleanliness

Customer must demonstrate that silicon levels have been maintained at or below 9 PPM by producing archived SOS reports. This program DOES NOT support engines affected by dust, dirt or debris ingress due to a faulty or compromised air intake system.

Condition 2: Excessive Crankcase Blowby

Customer must demonstrate that the engine is generating excessive blowby according to REHS7857, Special Instruction, "Testing for Excessive Cylinder Blowby in 3500 Engines". Some amount of blowby is generated by every engine and the amount of blowby typically increases with age as parts wear. The repairing Dealer must use REHS7857, Special Instruction, "Testing for Excessive Cylinder Blowby in 3500 Engines", in order to determine if the engine is exhibiting signs of excessive blowby. If both of these conditions are met, this Service Letter can be applied in one of the following two ways, but not both. This Service Letter can only be applied
one time for each affected product.

1. Out of Chassis Rebuilds*

(All cylinders replaced using Cuffed Cylinder System (20R-5616 Cylinder Pack).
This option is available for all qualifying engines up to 14,000 hours.

*For the out of chassis rebuild option, 10R9224 cylinder packs are NOT used.

OR

2. In Chassis Repairs**

(Individual cylinders replaced using Single Piece Cylinder System components.)
This option is only available for engines with 12,000 to 14,000 hours and up to
three (3516) cylinders needing repair.

**For the in chassis repair option, only 10R9224 cylinder packs and 4421340
gasket kits are used.

**DO NOT mix single piece forged steel pistons designed for the Single Piece
Cylinder System with single piece forged steel pistons designed for the Cuffed
Cylinder System. Rotating masses and system dynamics are different between the designs and are not compatible within the same engine.

Refer to SENR1126, Disassembly and Assembly, and M0064186, Service Magazine,
"New Cylinder Pack Components Are Now Available for Certain 793 and 797 High Displacement Off-Highway Truck Engines", for rework guidance.

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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%
0-6000 hrs, 0-32 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
6001-8000 hrs, 33-38 mo	73.0%	95.0%	0.0%	0.0%	20.0%	5.0%
8001-10000 hrs, 39-44 mo	67.0%	75.0%	0.0%	0.0%	25.0%	25.0%
10001-12000 hrs, 45-50 mo	40.0%	55.0%	0.0%	0.0%	45.0%	45.0%
12001-14000 hrs, 51-56 mo	7.0%	35.0%	0.0%	0.0%	70.0%	65.0%

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NOTE: This is a 352.0-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.
Note: Hours listed in allowance table are engine hours, not machine SMU. Out of Chassis Rebuilds: PARTS: All cylinders replaced using Cuffed Cylinder System (20R-5616 Cylinder Pack). 10R9224 cylinder packs are not used for out of chassis rebuilds. LABOR: 352 hours, which includes allowance for engine removal and installation. ******************************************************************************* In Chassis Repairs: In order to minimize downtime and increase likelihood of reaching targeted service life, customers may elect to replace cylinder packs with packs of like kind in up to three (3) of their worst performing cylinders while the engine remains in chassis. To qualify, engine hours must be between 12,000 and 14,000 and meet the failure conditions previously described. PARTS: 10R9224 cylinder packs (Up to 3 packs) 4421340 gasket kits (Up to 3 kits) Other components listed in the Parts Needed table are for out of chassis rebuilds only. LABOR: Up to 120 hours - 10 hours to troubleshoot, identify cylinders based on dynamic blowby testing - 40 hours allowed for removal and replacement of the first cylinder pack - 35 hours for each additional cylinder pack. - Maximum of three cylinder packs total.