PRODUCT SUPPORT PROGRAM FOR REPLACING 516-9693 CYLINDER LINERS ON CERTAIN 777E OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING 516-9693 CYLINDER LINERS ON CERTAIN 777E OFF-HIGHWAY TRUCKS

Usage:

TEBE7636-02

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24Jul2018

(Revised 23May2019)

D-381

O-388

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After Failure Only	PRODUCT SUPPORT PROGRAM FOR REPLACING 516-9693 CYLINDER LINERS ON CERTAIN 777E OFF-HIGHWAY TRUCKS
1201 1216 7555 1000		PS53826

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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 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 "PS53826" 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.

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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 24Jul2018 (Revised 26Sep2018) Service Letter. Changes have been made to the Affected Product.

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TERMINATION DATE

31Jul2020

PROBLEM

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The existing 516-9693 Cylinder Liners can crack in the bottom o-ring grooves on certain 777E Off-Highway Trucks. If the existing liner cracks it will allow oil and coolant mixing.

AFFECTED PRODUCT

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Model	Identification Number
777E	KDP00388-00790, 902-904 KDZ00201-00214, 216-220, 223-232, 234-248

PARTS NEEDED

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Qty	Part Number	Description
2	1R1808	FILTER-LUBE
1	3P0650	SEAL-O RING
2	5D5958	SEAL-O-RING
4	5E8771	SEAL-O-RING
3	5P0537	WASHER-HARD
1	5P8068	SEAL-O-RING
4	5P8356	SEAL-O-RING
2	5P8429	SEAL-O-RING
1	8C3089	SEAL-O-RING
12	8S9191	BOLT
12	9L5854	BAND-FILLER
12	9X7317	SEAL-FUEL SYSTEM
6	0315085	BOLT-LOCKING
2	1075769	SEAL-O-RING
1	1121102	SEAL-O-RING
1	1121574	SEAL-O-RING
1	1123259	SEAL-O RING
2	1178801	SEAL-O-RING
12	1550809	SEAL-LINER
12	1550810	SEAL-LINER
12	1552793	SEAL-LINER
2	1978418	GASKET
2	1978419	GASKET
12	2239159	RING-PISTON
2	2253099	GASKET-CYL HEAD
2	2265613	GASKET
12	2303728	SEAL-FUEL SYSTEM
12	2303775	SEAL-FUEL SYSTEM
12	2323226	BEARING-ROD
2	2391139	SEAL
12	2391388	GASKET
12	2465659	RING-PISTON-OIL
12	3445153	RING-PISTON
2	3499659	GASKET
1	3531648	GASKET-OIL PAN
2	3548484	GASKET-PLATE
48	3591439	SEAL AS-WATER
12	5560701	LINER-CYLINDER
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 5% 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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If the mixing of oil and coolant has occurred ensure that all appropriate trouble shooting is completed before removal of the liners for inspection.

If cracked liner is identified refer to the appropriate Disassembly and Assembly manual for repair.

NOTE: Date code of failed liner must be entered into warranty claim. Date Code is locate on bottom of liner, on rim.

NOTE: An AFA will be required for warranty claim if failure is beyond oil and coolant mixing.

If cooling system has been contaminated , follow the guidelines for cleaning the cooling system with a non-foaming dish detergent within SEBU6250, "Conventional Coolant/Antifreeze Cooling System Maintenance". Refer to appropriate OM&M / Special instructions for proper coolant fill procedure.

If cracked liner is identified refer to the appropriate Disassembly and Assembly manual for repair.

NOTE: Date code of failed liner must be entered into warranty claim. Date Code is locate on bottom of liner, on rim.

NOTE: An AFA will be required for warranty claim if failure is beyond oil and coolant mixing.

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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%
0-7500 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
7501-11000 hrs, 49-60 mo	53.0%	50.0%	0.0%	0.0%	35.0%	50.0%
11001-15000 hrs, 61-65 mo	27.0%	25.0%	0.0%	0.0%	55.0%	75.0%

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NOTE: This is a 122.0-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.
This is a 122 hour job: 80 hours to Remove and Install engine. 42 hours to rework engine. To include all related tasks including but not limited to: - Disconnect and connect - Disassembly - Cleaning - Reassembly - Testing of the repair NOTE: Due to the nature of this program additional Caterpillar parts that require replacement during the mechanical disassembly and assembly on the mid frame section may be claimed as required. These parts are limited to seals, gaskets, bolts, washers, nuts, locknuts, rings, clips, and clamps.