PRODUCT SUPPORT PROGRAM FOR INSTALLING CUFFED CYLINDER SYSTEM COMPONENTS ON CERTAIN 793, 793B, 793C, 793D, 797, AND 797B OFF-HIGHWAY TRUCKS, EQUIPPED WITH 3500 HIGH DISPLACEMENT ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING CUFFED CYLINDER SYSTEM COMPONENTS ON CERTAIN 793, 793B, 793C, 793D, 797, AND 797B OFF-HIGHWAY TRUCKS, EQUIPPED WITH 3500 HIGH DISPLACEMENT ENGINES

Usage:

TEBE7825-00

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11Sep2018

K030
R050
R120
R12Z
R180
Z800

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Containment - After Failure Only (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR INSTALLING CUFFED CYLINDER SYSTEM COMPONENTS ON CERTAIN 793, 793B, 793C, 793D, 797, AND 797B OFF-HIGHWAY TRUCKS, EQUIPPED WITH 3500 HIGH DISPLACEMENT ENGINES
1201 1225		PS61401

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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 "PS61401" 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

30Sep2020

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
*****Group 1*****
797	5YW00223-00225, 231, 237, 258-259, 271-276
797B	JSM00124, 129, 134, 165-178, 180-190, 214-215, 232-234, 240, 245, 247-250, 257, 287-292, 294-295, 297, 299-301, 318-319, 333-337, 354-363, 366-368, 383-385, 390-392, 396-397, 403, 410-411, 414, 416-417, 419-421, 423, 425, 427, 429, 431, 433, 442, 444-445, 452, 454-455, 458-460, 463-471, 473-475

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*****Group 2*****
793	3SJ00008
793B	1HL00018-00019, 80, 107, 146-147, 155, 163, 232, 378, 419-420, 438-440, 479, 482, 500-503, 510, 513
793C	4AR00105, 118, 122-123, 127, 131, 144, 280-281, 294, 313, 318-320, 337-338, 345-346, 348, 397 ATY00463, 515, 630, 634, 636, 846-848, 861-862, 866, 869-872, 887-888, 893, 896, 906, 916, 918-920, 929-931, 954, 967-969, 976, 1007, 1088-1089, 1092-1093
793D	FDB00158, 260-261, 300-303, 337-339, 343, 365, 494-496, 545, 828-829, 851-857, 879, 888, 912-913, 916, 955, 978, 992-993, 1660-1662, 1672, 1674, 1676, 1704, 1706-1707, 1718, 1736, 1749-1750, 1755

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
6	10R9224	CYLINDER PACK AS
24	20R5616	CYLINDER PACK AS
24	4421340	KIT-GASKET (SCH)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 4% 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.
*****Group 2*****
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 2% 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 each of the following three conditions is 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: Reduced Oil Change Intervals
Customer must demonstrate an increasing trend of Nitration and Oxidation by producing archived SOS reports. A trend is defined as at least three consecutive samples with Nitration and Oxidation levels greater than the guidelines listed below.

- Nitration 12 UFM
- Oxidation 24 UFM

Customer must demonstrate action taken to reverse the trend by reducing oil change intervals. A reduced oil change interval strategy is defined as at least three consecutive attempts.

Condition 3: 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 all of these conditions are met, this Service Letter can be applied in one of the following two ways:

1. Out of Chassis Rebuilds*
All cylinders replaced using 20R-5616 cylinder packs. (Cuffed Cylinder System)
This option is available for all qualifying engines up to 14,000 hours.

* For the out of chassis rebuild option, 10R-9224 cylinder packs are NOT used.

OR

2. In Chassis Repairs**
In order to minimize downtime and increase likelihood of reaching targeted service life, customers may elect to replace a limited number of cylinder packs of their worst performing cylinders while the engine remains in chassis.

(Individual cylinders replaced using Single Piece Cylinder System components.)

**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.

NOTE: Piston pins are highly reusable. For this reason, the Parts Needed tables do not list piston pins for each cylinder.

NOTE: 10R9224 cylinder packs are needed only for in chassis repairs.

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%
*****Group 1*****
0-6000 hrs, 0-33 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
6001-8000 hrs, 34-39 mo	73.0%	95.0%	0.0%	0.0%	20.0%	5.0%
8001-10000 hrs, 40-40 mo	67.0%	75.0%	0.0%	0.0%	25.0%	25.0%
10001-12000 hrs, 41-45 mo	40.0%	55.0%	0.0%	0.0%	45.0%	45.0%
12001-14000 hrs, 46-48 mo	7.0%	35.0%	0.0%	0.0%	70.0%	65.0%

NOTE: This is a 528.0-hour job for Group 1 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.
Out of Chassis Rebuilds: PARTS: All cylinders replaced using 20R-5616 cylinder packs.(Cuffed Cylinder System) 10R-9224 cylinder packs are not used for out of chassis rebuilds. LABOR: 528 hours. 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 six (6) of their worst performing cylinders while the engine remains in chassis. PARTS: 10R9224 cylinder packs (Up to 6 packs) 4421340 gasket kits (Up to 6 kits) Other components listed in the Parts Needed table are for out of chassis rebuilds only. LABOR: Up to 225 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 six cylinder packs total. One set of connecting rod bearings per cylinder pack is allowed (if required).

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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%
*****Group 2*****
0-6000 hrs, 0-33 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
6001-8000 hrs, 34-39 mo	73.0%	95.0%	0.0%	0.0%	20.0%	5.0%
8001-10000 hrs, 40-40 mo	67.0%	75.0%	0.0%	0.0%	25.0%	25.0%
10001-12000 hrs, 41-45 mo	40.0%	55.0%	0.0%	0.0%	45.0%	45.0%
12001-14000 hrs, 46-48 mo	7.0%	35.0%	0.0%	0.0%	70.0%	65.0%

NOTE: This is a 352.0-hour job for Group 2 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.
Out of Chassis Rebuilds: PARTS: All cylinders replaced using 20R-5616 cylinder packs.(Cuffed Cylinder System) 10R-9224 cylinder packs are not used for out of chassis rebuilds. LABOR: 352 hours. 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. 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 six cylinder packs total. One set of connecting rod bearings per cylinder pack is allowed (if required).