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

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

Usage:

TEBE7836-02

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09Jul2018

(Revised 29Nov2018)

T120
V27E

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Containment - After Failure Only (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING ENGINE CYLINDER BLOCK ON CERTAIN 793D OFF-HIGHWAY TRUCKS
1000 1201 1221 1217		PS61392

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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 "PS61392" 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 09Jul2018 (Revised 29Oct2018) Service Letter. Changes have been made to the Problem, and Action Required.

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TERMINATION DATE

31Jul2020

PROBLEM

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The existing cylinder block can crack of fret on certain 793D Off-Highway Trucks. If crack of fretting prevents further reuse of the block, then the block must be replaced by new.

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
18	1011198	BEARING-CAMSHAFT
16	2688154	KIT-GASKET-SFI
1	3193857	KIT-GASKET(WP)
1	3492848	KIT-GASKET(RS)
1	3492894	KIT-GASKET(WLG)
1	3533971	BLOCK GP-CYL
16	3535995	KIT-SEAL (SCL)
16	4421340	KIT-GASKET (SCH)
4	4461354	KIT-GASKET (T)
1	5120818	KIT-GASKET (OCL)
1	5120836	KIT-GASKET (FS)
1	5120842	KIT-GASKET (CL)
1	5123105	GASKET KT-ACL
1	BULK_OIL	DEO 15W40 288L (1 DRUM 208L and 4 CANISTERS 20L
8	CLEANER_500ML	CLEANER 500ML (procure Locally)
4	GRINDING_DISK	GRINDING DISK (procure locally)
1	LOCTITE_50ML	LOCTITE 50ML (procure locally)
2	SEALANT_FLANGE	SEALANT FLANGE (procure locally)
1	SEALANT_GASKET	SEALANT GASKET (procure locally)
1	TOWEL	TOWEL (procure locally)
1	WRAPING_MATERIAL	WRAPING MATERIAL (procure locally)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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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Follow Reuse and Salvage Guide for 3500 Engine Cylinder Blocks, Media Number SEBF8255, in order to find cracks and determine if the block is reusable.
If crack and/or fretting does not allow reuse according to the SEBF8255 - replace engine block.
To replace the block, use Disassembly and Assembly Guide for 3500 and 3500B High Displacement Engines for Caterpillar Built Machines, Media Number SENR1126.

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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%
0-18000 hrs, 0-18 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
18001-27000 hrs, 19-54 mo	67.0%	75.0%	0.0%	0.0%	25.0%	25.0%
27001-36000 hrs, 55-72 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%
36001-45000 hrs, 73-90 mo	13.0%	25.0%	0.0%	0.0%	65.0%	75.0%
45001-54000 hrs, 91-108 mo	0.0%	0.0%	0.0%	0.0%	75.0%	100.0%

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NOTE: This is a 244.0-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.
Hours in the allowance table are the engine hours, and not the truck hours. Maximum $300 per claim is allowed for all misc. items that must be procured locally. Additionally, 288 liters of Engine Oil (1 drum 208L and 4 canisters 20L each) allowed, not included into those $300.

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