PRODUCT SUPPORT PROGRAM FOR REPLACING THE 516-9693 CYLINDER LINERS ON CERTAIN 834K WHEEL DOZERS AND 836K LANDFILL COMPACTORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE 516-9693 CYLINDER LINERS ON CERTAIN 834K WHEEL DOZERS AND 836K LANDFILL COMPACTORS

Usage:

TEBE7908-03

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05Jul2018

(Revised 10Dec2018)

U-381

A-284

D-474

O-478

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Before/After	PRODUCT SUPPORT PROGRAM FOR REPLACING THE 516-9693 CYLINDER LINERS ON CERTAIN 834K WHEEL DOZERS AND 836K LANDFILL COMPACTORS
1201 1000		PS45942

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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 must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS45942" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "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 05Jul2018 (Revised 20Sep2018) Service Letter. Changes have been made to the Parts Needed, and Action Required.

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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 834K Wheel Dozers, and 836K Landfill Compactors. If the existing liner cracks it will allow oil and coolant mixing. If the existing liner cracks it will allow oil and coolant mixing.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
834K	TWY00708, 710
836K	TWZ00569, 623-624, 628-633, 636-640, 643-664, 666-668, 677-678

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*****Group 2*****
834K	L4Y00201-00203, 205 LWY00752-00764

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
8	0S1571	BOLT-HEX HEAD
2	1R1808	FILTER-LUBE
1	1S9540	DOWEL
24	3E6772	SEAL-WATER
2	3S9643	SEAL-LIP TYPE
1	4N0699	GASKET
1	4N1650	DOWEL
26	5H1504	WASHER-HARD
2	5P0840	SEAL-O-RING
1	6I1055	DOWEL
1	6V3250	SEAL-O-RING
1	6V5063	SEAL-O-RING
1	6V6609	SEAL-O-RING
4	7L6580	SEAL-O-RING
1	8C3089	SEAL-O-RING
6	8S9191	BOLT
1	8T9588	SEAL-O-RING
3	9N5085	CLAMP-V-BAND
1	9S8009	PLUG-LD STOR
1	1013125	GASKET
2	1090077	SEAL-O-RING
2	1135304	SEAL-O-RING
1	1142687	SEAL-O-RING
10	1241854	BOLT-12 POINT HD
16	1241855	BOLT-12 PT HEAD
1	1250434	SEAL-INTEGRAL
1	1262702	SEAL-INTEGRAL
1	1264935	SEAL-INTEGRAL
1	1422329	SEAL-DRAINBACK
1	1674407	SEAL-O-RING
1	1714358	SEAL-O-RING
1	1986068	SEAL-INTEGRAL
24	2133217	BOLT
1	2271204	GASKET
6	2382707	RING-PISTON
1	2385081	SEAL-O-RING-STOR
6	2481394	KIT-GASKET-SFI
6	2613450	BEARING-ROD
1	2722583	SEAL-O-RING
6	2818261	SLEEVE AS-EXH
1	2918145	SEAL-O-RING-STOR
1	3249290	BELLOWS AS
6	3403639	RING-PISTON-OIL
6	3409400	RING-PISTON-TOP
3	3411429	SEAL-PIP
6	3483295	KIT-GASKET(SCL)
1	3499659	GASKET
2	3535065	GASKET-OIL PAN
1	3590908	GASKET-CYL HEAD
1	5521780	HARNESS AS-ENG
6	5560701	LINER-CYLINDER
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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*****
8	0S1571	BOLT-HEX HEAD
2	1R1808	FILTER-LUBE
1	1S9540	DOWEL
24	3E6772	SEAL-WATER
2	3S9643	SEAL-LIP TYPE
1	4N0699	GASKET
1	4N1650	DOWEL
26	5H1504	WASHER-HARD
2	5P0840	SEAL-O-RING
1	6I1055	DOWEL
1	6V3250	SEAL-O-RING
1	6V5063	SEAL-O-RING
1	6V6609	SEAL-O-RING
1	8C3089	SEAL-O-RING
6	8S9191	BOLT
1	9S8009	PLUG-LD STOR
1	1013125	GASKET
2	1090077	SEAL-O-RING
1	1142687	SEAL-O-RING
10	1241854	BOLT-12 POINT HD
16	1241855	BOLT-12 PT HEAD
1	1250434	SEAL-INTEGRAL
1	1262702	SEAL-INTEGRAL
1	1264935	SEAL-INTEGRAL
1	1422329	SEAL-DRAINBACK
1	1674407	SEAL-O-RING
1	1714358	SEAL-O-RING
1	1986068	SEAL-INTEGRAL
24	2133217	BOLT
6	2239159	RING-PISTON
1	2271204	GASKET
6	2382707	RING-PISTON
1	2385081	SEAL-O-RING-STOR
6	2465659	RING-PISTON-OIL
6	2481394	KIT-GASKET-SFI
6	2613450	BEARING-ROD
6	2818261	SLEEVE AS-EXH
1	2918145	SEAL-O-RING-STOR
3	3411429	SEAL-PIP
6	3483295	KIT-GASKET(SCL)
1	3499659	GASKET
2	3535065	GASKET-OIL PAN
1	3590908	GASKET-CYL HEAD
6	5560701	LINER-CYLINDER
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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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It is recommended that the cylinder liners be replaced prior to failure. Refer to the Disassembly and Assembly manual.

If the mixing of oil and coolant has occurred ensure that all appropriate trouble shooting is completed before removal of the liners for inspection. Refer to the Disassembly and Assembly manual.

Follow the guidelines for cleaning the cooling system with a non-foaming dish detergent within SEBU6250, "Conventional Coolant/Antifreeze Cooling System Maintenance".

Refill the radiator and engine with coolant. Refer to Special Instruction, M0070968, "Coolant Drain and Vacuum Fill Procedure For Certain C9.3 Through C18 Tier 4 Engines" for proper coolant fill procedure.

Group 1: During the repair the replace the 552-1780 Harness.

Both Groups: During the repair, engines utilizing the 249-3360 Camshaft Gear or 361-8240 Camshaft Gear should replace the 0S-1571 Cam gear Damper retention bolts. The new bolts should be installed with 263 Red Loctite and tightened to 66NM.

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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*****
0-7500 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%

NOTE: This is a 71.0-hour job for Group 1
This is a 71 hours job to include all related tasks including but not limited to: - Removal and installation - Disassembly - Cleaning - Reassembly - Testing of the repair An additional 18 hours will be allowed for cleaning of the system after failure.

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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*****
0-7500 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%

NOTE: This is a 71.0-hour job for Group 2
This is a 71 hours job to include all related tasks including but not limited to: - Removal and installation - Disassembly - Cleaning - Reassembly - Testing of the repair An additional 18 hours will be allowed for cleaning of the system after failure.