PRODUCT SUPPORT PROGRAM FOR RESEALING THE CYLINDER HEAD TO BLOCK JOINT AND REPLACING THE VALVE SPRINGS AND REMANUFACTURED VALVES ON CERTAIN REMANUFACTURED ENGINES ON 785, 785B, AND 785C OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR RESEALING THE CYLINDER HEAD TO BLOCK JOINT AND REPLACING THE VALVE SPRINGS AND REMANUFACTURED VALVES ON CERTAIN REMANUFACTURED ENGINES ON 785, 785B, AND 785C OFF-HIGHWAY TRUCKS

Usage:

REBE4450-00

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06Nov2008

U-563

A-468

D-480

O-518

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR RESEALING THE CYLINDER HEAD TO BLOCK JOINT AND REPLACING THE VALVE SPRINGS AND REMANUFACTURED VALVES ON CERTAIN REMANUFACTURED ENGINES ON 785, 785B, AND 785C OFF-HIGHWAY TRUCKS
1124 1100 1108		PS42825

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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 "PS42825" 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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TERMINATION DATE

30Nov2010

PROBLEM

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The cylinder head gasket, valve springs, and remanufactured valves need to be replaced on certain remanufactured engines before 5000 hours that are installed on 785, 785B, and 785C Off-Highway Trucks before 5000 hours. The existing combustion sealing ring portion of the head gasket may leak combustion gas causing block damage.

AFFECTED PRODUCT

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Model	Identification Number
785	8GB00160-00697, 862, 75226-75229, 78001-78003, 78005-78008
785B	6HK00101-00987, 50409, 75001-75007, 76001-76003, 78001-78006, 99381
785C	1HW00085-00134 APX00160-00890
785C HA	5AZ00085-00114, 264-273, 400-427

PARTS NEEDED

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Qty	Part Number	Description
48	2A4429	LOCK-RETAINER
2	1106994	PLATE-SPACER (As Required)
24	1944897	VALVE-EXHAUST
48	1977055	LOCK-RETAINER
24	2102542	VALVE-INLET
48	3165976	SPRING
48	3165977	SPRING-VALVE
24	3165978	ROTOCOIL AS
24	3165979	ROTOCOIL AS
24	3165980	SEAL
24	3165981	WASHER
12	3268702	KIT-GASKET(SCH)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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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Determine the hours on the listed remanufactured. The remanufactured engines with less than 5000 hours need to have the cylinder head gaskets replaced with the 110-6991 gasket to prevent block damage from combustion leaks.

The 110-6994 Spacer Plate may have a large quantity of gasket material adhered to it. This material can be very difficult to remove. If the spacer plate cannot be easily cleaned, you are authorized to replace with a new part of the same part number.

Remove old valve springs, rotators, valves, seals, and washers and replace with new.

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Image1

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%
0-5000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%