PRODUCT SUPPORT PROGRAM FOR REPLACING THE CYLINDER LINER O-RINGS ON CERTAIN C175-16 PETROLEUM ENGINES AT PLANNED COMPONENT REBUILD Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE CYLINDER LINER O-RINGS ON CERTAIN C175-16 PETROLEUM ENGINES AT PLANNED COMPONENT REBUILD

Usage:

TEBE6081-00

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09May2017

U-255

D-202

O-208

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Before/After	PRODUCT SUPPORT PROGRAM FOR REPLACING THE CYLINDER LINER O-RINGS ON CERTAIN C175-16 PETROLEUM ENGINES AT PLANNED COMPONENT REBUILD
1201 1216		PS45475

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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 "PS45475" 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

31May2022

PROBLEM

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The existing top liner O-ring can fail on certain C175-16 Petroleum Engines. If the existing liner O-ring fails it can leak engine coolant between the head and block joint.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C175-16	P6L00100-00103, 105-160, 1000-1004

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*****Group 2*****
C175-16	P6L01005-01017

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
32	2539950	SEAL-O-RING
16	4226176	SEAL-O-RING
16	4935366	DOWEL AS
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*****
32	2539950	SEAL-O-RING
16	4226176	SEAL-O-RING
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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At planned component rebuild (Top End Overhaul or Major Overhaul) do the following:

For both Groups, replace the cylinder liner O-rings. Refer to the attached Rework Procedure.

For Group 1 only, replace the oil feed dowel. Refer to Engine News, M0072202, "A New Cylinder Head to Cylinder Block Oil Feed Dowel Is Now Used For C175 Commercial Engines".

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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*****
0-36000 hrs, 0-120 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 20.0-hour job for Group 1
This program is intended to be completed at Top End Overhaul or Major Overhaul. The labor provided assumes the cylinder heads have been removed from the engine during these overhaul periods.

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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*****
0-36000 hrs, 0-120 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 16.0-hour job for Group 2
This program is intended to be completed at Top End Overhaul or Major Overhaul. The labor provided assumes the cylinder heads have been removed from the engine during these overhaul periods.

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

NOTE: Ensure that the area around the cylinder head is properly cleaned prior to disassembly in order to prevent contamination of the oil system after cylinder head removal. Failure to thoroughly clean the area prior to head removal could result in engine failure.

1. Remove exhaust and intake manifold bolts from one cylinder head.

2. Remove the cylinder head per the Disassembly and Assembly Guide "Cylinder Head - Remove".
Note: 371-1079 is a cylinder head lifting device available for C175 engines.

Note: Refer to Reuse and Salvage Guidelines, SEBF9109, "Handling Procedures for the Components of the Common Rail Fuel System" for additional information in handling fuel system parts.

3. Install a barring device onto the rear housing of the engine.
Note: 279-3473 and 329-3831 are two barring devices available for C175 engines.

4. Rotate the flywheel to position the piston at the bottom of the liner.

5. Install the 442-5798 puller into the cylinder liner. Tighten the nut on the tooling to expand it against the liner.

6. Rotate the flywheel to raise the liner out of the block. Raise the liner high enough to expose all three liner O-rings.

Image1.1.1

7. Remove all three O-rings and clean the O-ring grooves.

8. Install two 253-9950 (purple color) O-ring into the lower grooves and one 422-6176 (red color) O-ring in the top groove.

Image1.2.1

9. Apply 207-1601 lubricant or a liquid soap solution on the O-rings.
Note: DO NOT APPLY ENGINE OIL OR OTHER PETROLEUM PRODUCTS TO LUBRICATE THE LINER O-RINGS.

10. Slowly rotate the flywheel to lower the liner into the block. Stop the rotation of the flywheel if the liner gets stuck at any point. Lower the liner until the top O-ring is roughly flush with the top deck of the block. See image 1.3.1 below.

Image1.3.1

11. Remove the 442-5798 puller from the cylinder liner.

Image1.4.1

12. Install tooling (2P-8260 and 288-9169) to fully seat the liner into the block.

Note: The fire ring (258-9925) should be in place to avoid contact between the tooling and the cuff ring.

Image1.5.1

13. Install the cylinder head components. Refer to the Disassembly and Assembly guide, "Cylinder Head - Install".

Repeat procedure for the remaining cylinders.