PRODUCT SUPPORT PROGRAM FOR REPLACING 516-9693 CYLINDER LINERS ON CERTAIN D11T TRACK-TYPE TRACTORS, 777G OFF-HIGHWAY TRUCKS, 854K WHEEL DOZERS, 992K, AND 993K WHEEL LOADERS Caterpillar


PRODUCT SUPPORT PROGRAM FOR REPLACING 516-9693 CYLINDER LINERS ON CERTAIN D11T TRACK-TYPE TRACTORS, 777G OFF-HIGHWAY TRUCKS, 854K WHEEL DOZERS, 992K, AND 993K WHEEL LOADERS

Usage:

TEBE7674-02

17Jul2018
(Revised 23May2019)


U-419

 

After Failure Only

  
  

PRODUCT SUPPORT PROGRAM FOR REPLACING 516-9693 CYLINDER LINERS ON CERTAIN D11T TRACK-TYPE TRACTORS, 777G OFF-HIGHWAY TRUCKS, 854K WHEEL DOZERS, 992K, AND 993K WHEEL LOADERS

1000 1216 1201 7555
PS53812
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 can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS53812" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

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.

 
NOTE:

This Revised Service Letter replaces the 17Jul2018 (Revised 11Sep2018) Service Letter. Changes have been made to Title, Problem, and Affected Product.


TERMINATION DATE

31Jul2020

PROBLEM

The existing 516-9693 Cylinder Liners can crack in the bottom o-ring grooves on certain D11T Track-Type Tractors, 777G Off-Highway Trucks, 854K Wheel Dozers, 992K, and 993K Wheel Loaders. If the existing liner cracks it will allow oil and coolant mixing.

AFFECTED PRODUCT

Model Identification Number
*******Group  1*******
D11T  JEL00438-00464
*******Group  2*******
777G  RDR00508, 511-521, 524, 529-531, 534-535, 539, 545
777G OEM  T5A00300-00301
*******Group  3*******
854K  KK600201-00202
992K KK200118, 121-122, 124

KK400101-00102, 106-109, 111-112, 114-115, 117, 120-121, 132, 134, 137, 140
993K  Z8D00101

PARTS NEEDED

Qty

Part Number Description
*******Group 1*******
2 1R1808 FILTER-LUBE
4 5E8771 SEAL-O-RING
3 5P0537 WASHER-HARD
3 5P8068 SEAL-O-RING
4 5P8356 SEAL-O-RING
1 8C3089 SEAL-O-RING
1 8J4351 SEAL-O-RING
1 8N0422 GASKET-O PAN RR
12 8S9191 BOLT
12 9L5854 BAND-FILLER
12 9X7317 SEAL-FUEL SYSTEM
6 0315085 BOLT-LOCKING
2 1075769 SEAL-O-RING
4 1092332 SEAL-O-RING
1 1121102 SEAL-O-RING
1 1121574 SEAL-O-RING
1 1123259 SEAL-O RING
4 1178801 SEAL-O-RING
12 1550809 SEAL-LINER
12 1550810 SEAL-LINER
12 1552793 SEAL-LINER
2 1978418 GASKET
2 1978419 GASKET
2 2253099 GASKET-CYL HEAD
2 2265613 GASKET
12 2303728 SEAL-FUEL SYSTEM
12 2303775 SEAL-FUEL SYSTEM
12 2323226 BEARING-ROD
12 2382707 RING-PISTON
2 2391139 SEAL
12 2391388 GASKET
4 3103953 SEAL-O-RING
12 3403639 RING-PISTON-OIL
12 3409400 RING-PISTON-TOP
4 3419211 GASKET
2 3499659 GASKET
1 3531648 GASKET-OIL PAN
2 3548484 GASKET-PLATE
48 3591439 SEAL AS-WATER
12 5560701 LINER-CYLINDER
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 5% 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*******
2 1R1808 FILTER-LUBE
1 3P0650 SEAL-O RING
2 5D5958 SEAL-O-RING
4 5E8771 SEAL-O-RING
3 5P0537 WASHER-HARD
1 5P8068 SEAL-O-RING
4 5P8356 SEAL-O-RING
2 5P8429 SEAL-O-RING
1 8C3089 SEAL-O-RING
12 8S9191 BOLT
12 9L5854 BAND-FILLER
12 9X7317 SEAL-FUEL SYSTEM
6 0315085 BOLT-LOCKING
2 1075769 SEAL-O-RING
4 1092332 SEAL-O-RING
1 1121102 SEAL-O-RING
1 1121574 SEAL-O-RING
1 1123259 SEAL-O RING
2 1178801 SEAL-O-RING
12 1550809 SEAL-LINER
12 1550810 SEAL-LINER
12 1552793 SEAL-LINER
2 1978418 GASKET
2 1978419 GASKET
2 2253099 GASKET-CYL HEAD
2 2265613 GASKET
12 2303728 SEAL-FUEL SYSTEM
12 2303775 SEAL-FUEL SYSTEM
12 2323226 BEARING-ROD
12 2382707 RING-PISTON
2 2391139 SEAL
12 2391388 GASKET
4 3103953 SEAL-O-RING
12 3403639 RING-PISTON-OIL
12 3409400 RING-PISTON-TOP
2 3499659 GASKET
1 3531648 GASKET-OIL PAN
2 3548484 GASKET-PLATE
48 3591439 SEAL AS-WATER
12 5560701 LINER-CYLINDER
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 5% 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 3*******
2 1R1808 FILTER-LUBE
1 3P0650 SEAL-O RING
2 5D5958 SEAL-O-RING
4 5E8771 SEAL-O-RING
3 5P0537 WASHER-HARD
1 5P8068 SEAL-O-RING
4 5P8356 SEAL-O-RING
2 5P8429 SEAL-O-RING
1 8C3089 SEAL-O-RING
12 8S9191 BOLT
12 9L5854 BAND-FILLER
12 9X7317 SEAL-FUEL SYSTEM
6 0315085 BOLT-LOCKING
2 1075769 SEAL-O-RING
4 1092332 SEAL-O-RING
1 1121102 SEAL-O-RING
1 1121574 SEAL-O-RING
1 1123259 SEAL-O RING
2 1178801 SEAL-O-RING
12 1550809 SEAL-LINER
12 1550810 SEAL-LINER
12 1552793 SEAL-LINER
2 1978418 GASKET
2 1978419 GASKET
2 2253099 GASKET-CYL HEAD
2 2265613 GASKET
12 2303728 SEAL-FUEL SYSTEM
12 2303775 SEAL-FUEL SYSTEM
12 2323226 BEARING-ROD
12 2382707 RING-PISTON
2 2391139 SEAL
12 2391388 GASKET
4 3103953 SEAL-O-RING
12 3403639 RING-PISTON-OIL
12 3409400 RING-PISTON-TOP
2 3499659 GASKET
1 3531648 GASKET-OIL PAN
2 3548484 GASKET-PLATE
48 3591439 SEAL AS-WATER
12 5560701 LINER-CYLINDER
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 5% 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

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

If cracked liner is identified refer to the appropriate Disassembly and Assembly manual for repair.

NOTE: Date code of failed liner must be entered into warranty claim. Date Code is locate on bottom of liner, on rim.

NOTE: An AFA will be required for warranty claim if failure is beyond oil and coolant mixing.

If cooling system has been contaminated , follow the guidelines for cleaning the cooling system with a non-foaming dish detergent within SEBU6250, "Conventional Coolant/Antifreeze Cooling System Maintenance". Refer to appropriate OM&M / Special instructions for proper coolant fill procedure.

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
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 162.0-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.

This is a 162 hour job:
120 hours to Remove and Install engine.
42 hours to rework engine.

To include all related tasks including but not limited to:
- Disconnect and connect
- Disassembly
- Cleaning
- Reassembly
- Testing of the repair

NOTE: Due to the nature of this program additional Caterpillar parts that require replacement during the mechanical disassembly and assembly on the mid frame section may be claimed as required. These parts are limited to seals, gaskets, bolts, washers, nuts, locknuts, rings, clips, and clamps.

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
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 122.0-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.

This is a 122 hour job:
80 hours to Remove and Install engine.
42 hours to rework engine.

To include all related tasks including but not limited to:
- Disconnect and connect
- Disassembly
- Cleaning
- Reassembly
- Testing of the repair

NOTE: Due to the nature of this program additional Caterpillar parts that require replacement during the mechanical disassembly and assembly on the mid frame section may be claimed as required. These parts are limited to seals, gaskets, bolts, washers, nuts, locknuts, rings, clips, and clamps.

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 3*******
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 122.0-hour job for Group 3

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.

This is a 122 hour job:
80 hours to Remove and Install engine.
42 hours to rework engine.

To include all related tasks including but not limited to:
- Disconnect and connect
- Disassembly
- Cleaning
- Reassembly
- Testing of the repair

NOTE: Due to the nature of this program additional Caterpillar parts that require replacement during the mechanical disassembly and assembly on the mid frame section may be claimed as required. These parts are limited to seals, gaskets, bolts, washers, nuts, locknuts, rings, clips, and clamps.



PARTS DISPOSITION

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

Caterpillar Information System:

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