PRODUCT SUPPORT PROGRAM FOR INSPECTING CONNECTING RODS AND POSSIBLY REPLACING A CYLINDER PACK ON CERTAIN 793F AND 794 OFF-HIGHWAY TRUCKS Caterpillar


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PRODUCT SUPPORT PROGRAM FOR INSPECTING CONNECTING RODS AND POSSIBLY REPLACING A CYLINDER PACK ON CERTAIN 793F AND 794 OFF-HIGHWAY TRUCKS [UEBE1268]
BASIC ENGINE
PISTON & ROD GP
PRODUCT SUPPORT PROGRAM FOR INSPECTING CONNECTING RODS AND POSSIBLY REPLACING A CYLINDER PACK ON CERTAIN 793F AND 794 OFF-HIGHWAY TRUCKS
UEBE1268-00

22Sep2020


R12Z
T080
T085

 

Before/After

 (Limited distribution) 
 Parts stock action needed 

PRODUCT SUPPORT PROGRAM FOR INSPECTING CONNECTING RODS AND POSSIBLY REPLACING A CYLINDER PACK ON CERTAIN 793F AND 794 OFF-HIGHWAY TRUCKS

1218 7750 1214
PS46857
NOTE:

AVSpare’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 AVSpare.

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 "PS46857" 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.

NOTE:

When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7755" as the Group Number, "56" as the Description Code.

NOTE:

Although this Program is to be administered as described above on the Affected Product, parts should be removed from parts stock as soon as possible.

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 AVSpare product analyst.


TERMINATION DATE

30Sep2022

PROBLEM

Certain existing connecting rods in certain C175 Engines may contain a machining issue on certain 793F and 794 Off-Highway Trucks. If the existing connecting rod contains the issue and continues operation it can fail and result in engine damage.

AFFECTED PRODUCT

Model Identification Number
793F CMD  RBT00127, 325, 330
794 AC  MT500157

PARTS NEEDED

Qty

Part Number Description
1 8C3132 SEAL-O RING (If Needed)
4 8T2223 BOLT-SOCKET HD (If Needed)
1 8T9524 SEAL-O-RING (If Needed)
1 20R8987 CYLINDER PACK AS (If Needed)
1 2287089 SEAL-O-RING-ORFS (If Needed)
1 2287100 SEAL-O-RING-STOR (If Needed)
1 2287108 SEAL-O-RING-STOR (If Needed)
1 2300940 SEAL-PIP (If Needed)
1 2435741 SEAL-FUEL SYSTEM (If Needed)
1 2435742 SEAL-FUEL SYSTEM (If Needed)
1 2464924 GASKET (If Needed)
1 2589925 GASKET-COMB (If Needed)
1 2589926 GASKET (If Needed)
1 2697852 SEAL-O-RING (If Needed)
1 3170808 SEAL-O-RING (If Needed)
1 3708028 GASKET (If Needed)
1 3766457 BEARING-CONN ROD (If Needed)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 20% 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

****Parts Stock ****

Inspect Engine Arrangement 514-4913 with Serial Number AJ801011 and Engine Arrangement 563-8712 with Serial Number D4W00126 in dealer parts stock.

Only the cylinder numbers noted in Parts Stock Image1 need to be inspected on each engine.

Refer to the attached Rework Procedure.

 
Image1
 
****Affected Product****
Only the cylinder numbers noted in Affected Product Image1 need to be inspected on each engine.

Refer to the attached Rework Procedure.
Image1

SERVICE CLAIM ALLOWANCES

****Parts Stock****

Submit one claim for each engine inspected. This is a 20 hour job. If a connecting rod fails the inspection procedure, an additional 8 hours may be allowed to change the cylinder pack. If the scavenge pump is required to be removed for inspection an additional 20 hours may be allowed to complete the removal and reinstallation.

 
 
****Affected Product****
Product smu/age whichever comes first
AVSpare
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
0-20000 hrs,
0-48 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 20.0-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.

If a connecting rod fails the inspection procedure, an additional 8 hours may be allowed to change the cylinder pack. If the scavenge pump is required to be removed for inspection an additional 20 hours may be allowed to complete the removal and reinstallation.



PARTS DISPOSITION

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

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



Rework Procedure


 
Identify the specific engine cylinders that require inspection for the machine using the image in the action required section of this service letter.

The inspection consists of gaining access to the connecting rod bolts, removing a singular bolt from each cylinder to be inspected, and measuring the bolt hole depth.

If an inspection measurement is not in the acceptable range, the cylinder pack should be exchanged.

If the inspection measurement is in the acceptable range, there is no further action required.

Refer to the machine engine Disassembly and Assembly guide to gain access to the connecting rod bolts of each cylinder under inspection.
 
A 10 or 12 in Vernier caliper should be used that is certified and calibrated.

Select one (1) of the bolt hole locations and remove the bolt from the connecting rod.

Note: Only one bolt should be removed for this inspection.

Place the depth checking end of the caliper flush on the top of the 366-5649 Spacer.

Note: The spacer must remain in place during the measurement.

Measure to the bottom of the bolt hole targeting the center of the hole.

Note: The bolt hole has a hemispherical bottom, so the center of the hole should be used for the measurement.

The acceptable measurement for the bolt hole depth is 178.725 +/- 0.50 mm (7.036 +/- 0.020 inch) including the retainer.
Image1.2.1
 
If the bolt hole is confirmed in the acceptable range. Re-install the bolt and snug hand tight. Loosen all remaining bolts without removing them, snugging each hand tight after loosening.

Tighten all bolts according to specification, reference KENR6052.
 
If a bolt hole is found not to be in the acceptable range, set the caliper back to zero. Measure the bolt hole again making sure that the center of the hole is being used to take the depth.

If the bolt hole is confirmed to not be in the acceptable range via the second check, replace the cylinder pack, reference KENR6052
 
Once the inspection and associated repair has been completed, reinstall all components according to the machine engine Disassembly and Assembly guide.
 
 

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