PRODUCT SUPPORT PROGRAM FOR INSPECTING THE CAMSHAFT ON CERTAIN 797F OFF-HIGHWAY TRUCKS, EQUIPPED WITH THE HIGH ALTITUDE ARRANGEMENT Caterpillar


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PRODUCT SUPPORT PROGRAM FOR INSPECTING THE CAMSHAFT ON CERTAIN 797F OFF-HIGHWAY TRUCKS, EQUIPPED WITH THE HIGH ALTITUDE ARRANGEMENT [UEBE1260]
BASIC ENGINE
CAMSHAFT GP
PRODUCT SUPPORT PROGRAM FOR INSPECTING THE CAMSHAFT ON CERTAIN 797F OFF-HIGHWAY TRUCKS, EQUIPPED WITH THE HIGH ALTITUDE ARRANGEMENT
UEBE1260-00

23Sep2020


A-464

 

Before/After

  
  

PRODUCT SUPPORT PROGRAM FOR INSPECTING THE CAMSHAFT ON CERTAIN 797F OFF-HIGHWAY TRUCKS, EQUIPPED WITH THE HIGH ALTITUDE ARRANGEMENT

1210
PS46860
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 "PS46860" 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:

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

The existing camshaft can fail on certain 797F Off-Highway Trucks, equipped with the high altitude air system. If the existing camshaft fails, it will cause unplanned downtime.

AFFECTED PRODUCT

Model Identification Number
797F  LAJ00195-00196, 231, 353, 355, 357, 359, 361, 363-364, 366, 376-377, 379, 386, 388, 392, 395, 398, 478, 537, 539, 544-553, 566-568, 572, 585-595, 597-598, 613-617, 620, 622-623, 625-627, 649-653, 657-658, 660-661

PARTS NEEDED

Qty

Part Number Description
1 9Y6089 GASKET AS
10 2300940 SEAL-PIP
1 4505112 CLAMP (AS-NEEDED FOR 4X4 ENGINE ONLY)
1 4674241 CLAMP (AS-NEEDED FOR 4X4 ENGINE ONLY)
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

Utilize a high quality borescope to inspect the nose and down ramp of each camshaft lobe for damage.

Tools Needed:
- Flexible borescope with a 4mm diameter lead that can be manipulated 6mm(1/4in) diameter thin wall guide tube 558mm (22in) long.

- 329-3831 Engine Turning Tool

Refer to Image1 for an example of an acceptable borescope.

Refer to the attached Rework Procedure for the inspection procedure for the proper method to inspect the camshaft lobes.

Please attach a report with photos from each inspection along with the recommended actions to the SIMSi entry.

Note: For 4x4 high altitude air system engines, valve cover removal on cylinder 20 is restricted by the turbocharger air lines. It is recommended to paint mark the elbows at each end for alignment to the turbocharger housings. Remove only the clamps at each end where the assembly connects to the turbocharger housing in order to allow for reuse of the bellows assembly. New clamps are provided in the Parts Needed. Refer to Image2.
Image1
Image2

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
AVSpare
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
0-18000 hrs,
0-48 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 14.0-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.

Note: This program is for proactive inspection claims only. It is not intended to be claimed for After Failure support.

Note: This program may be claimed multiple times. It is recommended to begin performing borescope inspections at 4,000 engine hours, repeating every 4,000 hours with lash adjustment intervals up to 18,000 hours. For engines that are exhibiting initial signs of camshaft spalling or skidding, the inspection interval should be reduced to 1,000 hours.



PARTS DISPOSITION

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


Rework Procedure


 
Refer to Image1.1.1 to identify the area to be inspected and the orientation of each camshaft lobe.
Image1.1.1
 
1. Remove the LEFT side valve covers ONLY (viewed from flywheel end).

2. Rotate the engine counter clockwise until the flywheel timing pin can be installed.

3. Using the KENR5397, Testing and Adjusting, ensure that the #1 piston is on the COMPRESSION stroke.

4. Remove and store the crankshaft timing pin.

5. If the borescope is equipped with a moveable handle, place it on the borescope lead.

6. Feed the borescope lead through the guide tube until it protrudes at least 50mm.

7. Move the handle down until it touches the top of the guide tube and secure it to borescope lead.

8. Using the joy stick, move the borescope end to ensure that movement is not restricted by the tube.

9. Pull the borescope lead part way out of the guide tube (far enough that the camera is not protruding out of the guide tube.

10. Holding the borescope lead and guide tube, insert the guide tube above the rocker arms and under the push rod opening. Refer to Image1.2.1.
Image1.2.1
 
11. Column one of Image1.3.1 shows what cam lobes can be inspected for a C175-20 starting with the flywheel on Top Center #1 Compression. Left and right refer to the push rods and our recommendation of which hole to probe for clearest view of the cam lobe.

12. After completing the first column, rotate the flywheel 90 degrees counter clockwise and inspect the lobes listed in column 2. Mark the damper to determine when 90 degrees has been reached.

13. Repeat inspections every 90 degrees until the crankshaft has been rotated two complete turns and all intake and exhaust lobes have been inspected. The tables in Image1.3.1 and Image1.3.2 need to be completed for a C175-20 engine.
Image1.3.1
Image1.3.2
 
14. Use Image1.4.1, Image1.4.2, and Image1.4.3 to evaluate the condition of the camshaft lobes and determine the recommended actions.

Camshaft lobes that match ImageI.4.1 are in acceptable condition and should be re-inspected in 4,000 hours. Fine debris scratches and minor indentations may be apparent and are acceptable.

Camshaft lobes that match Image1.4.2 show the signs of roller skidding and will progress to a spalled lobe. A repair should be scheduled as soon as possible. There will be a defined track(s) with disturbed material causing a rough finish and a visual contrast in roller path.

Camshaft lobes that match Image1.4.3 are failed and need replaced immediately.
Image1.4.1
Image1.4.2
Image1.4.3
 
 

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