850461 Mercruiser BALANCER-Harmonic

09Nov2016
L100
Containment -
After Failure Only
(Limited distribution)
PRODUCT SUPPORT PROGRAM FOR INSTALLING CUFFED CYLINDER SYSTEM COMPONENTS ON CERTAIN 793D OFF-HIGHWAY TRUCKS EQUIPPED WITH 3500 HIGH DISPLACEMENT ENGINES
1290 1201 1225 1239 1216 1214 1213 1331 7750 PS61336
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.
This Containment Program can only be administered after a failure occurs.The decision whether to apply the Program is made by the dealer and service rep. Obtain the service reps Goodwill Approver Code before completing the repair. EAME dealers should use their standard Industry Group specific goodwill approval codes. The Goodwill Approver Code must be included when submitting the claim.
When reporting the repair, use "PS61336" as the Part Number and "7777" as the Group Number. Use "96" as Warranty Claim Description Code and use "Z" as the SIMS Description Code.
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.
TERMINATION DATE
30Nov2018
PROBLEM
In high load conditions, certain single piece forged steel pistons used in the Single Piece Cylinder System may develop hard deposits at the top land of the piston.
If severe enough, deposits may wear the liner crosshatch, compromising oil control and contributing to additional deposit formation, wear, and blowby.
AFFECTED PRODUCT
Model Identification Number
793D FDB01140, 1145, 1300, 76001, 76003-76004
PARTS NEEDED
Qty
Part Number Description
3 10R9224 CYLINDER PACK AS
16 20R5616 CYLINDER PACK AS
16 4421340 KIT-GASKET (SCH)
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
This Service Letter provides support for replacing Single Piece Cylinder System components provided both of the following conditions are met AND supporting documentation is attached to the claim.
Condition 1: Air Intake System Cleanliness
Customer must demonstrate that silicon levels have been maintained at or below 9 PPM by producing archived SOS reports. This program DOES NOT support engines affected by dust, dirt or debris ingress due to a faulty or compromised air intake system.
Condition 2: Excessive Crankcase Blowby
Customer must demonstrate that the engine is generating excessive blowby according to REHS7857, Special Instruction, "Testing for Excessive Cylinder Blowby in 3500 Engines". Some amount of blowby is generated by every engine and the amount of blowby typically increases with age as parts wear. The repairing Dealer must use REHS7857, Special Instruction, "Testing for Excessive Cylinder Blowby in 3500 Engines", in order to determine if the engine is exhibiting signs of excessive blowby. If both of these conditions are met, this Service Letter can be applied in one of the following two ways, but not both. This Service Letter can only be applied
one time for each affected product.
1. Out of Chassis Rebuilds*
(All cylinders replaced using Cuffed Cylinder System (20R-5616 Cylinder Pack).
This option is available for all qualifying engines up to 14,000 hours.
*For the out of chassis rebuild option, 10R9224 cylinder packs are NOT used.
OR
2. In Chassis Repairs**
(Individual cylinders replaced using Single Piece Cyli