895178001 Mercury SEAL, Rubber

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 "PS5288" 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.
It is recommended that this program be implemented during Planned Component Rebuild when the engine is out. No labor is allowed to remove and install the engine.
Inspection of cracks and approval by product support representative is required before implementing this program.
Termination Date
June 30, 2000Problem
The rear engine mounts may crack in certain 793, 793B, and 793C Trucks.
Affected Product
Model & Identification Number
793 (3SJ1-Up)
793B (1HL1-Up)
793C (4AR77-148, 4AR150-158)
Inspection of cracks and approval by product support representative is required before implementing this program.
Parts Needed
1 - 1352578 Support-LH1 - 1387460 Support-RHAction Required
See the attached procedure.
Service Claim Allowances
This is a 95-hour job total to rework both sides including the time required to fabricate the plates. A maximum of $150.00 will be allowed for material to fabricate the plates. Both sides must be reworked at the same time. No time will be allowed to remove and install the engine.
A one time allowance not to exceed $10,000.00 will be allowed for labor and materials to fabricate the tooling. Limited to one time per Dealer.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.(1-Rework Procedure)Rework Procedure
Retrofit Of Rear Motor Mount Castings
Welding Procedure / Field Repair
The following procedure is written to cover the field replacement of the rear engine mounts on the 793 Off Highway Truck Frame. This procedure explains the steps necessary to reduce cracking and improve the life of the rear motor mount castings.
Welding Procedure
Welding operator personal protection should be provided to assure that total weld fume in the operators breathing zone does not exceed OHSA limits. All repair welding operators must be qualified for groove and fillet welding, as outlined in the current ANSI/AWS D14.3, or Caterpillar Manufacturing Practices MC1000-105 for the SMAW (Shielded Metal Arc Welding) process in all welding positions. The welding operator must also have used this welding process during the last six months or be re-certified for this process before welding. Documentation must be maintained of the weld operators qualifications.
The area to be repaired and the surrounding area must be at a minimum temperature of 16 degrees C (60 ° F)before and during all cutting, carbon arc gouging, and welding. The SMAW process shall be used with E7018 (ANSI/AWS A5.5) welding electrode. The weld deposited by these electrodes will have the following minimum mechanical properties:
500 MPA (72 kSI) Tensile Strength420 MPA (60 KSI) Yield Strength22% Elongation in 50mm (2 inches)27J (20 ft lbs) notch toughness at -29° C (-20° F)These are low hydrogen electrodes and must be stored in a electrode oven at 121 ° C (250 ° F) when not in use. If the electrodes get damp, scrap or recondition them to manufacturers specifications. The following chart relates to the electrode diameter and approximate current settings for welding:
Use the direct current electrode positive (DC reverse polarity) setting and remove the slag after every pass. The weld pass size shall not exceed two times the electrode diameter.
Use the direct current electrode positive (DC reverse polarity) setting and remove the slag after every pass. The weld pass size shall not exceed two times the electrode diameter.
As an alternative process the FCAW process may be used with E71T-1 (ANSI/AWS A5.20) welding electrode and the manufacturers specified shielding gas(es).The weld deposited by these electrodes will have the following minimum mechanical properties:500 MPA (72 KSI) tensile strength420 MPA (60 KSI) yield strength22% elongation in 50mm (2 inches)27J (20 ft lbs) notch toughness at -29 deg° C (-20° F)
This type of electrode has limitations of it is used to carry larger weld pass volumes in the flat welding position. Due to fast freezing characteristics of this electrode's slag system, there is a chance of trapping evolving gasses in the weld melt. Precaution should be taken by controlling weld pass size.
Welding parameters will vary due to weld position and manufacturer of the welding electrode. Use the direct current electrode positive (DC reverse polarity) setting and remove the slag after every pass. The weld pass size shall not exceed 8mm (0.31") fillet volume.
Repair
This procedure assumes that the engine, front cross member and associated plumbing have been removed.
1. Prepare to set the fabricated tool to the proper rear engine mount height for this individual truck. Attach hoist chains to the fabricated tool in the forward lift eyes provided. The forward lift eyes are used when the fixture is empty.
2. Remove left hand front round locating button from the fabricated tool.3. Position the fabricated tool down onto the front and rear motor mounts.4. Secure the fabricated tool (4 bolts per side) to the rear engine mounts.5. Equalize the fabricated tool between the rear engine mount using the etched lines on the fixture.6. Secure the two sliding members of the fabricated tool (4 bolts per side) so they can not move.7. Run the threaded bar knobs down until they just touch the top of the main rail behind the main strut castings. It helps to use a .010 inch feeler gage or a paper card to gage when the bar knob end contacts the main rail. Using a feeler gage guarantees that the fixture has not inadvertently raised while the bar knobs are being set.
8. Secure both lock nuts, against the fixture and one another. This procedure insures that the new rear engine mounts will be located at the same height as the old mounts.
9. Clean the rear motor mount weld area of oil, grease, paint, and dirt. Note the location of all affected blocks, brackets, and bosses.
10. Use a cutting torch to make a rough cut around the outside window area. Make cut line at approximately 1 inch from the inside of the weld all around. Do not cut into the inside reinforcement plates. After cutting outside window remove plate from frame.
11. Cut