ADAPTER 5M7932 - Caterpillar

Problem
At overhaul, the engine cylinder block may have cracks on the top deck of the cylinder block under the cylinder liner flange on some C Trucks, and Excavators.See Rework Procedures A and B.
Some cylinder blocks that were repaired using the previously available 7E2866 Inserts may develop coolant leaks externally at the cylinder head gasket joint or internally into the lubrication system prior to overhaul. See Rework Procedures C and D.
Affected Product
Model & Identification Number
D11N (74Z1-1152, 4HK1-635)
D11R (8ZR1-Up)
776B (6JC1-108)
776C (2TK1-114)
776D (5ER1-Up)
777B (4YC1-1866, 3NF1-69)
777C (4XJ1-1123)
777D (3PR1-Up)
784B (5RK1-UP)
785 (8GB1-697)
785B (6HK1-Up)
789 (9ZC1-699)
789B (7EK1-Up)
793 (3SJ1-56)
793B (1HL1-524)
793C (4AR1-Up)
992G (7HR1-Up)
994 (9YF1-Up)
5130 (5ZL1-Up)
5230 (7LL1-Up)
Parts Needed
Rework Procedure A
1 -7W5949 Liner Seat Insert (3.20 mm. (.125 inch))or1 - 1204334 Liner Seat Insert (5.08 mm. (.200 inch))or1 - 1204337 Liner Seat Insert (7.62 mm. (.300 inch)) Use one insert per cylinder.
Rework Procedures B, C or D
4 - 1B4367 Bolt 2 - 8S2332 Bolt 2 - 1011368 Thrust Washer 2 - 1121552 Idler Shaft 2 - 1121554 Idler Gear Assembly 1 - 1153503 Cylinder Block (for 3508 Engines)or 1 - 1155154 Cylinder Block (for 3512 Engines)or 1 - 1155160 Cylinder Block (for 3516 Engines)10 - 1161359 Camshaft Bearing (for 3508, 14 for 3512, and 18 for 3516 Engines)Action Required
Rework Procedure A, B, C or D are only to be used as follows:
Procedure A - Use Procedure A if a cylinder(s) of a product was not previously repaired for top deck cracks and cracks are now found during an overhaul.
Procedure B - Use Procedure B after inspecting the top deck of the cylinder block at overhaul to determine the location of the cracks, and finding cracks extending into a bolt hole or water passage.
Procedure C - Use Procedure C if the product was previously repaired for top deck cracks using the 7E2866 Insert and a repair is now necessary prior to overhaul due to external coolant leaks at the cylinder head gasket joint or internal leaks into the lubrication system.
Procedure D - Use Procedure D if the product was previously repaired for top deck cracks using the 7E2866 Insert and the engine is again being overhauled.
For details of the actual reworks, refer to the attached rework procedures.
Service Claim Allowances
As "Product" actually applies to the cylinder block rather that the engine, the claim comments MUST clearly state:
1. Which overhaul for the cylinder blockand
2. Which procedure was usedRepair Procedure A
For Procedures B, C and D, whenever a cylinder block is replace, record the cylinder block sequence number (located on to of the cylinder block in front of the number 1 cylinder) in the history folder.
Repair Procedure B
Repair Procedure C
Repair Procedure D
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.(1-Rework Procedure)Rework Procedure
Rework Procedure A
While the complete removal of a crack is the most positive repair, over five years of testing and field experience has proven that the replacement of a cylinder block just because a crack exists beyond 7.62 mm. (.300 inch) is not necessary. Whether using one of the three Caterpillar inserts or an outside supplied