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Service Magazine
New Cylinder Pack Components Are Now Available for Certain 793 and 797 High
Displacement Off-Highway Truck Engines {1213, 1214, 1216, 1225}
Media Number -M0064186-03 Publication Date -14/03/2016 Date Updated -14/03/2016

i06630646

New Cylinder Pack Components Are Now Available for Certain

793 and 797 High Displacement Off-Highway Truck Engines
{1213, 1214, 1216, 1225}
SMCS - 1213; 1214; 1216; 1225

Off Highway Truck

793D (S/N: FDB1-UP)
797 (S/N: 5YW1-UP)
797B (S/N: JSM1-UP)
Truck
793 (S/N: 3SJ1-UP)
793B (S/N: 1HL1-UP)
793C (S/N: CBR1-UP; 4AR1-UP; ATY1-UP; 4GZ1-UP)

Description Of Change: The new cylinder pack components improve engine reliability and
durability by reducing deposits attributed to wear and liner polishing.

• Cylinder Liner with Anti-Polishing Sleeve (Cuffed Cylinder System)

• Upper Liner Seal with improved thermal properties

• Single piece forged steel piston (SPFS) with rectangular steel compression ring and rectangular
steel intermediate ring

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Illustration 1 g06000695
The Illustration depicts the aforementioned enhancements.
(1) Steel Compression and Intermediate Rings (Improved Wear Resistance).
(2) Single Piece Forged Steel Piston (Structural Integrity).
(3) Anti-Polishing Sleeve (Reduced Deposit Formation and Liner Wear).

Adaptable To: The new cylinder pack components are direct replacements for previous cylinder pack
components used in certain 3500HD Engines, however they must be used consistently throughout an
entire engine. Do not mix components from different types of cylinder packs within the same engine.
The new cylinder pack components are equally adaptable to blocks with new, inserted, or sprayed
deck surfaces that meet or exceed minimum reuse criteria.

Individual Cylinder Repairs

When performing an individual cylinder repair, it is imperative to replace any components removed
with components of the same design. Rotating masses, injector types, and engine software are
designed as a system and must not be mixed within an engine.

Piston Cooling Jets and Retainers

The appropriate piston cooling jets and retainer should always be used. Failure to install the correct
cooling jets and corresponding retainers will result in engine failure.

The new cylinder pack components require the 204-5447 Oil Jet and 193-3283 Oil Jet Retainer.

Tooling
Steel piston rings are sensitive to bending. Failure to use proper ring expansion or compression
tooling will result in damage to piston rings and possible early hour engine failure.

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471-6593 is the installation tool which is required with standard ring compressor tooling when
installing cuffed cylinder system components.

Always reference SIS web for a list of tooling for use in assembly, service, and inspection of the
cylinder pack components.

Refer to Table 1for a list of the new part numbers. The new parts are adaptable back to the first
production of the serial numbers listed above.

Table 1
Cuffed Cylinder Articulated Cylinder Single Piece
Qty Part Name
System System Cylinder System
1 Cylinder Liner 454-9920 211-7826 211-7826
Anti-Polishing
1 458-7071 N/A N/A
Sleeve
1 Upper Liner Seal 480-7093 352-6061 352-6061
3 Lower Liner Seal 7N-2046 7N-2046 7N-2046
1 Piston Assembly 448-0574 173-7674 345-8541
1 Connecting Rod 10R-4030 10R-4030 10R-4030
Piston Ring -
1 448-3650 229-1632 229-1632
Compression
Piston Ring -
1 448-3651 144-5695 144-5695
Intermediate
Piston Ring - Oil
1 165-6668 165-6668 165-6668
Control
2 Pin Retainer 253-1238 8N-7296 253-1238
1 Piston Wrist Pin 302-3451 10R-3293 302-3451
1 Oil Jet 204-5447 162-3898 204-5447
1 Oil Jet Retainer 193-3282 121-3558 193-3282

Tooling and Installation Instructions

1. Install the cylinder liner and assemble the piston and rod as shown in SENR1126.

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Illustration 2 g06019508
(1) 471-6593 Installation Tool

2. The installation tool (1) has a lip on the bottom which fits down into the liner recess where the
anti-polishing sleeve will be installed later.

Note: The anti-polishing sleeve is installed after the piston and rod are installed and torqued,
and the installation tool has been removed.

Illustration 3 g06019538

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Illustration 4 g06019532

3. The standard ring compressor is installed on the piston. The piston and rod are then lifted and
installed into the liner through the installation tool.

Illustration 5 g06019536

4. The anti-polishing sleeve is installed after the piston and rod are installed and torqued and the
installation tool has been removed.

Note: Do not forget to install the anti-polishing sleeve into the top of the liner before installing
the head and related components.

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Illustration 6 g06023610
(1) Anti-Polishing Sleeve

Note: The anti-polishing sleeve slips smoothly and precisely into position when carefully installed
perpendicular to the cylinder bore. Manual rotation may aid in installation.

Note: Do not hammer or force the anti-polishing sleeve into position.

Table 2
HD Engine Arrangement and Injector Matrix with a Cuffed Cylinder System
Application Arrangement/s Injector/s Software
793 20R-6114 20R-2296 : 145° 428-8756
793B 20R-6114 20R-2296 : 145° 428-8756
423-7547 / 20R-2296 :
793C 488-8197 / 20R-6116 428-8023
145°
423-7547 / 20R-2296 :
793D 488-8194 / 20R-6115 485-5134
145°
793D 488-8195 423-7547 : 145° 485-5134
793D 488-8196 423-7547 : 145° 485-5134
385-6001 Primary
392-0213 / 20R-0850 : (Both Engines)
797 186-4197 / 0R-8668
150° 446-6678 (Rear Engine
Only)
797B 209-5259 / 10R-1676 / 392-0213 / 20R-0850 / 385-6003 Primary
10R-7929 ESD 20R-0850 : 150° (Both Engines)

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446-6679 (Rear Engine

Only)
385-6003 Primary
(Both Engines)
797B 472-1445 392-0213 : 150°
446-6679 (Rear Engine
Only)

Table 3
HD Engine Arrangement and Injector Matrix with an Articulated Cylinder System
Application Arrangements Injector/s Software
793 20R-3449 20R-0850 : 150° 321-2950
793B 20R-3449 20R-0850 : 150° 321-2950
793C 451-9857 / 20R-3451 392-0213 / 20R-0850 : 150° 329-2604
793D 451-9846 / 20R-3450 392-0213 / 20R-0850 : 150° 485-5133
793D 451-9847 392-0213 : 150° 485-5133
793D 451-9852 392-0213 : 150° 485-5133

Table 4
HD Engine Arrangement and Injector Matrix with a Single Piece Cylinder System
Application Arrangements Injector/s Software
793 10R-0946(1) 20R-2296 : 145° 428-8756
793B 10R-0946 (1) 20R-2296 : 145° 428-8756
423-7547 / 20R-2296 :
793C 147-0797 (2) / 0R-7568 (3) 428-8023
145°
423-7547 / 20R-2296 :
793D 235-0300 (4) / 10R-2852 (5) 485-5134
145°
793D 288-4348 (6) 423-7547 : 145° 485-5134
793D 373-9863 (7) 423-7547 : 145° 485-5134
385-6001 Primary
392-0213 / 20R-0850 : (Both Engines)
797 186-4197(8) / 0R-8668 (9)
150° 446-6678 (Rear
Engine Only)
385-6003 Primary
209-5259 (10) / 10R-1676 (11) / 392-0213 / 20R-0850 / (Both Engines)
797B
10R-7929 ESD (12) 20R-0850 : 150° 446-6679 (Rear
Engine Only)

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(1)
S/N:KNS00737-UP are produced with Cuffed Cylinder System
(2)
S/N:8WM03308-UP are produced with Cuffed Cylinder System
(3)
S/N:CPW01557-UP are produced with Cuffed Cylinder System
(4)
S/N:8WM03358-UP are produced with Cuffed Cylinder System
(5)
S/N:MSK00533-UP are produced with Cuffed Cylinder System
(6)
S/N:8WM03024-UP are produced with Cuffed Cylinder System
(7)
S/N:8WM03349-UP are produced with Cuffed Cylinder System
(8)
S/N:3TN00508-UP are produced with Cuffed Cylinder System
(9)
S/N:CND00448-UP are produced with Cuffed Cylinder System
(10)
S/N:3TN00995-UP are produced with Cuffed Cylinder System
(11)
S/N:NPM00528-UP are produced with Cuffed Cylinder System
(12)
S/N:NPM00528-UP are produced with Cuffed Cylinder System

This change is effective for the serial numbers listed in Table 5.

Table 5
Sales
Effective Serial Numbers
Model
793 S/N:3SJ00057-UP
793B S/N:1HL00525-UP
S/N:4AR00425-UP, ; S/N:4GZ00265-UP, ; S/N:ATY01122-UP, ; S/N:CBR00109-
793C
UP
793D S/N:FDB01856-UP
797 S/N:5YW00278-UP
797B S/N:JSM00489-UP

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