PRODUCT SUPPORT PROGRAM FOR REPLACING THE TIMING CHAIN AND FUEL FILTER ON CERTAIN 307D EXCAVATORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE TIMING CHAIN AND FUEL FILTER ON CERTAIN 307D EXCAVATORS

Usage:

REBE8169-00

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21Mar2012

D-136

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE TIMING CHAIN AND FUEL FILTER ON CERTAIN 307D EXCAVATORS
1241 1162 1151 1206 1274		PS43546

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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 "PS43546" 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.

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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 Caterpillar product analyst.

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TERMINATION DATE

31Mar2015

PROBLEM

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The existing timing chain can fail on certain 307D Excavators. If the existing timing chain fails, it can lead to additional internal engine failures.

AFFECTED PRODUCT

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Model

Identification Number

307D

DSG00105, 196-199, 209-210, 212-228, 230-250, 255-359, 368-509, 519-643, 649-1036, 1039-1093, 1107-1163, 1165-1221, 1227-1335, 1345-1378, 1394-1428, 1448-1463, 1480-1483, 1485-1541, 1545-1590, 1597-1701, 1703-1708, 1710-1714, 1716, 1718-1720, 1722-1727, 1729-1733, 1735-1740, 1742-1746, 1748-1752, 1754-1759, 1761-1765, 1767-1780, 1783, 1785-1788, 1790-1793, 1795-1802, 1804-2005, 2007-2017, 2019-2029, 2031-2041, 2043-2053, 2055-2066, 2068-2079, 2081-2092, 2094-2123, 2125-2134, 2136-2178, 2180-2191, 2193-2203, 2206-2217, 2219-2230, 2232-2243, 2245-2256, 2258-2269, 2271-2399, 2402-2454, 2457-2487, 2491-2628, 2636-2650, 2652-2655, 2658-2661, 2664-2667, 2670-2677, 2679-2685, 2687-2693, 2695-2701, 2703-2709, 2711-2717, 2719-2725, 2727-2733, 2735-2741, 2743-2749, 2751-2757, 2759-2764, 2766-2771, 2773-2778, 2780-2785, 2787-2792, 2794-2799, 2801-2826, 2828-2856, 2858-2883, 2886-2891, 2896-2906, 2908-2980, 2982-2986, 2991-2995, 2997, 2999-3001, 3003-3077, 3080-3092, 3094-3115, 3117-3125, 3128-3137, 3140-3149, 3152-3160, 3163-3168

PARTS NEEDED

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Qty	Part Number	Description
1	1P0436	GASKET-PRM PUMP
1	2M9780	SEAL-O-RING
1	3K0360	SEAL-O-RING
4	6V5048	SEAL-O-RING
2	6V8397	SEAL-O-RING-ORFS
1	6V8634	ADAPTER-STR
1	6V8918	BOLT
1	7X2501	BOLT
1	8T4205	WASHER-HARD
1	8T4224	WASHER-HARD
4	9S8002	PLUG-LD STOR
1	9X2134	ADAPTER-ELBOW
1	1288557	BASE AS-FILTER
1	1375541	PUMP AS-F PRM
1	3261641	FILTER AS
1	3435527	BOWL AS-FUEL
1	3831496	RETAINER (After Failure Only)
1	3831512	PIN-SET (CSHAFT) (After Failure Only)
1	3831514	TENSIONER (After Failure Only)
1	3831515	TOOL-SET (After Failure Only)
1	3908680	KIT-TIMING CHAIN (After Failure 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

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Inspect the timing chain tensioner. Refer to SEPD1254, Service Magazine, "Caterpillar Recommends an Inspection of the Timing Chain Tensioner on Certain Excavators Every 1000 Hours".

If an inspection of the timing chain tensioner reveals that the timing chain tensioner is extended beyond 26mm, or if the timing chain is broken, replace the timing chain. Replace the fuel filter only if PS43429 has NOT been previously applied to this machine. This is to be claimed as an AFTER FAILURE repair.

If an inspection of the timing chain tensioner reveals that the timing chain tensioner is not extended beyond 26mm, add the new fuel filter only if PS43429 has not been applied to this machine. This is to be claimed as a BEFORE FAILURE repair.

Follow the procedure in KENR5078, Mitsubishi Diesel Engine, Engine, General Inspection And Adjustment, "Replacement of Timing Chain", in order to replace the timing chain.

See the attached Rework Procedure in order to replace the fuel filter.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-4000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
4001-6000 hrs, 25-36 mo	53.0%	50.0%	0.0%	0.0%	35.0%	50.0%

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NOTE: This is a 8.0-hour job
The AFTER FAILURE repair procedure requires the use of 383-1496, 383-1512, 383-1514, and 383-1515 Service Tooling. This service tooling should be reused. Dealers may claim up to three (3) tools of each part number tooling to utilize for the repair at a dealer location.

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PARTS DISPOSITION

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

Rework Procedure

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1. Sub-assemble the new fuel filter. See Image1.1.1

Image1.1.1

2. Remove the existing fuel filter assembly. The fuel filter is located inside of the right side service door. Refer to Image1.2.1.

Image1.2.1

3. Loosen the hose clamps and pull off the inlet and the outlet fuel hoses from the fuel filter. Insert plugs into the hoses to prevent fuel from spilling. M8 bolts can be used as plugs temporarily. Refer to Image1.3.1.

Image1.3.1

4. Loosen the two bolts and remove the fuel filter assembly. Keep the two mounting bolts, these will be used to install the new fuel filter. Refer to Image1.4.1.

Image1.4.1

5. Remove two hose fittings from the fuel filter assembly. These hose fittings will be used on the fuel filter. Refer to Image1.5.1.

Image1.5.1

6. Install the new fuel filter assembly. Tighten the bolts to a torque of 28 +/- 7 N.m. Refer to Image1.6.1.

Image1.6.1

7. Install the hose fittings into the fuel filter assembly as shown in Image1.7.1. Tighten the fitting to a torque of 30 +/- 4 N.m.

Image1.7.1

8. Insert the fuel inlet and outlet hoses into the hose fittings an tighten the hose clamps. Refer to Image1.8.1. Tighten the clamps to a torque of 3.4 +/- 0.3 N.m.

Image1.8.1

9. Push the fuel priming pump on the filter base and feed the fuel. Start the engine and check for fuel leaks around the new fuel filter. Refer to Image1.9.1.