PRODUCT SUPPORT PROGRAM FOR INSPECTING THE CRANKSHAFT PAD AND COUNTERWEIGHT FOR THE CORRECT GAP ON CERTAIN 777D OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSPECTING THE CRANKSHAFT PAD AND COUNTERWEIGHT FOR THE CORRECT GAP ON CERTAIN 777D OFF-HIGHWAY TRUCKS

Usage:

TEBE0757-01

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18Dec2013

(Revised 11Jun2014)

K023
K590
K645
K646

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Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR INSPECTING THE CRANKSHAFT PAD AND COUNTERWEIGHT FOR THE CORRECT GAP ON CERTAIN 777D OFF-HIGHWAY TRUCKS
1202 1302		PS90349

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NOTE:

This Containment Program can be administered either before or after a failure occurs. In either case 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.

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NOTE:	When reporting the repair, use "PS90349" as the Part Number and "7777" as the Group Number. If administered before failure, use "56" as Warranty Claim Description and "T" as the SIMS Description Code. If administered after failure, use "96" as Warranty Claim Description Code and use "Z" as the SIMS Description Code.
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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NOTE:	This Revised Service Letter replaces the 18Dec2013 Service Letter. Changes have been made to the Affected Product and Parts Needed.

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TERMINATION DATE

31Dec2015

PROBLEM

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The clearance between the crankshaft pad and counterweight on 3508 Engines in 777D Off-Highway Trucks need to be verified.

AFFECTED PRODUCT

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Model	Identification Number
777D	FKR00743, 1006-1008, 1042-1045, 1085, 1125, 1127-1130, 1135-1136, 1169, 1171-1174, 1218-1220, 1269-1270, 1418-1419, 1421, 1460-1463, 1541-1542, 1641-1647, 1709, 1712, 1717-1722

PARTS NEEDED

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Qty	Part Number	Description
2	4F3765	GASKET-IDLER SFT
2	6V0973	SEAL-O-RING
1	7E2631	GASKET-OIL PAN
1	7X4810	SEAL-O-RING
2	1092332	SEAL-O-RING
18	1284845	BOLT AS
2	1326260	SEAL-INTEGRAL
2	2377623	SEAL-O-RING
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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Inspection Procedure

1. Remove the oil pan after draining the engine oil, removal of oil filters and/or oil filter housing may be required to remove all oil pan bolts.

2. Remove the oil scavenge pump.

3. Install an engine rotation device in left side of the rear housing.

4. Mark all the crankshaft counterweights (1 through 6) with respect to the front side of the machine (engine damper side) using a paint marker.

5. Measure the gap between the crankshaft pad and counterweight (across the width of the pad) as per Image 1. To measure the gap, insert a 5.0 mm diameter cylindrical pin at the marked zone "d" across the width of the crankshaft pad. The pin should sit in the counter weight radius (see Image 2). (The shank of a drill bit may be used, provided the shank diameter is between 5 to 5.5 mm)

If 5 mm pin does not enter, use 2, 3 and 4 mm pins (the shank of a drill bit may be used of these respective sizes) to see which maximum size of pin enters across the width.

6. Document your findings as per each counter weight as per point 5 in the following table

Truck SN ____________ Engine SN _____________ Hours ________
Crankshaft Counter Weight number
Pin Position 1 2 3 4 5 6
Right Side ___ ___ ___ ___ ___ ___
Left Side ___ ___ ___ ___ ___ ___

Note:

- Write the maximum size of the pin (2, 3, 4 or 5 mm) that enters

- If 2 mm pin does not enter, write "<2"

7. Mark all the crankshaft counterweight bolts with respect to the crankshaft counterweight using a paint marker. This will mark the original bolt position.

8. Check the static inspection torque of each crankshaft counterweight bolt for 225 Nm (166 lb ft) using a calibrated torque wrench.

9. Check if any counterweight bolts have rotated from their original position. If none of the bolts have moved, go to Step 15.

10. If a bolt rotates in a counterweight, note the counterweight number and mark an "X". Document which counterweight and which bolt/s are loose.

11. Remove all the existing bolts of the each counterweight with "X" mark.

12. Remove the counterweight. Check for any contamination or scratches or any abnormalities on the machined surfaces. Clean the counterweight machined surface and the crankshaft counterweight machined surface before assembly. Document what was found.

13. Lubricate new bolt threads, shank, washer, and bolt seat with molylube before assembly.

NOTE: Do not reuse the old counterweight bolts.

14. Assemble the counterweight back to the crankshaft. The center bolt needs to be tightened first, followed by the outside two bolts in each counterweight marked "X". The tightening sequence for each of the three bolts, after running them down, is as follows:

a. Tighten all bolts to 200 +/- 5 Nm (150 +/-4 lb ft).

b. Loosen all bolts.

c. Tighten all bolt to 70 +/- 5 Nm (50 +/-4 lb ft).

d. Mark the bolt positions.

e. Rotate all bolts by 120 +/- 5 degrees (1/3 turn).

f. Using a calibrated torque wrench set at 225 Nm (166 lb ft),
check all counterweight bolts to ensure that all bolts were
tightened correctly. If a bolt turns, repeat Step 14a through Step 14f.

15. Reassemble the oil scavenge pump with a new 237-7623 O-ring.

16. Reassemble the oil pan with a new 7E-2631 Gasket.

17. Reassemble oil filter housing/filters if removed.

18. Fill the engine with oil.

19. Report back to your dealer Technical Communicator on any observations with respect to the above Steps, especially on Step 6, 10 and 12. Provide the same information to your Local Engine Representative by sending an email to Ram Kesavarapu at Kesavarapu_Ram@cat.com.

20. Document what was found in the claims report.

Refer to RENR8434 for the disassembly and assembly of the oil pan.

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Image1

Image2

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%
0-15000 hrs, 0-30 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%