PRODUCT SUPPORT PROGRAM FOR RETIGHTENING THE 3524 FRONT AND REAR HOUSINGS ON CERTAIN 797 AND 797B OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR RETIGHTENING THE 3524 FRONT AND REAR HOUSINGS ON CERTAIN 797 AND 797B OFF-HIGHWAY TRUCKS

Usage:

TEBE3540-00

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02Sep2015

R120

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Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR RETIGHTENING THE 3524 FRONT AND REAR HOUSINGS ON CERTAIN 797 AND 797B OFF-HIGHWAY TRUCKS
7777 1162 1151 1206 7555 1157		PS90525

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NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

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 "PS90525" 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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TERMINATION DATE

30Sep2017

PROBLEM

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The existing Front and Rear housings on 3524 engines can leak on certain 797 and 797B Off-Highway Trucks. If the front or rear housing leak oil it can cause unplanned downtime.

AFFECTED PRODUCT

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Model	Identification Number
797	5YW00223-00225, 231, 237, 258-259, 271-276
797B	JSM00124, 129, 134, 165-175, 177-178, 180-190, 214-215, 232-234, 240, 245, 247-250, 257, 288-289, 292, 294-295, 297, 299-301, 318-319, 334-337, 354-363, 366-368, 383-384, 391-392, 396-397, 403, 410-411, 414, 416-417, 419-421, 423, 425, 427, 429, 431, 433, 442, 444-445, 452, 454-455, 458-460, 463-471, 473-475

PARTS NEEDED

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No parts needed for this program

ACTION REQUIRED

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Perform an extended DYNO test and re-torque the front and rear housings on all 3524 engines prior to shipping the engines to customers. Please refer to the rework procedure below. All Engine serial numbers are to be entered into SIMSi and detailed into the claim story before submission. proceed as detailed in the attached Rework Procedure.

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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%
0-80000 hrs, 0-84 mo	50.0%	50.0%	50.0%	50.0%	0.0%	0.0%

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NOTE: This is a 4.0-hour job If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
If the dealer needs to consider installing a Caterpillar REMAN Engine instead of a CRC unit due to availability, additional 38 hours of labor are allowed for the rework. A Miscellaneous charge up to $1,900.00 USD is allowed for associated DYNO testing costs for Cat REMAN Engines. A Miscellaneous charge up to $700.00 USD is allowed for associated DYNO testing costs for CRC Rebuilt Engines.

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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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Reference Special Instruction REHS4838. The housing gasket will naturally compress due to heat and vibration of the running engine. This results in reduced bolt stretch and reduced clamp load in the housing to block joints. This lost bolt stretch can be recovered and maintained by retightening the housing bolts.

Following a 5 hour dyno test of the engine package (front and rear engines coupled), retighten the bolts shown in REHS4838 Illustration 5. This does not require removal of the flywheel. The master ECM mounting bracket on the rear engine must be unbolted and moved to provide clearance to tighten the housing bolts. Torque the specified bolts to same torque used in Step 5.

A detailed record of which bolts were found loose will be required in the claim story.

Image1.1.1

Refer to Image1.1.1, A typical view of Front engine rear flywheel housing bolts. Bolt 11 is the first 1/2 inch bolt on the lower top left corner. Bolt 24 is last 1/2 inch bolt on the lower top right corner. Only retighten bolt 11 through 24 of the flywheel housing. Bolt numbers increase going clockwise.

Refer to Image1.1.1 Bolts 12,13,14 and 21,22,23 on the rear housings can be retightened without removal of the cam gear. The engine crankshaft must be rotated so that the elongated hole in the cam gear and timing ring aligns with the housing bolt to be tightened.

Image1.2.1

Refer to Image1.2.1, A typical view of rear engine front housing bolts. Bolt 11 is the first 1/2 inch bolt on the lower top left corner. Bolt 24 is last 1/2 inch bolt on the lower top right corner. Only retighten bolt 11 through 24 of the flywheel housing. Bolt numbers increase going clockwise.

Note: Retightening of the bolts is only required once after new gasket installation.

Note: Use the following torque:
Tighten the 1/2 inch bolts for the flywheel housing (1) to the following torque:
135 +/- 20 N.m (100 +/- 15 lb ft)