PSP FOR UPDATING THE DROPBOX ON CERTAIN 657E SCRAPERS - PS4384 - MAILED US, CANADA, CACO, COFA, COSA Caterpillar

PSP FOR UPDATING THE DROPBOX ON CERTAIN 657E SCRAPERS - PS4384 - MAILED US, CANADA, CACO, COFA, COSA

Usage:

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Caterpillar: Confidential Yellow

PSP FOR UPDATING THE DROPBOX ON CERTAIN 657E SCRAPERS - PS4384 - MAILED US, CANADA, CACO, COFA, COSA

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.


U-177
A-120
AU-119
O-111
3117   PS4384
NOTE: This Program can be administered either before or after a
failure. In either case the decision whether to apply the
Program is made by the dealer. When reporting the repair, use
"PS4384" as Part Number, "7755" as Group Number, and "96" as
Description Code.

Termination Date

September 30, 1990

Problem

The service life of the retarder and transfer gear group may not be as long
as desired on certain 657E Scrapers. New parts can be installed to increase
the service life.

Affected Product

Model Identification Number
657E 90Z1 - 192
91Z1-351, 353, 354

Parts Needed

1 - 7E1733 Flywheel Assembly
1 - 3J1907 Seal
2 - 6V8397 Seal
1 - 6V8724 Elbow
1 - 6V9836 Tee
1 - 8X1040 Gear Group-Retarder & Transfer
1 - 8X3773 Tube Assembly
1 - 9Y4851 Damper Assembly

Action Required

See the attached procedure.

Service Claim Allowances

Product Caterpillar Dealer Suggested Customer Suggested
smu/age Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
whichever (D/N) (Cost)  (C/L) (Sell)
comes
first
0-4000 100% 3 0 3 0 0
0-24 mo
4001-6000 33 1/3% 1.5 0 1.5 50% 3
25-36 mo
NOTE: This is a 6-hour job.
If a customer has participated in a previous failure, rebuild, or in
preventative maintenance to avoid a failure, part hours apply.

Parts Disposition

Handle the parts in accordance with your Warranty Bulletin on
warranty parts handling.
Rework Procedure
Dropbox Removal Procedure
1. Drain the oil from the dropbox.
2. Remove the lines from the scavenge pump and remove the scavenge pump.
3. Remove the tube assembly from between flywheel housing and the dropbox.
4. Disconnect the sending unit wires from the retarder valve.
5. Unbolt the retarder valve and move it out of the way.
6. Remove the 8 bolts from the drive tube assembly at the drop box.
7. Install a 5P9736 Link Bracket on the top of the dropbox.
8. Attach a suitable lifting device to the link bracket in the dropbox.
9. Remove the 19 bolts and one nut that holds the dropbox.
10. Remove the dropbox.
11. Attach the lifting device to the flywheel.
12. Remove the 12 bolts holding the flywheel on and remove the flywheel.
Dropbox Installation Procedure
1. Install the new 7E1733 Flywheel Assembly. Put 2P2506 Thread Lubricant
on the threads and face of the bolts. Tighten the bolts to a torque of
271 +/- 27 N.m (200 +/- 20 lb. ft.).
2. Install the 9W6166 Spring Coupling Assembly on the flywheel with 20-
308535 Bolts.
3. Install the 9H0846 Seal on the 8X1040 Gear Group.
4. Install a 5P9736 Link Bracket on the 8X1040 Gear Group and install gear
group in the flywheel housing. Make sure the spider is in alignment
with the spring coupling.
5. Install the 8 bolts that hold the drive tube to the dropbox. Tighten
the bolts to a torque of 435 +/- 20 N.m (321 +/- 15 lb. ft.).
6. Install O-rings in retarder valve and install retarder valve on dropbox.
7. Connect the sending unit wires to retarder valve.
-2 of 3-
8. Install the O-ring on scavenge pump and install the pump.
9. Install the O-rings on scavenge pump lines and Connect the lines.
10. Install the O-ring on tube assembly from flywheel housing to dropbox.
Install the tube assembly.
Damper Assembly Removal Procedure
1. Remove coolant conditioner bracket from radiator and lay it back on the
engine.
2. Remove the right-hand side fan guard.
3. Remove all fan belts from the lower pulley.
4. Loosen and remove the alternator belt.
5. Remove the four bolts that hold the pulley to damper.
6. Remove the six bolts that hold the damper and adapter to the crankshaft.
7. Remove the adapter from the damper assembly.
Damper Installation Procedure
1. Install the new 9Y4851 Damper Assembly on the adapter.
2. Put clean engine oil on the threads of the bolts that hold the vibration
damper in position. Install the vibration damper and bolts on the
crankshaft.
3. Install the pulley on the vibration damper and install the bolts that
hold it.
4. Install the alternator belt and adjust it to the proper specifications.
5. Install and adjust the fan belts.
6. Install fan guard.
7. Install the coolant conditioner bracket.
-3 of 3-
****** IMAGE: SEBE4130.00001.001
CAPTION: Location of Parts