PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY RETIGHTENING THE CRANKSHAFT COUNTERWEIGHT BOLTS ON CERTAIN 777D OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY RETIGHTENING THE CRANKSHAFT COUNTERWEIGHT BOLTS ON CERTAIN 777D OFF-HIGHWAY TRUCKS

Usage:

REBE8561-01

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24Jul2012

(Revised 05Mar2013)

D-339

O-358

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Priority Parts stock action needed	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY RETIGHTENING THE CRANKSHAFT COUNTERWEIGHT BOLTS ON CERTAIN 777D OFF-HIGHWAY TRUCKS
1202 7750		PI32064

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32064" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. Exception: If the repair is done after failure, use "PI32064" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:

When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7751" as the Group Number, "56" as the 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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NOTE:	This Revised Service Letter replaces the 24Jul2012 Service Letter. A change has been made to the Parts Stock Action Required.

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COMPLETION DATE	TERMINATION DATE
31Jan2013	31Jul2013

PROBLEM

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The crankshaft counterweight bolts may not have had the proper torque applied at the factory.

AFFECTED PRODUCT

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Model	Identification Number
777D	FKR00605, 736, 750, 814, 836, 856, 944, 965, 968, 1045, 1055-1058, 1069, 1074-1076, 1104, 1107, 1141, 1150, 1178, 1201, 1230-1231, 1245, 1247-1249, 1251-1255, 1263-1264, 1273-1275, 1292, 1299, 1303-1304, 1311, 1314-1334, 1342-1343, 1350

PARTS NEEDED

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Qty	Part Number	Description
1	7E2631	GASKET-OIL PAN
18	1284845	BOLT AS
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 39% 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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****Parts Stock ****

Rework the following engines in dealer parts stock with the engine arrangement 331-1423 and with the serial number C8T01325 or C8T01326.

For engines in dealer parts stock, refer to the Action Required for the Affected Product.

****Affected Product****

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Inspect the machine for the service hours.

If the machine has totaled less than 500 hours, perform the Rework Procedure in the Action Required for the Affected Product.

If the machine has totaled more than 500 hours, do not perform the Rework Procedure in the Action Required for the Affected Product.

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

5. Check the static inspection torque of each crankshaft counterweight bolt for 225 Nm using a calibrated torque wrench.

6. Check if any counterweight bolts have rotated from their original position. If none of the bolts have moved, go to step 12.

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

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

9. 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.

10. Lubricate new bolt threads, shank, washer, and bolt seat with molylube before assembly.
NOTE: Do not reuse the old counterweight bolts.

11. 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 11a through step 11f.

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

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

14. Reassemble oil filter housing/filters if removed.

15. Fill the engine with oil.

16. Report back to your dealer Technical Communicator on any observations with respect to the above steps, especially on step 7 and step 9. Document what was found in the claims report.

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

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OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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****Parts Stock****

Submit one claim for all engines reworked in dealer parts stock. The parts listed in the Parts Needed will be allowed for each engine that is reworked. 35 hours will be allowed for each engine that is reworked. Include the engine serial numbers and arrangement numbers in the service claim story.

****Affected Product****

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 1.0-hour job
1 hour is allowed to inspect for the product service hours. If the machine has totaled less than 500 hours, an additional 35 hours is allowed to Rework Procedure in the Action Required. If the machine has totaled more than 500 hours, do not perform the Rework Procedure in the Action Required.

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PARTS DISPOSITION

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****Parts Stock****

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

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****Affected Product****

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

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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR RETIGHTENING THE CRANKSHAFT COUNTERWEIGHT BOLTS ON CERTAIN 777D OFF-HIGHWAY TRUCKS

MODELS INVOLVED - 777D

Dear Caterpillar Product Owner:

The crankshaft counterweight bolts need to be inspected on the products listed below. The crankshaft counterweight bolts may not have had the proper torque applied at the factory. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

Please refer the dealer to their Service Letter dated 24Jul2012 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 24Jul2012 Service Letter