PRODUCT SUPPORT PROGRAM FOR REPLACING ROCKER ARM SHAFT BOLTS ON CERTAIN 775F OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING ROCKER ARM SHAFT BOLTS ON CERTAIN 775F OFF-HIGHWAY TRUCKS

Usage:

REBE9295-00

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12Dec2012

K314

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Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING ROCKER ARM SHAFT BOLTS ON CERTAIN 775F OFF-HIGHWAY TRUCKS
1123 1102 1292 1901		PS90228

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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 "PS90228" 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

31Dec2013

PROBLEM

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The existing rocker arm shaft bolts can fail on certain 775F Off-Highway Trucks. If the existing bolts fail it can cause the rocker arm shaft to break, and may cause resultant engine damage.

AFFECTED PRODUCT

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Model	Identification Number
775F	DLS00309-00310, 754, 1022, 1057

PARTS NEEDED

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Qty	Part Number	Description
24	3565212	BOLT-12 POINT HD
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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Replace the existing rocker arm shaft bolts with new 356-5212 Bolts.

Refer to 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%
0-12000 hrs, 0-72 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 6.0-hour job

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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. Park the machine in accordance with the Operation and Maintenance Manual.

2. Gain access to the six valve covers. The engine ECM will need to be removed.

3. Remove each valve cover, one at a time, and replace each rocker arm shaft bolt with a new 356-5212 Bolt in order to minimize outside contamination.

Image1.1.1

4. Tighten each 356-5212 Bolt to a torque of 55 +/- 5 Nm (41 +/- 4 lb ft); plus a 60 +/- 5 degree turn. The 356-5212 is 12 point bolt. Each point represents 30 degrees.

NOTE: If all the bolts were removed from the shaft, perform the following procedure (refer to Image1.2.1):

- a. Tighten the bolts in sequence 2, 3, 1, 4, 2 to a torque of 55 +/- 5 Nm (41 +/- 4 lb ft).
- b. Turn the bolts 60 +/- 5 degrees in a sequence of 2, 3, 1, 4.

Image1.2.1

5. Verify/Adjust the valve lash for the inlet valves and the exhaust valves. Refer to Testing and Adjusting, "Engine Valve Lash - Inspect/Adjust".

6. Verify/Adjust the electronic unit injectors. Refer to Testing and Adjusting, "Electronic Unit Injector - Adjust".

7. Install the valve mechanism cover. Tighten the bolts to a torque of 2.5 +/- 0.25 Nm (22 +/- 2 lb in).

8. Position the isolation mounts on electronic control module (3). Position the spacers, the washers, ground strap (2) and electronic control module (3) on the support assemblies. Install bolts (4). Image1.3.1

9. Connect the harness assembly to electronic control module (3). Tighten Allen head screw (1) to a torque of 6 +/- 1 Nm (53 +/- 9 lb in).