PRODUCT SUPPORT PROGRAM FOR REPLACING THE VIBRATION DAMPER ON CERTAIN 797F OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE VIBRATION DAMPER ON CERTAIN 797F OFF-HIGHWAY TRUCKS

Usage:

TEBE3470-01

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08Sep2015

(Revised 11Sep2015)

R120

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Containment - After Failure Only (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING THE VIBRATION DAMPER ON CERTAIN 797F OFF-HIGHWAY TRUCKS
7777 1210 1205 1160 1161		PS61309

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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 only be administered after a failure occurs. 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 "PS61309" as the Part Number and "7777" as the Group Number. Use "96" as Warranty Claim Description Code and use "Z" as the SIMS 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 08Sep2015 Service Letter. Changes have been made to the Affected Product.

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TERMINATION DATE

30Sep2017

PROBLEM

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The existing vibration damper can fail on certain 797F Off-Highway Trucks. If the vibration damper fails it can cause unplanned and significant downtime.

AFFECTED PRODUCT

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Model	Identification Number
797B	JSM00293
797F	LAJ00148-00150, 158-182, 185-187, 216-221, 230, 233-236, 247-250, 256-261, 263, 265, 397, 406, 408, 411, 414-415, 423, 425-427, 433, 435-438, 467, 471-473, 495-501

PARTS NEEDED

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Qty	Part Number	Description
4	1P7115	MOUNT AS
8	2S6160	WASHER-HARD
4	6V4249	BOLT-HEX HEAD
1	1463173	DOWEL
16	1485379	SPACER
1	1761378	SEAL-O-RING
4	2747709	BOLT
1	3373140	SEAL
1	3918715	DAMPER GP-BASIC
1	4383101	SEAL-CRANKSHAFT
2	4532317	BRACKET
2	4532318	BRACKET
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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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Reference KENR6052 for the disassembly and assembly of the vibration damper and the front crankshaft seal.

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%
0-36000 hrs, 0-72 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 9.0-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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Reference KENR6052 for the disassembly and assembly of the vibration damper and the front crankshaft seal.

1.) Remove current vibration damper guard assembly. Retain mounting bolts and spacers to be reused.

Image1.1.1

2.) Support the damper with an approved lifting device prior to removing the damper mounting bolts. Reference KENR8384 for the correct procedure to remove the engine damper. Two 323-4712 Guide Bolts can be used 180 degrees apart to support the damper during rework.

Note: The vibration damper is fed with engine oil. Some engine oil will leak from the damper to crankshaft connection once the bolts are loosened.

Image1.2.1

3.) Remove and replace failed damper mounting bolts, along with the remaining bolts in the counterbore locations on the 360-1190 Spacer Plate. The remaining bolts not in the counter-bore locations are to be reused if the bolts meet general reuse and salvage guidelines.

Refer to Reuse and Salvage Guidelines, SEBF8301, "Inspection and Reuse of Critical Fasteners Used in All Engines" for bolt specifications.

Image1.3.1

4.) Remove the 360-1190 Spacer Plate. Do not reuse the spacer plate.

Image1.4.1

5.) Remove the old front crankshaft seal and replace with the new 438-3101 Front Crankshaft Seal. Reference KENR6052 for the Disassembly and Assembly of the Front Crankshaft Seal.

6.) Install the new 146-3173 Dowel, 176-1378 Seal, 337-3140 Seal and the 391-8715 Vibration Damper.

7.) Lubricate the bolt threads and the bottom of the bolt head with a Molysulfide based lubricant. Install 148-5379 Spacers on each 274-7709 Damper Bolt. Install bolts into damper.

Image1.5.1

8.) Starting at the 12 o'clock position and working clockwise, label the bolts from 1 through 16. Tighten damper bolts 1 through 16 in the following order to a value of 800 +/- 100 Nm, which is standard torque.

Tightening Sequence: 1-9-5-13-2-10-3-11-4-12-6-14-7-15-8-16
9.) Repeat the tightening procedure only for bolts 1, 9, 5, and 13, tightening to 800 +/- 100 Nm.

Image1.6.1

Rework Procedure for the Vibration Damper Guard

1.) Disassemble the mounting brackets, isolation mounts, and hardware from the damper guard assembly.
2.) Retain the 2Y-5829 Nuts and 3E-4353 Washers to be reused. Refer to Image 1.7.1.

Image1.7.1

3.) Remove and do not reuse the mounting brackets, and remaining bolts, washers, and isolation mounts. Refer to Image 1.8.1.

Image1.8.1

4.) Install new 453-2317 Mounting Brackets on the top side of the vibration damper guard, along with the hardware shown below. Install the new 453-2318 Mounting Brackets on the bottom side of the vibration damper guard, along with the hardware shown below. Refer to Image 1.9.1. Tighten the bolts to 15 +/- 3 Nm.