Reuse and Salvage for Engine Dampers {1202, 1205} Caterpillar


Reuse and Salvage for Engine Dampers {1202, 1205}

Usage:

769C 01X
Caterpillar Products
All Cat Engines

Introduction

Table 1
Revision  Summary of Changes in SEBF8175 
22  Added serial number prefixes. 
21  Combined information from SEBF8152, SEBF8747, SEBF9226, and repaired 30 pixelated illustrations. 
20  Added serial number prefixes. 
19  Added serial number prefixes. 

© 2019 Caterpillar® All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law.

Information contained in this document is considered Caterpillar: Confidential Yellow.

This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

Canceled Part Numbers and Replaced Part Numbers

This document may not include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Important Safety Information



Illustration 1g02139237

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, ensure that it is safe for you and for other people to use. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

------ WARNING! ------

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.


Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the safety alert symbol which is followed by a signal word such as danger, warning, or caution. The "WARNING" safety alert symbol is shown below.



Illustration 2g00008666

This safety alert symbol means:

Pay attention!

Become alert!

Your safety is involved.

The message that appears under the safety alert symbol explains the hazard.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, you must determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.

Summary

This guideline contains the specifications for reusing viscous and rubber vibration dampers in 3500 engines. A damper that meets specifications found in this guideline should perform until the next overhaul when used in the same application.

A used damper must be inspected for the following symptoms: damage from dents , heat , discoloration, bulges and fluid leakage for viscous dampers, and rubber degradation for rubber dampers. The recommendations in this guideline will determine if the dampers are reusable.

Service Letters and Technical Information Bulletins


NOTICE

The most recent Service Letters and Technical Information Bulletins that are related to this component shall be reviewed before beginning work. Often Service Letters and Technical Information Bulletins contain upgrades in repair procedures, parts, and safety information that pertain to the parts or components being repaired.


Tooling and Equipment


NOTICE

Failure to follow the recommended procedure or the specified tooling that is required for the procedure could result in damage to components.

To avoid component damage, follow the recommended procedure using the recommended tools.


Table 2
Required Tooling and Equipment 
Part Number  Description  Quantity 
053-0088  Connector 
4C-6507  Pneumatic Gun with Hose 
4C-8648  Cleaner 
5P-1046  Connector 
5P-3238  Fitting 
6V-8926  Adapter 
8C-6866  Fitting 
9M-0387  Seat 
9X-6260  Rivet 
9X-7258  Teflon Washer 
138-7573  Link Brackets 
151-9263  Washer 
208-1341  Manifold Gauge Set 
208-1381  Vacuum Pump 
263-9070  Steel File 
303-9339  Lint Free Shop Towels 
436-0477  Oil Sample Set 
437-9760  Silicone Grease 
441-0714  Spring Tester 
Digital postal scale capable of 1 gram (0.035 ounce) increments with capability of at least 350 gram (12.250 ounce) 
1219.2 mm (48 inch)
Clear 9.525 mm (0.375 inch) I.D. tubing 

Replacement Parts

Consult the applicable Parts Identification manual for your engine.

------ WARNING! ------

When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material.

Failure to heed this warning can lead to premature failures, product damage, personal injury or death.


Measurement Requirements


NOTICE

Precise measurements shall be made when the component and measurement equipment are at 20° (68° F). Measurements shall be made after both the component and measurement equipment have had sufficient time to soak at 20° (68° F). This will ensure that both the surface and core of the material is at the same temperature.


Inspection Procedures for Welded Viscous Dampers and Rubber Isolation Dampers

The recommendation to replace the damper at the third major overhaul is not necessarily the best advice. The damper may still be reusable. At each rebuild, several recommendations can be followed to determine the specifications for reusability.

Nomenclature



Illustration 3g06305919
Cross-section of a typical viscous damper.
(1) Fluid cavity
(2) Weight
(3) Case
(A) Pilot hole, inside diameter

General Recommendations for Viscous Damper Replacement

Do not reuse the damper if any of the following conditions are present:

  1. The engine has had a failure because of a broken crankshaft.

  2. There is any sign of heat damage or discoloration of the damper.

    Note: Heat from welding or fires can warp the viscous damper housing. Heat can cause the metal ring inside the housing to seize. High temperatures can damage the fluid in viscous dampers and can also damage bearing elements in the housing. High temperatures can also damage the rubber on rubber dampers.

  3. There is a large amount of gear train wear that is not caused by lack of oil.

  4. Analysis of the oil has revealed that the front main bearing is badly worn.

  5. The damper is dented, cracked, or leaking.


NOTICE

Inspect the viscous vibration damper for signs of leaking and for signs of damage to the case. Either of these conditions can cause the weight to contact the case. This contact can affect damper operation.


Note: The fluid losing properties and/or the bearings wearing out limits the life of a viscous damper. These components cannot be inspected without destroying the damper. Environmental effects make estimating damper life difficult, if not impossible.

General Recommendations for Rubber Damper Replacement

Do not reuse the damper if any of the following conditions are present:



    Illustration 4g02270254
    Location of index marks (4) and (5).

  1. Inspection shows radial slippage of more than 1.50 mm (0.059 in) between the inner and outer member of the damper. Slippage can be detected by looking at the index marks (4) and (5) on the inner and outer member of the damper.


    Illustration 5g02270454

  2. Inspection indicates axial slippage between the inner and outer member as shown in Illustration 5. The outer member should be centered over the inner member.

  3. Inspection shows cracks in the rubber that cannot be attributed to age.

Inspection and Cleaning Procedures for Spring Dampers

Note: There are two different types of dampers used. One has 24 bolts securing the cover while the other has 48 bolts securing the cover. The dampers are physically the same otherwise. Graphics below are for illustrative purposes.

Nomenclature



Illustration 6g06305934
(1) Outer Clamping Ring
(2) End Plates
(3) Oil Passage
(4) Leaf Springs


Illustration 7g06305936
(A) Oil Chamber
(B) Leaf Spring
(C) Leaf Spring
(D) Oil Chamber

Engine oil flows into the damper through oil passages (3) and into oil chambers (A) and (D). As the damper rotates, leaf springs (B) and (C) flex and forces oil from one chamber to the next. This document details the oil passage cleaning procedure, leaf springs and inner adapter inspection procedure, maintenance intervals, and the damper assembly guide.

Inspection and Measuring Procedure

Visual Inspection



Illustration 8g06305945

Check for leakage with a visual inspection whenever possible. Look for leaks around the seal areas that are shown in Illustration 8

Inspection Intervals



Illustration 9g06305947
(1) Spring Washer
(2) Felt Pad and Dust Shield Assembly
(3) Cover
(4) O-ring Seal
(5) Rubber Seal (one per side of inner adapter)


Illustration 10g06305950

Refer to Illustration 9 and 10.

  • Separate the inner adapter (8) from the damper spring assembly (6) and clean all parts. Do NOT disassemble the damper spring assembly (6).

  • Check the wear of the damper spring blades. Refer to "Measuring Wear of Damper Spring Blades". If the spring blades are worn, replace the damper with a REMAN unit.

  • Clean the oil supply passages (7) of the inner adapter (8).

  • Replace felt pad and dust shield assemblies (2)

  • Replace seal (4) and seal (5).

Note: The damper spring assembly (6) and the inner adapter (8) are not serviceable. If excessive wear is found on the spring blades, replace the damper with a REMAN unit.

Note: Do not lift the damper spring assembly and inner adapter together after the cover plates are removed. Inner adapter should be supported and the spring assembly can be lifted off by the threaded holes in two opposite blocks.

Measuring Wear of Damper Spring Blades

A tool must be fabricated for the inspection of the spring blades. Use the following procedure to fabricate the tool and inspect the spring blades for wear.



    Illustration 11g06305960

  1. Remove felt pad and dust shield assembly (2). Remove bolts (1) and washers. Remove side plate (3).


    Illustration 12g06305963
    (A) GO side of the gage
    (B) NO-GO side of the gage
    (C) Gradient 1:30
    (D) 10.96 ± 0.02 mm (0.432 ± 0.001 inch)
    (E) 10 ± 0.02 mm (0.394 ± 0.001 inch)
    (F) 10.24 ± 0.05 mm (0.403 ± 0.002 inch)
    (G) 10 ± 0.02 mm (0.394 ± 0.001 inch)

  2. Fabricate a wedge that will be used as a testing tool. Use Illustration 12 for instructions on creating the wedge.


    Illustration 13g06305964
    (1) Spring packs
    (2) Measuring wedge
    (3) Inner star

  3. Use the wedge at every leaf spring pack. Place the wedge between the inner sides of the spring blades and against the inner adapter, as shown. With the wedge against the inner adapter, press the wedge down between the spring blades. A soft hammer may also be used to force the wedge against the spring blades.

  4. Observe the depth of the wedge. The further the wedge can be pressed between the spring blades, the more the spring blades and inner adapter are worn. The wedge acts like a Go/No Go Gage. Refer to Illustration 12. If the wedge can be inserted past the GO area on more than 25% of the springs, the spring blades and inner adapter must be replaced.

Guide for Assembly



Illustration 14g06305966


Illustration 15g06305968
Inner Y-seal orientation during assembly.


Illustration 16g06305970

The mating surface of the bolt head (A) and the mating surface of the parts of the damper (D) and (E) must be carefully cleaned. The threads of the bolts (B) and the tapped holes (C) must be cleaned.

If the contact surfaces have oxidized, the oxide layers must be removed with a wire brush or equivalent. The surfaces should be cleaned and degreased.



Illustration 17g06305973

Install the spring washers (F) as shown in Illustration 17.

Torque Sequence 12 Bolt Covers



Illustration 18g06305977

  1. Tighten four bolts in a star pattern as shown in Illustration 18 to approximately 22 N·m (16 lb ft), as shown in Illustration 18. Do not apply thread locking compound at this time.

  2. Apply Loctite® 243 to the remaining bolts. Install the remaining bolts and tighten the remaining bolts in a star pattern to 100 N·m (73.76 lb ft). After the bolts have been torqued to 100 N·m (73.76 lb ft), turn the bolts an additional 100° + 15 / - 0°.

  3. Remove the first four bolts that were installed and apply Loctite® 243. Tighten these bolts using a star pattern to 100 N·m (73.76 lb ft). After the bolts have been torqued to 100 N·m (73.76 lb ft), turn the bolts an additional 100° + 15 / - 0°.


Illustration 19g06053186

  1. Tighten the four inner bolts in a star pattern as shown in Illustration19 to approximately 22 N·m (16 lb ft), as shown in Illustration . Do not apply thread locking compound at this time.

  2. Apply Loctite® 243 to the remaining inner bolts. Install the remaining inner bolts in a star pattern and tighten the remaining bolts to 55 ± 10 N·m (41 ± 7 lb ft).

  3. Remove the first four bolts that were installed and apply Loctite® 243. Tighten these bolts using a star pattern to 55 ± 10 N·m (41 ± 7 lb ft). After the bolts have been torqued to 55 ± 10 N·m (41 ± 7 lb ft) turn the bolts an additional 95° ± 15°.

  4. Apply Loctite® 243 to the 24 outer bolts. Torque the bolts using a star pattern to 55 ± 10 N·m (41 ± 7 lb ft). After the bolts have been torqued to 55 ± 10 N·m (41 ± 7 lb ft) turn the bolts an additional 95° ± 15°.

Procedure to Rebuild Vibration Dampers for 3500 and C175 Engines

Nomenclature



Illustration 20g06305991
Damper GROUP that consists of a welded viscous damper (1) and a rubber damper (2).


Illustration 21g06305989
Single welded viscous damper (3).

Dampers with welded covers are not serviceable. Caterpillar recommends that both dampers in damper groups containing 193-3288 Viscous Damper and 7W-3193 Rubber Damper be changed at major overhaul. The damper should be replaced when the damper has experienced greater than two engine lives or 30,000 hours. Following this guidance is most important when these dampers are used in applications that feature large mechanical fan drives, high ambient temperatures, high hour crankshafts, or similar factors that increase demands on the damper system. Applications with lesser damper demands, or when dealing with damper groups that feature the 193-3288 Viscous Damper as a single damper. It may be possible to reuse these dampers if the dampers satisfy other reuse criteria. Failure to replace the dampers as recommended can result in failure of the crankshaft or other engine components. These dampers feature bolted covers and are serviceable units.



Illustration 22g06305993
Some 3508 and 3512 Dampers
(4) Viscous Damper
(5) Adapter
(6) Alignment Marks


Illustration 23g06305994
Some 3516 Dampers
(1) Alignment Marks
(2) Alignment Marks
(3) Viscous Damper
(4) Rubber Damper

Recommendations for Replacement

Bolted Viscous Damper

Do not reuse the damper if there is any fluid leakage. Do not use the damper if the housing is dented. Either condition could cause the metal ring to contact the housing. The damper becomes ineffective in these conditions. Damage to the housing can also affect the balance of the damper.



Illustration 24g06305996
(A) Sampling Ports

The following illustrations show the deterioration of the fluid in the damper and the effects the deteriorated fluid has on dampening ability.



Illustration 25g03151059
Fluid samples in various stages of discoloration. New fluid is on the left, and the worst fluid is on the right.


Illustration 26g06305997
Normal silicone fluid


Illustration 27g03151061
Fluid that is slightly discolored and cloudy


Illustration 28g03151062
This fluid is discolored but is still transparent


Illustration 29g03151078
This fluid has changed from gray to black and has also thickened. The fluid is also no longer transparent.


Illustration 30g03151079
The fluid has turned into a dark gray paste that is almost black

Certain viscous dampers require fluid analysis. Fluid analysis should be taken during the operational life of the damper regardless of visible damage. Collect the fluid from the sampling ports.

The following address will provide kits and analysis for fluid sampling. Use 436-0477 Oil Sample Set to obtain a fluid sample.

Hasse & Wrede GmbH
Georg-Knorr-Straße 4
12681 Berlin
Germany
Phone +49 30 9392-3135
Fax +49 30 9392-7-3135
Alternate Phone +49 30 9392-3156
Alternate Fax +49 30 9392-7-3156

Note: Fluid that has lost properties will limit the life of a damper. Bearings that wear out will limit the life of a damper.

Rebuild Procedure for the Bolted Viscous Dampers



    Illustration 31g06305998


    Illustration 32g03338765

  1. Remove bolts (1) and cover (2). The weight of cover (2) is approximately 12.6 kg (28 lb).

    Note: The fill plugs may need to be removed to release the vacuum on the damper cover (2).



    Illustration 33g03520967

  2. Remove O-ring seals (3) and (4). Remove bearing (5).


    Illustration 34g03520958
    (6) Case
    (7) Center Weight

  3. The center weight (7) can be removed by cleaning the top surface of the weight (7) and using a suitable lifting device, as shown. The approximate weight of the center weight (7) is 110 kg (243 lb).

    Note: The case (6) will adhere to the center weight (7) due to the suction force of the viscous fluid. Gravity will allow the case (6) to separate from the center weight (7). A soft rubber mallet may also be required to separate the case (6) from the center weight (7).



    Illustration 35g03338878


    Illustration 36g03339959
    The case has been thoroughly cleaned. Use compressed air to blow the bolt holes out ensuring the holes are clean, dry, and rust free.


    Illustration 37g03338880


    Illustration 38g03340072
    The center weight has been thoroughly cleaned. Ensure that the weight is clean, dry, and rust free.

  4. Most the viscous fluid can be removed with a putty knife. The remainder of the viscous fluid can be removed by using 4C-8648 Cleaner, or equivalent.

Table 3
Fill Quantities for Bolted Viscous Dampers 
Part Number  Grams of Silicon Fluid 
Service Kit Minimum  Nominal  Maximum 
102-7614 (1)  420-8778  787  808  829 
146-3740 (1)  420-8780  1149  1181  1213 
171-4570 (1)  420-8779  1149  1181  1213 
171-4571 (1)  420-8780  1149  1181  1213 
244-4508 (1)  420-8780  612  680  748 
247-0845 (1)  420-8780  612  680  748 
283-1678 (1)  418-1924  670  690  710 
317-1640 (1)  418-1924  880  930  980 
362-7672 (2)  418-1924  675  710  745 
476-2761 (2)  418-1924  708  743  778 
(1) Use 437-9760 Damper Kit for this damper part number.
(2) Use 437-9762 Damper Kit for this damper part number.


    Illustration 39g03520960

  1. Install one of the bearings (5).


    Illustration 40g03520962

  2. Weigh a full tube of silicon fluid using digital scale (A). Record the weight of the full tube.


    Illustration 41g03340172

  3. Apply approximately 50 percent of the total amount of viscous fluid that is required. Weigh the empty tubes to record the amount of fluid that is dispensed.


    Illustration 42g03520963

  4. Using a suitable lifting device and slowly lower the center weight (7) into the case (6). The approximate weight of the center weight (7) is 110 kg (243 lb).


    Illustration 43g03520966

  5. Once the weight (7) is installed, the weight should rotate freely within the case (6).


    Illustration 44g03438656

  6. Install bearing (5). Install O-ring seals (3) and (4).

  7. Apply Loctite 243 to the cover bolts (1)


    Illustration 45g03340370


    Illustration 46g03508860

  8. Install cover (2) and bolts (1). Tighten bolts (1) to a torque of 55 ± 7 N·m (40 ± 5 lb ft). Torque the inside bolts first then torque the outside bolts using a crisscross pattern.

    Note: The bolts must be torqued in a uniform pattern to the proper specification. If the bolts are not torqued properly, then leaks will occur.



    Illustration 47g03438665

  9. Remove both plugs from cover (2).


    Illustration 48g03520956

  10. Connect 5P-1046, 6V-8926 and 151-9263 (B) to one port on cover (2).

  11. Connect clear 3/4 clear tubing (C) to (B). One end of tooling (C) will remain open for now.


    Illustration 49g03520964

  12. Connect 053-0088, 6V-8926 and 151-9263 (D) to the remaining open port on cover (2).


    Illustration 50g03520965

  13. Connect (C) to 208-1381 (E) by sliding (C) over the open port on (E). Connect 208-1341 (F) to (E).


    Illustration 51g03439458

  14. Elevate (C) so that air can be purged from the damper without carrying the fluid through (C).


    Illustration 52g03520968

  15. Insert a tube of fluid into 4C-6507 (G).


    Illustration 53g03520959

  16. Thread the tube into (D). Install the top onto (G).


    Illustration 54g03520961

  17. Operate (E) so that (F) shows a vacuum between 33.9 kPa (10 inch mercury) and 67.7 kPa (20 inch mercury). Maintain this vacuum throughout the fill process. It is necessary to release the vacuum while changing out the fluid tubes.

  18. Continue to operate (G) and (E) until the damper is approximately 90% full. Continue to keep record of the amount of fluid dispensed into the damper.


    Illustration 55g03441317

  19. It is critical to not under fill or over fill the damper. Once the damper is close to full the operator will start to see air bubbles expelling from the damper into (C). Maintain a vacuum between 33.9 kPa (10 inch mercury) and 67.7 kPa (20 inch mercury). Slowly add more fluid by using (G) while air bubbles are being expelled from the damper. Continue to monitor the weight of fluid dispensed into the damper. Continue filling the damper with (G) until the fluid dispensed is within the specification in Table 3.

  20. Release the vacuum from the damper. Remove (B) ( C) ( D) from the damper.


    Illustration 56g03438665

  21. Install the two plugs into cover (2). Torque the plug to 17.0 ± 3.0 N·m (12.5 ± 2.2 lb ft)

  22. The damper is now ready to be returned to service.

Procedures to Rebuild Vibration Dampers for 3600 Engines

Procedure to Modify the Fittings



Illustration 57g01623273
5P-3238 fitting
Drill a hole with a 9.50 mm (0.374 inch) diameter in 5P-3238 fitting. 5P-3238 fitting is used on dampers with a 762 mm (30.0 inch) diameter.
(1) 9.50 mm (0.374 inch) hole


Illustration 58g01623373
8C-6866 Fitting
8C-6866 Fitting is used on dampers with a 597 mm (23.5 inch) diameter.
(1) 9.50 mm (0.374 inch) hole
(2) 7.50 mm (0.295 inch) hole

Drill a hole with a 7.50 mm (0.295 inch) diameter through the fitting. Drill a second hole with a 9.50 mm (0.374 inch) diameter that is 19.05 mm (0.750 inch) deep.

General Information

The 3600 engines use four variations of vibration dampers. The damper with a diameter of 597 mm (23.5 inch)has been released with two variations. One has a nylon coated weight. The second design requires a teflon bearing on the axial thrust surfaces near the inside diameter of the weight.

The damper with a diameter of 762 mm (30.0 inch) comes in narrow designs and wide designs. These dampers require nylon bearings for the inside diameter at the center hub surface at both axial thrust surfaces.

Inspection of Vibration Damper


NOTICE

When a vibration damper fails to operate correctly, torsional vibrations can be severe enough to result in main bearing failures, broken crankshafts, damaged cylinder blocks, and damage to external and internal engine components.


Inspect the vibration damper before disassembly for signs of leakage, nicks, broken fins, bulges in the cover, and dents. Any parts with signs of damage must be replaced during the procedure to rebuild the damper. Because vibration dampers are balanced at the factory, any damaged components must be replaced with a new part.

Signs of bulging on a vibration damper indicate excessive internal damage. Dampers with excessive internal damage must be replaced with a new damper assembly.

Check the cover on the damper with a 597.0 mm (23.50 inch) diameter for signs of leaks at vent holes. Leaks at vent holes will require a new cover.

Nomenclature



Illustration 59g01623724
Damper with coated nylon weight
(3) Coated Weight
(4) Disc


Illustration 60g01624183
(5) Rivet
(6) 7C-9689 Bearing
(7) 7C-9688 Bearing


Illustration 61g06306006
Narrow damper with nylon bearings
(8) 9Y-2997 Bearings


Illustration 62g06306007
Wide damper with nylon bearings
(8) 9Y-2997 Bearings

Disassembly of the Vibration Damper



Illustration 63g06306008
(9) Filler Plugs

  1. Lay the vibration damper flat. The filler plugs should be facing upward.

  2. Remove the filler plugs.


    Illustration 64g06306009
    (10) Cover
    (11) Hub
    (12) Ring

  3. Remove the bolts that hold the cover to the hub and the ring, and remove the cover.


    Illustration 65g06306010
    (13) Bearing Segment

  4. If the damper is equipped with axial thrust bearing segments, the segments must be removed.


    Illustration 66g06306011
    (13) Bearing Segment
    (14) Weight

  5. Fasten three 138-7573 Link Brackets and attach a hoist to the weight. Remove the weight from the damper housing.

    Three different weights are used in vibration dampers for the 3600 series of engines. The sizes are listed in Table 4.

    Table 4
    Diameter  Type  Weight 
    597 mm (23.5 inch)  Narrow  119 kg (262.3 lb) 
    762 mm (30.0 inch)  Narrow  171 kg (377.0 lb) 
    762 mm (30.0 inch)  Wide  339 kg (747.4 lb) 

  6. Remove the axial thrust bearing segments. If the damper has an inner radial bearing, remove the inner radial bearing.


    Illustration 67g06306013
    (15) O-ring seals

  7. Remove the O-ring seals.


    Illustration 68g06306015
    The cover is being removed from a damper with a 762 mm (30.0 inch) diameter.
    (10) Cover
    (12) Ring
    (15) O-ring seals

  8. Remove the bolts that hold the cover to the hub. Lift the cover and the ring off the hub and remove the O-ring seal.

  9. Separate the cover from the ring and remove the O-ring seal.

  10. Inspect all parts for damage and wear. The fins on the covers must not be broken. The covers are balanced at the factory. Damaged fins will affect the balance of the assembly.

Remove any nicks or burrs from all machined surfaces with a file or a hard stone. Do not reuse any parts which have missing pieces from handling damages.

Recommendations for Cleaning

  1. The interior surfaces and the exterior surfaces of the components of the damper can be cleaned with hot water 82 °C (180.0 °F).

  2. The center hub and weight have passages which must be cleaned. Use brushes with nylon bristles or air pressure to clear the passages of silicone and foreign material. Silicone and foreign material may restrict the new silicone that will be injected during the procedure to fill.

  3. Check the passages in the center hub and weight for cleanliness by flushing the passages with trichloroethane or liquid Freon. After the fluid has been flushed, collect the fluid with a glass beaker. Inspect the fluid for residual particles.

  4. Repeat the cleaning procedure and the inspection procedure until no particles are visible in the beaker.

  5. Spray or coat all surfaces with a light film of oil to avoid contamination from rust.

Procedure to Rebuild the Damper with a 597 mm (23.5 inch) Diameter

During the process for rebuilding these dampers, special procedures must be followed. The 7E-5489 Damper has a nylon coated weight. The nylon coated weight must be replaced with the parts that are listed in Table 5.

Table 5
Quantity  Part Number  Description 
7E-1614  Weight 
7C-9688  Radial Bearing 
7C-9689  Thrust Bearing 

Inspect the cover for the 7E-5489 Damper for signs of leakage at the two staked discs. If the signs of leakage are observed, replace the cover. Do not remove the two staked discs anytime during the procedure to rebuild the damper. If the cover is not damaged and there are no signs of silicone leakage, a hole should be drilled. Refer to Illustration 69 for the location of the hole that must be drilled.



Illustration 69g01625852
(16) Vent hole
(17) Fill hole

This is the vent hole that will indicate when the appropriate quantity of silicone has been injected. After the filling procedure, the hole should be plugged with one 9X-7258 Washer, one 9M-0387 Seat, and one 9X-6260 Rivet.

Assemble the Vibration Damper

Note: Skip Step 1 through Step 4 for the dampers with a diameter of 597 mm (23.5 inch).



Illustration 70g06306015
(10) Cover
(12) Ring
(15) O-ring seals

  1. Install a new O-ring seal on the outside diameter of the ring. Install the cover with the TDC mark for the first cylinder on the outside. The cover must engage with the dowel pins in the ring before installing the bolts. The dowel pins must project 5.00 mm (0.197 inch) to 7.00 mm (0.276 inch) above the surface of the ring and the hub.

  2. Install a new O-ring seal in the inside diameter of the hub. The fill ports must face downward against the table.

  3. Install the cover and the ring on the hub. The cover should be engaged with the dowel pins in the hub before the bolts are installed.

  4. The cover, the hub, and the ring should be turned over.


    Illustration 71g06306016
    (13) Axial thrust bearing segments

  5. Install the axial thrust bearing segments around the hub.


    Illustration 72g06306011
    (13) Bearing Segment
    (14) Weight

  6. Fasten 138-7573 Link Brackets to the weight.

    For the damper with a diameter of 597 mm (23.5 inch), the recommended quantity of silicone fluid is dependent upon the position of the weight in the case. Place the weight in the case. The large radius of the weight should be facing downward. The weep holes should be in a vertical position when the silicone is injected by aligning the weep holes and the two tapped fill ports on the inner diameter of the case.

  7. Lower the weight into the ring and onto the axial thrust bearing segments. The weep holes on the damper with a diameter of 597 mm (23.5 inch) must be aligned correctly.


    Illustration 73g06306017
    (13) Bearing Segment

  8. Install the radial bearing on dampers that have radial bearings.

  9. Install the axial thrust bearing segments.

  10. Install the O-ring seals on the inside diameter of the hub and on the outside diameter of the ring.


    Illustration 74g06306009
    (10) Cover
    (11) Hub
    (12) Ring

  11. Install the cover. The TDC mark for the first cylinder must be to the outside. Make sure that the cover is engaged with the dowel pins prior to the installation of the bolts.

Procedure to Fill the Damper

Note: All parts and fluid should be at a temperature of 20 °C (68.0 °F) to 25 °C (77.0 °F) for at least 2 hours before the damper is filled with silicone.



    Illustration 75g01627969

  1. Install two 138-7573 Link Brackets.


    Illustration 76g01627993

  2. Lift the damper with an overhead hoist. Position the damper at a 15 degree to 30 degree angle from the vertical plane.

  3. Install the appropriate adapter fitting into the bottom fill port. The top filler plug must be removed on the dampers with a diameter of 762 mm (30.0 inch).


    Illustration 77g01629354

    ------ WARNING! ------

    The vibration damper is filled with silicone. This substance is very thick and must be removed with a putty knife. Wear gloves in order to avoid skin irritation.


  4. Install the steel tube for the pneumatic gun over the adapter fitting.


    Illustration 78g01629537

  5. Place the silicone cartridge in the steel tube of the pneumatic gun. Engage the threads on the adapter fitting.

  6. Tighten the silicone cartridge and the adapter fitting into the bottom threaded hole.

  7. Install the air gun onto the steel tube. Lock the gun to the tube.


    Illustration 79g01629838

  8. Set the air regulator to 689.5 kPa (100.00 psi) for the maximum pressure. Install the air hose to the pneumatic gun. Depress the trigger to start the filling procedure.

  9. Refer to Table 6 for the appropriate number of cartridges to use on the different sizes of dampers.

    Table 6
    Diameter  Number of Cartridges 
    597 mm (23.5 inch)  3.5 
    762 mm (30.0 inch) narrow 
    762 mm (30.0 inch) wide 

  10. The first cartridges of silicone will empty in approximately 15 minutes. The silicone will flow at a slower rate as the damper becomes full. Approximately 30 minutes may be needed to inject the last tube. All silicone tubes should be emptied before starting a new tube.

    Note: The damper with a diameter of 597 mm (23.5 inch) must be injected with a minimum of 3 tubes. Steps 10a through Step 10e only apply to dampers with a diameter of 597 mm (23.5 inch).

    1. Fill the damper until 3 tubes have been injected. If the silicone fluid has not started to leak from the vent hole, stop filling the damper. The damper is filled with an adequate quantity of silicone fluid.

    2. If only three tubes have been injected and silicone fluid has started to leak from the vent hole, then the damper should lay horizontal for 30 minutes to allow the fluid to settle.

    3. Return the damper to the upright position and attempt to inject the remaining half of the tube of silicone.

    4. Do not continue to fill the damper if the fluid still leaks. The required amount does not need to be injected if the fluid still leaks. The damper is filled with an adequate quantity of silicone fluid.

    5. Remove the pneumatic gun and the cartridge.


    Illustration 80g01632216

  11. Install two filler plugs with new O-rings on the damper with a diameter of 762 mm (30.0 inch).

    The damper with a diameter of 597 mm (23.5 inch)requires the installation of two pipe plugs, one 9X-7258 Teflon Washer, one 9M-0387 Seat, and one 9X-6260 Rivet. One of the pipe plugs should be installed during Step 3.



    Illustration 81g01633587

  12. Remove the two lifting brackets.

  13. Scribe the dealer's code and the date of rebuild on the outside diameter of the ring.

  14. Protect the rebuilt damper during shipping and during the damper's storage life.

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