PRODUCT SUPPORT PROGRAM FOR REWORKING THE CRANKSHAFT TIMING WHEEL BOLTS ON CERTAIN C4.4 INDUSTRIAL ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE CRANKSHAFT TIMING WHEEL BOLTS ON CERTAIN C4.4 INDUSTRIAL ENGINES

Usage:

REBE8761-01

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09Nov2012

(Revised 17Jun2013)

U-600

A-475

D-512

O-551

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE CRANKSHAFT TIMING WHEEL BOLTS ON CERTAIN C4.4 INDUSTRIAL ENGINES
1912 1905 1204 1202 7553		PS52335

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS52335" as the Part Number and "7755" as the Group Number. Use "96" as the 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 09Nov2012 Service Letter. Changes have been made to the Service Claim Allowances, and Parts Disposition.

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TERMINATION DATE

30Nov2014

PROBLEM

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The existing timing wheel bolts can become loose on certain C4.4 Industrial Engines. If the existing timing wheel bolts fail it can cause the engine to run rough or an engine de-rate condition. Diagnostic code 190-8 may be present.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C4.4	44413043, 15293-15294

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*******Group 2*******

C4.4

44412945, 12967, 12970, 12976, 12978, 13003-13006, 13014, 13019, 13030-13041, 13053, 13058, 13085-13090, 13112-13120, 13171-13172, 13192-13194, 13196-13214, 13239, 13262, 13279-13292, 13313-13345, 13349-13382, 13415-13418, 13423, 13426-13428, 13430, 13432-13435, 13437-13458, 13466, 13483-13517, 13519, 13524-13528, 13530-13578, 13582-13591, 13593-13626, 13628-13639, 13648-13662, 13675-13678, 13682-13692, 13721-13722, 13724, 13726-13746, 13748-13802, 13813-13836, 13838-13870, 13872-13908, 13922-13926, 13932, 13934-13953, 13981, 13985, 13992-14006, 14009-14019, 14029-14052, 14058-14063, 14079-14083, 14093-14128, 14150-14175, 14184, 14191-14216, 14235, 14254-14292, 14295-14328, 14332-14337, 14358-14361, 14376-14378, 14406, 14419-14425, 14427-14435, 14437-14459, 14461-14482, 14500-14505, 14508-14512, 14514-14522, 14531-14533, 14537-14558, 14560-14582, 14584-14590, 14592-14597, 14599, 14606-14618, 14620-14621, 14623-14645, 14653-14657, 14660-14680, 14698, 14701-14705, 14708-14711, 14713-14715, 14717-14722, 14726, 14736-14739, 14742, 14763-14802, 14804-14814, 14817-14834, 14847-14850, 14854-14855, 14858, 14861-14889, 14892-14921, 14935-14936, 14983, 14994, 15031, 15047, 15057, 15100, 15113, 15215-15216, 15234, 15261-15263, 15265-15266, 15296, 15338-15342, 15344, 15346, 15376, 15402-15413, 15417, 15420, 15424-15427, 15430-15432, 15434, 15529-15531, 15591, 15701-15702, 15704, 15798, 15872, 15876, 15880-15881, 15886, 15897, 15899, 15960-15961, 15976, 15978, 15980, 15984-15985, 16005, 16007, 16041, 16052, 16056-16057, 16086, 16092, 16101, 16308, 16385-16389, 16392, 16425, 16446, 16461, 16463, 16476, 16489, 16552-16554, 16557, 16578, 16640, 16643, 16649, 16652

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*******Group 3*******

C4.4

44413042, 13137-13138, 13140-13170, 13173-13178, 13180-13188, 13190-13191, 13263-13278, 13436, 13459, 13467-13482, 13579-13581, 13640-13647, 13679-13681, 13909-13910, 13927-13931, 13977-13980, 14007-14008, 14020-14028, 14091-14092, 14149, 14217-14218, 14238-14253, 14331, 14338-14341, 14365-14371, 14379-14390, 14483, 14485-14499, 14648-14652, 14658, 14687, 14743, 14745, 14750, 14752-14757, 14759-14762, 14922-14923, 14927-14930, 14932-14934, 14990-14991, 15110, 15145-15149, 15171, 15182-15184, 15241-15256, 15260, 15267, 15362, 15400-15401, 15595, 15600-15601, 15606-15610, 15612-15615, 16210, 16218-16219, 16221, 16662, 16702, 16706, 16719, 16722

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*****Group 4*****
C4.4	44413414, 13419-13422, 13520-13523, 13529, 13592, 13804-13805, 13807-13809, 13812, 13921, 14342-14344, 14372-14375, 14506-14507, 14513, 14528-14530, 14605, 14647, 14659, 14681-14685, 14716, 14723-14725, 15536-15537, 15810, 15845, 15890, 16004

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*****Group 5*****
C4.4	44414534-14536, 15755, 15759

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	1652601	SEALANT-SILICONE
1	2256005	GASKET
1	2258019?	GASKET-PUMP-HSG
1	2258287?	GASKET-COVER
1	2327449	HOUSING AS
3	2767394	BOLT
1	2772923	GASKET
1	2773012	GASKET-COVER
1	2880422?	SEAL-OIL (FRONT)
8	3239312	BOLT
1	3373574	TUBE-FUEL HP PUM
1	3398780	DOWEL
1	3414028	TIMING WHEEL
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.
*****Group 2*****
1	1652601	SEALANT-SILICONE
1	2256005	GASKET
1	2258019?	GASKET-PUMP-HSG
1	2268766	GASKET-COVER
1	2327449	HOUSING AS
3	2767394	BOLT
1	2772923	GASKET
1	2773012	GASKET-COVER
1	2880422?	SEAL-OIL (FRONT)
8	3239312	BOLT
1	3373574	TUBE-FUEL HP PUM
1	3398780	DOWEL
1	3414028	TIMING WHEEL
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.
*****Group 3*****
1	1652601	SEALANT-SILICONE
1	2256005	GASKET
1	2258019?	GASKET-PUMP-HSG
1	2327449	HOUSING AS
3	2767394	BOLT
1	2772923	GASKET
1	2773012	GASKET-COVER
1	2880422?	SEAL-OIL (FRONT)
1	2916524	GASKET COV TIMIN
8	3239312	BOLT
1	3373574	TUBE-FUEL HP PUM
1	3398780	DOWEL
1	3414028	TIMING WHEEL
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.
*****Group 4*****
1	1652601	SEALANT-SILICONE
1	2258019?	GASKET-PUMP-HSG
1	2258287?	GASKET-COVER
1	2327449	HOUSING AS
1	2375932	GASKET-PAN
3	2767394	BOLT
1	2772923	GASKET
1	2773012	GASKET-COVER
1	2880422?	SEAL-OIL (FRONT)
8	3239312	BOLT
1	3373574	TUBE-FUEL HP PUM
1	3398780	DOWEL
1	3414028	TIMING WHEEL
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.
*****Group 5*****
1	1652601	SEALANT-SILICONE
1	2258019?	GASKET-PUMP-HSG
1	2268766	GASKET-COVER
1	2327449	HOUSING AS
1	2375932	GASKET-PAN
3	2767394	BOLT
1	2772923	GASKET
1	2773012	GASKET-COVER
1	2880422?	SEAL-OIL (FRONT)
8	3239312	BOLT
1	3373574	TUBE-FUEL HP PUM
1	3398780	DOWEL
1	3414028	TIMING WHEEL
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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Remove engine to allow access to replace the timing wheel and timing wheel 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%
*****Group 1*****
0-3000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 23.0-hour job for Group 1
Fully document any resultant damage being claimed. Pictures must be taken of any failed parts or damage and attached to the SIMS report for claim approval.

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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%
*****Group 2*****
0-3000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 23.0-hour job for Group 2
Fully document any resultant damage being claimed. Pictures must be taken of any failed parts or damage and attached to the SIMS report for claim approval.

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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%
*****Group 3*****
0-3000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 23.0-hour job for Group 3
Fully document any resultant damage being claimed. Pictures must be taken of any failed parts or damage and attached to the SIMS report for claim approval.

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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%
*****Group 4*****
0-3000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 23.0-hour job for Group 4
Fully document any resultant damage being claimed. Pictures must be taken of any failed parts or damage and attached to the SIMS report for claim approval.

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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%
*****Group 5*****
0-3000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 23.0-hour job for Group 5
Fully document any resultant damage being claimed. Pictures must be taken of any failed parts or damage and attached to the SIMS report for claim approval.

PARTS DISPOSITION

Hold all parts for 60 days for a possible Parts Return Request (PRR). Make sure to list the service letter program number on the packing slip and include the closed work order paperwork.

If a Parts Return Request (PRR) is not issued to you after 60 days through the Send-It-Back process, handle the parts in accordance with your warranty bulletin on warranty parts handling.

Rework Procedure

1. Remove the flywheel housing, Refer to Disassembly and Assembly, "Flywheel Housing - Remove and Install".

2. Remove the crankshaft rear seal. Refer to Disassembly and Assembly, "Crankshaft Rear Seal - Remove".

3. Remove the engine oil pan, Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".

4. Install a new 341-4028 Timing Wheel to the crankshaft. Refer to ?Crankshaft Timing Wheel - Remove and Install?.

Note: Ensure crankshaft timing wheel bolt holes are clean and free of oil before fitting new bolts.

Note: Ensure that the new 276-7394 bolts have the thread-locking patch present. (Image 1.1.1)

Image1.1.1

5. Install crankshaft. Refer to Disassembly and Assembly, "Crankshaft ? Install"

6. Install the engine oil pan, Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".

7. Install new crankshaft rear seal. Refer to Disassembly and Assembly, "Crankshaft Rear Seal - Install".

8. Install the flywheel housing, Refer to Disassembly and Assembly, "Flywheel Housing - Remove and Install".