60180-ZY6-003 Honda CABLE A, COVER LOCK (Honda Code 7635683).

December 1, 2001
U-324
A-225
AU-216
S-167
O-245
Afterfailure only PRODUCT SUPPORT PROGRAMFOR REDUCING ENGINE VIBRATION ON CERTAIN 302.5 MINI-HYDRAULIC EXCAVATORS
1152 PS50343
This Program can only be administeredafter a failure occurs. The decision whether to apply the Program is madeby the dealer. When reporting the repair, use "PS50343" as the Part numberand "7755" as the Group Number. Use "96" as the Warranty Claim DescriptionCode and use "Z" as the SIMS Description Code. The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst.TERMINATION DATE
December 31, 2003PROBLEM
Engine vibration can be reduced on certain302.5 Mini-Hydraulic Excavators. Engine vibration between 1400 RPM and1600 RPM may cause operator discomfort. Failure is complaint of excessivevibrations felt in the operator station with engine rpm between 1400 and1600. Vibrations at other speeds are due to some other reason and are notcovered by this program.AFFECTED PRODUCT
Model Identification Number
302.5 4AZ1-3362PARTS NEEDED
4 - 7X2549 Bolt
1 - 1537920 Gasket
1 - 1542656 Bracket Assembly - Right
1 - 1542657 Bracket Assembly - Left
8 - 1657095 Washer
4 - 2023310 Mount Assembly
2 - 2111624 SpacerACTION REQUIRED
See the attached Rework Procedure.SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
0-3000
/0-36 Months 100% 4 0 0 0 0
This is a 4?hour job.PARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.
Attach. (1-Rework Procedure)Rework Procedure
Lord Engine Mount Field ReplacementKit ? Assembly InstructionsAdditional tools required:Trolley Jack/Overhead Crane
Angle Grinder or Similar Tool
PhototachRework Procedure:
Remove Seat.
Remove Access Panel.
Remove Left Hand Corner Protector.
Remove Hood.
Detach Throttle Cable.
Remove Sump Guard.
Remove Exhaust Assembly.
Lift Engine - Take the weight of the rear of theengine using either a jack or an overhead crane. If using a crane, undothe hose clamp and remove the top air hose to get access to the enginelifting point. Take care not to contact the cab with lifting slings/chains.If necessary relocate the engine-lifting eye to the left-hand side of theengine. When jacking do nit use the sump as the jacking point.
Remove Existing Rear Engine Mounts - Remove thetwo 13-mm nuts and bolts locating each existing mount to the bell housing.Slacken off all four 16-mm bolts through each of the mounts, front andrear. Lift the engine sufficiently to allow removal of the mounts fromunderneath the bell housing. It may be necessary to remove the hydraulicpump if the feed hose is contacting with the frame before the engine ishigh enough. To do this remove the two 18mm bolts holding the pump to thebell housing, slacken the two 16mm bolts clamping the return hose to thecounterweight under the machine and slide the pump out of the bell housing.
Assemble New Mounts - (See Illustration 2) Positionthe new spacer (5) into the bell housing from underneath. Place one halfof the mount (4) on top of the spacer and check that the rubber does notcontact the bell housing. If the rubber is not clear of the bell housingthen the housing must be ground away using an angle grinder or other suitabletool until there is no contact with the rubber. Bolt the spacer into thebell housing using the two 13mm bolts from the original mounts, tightento 28 7 N.m. Position the new rubber mount (4) and washer (6) underneath thespacer, ensure the rubber is correctly located in the spacer. Place thetop rubber (4) on top of the spacer and insert the sleeve through the mountassembly. Reuse the 8T4821 Washer (40-mm diameter) from the original assembly,and fit above 1657095 Washer. Complete for both sides of the bell housingand lower the weight of the engine on to the mounts. Place the second washer(6) and the original washer on top of the mount, bolt (7) through to theframe.
Remove Front Engine Mounts - Reposition the liftinggear or jack to the front of the engine and take the weight from the existingmounts. Remove the front 16mm mount bolts. Undo the four 21-mm bolts andremove the front mount bracket either side of the engine.
Assemble New Mounts - Fit the new front RH mountbracket (2), loosely retighten the four original 21-mm bolts. Build upthe mount assembly around the new mount bracket as described in section10. Repeat the process for the LH side of the engine using the LH bracket(3). When the mounts are assembled, lower the weight of the engine on tothe mounts. Tighten the four 21mm bolts to 132 15 N.m either side of the engine. Tighten all four of the 16-mm mount bolts,front and rear, (6) to 100 20 N.m.
Refit Hydraulic Pump ? If removed. Tighten thetwo 18-mm pump bolts to 100 20 N.m. Tighten the two