56113-ZW4-H11 Honda METAL, JOINT (Honda Code 7532492).

20Dec2007
(Revised 07Jan2008)
U-679
A-548
D-551
O-591
Before/After
PRODUCT SUPPORT PROGRAM FOR REPLACING CRANKSHAFT REAR COUNTERWEIGHT BOLTS IN 3508B ENGINES USED IN 992G, 854G, 776D, AND 777D MACHINES
1202 1302 PS42588
This Program must be administered either before or after failure.In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS42588" as the Part Numberand "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code.If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
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.
This Revised Service Letter replaces the 20Dec2007 Service Letter. Changes have been made to the Title.
TERMINATION DATE
31Dec2009
PROBLEM
The crankshaft rear counterweight mounting bolts can fail.
AFFECTED PRODUCT
Model Identification Number
776D AFS00082-00100
777D AGC01327-02547
DCB00148-00262, 32223
FKR00200-00238
854G A4W00199-00283
AMP00344-00355
992G ADZ00569-00623, 75001-75002
AZX00297-00801, 807-808
PARTS NEEDED
Qty
Part Number Description
1 7E2631 GASKET-OIL PAN
3 1284845 BOLT AS
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 15% 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
The rear crankshaft counterweight (closest to flywheel) bolts need to be replaced on certain 992G, 854G, 776D, and 777D machine engines after 6000 hours.
Perform the following actions one time at the first available oil change interval after the machine has run for 6000 hours. This service is NOT to be performed prior to 6000 hours.
Refer to appropriate Service Manual as needed.
If a bolt from the rear counterweight has loosened and fallen into the oil pan perform Repair Procedure A.
If a bolt has broken, perform Repair Procedure B.
Repair Procedure A:
1. Remove all oil from the pan.
2. Remove the rear section of the oil pan (closest to flywheel).
DO NOT REMOVE THE COUNTERWEIGHT
3. On the rear counterweight (closest to flywheel) torque the two outside bolts to 200 +/-5 Nm (147 lbf-ft).
4. Remove the center counterweight bolt.
5. Prior to assembly, put 6V-4876 lubricant on the bolt threads, the shank, and the underside of the bolt head.
6. Install a new counterweight bolt in the center hole and torque to 70 +/-5 N.m (50 +/- 4 lb ft) then turn an additional 120 +/- 5 degrees.
7. Remove one outer counterweight bolt.
8. Install new counterweight bolt in the outer hole and torque to 70 +/- 5 N.m (50 +/- 4 lb ft) then turn an additional 120 +/- 5 degrees.
9. Remove the remaining outer counterweight bolt.
10. Install new counterweight bolt in the outer hole and torque to 70 +/- 5 N.m (50 +/- 4 lb ft) then turn an additional 120 +/-5 degrees.
11. Reinstall rear section of oil pan.
12. Refill oil to the appropriate level.
Repair Procedure B:
1. Mark the counterweight so that it can be reinstalled in the same orientation.
2. Remove the counterweight.
3. Remove the remaining part of the bolt from the crankshaft.
4. Prior to assembly, put 6V-4876 lubricant on the bolt threads, the shank, and the underside of the bolt head.
5. Reinstall the counterweight with 3 new bolts (Regardless if fretting is present).
6. Torque all bolts to 200 +/- 5 Nm (147 lbf-ft).
7. Loosen the bolt in the center hole and torque to 70 +/- 5 N.m (50 +/- 4 lb ft) then turn an additional 120 +/- 5 degrees.
8. Loosen one outer co