802702002 Mercury PLUG

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 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 "PS5286" 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.
Termination Date
June 30, 1998Problem
There have been a few bending failures of 3064 and 3066 Engine crankshafts installed in 311, 312, and 320 Hydraulic Excavators. This program provides support for 3064 and 3066 Engine crankshafts with bending failures. Bending failures are caused by forces exerted by the piston to the connecting rod to the crankshaft. See the Illustration below for a typical bending failure.
Eligibility For U.S. Dealers
For U.S. dealers to be reimbursed through this program, broken cranks must be returned to Caterpillar. Refer to the "Parts Disposition" section of this letter for details.
Affected Product
Model & Identification Number
Group 1
311 (9LJ1-9999 2KM1-9999 )
312 (6GK1-9999)
Group 2
320 (2DL1-2143, 2DL2160, 2DL2171, 2DL2178, 2DL2179, 2DL2223, 2DL2248)
320L (9KK1-4686, 9KK4688, 9KK4689, 9KK4691, 9KK4697, 9KK4698, 9KK4709, 9KK4710, 9KK4717 , 9KK4768, 9KK4785)
320N (1XM1-165)
Parts Needed
Group 1
1 - 5I4993 O-Ring1 - 5I5038 O-Ring2 - 5I7524 Seal1 - 5I7561 Gasket1 - 5I7588 Bearing Set8 - 5I7637 Bearing1 - 5I7656 Seal1 - 5I7657 Gasket1 - 5I7658 Gasket1 - 5I7660 Seal Assembly1 - 5I7661 Gasket1 - 5I7689 Gasket1 - 5I7742 Gasket1 - 5I7842 Gasket1 - 1R0739 Filter Assembly1 - 5I7844 Crankshaft AssemblyGroup 2
1 - 5I4993 O-Ring 1 - 5I5038 O-Ring 2 - 5I7524 Seal 1 - 5I7561 Gasket 1 - 5I7588 Bearing Set12 - 5I7637 Bearing 1 - 5I7656 Seal 1 - 5I7657 Gasket 1 - 5I7658 Gasket 1 - 5I7660 Seal Assembly 1 - 5I7661 Gasket 1 - 5I7666 Gasket 1 - 5I7689 Gasket 1 - 5I7742 Gasket 1 - 1R0739 Filter Assembly 1 - 1253005 Crankshaft AssemblyAction Required
For 3064 Engines refer to the Disassembly and Assembly Manual SENR5553-01, and 3064 Engine Supplement SENR6149.
For 3066 Engines refer to the Disassembly and Assembly Manual SENR5553-01, and 3066 Engine Supplement SENR5556-01.
1. Remove the engine from the chassis.2. Remove the crankshaft assembly.3. Install a new crankshaft assembly and bearings.4. Install oil pump suction tube, oil filler tube and oil pan.5. Install engine on dynamometer and check for any leaks or unusual noises.6. Install engine assembly into chassis.7. Install engine oil filler tube. For 3064 Engines, fill with 13 liters (3.4 U.S. gallons) of oil. For 3066 Engines, fill with 21 liters (5.4 U.S. gallons) of oil.
Service Claim Allowances
If it is more economical to replace the engine instead of the crankshaft, appropriate charges will be considered. The above hours for the repair are based on 14 hours to remove and replace the engine and 14 hours to replace the crankshaft.
Parts Disposition
For U.S. dealers to be eligible for this program, broken cranks must be returned to:
Caterpillar Inc.
Service Claims Room
Attn: Dennis Belcher - PS5286
8201 N. University
Peoria, Illinois 61615
All Other Dealers
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.