812639003 Mercury ROPE, Starter Safety

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PSP FOR INSTALLING NEW ALTERNATOR BELTS, PULLEYS AND GUARDS ON CERTAIN D11N TRACTORS; 776B TRACTORS; 777B,785, 789 TRUCKS; 350 8, 3512, 3516 ENGINES (SPARE) - MAILED CACO, COFA, BRAZIL, COSA, LIMITED CFEL
  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.
A-118 AU-116 B-27 E-79.1 O-108 1405, 7168, 1425 PS4344 This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4344" as Part Number, "7755" as Group Number, and "96" as Description Code. Termination Date
September 30, 1990
Problem
The service life of the alternator belts, may not be as long as desired on certain D11N Tractors; 776B Tractors; 777B, 785, and 789 Trucks; and 3508, 3512, and 3516 Engines (Spare).
Affected Product
Model Identification Number D11N 74Z0001-645 776B 6JC0001-77 777B 4YC0001-1062 3NF0001-28 785 8GB0001-365 789 9ZC0001-277 3508 99W308, 493, 495, 497, 555, 556, 558, 566, 590, 592, 618, 636, 637, 654, 670, 677, 678, 702, 712, 719, 748, 778, 783, 784, 790, 794, 797, 802, 808, 815, 825, 826, 836, 861, 882, 883, 900, 903, 905, 916, 921, 927, 982, 989, 1005, 1031, 1033, 1036, 1037, 1053, 1059, 1071, 1084, 1087, 1095, 1100, 1101, 1137, 1187, 1190, 1192, 1199, 1200, 1240, 1241, 1275-1277, 1280, 1368, 1407, 1436, 1437, 1444, 1464, 1470, 1493, 1495, 1564, 1584, 1597, 1599, 1602, 1605, 1625, 1631, 1638, 1648, 1650, 1651, 1652, 1653, 1695, 1696 3512 96Z225, 231, 232, 244, 276, 277, 292, 335, 338, 341, 349, 350, 371, 381, 391, 396, 399, 403, 411, 417, 420, 421, 422, 429, 430, 439, 442, 443, 463, 466, 472 3516 54Z170, 179, 190, 196, 206, 217, 233, 239, 240, 264, 284, 291, 293-296, 311
Parts Needed
1 - 7C2450 Support* 1 - 7C3290 Guard** 1 - 7E4840 Pulley*** 1 - 7E4839 Pulley 1 - 7E4841 V-Belt 2 - 7E5639 Spacer 1 - 2M4453 Seal 1 - 8M5255 Seal 1 - 9X4612 Seal * Only replace existing mounting bracket if pulleys are out of alignment according to rework procedure. ** Only replace if existing guard is cracked or broken. Also replace any steel belt guard with a 7C3290 Fiberglass Guard. ***If the 7E4840 Pulley Assembly is not available, order 1 - 7E4838 Pulley and 1 - 535065 Sleeve. Press the sleeve onto the pulley flush with the pulley mounting face as shown in Illustration 1. ****** IMAGE: SEBE4126.00001.001 CAPTION: Illustration 1
Action Required
1. Remove the alternator guard, belt, pulleys and alternator drive cover (7N5743). This cover must be removed to allow room for new pulley to be installed. 2. Install a new 9X4612 Seal in the 7N5743 Cover. 3. Before the cover is installed the alternator drive pulley must be placed down behind the oil lines next to the block to make room for installing the cover. See Illustration 2. ****** IMAGE: SEBE4126.00001.002 CAPTION: Illustration 2 - Place The Drive Pulley Here Before Installing The Cover. 4. Install the pulley after the cover is installed. 5. Install alternator without fiberglass cover and set belt to 180 lb beginning tension (110 lb working tension). Tension may be set using a Burroughs gauge # BT-33-109 or # BT-33-72C. 6. Lay a straight edge across the face of the pulleys to check alignment. There should be no more than 2.0 mm (.080") clearance between the edge of either pulley and the straight edge. 7. If the pulleys are misaligned more than 2.0 mm (.080) replace the bottom alternator bracket (7C2450).