PRODUCT IMPROVEMENT PROGRAM FOR REWORKING INTERFERENCE BETWEEN THE ENGINE BLOCK AND THE 217-3043 GEAR PLATE ON CERTAIN 3456 DEPLOYABLE POWER GENERATION AND DISTRIBUTION SYSTEMS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING INTERFERENCE BETWEEN THE ENGINE BLOCK AND THE 217-3043 GEAR PLATE ON CERTAIN 3456 DEPLOYABLE POWER GENERATION AND DISTRIBUTION SYSTEMS

Usage:

SEBE9330

September 12, 2005
U-297
D-227
O-242

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING INTERFERENCE BETWEEN THE ENGINE BLOCK AND THE 217-3043 GEAR PLATE ON CERTAIN 3456 DEPLOYABLE POWER GENERATION AND DISTRIBUTION SYSTEMS
1206		PI30860

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30860" as the Part number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI30860" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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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COMPLETION DATE	TERMINATION DATE
March 31, 2006	September 30, 2006

PROBLEM

3456 engines used in the military DPGDS (deployable power generation and distribution system) generator application have experienced failures of the 5p-4142 locking bolt in the 137-5961 Gear group. The root cause of this failure is interference between the engine block, and studs mounted in the 217-3043 Gear plate.

AFFECTED PRODUCT

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Model	Identification Number
3456	9BZ11-241

PARTS NEEDED

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Qty	Part Number	Description
1	5E8771	SEAL-O-RING
2	9H8872	GASKET
8	5M2894	WASHER-HARD
1	4N1151	GASKET-OIL P
2	3P1155	SEAL-O-RING
2	5P4142	BOLT-LOCKING
1	8T9022	GASKET-SILIC
1	8T9527	SEAL-O-RING
1	1075769	SEAL-O-RING
1	1178801	SEAL-O-RING
2	1209243	STUD (BRAKE)
1	1223772	SEAL-O-RING
9	1261757	WASHER-SEALI
2	1295427	WASHER
12	1295428	STUD
1	1425867	SEAL GP-CSHF
1	1446142	SEAL-INTEGRA
1	1559524	SEAL-INTEGRA
1	1591533	PLATE-SEALIN
1	1598524	ADAPTER AS
1	1658110	PLATE
1	1669144	GASKET
1	1974971	STUBSHAFT
2	2033940	SEAL-O-RING

ACTION REQUIRED

Special instruction REHS2705 details a procedure for replacing the old 217-3043 Gear Plate with the new 165-8110 Gear Plate. Change the old 128-8853 Gear Adapter with the new 159-8524 Gear Adapter. Change the old 117-8557 carrier seal with the new 159-1533 carrier seal, and replace the old 248-3008 idler stub shaft with the new 197-4971 idler stub shaft.

OWNER NOTIFICATION

U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
100%	33.5	0	0	0	0
NOTE: This is a 33.5 hour job. NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach. (1-Owner Notification)

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING INTERFERENCE BETWEEN THE ENGINE BLOCK AND THE 217-3043 GEAR PLATE

MODELS INVOLVED - CERTAIN 3456 DEPLOYABLE POWER GENERATION AND DISTRIBUTION SYSTEMS

Dear Caterpillar Product Owner:

The interference between the engine block and the 217-3043 gear plate needs to be reworked on the products listed below. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated September 12, 2005 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to September 12, 2005 Service Letter