PRODUCT IMPROVEMENT PROGRAM FOR REPLACING FLEX PLATE BOLTS ON CERTAIN 3412C GERERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING FLEX PLATE BOLTS ON CERTAIN 3412C GERERATOR SETS

Usage:

SEBE9338

September 17, 2005
U-305
A-220
D-233
O-248

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING FLEX PLATE BOLTS ON CERTAIN 3412C GERERATOR SETS
7751		PI30858

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30858" 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 "PI30858" 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

Flex plate bolts fail on certain generator sets with 592, 593, 595, 596, 597, and 598 frame size generators.

AFFECTED PRODUCT

****Group 1****

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Model

Identification Number

SR4B

1MS00744

4SJ01685

AFH00369

AFK00681

AFN01045

AGE01090

****Group 2****

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Model

Identification Number

3412C

4BZ7403, 7405, 7407, 7410, 7413, 7419, 7426, 7429, 7436, 7439, 7440-7441, 7443-7445, 7447, 7453, 7456-7459, 7461, 7463, 7465-7469, 7471, 7477-7480, 7485, 7487-7488, 7490, 7494, 7498-7499, 7501, 7505-7506, 7509, 7515-7522, 7524-7525, 7528, 7532-7534, 7536-7537, 7539, 7543-7544, 7553, 7556, 7618

9EP3426-3427, 3431, 3434, 3441-3450, 3460, 3465-3470, 3479, 3494-3495, 3515, 3519, 3522

BCW901

DJN457-458, 460, 464-466, 480, 484-486, 515-516, 526-527, 532-536, 540, 543, 548, 550-552, 556-557, 568, 570, 590-591

KAP319, 323-324, 326-328, 330-332, 334-335, 342-343

R7A105-106

TFT308

****Group 3****

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Model

Identification Number

3412C

4BZ7396, 7450, 7455, 7482, 7510, 7530, 7538, 7541, 7557, 7559

9EP3429, 3451, 3454, 3526-3527

DJN482-483, 494-495, 499-500, 502, 529, 598

PARTS NEEDED

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Qty	Part Number	Description
8	8T9400	BOLT

ACTION REQUIRED

See the attached Rework Procedure.

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%	100%	0	0	0	0
NOTE: This is a 1.0 hour job for Group 1. This is a 11.0 hour job for Group 2. This is a 20.0 hour job for Group 3. NOTE: Please include the number of broken bolts found in the claim comments. 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.

NOTE: Please return all broken bolts to:

Caterpillar Inc

445 Green Valley Rd

Griffin, GA 30224

Attn: JE Sanders

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

Attach. (1-Owner Notification)
(2-Rework Procedure)

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING FLEX PLATE BOLTS

MODELS INVOLVED - CERTAIN 3412C GERERATOR SETS

Dear Caterpillar Product Owner:

New flex plate bolts need to be installed 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 17, 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 17, 2005 Service Letter

Rework Procedure

Group 1 Rework Procedure

Inspect Flex Plate bolts. If bolts are found to be twelve point bolts, replace with known good bolts. Torque to spec.

Note: If bolts are found to be hex head, do not remove.

Group 2 Rework Procedure

Note: If the package is on a fuel tank, the engine/generator and base must first be removed from the fuel tank. Assure package has been disabled from starting and disconnected/ isolated from outside power source

1.Drain coolant and support radiator with hoist and chain.
Remove engine fan guard from radiator shroud.
Remove radiator bolts at base and remove radiator.
Support rear of generator to prevent leaning when engine is removed.
Remove bolts securing generator stator to flywheel housing and bolts securing generator rotor to engine flywheel.
Remove four bolts securing engine to base/tank. Carefully/slightly lift engine and move forward to obtain sufficient room to inspect/remove/replace generator flex plate bolts.
If bolts are found to be twelve point bolts, replace with known good bolts. Torque to spec.
Reinstall engine/generator and attachments.

Note: If bolts are found to be hex head, do not remove.

Group 3 Rework Procedure

Note: If the package is on a fuel tank, the engine/generator, base and canopy must first be removed from the fuel tank in one piece in order to perform the canopy removal.

Remove all nuts/bolts securing canopy to base

Note: There are 2 bolts inside the enclosure under the radiator that must also be removed.

Remove four nuts securing front muffler enclosure to main body enclosure. Must be done from inside of main enclosure
Remove front (muffler) enclosure.
Remove six nuts/bolts securing muffler base extension (hog trough) leaving muffler and pipes intact. Slide forward so as to not damage air deflectors on main body of enclosure
Disconnect exterior E-Stop wiring
Disconnect interior light wiring if so equipped.
Using the proper lifting device and lifting eyes - four 3/8" eye bolts - carefully lift enclosure off of base and sit aside.

Note: Open and secure center doors by air cleaners in canopy so as to not damage air deflector on doors or air cleaners.

Drain coolant and support radiator with hoist and chain.
Remove engine fan guard from radiator shroud.

10. Remove radiator bolts at base and remove radiator.

11. Support rear of generator to prevent leaning when engine is removed.

12. Remove bolts securing generator stator to flywheel housing and bolts securing generator rotor to engine flywheel.

13.Remove four bolts securing engine to base/tank. Carefully/slightly lift engine and move forward to obtain sufficient room to inspect/remove/replace generator flex plate bolts.

14. If bolts are found to be twelve point bolts, replace with known good bolts. Torque to spec.

15. Reinstall engine/generator and attachments.

Note: If bolts are found to be hex head, do not remove.