PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE CYLINDER PACKS AND EXHAUST COMPONENTS ON CERTAIN 3456 GENSETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE CYLINDER PACKS AND EXHAUST COMPONENTS ON CERTAIN 3456 GENSETS

Usage:

REBE2317-01

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04Oct2007

(Revised 12Feb2008)

U-504

D-406

O-437

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE CYLINDER PACKS AND EXHAUST COMPONENTS ON CERTAIN 3456 GENSETS
1239 1050 1225 7620 1901		PI10634

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10634" 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 "PI10634" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:	This Revised Service Letter replaces the 04Oct2007 Service Letter. Changes have been made to the Parts Needed and the Rework Procedure.

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PROBLEM

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The cylinder packs and exhaust components need to be replaced on certain 3456 Gensets. The existing pistons can seize when the unit is operated in high ambient temperatures. A piston seizure has the potential to create flying debris which may result in personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
DV-3456	9BZ00001-00208, 218-241, 400, 409-640 DPG00001-00036

PARTS NEEDED

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Qty	Part Number	Description
24	3E6772	SEAL-WATER
1	4N1151	GASKET-OIL PAN
1	4W9160	CLAMP-V-BAND
1	5E8771	SEAL-O-RING
1	5L8484	GASKET
2	5L8854	RING-SEALING
2	5P0840	SEAL-O-RING
1	5P4142	BOLT-LOCKING
1	5P5846	SEAL-O-RING
1	5P8068	SEAL-O-RING
1	8L2786	SEAL-O-RING
6	8S9191	BOLT
1	9N1943	SUPPORT-EXHAUST
1	9N3220	COUPLING-EXHAUST
1	9X6458	WASHER-HARD
6	9Y7735	BEARING-ROD
6	10R6473	CYLINDER PACK AS
1	1013125	GASKET
1	1142687	SEAL-O-RING
1	1178801	SEAL-O-RING
1	1262702	SEAL-INTEGRAL
1	1422329	SEAL-DRAINBACK
2	1714358	SEAL-O-RING
1	1972541	ELBOW AS
1	1986068	SEAL-INTEGRAL
1	2245122	GASKET
1	2271204	GASKET
6	2481394	KIT-GASKET-SFI
1	3255735	SOFTWARE GP - ELEK
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% of dealership population. This is an inital 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

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See attached rework procedure.

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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%

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NOTE: This is a 36.1-hour job

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PARTS DISPOSITION

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

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

Rework Procedure

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1. Isolate the Genset before commencing any work. Open the Genset breaker and disconnect the battery cables. Ensure that health and safety requirements are adhered to at all times.

2. Remove the genset from the enclosure.

3. Replace all six cylinder packs with the 10R-6473 Cylinder Pack Assembly in accordance with the procedures in Disassembly & Assembly, RENR2304. Perform the following procedure before reinstalling the camshaft gear:

a. Remove & discard the bolt and the washer from the adjustable idler.

b. Clean the bolt hole with a small wire brush and solvent (ie; brake clean).

c. Ensure that the bolt hole is clean and dry.

d. Install a new 5P-4142 Bolt and a new 9X-6458 Washer.

e. Tighten the bolt to a torque of 55 N.m (41 lb ft).

f. Tighten the bolt to a torque of 55 N.m (41 lb ft) again.

NOTE: If the backlash needs to be adjusted, remove each nut, clean each stud, and apply 9S-3263 Thread Lock Compound to each stud. Adjust the backlash using the procedure in RENR2303, Testing & Adjusting, "Gear Group (Front) - Time". Tighten the nuts and the bolt to a torque of 55 N.m (41 lb ft). Then, tighten the nuts and the bolt to a torqe of 55 N.m (41 lb ft) again.

4. Replace the exhaust elbow, support, and coupling. Refer to Image 1.4.1.

Image1.4.1

5. Install the genset in the enclosure.

6. Flash the Engine Control Module (ECM) with the new 325-5735 Software (Flash File).

7. Use Cat ET to verify that the values for "High Inlet Manifold Temperature" and "High Fuel Temperature" are programmed correctly in the monitoring system as shown in Image 1.7.1. If the values for the three parameters are not programmed correctly, reprogram the parameters to the values shown in Image 1.7.1.

Image1.7.1

8. Use a stamp to mark the engine with a "P" on the left side of the engine block and the right side of the engine block. Refer to Image 1.8.1 and Image 1.8.2 for the correct location of marks.