PRODUCT SUPPORT PROGRAM FOR INSPECTING AND, IF NECESSARY, REPLACING EXHAUST MANIFOLD CUP PLUGS ON 4EZ DV-3126 ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSPECTING AND, IF NECESSARY, REPLACING EXHAUST MANIFOLD CUP PLUGS ON 4EZ DV-3126 ENGINES

Usage:

REBE3304-00

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12Feb2008

D440
D447
G418

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Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR INSPECTING AND, IF NECESSARY, REPLACING EXHAUST MANIFOLD CUP PLUGS ON 4EZ DV-3126 ENGINES
1059		PS42614

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NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS42614" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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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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TERMINATION DATE

28Feb2010

PROBLEM

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The 151-5913 Exhaust Manifold has the potential to have the 4F-5695, 2M-6471, and 3B-0623 Cup plugs improperly installed. The Cup plugs could be installed too shallow or cocked in the bore. If a Cup plug is improperly installed it could cause a coolant leak and or possibly allow the cup plug to come loose and fall out of its bore.

AFFECTED PRODUCT

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Model	Identification Number
DV-3126	4EZ00444-00494

PARTS NEEDED

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Qty	Part Number	Description
1	1S7057	GASKET
3	2M6471	PLUG-CUP
4	3B0623	PLUG-CUP
4	3E8017	LOCKNUT
1	3J1907	SEAL-O-RING
1	4C5599	ANTI-SEIZE COMPD
1	4F5695	PLUG-CUP
1	4P7704	GASKET
12	6V5839	WASHER-HARD
1	6V6640	GASKET SEALER
1	6V8397	SEAL-O-RING
1	7B4910	GASKET
1	7C7613	GASKET-OUTLET
1	7W2398	GASKET
2	8T0280	SEAL-O RING
10	8T0355	BOLT
2	8T0644	BOLT
1	9M4849	SEAL-O RING
3	1136200	GASKET
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 15% of dealership population. This is an initial 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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A visual inspection of all Cup plugs installed in the 151-5913 Exhaust Manifold must be performed as follows:

1. The cup plugs must be installed so that the top edge of the Cup plug is recessed just below the chamfer of the bore. Refer to Image1.

2. The Cup plugs must be installed straight and not cocked in the bore.

3. Any Cup plugs that do not meet the installation criteria must be removed and replaced as outlined in the rework procedure.

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Image1

SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-1000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 5.0-hour job
Reasonable travel and mileage is covered. Please be sure to note the sister engine serial number that is installed in the vessel on the claim story as only one trip will be covered for a pair of engines in a vessel. - $200 per vessel for travel Service Claim hours to be allowed as follows: - 2 Hours to drain coolant, and remove turbo and exhaust manifold. - 1 hour to replace all 8 Cup plugs. - 2 Hours to reinstall exhaust manifold, turbo, and to refill coolant. For any questions regarding obtaining service, warranty claim submittal, or program eligibility please contact: Mike Weiland Caterpillar Defense and Federal Products Weiland_Michael_D@Cat.com 309-578-4562

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PARTS DISPOSITION

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

Rework Procedure

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Refer to appropriate Service Manual as necessary.

1. Drain the coolant from the engine.

2. Remove oil, air, and coolant lines from the turbo.

3. Remove exhaust riser piping from turbo outlet. Refer to Image 1.1.1

4. Remove the four retaining nuts from turbo mounting studs then remove the turbo from the exhaust manifold.

5. Remove the bolts from the exhaust manifold and remove the exhaust manifold from the engine.

6. Remove the Cup plugs from exhaust manifold that do not meet the installation requirements.

7. Thoroughly clean the Cup plug bores in the manifold that are being serviced with scotch bright pad or equivalent.

8. Order the required parts from provided list.

9. Using the 1P-0500 tooling group (or equivalent) choose the proper size tool to fit the Cup plug being serviced.

10. Wipe down the bore in the manifold and the Cup plug with brake cleaner or component cleaner to remove any oils or contaminants.

11. Install the proper Cup plugs (as required) by first lightly coating the bore in the manifold and the edges of the Cup plug with 6V-6640 anaerobic sealant and then drive the Cup plug into the bore straight and to the proper depth as shown in the Cup plug installation drawing (refer to Image1.1.1).

12. Repeat this procedure as necessary to correct all Cup plugs in the 151-5913 exhaust manifold that do not meet the installation requirements.

13. Clean all mating surfaces.

Image1.1.1

14. Reinstall the exhaust manifold to the cylinder head using new bolts and washers as follows.
a. Apply 4C-5599 Anti-Seize Compound to the threads of bolts 1-12.
b. Tighten bolts 1-12 in a numerical sequence (refer to Image 1.2.1) to a torque value of 4 +/- 1 N.m (35 +/- 9 lb in).
c. Tighten bolts 1-12 in a numerical sequence again (refer to Image 1.2.1) to a final torque value of 55 +/- 5 N.m (41 +/- 4 lb ft).

15. Install turbo with new locking nuts and tighten to a torque of 35 +/- 5 N.m (26 +/- 4 lb ft) .

16. Reinstall turbo air, oil, and coolant lines.

17. Reinstall turbo outlet exhaust riser piping.

18. Refill coolant and inspect for leaks.