CAMSHAFT GP-SINGLE 2W9608 - Caterpillar

REBE3304-00
12Feb2008
D440
D447
G418
Before/After
(Limited distribution)
PRODUCT SUPPORT PROGRAM FOR INSPECTING AND, IF NECESSARY, REPLACING EXHAUST MANIFOLD CUP PLUGS ON 4EZ DV-3126 ENGINES
1059 PS42614
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 Numberand "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.
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.
TERMINATION DATE
28Feb2010
PROBLEM
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
Model Identification Number
DV-3126 4EZ00444-00494
PARTS NEEDED
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
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.
Image1
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
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%
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
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Refer to appropriate Service Manual as necessary.
1. Drain the coolant from the engine.
2. Remove oil, air, and