STARTING MOTOR GP-ELECTRIC 3T4582 - Caterpillar

REBE1818-00
10May2007
U-177
D-152
O-163
TM-7
Before/After
PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXHAUST MANIFOLD ON CERTAIN C2.2 ENGINES
1059 PS42403
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 "PS42403" 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
31May2009
PROBLEM
The existing exhaust manifold on certain C2.2 engines has a coolant/air bleed passage that has not been drilled deep enough to break through into the water jacket, leaving a thin membrane of cast aluminum.
AFFECTED PRODUCT
Model Identification Number
C2.2 JAW00156, 158-159, 161-163, 169-180, 184, 187-189
TAG00610, 613-616
PARTS NEEDED
Qty
Part Number Description
1 2305118 GASKET
ACTION REQUIRED
Refer to the attached Rework Procedure.
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 2.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
1. Remove exhaust manifold and gasket from engine. The photograph below shows the blocked coolant/air bleed passage, indicated by the arrow.
Note: The exhaust manifold part number for the C2.2 engines is 230-5124. The exhaust manifold part number for the C2.2T engines is 281-9616.
Image1.1.1
2. Using a 10mm bit, drill the blocked coolant/air bleed passage until the aluminum membrane has been removed. The photographs below show the manifold with the coolant/air bleed passage cleared.
Image1.2.1
Image1.2.2
3. It is important the passage depth does not go beyond that necessary to remove the blockage.
4. Any swarf or debris that enters the manifold during the drilling of the aluminum membrane must be cleared.
5. Install a new exhaust manifold gasket, part number 230-5118, prior to reinstalling the manifold.