TRUNNION 4N7004 - Caterpillar

REBE2317-01
04Oct2007
(Revised 12Feb2008)
U-504
D-406
O-437
Safety
PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE CYLINDER PACKS AND EXHAUST COMPONENTS ON CERTAIN 3456 GENSETS
1239 1050 1225 7620 1901 PI10634
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 ClaimDescription 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.
This Revised Service Letter replaces the 04Oct2007 Service Letter. Changes have been made to the Parts Needed and the Rework Procedure.
PROBLEM
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
Model Identification Number
DV-3456 9BZ00001-00208, 218-241, 400, 409-640
DPG00001-00036
PARTS NEEDED
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
See attached rework procedure.
SERVICE CLAIM ALLOWANCES
Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
100% 100% 0% 0% 0% 0%
This is a 36.1-hour job
PARTS DISPOSITION
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
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.
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