PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE ALTERNATOR SUPPORT BEAM AND INSPECTING RADIATOR SUPPORT BRACKETS ON CERTAIN 3406C GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE ALTERNATOR SUPPORT BEAM AND INSPECTING RADIATOR SUPPORT BRACKETS ON CERTAIN 3406C GENERATOR SETS

Usage:

REBE5400-00

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21Dec2009

U-448

A-367

D-398

O-403

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE ALTERNATOR SUPPORT BEAM AND INSPECTING RADIATOR SUPPORT BRACKETS ON CERTAIN 3406C GENERATOR SETS
7060 7002		PI31710

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31710" 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 "PI31710" 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:

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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COMPLETION DATE	TERMINATION DATE
30Jun2010	31Dec2010

PROBLEM

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The existing 227-2440 Alternator Beam Assembly, which the alternator mounting feet are secured to, may bend during shipment on certain 3406C Generator Sets. Also, the 142-2992 Radiator Support Bracket may have been tightened to the incorrect torque and may be loose or missing after shipment.

AFFECTED PRODUCT

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Model

Identification Number

3406C

9ES06867-06892

C2G05169, 5176, 5179, 5182, 5186-5187, 5189, 5196, 5198, 5200, 5203-5204, 5209, 5215, 5217, 5220, 5231-5234, 5239, 5241-5242, 5251, 5253, 5255, 5257, 5260, 5262, 5269, 5275-5278, 5280-5281, 5292, 5294-5299, 5301, 5304-5305, 5308-5309, 5313, 5320-5324, 5331, 5347, 5351, 5360-5361, 5365-5366, 5368, 5370-5373, 5377-5378, 5381-5382, 5384-5387, 5389-5391, 5393-5394, 5398-5401, 5403-5405, 5407-5408, 5410, 5412-5417, 5419-5423, 5426, 5428, 5430, 5434-5436, 5441-5442, 5454, 5458, 5461, 5464-5465, 5468, 5470, 5475-5476, 5485, 5487, 5494-5495, 5497-5499, 5504-5505, 5508, 5510-5513, 5522-5524, 5526, 5530-5531, 5538, 5543-5544, 5548, 5571, 5583, 5588, 5590-5592, 5599, 5602-5610, 5615, 5617-5618, 5621, 5623, 5625, 5627-5630, 5633-5634, 5643, 5646, 5648, 5654, 5660-5661, 5663-5664, 5669, 5671, 5681-5682, 5686, 5688, 5699-5701, 5706, 5708, 5710-5711, 5713, 5719-5723, 5726, 5728-5730, 5732-5741, 5747, 5749, 5754-5755, 5757, 5759-5760, 5765, 5768-5769, 5771, 5773, 5775-5776, 5778, 5781, 5789-5791, 5794, 5800-5801, 5808, 5810, 5814, 5816, 5820-5822, 5824-5825, 5844-5845, 5848, 5851, 5853, 5856, 5858, 5861, 5863-5864, 5867-5868, 5870, 5883, 5885-5886, 5893, 5896-5897, 5899-5900, 5903, 5913, 5916, 5927, 5930, 5932-5933, 5935, 5939-5940, 5949, 5956, 5958, 5975, 5982, 6011, 6028, 6032, 6036-6040, 6049-6050

C2Y00150-00151, 217-218, 234, 241-242, 251, 253, 259, 261, 266, 268, 295, 309-310, 314, 317, 322-324, 327-328, 330, 337, 344, 363, 369-370, 376, 422, 437, 441-442, 444, 447, 453, 462-463, 468-472, 474-477, 483, 487, 492, 498-500, 502, 505-521, 523-526, 532-535, 537-539, 541-543, 550-564, 571-574, 582-585, 588-604, 608-632, 634-638, 645, 661, 683, 694, 707-709, 715-716, 724, 739-744, 752, 778-780, 941, 955, 987, 1003, 1016, 1029, 1061-1063, 1141, 1149, 1153-1154, 1167-1168, 1174, 1183, 1188-1192, 1221-1222, 1227-1228, 1232, 1234-1237, 1255-1257, 1259, 1263, 1265-1271, 1276-1278, 1285, 1287, 1303-1306, 1327-1331, 1336-1337, 1342-1344, 1356-1357, 1363, 1387, 1399, 1408-1410, 1419, 1433-1436, 1448, 1461-1462, 1465-1466, 1472-1473, 1476-1477, 1485, 1489, 1543, 1570, 1574-1575, 1581-1583, 1586, 1612-1613, 1616, 1645, 1647, 1651, 1654-1657, 1661, 1665, 1667

C5G03091-03095, 3099-3103, 3106-3111, 3127, 3169, 3177-3182, 3188-3192, 3200-3203, 3205-3207, 3211-3217, 3228-3229, 3237, 3240-3243, 3246-3247, 3252-3256, 3264, 3291-3301, 3307, 3361, 3428-3430, 3432-3436, 3439-3441, 3485-3490, 3543-3545, 3549, 3589-3593, 3597-3598, 3609-3611, 3650, 3660-3663, 3702-3711, 3721-3722

PARTS NEEDED

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Qty	Part Number	Description
1	6V8801	NUT (IF NEEDED)
4	8C4436	BOLT (IF NEEDED)
1	8T4223	WASHER-HARD (IF NEEDED)
4	8T4896	WASHER-HARD (IF NEEDED)
4	9B7237	BOLT (IF NEEDED)
2	1422993	PLATE (IF NEEDED)
2	1422994	BRACKET (IF NEEDED)
4	1422995	BRACKET (IF NEEDED)
8	1422996	BRACE (IF NEEDED)
1	3505395	BEAM AS-ALT
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 initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer. NOTE: The number of gensets requiring beam or radiator mounting hardware replacement is very low (less than 5%). Limit mounting hardware parts orders accordingly.

ACTION REQUIRED

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The existing support beam utilized on certain 3406C Generator sets needs to be replaced with a new 350-5395 Alternator Beam Assembly.

Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

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 3.0-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.

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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE ALTERNATOR SUPPORT BEAM AND INSPECTING RADIATOR SUPPORT BRACKETS

MODELS INVOLVED - 3406C Generator Sets

Dear Caterpillar Product Owner:

The generator support beam needs to be replaced and the radiator support brackets need to be inspected on the products listed below. The existing beam can bend and the radiator support brackets may be loose. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

Please refer the dealer to their Service Letter dated 21Dec2009 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 21Dec2009 Service Letter

Rework Procedure

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Rework Procedure

For additional detailed information refer to:
SENR3130 - Torque Specifications

1) Isolate the gen set before commencing any work on the unit, open gen set breaker, activate emergency stop, and disconnect battery cables.

Ensure all health and safety requirements are adhered to at all times. Also, ensure proper Lock Out-Tag Out procedures are followed at all times while work is being performed on the machine. Lock out generator before commencing any type of work.

Only qualified repair personnel should service this equipment.

2) Locate the existing 227-2440 Alternator Beam Assembly (A), 227-2427 Engine Beam Assembly (B), and the Horizontal Bolt Pads (C) on the left and right side of the flywheel housing. Refer to Image 1.1.1.

Image1.1.1

3) Loosen the two retaining bolts used to secure the engine mount assembly to the 227-2427 Engine Beam Assembly. Do not remove the retaining nut. The retaining nut should remain engaged onto the retaining bolt. Image 1.2.1 shows the retaining hardware and mount assembly.

Image1.2.1

4) Remove the retaining hardware used to secure the alternator mounting feet to the existing 227-2440 Alternator Beam Assembly. Refer to Image 1.3.1.

Image1.3.1

5) Install a suitable cross brace having sufficient length to span across the fuel tank base directly beneath the flywheel housing horizontal bolt pads. The cross brace must be able to effectively support the weight of the alternator. Refer to Image 1.1.1.
NOTE: The cross brace must be able to effective support 20 tons.

5.1) Install a suitable length 20 ton hydraulic or mechanical type jack underneath each of the flywheel housing horizontal bolt pads. Ensure that the jack is placed perpendicular to the cross brace and that the jack base is in proper contact with the cross brace at all times.

5.2) Using the jacks, lift the gen set sufficiently to allow clearance of the alternator mounting feet from the existing 227-2440 Alternator Beam Assembly. Remove the beam assembly and the associated mounting hardware.

6) Inspect all of the mounting hardware and retaining hardware for any physical deformation.

6.1) Replace damaged mounting or retaining hardware as applicable.

7) Install the new 350-5395 Alternator Beam Assembly and associated mounting hardware. Tighten the retaining hardware to the appropriate torque in accordance with publication SENR3130.

8) Using the jacks, lower the gen set onto the new 350-5395 Alternator Beam Assembly.

9) Secure the alternator mounting feet to the 350-5395 Alternator Beam Assembly by installing the retaining hardware removed in Step 4. Tighten the retaining hardware to the appropriate torque in accordance with publication SENR3130.

10) Tighten the retaining hardware used to secure the two front engine mount assemblies to the 227-2427 Engine Beam Assembly to the appropriate torque. Refer to Step 3 and SENR3130.

11) Inspect the 142-2992 Radiator Support Brackets (A) for any physical deformation and ensure that the mounting hardware and retaining hardware (B) are properly tightened. Replace any damaged or missing hardware. Tighten the hardware to the appropriate torque in accordance with publication SENR3130. Refer to Image 1.5.1.