PRODUCT SUPPORT PROGRAM FOR REPLACING THE MUFFLER AND MUFFLER BRACKET ON CERTAIN 320D, 320D L, 320D LRR, 320D RR, 323D L, 323D LN, AND 323D S EXCAVATORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE MUFFLER AND MUFFLER BRACKET ON CERTAIN 320D, 320D L, 320D LRR, 320D RR, 323D L, 323D LN, AND 323D S EXCAVATORS

Usage:

REBE4494-00

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08Oct2009

U-343

A-284

D-307

O-310

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After Failure Only Parts stock action needed	PRODUCT SUPPORT PROGRAM FOR REPLACING THE MUFFLER AND MUFFLER BRACKET ON CERTAIN 320D, 320D L, 320D LRR, 320D RR, 323D L, 323D LN, AND 323D S EXCAVATORS
1062		PS51735

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS51735" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

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NOTE:

When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7755" as the Group Number, "56" as the Description Code.

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NOTE:

Although this Program is to be administered as described above on the Affected Product, parts should be removed from parts stock as soon as possible.

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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

31Oct2011

PROBLEM

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The existing 2870218/">287-0218 Muffler can crack or break on certain 320D, 320D L, 320D LRR, 320D RR, 323D L, 323D LN, and 323D S Excavators. If the existing 2870218/">287-0218 Muffler fails, it will create more noise and exhaust gas can go into the engine compartment.

AFFECTED PRODUCT

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Model	Identification Number
320D	CXY00149-00415 DFT00164-00589 DHK00125-01061 JGZ00151-02934
320D L	MDE00114-01193
320D LRR	EBY00112-00118 FXK00190-00224
320D RR	GKL00136-00139
323D L	PBM00224-00520, 522-586 SDC00248-00933
323D LN	CYD00169-00614
323D OEM	GRL00100-00103, 106-108 GRN00100-00101
323D S	DKW00171-00334

PARTS NEEDED

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Qty	Part Number	Description
1	5I7679	GASKET
4	2977654	BOLT
1	3244157	MUFFLER
1	3244158	BRACKET AS
1	3244165	BRACKET AS
1	3244166	PIPE AS
1	3244167	CLAMP AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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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****Parts Stock ****

Scrap the existing 2870218 Muffler, 2666319 Bracket, and 2666320 Bracket from dealer parts stock.

****Affected Product****

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Refer to the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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****Parts Stock****

Submit one claim for all parts removed from dealer parts stock.

****Affected Product****

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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%
0-4000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
4001-6000 hrs, 25-48 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

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NOTE: This is a 3.0-hour job

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PARTS DISPOSITION

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****Parts Stock****

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

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****Affected Product****

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

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Rework Procedure

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1. Move the machine to a flat, level surface and position the front linkage on the ground. Turn the engine key off and leave the hydraulic lock lever in the locked position. Open the engine hood cover.

2. Remove four 6V-8231 Nuts from the muffler Bracket in order to remove the two 266-6321 U-Bolts.

Image1.2.1

3. Remove the 171-9072 Pipe-drain from the existing muffler.

4. Remove six 5I-7633 Nuts from the turbocharger in order to remove the existing muffler. Remove the 5I-7679 Gasket.

Image1.4.1

5. Remove four 8T-4136 Bolts and four 7X-0796 Washers in order to remove the 266-6319 and 266-6320 Muffler Brackets.

Image1.5.1

6. Install the new 324-4165 Bracket to the engine flywheel housing using two new 297-7654 Bolts and the two 7X-0796 Washers from Step-5. Tighten the bolts to a torque of 35+/-6 Nm. Set the muffler bracket to the correct position. Install the new 324-4158 Bracket to the engine flywheel housing using two new 297-7654 Bolts and two 7X-0796 Washers from Step-5. Tighten the bolts to a torque of 35+/-6 Nm. Set the muffler bracket to the correct position.

Image1.6.1

7. Install the new 5I-7679 Gasket to the turbocharger.

8. Insert the flange of the 324-4166 Pipe Assembly to the studs of the turbocharger. Insert the new 324-4167 Clamp Assembly to the 324-4166 Pipe Assembly. Put the new 324-4157 Muffler on the muffler bracket.

9. Install the 6V-8231 Nut from Step-2 as shown in Image 1.9.1.

Image1.9.1

10. Install the two 266-6321 U-Bolts using the four 6V-8231 Nuts from Step-2. Tighten the two bottom side nuts to a torque of 10+/-2 Nm. Then tighten the remaining two upper side nuts to a torque of 35+/-6 Nm.

Image1.10.1

11. Use six 5I-7633 Nuts from Step-4 in order to fix the flange of the new 324-4166 Pipe Assembly and the studs of the turbocharger. Tighten the six nuts to a torque of 21+/-3 Nm.

12. Use the new 324-4167 Clamps in order to join the muffler and the Pipe Assembly. Tighten the two nuts to a torque of 64+/-10 Nm.

Image1.12.1

13. Install the 171-9072 Pipe-drain from step-3 to the new muffler.

14. Run the engine and confirm non-leakage of exhaust gas at joint portion of the turbocharger and flange of the new pipe assembly, the new pipe assembly, and the new muffler. If there is exhaust gas leakage, re-setting the muffler and pipe assembly and re-tighten each nut.