PRODUCT SUPPORT PROGRAM FOR REPLACING THE ALTERNATOR SUPPORT BEAM ON CERTAIN 3406C GENSETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE ALTERNATOR SUPPORT BEAM ON CERTAIN 3406C GENSETS

Usage:

REBE5343-00

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10Jul2009

Q559

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Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING THE ALTERNATOR SUPPORT BEAM ON CERTAIN 3406C GENSETS
7060 7002		PS42940

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NOTE:

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 "PS42940" as the Part Number and "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.

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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

31Jul2011

PROBLEM

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The existing 227-2440 Alternator Beam Assembly, which the alternator mounting feet are secured to, may bend during shipment.

AFFECTED PRODUCT

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Model	Identification Number
3406C	C2Y01242-01252, 1261-1262, 1295-1302, 1307-1316, 1320-1326, 1338, 1345-1347, 1365, 1649-1650, 1652-1653, 1658-1660, 1662, 1664, 1668

PARTS NEEDED

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Qty	Part Number	Description
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 9% 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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The existing support beam utilized on certain 3406C Gensets needs to be replaced with a new 350-5395 Alternator Beam Assembly.

Refer to the attached Rework Procedure.

For additional detailed information refer to:
SENR3130 - Torque Specifications

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SERVICE CLAIM ALLOWANCES

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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%
0-12 mo	100.0%	100.0%	0.0%	0.0%	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.

Rework Procedure

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For additional detailed information refer to:
SENR3130 - Torque Specifications

Step1 - Isolate the Genset before commencing any work on the unit, open Genset 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.

Step 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

Step 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

Step 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

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

Step 5.1 ? Install a suitable length 20 ton hydraulic or mechanical type jack under 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.

Step 5.2 ? Use the jacks to lift the genset 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.

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

Step 6.1 ? Replace damaged mounting or retaining hardware as applicable.

Step 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.

Step 8 ? Using the jacks, lower the genset onto the new 350-5395 Alternator Beam Assembly.

Step 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 SENR3130.

Step 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.

Step 11 ? Remove the jack assemblies and the cross brace utilized in Step 5.

Step 12 ? Restore the genset to its proper operational condition