PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE EXHAUST MANIFOLDS ON CERTAIN 3412E LOCOMOTIVE ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE EXHAUST MANIFOLDS ON CERTAIN 3412E LOCOMOTIVE ENGINES

Usage:

SEBE8778-01

May 5, 2004
(Revised June 2004)
O-125

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE EXHAUST MANIFOLDS ON CERTAIN 3412E LOCOMOTIVE ENGINES
1059		PI30594

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30594" 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 "PI30594" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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.

NOTE: This Revised Service Letter replaces the May 5, 2004 Service Letter. Changes have been made to the Affected Product.

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COMPLETION DATE	TERMINATION DATE
November 30, 2004	May 31, 2005

PROBLEM

The Exhaust Manifolds need to be replaced on certain 3412E Locomotive Engines. Existing exhaust manifold group may not be providing leak free performance in locomotive applications.

AFFECTED PRODUCT

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Model

Identification Number

3412E

BDT126, 131, 219, 253, 254, 282, 303, 342, 347, 374-376, 380, 388, 400, 403, 406, 411, 429, 431, 433, 450, 451, 452, 496, 497, 514, 515, 534, 535, 537, 538, 550, 556, 583, 601, 603, 634, 635-637, 656, 658, 687-689, 693, 694, 700, 701, 703, 712, 713, 739, 741, 792, 793, 795, 827, 828, 888, 896, 897, 919, 921, 1102, 1105, 1108, 1128, 1130, 1137, 1190, 1193, 1194, 1129, 1213, 1215, 1216, 1227, 1228, 1230, 1248-1250, 1268, 1270, 1271, 1322, 1324-1326, 1369, 1372, 1378, 1379, 1416-1418, 1450

PARTS NEEDED

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Qty	Part Number	Description
16	6B2882	SPACER
1	6I2855	TUBE AS
4	7L8055	BELLOWS
8	5P2755	BOLT-HEX
8	2W4474	BRACKET
8	2W9779	CLAMP-BAND
8	1083612	SPACER
16	1149223	SPACER
1	1332232	TUBE AS
2	1634109	MANIFOLD-EXH
2	1654267	MANIFOLD-EXH
32	1687800	LOCKNUT
4	2350193	CLAMP-V-BAND
12	2391388	GASKET
2	2406039	MANIFOLD-EXH

ACTION REQUIRED

Refer to SENR1063 for removal of exhaust manifolds. Refer to attached specifications (SENR1032-02) for correct installation of the new manifold groups.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
100%	8.0	0	0	0	0
NOTE: This is a 8.0-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.

Attach. (1-Rework Procedure)

Rework Procedure

Illustration 1

Apply 5P3931 Anti-Seize Compound on the inside surface of bellows band clamp before assembly.
Apply 5P3931 Anti-Seize Compound on the stud threads and locknut load faces before assembly.
Apply 5P3931 Anti-Seize Compound on the bellows band clamp bolt threads and under head before assembly.

NOTE: Alternate high temperature anti-seize compound may be used.

Use a centering tool (Caterpillar part 1654638) in one oversize round hole per manifold section in order to align the manifolds.
Use the procedure that follows to tighten the exhaust manifold on the cylinder head.
In a numerical sequence, tighten locknuts 1 through 12.
Torque for locknuts 20 +/- 3 Nm (15 +/- 2 lbft).
In a numerical sequence, tighten locknuts 1 through 12 again.
Torque for locknuts 38 +/- 5 Nm (28 +/- 4 lbft).
Use the procedure that follows to tighten the bellows band clamp bolts.
Tighten each bellows band clamp bolt to standard torque.
Use a hammer to lightly tap around outer diameter of each band clamp.
Retighten bellows band clamp bolt to standard torque.

NOTE: Do not use high temperature manifold sealant on any joints.

Illustration 2

Apply 5P3931 Anti-Seize Compound on the inside surface of Vee-band clamp before assembly.
Apply 5P3931 Anti-Seize Compound on the Tee-bolt threads and locknut load faces before assembly.
Apply 5P3931 Anti-Seize Compound on the internal conical surface of the tube ends before assembly.

NOTE: Alternate high temperature anti-seize compound may be used.

Use the procedure that follows to tighten the Vee-band clamp bolts.
Tighten each Vee-band clamp bolt to standard torque.
Use a hammer to lightly tap around outer diameter of each Vee-band clamp.
Retighten Vee-band clamp bolt to standard torque.
Retighten Vee-band clamp bolt after engine has been run up to full load and exhaust manifold has reached normal operating temperature. Allow to cool before retightening.

NOTE: Do not use high temperature manifold sealant on any joints.