PRODUCT SUPPORT PROGRAM FOR INSTALLING ORIFICE PLATES ON CERTAIN G3520C LANDFILL ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING ORIFICE PLATES ON CERTAIN G3520C LANDFILL ENGINES

Usage:

REBE5475-01

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30Nov2009

(Revised 15Dec2009)

U-411

A-332

D-363

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR INSTALLING ORIFICE PLATES ON CERTAIN G3520C LANDFILL ENGINES
1380 1063		PS42995

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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 "PS42995" 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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NOTE:	This Revised Service Letter replaces the 03Nov2009 Service Letter. Changes have been made to the Parts Needed and the Rework Procedure.

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TERMINATION DATE

30Nov2011

PROBLEM

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Certain G3520C 1200 RPM Landfill Engines are experiencing high inlet manifold temperatures that lead to detonation. The coolant flow through the first stage 236-4256 Aftercooler Core is low causing marginal heat rejection to the JW. The lack of coolant flow leads to increased temperatures of the air/fuel mixture as it enters the intake manifold.

AFFECTED PRODUCT

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Model	Identification Number
G3520C	GZJ00161-00417 HAT00102, 200-211

PARTS NEEDED

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Qty	Part Number	Description
2	4N1320	GASKET-ADAPTER
1	6V1454	SEAL-O RING
4	6V5066	SEAL-O RING
1	6V5139	SEAL-O-RING
2	7N4945	GASKET
3	8T1919	SEAL-O-RING
1	9Y6893	GASKET
1	2006434	TUBE AS
2	3053447	SEAL
1	3235835	PLATE-ORIFICE
1	3235836	PLATE-ORIFICE
1	3304907	ELBOW
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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If the G3520C Landfill Engine is experiencing detonation, new orifice plates and some additional Separate Circuit Aftercooler Circuit (SCAC) parts need to be installed. Refer to the attached Rework Procedure.

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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%
0-40000 hrs, 0-84 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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1) In a suitable container, drain the engine coolant. The engine coolant will be reused at the end of this procedure.

2) Remove the 244-0525 Tube. The 261-7953 Joint Seal will be reused. The 6V-5139 O-ring seal will be replaced with a new o-ring.

3) Remove the 265-5221 Tube. The 261-7952 Seal will be reused. The 8T-1919 O-ring will be replaced with a new o-ring.

4) Remove the 236-5186 tube. The 261-7952 Seal will be reused. The 6V-5066 O-ring will be replaced with a new o-ring.

5) Remove the 324-6857 Tube Assembly and the 265-5220 Elbow-Blk Inlet. Remove the 9Y-6892 Elbow from the 265-5220 Elbow-Blk Inlet.

6) Replace the 265-5220 Elbow-Blk Inlet with the 330-4907 Elbow-Blk Inlet and attach the 9Y-6892 Elbow. Use a 9Y-6893 Gasket at this connection.

7) Add the 323-5835 Plate-Orifice to the proper surface of the 330-4907 Elbow. Place a 7N-4945 Gasket on each side of the orifice plate. Add a 6V-5066 O-Ring to the 330-4907 Elbow.

8) Replace the 324-6857 Tube Assembly with the 200-6434 Tube Assembly. Place an 8T-1919 O-Ring on each end of the tube.

9) Place the 330-4907 Elbow-Blk Inlet and 300-6434 Tube Assembly on the engine and reassemble. Ensure that all connections are sealed with either a gasket or o-ring and tighten bolts to proper torque.

10) It is necessary to remove a section of the exhaust manifold in order to gain access to the 203-7072 Elbow. Replace the 305-3447 Exhaust seals with new seals before reassembly.

11) Remove the 203-7072 Elbow and the 8N-0386 Flange.

12) Place the 323-5836 Plate-Orifice on the surface between the 8N-0386 Flange and the 160-4322 Adapter. Be sure to place a 4N-1320 Gasket on each side of the orifice plate.

13) Replace the 6V-5066 O-Ring on the 203-7072 Elbow Flange Assembly and replace the 6V-5066 O-Ring on the 8N-1989 Tube. Place the elbow flange assembly back on the engine and reassemble. Ensure that all connections are sealed and tighten bolts to the proper torque.

14) Reassembled the exhaust manifold and any other remaining parts.

15) Refill the engine coolant using the coolant that was drained in Step 1.