PRODUCT SUPPORT PROGRAM FOR INSTALLING HEAT SHIELDS TO PROTECT THE THERMO COUPLE HARNESS AND DETONATION HARNESS ON G3520C ENGINES WITH LANDFILL PACKAGES Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING HEAT SHIELDS TO PROTECT THE THERMO COUPLE HARNESS AND DETONATION HARNESS ON G3520C ENGINES WITH LANDFILL PACKAGES

Usage:

REBE5494-01

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12Mar2010

(Revised 17May2010)

U-81

A-64

D-74

O-77

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR INSTALLING HEAT SHIELDS TO PROTECT THE THERMO COUPLE HARNESS AND DETONATION HARNESS ON G3520C ENGINES WITH LANDFILL PACKAGES
1067		PS43050

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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 "PS43050" 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 12Mar2010 Service Letter. Changes have been made to the Service Claims Allowance to correct dealer labor reimbursement within normal warranty period, and to add reference to REBE3547.

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TERMINATION DATE

31Mar2011

PROBLEM

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Without heat shielding, the wiring harnesses may be exposed to excessive temperatures from an exhaust leak that may cause harness damage on certain G3520C landfill engines. Heat shields are needed to protect the detonation and thermocouple wiring harnesses. If exhaust leak has occurred, perform REBE3547 if applicable.

AFFECTED PRODUCT

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Model	Identification Number
G3520C	GZJ00161-00425 GZK00161, 163-183 HAT00102, 200-211 LGS00150-00162 MAD00101-00102, 200-201

PARTS NEEDED

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Qty	Part Number	Description
20	1A2029	BOLT
3	4P7581	CLIP-LADDER
1	4P8134	CLIP-LADDER
20	5M2894	WASHER-HARD
30	9X6772	STRAP-CABLE
2	3503693	SHIELD
8	3503694	SHIELD
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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Install metal heat shields above the detonation and thermocouple harnesses to protect them from possible exhaust gas leaks. The shields attach to the cam covers with the harnesses routed underneath.

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%
0-8000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
8001-88000 hrs, 13-120 mo	100.0%	0.0%	0.0%	0.0%	0.0%	100.0%

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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) Remove the exhaust manifold shielding and insulation to allow better access to thermocouple and detonation wiring harnesses.

2) Move existing ladder clips to the lower threaded holes on cam covers. The ladder clips should be oriented on top of the bolt as shown in Image 1.1.1. The wiring harnesses should be installed on the bottom of the ladder clip using cable ties. Be sure to leave adequate length on the thermocouple wire to get around the shield.

Image1.1.1

3) On the back of the engine, near the ITSM(if equipped) the wiring harness should go under the ITSM mounting bracket. Cable ties should be used accordingly to secure the harnesses. This can be seen in Image 1.2.1

Image1.2.1

4) Make sure water lines clamp bracket are aligned as shown in Image1.3.1. There should be a clip added to each bolt for this water line bracket. A 4P-7581 clip should be installed on the left bolt and a 4P-8134 should be added to the right bolt.

Image1.3.1

5) On the front side of the engine, An additional clip (4P-7581) is added to the oil distribution block. The wiring harness should be installed under the ladder clip using the cable ties. Another clip 4P-7581 should be added to the top left bolt in Cylinder #2 camshaft cover. This can be seen in Image 1.4.1.

Image1.4.1

6) The heat shield should be installed using the bolts (1A2029) in the top holes of the cam covers. This can be seen in Image 1.5.1.

Image1.5.1

7) The shields (350-3693) should be installed under cylinders 1&3 and under cylinders 20&18.

8) The shields (350-3694) should be installed under the rest of the cylinders. Final installation should look like image 1.6.1.