PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REWORKING THE INSULATION ON THE CEM ON CERTAIN 3516C GENERATOR SETS, AND 3516C HD GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REWORKING THE INSULATION ON THE CEM ON CERTAIN 3516C GENERATOR SETS, AND 3516C HD GENERATOR SETS

Usage:

TEBE0476-00

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14Oct2013

U-503

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REWORKING THE INSULATION ON THE CEM ON CERTAIN 3516C GENERATOR SETS, AND 3516C HD GENERATOR SETS
1067 1091 4460		PI32246

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32246" 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 "PI32246" as the Part Number, "7751" as the Group Number, "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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COMPLETION DATE	TERMINATION DATE
30Apr2014	31Oct2014

PROBLEM

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The 366-9578 Insulation Assembly needs to be inspected and possibly reworked on certain 3516C Generator Sets, and 3516C HD Generator Sets. The existing insulation could be incorrectly installed which can trap heat from the 374-2501 CEM (Cat Emission Module). The trapped heat can lead to a 4360-4 Aftertreatment SCR Catalyst Intake Gas Temperature: Voltage Below Normal code. This fault disables dosing and leads to the engine going into inducement.

AFFECTED PRODUCT

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Model	Identification Number
3516C	SCJ00113-00114
3516C HD	SCK00117, 119-123 SFK00101-00110 SKC00101-00115

PARTS NEEDED

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No parts needed for this program

ACTION REQUIRED

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Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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Owners in the following countries will receive the attached Owner Notification:
US
Canada

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 1.0-hour job
If the insulation is incorrectly installed, an additional 1 hour is allowed.

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PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REWORKING THE INSULATION ON THE CEM ON CERTAIN 3516C GENERATOR SETS, AND 3516C HD GENERATOR SETS

MODELS INVOLVED - 3516C, 3516C HD

Dear Cat Product Owner:

The 366-9578 Insulation needs to be inspected and possibly reworked on the products listed below. The existing insulation can be improperly installed. You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated.

Please refer the dealer to their Service Letter dated 14Oct2013 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 14Oct2013 Service Letter

Rework Procedure

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Make sure you have read and understood all of this document before beginning work.

Isolate the generator set before commencing any work on the unit, open generator set breaker, activate Emergency Stop, disconnect the battery cables and either disconnect or open the control circuit breaker for the AC power supply to the battery charger. 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 operation and disconnect/lockout all power sources before commencing any work.

Inspect the insulation for proper installation. Refer to Image 1.1.1 for a correctly installed insulation assembly. Refer to Image 1.1.2 for an incorrectly installed insulation assembly. If the insulation is not installed as shown in Image 1.1.1 refer to the steps below for proper installation of the insulation.

Image1.1.1

Image1.1.2

1 - Remove the insulation by unclasping the four springs that secure the insulation. Refer to Image 1.2.1
(1) Springs

Image1.2.1

2 - Remove four bolts (2) that attach the cover to the CEM electrical box. Refer to Image 1.3.1
(2) 8T-4189 Bolts

Image1.3.1

3 - Remove four bolts (3), four washers (4), eight spacers (5), and four nuts (6). Remove the 362-9628 Connection Box. Refer to Image 1.4.1 to view the underside of the 362-9628 Connection Box.
(3) 140-0174 Bolts
(4) 8T-5360 Washers
(5) 346-7499 Spacers
(6) 8T-3490 Nuts

Image1.4.1

4 - Install the 366-9578 insulation (7) on to the 362-9628 Connection Box. Refer to Image 1.5.1

Image1.5.1

5 - Install the previously removed 362-9628 Connection Box using the existing four bolts (3), four washers (4), eight spacers (5), and four nuts (6). Refer to Image 1.6.1 to view the underside of the 362-9628 Connection Box.

(3) 140-0174 Bolts
(4) 8T-5360 Washers
(5) 346-7499 Spacers
(6) 8T-3490 Nuts