PRODUCT SUPPORT PROGRAM FOR REWORKING THE INLET MANIFOLD AIR TEMPERATURE (IMAT) SWITCH ON CERTAIN G3412, AND G3412C GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE INLET MANIFOLD AIR TEMPERATURE (IMAT) SWITCH ON CERTAIN G3412, AND G3412C GENERATOR SETS

Usage:

TEBE4235-00

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12Jul2016

U-363

A-275

D-322

O-320

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After Failure Only	PRODUCT SUPPORT PROGRAM FOR REWORKING THE INLET MANIFOLD AIR TEMPERATURE (IMAT) SWITCH ON CERTAIN G3412, AND G3412C GENERATOR SETS
7400		PS53252

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NOTE:	Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.
NOTE:	This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS53252" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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

31Jul2018

PROBLEM

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On certain G3412, and G3412C Generator Sets, the existing inlet manifold air temperature (IMAT) switch may not sense the correct air temperature since it does not protrude far enough into the inlet manifold air stream to provide an accurate temperature reading. This erroneous temperature measurement may result in a SP1 fault (shutdown due to high IMAT).

AFFECTED PRODUCT

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Model	Identification Number
G3412	KAP00839-01120
G3412C	R7A00153-00217 SPY00151-00188

PARTS NEEDED

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Qty	Part Number	Description
1	3K0360	SEAL-O-RING
1	1461762	SWITCH AS-TEMP
1	5004238	ADAPTER-STR
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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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Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction, on the product, and in this product's Operation and Maintenance Manual (OMM). If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication, the warnings that are on the product, and the warnings that are in the OMM are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, the user must ensure that it is safe for the user and for other people to use.

The user should ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

WARNING: The generator set must be isolated electrically before and while the rework is performed. Follow the proper lockout tag out procedures to protect against the unexpected energizing or startup of the generator set. Failure to follow these warnings could result in injury to personnel during service. Attach a "Do Not Operate" warning tag to the machine start switch or the controls before you perform any service to the machine.

REPAIR ACTION REQUIRED

If the generator set experiences erroneous SP1 faults, and shutdowns due to high IMAT, replacement of the existing 212-7246 IMAT Switch with the longer 146-1762 IMAT Switch will be required.

The 212-7246 IMAT Switch is located in the aftercooler housing. An adapter will be required to install the 146-1762 IMAT since the thread size on the new switch does not match the thread size of the existing aftercoolers.

Note that there are 2 different styles of aftercoolers housings. Both use the 212-7246 IMAT Switch, but in different locations. One of the locations is at the back of engine. Refer to Image1 and Image2. The other location is at the front of the engine. Refer to Image3.

Refer to the attached Rework Procedure.

Using Cat ET, create a Product Status Report and make sure to include a histogram of Time vs Engine Speed and Engine Load Factor. Attach/upload the report to SIMSi.

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Image1

Image2

Image3

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%
0-20000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 1.0-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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Remove existing 212-7246 IMAT Switch and adapter if installed. Install 3K-0360 O-ring onto 146-1762 IMAT Switch. Refer to Image1.1.1

Install 500-4238 Adapter using appropriate thread sealant for NPT fittings. Install adapter in either the engine front or back location depending on aftercooler housing style. Install 146-1762 IMAT Switch into the adapter. Tighten IMAT switch to to 82 +/- 9 N-m (60.5 +/- 5.9 ft-lbs). Refer to Image1.1.2 and Image1.1.3.

Check generator set for proper operation.