PRODUCT SUPPORT PROGRAM FOR REPLACING THE DIESEL OXIDATION CATALYST AND SELECTIVE CATALYTIC REDUCTION PANEL GASKETS FOR 445-6900 CLEAN EMISSION MODULE ON CERTAIN 3516C GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE DIESEL OXIDATION CATALYST AND SELECTIVE CATALYTIC REDUCTION PANEL GASKETS FOR 445-6900 CLEAN EMISSION MODULE ON CERTAIN 3516C GENERATOR SETS

Usage:

TEBE4954-00

Show/hide table

25Aug2016

U-438

Show/hide table

After Failure Only	PRODUCT SUPPORT PROGRAM FOR REPLACING THE DIESEL OXIDATION CATALYST AND SELECTIVE CATALYTIC REDUCTION PANEL GASKETS FOR 445-6900 CLEAN EMISSION MODULE ON CERTAIN 3516C GENERATOR SETS
1091 1062		PS53274

Show/hide table

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 "PS53274" 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.

Show/hide table

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.

Show/hide table

TERMINATION DATE

31Aug2018

PROBLEM

Show/hide table

The existing gaskets 3519235/">351-9235 and 3752771/">375-2771 can fail on certain 3516C Generator Sets. If the existing gasket fails it can lead to exhaust leaking from the Diesel Oxidation Catalyst (DOC) and Selective Catalytic Reduction (SCR) panels.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
3516C	SCJ00112-00114
3516C HD	SCK00112-00123 SFK00101-00128 SKC00101-00130

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
24	5P7970	NUT-HEX
24	6V5219	BOLT-HEX HEAD
24	7X7729	WASHER-HARD
24	8T5005	BOLT-HEX HEAD
2	3519235	GASKET
1	3752771	GASKET
12	5128186	PLATE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 4% 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

Show/hide table

Add new 1 inch plates to the DOC and SCR cover panels corners to allow better compression of the gasket to prevent leaking. Refer to the attached Rework Procedure.

Show/hide table

SERVICE CLAIM ALLOWANCES

Show/hide table

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%
8001-16000 hrs, 13-48 mo	50.0%	50.0%	0.0%	0.0%	50.0%	50.0%

Show/hide table

NOTE: This is a 5.0-hour job

Show/hide table

PARTS DISPOSITION

Show/hide table

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

Rework Procedure

Show/hide table

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 or around the machine. Lock out generator operation and disconnect/lockout all power sources before commencing any work.

1 - Remove the SCR (selective catalyst reduction) side heat shields in order to gain access to the SCR cover. Remove all of the bolts, plates & SCR cover panel. Clean the old gasket material from the Clean Emission Module (CEM) & SCR cover panels.
Reference Image 1.2.1

Image1.2.1

2 - With a new gasket (3519235/">351-9235) install the SCR cover panel (351-6791), backing plates (351-6794 & 351-6795), washers (7X7729) and original M10 bolts (8T4182) onto the CEM in the following locations:
(7) top center holes
(7) bottom center holes
(1) LH middle hole
(1) RH middle hole
Hand tighten these bolts.
On each corner install a 1" thick plate (512-8186) with (2) washers (7X7729) and (2) longer M10 bolts (8T5005).
Hand tighten these bolts.
Install a nut (5P7970 onto each of the M8 bolts (6V5219) and install (2) each of the bolt/nut assemblies into the threaded holes on each of the 1" thick plates. Hand tighten the M8 bolts so the bolt end touches the backing plate.
Note: Use Anti-Seize on all bolt threads prior to installation
Reference Image 1.3.1 & 1.3.2

Image1.3.1

Image1.3.2

3 - Torque bolts 1 - 32 in numerical sequence to 10 nm. Fully torque bolts 1 - 32 in numerical sequence to 55 nm (M10 bolts) and 28 nm (M8 bolts).
Once all of the bolts are properly torqued, torque the M8 nuts to 28 nm.
Note: Ensure that the M8 nuts are backed out enough to allow proper torqueing of the bolts.
Reference Image 1.4.1

Image1.4.1

4 - Re-install the SCR (selective catalyst reduction) side heat shields.
Repeat this process for the other SCR cover on the opposite side of the CEM.

5 - Remove the DOC (diesel oxidation catalyst) heat shield in order to gain access to the DOC cover. Remove all of the bolts, plates & DOC cover panel. Clean the old gasket material from the CEM & DOC cover panel.
Reference Images 1.6.1, 1.6.2 & 1.6.3

Image1.6.1

Image1.6.2

Image1.6.3

6 - With a new gasket (3752771/">375-2771) install the DOC cover panel (374-4481), backing plates (374-4484 & 374-4485), washers (8T7934) and original M10 bolts (323-3730) onto the CEM in the following locations:
(18) top center holes
(18) bottom center holes
(2) LH middle hole
(2) RH middle hole
Hand tighten these bolts.
On each corner install a 1" thick plate (512-8186) with (2) washers (7X7729) and (2) longer M10 bolts (8T5005).
Hand tighten these bolts.
Install a nut (5P7970 onto each of the M8 bolts (6V5219) and install (2) each of the bolt/nut assemblies into the threaded holes on each of the 1" thick plates. Hand tighten the M8 bolts so the bolt end touches the backing plate.
Note: Use Anti-Seize on all bolt threads prior to installation
Reference Image 1.7.1 & 1.7.2

Image1.7.1

Image1.7.2

7 - Torque bolts 1 - 60 in numerical sequence to 10 nm. Fully torque bolts 1 - 60 in numerical sequence to 55 nm (M10 bolts) and 28 nm (M8 bolts).
Once all of the bolts are properly torqued, torque the M8 nuts to 28 nm.
Note: Ensure that the M8 nuts are backed out enough to allow proper torqueing of the bolts.
Reference Image 1.8.1