PRODUCT SUPPORT PROGRAM FOR INSPECTING/REPLACING THE AFTERCOOLER ON CERTAIN G3516H AND G3520H GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSPECTING/REPLACING THE AFTERCOOLER ON CERTAIN G3516H AND G3520H GENERATOR SETS

Usage:

TEBE5739-00

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10Apr2017

U-193

A-125

D-150

O-155

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After Failure Only	PRODUCT SUPPORT PROGRAM FOR INSPECTING/REPLACING THE AFTERCOOLER ON CERTAIN G3516H AND G3520H GENERATOR SETS
1064 1063		PS53453

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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 "PS53453" 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

30Apr2019

PROBLEM

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The existing aftercooler can leak boost air on certain G3516H and G3520H Generator Sets. If the existing aftercooler leaks it can/will emit an air/fuel mixture into the atmosphere at the aftercooler air inlet and/or outlet bonnet joints.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
G3516H HD	GLM00116, 119-124, 126-131, 134-139, 141-149, 151, 156-168, 170-178 GLN00116, 119-121, 124, 127-129, 131, 135-137

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*****Group 2*****
G3520H HD	GFP00117, 119-120, 122-124 GFR00115-00122, 125-132, 134-141, 175-176

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
80	0S1588	BOLT
4	4L3833	GASKET
3	5R9779	GASKET (raised face flange joints)
6	6D7128	SEAL-O-RING
1	6V1454	SEAL-O-RING
5	6V3250	SEAL-O-RING
2	7M8485	SEAL-O-RING-STOR
4	8T1919	SEAL-O-RING
2	9Y6893	GASKET
2	1058180	GASKET
80	1077954	SPACER-HIGH TEMP
2	1808424	SEAL-O-RING
1	2147568	SEAL-O-RING-STOR
4	2279012	GASKET
1	2287088	SEAL-O-RING-ORFS
4	2287089	SEAL-O-RING-ORFS
1	2287092	SEAL-O-RING-ORFS
3	2385080	SEAL-O-RING-STOR
1	3578765	GASKET
3	4522248	GASKET (flat faced flange joints only)
1	5195587	CORE AS-AFTCLR
2	5195853	GASKET
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.
*****Group 2*****
80	0S1588	BOLT
4	4L3833	GASKET
6	6D7128	SEAL-O-RING
1	6V1454	SEAL-O-RING
5	6V3250	SEAL-O-RING
2	7M8485	SEAL-O-RING-STOR
4	8T1919	SEAL-O-RING
2	9Y6893	GASKET
2	1058180	GASKET
80	1077954	SPACER-HIGH TEMP
3	1684987	GASKET
2	1808424	SEAL-O-RING
1	2147568	SEAL-O-RING-STOR
4	2279012	GASKET
1	2287088	SEAL-O-RING-ORFS
4	2287089	SEAL-O-RING-ORFS
1	2287092	SEAL-O-RING-ORFS
3	2385080	SEAL-O-RING-STOR
1	3578765	GASKET
1	5195587	CORE AS-AFTCLR
2	5195853	GASKET
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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At the next maintenance interval, inspect the aftercooler and air bonnet joints (top, bottom, and each side) for boost leaks. Two methods can be utilized, to inspect for a leak ("touch" and/or gas analyzer).

1. If a leak can be felt against the skin, replace the aftercooler core.

2. Using a gas analyzer, inspect for gas at the bonnet joints. If CH4 content exceeds 4000ppm within 2 inches of the bonnet joints, replace the aftercooler core.

If a leak is not detected no rework is required. If a leak is found using either detection method described above then proceed with aftercooler replacement as described in Special Instruction, M0081048, "Installation of the 519-5587 Aftercooler Core As on Certain G3500H Series Engines". Use Disassembly and Assembly, UENR0110, or UENR6159 for reference.

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Image1

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%
*****Group 1*****
0-40000 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 20.0-hour job for Group 1

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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%
*****Group 2*****
0-40000 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%