PRODUCT SUPPORT PROGRAM FOR REWORKING THE OXYGEN SENSOR ON CERTAIN G3306B (XQG135) GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE OXYGEN SENSOR ON CERTAIN G3306B (XQG135) GENERATOR SETS

Usage:

TEBE7289-00

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01Mar2018

U-129

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Before/After	PRODUCT SUPPORT PROGRAM FOR REWORKING THE OXYGEN SENSOR ON CERTAIN G3306B (XQG135) GENERATOR SETS
1021 1096 1403		PS45816

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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 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 "PS45816" 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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TERMINATION DATE

31Mar2020

PROBLEM

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The existing oxygen sensor can not operate correctly in its current location on certain G3306B (XQ135) Generator Sets. If the existing oxygen sensor fails it will cause issues with the emissions software.

AFFECTED PRODUCT

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Model	Identification Number
G3306B	AL400100-00119, 122-124, 135-136

PARTS NEEDED

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Qty	Part Number	Description
1	3E2331	PLUG-HD STOR
1	3993218	GROMMET
1	5082175	HARNESS AS
1	5104350	HARNESS AS
1	5393838	BOSS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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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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%
0-20000 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 16.0-hour job If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.

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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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ACTION REQUIRED
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 the 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, on the product, and in the OMM are not all inclusive. If a tool, procedure, work method, or operating technique 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 and that the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.
WARNING: The generator set must be isolated mechanically and 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.

1. Remove and plug (using 3E-2331) the oxygen sensor's original location in catalytic converter.

2. The recommended new location for the oxygen sensor is inside the radiator compartment downstream of the catalytic converter in the silencer inlet pipe. These harnesses will need to extend to the radiator compartment of the generator set enclosure. Drill a hole from the engine compartment into the radiator compartment. Add a 3 inch diameter grommet (399-3218) to ensure the harness is not damaged as it passes through to the radiator compartment above the radiator bulkhead panel. Weld a new boss (539-3838) in the silencer inlet pipe.

3. Install the existing oxygen sensor in the new port location. Reference Image 1.2.1 and Image 1.2.2.

Image1.2.1

Image1.2.2

4. Extend the existing sensor harness using two jumper harnesses (508-2175 and 510-4350). Using callout #1 as the connection point for 508-2175. And using callout #2 as the connection point for 510-4350. Reference Image 1.3.1.