PRODUCT IMPROVEMENT PROGRAM FOR REPLACING SCAC THERMOSTATS ON CERTAIN CG170-16, G3516H, AND G3520H GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING SCAC THERMOSTATS ON CERTAIN CG170-16, G3516H, AND G3520H GENERATOR SETS

Usage:

TEBE8250-00

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10Oct2018

U-576

A-418

D-502

O-509

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Priority	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING SCAC THERMOSTATS ON CERTAIN CG170-16, G3516H, AND G3520H GENERATOR SETS
1355		PI32942

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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 as soon as possible. When reporting the repair, use "PI32942" 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 "PI32942" 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
30Apr2019	31Oct2019

PROBLEM

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In certain regions of the world with elevated humidity levels, condensation can form in the second stage aftercooler which can cause air system corrosion and cylinder pack degradation.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
CG170-16	KSJ00165
G3516H	NWJ00102, 104-105, 107-108
G3516H HD	GLN00117-00118, 122-126, 130-134, 137
G3520H HD	GFP00118-00119, 124, 146, 148-149, 176-177 GFR00115-00116, 123-124, 128-129, 133, 139-173, 175-179, 181-186, 192-194

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*****Group 2*****
CG170-16	KSJ00167
G3516H	NWH00100-00105, 108, 114-116, 119-120, 125-127, 132, 134-136 NWJ00103
G3516H HD	GLM00121-00122, 129-131, 134, 136, 156-157, 161-163, 171-176, 184, 186-188 GLN00116, 119, 127, 136, 138
G3520H HD	GFP00117, 121-123, 125-129, 133, 135, 145, 147, 152, 166-167, 169-170, 172-175, 178, 181-182 GFR00130-00132, 174

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*****Group 3*****
G3520H HD	GFP00137-00138, 183-184 GFR00180, 187-190, 196-198, 208-210

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*****Group 4*****
G3516H	NWH00107, 122-124, 137-156, 158, 160, 162-167 NWJ00111-00112
G3520H HD	GFP00130-00132, 134, 136, 142-143, 165, 179-180, 185-192, 194-195 GFR00202, 204-205, 211, 213-216

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
2	6V1454	SEAL-O-RING
2	5258363	THERMOSTAT AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 22% 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*****
1	THERMOSTAT	Procure Locally - If Needed - See Rework Procedure
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 24% 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 3*****
2	6V1454	SEAL-O-RING
2	5258363	THERMOSTAT AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 22% 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 4*****
1	THERMOSTAT	Procure Locally - If Needed - See Rework Procedure
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 24% 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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Review of the generator set location and determine if the Rework Procedure is required.

For engines located in the yellow and red regions as defined in reference LEXE1247 (located in Electronic Media Center, emc.cat.com), follow the below rework procedure to increase the intake manifold temperature to 60 deg_C with a tolerance of +0/-3.

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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%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 0.5-hour job for Group 1
Note: 0.5 hours is allowed for review of unit location and determination if this rework procedure is required. Additional 4.5 hours is allowed for removal/installation of the on-engine thermostats.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 0.5-hour job for Group 2
Note: 0.5 hours is allowed for review of unit location and determination if this rework procedure is required. Additional 4.5 hours is allowed for removal, installation and/or other site adjustments needed of the off-engine thermostat control. Note: $110.00 USD allowance is available to cover cost of replacing customer provided thermostats if applicable.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 3*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 0.5-hour job for Group 3
Note: 0.5 hours is allowed for review of unit location and determination if this rework procedure is required. Additional 4.5 hours is allowed for removal/installation of the on-engine thermostats.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 4*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 0.5-hour job for Group 4
Note: 0.5 hours is allowed for review of unit location and determination if this rework procedure is required. Additional 4.5 hours is allowed for removal, installation and/or other site adjustments needed of the off-engine thermostat control. Note: $110.00 USD allowance is available to cover cost of replacing customer provided thermostats if applicable.

PARTS DISPOSITION

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 REPLACING SCAC THERMOSTATS

MODELS INVOLVED - CERTAIN CG170-16, G3516H, AND G3520H GENERATOR SETS

Dear Cat Product Owner:

The intake manifold temperature needs to be inspected and possibly adjusted on the products listed below. The existing thermostat (Caterpillar or customer supplied) can allow water to condense in the air system in certain geographical regions that may lead to future issues with component corrosion and affect cylinder pack health. 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 10Oct2018 when scheduling this service.

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

Caterpillar Inc.

Identification #(s)

Attached to 10Oct2018 Service Letter

Rework Procedure

Group Number 1 Group Number 3

Refer to appropriate service manual(s) as necessary.

Before-repair inspection:

1) Review site location and compare to the regional maps provided in reference media LEXE1247, available in the Electronic Media Center (EMC) and Gas Engine Rating Pro (GERP). Engines located in the defined yellow and red zones should follow the service letter to elevate the Intake Manifold Air Temperature (IMAT).

2) Refer to GERP to find the equivalent elevated rating for the particular generator set. Collect fuel sample and site conditions and run a site analysis.

At time of repair

For on-engine pumps:
1) Drain the coolant from the second stage aftercooler circuit.

2) Remove the existing SCAC thermostats and replace with new thermostats.

3) Fill the coolant circuit and check for leaks.

4) Adjust the configuration settings in Cat_ET in accordance with the new site specific datasheet (Engine set-point timing).

5) Start and run the engine. Increase the load to 100% and verify the IMAT temperature of 60 deg_C has been achieved. If the manifold temperature remains lower than desired, additional site adjustments to the return coolant temperature may be necessary. Check the NOx emissions and perform sensor calibration if needed.

Group Number 2 Group Number 4

Refer to appropriate service manual(s) as necessary.

Before-repair inspection:

1) Review site location and compare to the regional maps provided in reference media LEXE1247, available in the Electronic Media Center (EMC) and Gas Engine Rating Pro (GERP). Engines located in the defined yellow and red zones should follow the service letter to elevate the Intake Manifold Air Temperature (IMAT).

2) Refer to GERP to find the equivalent elevated rating for the particular generator set. Collect fuel sample and site conditions and run a site analysis.

At time of repair

For off-engine pumps:
1) Drain the coolant from the second stage aftercooler circuit as needed.

2) Remove the existing SCAC thermostats and replace with new thermostats if applicable. In some applications, this may be only an adjustment to a Programmable Controller on site for the water flow or temperature control circuit and will vary by site.

3) Fill the coolant circuit and check for leaks if the coolant was drained

4) Adjust the configuration settings in Cat_ET in accordance with the new site specific datasheet (Engine set-point timing).

5) Start and run the engine. Increase the load to 100% and verify the IMAT temperature of 60 deg_C has been achieved. If the manifold temperature remains lower than desired, additional site adjustments to the return coolant temperature and/or flow may be necessary. Check the NOx emissions and perform sensor calibration if needed.