PRODUCT SUPPORT PROGRAM FOR REWORKING THE AIR SYSTEM ON CERTAIN CG170-16, G3516H, AND G3520H GENERATOR SETS Caterpillar
PRODUCT SUPPORT PROGRAM FOR REWORKING THE AIR SYSTEM ON CERTAIN CG170-16, G3516H, AND G3520H GENERATOR SETS
Usage:
TEBE8251-00
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08Oct2018
U-566
A-410
D-492
O-499
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Before/After
PRODUCT SUPPORT PROGRAM FOR REWORKING THE AIR SYSTEM ON CERTAIN CG170-16, G3516H, AND G3520H GENERATOR SETS
1071 7555
PS46028
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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 "PS46028" 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
31Oct2020
PROBLEM
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The existing air system components between the aftercooler core and cylinder head can corrode and/or rust on certain CG170-16, G3516H, and G3520H Generator Sets when exposed to condensation. If the existing air system corrodes/rusts, the particles can flake off and travel through the cylinder packs which can affect engine performance.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 23% 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.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 26% 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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Inspect the Air System thoroughly from the Aftercooler outlet to the intake runners. If the air system components are corroded or rusted, apply this program and follow 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
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 1.0-hour job for Group 1
Note: 1.0 hours is allowed for the inspection to determine if the rework procedure is required. Additional 22 hours is allowed for performing the rework procedure.
$375.00 USD is allowed for primer, top-coat, surface treatment chemical, and other miscellaneous material needed.
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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
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%
NOTE: This is a 1.0-hour job for Group 2
Note: 1.0 hours is allowed for the inspection to determine if the rework procedure is required. Additional 26 hours is allowed for performing the rework procedure.
$375.00 USD is allowed for primer, top-coat, surface treatment chemical, and other miscellaneous material needed.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Refer to appropriate service manual(s) as necessary.
Before-repair inspection:
1) Use a borescope to evaluate the health of the air system downstream of the aftercooler core looking for signs of corrosion and/or rust. Normal surface oxidation of the raw metal components can be expected but does not warrant a need to complete the work described below. If the air system displays signs of corrosion (loose or scaling rust), it is required to perform cleaning and preservation. This includes the throttle, bypass, and related tubes. Clearly document with photos the air system in case there is an issue with the claim and questions arise. Photos will be requested for approval for parts and labor related to the air system cleaning.
Note: Follow Disassembly and Assembly Manual(s) for the appropriate removal and installation procedures. Cleanliness is an important factor. The exterior components should be thoroughly cleaned before beginning the disassembly procedure. This will help prevent dirt from entering the internal mechanism. Precision components can be damaged by contaminants and/or by dirt. Keep components covered and protected at all times.
At time of repair:
1) If the air system was determined to be corroded, remove the intake system parts from the engine. Use best practices to remove the corrosion from all the intake system parts. This work should be done in a controlled environment and not near the engine. After the corrosion is removed, ensure the parts are completely cleaned and no rust, metal, abrasives or other material is left behind that could find its way into the engine or affect the paint application.
2) Prepare the parts for the paint process. Mask off all finished surfaces where paint is not to be applied. Once the part(s) is ready, apply a water-based, no-rinse surface treatment to the bare metal in a spray or wipe form such as LOCTITE SF 7515, Oxsilan CR 100 WIPE, or local equivalent. Ensure to read and understand the chemical hazards associated with the product used and follow recommended ventilation and PPE specified by the supplier.
3) Follow the recommendations of the surface treatment chemical for when proper application of the primer coating can be performed. Use 458-9582 or 479-5395 Standard Performance Primer ? Yellow, whichever is available in your region, and apply to the part surface.
5) Once the primer has cured, apply the top coat paint. Use 458-9589 or 479-5402 Standard Performance Topcoat ? Matterhorn White, whichever is available in your region. After the paint has dried, re-install the air system with the supplied replacement gaskets and O-rings.
6) Start and load engine to 100% engine load. Using Caterpillar ET, verify engine is performing as expected. Check for any air system leaks and repair as necessary. Ensure the SCAC and IMAT temperatures align with expected values. Refer to GERP performance data.
