PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE EXHAUST MANIFOLD ON CERTAIN G3512H, G3516H, AND G3520H GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE EXHAUST MANIFOLD ON CERTAIN G3512H, G3516H, AND G3520H GENERATOR SETS

Usage:

TEBE8405-00

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20Dec2018

U-746

A-540

D-658

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Priority	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE EXHAUST MANIFOLD ON CERTAIN G3512H, G3516H, AND G3520H GENERATOR SETS
1059		PI32975

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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 "PI32975" 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 "PI32975" 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
30Jun2019	31Dec2019

PROBLEM

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The existing exhaust manifold bracket hardware does not provide adequate support on certain G3512H, G3516H, and G3520H Generator Sets. The potential for hardware to fail can lead to early-hours bellows failures.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
G3512H	GF500120-00143
G3516H	NWH00139-00167 NWJ00109-00112
G3520H HD	GFP00182-00195 GFR00199-00214

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*****Group 2*****
G3512H	GF500144-00149
G3516H	NWH00168-00184
G3520H HD	GFR00215-00220

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
4	0S1590	BOLT
36	3E6916	NUT-FULL
4	6L3143	BOLT-HIGH TEMP
8	6V3631	NUT-FULL
4	6V5766	BOLT
72	1077954	SPACER-HIGH TEMP
4	1984777	WASHER-HARD
16	2266575	WASHER - SST
6	3568647	SEAL
36	3767739	BOLT-HEX HEAD
2	3809647	BELLOWS AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 15% 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*****
4	0S1590	BOLT
4	6L3143	BOLT-HIGH TEMP
8	6V3631	NUT-FULL
4	6V5766	BOLT
4	1984777	WASHER-HARD
16	2266575	WASHER - SST
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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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Group 1 Machines: Requires alignment and hardware. Complete the attached Rework Procedure for Group 1 only.

Group 2 Machines: Requires only hardware update and NO alignment. Complete the following rework instructions:
Certain exhaust manifold bracket hardware will need to be replaced. Remove and replace one bolt at a time to ensure that the bellows alignment is not impacted. Refer to Image1 below for the location of hardware installations.

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Image1

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 3.0-hour job for Group 1

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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 1.5-hour job for Group 2

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 REWORKING THE EXHAUST MANIFOLD

MODELS INVOLVED ? CERTAIN G3512H, G3516H, AND G3520H GENERATOR SETS

Dear Cat Product Owner:

The exhaust manifold needs to be inspected and repaired on the products listed below. The existing brackets and hardware do not provide adequate support and can fail, leading to early-hours bellows failures. 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 20Dec2018 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 20Dec2018 Service Letter

Rework Procedure

1. Remove the side bellows. Remove the existing hardware for the front bellows on the flange mating with the elbow. Refer to Image1.1.1.

IMPORTANT: It is critical to remove this hardware so the alignment is successful.

Image1.1.1

2. Remove the existing four sets of bolts, nuts, and washers that mount the exhaust elbow to the support brackets. Refer to Image1.2.1.

Image1.2.1

3. Remove the existing two bolts to the front housing. Refer to Image1.3.1.

Image1.3.1

4. Install plate (5) with four bolt (12) and four spacers (13) on the front housing. Refer to Image1.4.1 and 1.4.2.

5. Install bracket (1), bracket (3), and plate (5) onto the left-hand side manifold with bolts (6) and (7), using appropriate washers and nuts. Leave bolts (7) and (11) loose.

Image1.4.1

Image1.4.2

6. Insert bellows alignment tool (15) between the elbow and the first cylinder side only. Torque 3/8 inch hardware to hold the tool in place. Refer to Image1.5.1.

7. Reassemble bellows (14) on the front of the engine between the elbow and Y-manifold using one seal (16), six bolts (17), twelve spacers (18), and six nuts (19).

Image1.5.1

8. Tighten the four bolts. Refer to Image1.6.1.

Image1.6.1

9. Remove the alignment tool and install bellows (14) between the elbow and first cylinder using two seals (16), twelve bolts (17), 24 spacers (18), and twelve nuts (19). Refer to Images1.7.1 and 1.7.2.

Note: Ensure that the bellows are installed in the correct direction using new hardware.