PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXHAUST SYSTEM ON CERTAIN G3520C BIOGAS ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXHAUST SYSTEM ON CERTAIN G3520C BIOGAS ENGINES

Usage:

REBE3547-01

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07Aug2008

(Revised 17May2010)

U-411

A-336

O-375

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXHAUST SYSTEM ON CERTAIN G3520C BIOGAS ENGINES
1059 1408		PS51532

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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 "PS51532" 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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NOTE:	This Revised Service Letter replaces the 07Aug2008 Service Letter. Changes have been made to extend the termination date; and a reference to REBE5494 has been added.

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TERMINATION DATE

31Mar2011

PROBLEM

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The exhaust system may corrode and leak on certain G3520C Biogas engines. If the exhaust system corrodes and leaks it may cause low power and/or burned wiring harnesses.

AFFECTED PRODUCT

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Model	Identification Number
G3520C	GZJ00161-00300 GZK00151-00182 HAT00102, 200-211 MAD00101-00102, 200-201

PARTS NEEDED

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Qty	Part Number	Description
44	3E6916	NUT-FULL
44	5L6887	BOLT
8	5M2894	WASHER-HARD
8	5P2603	STUD-TAPERLOCK
16	5P8247	WASHER-HARD
8	6V4605	LOCKNUT-TEMP
4	7L6443	BOLT-HEX HEAD
180	8C8491	WASHER
80	9L7373	BOLT-HIGH TEMP
8	9S8752	NUT-FULL
4	9X2068	BOLT-HIGH TEMP
8	1626466	BOLT-12 POINT HD
10	2006551	MANIFOLD-EXHAUST
10	2006552	MANIFOLD-EXHAUST
2	2006553	CAP
20	2034571	SEAL
2	2064171	ELBOW
1	2064807	HARNESS AS
5	2072371	SENSOR GP-TEMP
1	2202339	HARNESS AS-WRG
2	2303411	ELBOW
46	2448861	CLAMP
18	2645140	BELLOWS AS
5	2722655	SEAL
2	2774843	BELLOWS AS
2	2889046	BELLOW AS
44	3053447	SEAL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 18% 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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Rework exhaust system. Refer to the attached Rework Procedure.

NOTE: To protect the detonation and thermocouple harnesses from exhaust gas leaks, perform REBE5494 as applicable.

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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%
0-8000 hrs, 0-60 mo	100.0%	0.0%	0.0%	0.0%	0.0%	0.0%
8001-16000 hrs, 61-72 mo	80.0%	0.0%	0.0%	0.0%	20.0%	0.0%
16001-24000 hrs, 73-84 mo	60.0%	0.0%	0.0%	0.0%	40.0%	0.0%
24001-32000 hrs, 85-96 mo	40.0%	0.0%	0.0%	0.0%	60.0%	0.0%
32001-40000 hrs, 97-108 mo	20.0%	0.0%	0.0%	0.0%	80.0%	0.0%

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NOTE: This is a 0.0-hour job
NOTE: Total Labor hours for complete repair of Bellows and Manifold covered in this program is not to exceed 25 Hours. All labor should be claimed according to the pro-rate schedule in Image 1.1. NOTE: This service claims allowance table applies to the exhaust manifold castings and wiring harnesses only. Parts included are: 200-6551, 200-6552, 206-4171, 206-4807, 220-2339, and 230-3411. Refer to pro-rate schedule in Image 1.1 for other parts claims allowance. Parts identified in the parts list "As Required", should only be replaced as needed (Refer to attached Rework Procedure).

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Image1.1

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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Refer to appropriate Service Manual as necessary.

1) Identify location of exhaust leak.

2) Disassemble the exhaust manifold system in accordance to the Disassembly and Assembly manual.

3) Remove any burnt wiring harnesses. The detonation and/or thermocouple harnesses are located below the exhaust manifolds.

4) Clean exhaust manifold castings for reuse. It may be difficult to clean the seal groove of the manifolds due to excessive corrosion. Special cleaning methods and tools, such as a needle gun or glass beading, may be necessary to clean the seal groove. Manifolds should be replaced only if they are not reusable after attempted cleaning.

NOTE: Manifold castings should be replaced if: 1) cleaning cannot get the seal groove clean enough to allow a new seal to fit evenly in the groove, 2) cleaning the seal groove shows that the seal groove has corroded extensively and the new seal will not stay retained properly in the groove.

Image 1.1.1 is an example of an uncleaned seal groove.

Image1.1.1

5) Install any required wiring harnesses. Wiring harnesses should only be replaced if they are burnt through the harness braiding and wires are damaged.

6) Reassemble the exhaust system per the Disassembly and Assembly manual.

NOTE: Special attention should be used to ensure good alignment of exhaust bellows between manifold sections. Good alignment is critical to achieving expected bellows life.

NOTE: Use nickel based anti-sieze compound, see TIBU5269 on fastners during reassembly.

7) Load test unit and inspect for any exhaust leaks.