PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXHAUST MANIFOLD BRACKET FASTENING HARDWARE ON CERTAIN PMG3516C GENERATOR SETS (XQ1475G POWER MODULES) Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXHAUST MANIFOLD BRACKET FASTENING HARDWARE ON CERTAIN PMG3516C GENERATOR SETS (XQ1475G POWER MODULES)

Usage:

TEBE2126-02

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15Oct2014

(Revised 02Mar2015)

B26B
B94N
D35P
J520

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Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXHAUST MANIFOLD BRACKET FASTENING HARDWARE ON CERTAIN PMG3516C GENERATOR SETS (XQ1475G POWER MODULES)
7553 1059		PS44511

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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 "PS44511" 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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NOTE:	This Revised Service Letter replaces the 15Oct2014 (Revised 03Feb2015) Service Letter. Changes have been made to the Affected Product.

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TERMINATION DATE

31Oct2016

PROBLEM

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The fastening hardware used with the 218-8151 Bracket within the 210-7753 Exhaust Manifold Group may become loose and/or break on certain PMG3516C Generator Sets (XQ1475G Power Modules). Installation of improved fasteners for this bracket is required.

AFFECTED PRODUCT

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Model	Identification Number
PMG3516C	JKK00100-00118, 120-122, 124-126, 128-129, 131, 133, 135, 138-139, 145-147, 150-156, 158-160, 163-171, 173-179, 181-186, 188-189, 194, 210

PARTS NEEDED

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Qty	Part Number	Description
4	1F7958	NUT-FULL
8	1F7960	WASHER-HARD
4	6V3631	NUT-FULL
8	8C8589	BOLT-HIGH TEMP
6	1180275	WASHER
2	3656813	WASHER-HARD
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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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 this product's 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, the warnings that are on the product, and the warnings that are in the OMM are not all inclusive. If a tool, a procedure, a work method, or operating technique that is 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 or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

WARNING: The generator set must be isolated 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.

Repair Action Required

Installation of improved fasteners on the 218-8151 Bracket shown in Image1 is required. Installation of improved fasteners will be required for this bracket on both the right side and left side of the engine.

Refer to the attached Rework Procedure.

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Image1

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, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 2.0-hour job

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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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Remove exhaust manifold insulation in area shown in Image1.1.1.

Image1.1.1

On the right side of the engine, replace existing fastening hardware used on the end of the 218-8151 Bracket that attaches to the engine bracket. Replace existing bolts with quantity 2 of 8C-8589 Bolt (1). Use quantity 3 of 118-0275 Washer, quantity 1 of 365-6813 Washer (2), and quantity 2 of 1F-7958 Nut. Tighten to 120 N-m. Note that the 365-6813 Washer has a smaller outside diameter than the 118-0275 Washer and must be used at the location nearest the inside bend radius to prevent washer from sitting on the radius (2). Refer to Image1.2.1.

Image1.2.1

On the right side of the engine, replace existing fastening hardware used on the end of the 218-8151 Bracket that attaches to the exhaust pipe. Replace existing bolts with quantity 2 of 8C-8589 Bolt (3). Use quantity 4 of 1F-7960 Washer and quantity 2 of 6V-3631 Nut. Tighten to 120 N-m. Refer to Image1.3.1.

Image1.3.1

On the left side of the engine, replace existing fastening hardware used on the end of the 218-8151 Bracket that attaches to the engine bracket. Install quantity 2 of 8C-8589 Bolt (4). Use quantity 3 of 118-0275 Washer, quantity 1 of 365-6813 Washer (5), and quantity 2 of 1F-7958 Nut. Tighten to 120 N-m. Note that the 365-6813 Washer has a smaller outside diameter than the 118-0275 Washer and must be used at the location nearest the inside bend radius to prevent washer from sitting on the radius (5). Refer to Image1.4.1.

Image1.4.1

On the left side of the engine, replace existing fastening hardware used on the end of the 218-8151 Bracket that attaches to the exhaust pipe. Replace existing hardware with quantity 2 of 8C-8589 Bolt (6). Use quantity 4 of 1F-7960 Washer and quantity 2 of 6V-3631 Nut. Tighten to 120 N-m.. Refer to Image1.5.1.