PRODUCT SUPPORT PROGRAM FOR REPLACING CYLINDER PACKS ON CERTAIN CG170-16, G3516H, AND G3520H GENERATOR SETS Caterpillar


PRODUCT SUPPORT PROGRAM FOR REPLACING CYLINDER PACKS ON CERTAIN CG170-16, G3516H, AND G3520H GENERATOR SETS

Usage:

TEBE8262-00

23Oct2018


U-595
A-431
D-520
O-527

 

Before/After

  
  

PRODUCT SUPPORT PROGRAM FOR REPLACING CYLINDER PACKS ON CERTAIN CG170-16, G3516H, AND G3520H GENERATOR SETS

1213 1215
PS46046
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 "PS46046" 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.

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.


TERMINATION DATE

31Oct2020

PROBLEM

Certain CG170-16, G3516H, and G3520H Generator Sets in regions that experience elevated humidity levels are required to elevate the Intake Manifold and SCAC temperatures to eliminate condensation formation in the air system. In doing so, these engines may require additional derate due to fuel quality.

AFFECTED PRODUCT

Model Identification Number
*******Group  1*******
G3520H HD GFP00118, 121, 146, 152, 165-166, 170, 172-175, 178-181, 191-192

GFR00115-00116, 123-124, 128-129, 133, 139-171, 186-190, 194, 202, 204-205, 211
*******Group  2*******
CG170-16  KSJ00165, 167
G3516H NWH00100-00105, 107-108, 114-116, 119-120, 122-127, 132, 134-154, 158, 160, 162-164

NWJ00102, 105, 107, 111-112
G3516H HD GLM00134, 136, 156-157, 161-163, 172-176, 184, 186-188

GLN00117-00118, 122-124, 126, 130-134, 136-137
*******Group  3*******
G3516H NWH00155-00156, 165-167

NWJ00103-00104, 108
G3516H HD GLM00121-00122, 129-131, 171

GLN00116, 119, 125, 127, 138
*******Group  4*******
G3520H HD GFP00117, 119, 122-138, 142-143, 145, 147-149, 167, 169, 176-177, 182-190, 194-195

GFR00130-00132, 172-185, 192-193, 196-198, 208-210, 213-218

PARTS NEEDED

Qty

Part Number Description
*******Group 1*******
60 7N2046 SEAL-O-RING
40 8N7296 RETAINER
20 2236361 RING-PISTON
20 2302520 BEARING-CONN ROD
20 3488779 RING-PISTON
20 3526061 SEAL-LINER
20 3550765 KIT-GASKET(SCH)
20 4234277 SLEEVE
20 4247167 PISTON AS
20 4473915 LINER-CYLINDER
20 4501408 RING-PISTON
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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*******
48 7N2046 SEAL-O-RING
32 8N7296 RETAINER
16 2236361 RING-PISTON
16 2302520 BEARING-CONN ROD
16 3488779 RING-PISTON
16 3526061 SEAL-LINER
16 3550765 KIT-GASKET(SCH)
16 4234277 SLEEVE
16 4247167 PISTON AS
16 4473915 LINER-CYLINDER
16 4501408 RING-PISTON
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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*******
48 7N2046 SEAL-O-RING
32 8N7296 RETAINER
1 1845290 GASKET
16 2236361 RING-PISTON
16 2302520 BEARING-CONN ROD
1 3407683 RING-NOZZLE
16 3488779 RING-PISTON
16 3526061 SEAL-LINER
16 3550765 KIT-GASKET(SCH)
1 3693510 RING-LAMELLAR
16 4234277 SLEEVE
16 4247167 PISTON AS
16 4473915 LINER-CYLINDER
16 4501408 RING-PISTON
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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*******
60 7N2046 SEAL-O-RING
40 8N7296 RETAINER
1 1845290 GASKET
20 2236361 RING-PISTON
20 2302520 BEARING-CONN ROD
20 3488779 RING-PISTON
20 3526061 SEAL-LINER
20 3550765 KIT-GASKET(SCH)
1 3643678 RING-NOZZLE
1 3693510 RING-LAMELLAR
20 4234277 SLEEVE
20 4247167 PISTON AS
20 4473915 LINER-CYLINDER
20 4501408 RING-PISTON
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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

The Intake Manifold and SCAC water temperature are required to have been raised prior to exercising this letter. Correct operation temperatures should be verified prior to any new iron being installed. If the fuel methane number is below 80, the engine has a reduced full load capability. In some cases, the customer may not require the full load potential of the engine. In cases where the elevated temperature results in a reduction of the expected power export of the customer, the dealer should discuss with the customer the potential to change the rating strategy to the Humidity/Fuel Tolerant option.

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-8000 hrs,
0-12 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
8001-16000 hrs,
13-48 mo 
75.0%
75.0%
0.0%
0.0%
25.0%
25.0%
16001-24000 hrs,
49-60 mo 
50.0%
50.0%
0.0%
0.0%
50.0%
50.0%
24001-30000 hrs,
61-72 mo 
20.0%
20.0%
0.0%
0.0%
80.0%
80.0%
 NOTE: This is a 80.0-hour job for Group 1

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-8000 hrs,
0-12 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
8001-16000 hrs,
13-48 mo 
75.0%
75.0%
0.0%
0.0%
25.0%
25.0%
16001-24000 hrs,
49-60 mo 
50.0%
50.0%
0.0%
0.0%
50.0%
50.0%
24001-30000 hrs,
61-72 mo 
20.0%
20.0%
0.0%
0.0%
80.0%
80.0%
 NOTE: This is a 65.0-hour job for Group 2

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 3*******
0-8000 hrs,
0-12 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
8001-16000 hrs,
13-48 mo 
75.0%
75.0%
0.0%
0.0%
25.0%
25.0%
16001-24000 hrs,
49-60 mo 
50.0%
50.0%
0.0%
0.0%
50.0%
50.0%
24001-30000 hrs,
61-72 mo 
20.0%
20.0%
0.0%
0.0%
80.0%
80.0%
 NOTE: This is a 68.0-hour job for Group 3

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 4*******
0-8000 hrs,
0-12 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
8001-16000 hrs,
13-48 mo 
75.0%
75.0%
0.0%
0.0%
25.0%
25.0%
16001-24000 hrs,
49-60 mo 
50.0%
50.0%
0.0%
0.0%
50.0%
50.0%
24001-30000 hrs,
61-72 mo 
20.0%
20.0%
0.0%
0.0%
80.0%
80.0%
 NOTE: This is a 83.0-hour job for Group 4



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.

NOTE: When switching to the HFT configuration, use Piston As 424-7167 in place of the current 418-9359 Piston As or older 384-2884 Piston As in conjunction with the remaining parts listed. It is NOT acceptable to have a mixture of the 424-7167 Piston As with any other Piston As in the engine. Ratings for the HFT configuration are available in the Gas Engine Rating Pro (GERP) tool.

The current HFT offerings require a 340-7683 Nozzle Ring be used with the G3516H and a 364-3678 Nozzle Ring be used with the G3520H. The different population groups will identify in the respective parts list if the engine in question requires a nozzle ring change reflective of the configuration when the engine left the factory. Additional Labor has already been added to account for the time to required to change the nozzle ring.

Pre-repair:

1) Increasing the Intake manifold and SCAC temperature, should have been performed prior to attempting to exercise this letter.

2) Reference the provided chart of rating changes and note down the existing, elevated (ICA) and Humidity/Fuel Tolerant (HFT) product versions and compare the site results in Gas Engine Rating Pro (GERP). Ensure the same site conditions, generator efficiency, and power factor are the same. Determine the best rating for the customer?s needs and operation between the elevated and HFT options. Additional questions or support can be answered by the Customer Solutions Quoter (CSQ).

3) Collect a fuel sample for the engine operating location. In some cases, the fuel quality can vary throughout the course of the year. If this is the case you may need to work with the local gas supply company to obtain a fuel history summary to understand the operating range. Attach Fuel sample(s) analysis from the gas supplier to the SIMSi claim.

4) Inspect the air system for signs of rust/corrosion. Rust scaling is a potential result if the engine was exposed to condensation. Rust particles entering the cylinder can cause health issues such as cylinder liner scoring or piston ring sticking which can result in loss of oil control and detonation shutdowns. If rust persists, perform air system cleaning prior to the new hardware installation. Review for other product support programs prior to any new cylinder packs being installed. When possible, perform that work as applicable in conjunction with this program.

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:
5) Follow standard procedures to remove the cylinder packs assemblies from the engine.

6) Assemble the replacement cylinder packs ensuring that the new piston rings are installed properly, and not upside down. Install the cylinder packs and ensure a sleeve/cuff has been installed in the liner.

7) For Groups 3 and 4, remove the turbine outlet exhaust elbow and the turbine housing from the engine. Remove the existing Nozzle ring and install the replacement nozzle ring specified in the respective parts list. Reinstall the turbine housing and exhaust elbow.

8) Prior to starting, reset the engine set point timing according to your specific site conditions using the new HFT performance datasheet. Start and load engine to 30% engine load for 5 minutes. After 5 minutes, increase the load to 60% and allow the engine to run at this load for 10 minutes. Perform NOx sensor calibration if needed. After the ten minutes, increase the load to 100%. Monitor using Caterpillar ET, and verify that detonation is not present on the new cylinder packs for the first hour. After 1 hour of run time, reset valve lash on the cylinders, then resume normal operation.
 
 

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