LOCKNUT 6K3632 - Caterpillar

REBE3547-01
07Aug2008
(Revised 17May2010)
U-411
A-336
O-375
After Failure Only
PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXHAUST SYSTEM ON CERTAIN G3520C BIOGAS ENGINES
1059 1408 PS51532
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 Numberand "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
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.
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.
TERMINATION DATE
31Mar2011
PROBLEM
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
Model Identification Number
G3520C GZJ00161-00300
GZK00151-00182
HAT00102, 200-211
MAD00101-00102, 200-201
PARTS NEEDED
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
Rework exhaust system. Refer to the attached Rework Procedure.
To protect the detonation and thermocouple harnesses from exhaust gas leaks, perform REBE5494 as applicable.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
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%
This is a 0.0-hour job
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.
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).
Image1.1
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
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.
Manifold castings should be replaced if: