PRODUCT SUPPORT PROGRAM FOR REWORKING THE JACKET WATER HEATER SYSTEM ON CERTAIN C6.6 GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE JACKET WATER HEATER SYSTEM ON CERTAIN C6.6 GENERATOR SETS

Usage:

REBE5762-01

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23Dec2009

(Revised 19Jan2010)

U-458

A-376

O-411

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE JACKET WATER HEATER SYSTEM ON CERTAIN C6.6 GENERATOR SETS
1383		PS51786

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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 "PS51786" 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 23Dec2009 Service Letter. Changes have been made to Affected Product.

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TERMINATION DATE

31Dec2010

PROBLEM

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The existing Jacket Water Heater (JWH) hose routing on certain C6.6 Generator Sets is incorrect. In such instances, the hot water from the JWH is piped into the thermostat housing of the engine and activating the thermostat. As a result the hot water escapes into the radiator and not into the engine block as intended.

AFFECTED PRODUCT

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Model

Identification Number

C6.6

N6D00101-00106, 108-126, 128-132, 134-151, 153-154, 156-226, 228-246, 248-253, 255-262, 264-276, 278-279, 281-336, 338-379, 381-393, 397-498, 500-613, 616-651, 654-659, 661, 663-674, 676, 678-713, 715-768, 770-817, 819-894, 898-905, 907-921, 923-956, 958-971, 976-985, 988-989, 992-1074, 1076-1142, 1144-1147, 1149-1158, 1160-1201, 1203-1204, 1207, 1209-1214, 1217-1228, 1230-1260, 1262-1353, 1355-1356, 1400-1406, 1408-1433, 1435, 1438-1441, 1443-1446, 1448-1454, 1456-1457, 1459-1467, 1469-1475, 1477-1485, 1488-1489, 1491, 1493-1499

SDA00100-00101, 105-106, 108, 110-114, 117-119, 121-123, 126-131, 133-134, 139-149, 151-159, 161-164, 166-178, 180-183, 185, 187-188, 191-201, 203, 206, 208, 210-230, 233-234, 236, 238-253, 262-263, 265-276, 278-284, 286-290, 293-314, 316, 318, 320-324, 326-331, 341-373, 375-380, 384-387, 393-396, 407-423, 426-435, 465-549, 564-566, 570-571, 582-593, 595-601, 608-609

PARTS NEEDED

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Qty	Part Number	Description
200	2706792	HOSE-BULK
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% 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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Re-route the JWH coolant lines.

Refer to the attached Rework Procedure.

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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%
0-500 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
501-1000 hrs, 13-24 mo	100.0%	0.0%	0.0%	100.0%	0.0%	0.0%

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NOTE: This is a 1.0-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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Refer to Parts Manual, SEBP4548-12, 287-4953 Heater GP-Jacket Water for additional details.

1. Isolate the generator set before commencing any work on the unit, open the generator set breaker, activate the emergency stop, disconnect the auxiliary power supply for the battery charger and heaters, and disconnect the battery cables. Ensure health and safety requirements are adhered to at all times. Also, ensure proper Lock Out-Tag Out procedures are followed at all times while work is being performed on the machine. Lock out generator before commencing any type of work.

2. The current jacket water heater (JWH) arrangement is illustrated in Image 1.1.1.

Image1.1.1

3. Drain the coolant from the engine and radiator.

4. Unscrew and retain the jubilee clips (1), bolts, washer, and P-clips (2) securing the hose to the heater and the adaptors on the engine.

5. Remove the rubber hose (3) (to and from the heater). This will not be reused.

6. Retain all the adaptor fittings for the JWH system in their original positions on the engine.

7. Cut the new 270-6792 Hose, to length for the hot supply and cool return lines.

8. Fit the new hose (3) as shown in Image 1.2.1. Use the original jubilee clips (1) to secure the hose ends to the JWH and adaptors on the engine. Route the cold return as illustrated in Image 1.2.1 and secure to the engine at suitable locations using the original bolts, washers and P-clips (2).

NOTE: Ensure that the hose lengths allow the straightest and most vertical routing, without kinks. This is vitally important for the hot supply from the heater to the engine block.

Image1.2.1

9. Re-fill the radiator and engine with coolant.

10. Check the coolant level, ensuring that there are no air locks in the engine cooling system.

11. Run the generator set until the engine reaches operating temperature. Check for any leaks. Repair as necessary.