PRODUCT SUPPORT PROGRAM FOR REWORKING THE ENGINE JACKET WATER HEATER ON CERTAIN D13, D20, D25, AND D30 MODEL GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE ENGINE JACKET WATER HEATER ON CERTAIN D13, D20, D25, AND D30 MODEL GENERATOR SETS

Usage:

REBE6504-01

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09Feb2011

(Revised 11May2011)

U-52

A-40

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE ENGINE JACKET WATER HEATER ON CERTAIN D13, D20, D25, AND D30 MODEL GENERATOR SETS
1383		PS43232

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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 "PS43232" 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 09Feb2011 Service Letter. Changes have been made to the Affected Product.

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TERMINATION DATE

28Feb2013

PROBLEM

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The existing jacket water heater system can malfunction on certain D13, D20, D25, and D30 model generator sets. When the existing jacket water heater system malfunctions it may cause poor starting and load acceptance when these generator sets operate in low ambient temperatures.

AFFECTED PRODUCT

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Model	Identification Number
C1.5	GBD00206, 208, 211, 215, 223, 229, 232, 237, 239
C2.2	GBE00170, 180, 189, 192, 194, 198, 203, 227, 244, 258, 261, 275, 281, 289, 308, 311, 325, 339, 342, 373, 387, 390, 440, 454, 468, 499

PARTS NEEDED

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Qty	Part Number	Description
4	5D1026	CLAMP-HOSE
2	5P4115	WASHER-HARD
1	6V8843	HOSE-BULK
2	7X0510	WASHER-HARD
2	8T4121	WASHER-HARD
2	8T4138	BOLT-HEX HEAD
2	8T4186	BOLT
2	9X3959	ELBOW
2	1415453	BOLT-HEX HEAD
2	1542949	CLIP
2	3230049	CLIP-LOOP
1	3402435	ADAPTER - SWIVEL
1	3429073	CONNECTOR
1	3429074	CONNECTOR
1	3429076	ELBOW
1	3609541	BRACKET AS.
1	3610717	BRACKET AS.
2	3617622	VALVE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 14% 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 the existing jacket water heater, fittings, and hoses.

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%
0-2500 hrs, 0-24 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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1. Drain the coolant from the engine.

2. Remove all the existing hot water supply hoses and fittings (1). Do not reuse these parts.

3. Remove all the existing cool water return hoses and fittings (2). Do not reuse these parts.

4. Remove the heater (4) from the existing bracket (3). Retain the heater (4) for reuse. Remove the existing heater mounting bracket (3) from the engine. Do not reuse the existing bracket (3).

Image1.1.1

Image1.1.2

5. Remove two hex head M14 bolts from the engine right hand side mounting foot, one upper and one lower (rear most). Do not reuse these bolts.

6. Install the appropriate new heater bracket (13), 361-0717 Bracket (turbocharged engine) or 360-9541 Bracket (turbocharged and intercooled engine), to the right hand side of the engine by securing it to the engine mounting foot with two 141-5453 Bolts and two 7X-0510 Washers. Tighten both bolts to a torque of 160Nm +/- 30Nm.

7. Install the heater (4) to the new mounting bracket on the engine, using two 8T-4138 Bolts and 5P-4115 Washers (11).

8. Assemble the hot water supply fittings to the right hand side of the engine. These are 342-9073 Connector (5) into the engine, 342-9076 Elbow (6), 361-7622 Ball Valve (7), and 9X-3959 Elbow (8).

NOTE: Ensure that the ball valve does NOT slope downwards from heater hose to engine inlet. Apply Loctite 577 sealant to all threads prior to assembly.

9. Cut a piece of 6V-8843 Hose (9) to length to connect the hot water outlet in the top of the heater with the elbow on the end of the ball valve. Secure the hose in position with two 5D-1026 Band Clamps (10).

Image1.2.1

Image1.2.2

10. Assemble the cool water return fittings to the left hand side of the engine. These are 342-9074 Connector (14) into the engine, 340-2435 Swivel Adapter (15), 361-7622 Ball Valve (7), and 9X-3959 elbow (8).

NOTE: Apply Loctite 577 sealant to all threads prior to assembly.

11. Cut a piece of 6V-8843 Hose (12) to length to connect the cool water inlet in the bottom of the heater with the elbow on the end of the ball valve at the engine.

Image1.3.1

12. Place two appropriate hose clips (16) over the hose. Slide the clips along the hose until mid way along the length.

NOTE: Use two 154-2949 Hose Clips for a turbocharged engine, or two 323-0049 Hose Clips for a turbocharged and intercooled engine.

13. Secure the ends of the hose in position on the heater and engine with two 5D-1026 Band Clamps (10).

14. Secure the hose and hose clips in position on the front of the radiator pedestal. Use two 8T-4186 Bolts and 8T-4121 Washers.