PRODUCT SUPPORT PROGRAM FOR REPLACING THE 271-7013 FUEL COOLER ON CERTAIN C32 GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE 271-7013 FUEL COOLER ON CERTAIN C32 GENERATOR SETS

Usage:

TEBE1540-02

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04Jun2014

(Revised 20Apr2015)

U060
U150
U158

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Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING THE 271-7013 FUEL COOLER ON CERTAIN C32 GENERATOR SETS
1712		PS44334

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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 "PS44334" 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 04Jun2014 (Revised 18Nov2014) Service Letter. Changes have been made to increase the Affected Product and Service Claim Allowances.

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TERMINATION DATE

30Jun2016

PROBLEM

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The existing fuel cooler may fail on certain C32 Generator Sets.

AFFECTED PRODUCT

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Model	Identification Number
C32	SXC02695, 2697, 2699-2703, 2707-2722, 2724-2726, 2728-2730, 2733, 2735, 2739, 2743-2748, 2750-2754, 2756, 2761-2764, 2766-2768, 2776-2779, 2793-2795, 2797-2799, 2814, 2816-2817, 2819, 2830-2831, 2834-2835, 2846-2847, 2849, 2851, 2863, 2874-2877, 2880-2883, 2885, 2887-2890, 2892-2902, 2910-2915

PARTS NEEDED

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Qty	Part Number	Description
2	1V9020	PLUG-BUTTON
6	8T0389	LOCKNUT
6	8T4121	WASHER-HARD
2	8T4182	BOLT-HEX HEAD
2	8T4195	BOLT-HEX HEAD
2	1471702	COUPLING AS-PERM
2	2385080	SEAL-O-RING-STOR
1	3411886	COOLER AS-FUEL
1	PLATE	DEALER FABRICATED PART
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.

Replace 271-7013 Fuel Cooler with 341-1886 Fuel Cooler. Refer to Image 1: 271-7013 Fuel Cooler to be replaced.

The replacement fuel cooler will require additional hardware for mounting/fit-up, punching of holes in the radiator shroud for fuel line routing, along with some other adjustments to fuel line length/routing. Also, new couplings will need to be fitted to the fuel lines to connect to the new fuel cooler. Refer to Image 2: 341-1886 Fuel Cooler installed.

A steel plate will also need to be fabricated. The plate will be used for mounting of the new fuel cooler. Refer to Image 3: Fabricated steel plate installed for the new fuel cooler.

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%
0-20000 hrs, 0-90 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 5.0-hour job
A maximum of $38.00 USD is allowed for fabrication of steel mounting plate.

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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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A steel plate will need to be fabricated as shown in Image 1.1.1. Note that dimensions are in millimeters (mm). Use 3/16? (4.76 mm) thickness plate steel and paint black.

The new 341-1886 Fuel Cooler will need to be modified as shown in Image 1.2.1. Remove the weld nut bar (1) by removing the rivets (2) that secure the weld nut bar to the Fuel Cooler mounting bracket. Set the weld nut bar aside for later use.

Remove the rubber guard (3) from the bracket of the 341-1886 Fuel Cooler and install on the opposite bracket (4). Refer to Image 1.3.1.

Remove 2 support bracket bolts (3/8? ? 16). Tighten to 47 +/- 9 N-m when reinstalled. Refer to Image 1.4.1.

Remove the bolts from the upper brackets at the charge air cooler interface. Tighten to 55 +/- 10 N-m when when reinstalled. Refer to Image 1.5.1.

Remove 269-8462 Fan Guard if installed. Remove 4 bolts (2 each side). 3/8 - 16 bolts (5) connect the fan guard halves. Tighten to 47 +/- 9 N-m when reinstalled. Remove 8 bolts total (6). Tighten to 55 +/- 10 N-m when reinstalled. Refer to Image 1.6.1.

If 379-0103 Fan Guard is installed, see SEBD9792 for instructions. Note that the fan guard part number can be found stamped on a plate located towards the center of each guard.

Remove fuel lines at the connector of 270-7013 Fuel Cooler. Make sure fuel is drained from fuel cooler and lines before removal. Refer to Image 1.7.1.

Remove the remaining M10 shroud bolts (quantity 6) and place the shroud aside. Tighten to 55 +/- 10 N-m when reinstalled. Refer to Image 1.8.1. Verify that the fan tip to shroud clearance is at least 1/4" (6.4 mm) in all locations before final re-assembly.

Remove 4 bracket bolts for the 271-7013 Fuel Cooler from the top and bottom bracket. Refer to Image 1.9.1. Remove the fuel cooler and brackets from the ATAAC assembly.

Locate the bolt (7) between the 4 existing 271-7013 Fuel Cooler bracket bolt holes (8). Remove this bolt. This bolt hole will be used for mounting the new 341-1886 Fuel Cooler. The other bolt hole required to mount the 341-1886 Fuel Cooler will have to be drilled. Reinstall the original 271-7013 Fuel Cooler mounting hardware into the original mounting holes (8). This hardware is only used to plug the holes. Use 4 new 8T-0389 Nuts and tighten to 55 +/- 10 N-m. Refer to Image 1.10.1.

Install the plate as shown in Image 1.11.1. Use the existing bolt hole (9) to secure the plate for use as a template to mark the remaining holes to be drilled. Drill remaining 3 holes to 11.1 mm diameter (10). Make sure the bottom fuel cooler mounting hole (11) is drilled through the center of the internal support brace (12) as shown in Image 1.11.2.

Install the 2 bolts to secure the plate as shown in Image 1.12.1. Use qty 2 of 8T-4195 Bolts, qty 4 of 8T-4121 Washers, and qty 2 of 8T-0389 Nuts. The holes on the other side of the plate will be used to mount the 341-1886 Fuel Cooler. Tighten to 55 N-m +/-10 N-m.

Install the 2 bolts to secure the 341-1886 Fuel Cooler as shown in Image 1.13.1. Use qty 2 of 8T-4182 Bolts and qty 2 of 8T-4121 Washers. Thread the bolts into the weld nut bar. The weld nut bar requires hand alignment. Tighten to 55 N-m +/-10 N-m. Verify that the fuel cooler is installed in the proper location as shown in Image 1.13.2 and Image 1.13.3. This location is necessary to allow enough air flow for cooling.

The existing fuel lines will need to be shortened. The estimated length to be removed from the lower line (13) is approximately 254 mm. The estimated length to be removed from the upper line (14) is approximately 864 mm. Refer to Image 1.14.1. The lines lengths are an estimation. Optimal length should be determined based on actual line routing and fit-up. 147-1702 Coupler Fittings will need to be installed on the ends of the fuel hoses. The 147-1702 Coupler Fittings require 238-5080 O-rings. The fittings connect directly to the fuel cooler.

Re-install shroud. Punch holes in the shroud for fuel line routing in locations shown below. The hole diameter is 1.75 inches (44.5 mm). Remove the grommets from the original holes and install in the new holes. Refer to Image 1.15.1.

Route and connect the fuel cooler lines to the 341-1886 Fuel Cooler (both fuel cooler connections are acceptable for inlet or outlet flow). Tighten to 50 +/- 7 N-m. Be sure to route the fuel lines so that there is clearance between the fuel lines and shroud holes/grommets. This is to prevent fuel line rubbing. Adjustments will be needed using existing p-clips to secure lines. Refer to Image 1.16.1.

Install 1V-9020 Plug into each of the 2 original fuel line holes in the shroud. Refer to Image 1.17.1.

Reinstall fan guard, support bracket, and charge air cooler bracket. Run the unit and inspect for proper operation.