PRODUCT SUPPORT PROGRAM FOR REWORKING RADIATOR DRAIN BALL VALVE ON CERTAIN XQ35 AND XQ60 GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING RADIATOR DRAIN BALL VALVE ON CERTAIN XQ35 AND XQ60 GENERATOR SETS

Usage:

TEBE6113-00

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03May2017

U-248

A-164

D-195

O-201

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Before/After	PRODUCT SUPPORT PROGRAM FOR REWORKING RADIATOR DRAIN BALL VALVE ON CERTAIN XQ35 AND XQ60 GENERATOR SETS
1021 1372 1380		PS45472

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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 "PS45472" 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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TERMINATION DATE

31May2019

PROBLEM

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The existing radiator drain ball valve may be incorrectly oriented on certain XQ35 and XQ60 Generator Sets. If the existing radiator drain valve is incorrectly installed it will need to be reworked during the next coolant drain.

AFFECTED PRODUCT

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Model	Identification Number
XQ35	JK700100, 103-339
XQ60	CF600103-00275

PARTS NEEDED

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No parts needed for this program

ACTION REQUIRED

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Align the timing of doing this program with the next scheduled coolant drain of the radiator. 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%
0-8000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	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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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.

XQ35 Coolant Drain Ball Valve:

Inspect the radiator drain valve to ensure that it is the correct orientation using Image 1.2.1. If the radiator drain valve is assembled incorrectly proceed with the rework instructions below.

Image1.2.1

1. Locate the radiator drain ball valve inside and to bottom right hand of RH front Enclosure door.

2. Crimp the 11/16 OD hose (from the radiator) within 3 or 4 inches of the brass ball valve with a hose crimping vise grip with clamping force sufficient to cut off coolant flow and not damage hose.

3. If the handle is not bolted to the ball valve it will be attached to valve with a tie strap, remove the tie strap, and briefly install handle to valve to determine which direction the handle faces when open (parallel with ball valve) and valve can be rotated 90 degrees. If the handle when open is pointed toward the elbow that goes thru the base rail to the drain plug, the valve will have to be turned 180 degrees so that the handle will point toward the radiator (when open).

4. If the ball valve handle is bolted to the ball valve, and handle points toward the drain plug when open ( parallel), remove the ? inch nut, and remove handle. (If handle points straight toward radiator, and can rotate 90 degrees, no further change is required).

5. If it is determined that the handle points toward drain plug and can rotate 90 degrees, remove the hose clamp (from the 11/16 outside diameter hose from radiator), and pull the hose away from the valve. A small amount of coolant will exit the hose (between vise grip and valve), which will be held by the containment tray, and will evaporate naturally.

6. With handle removed, remove ball valve from the adapter that goes into the elbow at the drain thru base rail. You will need a 15/16 open end wrench (on the ball valve), and a 5/8 open end wrench on the adapter.

7. With the ball valve free of the Gen Set, remove the hose bead adapter from the ball valve, and install in the end that the straight adapter was. Use Locktite 536 (or equivalent), and tighten to 25 +/- 4 Nm (18 ft/lbs).

8. Re-install Ball valve (with end that bead adapter was removed) on to straight adapter at elbow to drain thru base rail, using same sealant and tighten as step 7. Tighten ball valve as required (up to one revolution) until handle is on top and able to rotate 90 degrees. When handle is parallel (open), it must point toward radiator. Rotate and leave handle at 90 degrees (closed position).

9. Push on hose, and tighten hose clamp 4.5 +/-1 (3.3 ft/lbs). Check to insure there is no coolant leak.

XQ60 Coolant Drain Ball Valve:

Inspect the radiator drain valve to ensure that it is the correct orientation using Image 1.4.1 and Image 1.4.2 as reference. If the radiator drain valve is assembled incorrectly proceed with the rework instructions below.

Image1.4.1

Image1.4.2

1. Install the handle for the radiator drain ball valve.

2. Rotate it 90 degrees to ensure that it is not hitting the fuel tank. If the handle hits the tank, the only fix necessary would be to loosen the bulkhead hex nut where the drain goes thru the base rail, and rotate the valve 1/8 turn counterclockwise until the handle could rotate 90 degrees without hitting tank.