PRODUCT SUPPORT PROGRAM FOR REWORKING THE ENGINE COOLING FAN AND REPLACING ENGINE COOLANT PUMP ASSEMBLY ON CERTAIN C2.2 INDUSTRIAL ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE ENGINE COOLING FAN AND REPLACING ENGINE COOLANT PUMP ASSEMBLY ON CERTAIN C2.2 INDUSTRIAL ENGINES

Usage:

TEBE6799-00

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14Nov2017

L010
L013
L040
L044
L145
L262

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Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REWORKING THE ENGINE COOLING FAN AND REPLACING ENGINE COOLANT PUMP ASSEMBLY ON CERTAIN C2.2 INDUSTRIAL ENGINES
1361 1356		PS45685

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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 "PS45685" 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

30Nov2018

PROBLEM

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The existing OEM supplied engine cooling fan can induce high axial vibrations into the engine coolant pump joint face leading to a coolant leak on certain C2.2 Industrial Engines. The existing OEM supplied engine cooling fan has insufficient clearance from mounted components leading to an induced axial vibration under certain operating speeds which eventually leads to the coolant pump mounting bolts loosening and allowing a coolant leak to occur between the coolant pump and block mounting gasket.

AFFECTED PRODUCT

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Model	Identification Number
C2.2	C6M03955, 3976, 4230-4234, 4238-4247, 4640, 4651-4653, 4698, 4709-4712, 4725-4727, 5041-5048, 5051-5058, 5635-5644, 6335-6339, 6488-6492, 6849, 6864-6872

PARTS NEEDED

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Qty	Part Number	Description
1	1535960	NUT-HEX FLANGE (CAT Part - After Failure Only)
4	1535961	BOLT AS (CAT Part - After Failure Only)
1	1831163	STUD (CAT Part - After Failure Only)
1	4235611	GASKET CAT Part - After Failure Only)
1	4394992	PUMP AS (CAT Part - After Failure Only)
1	CAT9950	FAN KIT-Puller (See Action Required for Ordering)
1	CAT9960	FAN KIT-Pusher (See Action Required for Ordering)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 15% 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 of the engine cooling fan needs to replaced to prevent coolant leaks from the engine coolant pump mounting joint. Repair should be completed at the next scheduled service if possible.

This Fan Kit is obtained by contacting Flemming Hjoellund at PON Power A/S (Denmark).

Email: Flemming.Hjoellund@pon-cat.com
FAX#: +45 76 14 64 01
Phone#: +45 76 14 64 47

Please provide the following upon request for each engine serial number. Form below must be completed and sent back to PON Power A/S via email or FAX before any part kits will be packaged and sent out.

Engine Serial Number:______________________________________________________________
Machine Serial Number:_____________________________________________________________
Hour Meter Reading:________________________________________________________________
Engine Fan Kit Required:___________________________________________________________
Dealer Name:_______________________________________________________________________
Shipping Address:__________________________________________________________________
Post Code / City:__________________________________________________________________
State:_____________________________________________________________________________
Country:___________________________________________________________________________
Contact Name:______________________________________________________________________
E-mail:____________________________________________________________________________
Phone#:____________________________________________________________________________
Fax#:______________________________________________________________________________

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, including human factors that can affect safety. This person should also have the necessary training, skills and tools to perform these functions properly.

Follow safety precautions and warnings are provided in this instruction, on the product and in the 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 warning 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, 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 repair procedures that are used.

REWORK ACTION REQUIRED:

Before Failure: Replace the engine cooling fan, fan spacer and retorque the engine coolant pump fasteners per the attached Rework Procedure.

After Failure: Replace the engine cooling fan, fan spacer and replace the engine coolant pump per the attached Rework Procedure.

After completion of the repair please photograph the installed new fan kit and attach this to the SIMSi claim story as part of the warranty claim submission.

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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%
0-4500 hrs, 0-72 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
Note: 1.0 hour is allowed for a Before Failure repair to install the engine cooling fan kit. Note: 1.0 hour is allowed for a After Failure repair to install the cooling fan kit. An additionally 2.0 hours is allowed to replace the engine coolant pump. Note: After completion of the repair please photograph the installed new fan kit and attach this to the SIMSi claim story as part of the warranty claim submission.

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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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Before Failure Rework Procedure:

Warning:
The engine must be cold with the cooling system depressurised, isolated electrically before and while the rework is performed. Follow the proper lockout tag out procedures to protect against the unexpected energizing or start-up of the engine. Failure to follow these warnings could result in injury to personnel during service. Attach a ?Do Not Operate? warning tag to the machine start key switch or controls before performing any service to the machine.

Step 1: Move radiator to access cooling fan:

a - Refer to the OEM machine manual for accessing the cooling fan without draining down the cooling system, so to allow access to the cooling fan.

Step 2: Remove Cooling Fan:

a - Remove fan bolts (1) and remove fan, refer to step 1 of ?Fan ? Remove and Install Procedure? in Disassembly and Assembly manual.
b - Discard fan.

Step 3: Remove OEM A/C Compressor V-Belt:

a - Remove A/C Compressor V-Belt (1), see Image 1.3.1. Refer to the OEM for the correct removal procedure.

Image1.3.1

Step 4: Remove engine fan V-Belt:

a - Remove V-Belt. Refer to steps 2 and 3 of ?V-Belts ? Remove and Install procedure? in Disassembly and Assembly manual.

Step 5: Remove Spacer and Pulley:

a - Remove bolts (1), remove spacer (2) and pulley (3) from water pump (4). Refer to step 2 of ?Fan ? Remove and Install Procedure? in Disassembly and Assembly manual for instructions.

Image1.5.1

Step 6: Apply Loctite 242 to Water Pump fasteners:

a - Refer to Image 1.7.1
b - Remove bolt (position 1), apply Loctite 242 to the first two threads of bolt and reinstall bolt (position 1), tightening to 5 Nm
c - Remove bolt (position 2), apply Loctite 242 to the first two threads of bolt and reinstall bolt (position 2), tightening to 5 Nm
d - Remove bolt (position 3), apply Loctite 242 to the first two threads of bolt and reinstall bolt (position 3), tightening to 5 Nm
e - Remove bolt (position 4), apply Loctite 242 to the first two threads of bolt and reinstall bolt (position 4), tightening to 5 Nm
f - Remove nut (position 5), apply Loctite 242 to the first two threads of nut and reinstall nut (position 5), tightening to 5 Nm
g - Tighten bolts and nut to a torque of 12 Nm in the sequence shown in Image 1.6.1

Image1.6.1

Step 7: Install Spacer and Pulley:

a - Ensure that all components are clean and free from damage. Replace any components that are worn or damaged.
b - OPTION for Puller Fan Kit, replace spacer with new spacer and replace bolts with new bolts from supplied kit of parts.
c - Position the pulley (3) and spacer (2) on the water pump (4). Ensure the bolt holes are aligned.
d - Install bolts (1) and tighten to a torque of 11Nm (97 lb in).

Image1.7.1

Step 8: Install ? engine fan V-Belt:

a - Install V-Belt. Refer to Installation procedure steps 1 to 3 of ?V-Belts ? Remove and Install procedure? in Disassembly and Assembly manual.

Step 9: Install OEM A/C Compressor V-Belt:

a - Install A/C Compressor V-Belt (1), see Image1.9.1. Refer to the OEM for the correct installation procedure.

Image1.9.1

Step 10: Install replacement cooling fan:

a - Position fan, ensuring the correct orientation of the fan, on the spacer. Ensure that the bolt holes are aligned.
b - Install bolts and tighten to a torque of 11Nm (97 lb in).

Step 11: Install radiator back to operational position:

a - Refer to the OEM machine manual for repositioning the radiator and tightening of bolts.

Rework Procedure ? After Failure

Warning:
The engine must be cold with the cooling system depressurised, isolated electrically before and while the rework is performed. Follow the proper lockout tag out procedures to protect against the unexpected energizing or start-up of the engine. Failure to follow these warnings could result in injury to personnel during service. Attach a ?Do Not Operate? warning tag to the machine start key switch or controls before performing any service to the machine.

Step 1: Move radiator to access cooling fan:

a - Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance manual, ?Cooling System Coolant ? Drain? for more information.
b - Refer to the OEM machine manual for accessing the cooling fan, tilting the radiator, so to allow access to the cooling fan.

Step 2: Remove Cooling Fan:

a - Remove fan bolts (1) and remove fan, refer to step 1 of ?Fan ? Remove and Install Procedure? in Disassembly and Assembly manual.
b - Discard fan.

Step 3: Remove OEM A/C Compressor V-Belt:

a - Remove A/C Compressor V-Belt (1), see Image 1.14.1. Refer to the OEM for the correct removal procedure.

Image1.14.1

Step 4: Remove engine fan V-Belt:

a - Remove V-Belt. Refer to steps 2 and 3 of ?V-Belts ? Remove and Install procedure? in Disassembly and Assembly manual.

Image1.16.1

Step 6: Replace Water Pump and Fasteners:

a - Replace the Water pump, gasket and fasteners, refer to ?Water Pump ? Remove and Install (C1.5 and C2.2 Engines)? in Disassembly and Assembly manual.
b - NOTE: When applying the second sequence of tightening the bolts and nut in Step 8 of the Installation procedure, the torque should be increased from 10Nm (89 lb in) to 12Nm (106 lb in).

Image1.18.1

Step 8: Install ? engine fan V-Belt:

a - Install V-Belt. Refer to Installation procedure steps 1 to 3 of ?V-Belts ? Remove and Install procedure? in Disassembly and Assembly manual.

Step 9: Install OEM A/C Compressor V-Belt:

a - Install A/C Compressor V-Belt (1), see Image 1.20.1. Refer to the OEM for the correct installation procedure.

Image1.20.1

Step 11: Install radiator back to operational position:

a - Refer to the OEM machine manual for repositioning the radiator and tightening of bolts.
b - Fill the cooling system with coolant. Refer to the Operation and Maintenance Manual, ?Cooling System Coolant ? Fill? for the correct procedure.