PRODUCT SUPPORT PROGRAM FOR REWORKING RADIATOR CORES ON CERTAIN 3512B GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING RADIATOR CORES ON CERTAIN 3512B GENERATOR SETS

Usage:

TEBE8772-00

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15May2019

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After Failure Only (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REWORKING RADIATOR CORES ON CERTAIN 3512B GENERATOR SETS
6901 1353		PS54055

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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 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 "PS54055" 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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TERMINATION DATE

31May2021

PROBLEM

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Radiator core tubes may become damaged due to thermal cycling and vibration on certain on certain 3512B be generator sets. This may lead to radiator core tube leakage.

AFFECTED PRODUCT

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Model	Identification Number
3512B	LY800107-00109, 111-113, 115-120, 122-129, 132-143, 148-155, 157-160, 162-165, 173-192, 194-218

PARTS NEEDED

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Qty	Part Number	Description
206	1313540	LOCKNUT-JAM
1	2468650	GASKET-HEADER
1	2468651	GASKET-HEADER
1	5664742	CORE AS-RDTR
1	ADHESIVE	Sprayon? SP9000 Heavy Duty Spray Adhesive
1	SEALANT	SAF-T-LOC? Polymeric Flange Sealant - PFS Blue
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 6% 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 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 and the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

WARNING: The generator set must be isolated mechanically and electrically before and while the rework is being performed. Follow the proper lock out tag out procedures to protect against unintended operation, unexpected movement, 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 and local and remote controls before you perform any service to the machine.

Repair Action Required

If radiator core leakage is detected, replace the existing core with 566-4742 CORE AS-RDTR (1). The top tank GASKET-HEADER 246-8650 (2) and bottom tank GASKET-HEADER 246-8651 (3) will need to be replaced. Also, replace all LOCNUT-JAM 131-3540. Refer to Image1.

Refer to RENR5060 for radiator disassembly and assembly instructions.

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Image1

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%
0-12000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
12001-15000 hrs, 25-37 mo	75.0%	75.0%	0.0%	0.0%	25.0%	25.0%
15001-20000 hrs, 38-50 mo	50.0%	50.0%	0.0%	0.0%	50.0%	50.0%

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NOTE: This is a 20.0-hour job
$40.00 USD is allowed for procurement of ADHESIVE and SEALANT.

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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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Remove core assembly from radiator assembly and remove tanks.

Remove the old gasket material from the gasket side of tanks. Make sure that all the gasket joints are cleaned and free from debris.

Apply ADHESIVE to tank header and install gasket. Note: ADHESIVE is used to secure gasket during assembly.

Once the gasket is installed along the header with thru holes lined up, apply SEALANT to all corner joints to fill any gaps in the gaskets.

Install bolts upward through the bottom tank and gasket. Refer to Image1.1.1.

Set core on top of bottom tank and locate on bolts.

Install core washers to headers.

Install new LOCNUT-JAM 131-3540.

Repeat the process for the top tank. Refer to Image1.1.2.

Tighten LOCNUT-JAM 131-3540 to 15 +/- 4 N-m (11 +/- 3 lb-ft) according to pattern shown in Image1.1.3.