2003/12/01 Caterpillar

Power Module:

PM3516 (S/N: BPD1-1056)

3516B (S/N: 7RN1089, 1091, 1118, 1128-1130, 1166-1167, 1169, 1171, 1173, 1180-1183, 1187-1190, 1192, 1194-1195, 1197-1199, 1201-1203, 1205, 1209, 1210-1214, 1216, 1219-1220, 1223-1226, 1228, 1231, 1233, 1235-1239, 1241-1242, 1244-1246, 1248-1253 and 1258)

Introduction

When 3516B Power Modules (Tier 1 only) are operating, signals from the radiator's door-open switch may indicate that the radiator door is open. These signals will result in unsolicited shutdowns. These shutdowns have been reported with an "SP2" indication. An "SP2" indication means that the radiator door is not closed, thus causing the shutdown.

Effected Product

These problems have been experienced on 3516B Power Modules (Tier 1 only) that are equipped with following radiator groups:

• 187-9703 Radiator

• 208-6899 Radiator

To correct this problem, perform one of the following procedures.

Procedure for 187-9703 Radiator

1. Ensure that the unit is shut down. Also ensure that the door is fully closed and that the latches are securely latched.

2. Measure 30 mm (1.18 inch) up from the top of each radiator latch (directly above latch center). Mark location. Refer to Illustration 1.

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Illustration 1	g01043657

3. For both right and left latches (with door still closed), use the 7 mm (17/64 inch) drill bit to drill a hole through the radiator door and the radiator support beam. The radiator support beam is located directly behind the right and left latches. Total drill-through distance should be at least 63.5 mm (2.5 inch).

4. Open the radiator door. Use a 5/16-18 THD tap to create threads through the hole created in the support beam. After creating the threads, screw a 6V-0825 Locking Bolt into the threaded hole to ensure that the threads are compatible. Perform this step on both holes in the support beam. Refer to Illustration 2.

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Illustration 2	g01043747

5. Close the radiator door. Through the radiator door only, use a 9 mm (3/8 inch) drill bit to drill through both existing 7 mm (17/64 inch) pilot holes. Do NOT drill through the threaded hole in the radiator support beam. Refer to Illustration 1.

6. In the right and left locations, insert the 6V-0825 Locking Bolt (with 3E-4352 Hard Washer ) through the hole in the radiator door and into the threaded hole. Tighten the 6V-0825 Locking Bolt to 25 ± 6 N·m (18.4 ± 4.4 lb ft). Refer to Illustration 3.

   Note: In order to provide the tightest fit, it may be necessary to exert a small amount of pressure on the radiator door while tightening the 6V-0825 Locking Bolt .

Illustration 3	g01043778

Procedure for the 208-6899 Radiator

1. Ensure that the unit is shut down. Also ensure that the door is fully closed and that the latches are securely latched.

2. Measure 305 mm (12.0 inches) down from the bottom of the radiator latch (directly below latch center). Mark location. Refer to Illustration 4.

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Illustration 4	g01043780

3. With door still closed, use the 7 mm (17/64 inch) drill bit to drill a hole through the radiator door and the radiator support beam. The radiator support beam is located directly behind the latch. Total drill-through distance should be at least 63.5 mm (2.5 inch).

4. Open the radiator door. Use a 5/16-18 THD tap to create threads through the hole created in the support beam. After creating the threads, screw a 6V-0825 Locking Bolt into the threaded hole to ensure that the threads are compatible. Refer to Illustration 5.

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Illustration 5	g01043785
(1) Threaded hole for installing 6V-0825 Locking Bolt.

5. Close the radiator door. Through the radiator door only, use a 9 mm (3/8 inch) drill bit to drill through the existing 7 mm (17/64 inch) pilot hole. Do NOT drill through the threaded hole in the radiator support beam. Refer to Illustration 4

6. Insert the 6V-0825 Locking Bolt (with 3E-4352 Hard Washer ) through the hole in the radiator door and into the threaded hole. Tighten the 6V-0825 Locking Bolt to 25 ± 6 N·m (18.4 ± 4.4 lb ft). Refer to Illustration 6.

   Note: In order to provide the tightest fit, it may be necessary to exert a small amount of pressure on the radiator door while tightening the 6V-0825 Locking Bolt .

Illustration 6	g01043796