PRODUCT SUPPORT PROGRAM FOR REWORKING CERTAIN 3412C SOUND ATTENUATED ENCLOSURE GENSET PACKAGES

Usage:

SEBE8564-01

November 9, 2003
(Revised January, 2004)
U-306
A-210

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*before or* *after failure*	PRODUCT SUPPORT PROGRAM FOR REWORKING CERTAIN 3412C SOUND ATTENUATED ENCLOSURE GENSET PACKAGES
1353 1356 1357 1360 7272		PS41435

NOTE: This Program can 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 "PS41435" as the Part number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

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.

NOTE: This Revised Service Letter replaces the November 9, 2003 Service Letter. Changes have been made to the Affected Product.

TERMINATION DATE

November 30, 2005

PROBLEM

Some 3412C, 750kW and 800 kW standby rated, sound attenuated enclosure packages may overheat when operated in high ambient temperature conditions.

AFFECTED PRODUCT

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Model

Identification Number

3412C

9EP2061, 2069, 2081-2083, 2124, 2170, 2176, 2177, 2184, 2196, 2201, 2202, 2204, 2205, 2217, 2230, 2233, 2236, 2245, 2254, 2274, 2289, 2321, 2331, 2338, 2339, 2343, 2349, 2352, 2361, 2366, 2380, 2390, 2398, 2399, 2402, 2406, 2407, 2413, 2420, 2426, 2436, 2439, 2443, 2445, 2447, 2448, 2450, 2460, 2461, 2473, 2484, 2507, 2510, 2513, 2525, 2527, 2529, 2535, 2537, 2549, 2552, 2560, 2567, 2580, 2587, 2602, 2607, 2609, 2610, 2615, 2616, 2623, 2650, 2651, 2657, 2661, 2662, 2668, 2672, 2673, 2676, 2689, 2690, 2693, 2694, 2696, 2699, 2713, 2717, 2718, 2729, 2731, 2741, 2752, 2765, 2774, 2784, 2792, 2793, 2797, 2810, 2811, 2821, 2845, 2848, 2861, 2862, 2868, 2873, 2874, 2879, 2881, 2888, 2909, 2910, 2917, 2918, 2927

BCW390, 426, 587, 592, 594, 595, 605, 609, 624, 629, 648, 665, 670, 672, 673, 680, 692, 701, 703, 704, 706, 722, 733, 740, 741

PARTS NEEDED

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Qty	Part Number	Description
1	7C4911	Adapter
1	2419874	PC

ACTION REQUIRED

See the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

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Product age	Caterpillar		Dealer Suggested		Customer Suggested
Product age	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
0-48 mos	100%	6.0	0	0	0	0
NOTE: This is a 6.0?hr job.

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Attach. (1-Rework Procedure)

Rework Procedure

Fan adapter installation:

Remove the 1497867 top radiator fan belt guard to gain access to the top belt pulley.
Remove the radiator fan guard(s) to gain access to the fan-to-adapter bolts.
Loosen the four (4) bolts on the radiator fan belt tensioner.
Loosen the belts enough so the top pulley is free to spin. (Spinning the pulley and fan is necessary to gain access to each fan-to-adapter bolt.)
Disconnect the radiator fan from the adapter.
Remove the shorter 6N4088 adapter from the belt pulley.
Install the longer 7C4911 fan adapter onto the belt pulley. Torque the adapter-to-pulley bolts to 47 +/- 9 Nm (34.7 +/- 6 ft-lb).
Install the fan onto the end of the adapter. Torque the fan-to-adapter bolts to 105 +/- 20 Nm (77.4 +/- 14.8 ft-lb).
Verify that the fan will not contact adjacent parts, particularly the shroud, during operation.
Adjust the tension of the radiator fan belts to 712 +/- 111 N (160 +/- 25 lb) for new belts and to 445 +/- 44 N (100 +/- 10 lb) for used belts.

NOTE: Used belts are defined as belts that have operated for 30 minutes or more at rated speed.

Install the radiator fan guard(s).
Verify fan clearance to avoid contacting adjacent parts during operation.
Install the top radiator fan belt guard.

Radiator duct seal installation:

Remove the enclosure front section to gain access to the discharge side of the radiator.

Remove the four bolts that attach the front section to the main section of the enclosure.
Remove the four bolts that attach the front section to the base.
Slide the enclosure front section back on the rails providing access to the discharge side of the radiator.

Remove the rubber seal located along the top of the radiator duct.
Place the rubber seal onto the 241-9874 plate. The seal needs to be installed opposite of the plate mounting holes.
Secure the plate and seal assembly to the enclosure bulkhead in order to prevent recirculation of radiator exhaust air around the top of the radiator. (Refer to Figure 1.)

Position the plate and seal assembly along the top of the enclosure bulkhead to close the gap between the bulkhead and the radiator.
Mark the location of the plate?s six mounting holes on the bulkhead.
Using a 3/16" drill bit, drill holes into the bulkhead where marked.
Attach assembly to the duct using 3/16" rivets.

Figure 1

Ensure the rubber seals around the radiator ductwork are tucked back in order to prevent radiator exhaust air from recirculating. (See Figure 2.)

Figure 2

Reinstall the enclosure front section and tighten the eight bolts to the appropriate bolt specification.
Recaulk the seam between the enclosure front and the middle sections using 1190781 caulking compound.