PRODUCT SUPPORT PROGRAM FOR INSPECTION AND POSSIBLE REWORK OF THE RADIATOR BELT GUARD ON CERTAIN 3516C GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSPECTION AND POSSIBLE REWORK OF THE RADIATOR BELT GUARD ON CERTAIN 3516C GENERATOR SETS

Usage:

REBE4040-00

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11Jul2008

U-370

A-299

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR INSPECTION AND POSSIBLE REWORK OF THE RADIATOR BELT GUARD ON CERTAIN 3516C GENERATOR SETS
7174 1353		PS42747

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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 "PS42747" 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

31Jul2010

PROBLEM

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The existing radiator fan belt guard and jacket water bypass tube can interfere on certain 3516C generator sets. If the existing radiator fan belt guard rubs a hole into the jacket water bypass tube it will result in a coolant leak and necessary replacement of the jacket water bypass tube.

AFFECTED PRODUCT

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Model	Identification Number
3516C	SBJ00228, 231-242, 244, 246-251, 253-258, 260, 262-269, 271-293, 297-298, 300-301, 303-305, 307, 310-338, 341-347, 349-374, 376-377, 381, 383-384, 387-406, 408-410, 412-423, 425-447, 449-450, 452-463, 468-469, 471-487, 489-503, 507, 509-511, 514-517, 519-533, 535-544, 546-547, 549-560, 562-563, 565-567, 569-595, 600-631

PARTS NEEDED

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Qty	Part Number	Description
1	5P6302	SEAL-O-RING
2	6V5066	SEAL-O RING
2	8N3640	RING-RETAINING
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% 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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Inspect the clearance between the jacket water bypass tube and radiator pulley guard flange as shown in Images 1 and 2. If the clearance is greater than 5mm, no rework is necessary.

If the clearance is less than 5mm, follow the rework procedure to cut the flange. Image 1 shows the area of interference (1) between the flange (2) and the tube (3).

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Image1

Image2

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 0.5-hour job
0.5 hours is allowed for inspection. An additional 2.5 hours will be allowed if the rework is required.

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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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Tools: Plasma Cutter 30A or greater
1U-6396 O-Ring Assembly Compound

1. Isolate Genset before commencing any work on the unit, activate Emergency stop, open Genset breaker, and disconnect battery cables. Ensure health and safety requirements are adhered to at all times. Make sure that a fire extinguisher is available. Be familiar with the operation of the fire extinguisher. Inspect the fire extinguisher and service the fire extinguisher regularly. Obey the recommendations on the instruction plate.

2. Drain the coolant from the cooling system into a suitable container for storage for reuse. Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Stop the engine and allow the engine to cool. Ensure that the engine will not start when the cooling system is drained. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap. Open the cooling system drain valve at the bottom of the radiator. Refer to Image 1.1.1

Image1.1.1

3. Remove coolant tube. Disconnect tube assembly (2) from water temperature regulator housing (6). Remove the O-ring seal from the tube assembly. Refer to Image 1.2.1

Image1.2.1

4. Remove bolts (1) and the retainers. Remove tube (2) from pump inlet elbow (8). Remove O-ring seal from the tube assembly. Refer to Image 1.3.1

Image1.3.1

5. Remove all electrical connections from ECM.

6. Attach the plasma cutter ground clamp to the flange that is being cut. Remove paint from flange to ensure electrical conductivity and attach plasma cutter ground as close as possible to the area that will be cut.

7. Cover the area near the cut with a large welding blanket as shown. Ensure that the blanket is located so that it will contain sparks from the plasma cutting. Refer to Image 1.4.1

Image1.4.1

8. Cut the flange as shown in Images 1.5.1 and 1.5.2. Remove the portion of the flange that is highlighted with white crosshatch.

Image1.5.1

Image1.5.2

9. Repair paint on newly cut flange and where ground clamp was attached. Dispose of the flange material that was removed after it has cooled.

10. Reinstall coolant tube removed in step 3 using the new O-rings and retaining rings shown in the Required Parts section. Install new O-ring seal and lubricate the O-ring seal on tube (2) with O-Ring Assembly Compound. Install tube (2) into pump inlet elbow (8) and install bolts (1) and retainers. Refer to Image 1.6.1

Image1.6.1

11. Install the O-ring seal on tube assembly (2). Lubricate the O-ring seal with O-Ring Assembly Compound. Install tube assembly (2). Refer to Image 1.7.1

Image1.7.1

12. Re-attach ECM electrical connections.

13. Refill coolant system with the coolant that was drained in step 2. Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks. Do not install the cooling system filler cap.

14. Clear generator area, reconnect batteries, and release emergency stop.

15. Start the engine. Inspect the cooling system for leaks and for proper operating temperature. Operate the engine in order to purge the air from the cavities of the engine block. Allow the coolant to warm and allow the coolant level to stabilize.

16. Stop the engine.

17. Check the coolant level. Maintain the coolant to the proper level on the sight gauge (if equipped). If a sight gauge is not equipped, maintain the coolant within 13 mm (0.5 inch) below the bottom of the filler pipe.

18. Run functional no load test on Genset and return to service.