PRODUCT SUPPORT PROGRAM FOR REWORKING THE COOLING SYSTEM VENT LINE ON 3516B GENERATOR SETS Caterpillar


PRODUCT SUPPORT PROGRAM FOR REWORKING THE COOLING SYSTEM VENT LINE ON 3516B GENERATOR SETS

Usage:

REBE7777-00

09Dec2011


D-481
O-484

 

Before/After

  
  

PRODUCT SUPPORT PROGRAM FOR REWORKING THE COOLING SYSTEM VENT LINE ON 3516B GENERATOR SETS

1813 1380
PS43459
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 "PS43459" 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.

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.


TERMINATION DATE

30Jun2012

PROBLEM

The 3516B Generator Sets is factory supplied with a small vent line that runs between the jacket water circuit and the separate circuit aftercooler (SCAC). This is acceptable if the radiator has one cooling circuit for the jacket water and SCAC. If however the radiator has separate cores then the factory installed vent line must be removed. The jacket water side is plugged and the SCAC is replaced with 337-6521 Aftercooler Vent Water Lines Group. If not the the SCAC circuit will flow into the jacket water circuit due to differential pressure and cause coolant to become expelled from the overflow pipe resulting in a low level coolant condition.

AFFECTED PRODUCT

Model Identification Number
3516B  YAP00272-00279, 282, 284, 288-293, 296, 298-299, 329, 332, 345, 360, 362
3516B HD  YAR00273-00276, 282-283, 292-293, 296-301, 313, 316, 321, 323

PARTS NEEDED

Qty

Part Number Description
1 3J7354 SEAL-O-RING
2 4J5477 SEAL-O-RING-ORFS
3 4L9337 BOLT
1 6V8628 ADAPTER-ELBOW
3 6V8801 NUT
1 6V9027 SEAL-O-RING
1 8C6866 ADAPTER-STR
6 8T4896 WASHER-HARD
1 9S4182 PLUG-LD STOR
3 0672551 CLIP
3 1106171 CLAMP
3 1106172 CLAMP
93 1226869 HOSE-HYDRAULIC
2 1540096 COUPLING AS-PERM
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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

Radiators that have a separate jacket water (JW) and SCAC system must be reworked using the list of parts in 337-6521 Aftercooler Vent Water Lines Group.

Refer to the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
0-10 hrs,
0-12 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 1.0-hour job



PARTS DISPOSITION

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


Rework Procedure


 
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 in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. 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 and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method or operating technique that is not specifically recommended by Caterpillar is used, you must ensure that it is safe for you and for other people to use.

You should ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance or the repair procedures that are used.

Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Caterpillar dealer for replacement manuals. Proper care is your responsibility.

When you service an electric power generation set or when you repair an electric power generation set, follow the procedure below:

Stop the engine.

Attach a "DO NOT OPERATE" or similar warning tag to the engine prime mover starting circuit as shown in Image1.1.1.
Disconnect the engine starting circuit.
Image1.1.1
 
Disconnect the generator from the distribution system.

Lock out the circuit breaker. Attach a "DO NOT OPERATE" or similar warning tag to the circuit breaker. Refer to the electrical diagram. Verify that all points of possible reverse power flow have been locked out.
 
1. Drain down at least 50 percent of the cooling system into suitable clean containers, this is to allow the coolant within the engine and radiator to fall below the thermostat height. This will aid in the removal of the vent line.

2. Remove 164-4487 Vent Lines Group as shown in Image1.3.1. and plug the regulator housing with a 9S-4182 Plug and 6V-9027 O-ring.
Image1.3.1
 
3. Assemble the 6V-8628 Adaptor Elbow with 3J-7354 O-ring and 4J-5477 O-ring to the aftercooler.

4. Remove the vent plug in the aftercooler section of the radiator top tank.

5. Assemble the 8C-6866 Adapter with 4J-5477 O-ring to the radiator.

6. Assemble the 337-6520 Hose Group (122-6869 Hose and 154-0096 Couplings) between the radiator and aftercooler.

7. Assemble three Clamps 110-6171, three 110-6172 Clamps and three 067-2551 Clips with three 4L-9337 Bolts, three 6V-8801 Nuts, and six 8T-4896 Washers as shown in Image1.4.1.
Image1.4.1
 
8. Refill radiator with the drained coolant to the specified level, remove the "DO NOT OPERATE" notice and start generator set.

9. Run to normal operating temperature and full load to check for leaks around disturbed joints.
 
 

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