PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING DEF FITTING AND AIR FITTING O-RINGS, REORIENTING THE WASHERS ON THE DOSING PUMP HEAD AND REPLACING THE BOLTS AND WASHERS ON THE DOSING PUMP MANIFOLD ON CERTAIN 3516C AND 3516C HD GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING DEF FITTING AND AIR FITTING O-RINGS, REORIENTING THE WASHERS ON THE DOSING PUMP HEAD AND REPLACING THE BOLTS AND WASHERS ON THE DOSING PUMP MANIFOLD ON CERTAIN 3516C AND 3516C HD GENERATOR SETS

Usage:

TEBE2411-00

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08Dec2014

U-736

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Priority	PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING DEF FITTING AND AIR FITTING O-RINGS, REORIENTING THE WASHERS ON THE DOSING PUMP HEAD AND REPLACING THE BOLTS AND WASHERS ON THE DOSING PUMP MANIFOLD ON CERTAIN 3516C AND 3516C HD GENERATOR SETS
108J 108H 1091 7579 5502		PI32425

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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 must be administered as soon as possible. When reporting the repair, use "PI32425" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. Exception: If the repair is done after failure, use "PI32425" as the Part Number, "7751" as the Group Number, "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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COMPLETION DATE	TERMINATION DATE
30Jun2015	31Dec2015

PROBLEM

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The DEF fitting O-ring and air fitting O-ring need to be installed on certain 3516C and 3516C HD Generator Sets. The existing O-rings can be missing from the factory supplied lines. The dosing pump can also develop a leak between the dosing pump head and DEF manifold due to an incorrect torque of the 8T-2396 Bolts. These bolts can interfere with the washers that hold the dosing pump head to the dosing pump and cause a low torque value. The washers that hold the pump head to the dosing pump will need to be realigned using a special tool provided by the factory. The bolts and washers that hold the DEF manifold to the dosing pump head will need to be replaced.

AFFECTED PRODUCT

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Model	Identification Number
3516C	SCJ00113-00114
3516C HD	SCK00117, 119-123 SFK00101-00112 SKC00101-00116

PARTS NEEDED

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Qty	Part Number	Description
1	3K0360	SEAL-O-RING
1	6V3250	SEAL-O-RING
10	7K1181	STRAP-CABLE
4	8T2922	BOLT-HEX SKT HD
8	9X8256	WASHER
1	4683785	KIT-VALVE AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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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Refer to the attached Rework Procedure.

Email David Schluttenhofer at schludh@cat.com to obtain the spacing tool. Please provide a shipping address for the tool to be sent to.

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OWNER NOTIFICATION

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Owners in the following countries will receive the attached Owner Notification:
US
Canada

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 4.0-hour job

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PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING DEF FITTING AND AIR FITTING O-RINGS, REORIENTING THE WASHERS ON THE DOSING PUMP HEAD AND REPLACING THE BOLTS AND WASHERS ON THE DOSING PUMP MANIFOLD ON CERTAIN 3516C AND 3516C HD GENERATOR SETS

MODELS INVOLVED - 3516C, AND 3516C HD GENERATOR SETS

Dear Cat Product Owner:

The DEF fitting O-ring and Air fitting O-ring need to be installed on the products listed below. The existing O-rings can be missing from the factory supplied lines.

The dosing pump can also develop a leak between the dosing pump head and DEF manifold due to an incorrect torque of the 8T-2396 Bolts. These bolts can interfere with the washers that hold the dosing pump head to the dosing pump and cause a low torque value. The washers that hold the pump head to the dosing pump will need to be realigned using a special tool provided by the factory. The bolts and washers that hold the DEF manifold to the dosing pump head will need to be
replaced.

You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated. Please refer the dealer to their Service Letter dated 10Nov2014 when
scheduling this service.
We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.
Identification #(s) Please refer the dealer to their Service Letter dated 08Dec2014 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 08Dec2014 Service Letter

Rework Procedure

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Make sure you have read and understood all of this document before beginning work.

Isolate the generator set before commencing any work on the unit, open generator set breaker, activate Emergency Stop, disconnect the battery cables and either disconnect or open the control circuit breaker for the AC power supply to the battery charger. Ensure all health and safety requirements are adhered to at all times. Also, ensure proper Lock Out-Tag Out procedures are followed at all times while work is being performed on the machine. Lock out generator operation and disconnect/lockout all power sources before commencing any work. Ensure that the Air Supply pressure and DEF Supply pressure have been turned off going to the Dosing Cabinet.

1 - The 030-8110 Air supply fitting and 345-4080 DEF supply fitting need to be removed from the Dosing Cabinet to verify the proper O-rings are installed. The 030-8110 Air supply fitting should have (1) 6V-3250 O-ring installed and the 345-4080 DEF supply fitting should have (1) 3K-0360 O-ring installed. Replace any O-rings that are missing. Refer to Image 1.1.1.

Image1.1.1

The dosing pump can also develop a leak between the dosing pump head and DEF manifold due to an incorrect torque of the 8T-2396 bolts. These bolts can interfere with the washers that hold the dosing pump head to the dosing pump and cause a low torque value. Refer to Images 1.2.1 and 1.2.2.

Image1.2.1

Image1.2.2

Rework Procedure:
1 - Refer to SEBU8546 Operation and Maintenance Manual for Diesel Exhaust Fluid Pump removal. Once the pump is removed, inspect the washer location in reference to manifold bolt hole location. Reference Image 1.3.1 showing interference. Reference Image 1.3.2 showing no interference.

Image1.3.1

Image1.3.2

2 - If any of the manifold threaded holes show interference with the washers, the bolts will need to be loosened and the washers moved to one side to allow the proper clearance. Loosen bolt number 1 and use the special factory provided tool to insert between the pump head radius and the washers. Tighten bolt number 1 to 5.5 nm. Care should be taken to not over tighten these bolts. Repeat for bolts 2, 3 and 4 in sequence. Reference Images 1.4.1 and 1.4.2.

Image1.4.1

Image1.4.2

3 - If the washers will not move enough in order to gain the proper clearance, then there could be too much material on the pump head radius. This additional material will need to be ground out with a die grinder. Grind out just enough material to allow proper clearance.
NOTE: Care must be taken to keep the pump clean if using a die grinder.
Refer to Images 1.5.1 for the area that would need to be ground out to allow the washers to move over enough to gain the proper clearance.

Image1.5.1

4 - Check the Dosing Pump check valves to ensure they are oriented correctly and have an 0-ring installed on each end of both check valves. If a check valve is missing an O-ring then the check valve will need to be replaced. Reference Image 1.6.1 for proper check valve orientation. Return any unused check valves to Morton if the existing O-rings are installed on the original check valves.
Note: Ensure the entire pump head is clean of any debris before proceeding to the next step.

Image1.6.1

5 - Once Check Valve O-rings have been checked and the dosing Pump Head holes 1 - 4 have had the washers moved over to allow the proper clearance for the DEF manifold bolts, reassemble the Dosing Pump into the Dosing Cabinet. Refer to SEBU8546 Operation and Maintenance Manual for Diesel Exhaust Fluid Pump removal and repeat steps in the reverse order. When assembling the DEF manifold to the Dosing Pump, install new bolts and washers. Install (1) 8T-2922 bolt with (2) 9X-8256 washers in each of the (4) locations and tighten to 12 +/- 3 nm. Refer to Image 1.7.1.