PRODUCT SUPPORT PROGRAM FOR REPLACING THE RADIATOR ASSEMBLY OR RADIATOR CORE ON CERTAIN 3516, AND 3516B HD GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE RADIATOR ASSEMBLY OR RADIATOR CORE ON CERTAIN 3516, AND 3516B HD GENERATOR SETS

Usage:

TEBE3627-00

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11Sep2015

D-414

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Before/After	PRODUCT SUPPORT PROGRAM FOR REPLACING THE RADIATOR ASSEMBLY OR RADIATOR CORE ON CERTAIN 3516, AND 3516B HD GENERATOR SETS
1353		PS44856

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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 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 "PS44856" 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

30Sep2017

PROBLEM

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The existing radiator core can leak on certain 3516, and 3516B HD Generator Sets assembled from March 1, 2015 to June 30, 2015. If the existing radiator core leaks it will need to be replaced.

AFFECTED PRODUCT

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Model	Identification Number
3516	JCG00100-00101
3516B HD	JCN00124-00160, 162-167

PARTS NEEDED

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Qty	Part Number	Description
4	5P5894	COATING (4 Metres)
1	BULK_COOLANT	Coolant (See OMM) - as needed - 5 Gal maximum
1	RADIATORGP	Radiator Core Assembly (See Action Required)
1	RADIATORGP_BASIC	Radiator Group Basic (See Action Required)
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

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For ordering the radiator assembly or the radiator core, contact Loring Yu at email Yu_Loring@cat.com or phone +86 510 8537 9799.

Refer to the attached Rework Procedure.

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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%
0-20000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 20.0-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.

Rework Procedure

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Rework Procedure For Replacing the Complete Radiator

1. Remove the plug on the ball valve on front of radiator and drain coolant from the cooling system into a suitable container for reuse. After draining remove ball valve and adapter from radiator.

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2. Disconnect fuel hose from fuel cooler.

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3. Remove coolant level sensor and ladder clip from radiator. Cut tie wraps holding harness to piping.

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4. Disconnect the 2 tube assemblies from radiator and engine leaving couplings on tubes.

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5. Disconnect tube assembly leaving couplings on tube.

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6. Remove clamps and disconnect tube assembly.

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7. Disconnect tube assembly from engine and radiator leaving coupling on tube.

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8. Disconnect the elbow.

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9. Remove fan guard.

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10. Remove bolts from both sides of radiator.

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11. Attach suitable lifting device to radiator group. The weight of the radiator is approximately 891 kg (1964 lb). Move radiator away from engine. It may be necessary to loosen the fasteners on the fan shroud in order to ensure the fan on engine is not damaged when lifting.

Image1.11.1

12. Attach suitable lifting device to new radiator group. The weight of the radiator is approximately 891 kg (1964 lb). Move radiator toward engine. It may be necessary to loosen the fasteners on the fan shroud in order to ensure the fan on engine is not damaged when positioning new radiator. After radiator is positioned retighten fan shroud bolts. When retightening the shroud ensure about 12 mm clearance all the way around between tip of fan blades and shroud.

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13. Install bolts on both side of radiator.

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14. Install fan guard on radiator.

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15. Connect elbow.

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16. Connect tube assembly to engine and radiator.

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17. Install tube assembly and clamps.

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18. Install tube assembly.

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19. Install the 2 tube assemblies.

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20. Install coolant level sensor and ladder clip ensuring the tip of sensor is free of debris. Tie wrap harness to tube assembly as required.

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21. Connect fuel hose to fuel cooler.

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22. Remove plug from front of radiator and install adapter and ball valve. Fill the cooling system. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" or Operation and Maintenance Manual, "Cooling System Coolant (DEAC) - Change".

Image1.22.1

Rework Procedure For Replacing the Radiator Core

1. Remove the plug on the ball valve on front of radiator and drain coolant from the cooling system into a suitable container for reuse. After draining remove ball valve and adapter from radiator.

Image1.23.1

2. Disconnect fuel hose from fuel cooler.

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3. Remove coolant level sensor from radiator.

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4. Disconnect the 3 tube assemblies from top of radiator by loosening the couplings on the tubes and sliding them back on the tubes.

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5. Disconnect tube from radiator by loosening coupling and sliding back on tube.

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6. Disconnect elbow from radiator by loosening coupling and sliding forward onto radiator tube.

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7. Attach lifting swivels to top tank.

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8. Remove all bolts between radiator and radiator core guard (18 bolts total).

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9. Remove all bolts between shroud and radiator assembly (22 bolts total, 11 each side).

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10. Attach suitable lifting device to radiator core. The weight of the radiator core is approximately 334 kg (736 lb).

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11. Remove the bolts from the radiator frame (4 bolts total, 2 on each side).

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12. Lift off radiator core assembly from frame and place flat on the ground with fuel cooler assembly facing up. Remove fuel cooler assembly and install on new radiator core assembly in the same location.

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13. Remove lifting swivels and attach to new radiator core assembly

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14. Attach suitable lifting device to radiator core. The weight of the radiator core is approximately 334 kg (736 lb). Lift radiator core assembly onto radiator frame aligning frame holes with holes in bottom tank. Insert frame bolts, attach locking nuts hand tight only at this time. (4 bolts total, 2 each side)

Image1.36.1

15. Align shroud and radiator holes, install and tighten all bolts (22 bolts total, 11 each side).

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16. Tighten frame bolts (4 bolts total, 2 each side).

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17. Attach core guard to radiator assembly. Align and tighten the core guard bolts (18 bolts total).

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18. Remove lifting swivels from top tank.

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19. Reconnect elbow to radiator.

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20. Reconnect tube to radiator.

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21. Reconnect the 3 tube assemblies to the top of radiator.

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22. Install coolant level sensor in radiator.

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23. Reconnect fuel hose to fuel cooler.

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24. Remove plug from front of radiator and install adapter and ball valve. Fill the cooling system. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" or Operation and Maintenance Manual, "Cooling System Coolant (DEAC) - Change".