PRODUCT SUPPORT PROGRAM FOR REWORKING THE CHARGE AIR COOLER (CAC) SPACER PLATE ASSEMBLY ON CERTAIN C32 GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE CHARGE AIR COOLER (CAC) SPACER PLATE ASSEMBLY ON CERTAIN C32 GENERATOR SETS

Usage:

TEBE0563-00

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29Oct2013

U060
U150
U158

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Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REWORKING THE CHARGE AIR COOLER (CAC) SPACER PLATE ASSEMBLY ON CERTAIN C32 GENERATOR SETS
1063 1353		PS44068

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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 "PS44068" 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

31Oct2015

PROBLEM

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The spacer plate assemblies 3621075 and 3621076 need to removed and replaced with a one piece spacer plate assembly on certain C32 Generator Sets. This new spacer plate assembly prevents the Charge Air Cooler (CAC) from developing holes due to rubbing on the radiator lower tank flange.

AFFECTED PRODUCT

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Model	Identification Number
C32	SXC02695-02700, 2702-2704, 2706, 2708-2721, 2723-2724, 2726, 2728-2732, 2734, 2736, 2738-2740, 2744-2748, 2750-2755, 2761-2763, 2766, 2768, 2775-2779, 2793, 2796-2799, 2815, 2818-2819, 2830-2831, 2833-2836, 2846-2847, 2850-2851, 2860-2862, 2865, 2874-2878, 2880-2885, 2887, 2889-2900, 2902, 2913-2914

PARTS NEEDED

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Qty	Part Number	Description
18	8T0389	LOCKNUT
1	PLATE	PLATE DO NOT ORDER - SEE REWORK PROCEDURE
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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Fabricate and install the improved spacer plate assembly. 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 1.5-hour job
Allowance for fabrication of spacer plate assembly is not to exceed $230.00 USD.

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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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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, on the product, and in this product's Operation and Maintenance Manual (OMM). 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, the warnings that are on the product, and the warnings that are in the OMM are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, the user must ensure that it is safe for the user and for other people to use.

The user 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.

WARNING: The generator set must be isolated electrically before and while the rework is performed. Follow the proper lockout tag out procedures to protect against the unexpected energizing or startup of the generator set. Failure to follow these warnings could result in injury to personnel during service. Attach a "Do Not Operate" warning tag to the machine start switch or the controls before you perform any service to the machine.

1) Fabricate spacer plate assembly (refer to specifications below).

Image1.1.1

Image1.1.2

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2)Remove radiator to frame M10 bolts (1). 4 total 2 on each side (See image 1.2.1).

Image1.2.1

3)Loosen radiator to charge air cooler (CAC) M10 mounting bolts (14 total-7 bolts each side), while leaving nuts engaged on the bolts. This allows radiator to CAC separation for inspection and prevents radiator from tipping or falling (See image 1.3.1 item 2).

SAFETY NOTE: Prior to completely removing bolts, make sure the radiator and charge air cooler assemblies are secure to prevent tipping or falling. Leaving nuts engaged on the bolts, but not tightened (3) may allow enough clearance to install spacer plates. However, under any circumstance, the radiator and CAC will need to be secured to prevent tipping or falling (See image 1.3.1 item 3).

Image1.3.1

4)Remove 3621075 and 3621076 spacer plates from each side of the radiator assembly(See image 1.4.1).

Image1.4.1

5)Verify that 1/4 inch spacer part numbers 3616868 and 3686870 are installed on both sides of the radiator assembly. Do not remove these spacers (See image 1.5.1).

Image1.5.1

6)If the CAC has been previously repaired, verify that steel shoulder washers are installed (See image 1.6.1).

Image1.6.1

7)Verify that excess tank gasket material from radiator tank has been trimmed. It not, this will need to be trimmed to prevent contact with charge air cooler. Below is an example of tank gasket material that has been trimmed (See image 1.7.1).