PLATE-LIFTING 4288204 - Caterpillar

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.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
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