RADIATOR GP 4152610 - Caterpillar

SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-40000 hrs 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 108.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
1) Contact In-Place Machinery Co. to schedule crankshaft drilling.
2) Remove any site installation related equipment from the front of the engine to allow access for removal of engine front housing and access to front of crankshaft.
Note: Use the G3520E D&A manual, RENR5980 and G3520E Specifications Manual, RENR5977 for reference.
3) Remove turbochargers and related plumbing from the engine.
4) Remove exhaust elbows and related mounting brackets to gain access for front housing removal.
5) Remove the vibration damper.
6) Remove the engine oil pump, oil cooler and related plumbing.
7) Remove engine driven water pumps, if installed.
8) Remove front housing and gear train.
9) Remove the #1 main bearing cap.
Note: The engine should now look like image 1.1.1
Image1.1.1
10) Cover the exposed section of the oil pan and seal with tape. This is to keep debris from entering the pan during drilling.
Note: See image 1.2.1 for an example of a shield to keep out debris.
Image1.2.1
11) In-Place Machinery will perform the crankshaft drilling procedure with dealer assistance.
Note: In-Place Machinery has a detailed procedure and tool kit specifically developed in conjunction with Caterpillar to perform this rework.
12) Ensure that the crankshaft drillings and engine oil pan have been flushed/cleaned throughly.
13) Install the #1 main cap and bearing.
14) Install the front housing and gear train.
15) Install water pumps, if required.
16) Install engine oil pump, oil cooler and related plumbing.
17) Install the 315-2616 damper gp. The alignment (dash) mark on damper must be aligned with alignment (dash) mark on crankshaft. Ensure that the 117-8801 and 324-2702 o-rings stay in-place during installation of the damper. Coat the 7B-8363 damper bolts with moly lubricant and torque to 1150 +/- 60 N-m (850 +/- 45 lb. ft).
18) Install exhaust components and related mounting brackets.
19) Install turbos and related lines.
20) Reinstall any site installation related equipment in front of the engine.
Note: For removing the drive coupling, make sure that the power cables and control wires connected to the generator have sufficient slack to allow the generator to be moved back from the engine. In most cases it will not be necessary to disconnect anything.
22) Unbolt the rubber boot retaining ring.
23) Remove the rubber boots.
24) Unbolt the generator from the rails and the engine flywheel housing.
25) Slide the generator back approximately 40 cm from the engine to gain access to the coupling components. Take care not to damage or mix up the shims under the generator feet.
26) Unbolt and remove the outer coupling element from the flywheel. Discard.
27) Unbolt and remove the inner element from the generator hub. Discard.
28) Clean any grease or dirt from the flywheel.
29) Install the new rubber element on the generator hub using the 9X-2119 bolts with 4M-6953 washers. Rotate the rubber element to line it up for insertion with the coupling ring. Tighten the