TERMINAL AS 1256536 - Caterpillar

Caterpillar: Confidential Yellow
This Program can 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 "PS40145" as the Part number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
Termination Date
March 31, 2001Problem
The routing of the hoses between the jacket water heater and engine needs to be changed on certain open 3306B Gensets with compact base frames.
Affected Product
Model & Identification Number
3306B (8NS684, 8NS1051-1052, 8NS1113, 8NS1115, 8NS1120, 8NS1125, 8NS1133-1134, 8NS1139-1140, 8NS1151, 8NS1159, 8NS1176, 8NS1179, 8NS1193, 8NS1195, 8NS1261, 8NS1270, 8NS1300, 8NS1372, 8NS1375, 8NS1405, 8NS1423, 8NS1438, 8NS1503, 8NS1509, 8NS1535, 8NS1551, 8NS1595-1596, 8NS1628-1629, 8NS1637-1638, 8NS1703, 8NS1722-1723, 8NS1727, 8NS1745, 8NS1758, 8NS1791-1792, 8NS1814-1815 , 8NS1820, 8NS1832-1833, 8NS1841, 8NS1910, 8NS1917-1918, 8NS1921-1922, 8NS1958, 8NS1965, 8NS1972, 8NS1987-1988, 8NS1990-1991, 8NS2003, 8NS2008, 8NS2017, 9DS849, 9DS778, 9DS842, 9DS785, 1CZ162, 1CZ287, 1CZ244, 1CZ270, 1CZ254, 1CZ235, 1CZ280, 1CZ220, 1CZ277, 1CZ239)
Parts Needed
2 - 1542949 CLIPAction Required
1. Close both feed and return ball valves on the JWH circuit.These valves are located on the left hand side of the engine.2. Remove hose assembly 143-4438 (inlet to heater) and 143-4439 (outlet to engine).3. Cut 190 mm of the engine side of hose 143-4439 (outlet to engine hose).4. Cut 60 mm of the engine side of hose 143-4438 (inlet to engine).5. On new type heaters only, part number (169-2176), loosen the "U" clamps on the JWH main support body and adjust the heater to ensure that the outlet of the heater is pointing up.Once this has been obtained, re-tighten the "U" clamps. The new heater is fitted to units with a genset serial number of 8NS02003 and above.
6. Connect hoses loosely to the jacket water heater. Route hoses underneath the engine oil pan and Connect to the engine fittings. Fittings on the engine may require adjustment at the engine to ensure hose connection.
7. Tighten all hose connections at JWH and engine, fit "p" clip 154-2949 to hose 143-4439 and secure to the 8th bolt on the L/H side of the oil pan.Tighten bolt to 47 N m. 8. Fit "P" clip 154-2949 to hose 143-4438 and secure to the 6th bolt on the L/H side of the oil pan. Tighten bolt to 47 N m.9. Adjust hoses to ensure a continuous flow upwards from jacket water heater to engine and then tighten "P" clips.10. Ensure the jacket water heater is bled to remove all air trapped in the circuit before operation. It is critical that a continuous flow up is maintained on both hoses especially the outlet hose to engine. Once this has been checked, the jacket water heater is ready for operation.
Service Claim Allowances
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.