Usage:
01Dec2011 |
(Revised 19Sep2012) |
Priority | PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE UPPER ATAAC TUBING ON CERTAIN 3516C XQ2000 POWER MODULES |
|
1071 1353 | PI31955 |
NOTE: | This Program must be administered as soon as possible. When reporting the repair, use "PI31955" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. Exception: If the repair is done after failure, use "PI31955" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code. |
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. |
NOTE: | This Revised Service Letter replaces the 01Dec2011 (Revised 23Apr2012) Service Letter. Changes have been made to the Affected Product, Action Required, and Rework Procedure. |
COMPLETION DATE |
TERMINATION DATE |
30Jun2012 | 31Dec2012 |
PROBLEM
The existing Air-To-Air Aftercooler (ATAAC) core can crack around the upper nozzles on certain 3516C XQ2000 Power Modules. If the existing ATAAC core fails it will cause reduced engine performance and in some situations require replacement of the radiator. |
AFFECTED PRODUCT
Model | Identification Number |
PM3516 | KEN00100-00104, 106-139, 141-157, 159-165, 167-173, 175-181, 183-189, 191-224, 226-227, 231-232 NAM00100-00101, 103, 105-115, 117-122, 124-130, 132-142, 144-145, 147-153, 156-158, 162-164, 166, 170-171, 173-174, 178-180, 182-185, 187, 189-190, 195-196, 198-203, 206-215, 219-224, 230, 232-234, 237, 239, 242-248, 250-259, 261-262, 265-266, 268-273, 275-285, 288-291, 293, 296-298, 300-302, 304, 309, 314, 324-326 |
PARTS NEEDED
Qty |
Part Number | Description |
4 | 1S4305 | SPACER |
16 | 2K4973 | LOCKNUT |
8 | 3P0648 | SEAL-O RING |
8 | 4L9337 | BOLT |
1 | 4W1211 | STRIP |
2 | 5P1075 | WASHER-HARD |
8 | 5P1076 | WASHER-HARD |
8 | 5P2566 | BOLT |
8 | 5S7383 | BOLT |
4 | 6V5729 | LOCKNUT |
8 | 6V8182 | NUT-FULL |
8 | 6V8188 | NUT-FULL |
10 | 6V8801 | NUT |
4 | 7X0311 | BOLT |
8 | 7X0370 | BOLT |
16 | 7X0582 | WASHER-HARD |
1 | 8C1215 | BOLT-U |
8 | 8T2501 | BOLT |
8 | 8T4223 | WASHER-HARD |
48 | 8T4896 | WASHER-HARD |
8 | 8T5360 | WASHER-HARD |
8 | 1356261 | CLAMP-T'BOLT |
8 | 2338484 | CLAMP-T'BOLT |
2 | 2478545 | GASKET |
1 | 2726462 | GASKET |
2 | 2733538 | HOSE-HUMP |
2 | 2834988 | HOSE AS-HUMP |
1 | 3184305 | SPACER |
1 | 3647460 | BRACKET |
1 | 3647461 | TUBE AS |
1 | 3716285 | TUBE AS |
1 | 3716286 | TUBE AS |
1 | 3716287 | SPACER |
1 | 3716293 | BRACKET |
8 | 3718153 | CLAMP AS |
8 | 3722626 | CLAMP AS |
2 | 3723272 | CLAMP AS |
2 | 3723273 | CLAMP AS |
4 | 3732024 | STRAP |
4 | 3732025 | STRAP |
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 43% 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
WARNING: Injury can occur to personnel if the procedure is done improperly. Areas of improvement need to be addressed in order to minimize stress caused by misalignment and vibration. These include replacing the upper tube assembly that has been redesigned with modified tubing and support structure, and replacing the hardware around the pipes leading to the lower radiator nozzles. The Rework Procedure includes the following two sections: 1. DISASSEMBLY OF THE UPPER TUBE ASSEMBLY AND HARDWARE REMOVAL FROM THE 6 INCH TUBE 2. ASSEMBLY AND INSTALLATION OF THE 8 INCH MODIFIED UPPER TUBE ASSEMBLY AND HARDWARE FOR THE 6 INCH TUBE WARNING: The power module must be isolated electrically before and while the rework is preformed. Follow the proper lockout tagout procedures to protect against the unexpected energization or start up of the power module. Failure to follow these warnings could result in injury to personnel during service. Refer to the attached Rework Procedure to determine the proper tools and equipment required to safely perform the rework. |
OWNER NOTIFICATION
U.S. and Canadian owners will receive the attached Owner Notification. |
SERVICE CLAIM ALLOWANCES
NOTE: This is a 8.0-hour job | |||||
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. |
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE. |
COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS XYZ Corporation 3240 Arrow Drive Anywhere, YZ 99999 PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE UPPER ATAAC TUBING ON CERTAIN 3516C XQ2000 POWER MODULES MODELS INVOLVED - 3516C XQ2000 Power Modules Dear Caterpillar Product Owner: The ATAAC radiator tubes need to be replaced on the products listed below. The existing radiator core can develop cracks which in some situations could cause reduced engine performance. You will not be charged for the service performed. Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated 01Dec2011 when scheduling this service. We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime. Caterpillar Inc. Identification #(s) Attached to 01Dec2011 Service Letter |
1. DISASSEMBLY OF THE UPPER TUBE ASSEMBLY AND HARDWARE REMOVAL FROM THE 6 INCH TUBE I. Remove Upper Tube Assembly Disconnect the tube from the rubber expansion joint. NOTE: A step ladder is required for sufficient access. Remove QTY 8 6V-8182 NUT-FULL QTY 16 7X-0582 WASHER-HARD QTY 8 7X-0369 BOLT NOTE: Leave a bolt in place to prevent the spacer ring from falling out. |
Image1.1.1 |
Disconnect the tube from engine inlet manifold and remove the old gasket. Refer to Image1.2.1. Remove QTY 8 6V-8801 NUT QTY 8 5S-7383 BOLT QTY 16 8T-4896 WASHER QTY 1 272-6462 GASKET |
Image1.2.1 |
Remove the upper tube with brackets and U-bolt attached leaving the rubber expansion joint attached to the radiator outlet. Refer to Image1.3.1. Remove QTY 4 8T-4223 WASHER QTY 4 6V-8188 NUT QTY 4 5P-1076 WASHER QTY 4 5P-2566 BOLT QTY 1 318-4305 SPACER |
Image1.3.1 |
Remove the spacers and rubber expansion joint from the radiator. Refer to Image1.4.1. Remove QTY 2 318-4305 SPACER QTY 1 282-6664 BELLOW QTY 8 6V-8182 NUT-FULL QTY 8 7X-0370 BOLT QTY 16 7X-0582 WASHER QTY 1 318-4305 SPACER |
Image1.4.1 |
II. Remove Lower and Upper Tube Hardware on Both LH and RH Sides Remove pipe clips and brackets from both sides. Remove (1) QTY 4 293-9809 CLIP QTY 4 293-9810 CLIP QTY 16 112-8989 SPACER QTY 8 6V-8801 NUT QTY 8 8T-2501 BOLT QTY 8 8T-4896 WASHER QTY 8 5P-1075 WASHER (2) QTY 1 331-0223 BRACKET QTY 4 7X-0515 WASHER QTY 4 7X-2553 BOLT (3) QTY 1 331-0224 BRACKET QTY 4 7X-0515 WASHER QTY 4 7X-2553 BOLT NOTE: Removal of the hardware is performed in the power module without removing the tubing from the engine. Image1.5.1 shows the removed tubing from the power module for clarity. |
Image1.5.1 |
Remove the hardware from both sides. Refer to Image1.6.1. Remove QTY 8 282-6679 CLAMP QTY 4 282-6680 STRAP QTY 8 5P-2566 BOLT QTY 8 6V-8188 NUT QTY 16 8T-4223 WASHER QTY 2 273-3538 HOSE-HUMP QTY 8 135-6261 CLAMP |
Image1.6.1 |
Remove the hardware from both sides. Refer to Image1.7.1. Remove QTY 2 294-0521 CLAMP QTY 2 294-0522 CLAMP QTY 4 7X-0311 BOLT QTY 4 3P-0648 SEAL QTY 8 8T-5360 WASHER QTY 8 1S-4305 WASHER QTY 4 7X-0447 NUT |
Image1.7.1 |
2. ASSEMBLY AND INSTALLATION OF THE 8 INCH MODIFIED UPPER TUBE ASSEMBLY AND HARDWARE FOR THE 6 INCH TUBE I. Subassemble and Install Upper Tube Assembly With the 364-7461 Tube Assembly, mark a centerline between two bolt holes as shown in Image1.8.1. Fully insert 283-4988 Hump Hose onto the tube and install two 233-8484 T-bolt Hose Clamps that are oriented 180 degrees apart. Parts Required QTY 1 364-7461 TUBE AS QTY 1 283-4988 HOSE-HUMP QTY 2 233-8484 CLAMP |
Image1.8.1 |
With the 371-6286 Tube mark, a centerline at the mitered weld joints as shown in Image1.9.1. Install two 233-8484 T-bolt Hose Clamps that are oriented 180 degrees apart and insert the tube into the hump hose with the marks aligned. Parts Required QTY 2 233-8484 CLAMP |
Image1.9.1 |
Install 283-4988 Hump Hose and two 233-8484 T-bolt Hose Clamps that are oriented 180 degrees apart. Parts Required QTY 1 283-4988 HOSE-HUMP QTY 2 233-8484 CLAMP |
Image1.10.1 |
With the 371-6285 Tube Assembly, mark a centerline between two bolt holes. Install two 233-8484 T-bolt Hose Clamps that are oriented 180 degrees apart and insert the tube assembly into hump hose with marks aligned. Parts Required QTY 1 371-6285 TUBE AS QTY 2 233-8484 CLAMP |
Image1.11.1 |
Use 5H-2471 Adhesive or standard rubber cement to join a 247-8545 Gasket, the 318-4305 Spacer, and another 247-8545 Gasket, as shown in Image1.12.1. Insert two 7X-0370 bolts into radiator outlet flange and attach gasket assembly. Place the 272-6462 Gasket on the engine inlet manifold. Refer to Image1.12.2 Parts Required QTY 2 247-8545 GASKET QTY 1 318-4305 SPACER QTY 1 272-6462 GASKET |
Image1.12.1 |
Image1.12.2 |
Install the upper tube assembly. Adjust the tubes as necessary to properly align the assembly. Parts Required (1) QTY 8 6V-8182 NUT QTY 16 7X-0582 WASHER QTY 8 7X-0370 BOLT (2) QTY 8 5S-7383 BOLT QTY 16 8T-4896 WASHER QTY 8 6V-8801 NUT |
Image1.13.1 |
Install the clamps and the straps at the top and bottom of the upper tube assembly. Parts Required (1) QTY 8 8T-2501 BOLT QTY 8 2K-4973 LOCKNUT QTY 16 8T-4896 BOLT (2) QTY 4 373-2024 STRAP (3) QTY 8 371-8153 CLAMP |
Image1.14.1 |
For each pair of clamps, tighten the bolts to 47 Nm on one side so that both tabs are in contact. On the other side, tighten the bolts to 15 Nm then turn an additional 180 degrees leaving a gap between the tabs as shown in Image1.15.1. |
Image1.15.1 |
Install the upper pipe support brackets and hardware. Tighten the U-bolt before the four bolts on the brackets. Parts Required (1) QTY 1 371-6293 BRACKET (2) QTY 4 5P-2566 BOLT QTY 4 5P-1076 WASHER QTY 4 8T-4223 WASHER QTY 4 6V-8188 NUT (3) QTY 1 364-7460 BRACKET (4) QTY 4 5P-2566 BOLT QTY 4 5P-1076 WASHER QTY 4 8T-4223 WASHER QTY 4 6V-8188 NUT (5) QTY 1 8C-1215 U-BOLT QTY 2 6V-8801 NUT QTY 2 5P-1075 WASHER (6) QTY 1 4W-1211 STRIP QTY 1 371-6287 SPACER |
Image1.16.1 |
II. Install 6 inch tube hardware Install new hardware for the ATAAC tubes on both sides of the engine. For each pair of clamps on the lower connection of the tubes (5) and (6), tighten the bolts to 47 Nm on one side so that both tabs are in contact. On the other side tighten the bolts to 20 Nm then turn the bolt an additional 180 degrees leaving a gap between the tabs. Parts Required (1) QTY 2 372-3272 CLAMP AS (2) QTY 4 7X-0311 BOLT QTY 4 1S-4305 WASHER QTY 8 3P-0648 SEAL QTY 4 6V-5729 LOCKNUT QTY 8 8T-5360 WASHER (3) QTY 2 372-3273 CLAMP (4) QTY 8 135-6261 CLAMP QTY 2 273-3538 HOSE-HUMP (5) QTY 8 372-2626 CLAMP AS (6) QTY 8 4L-9337 BOLT QTY 8 2K-4973 LOCKNUT QTY 16 8T-4896 WASHER (7) QTY 4 373-2025 STRAP |
Image1.17.1 |