PRODUCT SUPPORT PROGRAM FOR REPAIRING RADIATOR COOLANT LEAKS ON CERTAIN PM3516 POWER MODULES (XQ2000 POWER MODULES) Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPAIRING RADIATOR COOLANT LEAKS ON CERTAIN PM3516 POWER MODULES (XQ2000 POWER MODULES)

Usage:

TEBE8201-00

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03Oct2018

K645
K646

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After Failure Only (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPAIRING RADIATOR COOLANT LEAKS ON CERTAIN PM3516 POWER MODULES (XQ2000 POWER MODULES)
1353		PS53866

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NOTE:	Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.
NOTE:	This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS53866" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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

31Oct2020

PROBLEM

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The existing radiator assembly can leak coolant on certain PM3516 Power Modules(XQ2000 Power Modules). Replacement of the gaskets, and header joint hardware will be required to repair coolant leaks.

AFFECTED PRODUCT

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Model	Identification Number
PM3516	NBR00566, 571, 578-580, 583-588

PARTS NEEDED

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Qty	Part Number	Description
280	3E9860	LOCKNUT
96	4M6424	BOLT
8	5P4116	WASHER-HARD
12	6V8918	BOLT-HEX HEAD
60	7X0440	BOLT
124	8C3121	BOLT
564	8T4224	WASHER-HARD
16	4745626	PLATE
8	4745627	PLATE
4	4745628	PLATE
16	4745629	PLATE
8	4993431	GASKET-RDTR CORE
1	ADHESIVE	PERMATEX 81731 WEATHERSTRIP (quantity as needed)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 20% 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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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 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 and the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

WARNING: The generator set must be isolated mechanically and electrically before and while the rework is being performed. Follow the proper lock out tag out procedures to protect against unintended operation, unexpected movement, 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 and local and remote controls before you perform any service to the machine.

REPAIR ACTION REQUIRED

In some cases, the jacket water (JW) radiator core (1) within the 396-3513 Radiator Assembly can leak. Refer to Image1 and Image2. The entire radiator assembly will need to be removed from the container to perform the repair. Refer to Image3. The repair requires replacement of the gaskets (8 total), and header joint hardware. The core washers will need to be replaced with a thicker design for improved clamp load distribution. After new gaskets are installed, a total of 44 new core washers will be installed. 16 total (8 each side) of 474-5626 Plate will be installed as shown in Image4. 8 total of 474-5627 Plate (4 each side) will be installed as shown in Image5. 4 total of 474-5628 Plate will be installed between the cores as shown in Image6. 16 total of 474-5629 Plate (8 each side) will be installed as shown in Image7. The fastening hardware will also need to be replaced to accommodate the thicker core washers. After the radiator repair, and after installation in the package, an air leak test will be required. Test plugs, shop air regulated up to 14 psi, soapy water, and a pressure gage will be needed to perform the pressure test.

Refer to Special Instruction, M0070000 for the rework procedure.

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Image1

Image2

Image3

Image4

Image5

Image6

Image7

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%
0-12500 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
12501-20000 hrs, 61-84 mo	100.0%	0.0%	0.0%	0.0%	0.0%	100.0%