PRODUCT SUPPORT PROGRAM FOR REWORKING THE JACKET WATER RADIATORS ON CERTAIN XQC1600 POWER MODULES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE JACKET WATER RADIATORS ON CERTAIN XQC1600 POWER MODULES

Usage:

TEBE8892-01

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11Mar2019

(Revised 10Apr2019)

Q661

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Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REWORKING THE JACKET WATER RADIATORS ON CERTAIN XQC1600 POWER MODULES
1377 1380		PS46148

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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 must 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 "PS46148" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "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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NOTE:	This Revised Service Letter replaces the 11Mar2019 Service Letter. Changes have been made to the Affected Product.

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TERMINATION DATE

31Mar2021

PROBLEM

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The existing separate jacket water coolant levels, left and right sides, can become out of balance on certain XQC1600 Power Modules. If the existing jacket water sides become imbalanced, it may cause one side to overflow and result in coolant loss through the overflow tube. The units have only one low level alarm on the right side thus when the right side level elevates and overflows, no alarm is given. Installing a pressure balance line between the left and right jacket water filler necks results in a stable, more balanced system without overflow.

AFFECTED PRODUCT

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Model	Identification Number
XQC1600	N1M00168, 172, 177-182, 184-187, 189-200, 269-272, 274-275, 277, 279-280

PARTS NEEDED

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Qty	Part Number	Description
4	8T4196	BOLT-HEX HEAD
4	9M8406	CLIP-LOOP
2	1091145	CLAMP-HOSE
300	3496234	HOSE - BULK (300 CM)
2	FITTING	FITTING (See Action Required)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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 in order 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 or 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 performed. Follow the proper lockout tag out procedures to protect against the unexpected 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 or the controls before you perform any service to the machine.

Repair Action Required

The FITTING should have already been provided to the dealer. If a dealer does not have the parts, have the Dealer Technical Communicator (TC) submit a request for the parts to CPI number 432988 through CPI Feedback within the Service Information Management System (SIMSi).

Rework jacket water filler necks only and add a hose connecting both left and right jacket water filler necks. Refer to Image1. Refer to the attached Rework Procedure.

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Image1

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%
0-20000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 4.5-hour job

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PARTS DISPOSITION

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Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

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1. Ensure the unit has bee properly secured and de-engergized to prevent start-up during this operation.

2. Open radiator doors to gain access to the JW filler necks.

3. Remove and set aside the overflow tubes from each filler neck.

4. Remove the filler necks and add a 3/8 inch (9.5 mm) hole in the location indicated. Refer to Image1.1.1 for left side filler neck and refer to Image1.1.2 for right side filler neck.

5. Weld a FITTING to each filler neck.

6. Reinstall filler necks.

7. Install the 349-6234 flexible hose, approximately 300 cm, and secure the hose using the 9M-8406 p-clips, 8T-4196 bolts, and 109-1145 clamps.
Note: Route the hose in such a manner to allow any fluid trapped in the hose to flow downward into one of the JW top tanks. Refer to Image1.1.3.