- Power Module:
- PM3516 (S/N: NBR1-UP)
Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.
Problem
The radiator guard interferes with the 199-8939 Tube on certain XQ2000 power modules. The tube is installed correctly, however the hole that the tube passes through on the radiator guard is not correctly positioned. If the contact is not repaired, the guard will cut through the tube resulting in a loss of coolant.
Solution
Caterpillar is aware of this problem, and interim repair has been defined. Inspect for contact between the coolant tube and the radiator guard. If contact has been found, use the rework procedure below to eliminate the interference.
Rework Procedure
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Bodily contact with electrical potential can cause bodily injury or death. To avoid the possibility of injury or death, ensure that the main power supply has been disconnected before performing any maintenance or removing any modules. |
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High voltage is present. Work on this equipment must be performed by authorized trained personnel. Personnel must be wearing Personal Protective Equipment that meets regulatory requirements to protect the body for the work that is being performed. Failure to use appropriate PPE to protect the body will result in serious personal injury or death. |
Coolant Tube Rework
- Drain the coolant from the jacket water circuit.
- Remove the bottom radiator guard as shown in the illustration above to access the coolant tube.
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| Illustration 1 | g03704386 |
- Loosen the coolant tube bracket (1), support (2) and the bolts (3) on the floor for optimal adjustment.
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| Illustration 2 | g03704620 |
(1) Coolant Tube Bracket | |
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| Illustration 3 | g03704632 |
(2) Support (3) Bolts | |
- Loosen the Aeroquip connector (4) and connector (5) enough to move the tube.
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| Illustration 4 | g03704679 |
(4) Connector | |
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| Illustration 5 | g03704700 |
(5) Connector | |
- Use a rubber mallet to adjust the coolant tube. Verify that there is a minimum of 5mm around the tube. Refer to the illustration above for reference.
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| Illustration 6 | g03704709 |
- If the 5mm of clearance around the tube cannot be achieved, proceed to the guard rework procedure below to remove material around the hole.
- Retighten the Aeroquip connectors. Verify clearance between the tube and guard is maintained.
- Retighten the coolant tube mounting support and brackets. Verify clearance between the tube and guard is maintained.
- Reinstall the radiator guard.
- Refill the jacket water circuit with coolant.
- Proceed to verification testing.
Guard Rework (If Required)
Perform this procedure only if coolant tube cannot be adjusted to achieve a 5mm clearance all around.
- Trace the outline of the required tube clearance on the guard.
- Remove the radiator guard.
- Remove material from the hole around the coolant tube to meet the required clearance.
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| Illustration 7 | g03704721 |
(1) Cut/Trim the excess with a die grinder and bur carbide. | |
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| Illustration 8 | g03704737 |
(2) Clearance After Trimming | |
- Use touch-up paint on the affected area of the guard.
- Reinstall the guard.
Verification Testing
- Run the engine to circulate coolant through the radiator.
- Inspect the clearance around the coolant tube hole. Make sure that the clearance around the coolant tube is maintained when the unit is running.
- Continue to run for about 10-15 minutes to bring the coolant to operating temperature. Check coolant connections and verify that there is no leak. Check the coolant level and fill if needed.
- Stop the engine.
- Repair is complete and the power module can be returned to service.