Jacket Water Lines May Leak On Certain 3500 Power Modules{1380} Caterpillar

Power Module:

PM3516 (S/N: NBR1-UP)

PMG3516 (S/N: KAD1-UP)

XQC1200 (S/N: N1G1-UP)

XQC1600 (S/N: N1M1-UP)

Introduction

The problem that listed below does not have a known permanent solution. Until a know solution is known, use the solution that is listed below.

Problem

Some of the jacket water line joints using the 7L-4196 Tube Joint can have reduced seal life on certain 3500 Power Modules. This reduced life typically occurs on the engine jacket water outlet side that runs hotter than the engine inlet side. In some cases the seal life is less than 5,000 hours. There are three total affected joints, six seals total, on the jacket water outlet side.

Solution

If the coolant leak occurs at the jacket water line joint using the 7L-4196 Tube Joints , replace with the 216-2658 Seals .

Prior to replacing the seals, ensure that the joint is aligned properly.

Parts Required

Table 1 contains the parts that are required to complete this solution.

Installation Procedure

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Illustration 1	g03799381
(A) ±4 degrees

1. Check the alignment of the pipes. The joint must have less than 4 degrees of misalignment.

   Note: An alternative method of measurement is the maximum pipe offset of 12 mm (0.47 inch).

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Illustration 2	g03799596
(1) Coupling (2) Retainer (3) Seal (4) Sleeve

2. Debur and clean the end of the pipes. Visually check roundness of the pipes. A proper seal may be compromised if the roundness of the pipe is distorted.

   Note: Surfaces should be free of deep scratches, gouges, dents, and dirt.

3. Install coupling (1), retainer (2), seal (3), and sleeve (4) onto the end of one pipe. Refer to Illustration 2. Install the coupling, retainer, and seal to the proper depth of 44.5 mm (1.75 inch) to 52.6 mm (2.07 inch).

   Note: Assembly of gaskets can be made easier by dripping the fluid to sealed on the surfaces. The use of other rubber lubricants can be detrimental to the life of the gaskets. Never lubricate the metal parts.

4. Install coupling (1), retainer (2), and seal (3) on the other pipe. Install the components to the proper depth of 44.5 mm (1.75 inch) to 52.6 mm (2.07 inch).

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Illustration 3	g03800611

5. To simplify installation of the gasket, install lower gasket halfway onto the pipe first, leaving the split area in the steel retaining ring free at the top. Then, stretch the gasket and split area of the retaining ring until the rings slip over the tube or pipe and into position. Refer to Illustration 3.

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Illustration 4	g03800631
(1) Coupling (2) Retainer (3) Seal (4) Sleeve

6. Slide sleeve (4) to retainer (2). Move the retainer and coupling (1) into position as shown in Illustration 4. Pipe must be inserted to proper depth of 44.5 mm (1.75 inch) to 52.6 mm (2.07 inch) into both gaskets.

7. Tighten the couplings on each side of the sleeve to 34 ± 0.5 N·m (25 ± 0.5 lb ft).

   Note: Do not tighten each nut on the coupling to the full torque at one time. Tighten the nuts going back and forth from side to side in increments until full torque for each is reached.