PRODUCT SUPPORT PROGRAM FOR REPLACING THE AIR TO AIR AFTERCOOLER (ATAAC) ON CERTAIN 24M MOTOR GRADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE AIR TO AIR AFTERCOOLER (ATAAC) ON CERTAIN 24M MOTOR GRADERS

Usage:

REBE8909-01

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17Oct2012

(Revised 12Feb2013)

U-548

A-433

D-466

O-503

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE AIR TO AIR AFTERCOOLER (ATAAC) ON CERTAIN 24M MOTOR GRADERS
1063 1064		PS52313

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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 "PS52313" 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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NOTE:	This Revised Service Letter replaces the 17Oct2012 Service Letter. Changes have been made to Parts Needed and Rework Procedure.

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TERMINATION DATE

31Oct2014

PROBLEM

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The existing aftercooler can crack on certain 24M Motor Graders. If the existing aftercooler fails it can cause damage to the exhaust manifold and/or the turbo, creating high heat and derating the engine.

AFFECTED PRODUCT

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Model	Identification Number
24M	B9K00242-00639

PARTS NEEDED

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Qty	Part Number	Description
1	6V2499	SEAL
4	8D0983	MOUNTING
4	1156433	WASHER-HARD
2	2708390	SEAL
3	2725438	SEAL
1	3969735	CORE AS-AFTCLR
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% 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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Refer to the attached Rework Procedure.

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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%
0-8000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
8001-12000 hrs, 13-24 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

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NOTE: This is a 6.0-hour job If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.

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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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Reference SENR9832, "Aftercooler - Test". This test will indicate whether or not the ATAAC is defective.

The 274-7831 Aftercooler Core is replaced by a 396-9735 Aftercooler Core.

1. Remove the aftercooler core per KENR6020, "Aftercooler ? Remove and Install".

2. Do not reuse the four 121-3307 Mounts on the upper brackets. Four 8D-0983 Mounts will be used in their place.

Image1.4.1

3. Do not reuse the four of the 8T-4226 Washers. The four 115-6433 Washers will be used in their place at the base of the aftercooler.

Image1.5.1

4. Install the new 396-9735 Aftercooler Core according to KENR6020, "Aftercooler - Remove and Install".

5. Install two 270-8390 Foam Seals, one 6V-2499 Foam Seal, and three 272-5438 Radiator Seals.

NOTE: If your machine still has the 276-2386 Radiator Group, you will need to cut away a portion of the 300-1707 Expansion Tank as shown in Image1.7.1. 30mm needs to be removed off of the edge of the flat part of the expansion tank next to the ATAAC.