Usage:
NOTE: This Program can 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 "PS40229" as the Part number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
Termination Date
July 31, 2002Problem
Certain G3612 and G3616 Engines have experienced air leaks with the two stage Aftercooler Groups 130-5644 and 134-0510. These air leaks are occurring between the end flange and the body of the two stage Aftercooler Core 130-8130. A field weld procedure has been developed to correct this air leak.
Affected Product
Model & Identification Number
G3612 (1YG20-176)
G3616 (4CG24-175)
Parts Needed
Action Required
1. Inspect aftercooler core assembly for air leaks during routine maintenance procedures.
2. If an air leak is apparent in the seam between the core and the end plate, shut down the engine.
3. Drain the coolant from the aftercooler/oil cooler circuit.
4. Drain the coolant from the aftercooler/oil cooler circuit.
5. Remove the 130-8130 Aftercooler Core Assembly from the 123-3855 Housing.
6. Remove dirt and paint from area to be welded (refer to attached drawing).
7. Apply a single weld bead on seam between the core and end plate on the sides of the aftercooler core as indicated in the attached drawing. Use E6013 Welding Rod and a welder setting of 200 Amps DC. Care should be taken not to extend the weld bead past the top or bottom of the aftercooler core to avoid distortion of the sealing faces.
8. Clean the weld.
9. Apply paint to weld bead as needed.
10. Reinstall 130-8130 Aftercooler Core Assembly to the 123-3855 Housing using a 127-8177 Gasket.Assemble gasket with 'FRONT' marking towards the front of the engine. Apply 154-9731 Thread Locking Compound to the bolts.
11. Reinstall the 123-3855 Cover to the 130-8130 Aftercooler Core Assembly using a 127-8177 Gasket with 'FRONT' marking towards the front of the engine. Apply 154-9731 Thread Locking Compound to the bolts.
12. Fill the aftercooler/oil cooler circuit with coolant.
13. Operate engine to verify air leak has stopped.
Illustration
Service Claim Allowances
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.