PRODUCT IMPROVEMENT PROGRAM FOR REPAIRING THE RADIATOR DUCT SEAL ASSEMBLY ON CERTAIN 3412C ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPAIRING THE RADIATOR DUCT SEAL ASSEMBLY ON CERTAIN 3412C ENGINES

Usage:

SEBE8039-04

July 1, 2002
(Revised December 2002)
U-146
A-108

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REPAIRING THE RADIATOR DUCT SEAL ASSEMBLY ON CERTAIN 3412C ENGINES
7236		PI10125

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI10125" as the Part number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI10125" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

NOTE: This Revised Service Letter replaces the July 1, 2002 (Revised September 2002) Service Letter. Changes have been made to the Affected Product.

PROBLEM

The radiator seal on the top, bottom and both sides may be missing. The duct outlet on front of enclosure is missing drain holes for proper dispersal of moisture. Major system downtime, failures and potential personal injury or death from electrical shock may result by not performing this program.

AFFECTED PRODUCT

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Group 1
Model	Identification Number
3412C PU	9EP179, 221, 222, 224, 228-234, 239, 240, 242, 254, 256-260, 263, 285, 298, 308, 309, 313, 315, 316, 322, 323, 326-328, 334, 335, 357, 358, 332, 360, 361, 373, 374, 376, 379, 386, 410, 412, 417, 418, 423, 430, 435, 436, 440, 451, 455, 460, 465, 467, 469, 473, 474, 486, 488-493, 495-498, 506-509, 512, 516, 517, 522, 523, 527-531, 536, 538-540, 542, 544, 551-553, 555, 556, 558-563, 566, 568, 569, 572-574, 576, 578, 579, 582-584, 586, 590, 591, 595, 596, 598, 599, 602, 608, 611, 619, 622, 624, 625, 631, 632, 645, 652, 654, 656, 660, 664, 677, 679, 682, 692, 693, 699, 700, 710, 722, 723, 726, 728, 730, 733, 734, 745, 754, 755, 757, 768, 771, 772, 779, 785, 786, 788, 790, 793, 801, 804-806, 809-811, 814, 828, 829, 831, 844, 848, 849, 852, 855, 860, 861, 869-871, 878, 888, 893, 898, 902, 929, 955, 971, 1049, 1148, 1209, 1230, 1260, 1311, 1395, 1406, 1416, 1455, 1462, 1463, 1481, 1485, 1488, 1499, 1504-1506, 1510, 1511, 1515, 1517, 1519, 1522-1524, 1527, 1537, 1539-1541, 1548, 1552-1555, 1557-1560, 1606, 1658, 1686, 1689, 1700, 1705
3412C	BCW128, 155, 157, 158, 162, 168, 169, 172-174, 177, 180, 184, 186, 192, 196-198, 200, 201, 203-205, 208, 214, 217, 218, 226, 231, 242, 243, 247-249, 251, 253, 258, 261, 263, 264, 280, 282, 284-286, 296, 299, 305, 356, 361, 365, 395, 463, 464, 466, 467, 469, 479, 480
Group 2
Model	Identification Number
3412C PU	9EP822, 882, 883, 886, 897, 911, 917, 920, 923, 930, 964, 968, 973-975, 991, 992, 995, 1011-1013, 1027-1030, 1046, 1048, 1064, 1069-1072, 1083-1085, 1093, 1115-1119, 1122, 1125, 1127, 1143, 1150, 1158, 1246, 1275, 1310, 1313, 1317, 1318, 1321-1326, 1328, 1349, 1372, 1375, 1376, 1382, 1384, 1387-1389, 1396, 1407, 1414, 1421, 1426-1428, 1439, 1440, 1443, 1445, 1453, 1454, 1459, 1461, 1471, 1484, 1487, 1489, 1491-1493, 1584, 1588-1590, 1595, 1615, 1619, 1621, 1623, 1626, 1631, 1637, 1640, 1642, 1644, 1646, 1649-1651
3412C	BCW306, 313, 314, 324, 327, 341, 348, 350, 353-355, 362-364, 366-371, 375, 376, 379, 380, 383-385, 391-394, 402, 405-408, 412, 423, 425-427, 429, 430, 433, 435, 440, 441, 445-447, 451, 457-459, 421
Group 3
Model	Identification Number
3412C PU	9EP892, 925, 1047, 1063, 1327, 1358, 1422, 1441
3412C	BCW372, 399-401, 410, 411, 436, 443, 444
Group 4
Model	Identification Number
3412C PU	9EP226, 235, 236, 238, 241, 249, 264, 269, 289, 290, 305, 312, 314, 345, 387, 401, 405, 445, 456, 499, 502, 503, 532, 543, 546, 549-550, 557, 564-565, 575, 580, 587, 588, 592, 594, 600, 601, 612, 621, 623, 688, 742, 746, 767, 774, 791, 794, 815, 837, 843, 867, 874, 924, 1091, 1140, 1147, 1189, 1530, 1536, 1580, 1620, 1698
3412C	BCW189, 219, 227, 233, 239, 360, 381, 450

PARTS NEEDED

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Group 1 & 4
Quantity	Part Number	Description
5	1428194	Rivet
1	1190781	Adhesive
1	2010415	Angle
6 feet	1435072/">1435072*	Seal-Rubber

* 1435072 comes in 25 meter lengths.

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Group 2 & 3
Quantity	Part Number	Description
5	1428194	Rivet
1	1190781	Adhesive
1	2010415	Angle
19.5 feet	1435072/">1435072*	Seal-Rubber

* 1435072 comes in 25 meter lengths.

ACTION REQUIRED

See the attached Rework Procedure.

OWNER NOTIFICATION

U.S. and Canadian owners will receive the attached Owner Notification.

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
0-36 months	100%	*	0	0	0	0
NOTE: * Group 1 ? This is a 5.5-hr job. Group 2 ? This is a 6.5-hr job. Group 3 ? This is a 3.0-hr job. Group 4 ? This is a 2.0-hr job.

PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach. (1-Owner Notification)
(2-Rework Procedure)

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - REPAIRING THE RADIATOR DUCT SEAL ASSEMBLY

MODELS INVOLVED - ON CERTAIN 3412C ENGINES

Dear Caterpillar Product Owner:

The radiator duct seal assembly needs to be repaired on the products listed below. Major system downtime, failures and potential personal injury or death caused by electrical shock, may result if this action is not taken. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated July 1, 2002 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to July 1, 2002 Service Letter

Rework Procedure

Turn off all supply power, prevent the engine from starting and lock out the equipment before working on or inside equipment.

This equipment must be serviced by qualified Caterpillar technicians only.

Always use properly rated voltage sensing device to confirm power is off.

Replace all devices, doors and covers before turning power on to this equipment.

Make sure the tecnician uses the heat detection device in order to ensure that the muffler and radiator are cool enough to work around.

Observe all safety procedures as indicated in Caterpillar manuals.

It is necessary to take the front section around the muffler off on units from groups 1 and 2, in order to modify the 1808121 bottom duct assembly and also the 1435072 seal. In order to take off the front section around the muffler, remove the four bolts that attach the front section to the main body of the enclosure. Remove the other four bolts that attach the front section to the base extension that holds the muffler.
After removing the bolts, the front section can be lifted off (the front section weighs approximately 410 pounds and can be disassembled, if needed. The heaviest panel weighs about 80 pounds). This will allow access to the area of the duct and the seal.
Group 1 and Group 2 need to perform the following procedures. Group 3 and Group 4 need to proceed to step number 5. Drill a total of five 7/16 inch holes in the duct assembly. Measure 10 and 3/4 inches from either side and place each hole 10 and 3/4 inches apart from the last hole drilled. Drill the holes 3/8 of an inch from the edge of the duct. The edge of the duct assembly is next to the main body of the enclosure.
Apply touch up paint on the drilled holes.
Add the 2010415 angle to the bottom of the main enclosure. Drill five holes in (1679112) so that the 2010415 angle can be riveted (1428194) to the 1679112 enclosure piece. Make sure that the angle is placed so that the 1435072 seal can be placed on the 2010415 angle. Apply 1190781 caulk to the duct side of the angle in order to help prevent water ingress into the enclosure.
Inspect the radiator opening to see if the 1435072 seal is present or missing from the top, bottom and both sides of the radiator opening. If the 1435072 seal is present go to step 7 and reassemble the enclosure.
Cut the 1435072 seal to fit the sides of the radiator opening that is missing the 1435072 seal. Make sure that you miter or notch the top, bottom, left and right side 1435072 seals, so that they form a tight seal around the radiator opening and then go to step number 8.
After the duct assembly is corrected and the seal is installed, reattach the front section to the main body of the enclosure.
Make sure that all bolts are tightened to the proper specification.
Caulk with 1190781 caulking compound on the outside seam between the front section of the enclosure and the main body of the enclosure in order to make a water tight seal.