PRODUCT SUPPORT PROGRAM FOR ELIMINATING AIRSIDE COOLANT LEAKS ON CERTAIN G3612 AND G3616 SPARK IGNITED ENGINES

Usage:

SEBE8245-02

January 5, 2003
(Revised July 2003)
U-5
D-90
O-107

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*before or* *after failure*	PRODUCT SUPPORT PROGRAM FOR ELIMINATING AIRSIDE COOLANT LEAKS ON CERTAIN G3612 AND G3616 SPARK IGNITED ENGINES
0003		PS41187

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 "PS41187" 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.

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.

NOTE: This Revised Service Letter replaces the January 5, 2003 (Revised May 2003) Service Letter. Changes have been made to the Problem and Rework Procedure.

NOTE: Mail Codes D and O are out of order since they were added at the May 2003 revision.

TERMINATION DATE

January 31, 2005

PROBLEM

The G3612 and G3616 2-stage aftercooler core assembly (1308130 change level 07 and below) has experienced tube failures that result in coolant leaks into the inlet airstream. This program provides instructions and hardware to rework the core to eliminate airside coolant leaks.

AFFECTED PRODUCT

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Model	Identification Number
G3612	1YG38-40, 48, 66, 67, 70, 96
G3616	4CG26, 41, 45, 46, 50, 52, 62, 63, 65-67, 72, 73, 75, 77, 78, 82-91, 94-96, 121, 125-145, 148, 149, 152-154, 159-165, 174-187, 192, 193, 217-224, 226, 245 BLB174-176, 178, 179

PARTS NEEDED

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Qty	Part Number	Description
4	5R9779	GASKET
1	2W4766	GASKET
1	7W6340	GASKET
2	1278177	GASKET
1	1706504	GASKET-FRONT
1	1706505	GASKET-REAR
4	2322361	PLUG
1	2322362	KIT

ACTION REQUIRED

See the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

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Part smu	Caterpillar		Dealer Suggested		Customer Suggested
Part smu	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
0-10000	100%	50.0	0	0	0	0
10001-20000	75%	40.0	0	0	25%	10.0
20001-30000	50%	30.0	0	0	50%	20.0
30001-40000	25%	20.0	0	0	75%	30.0
NOTE: This is a 50.0?hr job.
NOTE: Some engines may have been updated in the field to the 2-stage aftercooler core design, therefore the above SMU ranges are for the total operating time of the 2-stage aftercooler core assembly from the time of installation. 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. NOTE: This program should not be applied to any 1308130 change level 08 Core Assembly ordered from the parts system. The 1308130-08 core assembly has already been updated to the improved design configuration.

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. Attach. (1-Rework Procedure)

Rework Procedure

NOTE: Thoroughly review these instructions prior to beginning the rework effort. Step 1: Remove aftercooler core in accordance with D&A Manual.

Step 2: Core Repair

Remove the end covers.
If the aftercooler core was previously welded to eliminate intake air leaks between the core sideplates and tube end plates, cut through the weld using a hand grinder.
Prior to removing the side plates from the core, mark the side plate and tube plate so that the parts can be reassembled to the same location.

NOTE: Reinstalling the sideplates in the same location is important in order to properly match the gasket surfaces of the sideplates and tubeplates.

NOTE: Prior to unbolting the sideplates from the stiffening cross-bars and core assembly tubeplates, properly secure the sideplates with lifting eyebolts.

Illustration 1

After properly marking sideplates and tubeplates, remove all 10mm and 12mm bolts that secure sideplates to core assembly and to the cross-bars.
Remove sideplates and top and bottom clamping bars.
Inspect central cross-bars:

If bars are rotated or can be moved with slight hand pressure, drive the bars out using a piece of wood and hammer.

NOTE: Do not remove central cross-bars if they are secured firmly in place and have not rotated.

Removal of all brass sidesheets from core assembly.

Using a propane torch, heat the solder joints while applying a slight pulling pressure to sidesheet until it breaks free from solder joint. Continue this process on all solder joints that appear to be holding the sidesheet in place.

NOTE: Do not attempt to remove solder from core assembly air-fins. The solder material is not detrimental to core performance. Attempting to remove solder material may create loose solder material that can become trapped in air fins and may eventually come loose and enter engine.

Thoroughly clean core assembly to remove loose debris on air fins and any material on gasket surfaces.
Inspection and plugging of worn core assembly water tubes:

If the brass sidesheets have worn through to the tube, inspect the tube for damage. If there appears to be tube contact with the brass side sheet, plug the tube using a tapered brass plug. Drive the 2322361 plug into the tube until it is flush with the tube end.

NOTE: Plug only those tube that appear to have made contact with the brass sidesheets.

NOTE: If more than 14 tube requiring plugging, the aftercore will have to be replaced to maintain cooling system performance.

NOTE: Any new 2-stage core assembly, 1308130 (change level 08 and greater), ordered from the parts system will not require rework per this program. Parts system core assemblies have already been updated to the improved design configuration.

Welding 20x20x20 mm bars to inside of sideplates:

Clean inside face of one sideplate prior to welding bars in place.
Temporarily install all cross-bars to allow proper positioning of the (6) turnstop blocks.

NOTE: If the central bars were not removed, use the one of the upper or lower cross-bars to positions the turnstop blocks.

Refer to the following graphic for more specific details.

Illustration 2

NOTE: The purpose of the bars is to help keep the cross-bars from rotating.

NOTE: After welding turnstop blocks in-place, the cross-bars can be removed. Clean all weld slag from sideplate surfaces.

Reworking cross-bars:

Remove the silicon pads on all cross-bars removed from the core assembly
Clean the silicon pads surfaces on the cross-bars
Install a new silicon pad using a contact adhesive. The silicon pads with the rounded edges are to be used with the central cross-bars.

NOTE: If a central cross-bar was removed, use wood wedges between the core assembly tube sections to allow the cross-bar to be inserted easier.

Install sideplates to core assembly:

Align the matching marks of the sideplate and tubeplate
Apply silicon sealant to last 25mm of 10mm bolts
Loosely install the 10mm and 12mm bolts
Prior to applying final torque to the bolts, properly align the upper and lower core assembly gasket surface using a straighedge and rubber mallet. The end bolts may have to be slightly tightened to keep the sideplate from moving out of place.
Torque the 10mm bolts to 55 +/- 10 Nm and the 12mm bolts to 100 +/- 20 Nm.