PRODUCT SUPPORT PROGRAM FOR REWORKING THE CHARGE AIR COOLER ASSEMBLY (CAC) ON CERTAIN C27 AND C32 GENERATOR SETS
Usage:
REBE6208-04
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| 13Aug2010 |
| (Revised 01Dec2010) |
U-321
A-251
D-275
O-279
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| Before/After | PRODUCT SUPPORT PROGRAM FOR REWORKING THE CHARGE AIR COOLER ASSEMBLY (CAC) ON CERTAIN C27 AND C32 GENERATOR SETS |
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| 1353 | PS43142 |
|
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| NOTE: | This Program must 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 "PS43142" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "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 13Aug2010 (Revised 25Oct2010) Service Letter. Changes have been made to various sections to change from dealer fabricated parts to production parts for the shims and plates. |
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TERMINATION DATE |
| 31Aug2012 |
PROBLEM
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| In some cases, certain C32 and C27 gensets may experience low power that may be caused by a leaking Charge Air Cooler (CAC). In some cases, holes may develop in the CAC due to rubbing on the radiator lower tank flange. |
AFFECTED PRODUCT
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| Model | Identification Number |
| C27 | DWB00102-00404, 406-659, 663, 665-681, 685-701, 704-710, 714, 793 |
| C32 | JSJ00100-00204, 206-207, 209-210, 212-238, 240-263, 266-271, 273-277, 279-284, 289-290, 294, 297, 299 K7C00101, 103-137, 139-265 SXC00300-00303, 305-593, 595-621, 627-658, 660-661, 665-676, 678-682, 684-775, 777-827, 829-855, 857-863, 865-874, 876-888, 890-899, 901-913, 915, 919-920, 922-934, 936-940, 942-945, 947-953, 956-961, 963, 965-977, 979-981, 983-991, 993-998, 1001-1007, 1009-1123, 1126-1185, 1187-1195, 1197-1295, 1297-1299, 1301-1402, 1406-1413, 1416-1434, 1436-1442, 1444-1447, 1449-1687, 1690-1691, 1693-1799, 1801-1870, 1872, 1874-1886, 1888-1891, 1893-1913, 1916, 1918-2051, 2054-2065, 2067-2075, 2077-2079, 2081-2089, 2092-2103, 2105-2160, 2164-2291, 2293-2775, 2777-2962, 2964-2967, 2969-2987, 2989-2994, 2996-3121, 3123-3124, 3126-3174, 3176-3194, 3196, 3198, 3200-3228, 3230-3266, 3268-3351, 3353-3378, 3380-3413, 3424-3426, 3428-3462, 3464-3481, 3483-3489, 3491-3517, 3525-3528, 3531-3552, 3556-3559, 3561-3589, 3591, 3594-3627, 3629-3667, 3669-3675, 3677-3682, 3685-3691, 3693, 3696, 3698-3700, 3703, 3705, 3708, 3711-3716, 3720-3735, 3741-3814, 3816-3892, 3896-3898, 3906-3907, 3910, 3914, 3917-3920, 3925, 3928-3931, 3934-4098, 4102-4108, 4110-4114, 4116, 4121-4125, 4130-4264, 4266-4273, 4276-4292, 4294-4299, 4303-4307, 4309-4334, 4337-4345, 4349-4410, 4412, 4414-4457, 4459-4497, 4499-4556, 4558-4687, 4690-4758, 4763-4767, 4770-4773, 4780-4803, 4807-4979, 4981-5134, 5136-5172, 5174-5232, 5236-5255, 5257-5258, 5260-5287, 5289-5292, 5294-5326, 5328-5335, 5342 TLD00455, 550-551 |
PARTS NEEDED
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Qty |
Part Number | Description |
| 14 | 8T4186 | BOLT |
| 4 | 2759423 | VIBRATION MOUNT (AFTER FAILURE ONLY) |
| 8 | 2819135 | WASHER-SHOULDER (AFTER FAILURE ONLY) |
| 8 | 3612904 | WASHER-SHOULDER (AFTER FAILURE ONLY) |
| 2 | 3616868 | SHIM |
| 2 | 3616870 | SHIM |
| 1 | 3621075 | PLATE AS |
| 1 | 3621076 | PLATE AS |
| In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 15% 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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| Inspect the Charge Air Cooler (CAC) for damage to determine the next steps and required repairs. - If the CAC IS NOT damaged, install the plates and shims. In some cases, painting of the shims and plate assemblies may be required. Paint to match radiator assembly color (gloss black). - If the CAC IS damaged, repair the CAC, install the plates and shims, and install the vibration mounts and associated hardware. In some cases, painting of the shims and plate assemblies may be required. Paint to match radiator assembly color (gloss black). Attach pictures of any damaged components (CAC, mounts, etc) to claim. This procedure requires 2 people. NOTE: Only repairs made after failure require the installation of the 275-9423 Vibration Mounts and the associated washers. Do not order the vibration mount or washers for repairs made Before Failure of the CAC. Historical failure rate requiring installation of vibration mounts on the Affected Product is approximately 5 percent. Before inspection/disassembly, locate a qualified radiator repair shop capable of welding holes using the appropriate process for aluminum base material (wall thickness is 0.508 mm). For details of CAC inspection and rework process refer to the attached Rework procedure. |
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SERVICE CLAIM ALLOWANCES
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0-60 mo |
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| NOTE: This is a 2.0-hour job | ||||||
| Before Failure: This is a 2.0 hour job. - In some cases, painting of the shims and plate assemblies may be required. Paint to match radiator assembly color (gloss black). Allowance for painting of shims and plates not to exceed $30 US. After Failure: - An additional 14 hours will be allowed for repair being performed after failure that requires the installation of Vibration Mounts. - In some cases, painting of the shims and plate assemblies may be required. Paint to match radiator assembly color (gloss black). Allowance for painting of shims and plates not to exceed $30 US. - Allowance for repair of charge air cooler (CAC) assembly not to exceed $1000 US. |
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PARTS DISPOSITION
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| Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. |
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| 1. CAC Inspection: Remove radiator to frame M10 bolts (1). 4 total ? 2 each side. |
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| Image1.1.1 |
| 2. CAC Inspection: NOTE: Remove bolts one at a time and install new bolts leaving nuts engaged but not tightened (3). Remove radiator to charge air cooler (CAC) M10 mounting bolts (14 total - 7 bolts each side) and replace with 8T4186 M10-1.5X40 Bolts (2). This allows radiator to CAC separation for inspection and prevents radiator from falling. If spacers have been installed, remove for inspection and set aside for re-assembly later. |
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| Image1.2.1 |
| 3. CAC Inspection: Inspect lower portion of CAC using mirror and bright flashlight. Use 36 inch minimum mirror handle length. Maintain separation using crow bar (or wedge). |
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| Image1.3.1 |
| 4. CAC Inspection : Inspect lower portion of CAC using mirror and flashlight. Use CAC header as a rest/guide for edge of mirror. |
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| Image1.4.1 |
| 5. CAC Inspection: If no damage is found, proceed to step 37. If damage if found, proceed to step 6. |
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| Image1.5.1 |
| 6. Radiator/CAC Disassembly: Drain coolant and store for reuse. Disconnect all hoses (upper and lower) at radiator interface (4 and 5). Re-torque value is 15 +/- 1 N-m. |
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| Image1.6.1 |
| 7. Radiator/CAC Disassembly: Secure radiator to crane to prevent tipping/falling during bolt removal and disassembly. Approximate weight of the radiator is 600 lbs. |
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| Image1.7.1 |
| 8. Radiator/CAC Disassembly: Remove radiator to CAC M10 bolts (6). 14 total - 7 bolts each side. Re-torque value is 55 +/- 10 N-m. |
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| Image1.8.1 |
| 9. Radiator/CAC Disassembly: Remove radiator using crane and set aside. Approximate weight of the radiator is 600 lbs. |
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| Image1.9.1 |
| 10. Radiator/CAC Disassembly: Secure charge air cooler to crane to prevent tipping/falling during bolt removal and disassembly. Approximate weight of the charge air cooler is 600 lbs. |
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| Image1.10.1 |
| 11. Radiator/CAC Disassembly: Remove fan guard. Remove 3/8 - 16 bolts connecting fan guard halves (7). 4 bolts - 2 each side. Re-torque value is 47 +/- 9 N-m. Remove fan guard (8). 8 bolts total. Re-torque value is 55 +/- 10 N-m |
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| Image1.11.1 |
| 12. Radiator/CAC Disassembly: Disconnect upper/lower pipes (9) and upper brackets (10) at the charge air cooler interface. Re-torque value for hoses (9) is 15 +/- 1 N-m. Re-torque value for CAC bracket (10) is 55 +/- 10 N-m. |
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| Image1.12.1 |
| 13. Radiator/CAC Disassembly: Disconnect hoses at oil cooler (11). Re-torque value is 40 +/- 3 N-m. |
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| Image1.13.1 |
| 14. Radiator/CAC Disassembly: Remove charge air cooler to frame bolts (12). Quantity 4 ? 2 each side. Re-torque value is 55 +/- 10 N-m. |
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| Image1.14.1 |
| 15. Radiator/CAC Disassembly: Remove support bracket. Remove 3/8? ? 16 bolts (13). Quantity 4 ? 2 each side. Re-torque value is 47 +/- 9 N-m. |
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| Image1.15.1 |
| 16. Radiator/CAC Disassembly: Remove charge air cooler and place shroud side up, resting on wooden blocks. Approximate weight of the charge air cooler is 600 lbs. Cover all inlets to prevent debris from entering the CAC (14). |
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| Image1.16.1 |
| 17. Radiator/CAC Disassembly: Remove remaining M10 shroud bolts (quantity 6 each side) and place shroud aside. Re-torque value is 55 +/- 10 N-m. Verify fan tip to shroud clearance is at least 1/4" in all locations before final re-assembly. |
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| Image1.17.1 |
| 18. Radiator/CAC Disassembly: Remove center brace bolts (15). Quantity 4 - 2 each end. Re-torque value on bolts is 38 N-m +/- 2 N-m. |
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| Image1.18.1 |
| 19. Radiator/CAC Disassembly: Remove qty 4 upper (16) and qty 4 lower (17) mounts. Re-torque value is 48 +/- 7 N-m. |
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| Image1.19.1 |
| 20. Radiator/CAC Disassembly: Remove lower frame mounting bracket bolts (18). Quantity 6 total ? 3 each side. Lift from assembly (2 man job) and set aside. Re-torque value on bolts is 38 N-m +/- 2 N-m. |
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| Image1.20.1 |
| 21. Radiator/CAC Disassembly: Remove brackets attached to CAC (19). Quantity 4 total ? 2 per CAC. Re-torque value is 66 +/- 3 N-m. |
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| Image1.21.1 |
| 22. Radiator/CAC Disassembly: Remove upper frame mounting bracket bolts (20). Quantity 6 total ? 3 each side. After bolts are removed from each side, the side frame will be free to remove. Remove each of the sides frames and set aside (2 man job). Remove upper frame (2 man job). CAC is now ready for repair. Re-torque is 38 +/- 2 N-m |
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| Image1.22.1 |
| 23. CAC Repair: CAC is to be repaired by a qualified radiator repair shop. Clean damaged areas with aluminum wire brush. Thoroughly clean damaged areas with solvent and allow to dry. Weld holes using appropriate process for aluminum base material (wall thickness is 0.508 mm). Check for leaks. Be very careful to not introduce debris into the CAC. Internally flush (clean) CAC before installation on the generator set. |
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| Image1.23.1 |
| 24. Radiator/CAC Re-assembly: Lay CAC flat (resting on wooden supports) using same orientation as used for disassembly. Insert vibration mounting bolts and washer in CAC brackets (21). Quantity 2 per bracket. Install CAC bracket to CAC(22). Tighten to a torque of 66 +/- 3 N-m. |
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| Image1.24.1 |
| 25. Radiator/CAC Re-assembly: Assemble lower frame mounting bracket. Use new 275-9423 Rubber Vibration Mounts. Install short half of rubber vibration mount over bolts and install 361-2904 Steel Washer oriented as shown (4 locations). Orient the small mount half with the outside diameter chamfer oriented away from the steel washer. Place lower frame mounting bracket over bolts as shown (2 man job). Refer to Image1.25.1 for complete mount assembly. |
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| Image1.25.1 |
| 26. Radiator/CAC Re-assembly: Assemble lower frame mounting bracket. Important: Align steel washer to allow shoulder of washer to fit within mounting hole. |
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| Image1.26.1 |
| 27. Radiator/CAC Re-assembly: Assemble lower frame mounting bracket. Install steel washer over longer half of rubber vibrating mount (4 total) as shown. Install assembly onto bolt, aligning shoulder of steel washer to mounting bracket hole (4 locations). Install flat snubber washer and nut (4 assemblies). |
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| Image1.27.1 |
| 28. Radiator/CAC Re-assembly: Assemble lower frame mounting bracket. Important: before final torque, verify proper alignment of washers to mounting hole. Tighten to a torque of 48 +/- 7 N-m. |
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| Image1.28.1 |
| 29. Radiator/CAC Re-assembly: Place side frames to lower frame. Install mounting bracket bolts (23). 6 total ? 3 each side. Tighten to a torque of 38 +/- 2 N-m. |
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| Image1.29.1 |
| 30. Radiator/CAC Re-assembly: Assemble upper frame to side frames. Insert mounting bracket bolts (24). Quantity 6 total ? 3 each side. Tighten bolts to a torque of 38 +/- 2 N-m. |
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| Image1.30.1 |
| 31. Radiator/CAC Re-assembly: Install center brace and bolts (qty 2 each end). Tighten bolts to a torque of 38 +/- 2 N-m. |
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| Image1.31.1 |
| 32. Radiator/CAC Re-assembly: Assemble shroud to frame. Insert previously removed M10 shroud bolts (quantity 6 each side). Tighten to a torque of 55 +/- 10 N-m. |
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| Image1.32.1 |
| 33. Radiator/CAC Re-assembly: Assemble upper vibration isolators. Inspect original rubber vibration mounts for damage. If not damaged, reuse. Place short half of rubber vibration mount and new nylon washer behind mounting brackets (4 locations). Orient the small mount half with the outside diameter chamfer oriented away from the nylon washer. |
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| Image1.33.1 |
| 34. Radiator/CAC Re-assembly: Assemble upper vibration isolators. Install new 281-9135 Nylon Washer, longer mount,and snubber washer over bolt as shown. Install assembly into CAC making sure nylon washer shoulder fits into mounting slot. Tighten to a torque of 48 +/- 7 N-m. |
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| Image1.34.1 |
| 35. Radiator/CAC Re-assembly: Assemble CAC to genset (refer to previous disassembly steps 10 through 16). Approximate weight of the charge air cooler is 600 lbs. Remove CAC inlet/outlet debris covers. Re-connect CAC assembly to crane. Place CAC to genset frame and align mounting holes. Verify fan tip to shroud clearance is at least 1/4" in all locations before final re-assembly. Install CAC to frame M10 bolts (quantity 4 ? 2 each side) and tighten to a torque of to 55 +/- 10 N-m. Install 3/8 ? 16 bolts for support bracket (quantity 4 - 2 each side) and tighten to a torque of 47 +/- 9 N-m. Re-connect hoses at oil cooler and tighten to a torque of 40 +/- 3 N-m. Re-connect all hoses/lines/brackets (upper and lower) at the charge air cooler interface and re-tighten. Tighten CAC tube bracket M10 bolts to a torque of 55 +/- 10 N-m. Torque CAC tube clamps to 15 +/- 1 N-m. Using M10 bolts, install fan guard halves to shroud and torque to 55 +/- 10 N-m. Install 3/8 ? 16 bolts connecting guard halves (4 bolts - 2 each side) and tighten to a torque of 47 +/- 9 N-m. Verify fan to shroud and guard clearance. |
| 36. Radiator/CAC Re-assembly: Assemble radiator to CAC (refer to previous disassembly steps 6 through 9). Re-connect radiator to crane. Approximate weight of the radiator is 600 lbs. Place radiator to genset frame. Install radiator to CAC bolts with nuts engaged but not tightened. This prevents radiator from falling. |
| 37. Radiator/CAC Re-assembly: Add spacers (Shims: 361-6868 and 361-6870) between radiator and CAC. In some cases, painting of the shims and plate assemblies may be required. Paint to match radiator assembly color (gloss black). Orient spacers such that edge of spacer is even with outer edge of radiator/CAC flange. Install M10 bolts, washers, and nuts to secure radiator to CAC (quantity 14 ? 7 each side). |
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| Image1.37.1 |
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| Image1.37.2 |
| 38. Radiator/CAC Re-assembly: Add lower fail safe spacers (Plate Assemblies: 362-1075 and 362-1076) installing flat side towards radiator tank. Important: Make sure spacer is level. In some cases, painting of the shims and plate assemblies may be required. Paint to match radiator assembly color (gloss black). |
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| Image1.38.1 |
| 39. Radiator/CAC Re-assembly: Level fail safe spacer (may need to push on bottom of spacer). Square spacer end to ends of flanges. Using a flashlight, look into the radiator to CAC gap to visually verify spacer is level along entire length. |
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| Image1.39.1 |
| 40. Radiator/CAC Re-assembly: Re-tighten M10 bolts (26) to a toque of 55 +/- 10 N-m (14 total - 7 bolts each side). |
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| Image1.40.1 |
| 41. Radiator/CAC Re-assembly: Modify radiator base to allow M10 bolt engagement to frame. |
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| Image1.41.1 |
| 42. Radiator/CAC Re-assembly: Install radiator to frame M10 bolts (27). Quantity 4 ? 2 each side. Re-tighten to a torque of 55 +/- 10 N-m. |
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| Image1.42.1 |
| 43. Radiator/CAC Re-assembly: Refill radiator and test unit. |
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