PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE UPPER ATAAC TUBING ON CERTAIN 3516C XQ2000 POWER MODULES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE UPPER ATAAC TUBING ON CERTAIN 3516C XQ2000 POWER MODULES

Usage:

REBE7517-02

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01Dec2011

(Revised 19Sep2012)

U-532

A-438

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE UPPER ATAAC TUBING ON CERTAIN 3516C XQ2000 POWER MODULES
1071 1353		PI31955

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31955" 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 "PI31955" as the Part Number, "7751" as the Group Number, "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 01Dec2011 (Revised 23Apr2012) Service Letter. Changes have been made to the Affected Product, Action Required, and Rework Procedure.

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COMPLETION DATE	TERMINATION DATE
30Jun2012	31Dec2012

PROBLEM

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The existing Air-To-Air Aftercooler (ATAAC) core can crack around the upper nozzles on certain 3516C XQ2000 Power Modules. If the existing ATAAC core fails it will cause reduced engine performance and in some situations require replacement of the radiator.

AFFECTED PRODUCT

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Model

Identification Number

PM3516

KEN00100-00104, 106-139, 141-157, 159-165, 167-173, 175-181, 183-189, 191-224, 226-227, 231-232

NAM00100-00101, 103, 105-115, 117-122, 124-130, 132-142, 144-145, 147-153, 156-158, 162-164, 166, 170-171, 173-174, 178-180, 182-185, 187, 189-190, 195-196, 198-203, 206-215, 219-224, 230, 232-234, 237, 239, 242-248, 250-259, 261-262, 265-266, 268-273, 275-285, 288-291, 293, 296-298, 300-302, 304, 309, 314, 324-326

PARTS NEEDED

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Qty	Part Number	Description
4	1S4305	SPACER
16	2K4973	LOCKNUT
8	3P0648	SEAL-O RING
8	4L9337	BOLT
1	4W1211	STRIP
2	5P1075	WASHER-HARD
8	5P1076	WASHER-HARD
8	5P2566	BOLT
8	5S7383	BOLT
4	6V5729	LOCKNUT
8	6V8182	NUT-FULL
8	6V8188	NUT-FULL
10	6V8801	NUT
4	7X0311	BOLT
8	7X0370	BOLT
16	7X0582	WASHER-HARD
1	8C1215	BOLT-U
8	8T2501	BOLT
8	8T4223	WASHER-HARD
48	8T4896	WASHER-HARD
8	8T5360	WASHER-HARD
8	1356261	CLAMP-T'BOLT
8	2338484	CLAMP-T'BOLT
2	2478545	GASKET
1	2726462	GASKET
2	2733538	HOSE-HUMP
2	2834988	HOSE AS-HUMP
1	3184305	SPACER
1	3647460	BRACKET
1	3647461	TUBE AS
1	3716285	TUBE AS
1	3716286	TUBE AS
1	3716287	SPACER
1	3716293	BRACKET
8	3718153	CLAMP AS
8	3722626	CLAMP AS
2	3723272	CLAMP AS
2	3723273	CLAMP AS
4	3732024	STRAP
4	3732025	STRAP
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 43% 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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WARNING: Injury can occur to personnel if the procedure is done improperly.

Areas of improvement need to be addressed in order to minimize stress caused by misalignment and vibration. These include replacing the upper tube assembly that has been redesigned with modified tubing and support structure, and replacing the hardware around the pipes leading to the lower radiator nozzles. The Rework Procedure includes the following two sections:

1. DISASSEMBLY OF THE UPPER TUBE ASSEMBLY AND HARDWARE REMOVAL FROM THE 6 INCH TUBE

2. ASSEMBLY AND INSTALLATION OF THE 8 INCH MODIFIED UPPER TUBE ASSEMBLY AND HARDWARE FOR THE 6 INCH TUBE

WARNING: The power module must be isolated electrically before and while the rework is preformed. Follow the proper lockout tagout procedures to protect against the unexpected energization or start up of the power module. Failure to follow these warnings could result in injury to personnel during service.

Refer to the attached Rework Procedure to determine the proper tools and equipment required to safely perform the rework.

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OWNER NOTIFICATION

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

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 8.0-hour job

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PARTS DISPOSITION

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

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

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE UPPER ATAAC TUBING ON CERTAIN 3516C XQ2000 POWER MODULES

MODELS INVOLVED - 3516C XQ2000 Power Modules

Dear Caterpillar Product Owner:

The ATAAC radiator tubes need to be replaced on the products listed below. The existing radiator core can develop cracks which in some situations could cause reduced engine performance. 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 01Dec2011 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 01Dec2011 Service Letter

Rework Procedure

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1. DISASSEMBLY OF THE UPPER TUBE ASSEMBLY AND HARDWARE REMOVAL FROM THE 6 INCH TUBE

I. Remove Upper Tube Assembly

Disconnect the tube from the rubber expansion joint.

NOTE: A step ladder is required for sufficient access.

Remove
QTY 8 6V-8182 NUT-FULL
QTY 16 7X-0582 WASHER-HARD
QTY 8 7X-0369 BOLT

NOTE: Leave a bolt in place to prevent the spacer ring from falling out.

Image1.1.1

Disconnect the tube from engine inlet manifold and remove the old gasket. Refer to Image1.2.1.

Remove
QTY 8 6V-8801 NUT
QTY 8 5S-7383 BOLT
QTY 16 8T-4896 WASHER
QTY 1 272-6462 GASKET

Image1.2.1

Remove the upper tube with brackets and U-bolt attached leaving the rubber expansion joint attached to the radiator outlet. Refer to Image1.3.1.

Remove
QTY 4 8T-4223 WASHER
QTY 4 6V-8188 NUT
QTY 4 5P-1076 WASHER
QTY 4 5P-2566 BOLT
QTY 1 318-4305 SPACER

Image1.3.1

Remove the spacers and rubber expansion joint from the radiator. Refer to Image1.4.1.

Remove
QTY 2 318-4305 SPACER
QTY 1 282-6664 BELLOW
QTY 8 6V-8182 NUT-FULL
QTY 8 7X-0370 BOLT
QTY 16 7X-0582 WASHER
QTY 1 318-4305 SPACER

Image1.4.1

II. Remove Lower and Upper Tube Hardware on Both LH and RH Sides

Remove pipe clips and brackets from both sides.

Remove
(1)
QTY 4 293-9809 CLIP
QTY 4 293-9810 CLIP
QTY 16 112-8989 SPACER
QTY 8 6V-8801 NUT
QTY 8 8T-2501 BOLT
QTY 8 8T-4896 WASHER
QTY 8 5P-1075 WASHER

(2)
QTY 1 331-0223 BRACKET
QTY 4 7X-0515 WASHER
QTY 4 7X-2553 BOLT

(3)
QTY 1 331-0224 BRACKET
QTY 4 7X-0515 WASHER
QTY 4 7X-2553 BOLT

NOTE: Removal of the hardware is performed in the power module without removing the tubing from the engine. Image1.5.1 shows the removed tubing from the power module for clarity.

Image1.5.1

Remove the hardware from both sides. Refer to Image1.6.1.

Remove
QTY 8 282-6679 CLAMP
QTY 4 282-6680 STRAP
QTY 8 5P-2566 BOLT
QTY 8 6V-8188 NUT
QTY 16 8T-4223 WASHER
QTY 2 273-3538 HOSE-HUMP
QTY 8 135-6261 CLAMP

Image1.6.1

Remove the hardware from both sides. Refer to Image1.7.1.

Remove
QTY 2 294-0521 CLAMP
QTY 2 294-0522 CLAMP
QTY 4 7X-0311 BOLT
QTY 4 3P-0648 SEAL
QTY 8 8T-5360 WASHER
QTY 8 1S-4305 WASHER
QTY 4 7X-0447 NUT

Image1.7.1

2. ASSEMBLY AND INSTALLATION OF THE 8 INCH MODIFIED UPPER TUBE ASSEMBLY AND HARDWARE FOR THE 6 INCH TUBE

I. Subassemble and Install Upper Tube Assembly

With the 364-7461 Tube Assembly, mark a centerline between two bolt holes as shown in Image1.8.1.

Fully insert 283-4988 Hump Hose onto the tube and install two 233-8484 T-bolt Hose Clamps that are oriented 180 degrees apart.

Parts Required
QTY 1 364-7461 TUBE AS
QTY 1 283-4988 HOSE-HUMP
QTY 2 233-8484 CLAMP

Image1.8.1

With the 371-6286 Tube mark, a centerline at the mitered weld joints as shown in Image1.9.1. Install two 233-8484 T-bolt Hose Clamps that are oriented 180 degrees apart and insert the tube into the hump hose with the marks aligned.

Parts Required
QTY 2 233-8484 CLAMP

Image1.9.1

Install 283-4988 Hump Hose and two 233-8484 T-bolt Hose Clamps that are oriented 180 degrees apart.

Parts Required
QTY 1 283-4988 HOSE-HUMP
QTY 2 233-8484 CLAMP

Image1.10.1

With the 371-6285 Tube Assembly, mark a centerline between two bolt holes. Install two 233-8484 T-bolt Hose Clamps that are oriented 180 degrees apart and insert the tube assembly into hump hose with marks aligned.

Parts Required
QTY 1 371-6285 TUBE AS
QTY 2 233-8484 CLAMP

Image1.11.1

Use 5H-2471 Adhesive or standard rubber cement to join a 247-8545 Gasket, the 318-4305 Spacer, and another 247-8545 Gasket, as shown in Image1.12.1. Insert two 7X-0370 bolts into radiator outlet flange and attach gasket assembly. Place the 272-6462 Gasket on the engine inlet manifold. Refer to Image1.12.2

Parts Required

QTY 2 247-8545 GASKET
QTY 1 318-4305 SPACER
QTY 1 272-6462 GASKET

Image1.12.1

Image1.12.2

Install the upper tube assembly. Adjust the tubes as necessary to properly align the assembly.

Parts Required
(1)
QTY 8 6V-8182 NUT
QTY 16 7X-0582 WASHER
QTY 8 7X-0370 BOLT

(2)
QTY 8 5S-7383 BOLT
QTY 16 8T-4896 WASHER
QTY 8 6V-8801 NUT

Image1.13.1

Install the clamps and the straps at the top and bottom of the upper tube assembly.

Parts Required
(1)
QTY 8 8T-2501 BOLT
QTY 8 2K-4973 LOCKNUT
QTY 16 8T-4896 BOLT

(2)
QTY 4 373-2024 STRAP

(3)
QTY 8 371-8153 CLAMP

Image1.14.1

For each pair of clamps, tighten the bolts to 47 Nm on one side so that both tabs are in contact. On the other side, tighten the bolts to 15 Nm then turn an additional 180 degrees leaving a gap between the tabs as shown in Image1.15.1.

Image1.15.1

Install the upper pipe support brackets and hardware. Tighten the U-bolt before the four bolts on the brackets.

Parts Required
(1)
QTY 1 371-6293 BRACKET

(2)
QTY 4 5P-2566 BOLT
QTY 4 5P-1076 WASHER
QTY 4 8T-4223 WASHER
QTY 4 6V-8188 NUT

(3)
QTY 1 364-7460 BRACKET

(4)
QTY 4 5P-2566 BOLT
QTY 4 5P-1076 WASHER
QTY 4 8T-4223 WASHER
QTY 4 6V-8188 NUT

(5)
QTY 1 8C-1215 U-BOLT
QTY 2 6V-8801 NUT
QTY 2 5P-1075 WASHER

(6)
QTY 1 4W-1211 STRIP
QTY 1 371-6287 SPACER

Image1.16.1

II. Install 6 inch tube hardware

Install new hardware for the ATAAC tubes on both sides of the engine. For each pair of clamps on the lower connection of the tubes (5) and (6), tighten the bolts to 47 Nm on one side so that both tabs are in contact. On the other side tighten the bolts to 20 Nm then turn the bolt an additional 180 degrees leaving a gap between the tabs.

Parts Required
(1)
QTY 2 372-3272 CLAMP AS

(2)
QTY 4 7X-0311 BOLT
QTY 4 1S-4305 WASHER
QTY 8 3P-0648 SEAL
QTY 4 6V-5729 LOCKNUT
QTY 8 8T-5360 WASHER

(3)
QTY 2 372-3273 CLAMP

(4)
QTY 8 135-6261 CLAMP
QTY 2 273-3538 HOSE-HUMP

(5)
QTY 8 372-2626 CLAMP AS

(6)
QTY 8 4L-9337 BOLT
QTY 8 2K-4973 LOCKNUT
QTY 16 8T-4896 WASHER

(7)
QTY 4 373-2025 STRAP