PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXPANSION TANK MOUNTING HARDWARE ON CERTAIN PM1360 POWER MODULES Caterpillar


PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXPANSION TANK MOUNTING HARDWARE ON CERTAIN PM1360 POWER MODULES

Usage:

Information for equipment:


COOLING SYSTEM
RADIATOR GP

Radiator - Clean PM3516 Power Modules
Cooling System Supplemental Coolant Additive (SCA) - Test/Add PM3516 Power Modules
Coolant Sample (Level 1) - Obtain PM3516 Power Modules
Coolant Sample (Level 1) - Obtain PM3516 Power Modules
Coolant Level - Check PM3516 Power Modules
Coolant (DEAC) - Change PM3516 Power Modules
Coolant (ELC) - Change PM3516 Power Modules
Coolant Sample (Level 2) - Obtain PM3516 Power Modules

PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXPANSION TANK MOUNTING HARDWARE ON CERTAIN PM1360 POWER MODULES PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXPANSION TANK MOUNTING HARDWARE ON CERTAIN PM1360 POWER MODULES


Radiator Mounting 3500B Engines for Caterpillar Built Power Modules
Radiator Mounting 3500B Engines for Caterpillar Built Power Modules

Testing the Radiator and Cooling System for Leaks 3500B Engines for Caterpillar Built Power Modules


TEBE1844-00

08Aug2014


A-343
O-397

 

Before/After

  
  

PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXPANSION TANK MOUNTING HARDWARE ON CERTAIN PM1360 POWER MODULES

1360
PS44442
NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

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 "PS44442" 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.

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.


TERMINATION DATE

31Aug2016

PROBLEM

The existing expansion tank mounting can fail. If the existing threads of the holes in the overhead sturctural tubing strip the tank can become unsupported.

AFFECTED PRODUCT

Model Identification Number
PM3512  TC800100-00102, 104, 106, 108-114, 116-123, 126-129, 131-132, 134-149, 152-159, 161-165, 168-169, 171, 173, 192-193, 199

PARTS NEEDED

Qty

Part Number Description
4 8T4185 BOLT-HEX HEAD
4 8Y3925 BOSS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 18% 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

Hardware improvements need to be addressed in order to prevent possible failure of supporting the coolant expansion tank. This involves the addition of threaded weld bosses, and bolt replacement.

Refer to the attached Rework Procedure to determine the proper tools and equipment
required to safely perform the rework.
Image1

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
0-15000 hrs,
0-12 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 5.0-hour job



PARTS DISPOSITION

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


Rework Procedure


 
WARNING: Injury can occur to personnel if the rework is done improperly. Personal Protective Equipment (PPE) suitable to the work being performed must be worn when performing the rework.

WARNING: The power module must be isolated electrically before and while the rework is performed. Follow the proper lockout tag out 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.

Ensure that the coolant has reduced to a safe temperature before removing the expansion tank.
Drain the coolant into a container.
Disconnect the hoses and lines to the expansion tank.
Image1.1.1
 
Remove the conduit from the mounting brackets.
Image1.2.1
 
Use a forklift truck to support the expansion tank with extended forks and blocks. Carefully lower the tank.

NOTE: The following instruction outlines a alternative method for supporting the tank if a forklift truck is not available.

Secure two steel angles each around 800mm in length. Drill two holes in each angle at the locations specified in Image1.3.1
Mount 2 steel angles onto the flange of the exhaust silencer with screws to support the expansion tank once the mounting bolts are removed Place suitable blocks of wood (approximately 80x100x400mm) between the angle and the bottom of the expansion tank as shown in Image1.3.2.
Image1.3.1
Image1.3.2
 
Unscrew the 4 M10 bolts at each of the corners of the expansion tank. Remove the bolts, washers, and spacers. Retain the washers for reuse. Push the tank as far as possible to the side exposing the threaded holes overhead.
Image1.4.1
 
To prep for welding remove the paint around the holes to a diameter of around 40mm. Screw a 8T-4185 bolt into a 8Y-3925 threaded boss leaving approximately 5mm sticking out the other end to position the boss in the proper location for welding. Screw the assembly into the threaded hole overhead until the boss is secure and flush against the structural tube. Weld the boss in place. Remove the bolt, clean the weld, and paint all exposed metal.
Repeat the steps for the adjacent hole.
Push the tank to the other side and repeat for the remaining two holes.

Parts Required
4 8T4185 Bolt
4 8Y3925 Boss
Image1.5.1
 
Return the expansion tank to its original position, and install a washer and bolt in each mounting location.
Tighten the bolts with 55+-10 Nm of torque.
Image1.6.1
 
Reconnect the hoses, lines and clamps to the expansion tank. Reinstall the conduit into the mounting brackets. Fill the tank with coolant. Check the connections of the coolant system for leaks. The power module can now be returned to service.
Image1.7.1
 
 

Caterpillar Information System:

PRODUCT SUPPORT PROGRAM FOR REWORKING THE GROUND FAULT PROTECTION ON CERTAIN PM1360 POWER MODULES PRODUCT SUPPORT PROGRAM FOR REWORKING THE GROUND FAULT PROTECTION ON CERTAIN PM1360 POWER MODULES
PRODUCT SUPPORT PROGRAM FOR REPLACING THE AUXILIARY WATER PUMP ON CERTAIN G3508, G3508B, G3516B ENGINES, G3516, G3516B GENERATOR SETS, 3512B, 3512B HD, 3512C, 3516B, 3516B HD GENERATOR SETS, AND PM3516 POWER MODULES PRODUCT SUPPORT PROGRAM FOR REPLACING THE AUXILIARY WATER PUMP ON CERTAIN G3508, G3508B, G3516B ENGINES, G3516, G3516B GENERATOR SETS, 3512B, 3512B HD, 3512C, 3516B, 3516B HD GENERATOR SETS, AND PM3516 POWER MODULES
PRODUCT SUPPORT PROGRAM FOR REPLACING TURBO SUPPORT STRUCTURE BOLTS ON 3512CHD LAND ELECTRIC DRILLING ENGINES PRODUCT SUPPORT PROGRAM FOR REPLACING TURBO SUPPORT STRUCTURE BOLTS ON 3512CHD LAND ELECTRIC DRILLING ENGINES
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING THE TURBOCHARGERS ON CERTAIN 3412C GENERATOR SETS PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING THE TURBOCHARGERS ON CERTAIN 3412C GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING THE BREAKER LABELS ON CERTAIN UPS 500G, AND UPS 600G UPS UNINTERRUPTIBLE POWER SUPPLIES EQUIPPED WITH THE UTILITY MAINTENANCE BYPASS OPTION PRODUCT SUPPORT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING THE BREAKER LABELS ON CERTAIN UPS 500G, AND UPS 600G UPS UNINTERRUPTIBLE POWER SUPPLIES EQUIPPED WITH THE UTILITY MAINTENANCE BYPASS OPTION
PRODUCT SUPPORT PROGRAM FOR REPLACING THE ELECTRONIC MODULAR CONTROL PANEL (EMCP 4.1 OR EMCP 4.2) ON CERTAIN C2.2, C4.4, C6.6, C7.1, C9, C13, C15, C18, C27, C32, 3406C 3412C, G3406, G3412, 3512, 3512B, 3512C, 3516, 3516B, 3516C, C175-16, AND C175-20 PRODUCT SUPPORT PROGRAM FOR REPLACING THE ELECTRONIC MODULAR CONTROL PANEL (EMCP 4.1 OR EMCP 4.2) ON CERTAIN C2.2, C4.4, C6.6, C7.1, C9, C13, C15, C18, C27, C32, 3406C 3412C, G3406, G3412, 3512, 3512B, 3512C, 3516, 3516B, 3516C, C175-16, AND C175-20
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING THE UNDERVOLTAGE COIL ON CERTAIN UPSB125, UPSB130, AND UPSB505 UNINTERRUPTIBLE POWER SUPPLIES PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING THE UNDERVOLTAGE COIL ON CERTAIN UPSB125, UPSB130, AND UPSB505 UNINTERRUPTIBLE POWER SUPPLIES
PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS
PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 365-1772 AIR COMPRESSOR GROUP ON CERTAIN 3516C HD GENERATOR SETS PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 365-1772 AIR COMPRESSOR GROUP ON CERTAIN 3516C HD GENERATOR SETS
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REWORKING THE CYLINDER HEADS ON CERTAIN G3512C, G3512E, G3516C, G3520C, AND G3520E ENGINES PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REWORKING THE CYLINDER HEADS ON CERTAIN G3512C, G3512E, G3516C, G3520C, AND G3520E ENGINES
PRODUCT SUPPORT PROGRAM FOR REWORKING THE DIRECT RACK WIRING ON CERTAIN 3512B PETROLEUM GENERATOR SET ENGINES PRODUCT SUPPORT PROGRAM FOR REWORKING THE DIRECT RACK WIRING ON CERTAIN 3512B PETROLEUM GENERATOR SET ENGINES
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY RELOCATING POWER CABLES ON CERTAIN 4-WIRE UPS 250, AND UPS 500G UNINTERRUPTIBLE POWER SUPPLIES PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY RELOCATING POWER CABLES ON CERTAIN 4-WIRE UPS 250, AND UPS 500G UNINTERRUPTIBLE POWER SUPPLIES
PRODUCT SUPPORT PROGRAM FOR REWORKING THE RADIATOR FAN BELT GUARD BRACKET ON CERTAIN 3512C, AND 3516C GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE RADIATOR FAN BELT GUARD BRACKET ON CERTAIN 3512C, AND 3516C GENERATOR SETS
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REMOVING CERTAIN PISTON SKIRTS FROM DEALER PARTS STOCK AND INSPECTING AND POSSIBLY REWORKING CERTAIN 3456 AND C-16 CYLINDER PACKS, SHORT BLOCKS, AND LONG BLOCKS IN DEALER PARTS STOCK PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REMOVING CERTAIN PISTON SKIRTS FROM DEALER PARTS STOCK AND INSPECTING AND POSSIBLY REWORKING CERTAIN 3456 AND C-16 CYLINDER PACKS, SHORT BLOCKS, AND LONG BLOCKS IN DEALER PARTS STOCK
PRODUCT SUPPORT PROGRAM FOR REPLACING THE JACKET WATER HEATER ON CERTAIN 3512B PETROLEUM LAND DRILLING GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REPLACING THE JACKET WATER HEATER ON CERTAIN 3512B PETROLEUM LAND DRILLING GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE RADIATOR ON CERTAIN PMG3516C GENERATOR SETS (XQ1475G POWER MODULES) PRODUCT SUPPORT PROGRAM FOR REWORKING THE RADIATOR ON CERTAIN PMG3516C GENERATOR SETS (XQ1475G POWER MODULES)
PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXHAUST MANIFOLD BRACKET FASTENING HARDWARE ON CERTAIN PMG3516C GENERATOR SETS (XQ1475G POWER MODULES) PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXHAUST MANIFOLD BRACKET FASTENING HARDWARE ON CERTAIN PMG3516C GENERATOR SETS (XQ1475G POWER MODULES)
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REMOVING CERTAIN 150-1240 PRESSURE SWITCHES FROM DEALER PARTS STOCK PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REMOVING CERTAIN 150-1240 PRESSURE SWITCHES FROM DEALER PARTS STOCK
PRODUCT IMPROVEMENT PROGRAM INSPECTING AND POSSIBLY REWORKING THE LOAD CABLES ON CERTAIN PM1360 POWER MODULES PRODUCT IMPROVEMENT PROGRAM INSPECTING AND POSSIBLY REWORKING THE LOAD CABLES ON CERTAIN PM1360 POWER MODULES
PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE RADIATOR FAN BEARING ON CERTAIN PM3516B POWER MODULES PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE RADIATOR FAN BEARING ON CERTAIN PM3516B POWER MODULES
PRODUCT SUPPORT PROGRAM FOR REPLACING 197-9732 U-BOLT ON THE AIR INLET TUBE ON CERTAIN 3516B LOCOMOTIVE ENGINES, 3516B GENERATOR SETS, 3516C GENERATOR SETS, AND PM3516 POWER MODULES PRODUCT SUPPORT PROGRAM FOR REPLACING 197-9732 U-BOLT ON THE AIR INLET TUBE ON CERTAIN 3516B LOCOMOTIVE ENGINES, 3516B GENERATOR SETS, 3516C GENERATOR SETS, AND PM3516 POWER MODULES
PRODUCT SUPPORT PROGRAM FOR REPLACING THE OIL TEMPERATURE SENSOR ON CERTAIN PM3516 POWER MODULES PRODUCT SUPPORT PROGRAM FOR REPLACING THE OIL TEMPERATURE SENSOR ON CERTAIN PM3516 POWER MODULES
PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING TURBOCHARGER SHIELDS ON CERTAIN G3520C 1200RPM LANDFILL GENERATOR SETS PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING TURBOCHARGER SHIELDS ON CERTAIN G3520C 1200RPM LANDFILL GENERATOR SETS
PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING DEF FITTING AND AIR FITTING O-RINGS, REORIENTING THE WASHERS ON THE DOSING PUMP HEAD AND REPLACING THE BOLTS AND WASHERS ON THE DOSING PUMP MANIFOLD ON CERTAIN 3516C AND 3516C HD GENERATOR SETS PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING DEF FITTING AND AIR FITTING O-RINGS, REORIENTING THE WASHERS ON THE DOSING PUMP HEAD AND REPLACING THE BOLTS AND WASHERS ON THE DOSING PUMP MANIFOLD ON CERTAIN 3516C AND 3516C HD GENERATOR SETS
Back to top
The names Caterpillar, John Deere, JD, JCB, Hyundai or any other original equipment manufacturers are registered trademarks of the respective original equipment manufacturers. All names, descriptions, numbers and symbols are used for reference purposes only.
CH-Part.com is in no way associated with any of the manufacturers we have listed. All manufacturer's names and descriptions are for reference only.