PRODUCT SUPPORT PROGRAM FOR REWORKING THE RADIATOR ON CERTAIN PMG3516C GENERATOR SETS (XQ1475G POWER MODULES) Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE RADIATOR ON CERTAIN PMG3516C GENERATOR SETS (XQ1475G POWER MODULES)

Usage:

TEBE2122-03

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16Oct2014

(Revised 01Jun2015)

D35P
J520

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Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REWORKING THE RADIATOR ON CERTAIN PMG3516C GENERATOR SETS (XQ1475G POWER MODULES)
1353		PS44514

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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 "PS44514" 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 16Oct2014 (Revised 12Dec2014) Service Letter. Changes have been made to the Parts Needed, Action Required, and Rework Procedure.

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TERMINATION DATE

31Oct2016

PROBLEM

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The existing radiator assembly on certain PMG3516C Generator Sets (XQ1475G Power Modules) can leak coolant. Tightening of the radiator core tank bolts, and replacing certain radiator connection hoses will be required to repair coolant leaks.

AFFECTED PRODUCT

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Model	Identification Number
PMG3516C	JKK00102-00103, 107, 109-110, 112, 121, 126, 128, 133, 138-139, 145-146, 150-151, 155, 164, 166-167, 178, 182, 189, 194

PARTS NEEDED

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Qty	Part Number	Description
2	1239362	CAP-FILLER
2	4221428	FILLER-COOLANT
2	4221429	GASKET
1	4738710	HOSE
3	HOSE_COOLANT	COOLANT HOSE (SEE ACTION REQUIRED)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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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Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident
occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction, on the product, and in this product's Operation and Maintenance Manual (OMM). If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication, the warnings that are on the product, and the warnings that are in the OMM are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, the user must ensure that it is safe for the user and for other people to use.

The user should ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

WARNING: The generator set must be isolated electrically before and while the rework is performed. Follow the proper lockout tag out procedures to protect against the unexpected energizing or startup of the generator set. Failure to follow these warnings could result in injury to personnel during service. Attach a "Do Not Operate" warning tag to the machine start switch or the controls before you perform any service to the machine.

Repair Action Required

Both the Jacket Water (JW) radiator (1) and Separate Circuit Aftercooler (SCAC) radiator (2) bolts will need to be tightened on the 391-3895 Radiator Assembly. Refer to Image1. The entire radiator assembly will need to be removed from the container to access all bolts for re-tightening. Refer to Image2. The radiator assembly will then need to be disassembled to access all bolts. Refer to Image3. Before and after the bolts are re-tightened, a leak test will be required. Test plugs, shop air regulated up to 14 psi, soapy water, and a pressure gage will be needed to perform the pressure test. Include the following information in the claim for both the JW radiator and SCAC radiator: picture indicating the exact location of the leak(s), bolt torque at the area of leak. Also indicate if the radiator leaks on the unit, but not on the leak test.

Replacement of 3 radiator connection hoses is also needed. Refer to Image4. Use quantity 2 of Flexfab part number 5581-250 cut to 9 inches in length, and quantity 1 of Flexfab part number 5581-600 cut to 12 inches in length. An additional radiator connection hose will also be replaced.

Replacement of radiator filler necks, associated gaskets, and radiator caps will also be required.

Refer to the attached Rework Procedure.

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Image1

Image2

Image3

Image4

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%
0-20000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 128.0-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.

Rework Procedure

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Drain coolant from 391-3895 Radiator Assembly and retain for reuse. Disconnect all container lines/hoses/wiring and remove radiator assembly from container.

Image1.1.1

Disconnect and remove radiator vent lines at 5 locations shown in Image1.2.1 and Image1.2.2.

Image1.2.1

Image1.2.2

Disconnect tank overflow hoses at 2 locations shown in Image1.3.1.

Image1.3.1

Disconnect fittings at 2 locations shown in Image1.4.1.

Image1.4.1

Remove tanks by removing 3 bolts on each side as shown in Image1.5.1. To reassemble, tighten bolt to 110 ft-lbs.

Image1.5.1

To remove top radiator, remove bolts highlighted in Image1.6.1 (12 each side/24 total). To reassemble, tighten bolts to 150 ft-lbs.

Image1.6.1

To remove bottom radiator, remove bolts highlighted in Image1.7.1 (12 each side/24 total). To reassemble, tighten bolts to 150 ft-lbs.

Image1.7.1

Remove top radiator core, then bottom radiator core. To remove radiator core, place lifting eyes in the locations shown in Image1.8.1 (1 each corner/4 total per radiator core). Approximate weight of each radiator core is 1400 pounds.

Image1.8.1

Remove radiator cores using a four point lift attached to each of 4 radiator corners. Approximate weight of each radiator core is 1400 lbs. Refer to Image1.9.1.

Image1.9.1

Before tightening the bolts, perform leak test on both the JW and SCAC core while resting in a horizontal position. Orient the core such that the pipes face down towards the ground. Refer to Image1.10.1. To perform leak test, make sure all radiator ports are plugged. Pressurize the assembly to 5 psi and hold for 5 minutes. Increase pressure to 10 psi and hold for 5 minutes. Increase pressure to 13 psi and hold for 5 minutes. Check for leaks at every step. Do not test for more than 20 minutes. Do not exceed 14 psi. Spray bolt heads and nuts with soapy water and check for leaks. Spray tube to header joints with soapy water and check for leaks.

Include the following information in the claim for both the JW radiator and SCAC radiator: picture indicating the exact location of the leak(s), bolt torque at the area of leak. Also indicate if the radiator leaks on the unit, but not on the leak test.

Image1.10.1

Place radiator core in a vertical position before re-tightening bolts. Radiator should rest on tank pads as shown in Image1.11.1. Rest on blocks to provide clearance for tubes and fittings. Secure radiator core to prevent tipping or falling.

Image1.11.1

Tighten all radiator 5/16 inch nuts on the radiator to 25 +/- 5 ft-lbs (300 +/- 60 in-lbs, 33.9 +/- 6.8 N-m) using the sequence shown in Image1.11.1 (start at center and work outwards). Use a back-up wrench. Tighten nuts while radiator core is in a vertical position. Refer to Image1.12.1

Image1.12.1

Perform leak test as described earlier in the procedure. Verify no leaks exist before reassembling and installing in container.

Reassemble radiator assembly and reinstall in container. Replace existing radiator 2 1/2 inch connection hoses (1) with Flexfab part number 5581-250 cut to 9 inches in length. Replace existing 6 inch radiator connection hose (2) with Flexfab part number 5581-600 cut to 12 inches in length. Refer to Image1.14.1.

Image1.14.1

Replace existing 6 inch radiator connection hose with 473-8710 HOSE. Refer to Image1.15.1.

Image1.15.1

Refill radiator assembly with coolant that was previously drained. Replace existing filler neck and gasket with 422-1428 FILLER-COOLANT, and 422-1429 GASKET. Replace existing filler caps with 123-9362 CAP-FILLER. Refer to Image1.16.1.

Run package and check for proper operation.