PRODUCT SUPPORT PROGRAM FOR REPAIRING RADIATOR COOLANT LEAKS ON CERTAIN PMG3516C GENERATOR SETS (XQ1475G POWER MODULES) Caterpillar


PRODUCT SUPPORT PROGRAM FOR REPAIRING RADIATOR COOLANT LEAKS ON CERTAIN PMG3516C GENERATOR SETS (XQ1475G POWER MODULES)

Usage:

TEBE2438-02

12Dec2014
(Revised 16Jun2015)


D35P
J520

 

Before/After

 (Limited distribution) 
  

PRODUCT SUPPORT PROGRAM FOR REPAIRING RADIATOR COOLANT LEAKS ON CERTAIN PMG3516C GENERATOR SETS (XQ1475G POWER MODULES)

1353
PS44604
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 "PS44604" 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.

 
NOTE:

This Revised Service Letter replaces the 12Dec2014 (Revised 01Jun2015) Service Letter. Changes have been made to the Affected Product.


TERMINATION DATE

31Dec2016

PROBLEM

The existing jacket water radiator assembly can leak coolant on certain PMG3516C Generator Sets (XQ1475G Power Modules). Replacement of some of the header joint hardware will be required to repair coolant leaks.

AFFECTED PRODUCT

Model Identification Number
PMG3516C  JKK00115-00116, 152, 155-156, 160, 176, 179, 181

PARTS NEEDED

Qty

Part Number Description
280 3E9860 LOCKNUT
96 4M6424 BOLT
8 5P4116 WASHER-HARD
12 6V8918 BOLT
60 7X0440 BOLT
124 8C3121 BOLT
564 8T4224 WASHER-HARD
2 1239362 CAP-FILLER
2 4221428 FILLER-COOLANT
2 4221429 GASKET
1 4738710 HOSE
3 HOSE_COOLANT COOLANT HOSE (SEE ACTION REQUIRED)
16 WASHER1 CORE WASHER (SEE ACTION REQUIRED)
8 WASHER2 CORE WASHER (SEE ACTION REQUIRED)
4 WASHER3 CORE WASHER (SEE ACTION REQUIRED)
16 WASHER4 CORE WASHER (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

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

In some cases, the jacket water (JW) radiator core (1) within the 391-3895 Radiator Assembly can leak. Refer to Image1 and Image2. The entire radiator assembly will need to be removed from the container to perform the repair. Refer to Image3. The repair requires replacement of some of the existing header joint hardware . The core washers will need to be replaced with a thicker design for improved clamp load distribution. A total of 44 new core washers will be installed. 16 total (8 each side) of WASHER1 will be installed as shown in Image4. 8 total of WASHER2 (4 each side) will be installed as shown in Image5. 4 total of WASHER3 will be installed between the cores as shown in Image6. 16 total of WASHER4 (8 each side) will be installed as shown in Image7. The fastening hardware will also need to be replaced to accommodate the thicker core washers. The thicker core washers will need to be supplied by the dealer per the prints contained within the rework procedure. Repair one side of radiator at a time. Do not repair the front and back of a given core at the same time. Complete one tank joint at a time. Loosening all hardware at the same time may load the joints improperly.

After the radiator repair, and after installation in the package, an air 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.

Replacement of 3 radiator connection hoses is also needed. Refer to Image8. 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 Image8.

Refer to the attached Rework Procedure.
Image1
Image2
Image3
Image4
Image5
Image6
Image7
Image8

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
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%
 NOTE: This is a 72.0-hour job
A maximum of $678.00 USD is allowed for fabrication of steel washers.



PARTS DISPOSITION

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


Rework Procedure


 
Steel washers will need to be fabricated as shown in Image1.1.1, Image1.1.2, Image1.1.3, and Image1.1.4.

Note that dimensions are in inches.

Washers are to be painted after assembly using Cat yellow spray paint.

The parts material is to be Carbon Steel conforming to one of the following material specifications:
SAE 1008, ASTM A109, ASTM A1008, ASTM A1011, ASTM A1018, ASTM A510, GB699, GB710, JIS G3131, JIS G3141, NBR5906, NBR5915, NBR6656, KS D3501, KS D3512, IS 513, IS 1079.

Hole diameter tolerance to be +0.006/-0.003 inches. Tolerance for features other than holes is +/-0.03 inches. Profile tolerance to be 0.157 inch(4 mm). Flatness tolerance to be 0.118 inch (3 mm).
Image1.1.1
Image1.1.2
Image1.1.3
Image1.1.4
 
Drain coolant from 391-3895 Radiator Assembly and retain for reuse. Disconnect all container lines/hoses/wiring and remove radiator assembly from container. Refer to Image1.2.1.
Image1.2.1
 
Disconnect and remove radiator vent lines at 5 locations shown in Image1.3.1 and Image1.3.2.
Image1.3.1
Image1.3.2
 
Disconnect tank overflow hoses at 2 locations shown in Image1.4.1.
Image1.4.1
 
Disconnect fittings at 2 locations shown in Image1.5.1.
Image1.5.1
 
Remove tanks by removing 3 bolts on each side as shown in Image1.6.1. To reassemble, tighten bolt to 110 ft-lbs.
Image1.6.1
 
To remove top 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. 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 the JW radiator assembly is 1400 pounds.
Image1.8.1
 
Remove radiator cores using a four point lift attached to each of 4 radiator corners. Approximate weight of the JW radiator assembly is 1400 lbs. Refer to Image1.9.1.
Image1.9.1
 
The following rework steps are to be used on the end tank joints shown in Image1.10.1 and Image1.10.2. Rework is to be performed with the JW radiator standing up vertically, resting on wooden blocks.
Image1.10.1
Image1.10.2
 
Remove core spacers from both sides of the radiator. Remove quantity 4 of 5/16-18X1 inch bolts total on one side. Refer to Image1.11.1. Remove quantity 16 of 5/16-18X1 inch bolts total on the other side. Refer to Image1.11.2. Core spacers and hardware will be re-used with slight modifications.
Image1.11.1
Image1.11.2
 
Loosen quantity 2 fasteners from quantity 6 corner reinforcements at the tank joints to be reworked. All hardware and fasteners will be reused. Refer to Image1.12.1.
Image1.12.1
 
Remove quantity 2 of center core washers and associated hardware at locations for the tank joints to be reworked. Discard these cores washers and fastening hardware. Refer to Image1.13.1. Note that brackets are installed on top of the core washers on one side of the radiator. Do not discard brackets since they will be reused. Refer to Image1.13.2.
Image1.13.1
Image1.13.2
 
Remove existing core washers and fastening hardware. Install quantity 6 of WASHER4 (5) and quantity 6 of WASHER1 (6). Refer to Image1.14.1, Image1.14.2 and Image1.14.3. Existing fastening hardware will be used for WASHER4 (5). New fastening hardware will be used for WASHER1 (6). For WASHER1 (6), use total quantity 120 of 8C-3121 BOLTS, total quantity 120 of 3E-9860 LOCK NUTS, quantity 240 of 8T-4224 WASHERS. Tighten all joints to 25 +/- 5 ft-lbs (300 +/- 60 in-lbs, 33.9 +/- 6.8 N-m). Use back-up wrench on bolt and tighten nut. Repair one side of radiator at a time. Do not repair the front and back of a given core at the same time. Complete one tank joint at a time. Loosening all hardware at the same time may load the joints improperly.
Image1.14.1
Image1.14.2
Image1.14.3
 
The following steps are to be used on the end tank joints shown in Image1.15.1. This end tank contains an air baffle that will need to be relocated.
Image1.15.1
 
Loosen quantity 2 fasteners from quantity 2 corner reinforcements at the tank joints to be reworked. Refer to Image1.16.1. The other 2 fasteners will be removed from quantity 2 corner reinforcements at the tank joints to be reworked. These fasteners will not be reused. Refer to Image1.16.1.
Image1.16.1
 
Remove existing core washers, air baffle and fastening hardware. Discard the existing core washers and fastening hardware. The air baffle will be re-used. Install quantity 2 of WASHER4 (7) and quantity 2 of WASHER1 (8). Install air baffle (9) to the outside of the tank flange (10). Refer to Image1.17.1 and Image1.17.2. For WASHER4 (7), use total quantity 4 of 8C-3121 BOLTS, total quantity 4 of 3E-9860 LOCK NUTS, quantity 8 of 5P-4116 WASHERS. For WASHER1, use quantity 40 of 7X-0440 BOLTS, quantity 40 of 3E-9860 LOCK NUTS , and quantity 80 of 8T-4224 WASHERS. Tighten all bolts to 25 +/- 5 ft-lbs (300 +/- 60 in-lbs, 33.9 +/- 6.8 N-m). Use back-up wrench on bolt and tighten nut. Repair one side of radiator at a time. Do not repair the front and back of a given core at the same time. Complete one tank joint at a time. Loosening all hardware at the same time may load the joints improperly.
Image1.17.1
Image1.17.2
 
Remove existing end tank core washers and fastening hardware from both sides of the radiator. Discard the existing core washers and fastening hardware. Install quantity 2 of WASHER2 on each side of radiator (4 total quantity). Refer to Image1.18.1 and Image1.18.2. Use total quantity 20 of 7X-0440 BOLTS, total quantity 20 of 3E-9860 LOCK NUTS, quantity 40 of 8T-4224 Washers. Tighten all bolts to 25 +/- 5 ft-lbs (300 +/- 60 in-lbs, 33.9 +/- 6.8 N-m). Use back-up wrench on bolt and tighten nut. Repair one side of radiator at a time. Do not repair the front and back of a given core at the same time. Complete one tank joint at a time. Loosening all hardware at the same time may load the joints improperly.
Image1.18.1
Image1.18.2
 
Remove existing end tank core washers and fastening hardware from center of the radiator cores. Discard the existing core washers and fastening hardware. Refer to Image1.19.1 and Image1.19.2. Install quantity 1 of WASHER3 at center of each tank (2 total quantity). Refer to Image1.19.3. Use total quantity 12 of 6V-8918 BOLTS, total quantity 12 of 8T-4224 Washers. NOTE: ADD PERMATEX BLUE RTV SILICONE GASKET MAKER TO EACH BOLT ON AT LEAST 3 THREADS AT END OF THE BOLT BEFORE INSTALLING. Tighten all bolts to 25 +/- 5 ft-lbs (300 +/- 60 in-lbs, 33.9 +/- 6.8 N-m). Use back-up wrench on bolt and tighten nut. Repair one side of radiator at a time. Do not repair the front and back of a given core at the same time. Complete one tank joint at a time. Loosening all hardware at the same time may load the joints improperly.
Image1.19.1
Image1.19.2
Image1.19.3
 
Using new hardware previously installed, reinstall brackets at both end tanks on top of new core washers. Refer to Image1.20.1. Note that brackets are installed on the side opposite of 6 inch pipe connections. Tighten all joints to 25 +/- 5 ft-lbs (300 +/- 60 in-lbs, 33.9 +/- 6.8 N-m). Use back-up wrench on bolt and tighten nut. Repair one side of radiator at a time. Do not repair the front and back of a given core at the same time. Complete one tank joint at a time. Loosening all hardware at the same time may load the joints improperly.
Image1.20.1
 
The following steps are to be used to rework the center tank joints. Refer to Image1.21.1.
Image1.21.1
 
Remove existing core washers and fastening hardware. Install quantity 4 of WASHER4 (11) and quantity 4 of WASHER1 (12) on each side of the radiator (8 total for each). Refer to Image1.22.1 and Image1.22.2. Existing fastening hardware will be used for WASHER4 (11). New fastening hardware will be used for WASHER1 (12). For WASHER1, use total quantity 80 of 4M-6424 BOLTS, total quantity 80 3E-9860 LOCK NUTS, quantity 160 of 8T-4224 WASHERS. Tighten all joints to 25 +/- 5 ft-lbs (300 +/- 60 in-lbs, 33.9 +/- 6.8 N-m). Use back-up wrench on bolt and tighten nut. Repair one side of radiator at a time. Do not repair the front and back of a given core at the same time. Complete one tank joint at a time. Loosening all hardware at the same time may load the joints improperly.
Image1.22.1
Image1.22.2
 
Remove existing center tank core washers and fastening hardware from center tank of the radiator cores. Discard the existing core washers and fastening hardware. Refer to Image1.23.1 and Image1.23.2. Install quantity 1 of WASHER3 at top and bottom of tank (2 total quantity). Refer to Image1.23.3. Use total quantity 6 of 4M-6424 BOLTS, total quantity 12 of 8T-4224 WASHERS, total quantity 6 of 3E-9860 LOCK NUTS. Tighten all bolts to 25 +/- 5 ft-lbs (300 +/- 60 in-lbs, 33.9 +/- 6.8 N-m). Use back-up wrench on bolt and tighten nut. Repair one side of radiator at a time. Do not repair the front and back of a given core at the same time. Complete one tank joint at a time. Loosening all hardware at the same time may load the joints improperly.
Image1.23.1
Image1.23.2
Image1.23.3
 
Remove existing center tank core washers and fastening hardware from both sides of the radiator. Discard the existing core washers and fastening hardware. Install quantity 2 of WASHER2 on each side of radiator (4 total quantity). Refer to Image1.24.1 and Image1.24.2. Use total quantity 10 of 4M-6424 BOLTS, total quantity 10 of 3E-9860 LOCK NUTS, quantity 20 of 8T-4224 Washers. Tighten all bolts to 25 +/- 5 ft-lbs (300 +/- 60 in-lbs, 33.9 +/- 6.8 N-m). Use back-up wrench on bolt and tighten nut. Repair one side of radiator at a time. Do not repair the front and back of a given core at the same time. Complete one tank joint at a time. Loosening all hardware at the same time may load the joints improperly.
Image1.24.1
Image1.24.2
 
Using new hardware previously installed, reinstall brackets at center tank on top of new core washers. Refer to Image 1.25.1. Note that brackets are installed on side opposite of 6 inch pipe connections. Tighten all joints to 25 +/- 5 ft-lbs (300 +/- 60 in-lbs, 33.9 +/- 6.8 N-m). Use back-up wrench on bolt and tighten nut . Repair one side of radiator at a time. Do not repair the front and back of a given core at the same time. Complete one tank joint at a time. Loosening all hardware at the same time may load the joints improperly.
Image1.25.1
 
Modification of 2 of the core spacers will now be required before re-installation. 1.06 inches will be cut off of each end, 2 additional holes are drilled (13), and one end is notched (14) on each of the 2 core spacers. Refer to Image1.26.1 and Image1.26.2. Dimensions are in inches.
Image1.26.1
Image1.26.2
 
Install core spacers. Install tubular core spacer first (4 bolts total). Notch allows bracket clearance for assembly. Refer to Image1.27.1 and Image1.27.2. Install angular core spacer last (16 bolts total). Apply Loctite 242 (blue) to these bolts. Refer to Image1.27.3.
Image1.27.1
Image1.27.2
Image1.27.3
 
Perform leak test on the JW core while resting in a horizontal position. Orient the core such that the 6 inch pipe connections face down towards the ground. 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.
 
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 Image1.29.1.
Image1.29.1
 
Replace existing 6 inch radiator connection hose with 473-8710 HOSE. Refer to Image1.30.1.
Image1.30.1
 
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 Image1.31.1.

Run package and check for proper operation.
Image1.31.1
 
 

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