PRODUCT SUPPORT PROGRAM FOR REWORKING THE AIR TO AIR AFTER COOLER (ATAAC) ON CERTAIN C27 GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE AIR TO AIR AFTER COOLER (ATAAC) ON CERTAIN C27 GENERATOR SETS

Usage:

TEBE2558-00

Show/hide table

05Feb2016

U-64

A-50

Show/hide table

After Failure Only	PRODUCT SUPPORT PROGRAM FOR REWORKING THE AIR TO AIR AFTER COOLER (ATAAC) ON CERTAIN C27 GENERATOR SETS
1063 1353		PS53137

Show/hide table

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 can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS53137" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

Show/hide table

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.

Show/hide table

TERMINATION DATE

28Feb2018

PROBLEM

Show/hide table

The Air to Air After Cooler (ATTAC) flange can crack where the radiator assembly support braces attach. If cracking occurs in this location, it will be necessary to rework the ATAAC and add additional support.

AFFECTED PRODUCT

Show/hide table

Model

Identification Number

C27

GDS00100, 104-113, 115-120, 124-133, 135, 146-147, 149-155, 158-159, 163, 166-169, 171, 173-174, 176-178, 183-187, 189-216, 219, 221-234, 240, 242, 245-248, 250, 252-269, 271-277, 279-281, 284-288, 291-296, 298-308, 310-314, 316-319, 321-337, 340-351, 353-387, 390, 392-395, 397-401, 403-414, 416-420, 422-424, 427-428, 437, 439-444, 448-451, 453-472, 474-475, 477-490, 493-495, 503-504, 506-508, 521-522, 527-530, 532-536, 538-541, 544-551, 553, 560-561, 563, 565-575, 583-591, 593-594, 596-598, 627-631, 633-638, 643-652

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
12	7X7729	WASHER-HARD
4	8T4133	NUT
4	8T4196	BOLT-HEX HEAD
2	BRACE_SUPPORT	DEALER FABRICATED PART- SEE REWORK PROCEDURE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 4% 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

Show/hide table

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.

Rework Action Required

The Air to Air After Cooler (ATTAC) flange can crack where the radiator assembly support braces attach. If cracking occurs in this location, it will be necessary to remove the ATTAC, weld the cracked area, reposition the ATTAC?s, and add extra support to prevent future failure. This repair will require purchase of general purpose low carbon steel square tubes. Refer to Image1 and Image2.

Using Cat ET, create a Product Status Report and make sure to include a histogram of Time vs Engine Speed and Engine Load Factor. Attach/upload the report to SIMSi.

Refer to the attached Rework Procedure.

Show/hide table

Image1

Image2

SERVICE CLAIM ALLOWANCES

Show/hide table

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%

Show/hide table

NOTE: This is a 5.0-hour job
A maximum of $40.00 USD is allowed for purchase of steel tube material. A maximum of $150.00 USD is allowed for welding of each ATAAC ($300.00 USD maximum for 2 ATAAC's).

Show/hide table

PARTS DISPOSITION

Show/hide table

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

Rework Procedure

Show/hide table

Quantity 2 of steel support braces will need to be fabricated by the dealer as shown for reference in Image1.1.1. Note that dimensions are in inches. Braces to be painted black. Material for braces is to be general purpose low carbon steel ? square tubes ? rough finish (hot rolled). Dimensions of square tubes to be 1.5 inch (38.1mm) x 1.5 inch (38.1mm). Wall thickness is to be 0.120 inch (3.05 mm). Reference McMaster-Carr part number 6527K324.

Note that these are reference dimensions. As an alternate method, approximately 19 inches of length can be cut, placed, and marked using existing bolt holes (1) as a template. 2 addition hole locations (2) can be approximated. Refer to Image1.1.2.

Before final assembly, make sure sides of the tube rest flush against the side of the ATAAC and flange. It may be necessary to grind the corner of tube to fit curvature of ATAAC flange bend radius.

Image1.1.1

Image1.1.2

Disconnect all ATAAC pipes. Disconnect upper and lower pipes (3) at the ATAAC interface. Re-tighten hose clamps to 11 +/- 1 N-m for re-assembly. Refer to Image1.2.1.

Image1.2.1

Remove fastening hardware (4) from top of stabilizer brace (2 bolts each side). Re-tighten to 55 +/- 10 N-m for re-assembly. Refer to Image1.3.1. All hardware will be reused except the washer plates (5). Refer to Image1.3.2.

Image1.3.1

Image1.3.2

Remove ATAAC?s from both sides of the radiator assembly. Removal of the radiator fan guard will be required to access all of the ATAAC mounting bolts.

Remove fan guard by first removing the bolts that attach the fan guard halves (6). Remove bolts that attach the fan guard to the shroud (7). All fastening hardware will be re-used. Tighten all hardware to 55 +/- 10 N-m for re-assembly. Refer to Image1.4.1.

Remove existing bolts on the sides of the ATAAC?s (4 each side - 8 bolts total). For re-assembly, tighten to 30 N-m. Refer to Image1.4.2.

Remove existing bolts on the front and back of the ATTAC?s (12 each side ? 24 total). All fastening hardware will be re-used. Refer to Image1.4.3. Remove both ATAAC?s. Tighten all hardware to 30 N-m for re-assembly.

Image1.4.1

Image1.4.2

Image1.4.3

Weld cracked area on ATAAC using aluminum weld process. Refer to Image1.5.1.

Image1.5.1

Rotate ATAAC?s 180 degrees from original orientation, and install on opposite sides of the radiator assembly (install right side ATAAC on left side and left side ATAAC on right side). This will result in the welded area being at the bottom of the radiator assembly where operating stresses are much lower. Refer to Image1.6.1.

Image1.6.1

Install stabilizer braces and new support braces to both ATTAC flanges using existing fastening hardware and additional quantities ordered. Tighten all nuts to 55 +/- 10 N-m . Refer to Image1.7.1.