PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE EXHAUST MANIFOLD BRACKET FASTENING HARDWARE, RELOCATING THE PRELUBE PUMP, AND REPAIRING RADIATOR COOLANT LEAKS ON CERTAIN PMG3516C POWER MODULES (XQ1475G POWER MODULES)- MULTIPLE REPAIRS Caterpillar


PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE EXHAUST MANIFOLD BRACKET FASTENING HARDWARE, RELOCATING THE PRELUBE PUMP, AND REPAIRING RADIATOR COOLANT LEAKS ON CERTAIN PMG3516C POWER MODULES (XQ1475G POWER MODULES)- MULTIPLE REPAIRS

Usage:



TEBE2641-00

01Jun2015


O-221

 

Priority

  
  

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE EXHAUST MANIFOLD BRACKET FASTENING HARDWARE, RELOCATING THE PRELUBE PUMP, AND REPAIRING RADIATOR COOLANT LEAKS ON CERTAIN PMG3516C POWER MODULES (XQ1475G POWER MODULES)- MULTIPLE REPAIRS

1319 1059 1380 1353
PI32492
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 as soon as possible. When reporting the repair, use "PI32492" 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 "PI32492" as the Part Number, "7751" as the Group Number, "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.


COMPLETION DATE

TERMINATION DATE

31Dec2015 30Jun2016

PROBLEM

The fastening hardware used with the 218-8151 Bracket within the 210-7753 Exhaust Manifold Group may become loose and/or break on certain PMG3516C Power Modules(XQ1475G Power Modules). Installation of improved fasteners for this bracket is required.

The existing prelube pump mounting bracket can fail on certain PMG351C Power Modules (XQ1475G Power Modules). To prevent bracket failure, the prelube pump needs to be relocated from the engine to the floor of the container.

The existing radiator assembly on certain PMG3516C Generator Sets (XQ1475G Power Modules) can leak coolant. Replacing certain radiator connection hoses will be required to repair coolant leaks.

AFFECTED PRODUCT

Model Identification Number
PMG3516C  JKK00119, 134, 140, 172, 187, 190-191, 195, 198, 206-207, 212, 215, 219, 221-223, 225, 227, 229-230, 232

PARTS NEEDED

Qty

Part Number Description
4 0S1618 BOLT
4 1F7958 NUT-FULL
8 1F7960 WASHER-HARD
4 6V3631 NUT-FULL
8 8C8589 BOLT-HIGH TEMP
6 1180275 WASHER
2 1239362 CAP-FILLER
1 2109599 HOSE AS
2 3242755 HOSE
2 3656813 WASHER-HARD
2 4221428 FILLER-COOLANT
2 4221429 GASKET
2 4738710 HOSE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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.

Rework Action Required

Installation of improved fasteners on the 218-8151 Bracket shown in Image1 is required. Installation of improved fasteners will be required for this bracket on both the right side and left side of the engine.

The 276-2910 Prelube Pump Assembly needs to be relocated from the engine to the container floor location directly below existing mounting location. This will require fabrication of one new hose assembly. Refer to the Hydraulic Information System (HIS) for information on building the 210-9599 Hose Assembly. The existing 241-0117 Hose Assembly will be re-used. Wiring and conduit lengths are sufficient. Drilling and tapping of additional mounting holes will be required. Refer to Image2 and Image3.

Replacement of 4 radiator connection hoses, 2 radiator filler necks, and 2 radiator caps will also be required. Refer to Image4 and Image5.

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

OWNER NOTIFICATION

Owners in the following countries will receive the attached Owner Notification:
US
Canada

SERVICE CLAIM ALLOWANCES

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

 NOTE: This is a 11.0-hour job


PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
 
 
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
 
 
 
EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE EXHAUST MANIFOLD BRACKET FASTENING HARDWARE, RELOCATING THE PRELUBE PUMP, AND REPAIRING RADIATOR COOLANT LEAKS ON CERTAIN PMG3516C POWER MODULES (XQ1475G POWER MODULES)- MULTIPLE REPAIRS

MODELS INVOLVED - PMG3516C

Dear Cat Product Owner:

The exhaust manifold bracket fastening hardware, prelube pump, and radiator need to be reworked on the products listed below. The existing manifold bracket fastening hardware can loosen or break, the prelube pump mounting bracket can break, and the radiator connections hoses can leak. You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated. Please refer the dealer to their Service Letter dated 01Jun2015 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 01Jun2015 Service Letter


Rework Procedure


 
PROCEDURE FOR REPLACING THE EXHAUST MANIFOLD BRACKET FASTENING HARDWARE
 
Remove exhaust manifold insulation in area shown in Image1.2.1.
Image1.2.1
 
On the right side of the engine, replace existing fastening hardware used on the end of the 218-8151 Bracket that attaches to the engine bracket. Replace existing bolts with quantity 2 of 8C-8589 Bolt (1). Use quantity 3 of 118-0275 Washer, quantity 1 of 365-6813 Washer (2), and quantity 2 of 1F-7958 Nut. Tighten to 120 N-m. Note that the 365-6813 Washer has a smaller outside diameter than the 118-0275 Washer and must be used at the location nearest the inside bend radius to prevent washer from sitting on the radius (2). Refer to Image1.3.1.
Image1.3.1
 
On the right side of the engine, replace existing fastening hardware used on the end of the 218-8151 Bracket that attaches to the exhaust pipe. Replace existing bolts with quantity 2 of 8C-8589 Bolt (3). Use quantity 4 of 1F-7960 Washer and quantity 2 of 6V-3631 Nut. Tighten to 120 N-m. Refer to Image1.4.1.
Image1.4.1
 
On the left side of the engine, replace existing fastening hardware used on the end of the 218-8151 Bracket that attaches to the engine bracket. Install quantity 2 of 8C-8589 Bolt (4). Use quantity 3 of 118-0275 Washer, quantity 1 of 365-6813 Washer (5), and quantity 2 of 1F-7958 Nut. Tighten to 120 N-m. Note that the 365-6813 Washer has a smaller outside diameter than the 118-0275 Washer and must be used at the location nearest the inside bend radius to prevent washer from sitting on the radius (5). Refer to Image1.5.1.
Image1.5.1
 
On the left side of the engine, replace existing fastening hardware used on the end of the 218-8151 Bracket that attaches to the exhaust pipe. Replace existing hardware with quantity 2 of 8C-8589 Bolt (6). Use quantity 4 of 1F-7960 Washer and quantity 2 of 6V-3631 Nut. Tighten to 120 N-m. Refer to Image1.6.1.
Image1.6.1
 
Replace exhaust manifold insulation.
 
PROCEDURE FOR RELOCATING THE PRELUBE PUMP
 
Remove the pump assembly from engine. Rotate the pump assembly 180 degrees from the original position and place it on floor using the original spacers under the mounting bracket. Refer to Image1.9.1.
Image1.9.1
 
Rotate the elbow down 15 to 45 degrees to allow fit-up of the existing hose. Refer to Image1.10.1.
Image1.10.1
 
Turn the elbow adapters on pump upwards with pump assembly resting flat on the pump mounting bracket. Fit new 210-9599 Hose Assembly (1) and existing 241-0117 Hose Assembly(2). Position pump to prevent hose rubbing (3). Once the best positioning is determined, use bracket bolt holes (4) as a template to mark the mounting bolt hole pattern. Refer to Image1.11.1.
Image1.11.1
 
Drill and tap 5/16-18 THD mounting holes and mount pump to floor. Maximum hole depth should not exceed 12 mm depth to avoid penetration of spill containment area. Also, hole depth must be approximately 10 mm deep to prevent bottoming of bolts (thread engagement is approximately 8 mm). Use existing spacers with new 0S-1618 Bolts (4 total) to mount the pump to the floor. Original bolts will not be used. Verify bolts are not hitting the bottom of the hole. Refer to Image1.12.1.
Image1.12.1
 
Mount the relay box to the floor. Remove cover from relay box, and use the three mounting holes in the box as a template to mark mounting holes. Drill and tap holes in the floor and mount the relay box. Refer to Image1.13.1 and Image1.13.2.
Image1.13.1
Image1.13.2
 
Tighten all hose connections and verify that all hoses and conduit are routed and secured to prevent rubbing. Refer to Image 1.14.1.
Image1.14.1
 
PROCEDURE FOR REPAIRING RADIATOR COOLANT LEAKS
 
Drain coolant from 391-3895 Radiator Assembly and retain for reuse.
 
Replace existing radiator 2 1/2 inch connection hoses (1) with 324-2755 Hose. Replace existing 6 inch radiator connection hose (2) with 473-8710 Hose. Refer to Image1.17.1.
Image1.17.1
 
Replace existing 6 inch radiator connection hose with 473-8710 Hose. Refer to Image1.18.1.
Image1.18.1
 
Refill radiator assembly with coolant that was previously drained. Replace existing filler neck and gasket with 422-1428 Coolant Filler, and 422-1429 Gasket. Replace existing filler caps with 123-9362 Filler Cap. Refer to Image1.19.1.

Run the generator set and verify proper operation.
Image1.19.1
 
 

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