PRODUCT SUPPORT PROGRAM FOR REPAIRING THE ENGINE JACKET WATER LINE LEAKS ON CERTAIN PM3516 POWER MODULES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPAIRING THE ENGINE JACKET WATER LINE LEAKS ON CERTAIN PM3516 POWER MODULES

Usage:

TEBE2674-01

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03Mar2015

(Revised 02May2016)

B26B
D35P
J210
J212
J590
K645
K646
L151
P380
Q305
Q315
Q550
Q559
Q661
T080
T088
T300
Z75F
Z800

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After Failure Only (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPAIRING THE ENGINE JACKET WATER LINE LEAKS ON CERTAIN PM3516 POWER MODULES
1393 1355 1380		PS52887

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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 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 "PS52887" 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.

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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 03Mar2015 Service Letter. Changes have been made to the Affected Product.

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TERMINATION DATE

31Mar2017

PROBLEM

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Some of the existing engine jacket water (JW) line joints utilizing 7L-4196 Joint Assembly can have reduced seal life on certain PM3516 Power Modules. This reduced life typically occurs on the engine JW outlet side that runs hotter than the engine inlet side. In some cases, the seal life is less than 5000 operating hours.

AFFECTED PRODUCT

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Model	Identification Number
PM3516	NBR00233-00234, 243-244, 256-259, 265, 268, 271-272, 274, 280-284, 289, 291-294, 296-315, 317-359, 362-459, 470-495, 497-498, 500-558, 560, 562-669, 695-720, 722-729, 755-770, 773-794, 799, 805-819, 822, 824-830, 832, 845-855, 857-859, 861, 869-884, 886-887, 891-897, 899, 902-907, 909-910, 914-921, 923-928

PARTS NEEDED

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Qty	Part Number	Description
6	2162658	SEAL-JOINT
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 10% 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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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

There are three total affected joints (6 total seals) on the JW outlet side that will need to be replaced. Refer to Image1.

If coolant leakage occurs at the jacket waster line joint utilizing the 7L-4196 Joint Assembly, verify tube alignment, and replace the 9X-7530 Seals with 216-2658 Seals. Refer to Image2.

Refer to the attached Rework Procedure.

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Image1

Image2

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%
0-12000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 3.0-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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Check tube alignment. The fitting must have +/- 4 degrees or less angular misalignment. Refer to Image1.1.1.

As an alternate method to measure alignment, the maximum angular misalignment corresponds to a maximum pipe offset value of 12 mm. Note that a straight edge can be used with the fitting removed. The offset distance should be measured at the point corresponding to the end of the fitting to take in to account any angular misalignment of the pipe. Refer to Image1.2.1.

Image1.1.1

Image1.1.2

Deburr and clean pipe ends. Surface should be free of deep scratches, gouges, dents, dirt, etc. Visually check roundness of pipe. A proper seal may be comprised if the roundness of the pipe is distorted.

Install retainer (1), gasket (2) and sleeve (3) on one side of pipe in the sequence shown. Assembly of gaskets can be made easier by dipping gaskets in water or the fluid to be sealed. The use of other rubber lubricants can be detrimental to the life of the gaskets. Never lubricate the metal parts. Install remaining retainer (4) and gasket (5) on other pipe end. Position retainer (4) and gasket (5) to proper pipe insertion depth ("D" = 44.5 mm minimum to 52.6 mm maximum). Refer to Image1.2.1.

Note: To simplify installation of the gasket, install lower gasket halfway onto the pipe first, leaving the split area in the steel retaining ring free at the top. Then, stretch the gasket and split area of the retaining ring until they slip over the tube or pipe and into position. Refer to Image1.2.2

Slide sleeve (3) to gasket (5) and move gasket (2) and retainer (1) into position. Pipe must be inserted to proper depth ("D" = 44.5 mm minimum to 52.6 mm maximum) into both gaskets. Refer to Image1.2.3.

Install both V-couplings, encompassing the retainer, gasket and sleeve. Do not tighten either coupling until the entire joint is assembled. The final tightening value for the nuts is 34 +/- 0.5 N-m. Refer to Image1.2.4.

Note: it is very important to increment ally tighten each nut while alternating from nut to nut for the entire joint assembly. Tightening must be slow, consistent, and must alternate from nut to nut to ensure the correct load distribution on the seal. In other words, do not fully tighten one nut and then the next. Visually inspect the distance between the retainer tabs to make sure they have roughly the same gap for each joint.