PRODUCT SUPPORT PROGRAM FOR REPAIRING RADIATOR COOLANT LEAKS ON CERTAIN PM3516 POWER MODULES (XQ2000 POWER MODULES) Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPAIRING RADIATOR COOLANT LEAKS ON CERTAIN PM3516 POWER MODULES (XQ2000 POWER MODULES)

Usage:

TEBE4667-00

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05May2016

D-202

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After Failure Only	PRODUCT SUPPORT PROGRAM FOR REPAIRING RADIATOR COOLANT LEAKS ON CERTAIN PM3516 POWER MODULES (XQ2000 POWER MODULES)
1353		PS53209

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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 "PS53209" 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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TERMINATION DATE

31May2018

PROBLEM

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The existing radiator assembly can leak coolant on certain PM3516 Power Modules(XQ2000 Power Modules). Replacement of the gaskets, and header joint hardware will be required to repair coolant leaks.

AFFECTED PRODUCT

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Model	Identification Number
PM3516	NBR00436, 438, 562, 564

PARTS NEEDED

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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
8	9Y5992	GASKET-RAD CORE
1	ADHESIVE	PERMATEX 81731 WEATHERSTRIP (quantity as needed)
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 20% 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

In some cases, the jacket water (JW) radiator core (1) within the 396-3513 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 the gaskets (8 total), and header joint hardware. The core washers will need to be replaced with a thicker design for improved clamp load distribution. After new gaskets are installed, 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 fabricated by the dealer per the prints contained within the rework procedure. 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.

Refer to the attached Rework Procedure.

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Image1

Image2

Image3

Image4

Image5

Image6

Image7

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%
0-12500 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 40.0-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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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

Disassemble radiator assembly. Remove core washers, core spacers, tanks, corner braces, and side members. Note that existing core washers and associated fastening hardware will not be re-used. Place cores on flat, hard, and smooth surface. Refer to Image1.10.1.

Image1.10.1

Remove old gasket material from gasket side of core header (1) and tanks (2). Make sure all gasket joints are cleaned and free from debris. Refer to Image1.11.1.

Image1.11.1

Apply Permatex Super Weatherstrip Adhesive (Permatex Item # 81731) to tank surfaces in pattern shown (3). Apply 9Y-5992 GASKET to tank surfaces (8 total gaskets required) with all bolt holes aligned (4). Refer to Image1.12.1. Note that the adhesive is used to hold the gasket in place during subsequent assembly.

Image1.12.1

Set the cores into position on the tanks. This can be done manually using 2 people, or with a lifting device that will not damage the cores. Align the holes in the header to the bolts in the tank. Note that cores must be held secure to prevent tipping or falling during the assembly process. The tanks and cores must be secured in a way as to not damage the components. Refer to Image1.13.1.

Image1.13.1

Install corner braces, side members, brackets, baffles, and new (thicker) core washers, working from the bottom up. Refer to Image1.14.1. Installation of new core washers is explained in more detail in the following steps. Note that the core washers should be tightened using the sequence shown in Image1.14.2.

Image1.14.1

Image1.14.2

Intall new core washers with the JW radiator in a vertical position. Secure radiator to prevent tipping and/or falling. Approximate weight of dry radiator is 1400 lbs. Refer to Image1.15.1.

Image1.15.1

Install new core washers and fastening hardware to end tanks. Install quantity 6 of WASHER4 (5) and quantity 6 of WASHER1 (6). Refer to Image1.16.1, Image1.16.2 and Image1.16.3. Existing fastening hardware will be used for WASHER4 (5). New fastening hardware will be used for WASHER1 (6). For WASHWER1 (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.

Image1.16.1

Image1.16.2

Image1.16.3

Install new core washers, air baffle and fastening hardware to end tank. 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.

Image1.17.1

Image1.17.2

Install new end tank core washers and fastening hardware to 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.

Image1.18.1

Image1.18.2

Install new end tank core washers and fastening hardware in center of the radiator cores. Discard the existing core washers and fastening hardware. Install quantity 1 of WASHER3 at center of each tank (2 total quantity). Refer to Image1.19.1 and Image1.19.2. 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.

Image1.19.1

Image1.19.2

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.

Image1.20.1

Install new core washers and fastening hardware to the center tank joints. Install quantity 4 of WASHER4 (11) and quantity 4 of WASHER1 (12) on each side of the radiator (8 total for each). Refer to Image1.21.1 and Image1.21.2. 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.

Image1.21.1

Image1.21.2

Install new center tank core washers and fastening hardware between the cores. Discard the existing core washers and fastening hardware. Install quantity 1 of WASHER3 at top and bottom of tank (2 total quantity). Refer to Image1.22.1 and Image1.22.2. 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.

Image1.22.1

Image1.22.2

Install new center tank core washers and fastening hardware to 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 Image1.23.1 and Image1.23.2. 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.

Image1.23.1

Image1.23.2

Using new hardware previously installed, reinstall brackets at center tank on top of new core washers. Refer to Image 1.24.1. 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 .

Image1.24.1

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 Image1.25.1 and Image1.25.2. Dimensions are in inches.

Image1.25.1

Image1.25.2

Install core spacers. Install tubular core spacer first (4 bolts total). Notch allows bracket clearance for assembly. Refer to Image1.26.1 and Image1.26.2. Install angular core spacer last (16 bolts total). NOTE: APPLY LOCTITE 242 (BLUE)TO THESE BOLTS. Refer to Image1.26.3.

Image1.26.1

Image1.26.2

Image1.26.3

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. Note that core washers are to be painted after assembly using Cat yellow spray paint.

Refill radiator assembly with coolant that was previously drained.

Run package and check for proper operation.