PRODUCT SUPPORT PROGRAM FOR REWORKING THE CHARGE AIR COOLER (CAC) ON CERTAIN C32 GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE CHARGE AIR COOLER (CAC) ON CERTAIN C32 GENERATOR SETS

Usage:

TEBE0656-02

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09Dec2013

(Revised 06Oct2014)

U060
U150
U158

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Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REWORKING THE CHARGE AIR COOLER (CAC) ON CERTAIN C32 GENERATOR SETS
1353 7060 7553		PS44118

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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 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 "PS44118" 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.

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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 09Dec2013 (Revised 19Aug2014) Service Letter. A change has been made to the Service Claim Allowances.

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TERMINATION DATE

31Dec2015

PROBLEM

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In some cases, certain C32 Generator Sets may experience low power caused by a leaking Charge Air Cooler (CAC). A leak may occur in the CAC due to rubbing on the radiator lower tank flange.

AFFECTED PRODUCT

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Model	Identification Number
C32	SXC02695-02697, 2699, 2703, 2706-2711, 2713-2721, 2723-2724, 2726, 2728, 2731-2732, 2734, 2736, 2738-2740, 2742, 2744-2753, 2755-2756, 2762-2763, 2765-2767, 2775-2778, 2793, 2796-2799, 2815, 2818-2819, 2832, 2834-2835, 2846-2847, 2850-2851, 2860, 2862-2863, 2865-2866, 2874-2877, 2879-2880, 2882-2885, 2887-2893, 2896-2899, 2901-2902, 2910, 2912-2913, 2915

PARTS NEEDED

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Qty	Part Number	Description
8	3612904	WASHER-SHOULDER
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

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If holes have developed it the Charge Air Cooler (CAC) due to rubbing on the radiator lower flange as shown below (1), complete disassembly of the radiator and CAC assemblies(2) will be required to repair the CAC. Refer to the attached Rework Procedure.

Repair of the CAC will require the services of a qualified radiator repair shop capable of welding holes using the appropriate process for aluminum base material (wall thickness is 0.508 mm).

Important: When reassembling the CAC assembly, replace the nylon (plastic) shoulder washers on the lower CAC mount assemblies with steel shoulder washers (part number 361-2904), and inspect the rubber mounts for damage. Also, make sure the steel washers are seated properly during assembly. The lower vibration mounts support the weight of the CAC, and the nylon (plastic) washers will deform and/or break over time. If steel washers are not used, it is more likely that the CAC will contact the radiator tank flange and create holes. Also, when reassembling the CAC assembly, make sure all spacers are in place between the CAC and radiator. These should be in place as a result of previous rework efforts.

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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%
0-500 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
501-20000 hrs, 25-80 mo	40.0%	40.0%	60.0%	60.0%	0.0%	0.0%

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NOTE: This is a 8.0-hour job
Labor 8 hours is allowed for the repair of 1 CAC per unit. An additional 1 hour will be allowed for repair of 2 CAC's per unit. Repair allowance for each charge air cooler (CAC) shall not exceed $304.00 USD. Ex: 1 damaged CAC per unit = $304.00 USD. 2 damaged CAC's per unit = $608.00 USD. Include outside expenses at cost. Retain a copy of all invoices for outside expenses in the product's history folder for audit purposes.

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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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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.

1. Radiator/CAC Disassembly: Drain coolant and store for reuse (3). Disconnect all hoses (upper and lower) at radiator interface (4 and 5). Re-torque value is 15 +/- 1 N-m.

Image1.2.1

2. Radiator/CAC Disassembly: Secure radiator to crane to prevent tipping/falling during bolt removal and disassembly. Approximate weight of the radiator is 600 lbs.

Image1.3.1

3. Radiator/CAC Disassembly: Remove radiator to frame M10 bolts (1). 4 total ? 2 each side. Re-tighten to a torque of 55 +/- 10 N-m.

Image1.4.1

4. Radiator/CAC Disassembly: Remove radiator to CAC M10 bolts (6). 14 total - 7 bolts each side. Re-torque value is 55 +/- 10 N-m.

Image1.5.1

5. Radiator/CAC Disassembly: Remove radiator using crane and set aside. Approximate weight of the radiator is 600 lbs.

Image1.6.1

6. Radiator/CAC Disassembly: Secure charge air cooler to crane to prevent tipping/falling during bolt removal and disassembly. Approximate weight of the charge air cooler is 600 lbs.

Image1.7.1

7. Radiator/CAC Disassembly: Remove fan guard. Remove 3/8 - 16 bolts connecting fan guard halves (7). 4 bolts - 2 each side. Re-torque value is 47 +/- 9 N-m.

Remove fan guard (8). 8 bolts total. Re-torque value is 55 +/- 10 N-m

Image1.8.1

8. Radiator/CAC Disassembly: Disconnect upper/lower pipes (9) and upper brackets (10) at the charge air cooler interface. Re-torque value for hoses (9) is 15 +/- 1 N-m. Re-torque value for CAC bracket (10) is 55 +/- 10 N-m.

Image1.9.1

9. Radiator/CAC Disassembly: Disconnect hoses at fuel cooler (11). Re-torque value is 28 +/- 4 N-m.

Image1.10.1

10. Radiator/CAC Disassembly: Remove charge air cooler to frame bolts (12). Quantity 4 ? 2 each side. Re-torque value is 55 +/- 10 N-m.

Image1.11.1

11. Radiator/CAC Disassembly: Remove support bracket. Remove 3/8? ? 16 bolts (13). Quantity 4 ? 2 each side.
Re-torque value is 47 +/- 9 N-m.

Image1.12.1

12. Radiator/CAC Disassembly: Remove charge air cooler and place shroud side up, resting on wooden blocks. Approximate weight of the charge air cooler is 600 lbs. Cover all inlets to prevent debris from entering the CAC (14).

Image1.13.1

13. Radiator/CAC Disassembly: Remove remaining M10 shroud bolts (quantity 6 each side) and place shroud aside. Re-torque value is 55 +/- 10 N-m. Verify fan tip to shroud clearance is at least 1/4" in all locations before final re-assembly.

Image1.14.1

14. Radiator/CAC Disassembly: Remove center brace bolts (15). Quantity 4 - 2 each end. Re-torque value on bolts is 38 N-m +/- 2 N-m.

Image1.15.1

15. Radiator/CAC Disassembly: Remove qty 4 upper (16) and qty 4 lower (17) mounts. Re-torque value is 48 +/- 7 N-m.

Image1.16.1

16. Radiator/CAC Disassembly: Remove lower frame mounting bracket bolts (18). Quantity 6 total ? 3 each side. Lift from assembly (2 man job) and set aside. Re-torque value on bolts is 38 N-m +/- 2 N-m.

Image1.17.1

17. Radiator/CAC Disassembly: Remove brackets attached to CAC (19). Quantity 4 total ? 2 per CAC. Re-torque value is 66 +/- 3 N-m.

Image1.18.1

18. Radiator/CAC Disassembly: Remove upper frame mounting bracket bolts (20). Quantity 6 total ? 3 each side. After bolts are removed from each side, the side frame will be free to remove. Remove each of the sides frames and set aside (2 man job). Remove upper frame (2 man job). CAC is now ready for repair. Re-torque is 38 +/- 2 N-m

Image1.19.1

19. CAC Repair: CAC is to be repaired by a qualified radiator repair shop. Clean damaged areas with aluminum wire brush. Thoroughly clean damaged areas with solvent and allow to dry. Weld holes using appropriate process for aluminum base material (wall thickness is 0.508 mm). Check for leaks. Be very careful to not introduce debris into the CAC. Internally flush (clean) CAC before installation on the generator set.

Image1.20.1

20. Radiator/CAC Re-assembly: Lay CAC flat (resting on wooden supports) using same orientation as used for disassembly. Insert vibration mounting bolts and washer in CAC brackets (21). Quantity 2 per bracket. Install CAC bracket to CAC(22). Tighten to a torque of 66 +/- 3 N-m.

Image1.21.1

21. Radiator/CAC Re-assembly: Assemble lower frame mounting bracket. Important: Replace lower Rubber Vibration Mounts if damaged. Install short half of rubber vibration mount over bolts and install 361-2904 Steel Washer oriented as shown (4 locations). Orient the small mount half with the outside diameter chamfer oriented away from the steel washer. Place lower frame mounting bracket over bolts as shown (2 man job). Refer to Image 1.22.1 for complete mount assembly.

Image1.22.1

22. Radiator/CAC Re-assembly: Assemble lower frame mounting bracket. Important: Align steel washer to allow shoulder of washer to fit within mounting hole.

Image1.23.1

23. Radiator/CAC Re-assembly: Assemble lower frame mounting bracket. Install steel washer over longer half of rubber vibrating mount (4 total) as shown. Install assembly onto bolt, aligning shoulder of steel washer to mounting bracket hole (4 locations). Install flat snubber washer and nut (4 assemblies).

Image1.24.1

24. Radiator/CAC Re-assembly: Assemble lower frame mounting bracket. Important: before final torque, verify proper alignment of washers to mounting hole. Tighten to a torque of 48 +/- 7 N-m.

Image1.25.1

25. Radiator/CAC Re-assembly: Place side frames to lower frame. Install mounting bracket bolts (23). 6 total ? 3 each side. Tighten to a torque of 38 +/- 2 N-m.

Image1.26.1

26. Radiator/CAC Re-assembly: Assemble upper frame to side frames. Insert mounting bracket bolts (24). Quantity 6 total ? 3 each side. Tighten bolts to a torque of 38 +/- 2 N-m.

Image1.27.1

27. Radiator/CAC Re-assembly: Install center brace and bolts (qty 2 each end). Tighten bolts to a torque of 38 +/- 2 N-m.

Image1.28.1

28. Radiator/CAC Re-assembly: Assemble shroud to frame. Insert previously removed M10 shroud bolts (quantity 6 each side). Tighten to a torque of 55 +/- 10 N-m.

Image1.29.1

29. Radiator/CAC Re-assembly: Assemble upper vibration isolators. Inspect original rubber vibration mounts and washers for damage. If not damaged, reuse. Place short half of rubber vibration mount and nylon washer behind mounting brackets (4 locations). Orient the small mount half with the outside diameter chamfer oriented away from the nylon washer.

Image1.30.1

30. Radiator/CAC Re-assembly: Assemble upper vibration isolators. Install new Nylon Washer if damaged, install longer mount,and snubber washer over bolt as shown. Install assembly into CAC making sure nylon washer shoulder fits into mounting slot. Tighten to a torque of 48 +/- 7 N-m.

Image1.31.1

31. Radiator/CAC Re-assembly: Assemble CAC to genset (refer to previous disassembly steps and torque values). Approximate weight of the charge air cooler is 600 lbs. Remove CAC inlet/outlet debris covers. Re-connect CAC assembly to crane. Place CAC to genset frame and align mounting holes. Verify fan tip to shroud clearance is at least 1/4" in all locations before final re-assembly. Install CAC to frame M10 bolts (quantity 4 ? 2 each side) and tighten to a torque of to 55 +/- 10 N-m. Install 3/8 ? 16 bolts for support bracket (quantity 4 - 2 each side) and tighten to a torque of 47 +/- 9 N-m. Re-connect hoses at oil cooler and tighten to a torque of 40 +/- 3 N-m. Re-connect all hoses/lines/brackets (upper and lower) at the charge air cooler interface and re-tighten. Tighten CAC tube bracket M10 bolts to a torque of 55 +/- 10 N-m. Torque CAC tube clamps to 15 +/- 1 N-m. Using M10 bolts, install fan guard halves to shroud and torque to 55 +/- 10 N-m. Install 3/8 ? 16 bolts connecting guard halves (4 bolts - 2 each side) and tighten to a torque of 47 +/- 9 N-m. Verify fan to shroud and guard clearance and install fan guard.

32. Radiator/CAC Re-assembly: Assemble radiator to CAC (26). Make sure all spacers from previous reworks are installed. Re-connect radiator to crane. Approximate weight of the radiator is 600 lbs. Place radiator to genset frame. Install radiator to CAC bolts with nuts (14 total M10 bolts - 7 bolts each side). Re-torque value is 55 +/- 10 N-m.