Procedure for Reworking Radiator Cores With New Core Washers and Gaskets on Certain XQC1600 Power Modules {1353} Caterpillar

Power Module

XQC1600 (S/N: N1M1-315)

Reference: Disassembly and Assembly, UENR3310, "XQC1200 and XQC1600 Power Modules"

Introduction

This Special Instruction provides procedure for reworking the radiator cores with new washers and gaskets.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

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 to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. 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 and the warnings that are on the product are not all inclusive. If the tools, the procedure, the work method, or your actions are not recommended by Caterpillar, ensure that the tools and your actions are safe for you and for others.

Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures.

Follow all safety warnings. Most accidents that involve product operation, maintenance, or repair are caused by failure to observe safety warnings. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. Personnel should be properly trained to perform maintenance, repair, or operate any machine. Safety precautions and warnings are provided this instruction and on Caterpillar products. These warnings should be observed before performing any procedures. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are not all inclusive.

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

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Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.

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When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.

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Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below.

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Personal injury can result from improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.

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Climbing equipment may be required to access this service point. Refer to the Operation and Maintenance Manual, "Mounting and Dismounting" topic for safety information.

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Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.

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Do not operate the machine if any guards or covers are missing or inadequately secured. Personnel could be seriously injured or machine damage may occur.

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Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.

Required Parts

Installation Procedure

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Illustration 1	g06328079
(A) Separate circuit after cooler (SCAC) radiator (B) Jacket water radiator

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Illustration 2	g06328081
(A) Separate circuit after cooler (SCAC) radiator (B) Jacket water radiator

1. Remove the Separate Circuit After Cooler (SCAC) radiator (A) and Jacket Water (JW) radiator (B) from the container.

   Reference: Disassembly and Assembly, UENR3310, "XQC1200 and XQC1600 Power Modules", Radiator - Remove and Install

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   Illustration 3	g06328083
   View of radiator cores placed in flat and smooth surface

2. Remove cores from the radiator group. Place the cores on a flat, hard and smooth surface as shown in Illustration 3.
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   Illustration 4	g06328088
   View of gasket side of core header

3. If the cores are to be used again, remove the old gasket material from the gasket side of core headers. Ensure that all the gasket joints are cleaned and free from debris.
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   Illustration 5	g06328089

4. Remove the old gasket material from the gasket side of the tanks. Ensure that all the gasket joints are cleaned and free from debris.
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   Illustration 6	g06328091
   View of radiator tank surface.

5. Apply Permatex^® super weather strip adhesive to the tank surfaces as shown in illustration 6.

   Note: The adhesive is used to hold the gasket in place during assembly.

6. Reassemble the radiator using the new parts as shown in following steps.
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   Illustration 7	g06329011
   (C) M8 Locknut

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   Illustration 8	g06329012
   View of tightening sequence of M8 Locknuts

7. Tighten all radiator M8 locknuts on the radiator to 33.9 ± 6.7 N·m (300.04 ± 59.30 lb in) using sequence shown in Illustration 8. Start at the center and work outwards. Using back-up wrench tighten the locknuts while radiator core is in vertical position.

   Note: Do not reuse M8 locknuts. Replace existing locknuts with 3T-0852 locknut (23) of 862 quantity.

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   Illustration 9	g06329013
   (C) M8 Locknut

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   Illustration 10	g06329014
   (C) M8 Locknut

8. Tighten all M8 locknuts in the joints where gaskets are used.
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   Illustration 11	g06328119

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   Illustration 12	g06328135
   (1) 562-8201 Plate (2) Plate (3) Gasket

9. Install four plates (1) as shown in Illustration 12. Repeat the same on the other side of the radiator group.

10. Install four plates (2) with four gaskets (3) as shown in Illustration 12. Repeat the same on other side of the radiator group.
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    Illustration 13	g06328137

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    Illustration 14	g06328145
    (4) 562-8203 Plate

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    Illustration 15	g06328155
    (4) 562-8203 Plate

11. Install 30 plates (4) as shown in Illustration 14 and Illustration 15.
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    Illustration 16	g06328262
    (5) 562-8204 Plate

12. Install 26 plates (5) as shown in Illustration 16.
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    Illustration 17	g06328552

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    Illustration 18	g06328294
    (6) 562-8206 Plate

13. Install two plates (6) as shown in Illustration 18.
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    Illustration 19	g06328576
    (7) 562-8207 Plate

14. Install four plates (7) as shown in Illustration 19. Repeat the same on all four corners of the radiator group.
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    Illustration 20	g06328585
    (8) 562-8209 Plate

15. Install four plates (8) as shown in Illustration 20.
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    Illustration 21	g06328593
    (9) 562-8241 Bracket

16. Install two brackets (9) as shown in Illustration 21.
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    Illustration 22	g06328609
    (10) 8T-0389 Locknut (11) 8T-4121 Hard Washer

17. Install the fuel cooler mounting using eight washers (11) and four locknuts (10) as shown in Illustration 22.
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    Illustration 23	g06328615
    (12) 208-9282 Bolt

18. Install bolts (12) on triangle brackets at all four corners of the cores.
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    Illustration 24	g06328625
    (13) 112-8293 Bolt

19. Install bolt (13) in areas as shown in Illustration 24. Install bolt (13) in other side of the radiator also.
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    Illustration 25	g06328634
    (14) 6I-4374 Bolt

20. Install bolt (14) in areas shown in Illustration 25.
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    Illustration 26	g06328688
    (15) 562-8205 Plate

21. Install two plates (15) as shown in Illustration 26.
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    Illustration 27	g06328696
    (16) 6I-1090 Bolt

22. Install bolt (16) in area shown in Illustration 27. Install bolt (16) also on the other side of the radiator group.
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    Illustration 28	g06328703
    (17) 6I-0839 Bolt

23. Install bolts (17) in areas as shown in Illustration 28.
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    Illustration 29	g06328766
    (18) 113-8129 Bolt

24. Install four bolts (18) in area as shown in Illustration 29.
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    Illustration 30	g06413309
    (23) 419-6773 Radiator Core Gasket

25. Install radiator core gasket (23) in areas shown in Illustration 30.
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    Illustration 31	g06413304
    (19) 3T-0852 Locknut

26. Locknut (19) is used to fasten the radiator parts as shown in Illustration 31.
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    Illustration 32	g06413305
    (20) 562-8199 Spacer Bracket (21) 291-4179 Bolt

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    Illustration 33	g06413306
    (20) 562-8199 Spacer Bracket (21) 291-4179 Bolt

27. Install spacer bracket (20) using six bolts (21) as shown in Illustration 32 and Illustration 33.
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    Illustration 34	g06413307
    (21) 291-4179 Bolt (22) 562-8200 Space Bracket

28. Install spacer bracket (22) using two bolts (21) as shown in Illustration 34.

Leak Test Procedure

1. Position the JW radiator vertically prior to leak test.

2. Cooling sections should be placed vertical so that the connections will be facing each other in the container.

3. Ensure that all radiator ports are plugged to perform the leak test.

   Note: Do not exceed 48 kPa (7 psi). Do not test more than 20 minutes.

4. Pressurize the assembly to 17 kPa (2.5 psi) and hold for five minutes.

5. Spray bolt heads and nuts with soapy water and check for leaks. Spray tube to header joints with soapy water and check for leaks.

6. Increase the pressure to 34 kPa (5 psi) and hold for five minutes.

7. Spray bolt heads and nuts with soapy water and check for leaks. Spray tube to header joints with soapy water and check for leaks.

8. Increase pressure to 41 kPa (6 psi) and hold for five minutes.

9. Spray bolt heads and nuts with soapy water and check for leaks. Spray tube to header joints with soapy water and check for leaks.

10. Reassemble the radiator assembly. Reinstall the radiator assembly with the coolant that was previously drained.

11. Run the generator set and check for proper operation.