Usage:
January 5, 2003
(Revised July 2003)
U-5
D-90
O-107
before
or after failure |
PRODUCT SUPPORT PROGRAM FOR ELIMINATING AIRSIDE COOLANT LEAKS ON CERTAIN G3612 AND G3616 SPARK IGNITED ENGINES |
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0003 |
PS41187
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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.
NOTE: This Revised Service Letter replaces the January 5, 2003 (Revised May 2003) Service Letter. Changes have been made to the Problem and Rework Procedure.
NOTE: Mail Codes D and O are out of order since they were added at the May 2003 revision.
TERMINATION DATE
January 31, 2005PROBLEM
The G3612 and G3616 2-stage aftercooler core assembly (1308130 change level 07 and below) has experienced tube failures that result in coolant leaks into the inlet airstream. This program provides instructions and hardware to rework the core to eliminate airside coolant leaks.AFFECTED PRODUCT
Model | Identification Number |
G3612 | 1YG38-40, 48, 66, 67, 70, 96 |
G3616 | 4CG26, 41, 45, 46,
50, 52, 62, 63, 65-67, 72, 73, 75, 77, 78, 82-91, 94-96, 121, 125-145,
148, 149, 152-154, 159-165, 174-187, 192, 193, 217-224, 226, 245
BLB174-176, 178, 179 |
PARTS NEEDED
Qty |
Part Number | Description |
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5R9779 | GASKET |
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2W4766 | GASKET |
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7W6340 | GASKET |
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1278177 | GASKET |
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1706504 | GASKET-FRONT |
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1706505 | GASKET-REAR |
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2322361 | PLUG |
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2322362 | KIT |
ACTION REQUIRED
See the attached Rework Procedure.SERVICE CLAIM ALLOWANCES
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NOTE: This program should not be applied to any 1308130 change level 08 Core Assembly ordered from the parts system. The 1308130-08 core assembly has already been updated to the improved design configuration. |
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.Rework Procedure
Step 2: Core Repair
- Remove the end covers.
- If the aftercooler core was previously welded to eliminate intake air leaks between the core sideplates and tube end plates, cut through the weld using a hand grinder.
- Prior to removing the side plates from the core, mark the side plate and tube plate so that the parts can be reassembled to the same location.
NOTE: Prior to unbolting the sideplates from the stiffening cross-bars and core assembly tubeplates, properly secure the sideplates with lifting eyebolts.
Illustration 1
- After properly marking sideplates and tubeplates, remove all 10mm and 12mm bolts that secure sideplates to core assembly and to the cross-bars.
- Remove sideplates and top and bottom clamping bars.
- Inspect central cross-bars:
- If bars are rotated or can be moved with slight hand pressure, drive the bars out using a piece of wood and hammer.
- Removal of all brass sidesheets from core assembly.
- Using a propane torch, heat the solder joints while applying a slight pulling pressure to sidesheet until it breaks free from solder joint. Continue this process on all solder joints that appear to be holding the sidesheet in place.
- Thoroughly clean core assembly to remove loose debris on air fins and any material on gasket surfaces.
- Inspection and plugging of worn core assembly water tubes:
- If the brass sidesheets have worn through to the tube, inspect the tube for damage. If there appears to be tube contact with the brass side sheet, plug the tube using a tapered brass plug. Drive the 2322361 plug into the tube until it is flush with the tube end.
NOTE: If more than 14 tube requiring plugging, the aftercore will have to be replaced to maintain cooling system performance.
NOTE: Any new 2-stage core assembly, 1308130 (change level 08 and greater), ordered from the parts system will not require rework per this program. Parts system core assemblies have already been updated to the improved design configuration.
- Welding 20x20x20 mm bars to inside of sideplates:
- Clean inside face of one sideplate prior to welding bars in place.
- Temporarily install all cross-bars to allow proper positioning of the (6) turnstop blocks.
Refer to the following graphic for more specific details.
Illustration 2
NOTE: After welding turnstop blocks in-place, the cross-bars can be removed. Clean all weld slag from sideplate surfaces.
- Reworking cross-bars:
- Remove the silicon pads on all cross-bars removed from the core assembly
- Clean the silicon pads surfaces on the cross-bars
- Install a new silicon pad using a contact adhesive. The silicon pads with the rounded edges are to be used with the central cross-bars.
- Install sideplates to core assembly:
- Align the matching marks of the sideplate and tubeplate
- Apply silicon sealant to last 25mm of 10mm bolts
- Loosely install the 10mm and 12mm bolts
- Prior to applying final torque to the bolts, properly align the upper and lower core assembly gasket surface using a straighedge and rubber mallet. The end bolts may have to be slightly tightened to keep the sideplate from moving out of place.
- Torque the 10mm bolts to 55 +/- 10 Nm and the 12mm bolts to 100 +/- 20 Nm.
- Drive in the 0.5mm shim pieces (provided in the parts kit) between the sideplate and tubeplate. See following graphic.
- Reweld the sideplate to tubeplate joint at all four joints with a 3mm 1E0099A weld.
- Reinstall core assembly to engine using new gaskets as required.
Illustration 3
Illustration 4
NOTE: Weld should extend to top and bottom gasket surfaces. Grind weld flush with gasket surfaces, all 8 joints.
NOTE: After weld has cooled, applying silicon sealant to gap between sideplate and tubeplate, 8 places.