Product support program for reworking lines gp - water 279-0117 on power module aftercoolers for certain PM3516B Engines Caterpillar

Product support program for reworking lines gp - water 279-0117 on power module aftercoolers for certain PM3516B Engines

Usage:

SEBE9992-02

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06Jul2006

(Revised 25Aug2006)

O-534

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REWORKING LINES GP - WATER 279-0117 ON POWER MODULE AFTERCOOLERS FOR CERTAIN PM3516B ENGINES
1063 1380		PS42226

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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 "PS42226" 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 SEBE9992-00 on the 06 July 2006 Service Letter. Changes have been made to Affected Product and the Rework Procedure.

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TERMINATION DATE

31Jul2008

PROBLEM

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The existing Lines GP - Water 279-0117 are plumbed incorrectly by the radiator supplier on Power module serial prefix BPD.

AFFECTED PRODUCT

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Model	Identification Number
PM3516B	BPD01132-01156, 1160-1177, 1179-1197, 1200-1202

PARTS NEEDED

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Qty	Part Number	Description
1	2162285	JOINT ASSEMBLY
1	2949709	TUBE
2	9Y6893	GASKET

ACTION REQUIRED

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Refer to attached rework procedure.

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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%
0-50 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 5.0-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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1. All rework material is provided in 294-9710 LINES GP-WATER.

2. Record and e-mail to David Noble, Electric Power Division Customer Service Engineer at Dnoble@CAT.com the following information:

a. Dealer Claim number
b. Package Serial Number
c. Radiator Serial Number

3. Thoroughly read this procedure before beginning work.

4. With reference to 279-0117 LINES GP-WATER and 208-0822 LINES GP-WATER and Figure 1 below, fully drain radiator coolant from radiator and radiator lines via provided drain lines at rear of module. Store coolant in a clean container capable of holding 770L (203 gal) of coolant.

5. Coolant may be reused if properly stored. Keep stored coolant free from dust and debris to avoid ingesting foreign objects into cooling system.

6. With reference to 279-0117 LINES GP-WATER and Figure 2 below, unbolt both aftercooler regulator housing flanged elbows (203-6545 TUBE AS and 203-6546 TUBE AS). Loosen both joint elbow assemblies (203-6547 ELBOW AS) from 203-6545 TUBE AS and 203-6546 TUBE AS and from aftercooler tubes (279-0113 TUBE AS and 279-0115 TUBE AS). Set these parts aside as they will be reused. Keep all mounting hardware; it will be reused.

7. Cut 279-0113 TUBE AS and 279-0115 TUBE AS as shown below in Figure 3. 279-0113 TUBE AS will be reduced in length approximately 382 mm (15 in.) and 279-0115 TUBE AS will be reduced in length approximately 359 mm (14 in). The 382 mm and 359 mm lengths are scrap. After cutting is completed, deburr edges of remaining, longer pipes.

8. Remove old gasket material from aftercooler regulator housing ports and from flanged faces of 203-6545 TUBE AS and 203-6546 TUBE AS.

9. Re-assemble one (1) 203-6547 ELBOW AS to 279-0113 TUBE AS.

10. Assemble the 216-2285 JOINT AS (from kit) to the 279-0115 TUBE AS, then assemble the 294-9709 TUBE (from kit) to the other end of the new 216-2285 JOINT AS.

11. Assemble the remaining one (1) 203-6547 ELBOW AS to the other end of the above referenced, new 294-9709 TUBE.

12. Insert bottom, non-flanged end of 203-6545 ELBOW AS in open end of 203-6547 ELBOW AS attached to 279-0113 TUBE AS.

13. Insert bottom, non-flanged end of 203-6546 ELBOW AS in open end of 203-6547 ELBOW AS attached to new 294-9709 TUBE.

14. Hand-tighten all joint elbows and straights to secure entire assembly.

15. Install 9Y-6893 GASKET (from kit) on flange faces of 203-6545 TUBE AS and
203-6546 TUBE AS.

Image1.1.1

Image1.1.2

Image1.1.3

Image1.1.4

16. Refer to above Figures 4 and 5. Per 1E0279A TIGHTENING, use existing hardware to bolt 203-6545 TUBE AS to the front aftercooler regulator housing port and bolt 203-6546 TUBE AS to the rear aftercooler regulator housing port. 203-6545 TUBE AS and 203-6546 TUBE AS will now be bolted to ports opposite from the original build.

17. Tighten all fluid line fittings and joints per 1E0279P TIGHTENING and 1E0279A TIGHTENING.

18. Refill cooling system with original, properly stored coolant.

19. Check and correct any cooling system leaks.