PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXPANSION TANK MOUNTING HARDWARE ON CERTAIN PM1360 POWER MODULES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXPANSION TANK MOUNTING HARDWARE ON CERTAIN PM1360 POWER MODULES

Usage:

TEBE1844-00

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08Aug2014

A-343

O-397

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXPANSION TANK MOUNTING HARDWARE ON CERTAIN PM1360 POWER MODULES
1360		PS44442

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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 "PS44442" 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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TERMINATION DATE

31Aug2016

PROBLEM

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The existing expansion tank mounting can fail. If the existing threads of the holes in the overhead sturctural tubing strip the tank can become unsupported.

AFFECTED PRODUCT

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Model	Identification Number
PM3512	TC800100-00102, 104, 106, 108-114, 116-123, 126-129, 131-132, 134-149, 152-159, 161-165, 168-169, 171, 173, 192-193, 199

PARTS NEEDED

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Qty	Part Number	Description
4	8T4185	BOLT-HEX HEAD
4	8Y3925	BOSS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 18% 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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Hardware improvements need to be addressed in order to prevent possible failure of supporting the coolant expansion tank. This involves the addition of threaded weld bosses, and bolt replacement.

Refer to the attached Rework Procedure to determine the proper tools and equipment
required to safely perform the rework.

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Image1

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%
0-15000 hrs, 0-12 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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WARNING: Injury can occur to personnel if the rework is done improperly. Personal Protective Equipment (PPE) suitable to the work being performed must be worn when performing the rework.

WARNING: The power module must be isolated electrically before and while the rework is performed. Follow the proper lockout tag out procedures to protect against the unexpected energization or start up of the power module. Failure to follow these warnings could result in injury to personnel during service.

Ensure that the coolant has reduced to a safe temperature before removing the expansion tank.
Drain the coolant into a container.
Disconnect the hoses and lines to the expansion tank.

Image1.1.1

Remove the conduit from the mounting brackets.

Image1.2.1

Use a forklift truck to support the expansion tank with extended forks and blocks. Carefully lower the tank.

NOTE: The following instruction outlines a alternative method for supporting the tank if a forklift truck is not available.

Secure two steel angles each around 800mm in length. Drill two holes in each angle at the locations specified in Image1.3.1
Mount 2 steel angles onto the flange of the exhaust silencer with screws to support the expansion tank once the mounting bolts are removed Place suitable blocks of wood (approximately 80x100x400mm) between the angle and the bottom of the expansion tank as shown in Image1.3.2.

Image1.3.1

Image1.3.2

Unscrew the 4 M10 bolts at each of the corners of the expansion tank. Remove the bolts, washers, and spacers. Retain the washers for reuse. Push the tank as far as possible to the side exposing the threaded holes overhead.

Image1.4.1

To prep for welding remove the paint around the holes to a diameter of around 40mm. Screw a 8T-4185 bolt into a 8Y-3925 threaded boss leaving approximately 5mm sticking out the other end to position the boss in the proper location for welding. Screw the assembly into the threaded hole overhead until the boss is secure and flush against the structural tube. Weld the boss in place. Remove the bolt, clean the weld, and paint all exposed metal.
Repeat the steps for the adjacent hole.
Push the tank to the other side and repeat for the remaining two holes.

Parts Required
4 8T4185 Bolt
4 8Y3925 Boss

Image1.5.1

Return the expansion tank to its original position, and install a washer and bolt in each mounting location.
Tighten the bolts with 55+-10 Nm of torque.

Image1.6.1

Reconnect the hoses, lines and clamps to the expansion tank. Reinstall the conduit into the mounting brackets. Fill the tank with coolant. Check the connections of the coolant system for leaks. The power module can now be returned to service.