PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE RADIATOR FAN GUARD ON CERTAIN C27 GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE RADIATOR FAN GUARD ON CERTAIN C27 GENERATOR SETS

Usage:

TEBE2017-01

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05Dec2014

(Revised 15Dec2014)

U-731

A-541

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Safety	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE RADIATOR FAN GUARD ON CERTAIN C27 GENERATOR SETS
1063 1353 1356		PI11000

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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 as soon as possible. When reporting the repair, use "PI11000" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code.
Exception: If the repair is done after failure, use "PI11000" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:	This Revised Service Letter replaces the 05Dec2014 Service Letter. Changes have been made to the Parts Needed, Action Required, and Rework Procedure.

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PROBLEM

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The radiator fan guard needs to be replaced on certain C27 Generator Sets. The wire that forms the existing radiator fan guard may break and come loose. A flying object hazard may result if the loose pieces contact the radiator fan during operation.

AFFECTED PRODUCT

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Model	Identification Number
C27	GDS00505, 509-520, 523-526, 552, 554-559, 564

PARTS NEEDED

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Qty	Part Number	Description
2	1V9020	PLUG-BUTTON
12	7X7729	WASHER-HARD
12	8T4121	WASHER-HARD
4	8T4133	NUT
8	8T4195	BOLT-HEX HEAD
4	8T4196	BOLT-HEX HEAD
2	1862002	HOSE-HUMP
2	4506010	GUARD AS
1	4594843	SHROUD AS
1	4658889	PLATE
1	4658890	PLATE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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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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.

REPAIR ACTION REQUIRED

Replace the existing 379-0103 Fan Guard (1) with 450-6010 Fan Guard (2). To accommodate the new fan guard, the existing 442-7509 Radiator Shroud (3) will also need to be removed and replaced by 459-4843 Radiator Shroud (4). Note that the new shroud will require punching of holes to accommodate fuel line routing. Shroud replacement requires radiator removal from the package. The new shroud also includes changes to include more robust radiator stabilizer plates. The existing 350-4028 Right Side Stabilizer Plate (5) and 350-4029 Left Side Stabilizer Plate (6) will need to be replaced with 465-8889 Right Side Stabilizer Plate (7) and 465-8890 Left Side Stabilizer Plate (8). Refer to Image1 and Image2.

The 2 lower hoses (1 on each side) that connect the charge air pipes to the charge air cooler will need to be replaced with 186-2002 Hose (9). These longer hoses are needed to allow proper alignment on the opposite end of the pipe that connects to the turbocharger.

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Image1

Image2

Image3

OWNER NOTIFICATION

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Owners in the following countries will receive the attached Owner Notification:
US
Canada
Australia
New Zealand

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 16.0-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.

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE RADIATOR FAN GUARD ON CERTAIN C27 GENERATOR SETS

MODELS INVOLVED - C27

Dear Cat Product Owner:

The radiator fan guard needs to be replaced on the products listed below. The wires that form the existing radiator fan guard can break and come loose. A flying object hazard may result if the loose pieces contact the radiator fan during operation. This flying object hazard may, in conjunction with other factors or circumstances, result in a risk of personal injury or death. You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated.

You may now search for open Safety Service Letters by entering your product serial number(s). Visit the SAFETY.CAT.COM website and click on the Product Safety page for more information. Please refer the dealer to their Service Letter dated 05Dec2014 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 05Dec2014 Service Letter

Rework Procedure

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Remove the stabilizer plates from each side of the generator set (1). Remove fastening hardware (2) from top of stabilizer plate (2 bolts each side). This hardware will not be reused. Remove fastening hardware (3) from the bottom of the stabilizer plates (2 bolts each side). This hardware will be re-used to attach the new stabilizer plates. Refer to Image1.1.1.

Image1.1.1

Remove the existing fan guard (4). Remove 8 bolts (5) that connect the halves together. Save these since they will be used to install the new fan guard. The washers will not be needed. Remove 8 bolts that connect the fan guard to the shroud (6). Save these bolts and washers since they will be used to install the new fan guard. For re-assembly, tighten to 55 +/- 10 N-m. Refer to Image1.2.1.

Image1.2.1

Drain coolant and store for reuse. Disconnect all hoses (upper and lower) at radiator interface (7 and 8). Re-tighten to 15 +/- 1 N-m for re-assembly. Refer to Image1.3.1 and Image1.3.2.

Image1.3.1

Image1.3.2

Disconnect all charge air cooler (CAC) pipes. Disconnect upper/lower pipes (9) and upper brackets (10) at the charge air cooler interface. Note that the lower charge air cooler hoses will not be re-used. Re-tighten hose clamps (9) to 11 +/- 1 N-m, and re-tighten upper CAC brackets (10) to 55 +/- 10 N-m for re-assembly. Refer to Image1.4.1.

Image1.4.1

Disconnect radiator drain line from the ball valve. Tighten to 28 +/- 4 N-m for re-assembly. Refer to Image1.5.1.

Image1.5.1

Disconnect fuel cooler lines from the adapters at the fuel cooler inlet and outlet. Make sure fuel is drained from fuel cooler and lines before removal. Tighten the fuel line fitting to the fuel cooler adapter to 110+/- 17 N-m for re-assembly. Note that this tightening value refers only to the o-ring face seal connection for the fuel cooler line. A back-up wrench will be needed on the adapter in the fuel cooler housing. Refer to Image1.6.1.

Image1.6.1

Insert lifting eyes in top of radiator in location shown. 2 total lifting eyes will be needed (1 on each end of radiator). Approximate dry weight of radiator is 725 lbs. Refer to Image1.7.1. For re-assembly, make sure fan tip to shroud clearance is equally spaced for each blade.

Image1.7.1

Attach lifting straps to lifting eyes and secure radiator to prevent tipping or falling. Disconnect radiator from frame (8 bolts total). Approximate dry weight of radiator is 725 lbs . Tighten to 55 +/- 10 N-m for re-assembly. Refer to Image1.8.1.

Image1.8.1

Locate radiator on flat surface and secure with lifting straps to prevent tipping or falling. Remove existing shroud (4 bolts each side - 8 bolts total). Retain all M10 fastening hardware for re-attaching new shroud. Refer to Image1.9.1.

Image1.9.1

Punch fuel line routing holes in new 459-4843 Shroud as shown below (dimensions in mm). Install existing rubber grommets in new holes. Plug original holes with 1V-9020 Plug. Refer to Image1.10.1.

Image1.10.1

Install new 459-4843 Shroud using original fastening hardware and additional quantities ordered. Use quantity 12 of 8T-4196 Bolts (Qty 6 each side), quantity 12 of 8T-4133 nuts, and quantity 24 of 7X-7729 washers. Tighten to 30 N-m. Refer to Image1.11.1.

Image1.11.1

Install radiator assembly to frame using the reverse of procedures described earlier. Make sure fan tip to shroud clearance is equally spaced for each blade. Install fuel cooler lines and radiator drain line.

Install new 450-6010 Fan Guard using some of the original fastening hardware and additional quantities ordered. Use quantity 12 of 8T-4195 Bolts and quantity 12 of 8T-4121 Washers to attach the fan guard to the shroud (11). Use quantity 8 of 8T-4195 Bolts and quantity 8 of 8T-4121 Washers to attach the fan guard halves together (12). Tighten all hardware to 55 +/- 10 N-m. Refer to Image1.13.1.

Image1.13.1

Install new 465-8889 Right Side Stabilizer Plate (13) and 465-8890 Left Side Stabilizer Plate (14) using some of the original fastening hardware and additional quantities ordered. Fasten the top of each stabilizer plate using quantity 2 of 8T-4195 Bolts and quantity 2 of 7X-7729 Washers (15). Tighten to 55 +/- 10 N-m. Fasten bottom of each stabilizer plate using quantity 2 of 7X-2554 Bolt, quantity 2 of 8T-4132 Nut, quantity 4 of 9X-8257 Washer (16). Tighten to 240 +/- 40 N-m. Refer to Image1.14.1.

Image1.14.1

Install total quantity 2 (1 on each side) of 186-2002 hoses (17). These are the lower hoses that connect the charge air pipes to the charge air cooler. These longer hoses are needed to allow proper alignment on the opposite end of the pipe that connects to the turbocharger (18), after the radiator position is adjusted to allow fit-up of the new fan guard. Refer to Image1.15.1 and Image1.15.2.