PRODUCT SUPPORT PROGRAM FOR REPLACING THE FAN PULLEY ON CERTAIN C32 GENERATOR SETS (APS1000A POWER MODULES) Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE FAN PULLEY ON CERTAIN C32 GENERATOR SETS (APS1000A POWER MODULES)

Usage:

TEBE3446-00

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20Aug2015

U-446

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Before/After	PRODUCT SUPPORT PROGRAM FOR REPLACING THE FAN PULLEY ON CERTAIN C32 GENERATOR SETS (APS1000A POWER MODULES)
1359		PS44834

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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 "PS44834" 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

31Aug2017

PROBLEM

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The existing fan belts can fail on certain C32 Generator Sets (APS1000A Power Modules). The current drive ratio causes the fan to exceed the power capability of the 4 belt system.

AFFECTED PRODUCT

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Model	Identification Number
C32	AL600102-00121, 123-125, 132, 136

PARTS NEEDED

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Qty	Part Number	Description
1	3102199	V-BELT SET (See Action Required for Ordering)
2	3332408	BEARING-BALL (See Action Required for Ordering)
1	3464803	PULLEY-FAN (See Action Required for Ordering)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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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Replacement of the fan pulley, bearings, and belts needs to be performed.
Repair should be completed before rental if possible.

All parts request may be made by contacting Shay Leskovisek at ALTORFER Packaging.

Email:sleskovisek@altorfer.com
Fax# 309 282-7546
Phone# 309 697-1234 ext 5119

Please provide the following information upon request for each serial number. Form number must completed and sent back to Altorfer via email or fax before any parts will be packaged and sent out.

Package Serial Number______________________________________________________
Hour Meter Reading_________________________________________________________
Qty (Max 1 per serial number) of Fan Pulley__________________
Qty (Max 2 per serial number) of Fan Bearings___________________________
Qty (Max 1 per serial number) of V belt set of 4_______________________
Dealer Name________________________________________________________________
Shipping Address___________________________________________________________
City_______________________________________________________________________
State/Zip Code_____________________________________________________________
Contact Name_______________________________________________________________
Email:_____________________________________________________________________
Phone #:___________________________________________________________________
Fax #:_____________________________________________________________________

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.

Rework Action Required

Replace the fan pulley 356-9922 and existing belts with a .625 ratio pulley 346-4803 and v belt set 310-2199 containing "9L-6649" belts. Fan bearings 333-2408 will also be replaced.

Refer to the 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%
0-5000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 6.0-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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Lock-Out / Tag-Out the unit
Remove all 4 fan guard sections and set them aside.

Image1.1.1

Place cardboard against the radiator core to protect the fins from damage.
Remove the fan and set it aside.

Image1.2.1

Remove the belt guards and set them aside.
Take tension off the belts with the tension set screw
Remove the belts
Loosen the nuts securing fan adapter

Image1.3.1

Image1.3.2

Remove the fan adapter and spacer.
Support the fan pulley and remove.

Image1.4.1

Image1.4.2

Image1.4.3

Remove the bolt securing the plate to the shaft.
Remove the plate.

Image1.5.1

Remove the remaining fan hub assembly from the shaft and move it to a work space to remove the bearings. Leave the rear spacer on the fan shaft. Image 1.6.2

Image1.6.1

Image1.6.2

Parts Required
2 333-2408 Ball Bearings

Carefully remove both bearings and retain the spacer located in between both bearings.

Begin by installing the bearing located closest to the fan with a bearing driver and mallet. Make sure that the bearing is properly seated. Turn the hub assembly over and insert the spacer.

CAUTION: Install the spacer that is located in between the two bearings before installing the second bearing.

Install the rear bearing with the red seal facing outwards. Verify that the spacer is centered. Seat the bearing properly.

Image1.7.1

Image1.7.2

Image1.7.3

Install the fan hub assembly back onto the fan shaft. Install the shaft plate and apply thread locker to threads on the 1/2-13 center shaft bolt. Tighten to 115 +/- 5 Nm

Image1.8.1

Parts Required
1 346-4803 Fan Pulley
1 310-2199 Belt Set

Install new fan pulley 346-4803 with existing hub, spacer and fan adapter. Tighten each nut holding the fan adapter to 35 +/-5 Nm.

Image1.9.1

Image1.9.2

Image1.9.3

Ensure the end of the tensioning bolt is seated in the correct location.

Install the belt set
Tension belts to 180 +/- 10 lbs (refer to Specifications, "Belt Tension Chart")

Tighten fan bracket nuts to 65 +/- 10 Nm. Image 1.10.1

Note: Since matched set of belts are being used, please check the tension of all the belts in order to verify that the lowest belt is in the acceptable tolerance range.
Reinstall fan
Reassemble fan and belt guards

Since new belts are being installed run the engine for 30 mins. at rated speed with no load.

CAUTION: Allow belts to cool down before verifying belt tension.

Check the belt tension again on each belt. Verify that the lowest belt is in the acceptable tolerance range. Retighten if necessary.