PRODUCT SUPPORT PROGRAM FOR REWORKING RADIATOR FAN ON CERTAIN 3516, AND 3516B GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING RADIATOR FAN ON CERTAIN 3516, AND 3516B GENERATOR SETS

Usage:

TEBE4956-00

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15Jul2016

U-373

D-327

O-325

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Before/After	PRODUCT SUPPORT PROGRAM FOR REWORKING RADIATOR FAN ON CERTAIN 3516, AND 3516B GENERATOR SETS
1356 1360		PS45154

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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 "PS45154" 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

31Jul2018

PROBLEM

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The existing radiator fan may be installed backwards on certain 3516, and 3516B Generator Sets assembled from November 1, 2015 to June 15, 2016. If the existing radiator fan orientation is not addressed the airflow would drop to 30 percent of requirement.

AFFECTED PRODUCT

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Model	Identification Number
3516	YAS01000-01001
3516B	YAT01000-01001 ZAP02000-02003

PARTS NEEDED

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No parts needed for this program

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.

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%
0-20000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 20.0-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. Inspect radiator fan for proper orientation before attempting rework instructions below. If radiator fan is installed correctly from the factory, no further action is required. The leading edge of the fan blade should be on the engine side and trailing edge on the radiator side.

Radiator Fan Inspection

The distance from the radiator fan edge (blue and green arrows) to the fan adapter center (red line) is different. The shorter length (green arrow) should be towards the engine.
Reference Image 1.1.1 for proper radiator fan orientation.

Image1.1.1

Rework Procedure For Removing and Reinstalling the Radiator Fan

2. Remove the plug on the ball valve on front of radiator and drain coolant from the cooling system into a suitable container for reuse. After draining remove ball valve and adapter from radiator.

Image1.2.1

3. Disconnect fuel hose from fuel cooler.

Image1.3.1

4. Remove coolant level sensor and ladder clip from radiator. Cut tie wraps holding harness to piping.

Image1.4.1

5. Disconnect the 2 tube assemblies from radiator and engine leaving couplings on tubes.

Image1.5.1

6. Disconnect tube assembly leaving couplings on tube.

Image1.6.1

7. Remove clamps and disconnect tube assembly.

Image1.7.1

8. Disconnect tube assembly from engine and radiator leaving coupling on tube.

Image1.8.1

9. Disconnect the elbow.

Image1.9.1

10. Remove fan guard.

Image1.10.1

11. Remove bolts from both sides of radiator.

Image1.11.1

12. Attach suitable lifting device to radiator group. The weight of the radiator is approximately 891 kg (1964 lb). Move radiator away from engine so as to have enough clearance to remove and reinstall the radiator fan. It may be necessary to loosen the fasteners on the fan shroud in order to ensure the fan on engine is not damaged when lifting.

Image1.12.1

13. Attach suitable lifting device to the radiator fan.

Disconnect the 6 bolts, PN 8T-4835, securing the radiator fan to the engine.
Rotate radiator fan and secure the fan to the engine with the 6 bolts, PN 8T48345 and 6 washers PN 8T-4223. Pre-tighten the bolts by hand and finally tighten to the rated torque value. Torque bolts in accordance with 1E0279A, to 105Nm.
Reference step 1 to verify proper radiator fan inspection and orientation.

Image1.13.1

14. Attach suitable lifting device to the radiator group. The weight of the radiator is approximately 891 kg (1964 lb). Move radiator toward engine. It may be necessary to loosen the fasteners on the fan shroud in order to ensure the fan on engine is not damaged when positioning the radiator. After radiator is positioned retighten fan shroud bolts. When retightening the shroud ensure about 12 mm clearance all the way around between tip of fan blades and shroud.

Image1.14.1

15. Install bolts on both side of radiator.

Image1.15.1

16. Install fan guard on radiator.

Image1.16.1

17. Connect elbow.

Image1.17.1

18. Connect tube assembly to engine and radiator.

Image1.18.1

19. Install tube assembly and clamps.

Image1.19.1

20. Install tube assembly.

Image1.20.1

21. Install the 2 tube assemblies.

Image1.21.1

22. Install coolant level sensor and ladder clip ensuring the tip of sensor is free of debris. Tie wrap harness to tube assembly as required.

Image1.22.1

23. Connect fuel hose to fuel cooler.

Image1.23.1

24. Remove plug from front of radiator and install adapter and ball valve. Fill the cooling system. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" or Operation and Maintenance Manual, "Cooling System Coolant (DEAC) - Change".