PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE RADIATOR FAN DRIVE PULLEY ON CERTAIN 3516C 50 HZ GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE RADIATOR FAN DRIVE PULLEY ON CERTAIN 3516C 50 HZ GENERATOR SETS

Usage:

TEBE8154-01

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29Aug2018

(Revised 02Jan2019)

U-513

A-375

D-450

O-453

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Safety	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE RADIATOR FAN DRIVE PULLEY ON CERTAIN 3516C 50 HZ GENERATOR SETS
1359		PI11162

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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 "PI11162" 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 "PI11162" 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 29Aug2018 Service Letter. A change was made to the Affected Product.

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PROBLEM

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The diameter of the radiator fan drive pulley may be larger than intended, thus resulting in higher than intended radiator fan speed on certain 3516C 50 Hz generator sets using 438-5662 Radiator Group. If the radiator fan runs at higher than intended speed, fan blade breakage may occur and parts may exit the fan guard or radiator shroud. This flying object hazard may, in conjunction with other factors or circumstances, result in a risk of personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
3516C	LYM00102-00104, 114 SBK02002, 2004, 2007-2008, 2017, 2022, 2024, 2026, 2030, 2039, 2041, 2043, 2115, 2118, 2133, 2316, 2321, 2325, 2349, 2357, 2362, 2476-2478, 2480, 2484-2485, 2560-2561, 2565-2566, 2584, 2596, 2598-2599, 2601-2603, 2605, 2613, 2617, 2657, 2696
3516C HD	SEK00352, 521-524, 528, 532-535, 541, 592, 668, 681, 701, 746-747, 751, 797-800, 806, 848, 850, 870-871, 876, 893, 975-979, 981-985, 988-990, 993, 1000-1001, 1027, 1042-1043, 1045, 1106-1107, 1111, 1130, 1147, 1149, 1158, 1228, 1236-1237, 1250-1251, 1253-1254, 1256-1258, 1278-1280

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 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 and the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

WARNING: The generator set must be isolated mechanically and electrically before and while the rework is being performed. Follow the proper lock out tag out procedures to protect against unintended operation, unexpected movement, 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 and local and remote controls before you perform any service to the machine.

Action Required

Dealers must notify customers of following items:

1. In addition to the radiator fan drive pulley inspection and possible rework, fan replacement may be needed in certain cases depending on several factors currently under review.

2. If the product must be operated before Caterpillar communicates fan replacement criteria, DO NOT STAND NEAR THE RADIATOR AND RADIATOR FAN GUARD OR RADIATOR SHROUD while the engine is running. Remain alert and maintain a safe distance and an unobstructed egress path from the radiator and radiator fan guard or radiator shroud while the engine is running.

Rework Action Required

Measure the outside diameter of the fan pulley assembly (1), idler pulley assembly (2), and drive pulley assembly (3) used with the 438-5662 Radiator Group. Refer to Image1. If all the diameters and identification marks MATCH those shown in Image2, the idler pulley assembly (2) and drive pulley assembly (3) MUST be removed and installed in the reverse location. This rework results in a pulley ratio of 0.47, and yields the expected fan speed of 705 rpm.

If any diameters and identification marks do not match those shown in Image2, the Dealer Technical Communicator shall notify the factory and submit a request to CPI number 426763 through CPI Feedback within the Service Information Management System (SIMSi).

Refer to the attached Rework Procedure.

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Image1

Image2

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 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.

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 REWORKING THE RADIATOR FAN DRIVE PULLEY ON CERTAIN 3516C 50 HZ GENERATOR SETS

MODELS INVOLVED - CERTAIN 3516C 50 HZ GENERATOR SETS

Dear Cat Product Owner:

The radiator fan drive pulley on the engine stub shaft needs to be inspected and possibly reworked on the products listed below. The diameter of the radiator fan drive pulley may be larger than intended, thus resulting in higher than intended radiator fan speed. If the radiator fan runs at higher than intended speed, fan blade breakage may occur and parts may exit the fan guard or radiator shroud. 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.

In addition to the radiator fan drive pulley inspection, fan replacement may be needed in certain cases depending on several factors currently under review.

If the product must be operated before Caterpillar communicates fan replacement criteria, DO NOT STAND NEAR THE RADIATOR AND RADIATOR FAN GUARD OR RADIATOR SHROUD while the engine is running. Remain alert and maintain a safe distance and an unobstructed egress path from the radiator and radiator fan guard or radiator shroud while the engine is running.

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 CAT.COM/SAFETY website and click on SUPPORT, then SAFETY SERVICES for more information. Please refer the dealer to their Service Letter dated 29Aug2018 when scheduling this service.

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

Caterpillar Inc.

Identification #(s)

Attached to 29Aug2018 Service Letter

Rework Procedure

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Remove air pipes as required, remove fan belt guards, and remove fan belts. Refer to Special Instruction, REHS3403.

Remove the existing 297-3160 Idler Pulley Assembly and 300-6296 Drive Pulley Assembly. Install the existing 297-3160 Idler Pulley Assembly to the engine stub shaft. Refer to Image1.2.1. Install the existing 300-6296 Drive Pulley Assembly to the idler pulley shaft. Refer to Image1.2.2.

Reuse existing hardware to install each pulley.

287-8585 Kit-Bushing is common between 297-3160 Idler Pulley Assembly and 300-6296 Drive Pulley Assembly.

The existing 328-6142 V-Belt Set can be used with the new pulley arrangement.

The 300-6296 Drive Pulley Assembly may have been factory installed on the engine stub shaft with the 3 bolts facing towards the engine (refer to Image1.2.3) or with the 3 bolts facing away from engine (refer to Image1.2.4). For consistency, install 297-3160 Idler Pulley Assembly on the engine stub shaft in the original factory orientation.

Refer to Special Instruction, REHS3403 for pulley assembly instructions. In addition, the following steps should be completed.

Verify the torque on both pulleys.

Tighten the bolts that secure the pulley onto bushing kit assembly to 39 N.m (29 lb ft). Repeat the torque procedure using a star pattern, alternating bolts until fully torqued. Refer to Image1.2.3 or Image1.2.4.

Verify that the bolts are torqued to 39 N.m (29 lb ft).

Image1.2.1

Image1.2.2

Image1.2.3

Image1.2.4

Verify alignment of the idler pulley, fan pulley, and crank pulley. Refer to Special Instruction, REHS3403.

Adjust belt tension. Refer to Specifications, RENR9362.

Reinstall fan belt guards, and air pipes. Refer to Special Instruction, REHS3403.

Verify proper operation of generator set.