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

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

Usage:

TEBE8475-03

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17Dec2018

(Revised 18Mar2019)

A-522

D-638

O-118

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Safety	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE RADIATOR FAN ON CERTAIN 3516C 50 HZ GENERATOR SETS
1356		PI11193

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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 "PI11193" 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 "PI11193" 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 17Dec2018 (Revised 17Jan2019) Service Letter. Changes have been made to the Affected Product.

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PROBLEM

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The 3587636/">358-7636 Radiator Fan may have run at higher than intended speed on certain 3516C 50 HZ Generator Sets using 438-5662 Radiator Group. 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	SBK02039, 2041, 2584
3516C HD	SEK00352, 701, 751, 797-800, 806, 1228, 1236-1237

PARTS NEEDED

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Qty	Part Number	Description
1	2762444	FAN KEY 7/8
1	3587636	SPIDER AS-FAN
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 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

Check your records for a product improvement program for reworking the radiator fan drive pulley. The product improvement program for reworking the radiator fan drive pulley must be completed prior to the fan rework for this program. Once the product improvement program for reworking the radiator fan drive pulley is completed, complete this program.

Include the serial number of the fan that was removed in the claim. The serial number will be a 5 or 6 digit number on the hub of the fan. Render the removed fan useless.

Refer to the attached Rework Procedure for fan replacement instructions.

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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 24.0-hour job
Include the serial number of the fan that was removed in the claim.

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PARTS DISPOSITION

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Hold the old fan that was removed for 30 days for a possible Parts Return Request (PRR). Make sure to list the service letter program number on the packing slip and include the closed work order paperwork. Handle all other parts in accordance with your Warranty Bulletin on warranty parts handling.

If a Parts Return Request (PRR) is not issued to you after 30 days through the Send-It-Back process, 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

MODELS INVOLVED - CERTAIN 3516C 50 HZ GENERATOR SETS

Dear Cat Product Owner:

The radiator fan needs to be reworked on the products listed below. The radiator fan may run 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.

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 17Dec2018 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 17Dec2018 Service Letter

Rework Procedure

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1. Drain coolant from engine and radiator.

2. Disconnect charge air and coolant lines from system in preparation
for core removal.

3. Remove core guards from discharge side of cooling system. This will
allow for the core assembly to be laid on its face in a later step.

4. Connect lifting device to the top of the side channels. This will provide support while bolts connecting core to substructures are disconnected. Refer to Image1.1.1

Image1.1.1

5. Remove all bolts connecting the core assembly to the support structure. Repeat this step for opposite side as well. Refer to Image1.2.1

Image1.2.1

6. Remove bolts attaching fan guards to core assembly. In Image1.3.1, only the top is shown, remove bolts on each side and bottom of the core assembly.

Image1.3.1

7. With lifting device in place, and all bolts removed, slowly lift the core assembly off the support assembly. Lay core on its face. The weight of core assembly is approximately 2050 kg (4500 lb).

8. Remove the cap screws attaching fan hub to the bushing.

9. The fan can now be moved away from the bushing. Use an Allen wrench to loosen set screws and remove the bushing.

10. Be sure to properly secure fan with a lifting device supporting at least two blades. Remove the 3587636/">358-7636 Spider Fan Assembly. The weight of the fan assembly is approximately 234 kg (515 lb). Refer to Image 1.4.1 for an example of the lifting technique on a 8 blade fan. Note that the 3587636/">358-7636 Spider Fan Assembly has 13 blades, but the lifting technique is the same.

NOTE:
- Use only NYLON LIFTING STRAPS when lifting fan. Wrap strap around two shanks when lifting.
- Do not use chain or wire sling for lifting.
- Always use at least two blades/blade shanks when lifting. Do not lift by only one blade/blade shank.

Image1.4.1

3587636/">358-7636 Spider Fan - Installation

1. Remove Tapered Bushing from the hub. Refer to Image1.5.1 and Image1.5.2.

2. Use a petroleum solvent to remove the anti-corrosion coating from the tapered bushing and bore. Use all safety precautions stated in the solvent manufacturer's Material Safety Data Sheet. Use proper personal protective equipment (PPE) for handling solvent.

Image1.5.1

Image1.5.2

3. Inspect to insure there is no rust, damage, or any foreign material on the bushing, tapped holes, or hub bore. Do not install until all contamination and protective coatings are completely removed from all components.

4. Clean the shaft using a petroleum solvent to insure cleanliness before the fan is installed onto shaft. Use all safety precautions stated in the solvent manufacturer's Material Safety Data Sheet. Use proper personal protective equipment (PPE) for handling solvent. Refer to Image1.6.1.

Image1.6.1

5. Lift fan to desired position and center on shaft. The weight of the fan assembly is approximately 234 kg (515 lb). Refer to Image1.7.1 for an example of the lifting technique on a 8 blade fan. Note that the 3587636/">358-7636 Spider Fan Assembly has 13 blades, but the lifting technique is the same.

NOTE:
- Use only NYLON LIFTING STRAPS when lifting fan. Wrap strap around two shanks when lifting.
- Do not use chain or wire sling for lifting.
- Always use at least two blades/blade shanks when lifting. Do not lift by only one blade/blade shank.

6. Reinstall tapered bushing (and 276-2444 Fan Key, if provided) in hub bore. Replace 276-2444 Fan Key if damaged. Install cap screws and washers in thru holes in bushing flange. Line up cap screws with tapped holes in the fan hub. Finger tighten the three bushing cap screws evenly. If the cap screws do not install easily or there is a noticeable "drag" during installation, check to make sure there are no damaged threads or contamination one either the cap screw or threaded hole. DO NOT APPLY ANY LUBRICANT TO THE BUSHING OR HUB. ALSO, DO NOT APPLY ANY LOCTITE ON BUSHING CAP SCREWS. Refer to Image1.7.2 and Image1.7.3.

Image1.7.1

Image1.7.2

Image1.7.3

7. Secure the bushing to the shaft with the bushing set screw when the desired fan position is determined. Slide the fan hub back to allow access to the set screw on the flange of the bushing. Refer to Image1.8.1.

Image1.8.1

8. Reposition the fan hub on the bushing after the set screw is tightened.

9. Insert bolts ensuring lock washers are on the bolts and tighten with wrench. Ensure the flange of the bushing does not set completely against the hub as some gap is required. Do not use an impact wrench to tighten.

Note: It is very important to use care in pulling the fan hub evenly and squarely on the bushing taper. Make sure mating surfaces are clean and make partial turns on bushing bolts to pull up slowly and evenly. If the cap screws do not install easily, or noticeable "drag" is felt during installation, check to make sure there are no damaged threads or contamination on either the cap screw or the threaded hole.

10. Tighten bolts sequentially until each is tightened to 43.4 N-m +0/-4 N-m (32 ft-lbs +0/-3 ft-lbs).

11. Tighten bolts for a 2nd time in a clockwise pattern to 43.4 N-m +0/-4 N-m (32 ft-lbs +0/-3 ft-lbs).

12. After bolts have been tightened twice, wait approximately 5 minutes and then tighten bolts for a third time in a clockwise pattern to assure that all bolts are tightened to 43.4 N-m +0/-4 N-m (32 ft-lbs +0/-3 ft-lbs). Refer to Image1.9.1.

Image1.9.1

13. Mark each bolt head with a permanent marker after the bolts have been tightened to 43.4 N-m +0/-4 N-m (32 ft-lbs +0/-3 ft-lbs). Mark the bolts with a continuous line across the entire top of the bolt head, down the side of the bolt, then across the bushing face as shown in Image1.10.1.

Image1.10.1

14. Check the blade track by rotating the fan manually and measuring from the back-end cross-member (or other suitable reference point on frame) to the edge of the blade. Variance in blade distance from the reference point should not exceed 9.5 mm (3/8 inch) when all blades are rotated to the same position. Refer to Image1.11.1.

15. If the variation in distance exceeds 9.5 mm (3/8 inch), check the seating of the blades in the hub sockets, the blade angle of each blade, and that the fan is square on the drive.

Image1.11.1

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

17. Install belts and adjust belt tension. Refer to Specifications, RENR9362.

18. Reinstall radiator core, all guards, and air pipes. Refer to Special Instruction, REHS3403.

19. Check for proper operation of the generator set.