PRODUCT SUPPORT PROGRAM FOR REWORKING THE TERMINAL BOXES LOCATED ON THE GENERATOR AND REWORKING THE SUPPORTS ON THE RADIATOR ON CERTAIN 3516C-HD GENSETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE TERMINAL BOXES LOCATED ON THE GENERATOR AND REWORKING THE SUPPORTS ON THE RADIATOR ON CERTAIN 3516C-HD GENSETS

Usage:

REBE2971-01

Show/hide table

28Mar2008

(Revised 04Aug2008)

Z850
U130
E081
E090
Z768
H374
H070
B153
N020
B360
E140
H335
D447

Show/hide table

Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REWORKING THE TERMINAL BOXES LOCATED ON THE GENERATOR AND REWORKING THE SUPPORTS ON THE RADIATOR ON CERTAIN 3516C-HD GENSETS
1381 4460 7426 1356 1353 1357		PS42653

Show/hide table

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 "PS42653" 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.

Show/hide table

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.

Show/hide table


NOTE:	This Revised Service Letter replaces the 28Mar2008 Service Letter. Changes have been made to the Title, Problem, Parts Needed, Service Claims Allowance, and Rework Procedure.

Show/hide table

TERMINATION DATE

31Mar2010

PROBLEM

Show/hide table

The existing supports for the terminal box and radiator fan guard can fatigue due to unit resonance on certain 3516C-HD Gensets.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
3516C	SBK00150-00157, 161, 163-167, 171-175, 177-178, 180, 182-197, 199, 203-204, 206-207, 216-217, 220, 223-226, 229

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
4	5P2566	BOLT
2	5P8167	BOLT
4	6V8188	NUT-FULL
8	8T4223	WASHER-HARD
2	8T4896	WASHER-HARD
1	3079190	GUARD AS (As Required)
1	3079191	GUARD AS (As Required)
2	3125098	BRACKET
2	3125099	BRACKET
2	3125100	BRACKET
1	3136505	BRACKET
2	3136513	ANGLE
2	3136514	ANGLE
4	3139369	ANGLE
4	3139429	ANGLE
2	3160183	BRACKET AS
1	3160184	BRACKET AS
1	3207920	DRIVE BELT
2	3221542	PLATE
1	3265941	PLATE
2	3265942	PLATE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% 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

Show/hide table

Rework the Radiator Guard and the Generator Terminal Box. Refer to the attached Rework Procedure.

Show/hide table

SERVICE CLAIM ALLOWANCES

Show/hide table

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%
0-3120 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

Show/hide table

NOTE: This is a 54.0-hour job

Show/hide table

PARTS DISPOSITION

Show/hide table

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

Show/hide table

Refer to appropriate service manual as necessary.

3516C-HD Radiator Guard Rework Procedure

1. Lock out and tag generator and insure all power cables are disconnected. Any procedure to fully remove the generator from the grid must be completed at this time.

Refer to Image 1.1.1 for steps 2 to 6.

2. On right side of generator, remove (qty. 9) 5/16 inch bolts located at the four corners of the fan guards. These bolts will be above the top fan bearing support piece.

3. Place 312-5100 (2) in the inside (towards fan bearing) corner.

4. Place 312-5098 (3) vertically against the outside flange. Notched section should be towards the engine and will fit below the fan bearing support.

5. Place 312-5099 (1) against 312-5098 in the corner against the guard mounting tabs.

6. Replace all bolts and tighten to 30 +/- 7 N-m (22 +/- 5 lb ft).

7. Repeat steps 2 through 6 on opposite side of generator.

Image1.1.1

8. Inspect pulley guards for any signs of cracking. If cracking is found, replace both guards as needed (307-9190 and 307-9191).

9. With pulley guards removed, remove all (qty. 6) 291-5409 Drive Belts.

10. Install 320-7920 Banded Drive Belt. Tension belt to 160 +/- 25 lb (712 +/- 111 N) initial and after 30 min. of operation, check tension and adjust accordingly. 100 +/- 10 lb (445 +/- 44 N) used.

11. Remove three bolts on top section of pulley guard. Bolts will be holding the two halves together.

12. Install 316-0184 Bracket Assembly and fasten bolts. 316-0184 is a pre-fabricated assembly and will not require welding.

13. The two top bolt holes should now line up with the angled supports for the air system return tube.

14. Mark the hole locations on the angled supports and drill a 1/2 inch hole through the support. Bracket assembly can be removed if needed.

15. Fasten 316-0184 Bracket Assembly to the angled support using 5P-2566 Bolt, 8T-4223 Washers (qty. 2), and 6V-8188 Nut. Tighten support to 135 +/- 20 N-m (100 +/- 15 lb ft). Refer to image 1.3.1.

Image1.3.1

16. Position 322-1542 Plate on the underside of the pulley guard. Plate should be positioned as far forward as possible and to the outside of the bottom of the pulley guard. Allow enough room for an adequate weld bead around the entire plate. There is one assembly per side of guard.

17. Fit 316-0183 to the underside, be sure that each flat section will fit flush with the 322-1542 Plate (mounted to the underside of pulley guard) and the underside of the horizontal fan bearing channel support.

18. Weld 322-1542 Plate onto underside of pulley guard on each side.

19. Mark the position of the support on the underside of the center support section and drill a 1/2 inch hole.

20. Install 316-0183 with gusset section on top, with 5P-2566 Bolt, 8T-4223 Washers (qty. 2), and 6V-8188 Nut on the top section. Tighten bolts to 135 +/-20 N-m (100 +/- 15 lb ft).

21. Thread 5P-8167 into plate on bottom of pulley guard with 8T-4896 Washer. Tighten bolt to 55 +/- 10 N-m (40 +/- 7 lb ft). Refer to image 1.4.1. Reference number 1 identifies the 5P-2566 Bolt going through the fan bearing support structure. Reference number 2 identifies the 316-0183 Bracket. Reference number 3 identifies the 322-1542 Plate welded to the bottom of the pulley guard. Refer to Image 1.4.2 for an additional view of the pulley guard.

Image1.4.1

Image1.4.2

Generator Terminal Box Rework Procedure

1. Lock out and tag generator and insure all power cables are disconnected. Any procedure to fully remove the generator from the grid must be completed at this time.

2. Remove the side panels from the terminal box with 1/4 inch wrench and set aside.

3. All welds should be seamless unless specified. It is important to have all added material securely attached to the box.

4. Remove 168-5168 Side Box using 1/4 inch wrench.

5. Complete factory intermittent welds on both inside corners of the 168-5168 Side Box while it is removed from the generator. Refer to image 1.5.1 and image 1.5.2. In both images reference 1 identifies the area requiring a continuous weld for the entire length of the side box. NOTE: Weld should be seamless from top to bottom.

Image1.5.1

Image1.5.2

Image1.5.3

Refer to Image 1.5.3. Angle welded across front side of side box, process should also be repeated on the back end.

6. Weld 313-6513 Angle diagonally across the front and back panel of side box. Refer to Image 1.5.3.

7. Weld 313-6514 lengthwise across the front panel of the 166-5176 Center Box.

NOTE: Angle should fit with each end contacting the return flanges on both sides of the main box. Locate the angle 5 inches above bottom of box.

8. Weld piece at each end to attach it to the return flange as shown in Figure 1.6.1.

9. Weld the entire top and bottom of the angle.

Image1.6.1

10. Place 313-6514 Angle on top on inner box on the inside of the 166-5176 Main Box. Angle should fit with each end contacting the return flanges on both sides of the main box.

11. Weld piece at each end, connect it to the return flanges as seen in image 1.5.3.

12. Apply a continuous weld to the entire top of angle.

13. Weld the entire bottom portion of angle and across the inner box section. All angle iron edges contacting the box should be welded.

Image1.7.1

14. Vertically weld (qty. 2) 313-9369 1 3/4 inches above the bottom of the box. Weld one piece to the inner box and the other piece to the inside of the return flange. Refer to image 1.7.1.

15. Horizontally weld (qty. 2) 313-9429 angle between top and bottom of 313-9369 installed in step 14. Pieces should be attached to rear panel of terminal box and the other angle pieces.

16. Repeat steps 14 and 15 on the opposite side of main box.

NOTE: The next steps require the center box to be mounted on the unit and will permanently attach the box to the unit.

17. Place 326-5941 Plate between the uni-strut and front panel of the center box. The piece is designed to fit length wise between the return flanges used to bolt the center box to the generator barrel on each side. Cut the piece to length to insure proper fit as required. (Refer to Image 1.8.1.)

18. Weld top and bottom of 326-5941 into the box. Be sure to weld the piece to the return flanges on each end. It is acceptable to not weld at each uni-strut location. (Refer to Image 1.8.1) Alternate ends as needed to control heat.

Image1.8.1

19. Place 326-5942 on the bottom of the box below the angle boxing in the rear. Plate should fit between return flange and innerbox.

20. Weld piece in place to securely attach the new piece in the three corners. Image 1.9.1 shows 326-5942 fully welded into box.

21. Reattach side box.

22. Mount 313-6505 Bracket to the underside of the side box. This will connect the box directly to the generator barrel.

Image 1.9.2 shows underside bracket fully installed. Bracket uses existing bolts on generator barrel and underside of side box.