PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 259-9150 RADIATOR SPIDER FAN WITH THE VALIDATED 319-5217 RADIATOR SPIDER FAN ON CERTAIN 3516C GENSETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 259-9150 RADIATOR SPIDER FAN WITH THE VALIDATED 319-5217 RADIATOR SPIDER FAN ON CERTAIN 3516C GENSETS

Usage:

REBE6642-00

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15Nov2010

U-459

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 259-9150 RADIATOR SPIDER FAN WITH THE VALIDATED 3195217/">319-5217 RADIATOR SPIDER FAN ON CERTAIN 3516C GENSETS
1353		PI10829

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10829" 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 "PI10829" 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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PROBLEM

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The 259-9150 Spider Fan needs to be replaced on certain 3516C gensets because the fan is susceptible to fractures and can fail due to fatigue during operation. The existing 259-9150 Spider Fan can damage the fuel cooler, after cooler and other components when the blades become detached leading to a complete radiator replacement. In addition, the existing 259-9150 Spider Fan 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	SBJ00339-00340, 378-380, 382 SBK00324, 328, 331, 365, 415-416

PARTS NEEDED

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Qty	Part Number	Description
1	2762444	FAN KEY 7/8
1	3195217	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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Replace the existing 259-9150 Spider Fan with a new 3195217/">319-5217 Spider Fan.

Refer to the attached Rework Procedure for details.

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OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

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

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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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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 259-9150 RADIATOR SPIDER FAN WITH A VALIDATED 3195217/">319-5217 RADIATOR SPIDER FAN

MODELS INVOLVED - 3516C Gensets

Dear Caterpillar Product Owner:

The 259-9150 Radiator Spider Fan needs to be replaced on the 3516C Generator Sets listed below. The existing 259-9150 Radiator Spider Fan is susceptible to fractures and can fail due to fatigue during operation. In addition, the 259-9150 Spider Fan may cause a flying object hazard and, in conjunction with other factors or circumstances, result in a risk of personal injury or death. A new validated fan, 3195217/">319-5217, is available as a direct replacement. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

Please refer the dealer to their Service Letter dated 15Nov2010 when scheduling this service.

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

Caterpillar Inc.

Identification #(s)

Attached to 15Nov2010 Service Letter

Rework Procedure

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1. Lock out and tag generator.

2. Drain coolant from engine and radiator.

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

4. 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.

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

Image1.1.1

6. Remove all bolts connecting the core assembly to the support structure. Repeat this step for opposite side as well.

Image1.2.1

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

Image1.3.1

8. With lifting device in place, and all bolts removed, slowly lift the core assembly off the support assembly. Lay core on its face.

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

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

11. Be sure to properly secure fan with a lifting device supporting at least two blades. Remove the 259-9150 Spider Fan Assembly.

3195217/">319-5217 Spider Fan - Installation.

1. Remove Tapered Bushing from the hub.

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.

Image1.5.1

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. Image1.6.1.

Image1.6.1

NOTE:
- Use only NYLON LIFTING STRAPS when lifting fan. Wrap strap around two shanks when lifting as shown in Image1.7.1.
- 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.

Image1.7.1

5. Lift fan to desired position and center on shaft.

6. Reinstall tapered bushing (and key, if provided) in hub bore. 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.

Image1.8.1

7. Secure the R1 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.

Image1.9.1

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

9. 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 the bushing bolts to the appropriate standard torque specification.

NOTE: When tightening bolts, make sure to gradually and equally tighten bolts in a uniform manner. DO NOT TIGHTEN COMPLETELY "ONE AT A TIME".

Image1.10.1

11. Mark each bolt head with a permanent marker after the bolts have been tightened to the appropriate standard torque specification. 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 Image1.11.1.

Image1.11.1

12. 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 3/8" when all blades are rotated to the same position.

13. If the variation in distance exceeds 3/8", 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.