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PRODUCT SUPPORT PROGRAM FOR REWORKING THE RADIATOR FAN BELT GUARD BRACKET ON CERTAIN 3512C, AND 3516C GENERATOR SETS Caterpillar


PRODUCT SUPPORT PROGRAM FOR REWORKING THE RADIATOR FAN BELT GUARD BRACKET ON CERTAIN 3512C, AND 3516C GENERATOR SETS

Usage:

REBE7975-00

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22Mar2012


U-154
A-129
D-139

 
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After Failure Only
  
  

PRODUCT SUPPORT PROGRAM FOR REWORKING THE RADIATOR FAN BELT GUARD BRACKET ON CERTAIN 3512C, AND 3516C GENERATOR SETS
1381 7155 1353 1356
PS52198
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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS52198" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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
31Mar2014

PROBLEM

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The existing radiator fan belt guard left and right bracket can break on certain 3512C, and 3516C Generator Sets.

AFFECTED PRODUCT

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Model Identification Number
*******Group  1*******
3516C  SBK00150-00157, 161, 163-167, 173-175, 177-178, 180, 182-195, 199, 202-204, 206-207, 221-251, 253-323, 325-327, 329-330, 333, 337, 341-347, 349-364, 366-395, 397-401, 403-414, 417-420, 422-427, 429-430, 432-437, 439-442, 447, 449-463, 465, 468, 471-497, 499-501
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*******Group  2*******
3512C  SBG00152-00342, 344-361, 363-375, 377-430, 433-502, 504-533
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*******Group  3*******
3516C  SBJ00150-00223, 226, 228-242, 244, 246-251, 253-258, 260, 262-269, 271-293, 297-298, 300-301, 303-305, 307, 310-338, 341-347, 349-374, 376-377, 381, 383-384, 387-406, 408-410, 412-423, 425-447, 449-450, 452-463, 468-469, 471-487, 489-503, 507, 509-511, 514-517, 519-533, 535-544, 546-547, 549-560, 562-563, 565-567, 569-595, 600-631, 641-642, 644-648, 650-654, 656-657, 659, 661-671, 674, 677-685, 688-690, 692-693, 695-698
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*******Group  4*******
3516C SBJ00224-00225, 227, 243, 245, 252, 270, 294, 296, 302, 309, 385-386, 448, 451, 1003

SBK00215-00220
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*******Group  5*******
3516C SBJ00378-00380, 382

SBK00196-00198, 324, 328, 331, 365, 415-416
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*******Group  6*******
3512C  SBG00343, 376, 861

PARTS NEEDED

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Qty

 Part Number Description
*******Group 1*******
6 4L6454 BOLT
8 5P1076 WASHER-HARD
4 6V8188 NUT-FULL
3 6V8801 NUT
2 7X0447 NUT-FULL
4 7X0589 WASHER-HARD
10 8T4896 WASHER-HARD
2 8T8916 BOLT
4 8T8917 BOLT
4 1476327 NUT-RIVET
1 3304113 BRACKET
1 3304114 BRACKET AS
1 3802935 BRACKET
1 3802936 BRACKET
1 3889426 COVER-PLATE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 6% 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.
*******Group 2*******
6 4L6454 BOLT
8 5P1076 WASHER-HARD
4 6V8188 NUT-FULL
3 6V8801 NUT
2 7X0447 NUT-FULL
4 7X0589 WASHER-HARD
10 8T4896 WASHER-HARD
2 8T8916 BOLT
4 8T8917 BOLT
4 1476327 NUT-RIVET
1 3304363 BRACKET AS
1 3304364 BRACKET
1 3805127 BRACKET
1 3805128 BRACKET
1 3889426 COVER-PLATE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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.
*******Group 3*******
6 4L6454 BOLT
8 5P1076 WASHER-HARD
4 6V8188 NUT-FULL
3 6V8801 NUT
2 7X0447 NUT-FULL
4 7X0589 WASHER-HARD
10 8T4896 WASHER-HARD
2 8T8916 BOLT
4 8T8917 BOLT
4 1476327 NUT-RIVET
1 3304114 BRACKET AS
1 3304362 BRACKET
1 3802935 BRACKET
1 3802936 BRACKET
1 3889426 COVER-PLATE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 6% 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.
*******Group 4*******
6 4L6454 BOLT
8 5P1076 WASHER-HARD
4 6V8188 NUT-FULL
3 6V8801 NUT
2 7X0447 NUT-FULL
4 7X0589 WASHER-HARD
10 8T4896 WASHER-HARD
2 8T8916 BOLT
4 8T8917 BOLT
4 1476327 NUT-RIVET
1 3304113 BRACKET
1 3304114 BRACKET AS
1 3805131 BRACKET
1 3805132 BRACKET
1 3889426 COVER-PLATE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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.
*******Group 5*******
6 4L6454 BOLT
8 5P1076 WASHER-HARD
4 6V8188 NUT-FULL
3 6V8801 NUT
2 7X0447 NUT-FULL
4 7X0589 WASHER-HARD
10 8T4896 WASHER-HARD
2 8T8916 BOLT
4 8T8917 BOLT
4 1476327 NUT-RIVET
1 3304359 BRACKET AS
1 3304360 BRACKET
1 3805133 BRACKET
1 3805134 BRACKET
1 3889426 COVER-PLATE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 6% 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.
*******Group 6*******
6 4L6454 BOLT
8 5P1076 WASHER-HARD
4 6V8188 NUT-FULL
3 6V8801 NUT
2 7X0447 NUT-FULL
4 7X0589 WASHER-HARD
10 8T4896 WASHER-HARD
2 8T8916 BOLT
4 8T8917 BOLT
4 1476327 NUT-RIVET
1 3304114 BRACKET AS
1 3304362 BRACKET
1 3805129 BRACKET
1 3805130 BRACKET
1 3889426 COVER-PLATE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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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Overview:

This procedure is to address the failures seen on belt guards installed on certain 3500C Generator Sets. The procedure assumes that the guard has already failed. The procedure will have two major components, replacing the mounting brackets and adding additional brackets to stiffen the structure.

Inspection:

1. Determine if the unit to be reworked has the top and bottom bracket installed. If not order the top and bottom bracket from the parts list. Refer to Image1.

2. Review Image2 to identify the brackets to inspect and replace with the attached Rework Procedure.
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Image1
Image2
Image3

SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-6000 hrs,
0-96 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 16.0-hour job for Group 1

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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-6000 hrs,
0-96 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 16.0-hour job for Group 2

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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 3*******
0-6000 hrs,
0-96 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 16.0-hour job for Group 3

Show/hide table
Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 4*******
0-6000 hrs,
0-96 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 16.0-hour job for Group 4

Show/hide table
Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 5*******
0-6000 hrs,
0-96 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 16.0-hour job for Group 5

Show/hide table
Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 6*******
0-6000 hrs,
0-96 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 16.0-hour job for Group 6



PARTS DISPOSITION

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


Rework Procedure


 
Left and Right Bracket Installation:

1. Isolate the generator set before commencing any work on the unit, open generator set breaker, activate Emergency Stop, disconnect the battery cables and either disconnect or open the control circuit breaker for the AC power supply to the battery charger. Ensure all health and safety requirements are adhered to at all times. Also, ensure proper Lock Out-Tag Out procedures are followed at all times while work is being performed on the machine. Lock out generator operation and disconnect/lockout all power sources before commencing any work.

2. Remove bolt and hardware from left hand side bracket (see Image1.1.1).

3.With a cutting tool, remove bracket from belt guard. Removing the air tubes from the Air to Air Aftercooler (ATAAC) may be necessary.

4. Clean remaining debris and paint from guard surface.

5. Using new left side bracket as a template, mark and drill two 0.5 inch bolt clearance holes (~0.55 inch).
Image1.1.1
 
6. Remove the access cover located above the bracket on the left side guard (see Image1.2.1).

7. Using the opening, bolt the new left side bracket to guard and bearing support structure (two 8T-8917 Bolts, two 6V-8188 Nuts, and four 5P-1076 Washers).

8. Tighten bolts to standard torque (85 N-m).
Image1.2.1
 
9. Remove bolt and hardware from right side bracket (see Image1.3.1).

10. With a cutting tool, remove bracket from belt guard (Image1.3.1). Removing the air tubes from the Air to Air Aftercooler (ATAAC) may be necessary.
Image1.3.1
Image1.3.2
 
11. Approximately three inches below the bracket, cut a 6 inch (152.4 mm) long by 4 inch (101.6 mm) wide hole in the side of the right side guard (see Image1.3.2).

12. Place 388-9426 Cover Plate over cut-out created in Step 11 and mark the position of the four holes.

13. Drill four 0.53 inch (13.49 mm) holes.

14. Clean remaining debris and paint from guard surface where the right side bracket was removed in Step 11.

15. Using new right side bracket as a template, mark and drill two 0.5 inch bolt clearance holes (~0.55 inch).

16. Install four 3/8 inch 147-6327 Rivet Nuts into holes drilled in Step 13 (a rivet nut installation tool will be required to install the rivet nuts). For an alternate method see below.

****Alternate method to install the rivet nut (see Image1.4.1)****

Needed parts:

1. A Plate with a hole slightly larger than the thread size of insert (slip fit)

2. A high strength bolt of the matching thread size and a good length of threads, and a stack of hard washers (to adjust for thickness of parts).

Installation:

1. Insert the rivet nut.

2. Place the plate over the rivet nut.

3. Put bolt through washers stack and thread into the insert so that end of bolt is near end of insert when bolt stops at finger tight.

4. Tighten bolt to standard torque. Note: For the round rivet nut the plate may need to be big enough to be able to hold and prevent spinning and to push insert against surface.

*** End of alternate method to install the rivet nut****
Image1.4.1
 
17. Using the opening for access to the backside, install the new right side bracket with provided hardware (two 8T-8917 Bolts, two 6V-8188 Nuts, four 5P-1076 Washers).

18. Tighten bolts to standard torque (85 N-m).

19. Install 388-9426 Cover Plate over right side opening using supplied 3/8 inch 4L-6454 Bolt. Tighten to low torque (19 N-m).
 
Top and Bottom Bracket installation:

20.If the top and bottom bracket were not installed, proceed with the installation instruction below.

Top Bracket Installation:

21. Using the existing hardware, attach top bracket to the top belt drive guard where the two halves bolt together. (see Image1.6.1)

22. Locate position and drill two standard 7/16 inch (13.8 mm) bolt clearance holes to the two support pieces that support the large upper air tube. (see Image1.6.1)

23. Tighten all 7/16 inch bolts to standard torque (70N-m), and all 3/8 inch bolts to 47 N-m.
Image1.6.1
 
Bottom Bracket Installation:

24. Using the existing hardware, attach bottom bracket to the bottom belt drive guard where the two halves bolt together. (see Image1.7.1)

25. Locate position and drill three standard 3/8 inch (12.2 mm) bolt clearance holes to under side of idler support shelf. (see Image1.7.1)

26. Tighten all the bolts (3/8 inch) to standard torque (47N.m).
Image1.7.1
 
 

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