PRODUCT SUPPORT PROGRAM FOR REWORKING THE RADIATOR FAN MOTOR ON CERTAIN PM3516 POWER MODULES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE RADIATOR FAN MOTOR ON CERTAIN PM3516 POWER MODULES

Usage:

REBE9707-00

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06May2013

D35P
Z75F

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Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REWORKING THE RADIATOR FAN MOTOR ON CERTAIN PM3516 POWER MODULES
1353		PS43906

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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 "PS43906" 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.

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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

31May2015

PROBLEM

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The radiator on certain PM3516 Power Modules may contain a defective motor. The existing electric fan motor can fail due to rotor slip and will require replacement.

AFFECTED PRODUCT

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Model	Identification Number
PM3516	NBR00233, 244, 256-257, 259, 274, 281, 292-293, 296-297, 299-305, 310-315, 317-322, 325-330, 335, 339-341, 347, 351-359, 362-413, 415-419

PARTS NEEDED

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Qty	Part Number	Description
2	BEARINGF	RPB BEARING (See Action Required)
2	BEARINGM	6316 C3 BALL BEARING (See Action Required)
6	BOLT	FAN HUB BOLT (See Action Required)
2	COLLAR	SHAFT COLLAR (See Action Required)
1	COMPOUND	THREAD LOCKING COMPOUND (See Action Required)
1	DOME	RUBBER DOME (See Action Required)
1	ENDPLATE	MOTOR ENDPLATE (See Action Required)
1	GREASE	BEARING GREASE (See Action Required)
1	HUB	FAN HUB (See Action Required)
6	NUT	FAN HUB NUT (See Action Required)
1	SEAL	INPRO MOTOR SEAL (See Action Required)
1	SEALANT	BLACK AND WHITE IND. SILICON (See Action Required)
1	SHAFT	FAN SHAFT (See Action Required)
12	WASHER	FAN HUB (See Action Required)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 22% 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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WARNING: Injury can occur to personnel if the rework is done improperly. Personal Protective Equipment (PPE) suitable to the work being performed must be worn when performing the rework.

WARNING: The power module must be isolated electrically before and while the rework is performed. Follow the proper lockout tag out procedures to protect against the unexpected energization or start up of the power module. Failure to follow these warnings could result in injury to personnel during service.

Areas of improvement need to be addressed in order to prevent possible failure of the radiator fan motor. These include rework of the motor, and replacement of the fan bearings. The rework procedure includes the following sections:

1. REMOVAL OF THE ELECTRIC MOTOR
2. ELECTRIC MOTOR REWORK
3. FAN BEARING REMOVAL AND REPLACEMENT
4. INSTALLATION OF THE ELECTRIC MOTOR

Refer to the attached Rework Procedure to determine the proper tools and equipment required to safely perform the rework.

Parts and specialty tooling delivery will be coordinated by EPD service engineer Jo Liang, 770-233-3973, Liang_Jo@cat.com.

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SERVICE CLAIM ALLOWANCES

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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%
0-10000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 2.0-hour job
Include ouside expenses at cost. Retain a copy of all invoices for outside expenses in the product history folder for audit purposes.

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PARTS DISPOSITION

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

Rework Procedure

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1. REMOVAL OF THE ELECTRIC MOTOR
Remove the following items
Doors, door hinges, upper radiator channel.
NOTE: Hinges may remain on doors. Doors can be removed simply by lifting them off of hinges. Hinges need to be removed from the radiator frame. U-Bolt securing pipe needs to be removed from the rear of the radiator channel.

Grease lines
NOTE: Each of the two lines need to be disconnected and removed from the top and bottom of the motor and frame. Use a open end wrench that will fit over the line and press it evenly against the connector to release the line. The line should easily disconnect. If not check and remove debris around the connector that may prevent it from being pressed in. Store the lines to keep free from damage and contamination.

Image1.1.1

Image1.1.2

Belts
Store belts in the personnel access room to keep free from damage and contamination.
Radiator fan door switch and wiring
Auto Lube System
NOTE: Remove hardware from mounting bracket to remove auto lube system.
Motor Wiring Harness
Label the wires on the motor harness with the corresponding "T1,T2,T3" wire from the motor for reconnection to ensure correct fan rotation. Disconnect and remove motor wiring harness. Cover the wire ends with the rubber caps to protect from damage and insulate.
Remove one motor pivot rod. Turn the nut to the other pivot rod to bring the motor against the radiator frame.

Image1.2.1

Wrap a strap securely around the top of the radiator frame by eliminating all slack. Attach the other end to a winch secured to the lift truck to prevent the frame from falling backwards from the weight of the motor and damaging the cover
Insert the forks underneath top support with the motor centered between the forks.
Place 2 hardwood blocks approximately 203 mm (8 inch) by 203mm (8 inch) stacked underneath the radiator frame to support the frame and motor.
Crank the winch to tighten the strap.
Remove all four upper bolts to the radiator motor frame.

NOTE: The bolts are secured with nuts that can be accessed from the front between the container wall and the radiator frame.

Image1.3.1

Verify the that the motor and frame is supported by the lift truck. Once bolts are removed loosen the bottom bolts.
Winch the motor frame forward while carefully lowering the forks to prevent a sudden forward pivot. Continue pivoting the motor frame until the radiator frame is in a horizontal position supported by the hardwood blocks.

Image1.4.1

Secure a strap around the fork of the lift truck and the lifting eye of the motor. Ensure that the motor is supported directly vertical of the lifting eye so that sway is limited upon removal.

Lift fork to eliminate slack in the strap.

Remove the four 3/4" motor mounting bolts, and remove the motor from the base.

The motor is now ready to be transferred to the shop for rework.

Image1.5.1

2. ELECTRIC MOTOR REWORK
Position the motor horizontally on a level work surface able to support the weight.

Remove all grease extensions and fittings. Remove the plug from the top of the drive end DE endplate. Store all hardware for reuse.
Remove the rear fan cover by removing the fasteners and inspect for damage. Set aside for reinstallation.
Remove the fan by loosening the hose clamp and prying it away from the end plate evenly on both sides. Inspect the fan blades for damage. Store for reuse.

Loosen the taper lock bushing by removing the bolts and threading them into the removal holes.
NOTE: If the bushing is severely corroded holes may need to be tapped before removal.
Remove the pulley.
Store for reuse.

Image1.6.1

Image1.6.2

Starting with the opposite drive end ODE endplate, remove the bolts to the bearing cap and endplate mounting bolts.

Image1.7.1

Support the endplate with an overhead hoist or other meanns. Pry on both sides between the end plate and frame evenly to remove the endplate from the motor frame. Once endplate is free from frame, continue to work endplate away from motor frame until its bearing housing is free from the bearing.

NOTE: The endplate must be completely supported with overhead hoist or other means during this entire operation.

Remove endplate from shaft and set aside for reuse.

Image1.8.1

Remove the rubber seal around shaft and discard. With the drive end DE endplate remove the bolts to the bearing cap and mounting bolts. Support the endplate, and pry on both sides between the end plate and frame evenly to remove the endplate from the motor frame. Continue to work the endplate away from motor frame until its bearing housing is free from the bearing. Remove the endplate from the shaft.
Look into the endplate. Make sure the wave spring is still in the endplate bearing cavity. If not, look for it in the endplate bottom. Remove and store the wave washer for reuse. DE endplate will not be reused.

Remove and discard used grease from the bearing housing of the ODE endplate. Thoroughly clean endplate and store for reuse.

Image1.9.1

Set up rotor lifting device for proper counterbalance.
Place the rotor lifting device around the motor shaft.
Using the rotor lifting tool, remove the rotating assembly from the rest of the motor.

CAUTION: Care must be taken during this step to make sure not to damage the winding as the rotating assembly is withdrawn.

Image1.10.1

Prep the shaft for bearing removal by removing heavy corrosion with sanding wheel.
Use a bearing puller to remove the bearings from the motor shaft. Mark, remove, and set the bearing caps aside for reuse.

Image1.11.1

Clean the shaft and rotor surface. Use a set of calipers and measure the distance between the bearing journal step and the rotor surface as shown in the image. Record this value in the spreadsheet.

Image1.12.1

Prep the motor shaft and the rotor surface for welding.
Before welding verify that all welding personal protective equipment is on and/or being held in place.
Attach the welder ground to the DE end ring fins. Tack weld rotor to the shaft at the opposite drive end 75-80 degrees away from the key. Weld should be 1/4" to 3/8" in dimension. Verify that the weld makes contact with the shaft and rotor with adequate penetration. On the same end tack weld the rotor to the shaft 180 degrees opposed to the the previous weld. Tack weld key to shaft if the key is loose in the key way

CAUTION: Take precaution not to allow weld slag from coming into contact with the rotor.

Using an emery cloth, remove any rust on the bearing surfaces of the shaft. Inspect the shaft for damage such as nicks and burrs, especially on the bearing journals. Remove small amounts of damage with a sanding wheel. If damage is severe, shaft made need to be replaced.

Image1.13.1

Parts Required:
NEW
2 6316 C3 Bearings

Install bearing caps on each end of the rotor assembly making sure that the correct cap is on the correct end.

NOTE: The shoulder depth on the ODE bearing cap is greater then the DE bearing cap.
Install new bearings on rotating assembly by heating bearings and quickly sliding them onto the shaft all the way to the bearing shoulder and momentarily held in place. Heating of bearings should be even across the whole bearing, not localized, and not with an open flame. Heating with an induction heater or oil bath is best. The bearing temperature should not exceed 250 degrees F.
Install bearing onto shaft.
Heat and install the other bearing in the same manner. Let the bearings cool.
Push both DE,ODE bearing caps up against the bearings. Wrap bearings with aluminum foil to prevent contamination.

Image1.14.1

Clean the motor stator with compressed air to remove debris.

Using the rotor lifting tool, reinstall the rotating assembly into the motor. Center the rotating assembly, lower it, and remove the lifting tool.

CAUTION: Care must be taken during this step to make sure not to damage the winding as the rotating assembly is reinstalled.

Parts Required:
Grease
Pack the bearings 60 percent full with grease.

Image1.15.1

Insert two threaded rods into the ODE bearing cap. With the lifting device position the ODE endplate, with the larger grease exit port facing downwards, over the rear of the motor shaft while the threaded rods are inserted in the bearing cap holes. Continue to insert the endplate so that the bearing seats into the bearing housing. Apply black silicon around the shoulder of the endplate. Use a mallet to gently tap on each side of the endplate so that it comes close enough to the frame to install the bracket mounting bolts. Install and tighten the mounting bolts, diagonally opposite each other until the endplate is seated into the frame. Pull the two threaded rods forward until bearing cap is positioned firmly against the bearing housing. Insert and thread a bearing cap bolt into the third hole. Remove the threaded rods and install the remaining two bolts. Torque cap bolts evenly to 33 ft-lb.

Parts Required:
NEW
1 Endplate

Secure the replacement DE endplate, with the counter bore for the Inpro Seal. Rub general machine oil around the surface of the bearing housing and wave spring. Insert the wave spring in the bearing housing. Position the endplate with the larger grease exit port facing downwards. Supporting it with an overhead hoist, carefully slip it over the DE shaft and onto the bearing. Apply silicon around the shoulder of the endplate while rotating it. Work the bearing housing onto the bearing using a slight rocking motion and alternating soft blows on either side of the endplate with a large mallet. Continue working the endplate up until it is close enough to the frame to install the bracket mounting bolts. Tighten the endplate mounting bolts, diagonally opposite each other until the endplate fit is seated into the frame. Torque all bracket mounting bolts to 155 ft-lb.

Secure two longer bolts or threaded rods with the same threads as the cap bolts (3/8?-16). Insert one of these bolts into a cap bolt hole in the endplate. Spin the shaft in order to find a threaded hole on the bearing cap ? once the threaded hole is found, start the longer bolt by hand. Insert the other longer bolt into another cap bolt hole and start it into the threaded hole in the bearing cap. Pull with a slight rocking motion on both of these bolts until the bearing cap is firmly against the bearing housing of the endplate.

Install a bearing cap bolt into the third hole, and tighten it loosely. Remove the two longer bolts and install the other two cap bolts into those holes. Tighten all cap bolts evenly to 33 ft-lb.

Make sure the shaft will spin by hand. If not, remove the endplate and investigate.

Image1.16.1

Parts Required:
NEW
1 Inpro Seal

Fit Inpro seal installation tool over shaft. If tool does not fit, clean the shaft with sandpaper.

Secure the Inpro seal and apply the supplied white lubricant to the inside of the seal (where the shaft contacts the seal), and also to the outside of the seal that contacts the endplate. Carefully slide the Inpro seal onto the shaft and up to the junction of the endplate and shaft.

Using the supplied seal installation tool, carefully drive the Inpro Seal into the endplate with a mallet. Even pressure must be applied to not misalign the seal. There is a small lip on the outer diameter of the Inpro Seal that must seat against the endplate.

NOTE: As the seal is installed into the endplate the installer will feel it bottom out on the lip.
CAUTION: Do not overdrive past the lip.

Make sure the shaft will spin by hand, if not, the seal may be cocked. The endplate will need to be removed and the installation of the seal inspected.
Install grease hardware and a plug on the DE endplate. Verify proper installation of the grease fittings. The grease supply fitting is located on top while the relief fitting is located on the bottom.
CAUTION: Failure to install the plug will compromise water ingress protection of the motor.
Reinstall fan, fan cover, and grease hardware on ODE endplate.

Image1.17.1

Image1.17.2

Image1.17.3

Parts Required:
NEW
1 Rubber Dome
1 Sealant

Clean the motor shaft with a cleaning agent and towel.

Apply silicon sealant to the shoulder on the shaft. Rotate shaft while applying sealant. Run finger over the sealant while rotating the shaft.
Confirm that the shoulder is completely covered with sealant, this will prevent water leak through.

Install the rubber dome onto the motor shaft

CAUTION: Make sure not to damage the dome by catching the rubber on the edges of the key way

Push the dome so that it is fully seated against the shoulder of the shaft adhering to the silicon underneath.
Apply silicon sealant around the edge of the rubber dome and shaft.
Rotate the shaft while applying sealant. Run finger over the sealant while rotating the shaft.
Make sure the dome is completely covered with sealant.
The motor is ready to be installed onto the radiator frame

Image1.18.1

3. FAN BEARING REMOVAL AND REPLACEMENT

Remove louvers for access.

Image1.19.1

With a rope secure the fan pulley to the radiator frame. Remove the bolts to the taper bushing and thread them into the removal holes. If heavy corrosion in present holes may have to be tapped before proceeding. Tighten removal bolts to release the bushing and pulley.

CAUTION: Make sure that the pulley is supported during the entire operation.

Image1.20.1

Place a metal bar across the radiator beams to support the fan assembly once lowered.
Place a jack underneath the shaft. Confirm that the jack is has been actuated and will assist in supporting the weight of the fan assembly once released.

Remove both grease lines and fittings from the upper and lower pillow block bearings. Use a open end wrench that will fit over the line and press it evenly against the connector to release the line. The line should easily disconnect. If not check and remove debris around the connector that may prevent it from being pressed in. Store for reuse. Mark any shims "Bottom" and "Top" that are beneath each bearing to aid in reinstallation. Remove bearing mounting bolts and shims to the top bearing. Remove mounting bolts to the lower bearing while the fan assembly is being supported by two people.
Carefully lower the fan assembly onto the radiator beam and metal support bar.

Image1.21.1

Remove the 6 bolts and attached hardware from the fan hub while the shaft assembly is supported and lower the shaft assembly so that there is enough room to use a bearing puller on the top bearing. The hardware will not be reused.

CAUTION: If the fan hub is seized on the fan. Support the shaft assembly and strike the fan hub with a heavy mallet to release the fan shaft assembly.

Image1.22.1

Remove the top bearing with a puller and lower the rest of the shaft assembly through
the fan and out.

Image1.23.1

Remove two shaft collars from the original shaft assembly these will be reinstalled on the new assembly.

Set up the new shaft.
Start by collecting all components needed for the new shaft assembly.

Parts Required:
New
2 RPB Fan Bearings
2 Shaft Collars (2 reused)
1 Fan Hub Kit w/key and set screw
1 Shaft
Thread Locking Compound

Reused
2 Shaft Collars
2 Grease fittings

Properly orient the fan shaft on a clean work surface. Remove new grease fittings from bearings and discard. Install a bearing, two shaft collars, and a fan hub.

NOTE: Bearing will install easily onto the shaft however the fit is in close tolerance. Resistance will occur upon misalignment. If there is resistance remove and reinstall.

Position the bottom bearing 6 1/2 inches from the shaft end that is keyed for the fan pulley. Tighten and torque bearing set screws to 25 ft-lbs.
NOTE: Thread locking compound is not required at this step but will be added later. The bearing set screws will be loosened once the shaft assembly is installed.

Position the fan hub 9 1/8 inches from the opposite end. Install the key, apply thread locking compound to the set screws and install and tighten them into the fan hub. Torque fan hub set screws to 50ft-lbs. Position a shaft collar firmly against the bearing and the other against the fan hub. Tighten set screws. Install another shaft collar and position it against the top of the fan hub and tighten set screws. Torque shaft collars to 27ft-lbs. Add another shaft collar on top of the previous and loosely tighten. This collar will be secured once the top bearing is installed. Install grease fittings in both installed bearing and loose top bearing.

Stage shaft assembly and top bearing with the unit being worked.

Image1.24.1

Secure the fan shaft lift collar around the end of the fan shaft assembly and the floor jack extension. Lift the new shaft assembly through the fan with the jack.
Install the top bearing flush with the end of the shaft, remove and apply compound to the set screws, install, tighten and torque bearing set screws to 25 ft-lbs. Loosen, and reposition shaft collar underneath the top bearing. Torque collar set screws to 27 ft-lbs.

Parts Required:
NEW
6 Bolts
12 Washers
6 Nuts

Lift assembly with the floor jack until the fan hub is through the fan.
Install the 6 new fan bolts with nuts and washers and torque to 60ft-lbs.

Image1.25.1

Lift the fan assembly until the bearings line up with their bolt holes on the frame. Install the shims where they were originally located. Loosely install the 5/8" bearing mounting bolts. Slightly tighten the bearing bolts until bearing is held flush against radiator beam.

Align fan
Select a fan blade and measure the distance between the blade edge and
the shroud. Rotate the fan every 90 degrees and take measurements using the same fan blade. The fan should be set within an 1/8" all around. and within an 1/8" top and bottom. Fan insertion should be 0 to .5" from the edge of the shroud. Adjust the fan position by tapping on the base of the floor jack with a mallet. Tighten the bearing bolts and take fan blade measurements. Loosen and readjust if needed. After fan is set, tighten and torque bearing bolts to 150 ft-lbs

Parts Required:
NEW
Thread Locking Compound
The following steps need to be taken to relieve possible stress applied during installation.
Supporting the fan assembly at with the floor jack loosen bearing set screws and shaft collars against bearings. If excessive stress exists the shaft will slide in the bearings. If the shaft moves, lift or lower the shaft assembly until the top bearing is flush with the end of the shaft and apply compound to the threads and tighten back down.
Remove the shaft collar set screws, apply compound, install and torque to 27ft-lbs.
Apply compound to bearing set screws reinstall and torque to 25ft-lbs.

Image1.27.1

Image1.27.2

Secure large fan pulley, taper bushing, bolts and a rope. Clean pulley surface, grooves and bolt threads to remove any grease. Tie off an end of the rope to the pulley. Feed the rope through the fan back through the pulley and over the radiator frame as shown by the image. Pull the rope and hoist the pulley high on the fan shaft. Slide the taper bushing over the fan shaft, insert key and position it 3/4 inch from the end of the shaft. Lower the fan pulley onto the bushing while aligning mounting holes. Insert and evenly tighten bolts. Torque bolts to 110 ft-lbs. Remove rope.

NOTE: The floor jack can also be used to hoist the pulley and bushing together with a custom collar attachment shown in image. The collar is designed to accommodate the key and set the bushing at the correct depth.

Image1.28.1

Image1.28.2

4. INSTALLATION OF THE ELECTRIC MOTOR

CAUTION: Verify that radiator serial number on the frame matches the motor serial number and container unit number on the spreadsheet before assembly! It is important that the serialized components are assembled back into the corresponding power module.

Install the taper lock bushing and pulley on the motor shaft.

NOTE: Pulley may have to be adjusted during alignment with fan pulley.

Place 2 hardwood blocks approximately 203 mm (8 inch) by 203mm (8 inch) stacked underneath the radiator frame. Flip the radiator frame down onto the blocks so that it lies horizontal.
Lift the motor and place it onto the base of the radiator frame. Use tapered dowel to align the mounting holes. Install the 3/4" bolts and torque to 150 ft-lbs. Install pivot rods. Confirm that the pivot rods hold the motor base against the motor frame.

Image1.29.1

Image1.29.2

Wrap a strap around the radiator frame a couple of times. Eliminate slack by pulling strap tight. Attach a winch securely to lift truck frame. Hook the end of the chain to the strap.
Lift the radiator motor frame up with the winch at a 45 degree angle. The frame will pivot backwards once it reaches a tipping point.
CAUTION: Crank the winch slowly when approaching the point of pivot to prevent contact of the motor with the container floor and drain pipes. Depending on the weight of the lift truck the pivoting action can cause a slight forward movement.
Use a tapered dowel to align mounting holes, install the 3/4" nuts and bolts.
NOTE: Use a bottle jack underneath the radiator frame to aid in hole alignment.
Once all bolts are installed the radiator frame will have a tendency to rock forward at the bottom. The frame will have to be pushed back towards the engine in order to ensure enough clearance for door installation. Either push the radiator frame back with the lift truck or use a come along winch attached to the bottom of the frame and radiator support beam to pull the frame back.
Torque the 3/4" bolts to 250 ft-lbs

Image1.30.1

Clean and install the belts. Tighten the belts by adjusting the pivot rods. Check pulley alignment with a level. Adjust the motor pulley if needed so that alignment is within an 1/8? between fan and motor pulley.
NOTE: Start with motor pulley slightly higher than the fan pulley. Increasing the tension will bring the pulleys into alignment.
Torque taper lock bushing on the motor to 60ft-lbs after adjusting.
Install and tension the belts between 26hz and 27hz using the threaded rod jam nuts and verifying with a frequency based tension meter. Adjustment of the pivot rods will also aid in bringing the motor pulley level. Once belts are properly tensioned torque the pivot rod bolts to 110ft-lbs

Image1.31.1

Install the hinges on the radiator frame reusing screws. Retap threads if needed. Hang doors on the hinges. Close doors to confirm no interference. Verify that the doors are square. Fasten the right side door closed. Check that the left side door will latch properly by fully turning the latch and ensuring no play by moving it forwards and backwards.
Install radiator door switch as far forward so that the switch is fully depressed when the door is securely latched.
Position and install the auto lube system reusing the 3/8-16? fasteners and verifying proper vertical alignment within the access window when the door is closed. Route and secure grease lines through p clips attached to the frame.

Image1.32.1

The auto lube system will need to be reconfigured and reprogrammed.
With the original configuration the grease lines to the fan bearings are connected to ports 1 & 2 and the grease lines to the motor bearings are connected to ports 11 & 12.
The following changes will be made to only the grease lines to the motor bearings.

Remove plugs in ports 9 & 10
Remove fittings from ports 11 & 12
Install plugs in ports 11 & 12
Install fittings in ports 9 & 10

Image1.33.1

WARNING: Check to verify that all personnel are clear of the radiator.
Install battery jumper cables.
Turn the engine key switch to the on position.
Reprogram P1 to 17hrs by following these steps

Start programming mode: press both buttons (the green and red) at the same time for about 4 seconds, so that "P1" appears in the display.
When releasing the two buttons, the factory set value will appear. Make sure "hour" is selected, a decimal point on the right-hand side of the display above the "h". Press the green button to change the number to "17?
Press the green button to complete the programming and to save the entered parameters. If button is not pressed within 30 seconds all values will change back to factory settings.

After completion of the programming, double check the parameter settings. To do so press both green and red buttons at the same time for about 4 seconds, so that "P1" appears in the display.
Remove the Auto Lube Programming label on radiator access door.

Image1.34.1

To verify if grease is purging from the auto lube device remove the grease lines from the fittings at the fan bearings and the motor. Push in on the fitting with an open ended wrench just large enough to accommodate the diameter of the grease line while pulling on the line to disconnect.
Check the end of each line for damage. The end should be free of debris and perfectly round. If the end is deformed it will have to be recut.
CAUTION: Do not cut the line by pushing down with a razor. This will damage the line preventing proper delivery of grease to the bearings. Instead roll the line with a razor for a proper cut.
After line removal is complete, the auto lube must be ran to check for grease purge.
Press the green button for about 2 seconds, this will trigger a lubrication cycle.
A rotating symbol is visible on the display throughout the duration of the lubrication cycle. The cycle must be performed multiple times until grease is being purged out of every line by the auto lube device.

After grease purge has been verified reinstall all grease lines to their correct fittings. Make sure the installer hears or feel a double click to assure the lines have been connected properly. Refer to the image for correct grease lines routing to the fan motor. The grease supply lines are connected at the rear of the motor and the grease relief fitting is located at the top front of the motor looking into the container.
The auto lube must be ran to check for leaks at all fittings. Press the green button for about 2 seconds, this will trigger an additional lubrication cycle.
This must be performed at least 7 times. Check for leaks at the auto lube device as well as the fan bearings and motor. If leaks are found disconnect and reconnect the grease line. Repeat the cycles for verification.

Image1.35.1

Image1.35.2

Image1.35.3

Parts Required:
Sealant

Apply white silicon sealant around the container opening and install the louvers.
For testing purposes a portable generator of at least 300kVA can be connected to power the radiator fan motor as installed.
Properly connect each phase of the generator cable to T1,T2, and T3 on the electric motor.

WARNING: Before starting the generator check to verify that all unauthorized personnel are clear of the radiator and generator, that all personal protective equipment is on, and that a safety boundary is defined and clearly visible.

Start the generator and bring it up to rated speed. Secure an ammeter around one of the phases. Close the breaker powering the electric fan motor and note start up amperage and the proper counter clockwise rotation of the fan. Record start up and steady state amperage on the spreadsheet.
NOTE: If the fan rotation is incorrect trip the breaker and shut down the genset. Double check the cable connections. If connections are correct record reverse rotation on the spreadsheet. Reconnect cable for proper rotation, power the motor and record start up and steady state amperage.
Allow the fan to run for a minute to seat the belts. Turn off the motor. Rotate the fan drive by hand. Check the tension on the top and bottom belt . Adjust if needed to keep tension within 26 to 27 Hz. Record final top and bottom tension values on the spreadsheet.

Test and Adjust
1. Top Belt Tension
2. Bottom Belt Tension
3. Start Up Current
4. Steady State Current
5. Direction of Fan Rotation on Start Up

CAUTION: Connect each lead of the motor harness back to T1,T2,T3 according to the original labeled configuration.

Image1.36.1

Complete the final audit checklist and record on spreadsheet.
Replace the bolts and nuts to the radiator access door. Verify all hardware has been installed and all tools have been collected.
Turn engine key switch to the off position. Disconnect battery jumper cables and store. Confirm that all items removed from the power module have been placed back securely. Clean doors and radiator. Close both radiator access doors and
container doors. Secure and lock the padlocks to the container and personnel access door.

Image1.37.1

Final Audit Checklist
1. Overall condition of the unit and proof of rework captured in photos a (ie coolant leaks, grease, damage)
2. Auto lube lines are secure and are routed correctly.
3. Turn unit on. Check to see if Auto Lube is powered. Cycle Auto Lube.
4. Secure installation of the radiator door switch at the correct position for switch engeagement when door is closed.
5. Plug on top of DE motor endplate is present
6. Radiator caps and radiator fill access panels are secure.
7. Radiator drain pipes are securely fastened to container floor and valves are turned to the off position.
8. Marks are removed from the container, loose hardware and trash removed.
9. Radiator access doors are square and can be securely latched.
10. Plywood shipping panels on side and top are secure.
11. Unit is powered off. Keyswitch is in off position.
12. Container is locked and keys are placed behind personnel access door.