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:

TEBE1866-01

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20Oct2014

(Revised 17Nov2014)

U-600

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Before/After	PRODUCT SUPPORT PROGRAM FOR REWORKING THE RADIATOR FAN BELT GUARD BRACKET ON CERTAIN 3512C, AND 3516C GENERATOR SETS
1353		PS44516

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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 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 "PS44516" 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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NOTE:	This Revised Service Letter replaces the 20Oct2014 Service Letter. Changes have been made to the Service Claim Allowances.

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TERMINATION DATE

31Oct2016

PROBLEM

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

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
3516C	SBK00225-00229, 238-243, 254, 257, 265-267, 270-276

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*****Group 2*****
3512C	SBG00495-00496

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*****Group 3*****
3516C	SBJ01305, 1307, 1309, 1331

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*****Group 4*****
3516C	SBK00473-00475, 478, 701, 703-705, 865-867, 967-969, 991-993, 1165, 1172-1173, 1221-1224, 1244-1245, 1249-1250, 1262, 1264, 1266, 1268

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 32% 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 32% 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	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 32% 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	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 32% 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 3512C, and 3516C Generator Sets. The procedure will have two major components, replacing the existing left and right side mounting brackets, and in some cases, adding top and bottom brackets to stiffen the structure if none exist.

Refer to Affected Product to identify the serial number and associated group number. Once the group number is known, refer to the Parts Needed to identify what parts need to be ordered. Note that for Group 3 and Group 4, only the two side brackets (left side and right side) are listed since the top and bottom bracket are already in place based on the build date of the unit.

Refer to Image 1 for location of the top and bottom brackets. Refer to Image 2 for location of the left and right brackets.

In addition to the Parts Needed, Image 3 shows a reference table that can be used to identify the parts needed based on radiator part number. Note that this is for reference only. The Parts Needed should be used when ordering parts.

Refer to 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
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
0-20000 hrs, 0-99 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 13.0-hour job for Group 1

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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%
*****Group 2*****
0-20000 hrs, 0-99 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 13.0-hour job for Group 2

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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%
*****Group 3*****
0-20000 hrs, 0-99 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 11.0-hour job for Group 3

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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%
*****Group 4*****
0-20000 hrs, 0-99 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 11.0-hour job for Group 4

PARTS DISPOSITION

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

Rework Procedure

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 in order 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 or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

WARNING: The generator set must be isolated electrically before and while the rework is performed. Follow the proper lockout tag out procedures to protect against the unexpected 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 or the controls before you perform any service to the machine.

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).