PRODUCT SUPPORT PROGRAM FOR REPLACING THE RADIATOR FAN ON CERTAIN 3516B GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE RADIATOR FAN ON CERTAIN 3516B GENERATOR SETS

Usage:

TEBE6222-00

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29Sep2017

R050
R100
R120

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After Failure Only (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING THE RADIATOR FAN ON CERTAIN 3516B GENERATOR SETS
1356		PS53579

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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 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 "PS53579" 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

30Sep2019

PROBLEM

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The blades on the existing radiator fan assembly may become loose and/or fracture on certain 3516B Generator Sets.

AFFECTED PRODUCT

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Model

Identification Number

3516B

YAT00452-00453, 496-497, 500-501, 557, 560-563, 565, 567-569, 571-572, 864, 866, 868-869, 871

YBT00108-00109, 111, 115, 176-179, 258-259, 263-264, 266-269, 271-272, 275-278, 280-282, 287, 290-293, 295-299, 304-306, 348-368, 370-381, 383-385, 388-390, 394-395, 400, 404-406, 410, 415-417, 420, 558, 561, 563-564, 609-614

ZAP00796-00798, 813-824, 845, 849-852, 973-974, 976-977, 981, 983-984, 986, 988-996, 1000-1002, 1212, 1242, 1245, 1248, 1257-1259, 1261-1262, 1264, 1266, 1268, 1270-1276, 1278, 1280, 1293, 1296-1300, 1302-1303, 1313, 1317-1319, 1323

PARTS NEEDED

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Qty	Part Number	Description
1	5327856	FAN AS-RDTR
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% 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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Important Safety Information where

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, on the product, and in the OMM are not all inclusive. If a tool, procedure, work method, or operating technique 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 and that the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

WARNING: The generator set must be isolated mechanically and 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.

Repair Action Required

At the next scheduled maintenance, inspect the 442-1528 Fan for blade loosening. Check looseness by placing a dial indicator at edge of the blade tip in the location shown in Image1. Grab the blade at the tip and gently move the blade up and down in the direction shown by the arrows in Image2. Inspect the joint between the composite blade and the aluminum hub as shown in Image3. If total blade movement greater than 7 mm is measured as a result of movement at this joint, replace the fan with 532-7856 Fan.

Installation of the 532-7856 Fan requires 442-1528 Fan removal along with fan shaft and bearing assembly removal. Refer to Image4.

The fan bushing used on 442-1528 Fan is installed on the radiator side. Refer to Image5. This same bushing is to be used to install 532-7856 Fan, but it will be installed on the engine side instead. Refer to Image6.

The collar used on 442-1528 Fan will not be needed for the 532-1528 Fan. Refer to Image7.

Refer to Rework Procedure

Also refer to Disassembly and Assembly, RENR5060 for the radiator fan disassembly and assembly instructions.

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Image1

Image2

Image3

Image4

Image5

Image6

Image7

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%
0-15000 hrs, 0-144 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 7.0-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.

Rework Procedure

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Remove fan guard, fan shaft guard, and belt guard. Refer to Image1.1.1, Image 1.1.2 and Image1.1.3.

Image1.1.1

Image1.1.2

Image1.1.3

Remove belts and top pulley. Refer to Image1.2.1.

Image1.2.1

Support weight of fan assembly using lifting straps. Refer to Image1.3.1. Remove four bearing assembly bolts. Refer to Image1.3.2. Remove fan, shaft and bearing assembly as one piece. Note that combined weight of fan, shaft, and bearing assembly is approximately 150 lbs (68 kg).

Image1.3.1

Image1.3.2

Place fan, shaft, and bearing assembly on work bench. Remove bushing bolts and install in adjacent holes. Remove fan and bushing from shaft. Tighten bolts to force fan off the bushing. Refer to Image1.4.1.

Image1.4.1

To install 532-7856 Fan, install bushing approximately 3/8? (10 mm) from the end of shaft. Refer to Image1.5.1.

Image1.5.1

Install 532-7856 Fan onto shaft so that the face of the fan hub is flush with the end of the shaft. Refer to Image1.6.1.

Image1.6.1

Tighten 3 bushing bolts to seat bushing onto shaft. Bolts should be tightened slowly, one after another in a circular pattern. A minimuim of 5 rotations is needed to seat the bushing correctly. Tighten bolts to 30 ft-lbs (40.7 N-m) to complete assembly. Refer to Image1.7.1.

Image1.7.1

Install fan, shaft and bearing assembly as one piece onto radiator support assembly. Note that combined weight of fan, shaft, and bearing assembly is approximately 150 lbs (68 kg). Refer to Image1.8.1. Verify distance from end of shaft to front face of ?C? channel is 6 inches (152 mm). Refer to Image1.8.2 and Image1.8.3.

Image1.8.1

Image1.8.2

Image1.8.3

Verify distance from tip of fan blade to inside diameter of the ring shroud is 1/4 inch (6.4 mm). Use same blade to measure clearance at 4 positions in 90 degree increments. Difference in measurements for each position should not exceed 2 mm. Refer to Image1.9.1.