PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING THE FAN ON CERTAIN C18, C27, 3412, 3412C, G3412, AND G3412C GENERATOR SETS Caterpillar


PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING THE FAN ON CERTAIN C18, C27, 3412, 3412C, G3412, AND G3412C GENERATOR SETS

Usage:

TEBE8343-02

22Oct2018
(Revised 17Mar2019)


U-593
A-429
D-518
O-525
TM-15

 

Safety

  
  

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING THE FAN ON CERTAIN C18, C27, 3412, 3412C, G3412, AND G3412C GENERATOR SETS

4457
PI11172
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 as soon as possible. When reporting the repair, use "PI11172" 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 "PI11172" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

 
NOTE:

This Revised Service Letter replaces the 22Oct2018 (Revised 16Nov2018) Service Letter. Changes have been made to the Title, Problem, Parts Needed, Action Required, Service Claim Allowances, and Rework Procedure.



PROBLEM

The generator fan needs to be inspected and possibly replaced on certain C18, C27, 3412, 3412C, G3412, and G3412C Generator Sets. The existing fan can crack (Image 1 in Action Required) during very early hour operation and may result in a flying object hazard. In conjunction with other factors or circumstances, these failures could result in a risk of personal injury or death.

AFFECTED PRODUCT

Model Identification Number
*******Group  1*******
C27 2A300412-00413, 417-418, 420-421, 425-426, 432, 434-435, 437, 439, 442-444, 448-450, 458-465, 470, 474

DWB02889
*******Group  2*******
G3412 GNA00155-00157

KAP01167-01170, 1172
G3412C R7A00226

SPY00246-00247, 249-253, 255
*******Group  3*******
C18 SSM00196-00197, 200-211

SSW00155-00172
*******Group  4*******
3412  TWL00143-00146, 149-150
3412C  DK601038, 1043, 1057, 1075, 1081, 1096, 1136-1137, 1147-1150, 1158, 1161, 1169-1170, 1270, 1272-1276

PARTS NEEDED

Qty

Part Number Description
*******Group 1*******
1 2N2030 FAN-VENT
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.

*******Group 2*******
1 2N2030 FAN-VENT
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.

*******Group 3*******
1 2N2030 FAN-VENT
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.

*******Group 4*******
1 2N2030 FAN-VENT
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

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 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 and the product will not be made unsafe by the operation, lubrication, maintenance, and the repair procedures that are used.

WARNING: The generator set must be isolated mechanically and electrically before and while the rework is being performed. Follow the proper lock out tag out procedures to protect against unintended operation, the unexpected movement, energizing, and 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.

Action Required

The affected generator fan may not meet the required dimensional specifications. The generator fan will need to be inspected and possibly replaced. The affected generator fan will have a stamp "FYMSA" located on the front face of the fan. Refer to Image 2 for location. Refer to the attached Rework Procedure for inspecting and replacing the fan. If an affected generator fan is discovered during the inspection, replace with a new fan. The following actions are required until the fan is replaced.

1. If possible, do not operate the product.

2. If the product must be operated, do not enter the enclosure or engine room near the generator front fan area while the unit is in operation.

3. Maintain a safe distance from the generator while it is in operation.

4. All fans identified with the "FYMSA" stamp will need to be replaced. If the fan does not have the "FYMSA" stamp, no replacement is necessary.

"NOTE: There is currently a limited supply of parts available for this program. The 2N-2030 Fan is frozen and allocation will be manually prioritized until sufficient quantities are available. Please work with your Customer Service Representative for parts availability?
Image1
Image2

OWNER NOTIFICATION

Owners in the following countries will receive the attached Owner Notification:
US
Canada
Australia
New Zealand

SERVICE CLAIM ALLOWANCES

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%
 NOTE: This is a 1.5-hour job for Group 1
1.5 hours are allowed for fan inspection.
An additional 10.0 hours are allowed for fan replacement.

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%
 NOTE: This is a 1.5-hour job for Group 2
1.5 hours are allowed for fan inspection.
An additional 12.0 hours are allowed for fan replacement.

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%
 NOTE: This is a 1.5-hour job for Group 3
1.5 hours are allowed for fan inspection.
An additional 12.0 hours are allowed for fan replacement.

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%
 NOTE: This is a 1.5-hour job for Group 4
1.5 hours are allowed for fan inspection.
An additional 12.0 hours are allowed for fan replacement.


PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
 
 
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
 
 
 
EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING THE FAN

MODELS INVOLVED - CERTAIN C18, C27, 3412, 3412C, G3412, AND G3412C GENERATOR SETS

Dear Cat Product Owner:

The fan inside the generator needs to be inspected and possibly replaced on the products listed below. The existing fan may have a nonconforming fit diameter. This may affect the safe operation of the generator set. If the fan has the nonconforming fit diameter, there is a risk that the fan could have been cracked during assembly and may break apart during operation causing a flying object hazard. If the fan has a nonconforming fit diameter causing a crack, creating a flying object hazard, this may, in conjunction with other factors or circumstances, result in a risk of personal injury or death. You will not be charged for the service performed.

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

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated.

You may now search for open Safety Service Letters by entering your product serial number(s). Visit the CAT.COM/SAFETY website and click on SUPPORT, then SAFETY SERVICES for more information. Please refer the dealer to their Service Letter dated 22Oct2018 when scheduling this service.

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



Caterpillar Inc.

Identification #(s)



Attached to 22Oct2018 Service Letter


Rework Procedure


 
NOTE: The below procedure is to be executed in two phases: First, inspect the fan to determine if it has the ?FYMSA? stamp. If the ?FYMSA? stamp is not found, complete phase 1 only. Do not replace fan. If the ?FYMSA? stamp is found, proceed to the second phase and replace the fan.

NOTE: Ensure that health and safety requirements are adhered to at all times.

Phase 1. Instructions for Fan Inspection

1. Remove generator drip cover. Store drip cover and hardware for reuse.

2. Remove fan guard. Store fan guard and hardware for reuse.

3. Remove access plate to the flywheel and store hardware for reuse.

4. Use a barring tool. Turn the engine over and inspect the fan for any visible cracks.

5. If any cracks are observed, do not re-assemble. Do not operate the generator set. Replace with new fan. Proceed to step 17, Instructions for Fan Replacement.

6. If no cracks are observed, remove the fan bolts. Store the fan bolts for reuse.

7. Carefully slide the fan back to allow for room to view the front of the fan.

8. Using a mirror or bore scope, inspect the front of the fan for stamp "FYMSA".

9. If stamp "FYMSA" is observed, refer to the Action Required section. Replace with new fan as soon as possible.

10. If "FYMSA" is not stamped on fan, carefully slide the original fan back into place.

11. Thread the fan bolts by hand. Run down fan bolts using the alternating pattern.

12. Tighten the fan bolts to 258 +/- 40NM using an alternating pattern for proper installation.

13. Install fan guard

14. Install drip cover.

15. Install access plate on flywheel housing.

16. Return to service.

Phase 2. Instructions for Fan Replacement.

17. Decouple the generator from the engine. NOTE: If generator contains a permanent magnet generator option, remove the PMG stator before proceeding.
a. For SR4B generators on 3412 and G3412 models, refer to SENR5359 for disassembly and assembly instructions.
b. For SR5 generators on C27 models, refer KENR5284 to for disassembly and assembly instructions.
c. For SR4B generators on C18 models, refer to UENR6704 for disassembly and assembly instructions.

18. Remove drive disc bolts. Store hardware for reuse. See image 1.1.1

19. Carefully remove drive disc and store for reuse.

20. Remove fan and install new replacement fan.

21. Install the drive discs. Use a 5/8 inch or 16mm diameter alignment pin or bolt to align drive disc holes. Do not remove the pin or bolt until the discs bolts have been torqued. See image 1.1.2

22. Apply loctite 242 to each bolt and thread into disc by hand. See image 1.1.3. and 1.1.4

23. Review bolt assembly sequence. See image 1.1.5.

24. Follow the sequence, run down each bolt using a hand tool.

25. Follow the sequence, torque each bolt to 450FT/LBS. Mark each bolt with a line after being torqued.

26. Remove alignment pin.

27. Reinstall generator and verify proper operation.
a. For SR4B generators on 3412 and G3412 models, refer to SENR5359 for disassembly and assembly instructions.
b. For SR5 generators on C27 models, refer to KENR5284 for disassembly and assembly instructions.
c. For SR4B generators on C18 models, refer to UENR6704 for disassembly and assembly instructions.

21. Return to Service
Image1.1.1
Image1.1.2
Image1.1.3
Image1.1.4
Image1.1.5
Image1.1.6
 
 

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