PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE RADIATOR ON CERTAIN PM3516B POWER MODULES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE RADIATOR ON CERTAIN PM3516B POWER MODULES

Usage:

TEBE0290-01

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30Sep2013

(Revised 26Mar2014)

U-461

O-388

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE RADIATOR ON CERTAIN PM3516B POWER MODULES
1353		PI32233

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32233" 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 "PI32233" as the Part Number, "7751" as the Group Number, "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 30Sep2013 Service Letter. Changes have been made to the Affected Product.

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COMPLETION DATE	TERMINATION DATE
31Mar2014	30Sep2014

PROBLEM

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The radiator on certain PM3516B Power Modules contains bearings that can fail and will require replacement.

AFFECTED PRODUCT

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Model	Identification Number
PM3516	NBR00243, 265, 268, 271-272, 280, 282, 284, 289, 291, 294, 298, 307-308, 323-324, 331-333, 336-338, 342-346, 348-350

PARTS NEEDED

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Qty	Part Number	Description
1	8C0882	FITTING-RELIEF V
1	1239327	SHAFT-FAN
2	4370099	BEARING-ROLLER
1	4378851	KIT-FAN HUB
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

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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. This involves the removal and replacement of the fan bearings, hub, and shaft. The rework procedure includes the following sections:

1. FAN BEARING REMOVAL AND REPLACEMENT
2. AUTO LUBE REPROGRAMMING (if equipped)
3. FINAL AUDIT

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

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OWNER NOTIFICATION

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

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 10.0-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.

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE RADIATOR ON CERTAIN PM3516B POWER MODULES

MODELS INVOLVED - PM3516B

Dear Cat Product Owner:

The radiator needs to be reworked on the products listed below. The existing radiator contains bearings that can fail. 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. Please refer the dealer to their Service Letter dated 30Sep2013 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 30Sep2013 Service Letter

Rework Procedure

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1. FAN BEARING REMOVAL AND REPLACEMENT

Remove louvers for access.

Remove Belts
Store belts in the personnel access room to keep free from damage and contamination.

Image1.1.1

Image1.1.2

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.

Image1.2.1

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 grease 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.

Image1.3.1

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.

Image1.4.1

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

Image1.5.1

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
2 437-0099 Bearings
1 Fan Hub (Fan Hub Kit)
1 123-9327 Shaft
2 Shaft Collars (Fan Hub Kit)
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. Replace with original Quicklinc fittings. 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 the 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. Tighten the fan hub set screws to 50ft-lbs. Position a shaft collar firmly against the bearing and the other against the fan hub. Tighten the set screws. Install another shaft collar and position it against the top of the fan hub and tighten the set screws. Tighten the 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.

Image1.6.1

Fabricate fan lift collar and modified floor jack as shown in Image 1.7.1 and 1.7.2.
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 the bearing set screws to 25 ft-lbs. Loosen, and reposition shaft collar underneath the top bearing. Tighten the collar set screws to 27 ft-lbs.

Parts Required:
NEW
6 Bolts (Fan Hub Kit)
12 Washers (Fan Hub Kit)
6 Nuts (Fan Hub Kit)

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 tighten to 60ft-lbs.

Image1.7.1

Image1.7.2

Image1.7.3

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 the 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 tighten to 27ft-lbs.
Apply compound to bearing set screws reinstall and tighten to 25ft-lbs.

Image1.9.1

Image1.9.2

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. Tighten the 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 1.10.2. The collar is designed to accommodate the key and set the bushing at the correct depth.

Image1.10.1

Image1.10.2

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.
Tighten the 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, tighten the pivot rod bolts to 110ft-lbs.

Image1.11.1

2. AUTO LUBE REPROGRAMMING (if equipped)

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

Image1.12.1

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?

Note: Count goes up to 60 then starts over

Press the red button so that "P2" appears on the display. When releasing the button, the factory set value will appear. No change is made here, verify it to be "00".

Press the red button so that "P3" appears on the display. When releasing the button, the factory set value will appear. No change is made here, verify it to be "1".

Press the red button so that "P4" appears on the display. When releasing the button, the factory set value will appear. No change is made here, verify it to be "no".

Press the red button so that "P5" appears on the display. When releasing the button, the factory set value will appear. No change is made here, verify it to be "--".

Press the red button so that "P6" appears on the display. When releasing the button, the factory set value will appear. No change is made here, verify it to be "SP".

Press the red button so that "P-" appears on the display.

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.

After verification of "P1" press the red button to continue and verify each setting as you go.
Remove the Auto Lube Programming label on radiator access door.

Image1.13.1

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 to inspect for correct grease line routing to the fan motor. The lines should be connected at the rear of the motor on top and on bottom. If the supply line on top is connected to the front of the motor disconnect the grease line and remove the fitting assembly. Remove the reducer attached to the Quicklinc fitting and install the fitting in the rear after removing the plastic plug. Route the line to the rear of the motor and connect.

Note: Avoid sharp bends of the plastic tubing and moving parts that could damage the lubrication lines. Minimum bending radius is 50mm (2in).

Install the reducer and a 8C-0882 grease relief fitting in the port that the Quicklinc fitting was removed from as shown in Image 1.14.3.
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 lines ensuring that they are fully seated into the Quicklinc fittings. Verify that all threaded connections are tightened properly. Repeat the cycles for verification.

Parts Required:
1 8C-0882 Relief Fitting

Image1.14.1

Image1.14.2

Image1.14.3

3. FINAL AUDIT

Parts Required:
Sealant

Apply white silicon sealant around the container opening and install the louvers.
Allow the fan to run for a minute to seat the belts. Turn off the power module. 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.

Test and Adjust
1. Top Belt Tension
2. Bottom Belt Tension

Final Audit Checklist
1. Replace the bolts and nuts to the radiator access door.
2. Verify all hardware has been installed and all tools have been collected.
3. Overall condition of the unit and capture proof of rework with photos and attach to SIMS entry.
4. Verify Auto lube lines are secure and are routed correctly.
5. Turn unit on. Check to see if Auto Lube is powered. Cycle Auto Lube.
6. Confirm radiator caps and radiator fill access panels are secure.
7. Turn engine key switch to the off position.
8. Disconnect battery jumper cables and store.
9. Confirm that all items removed from the power module have been placed back securely.
10. Clean doors and radiator. Close both radiator access doors.