PRODUCT SUPPORT PROGRAM FOR REMOVING THE RADIATOR FAN DRIVE ON CERTAIN 3508, 3508B, 3512, 3512B, AND 3516B GENERATOR SETS

Usage:

SEBE8755

April 24, 2004
U-128
A-88
D-104
O-107

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*After failure only*	PRODUCT SUPPORT PROGRAM FOR REMOVING THE RADIATOR FAN DRIVE ON CERTAIN 3508, 3508B, 3512, 3512B, AND 3516B GENERATOR SETS
1353		PS50764

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 "PS50764" 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.

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.

TERMINATION DATE

April 30, 2006

PROBLEM

The radiator fan drive needs to be removed on certain 3508, 3508B, 3512, 3512B, and 3516B generator sets. The drive end bearing can turn on the main drive shaft.

AFFECTED PRODUCT

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Model	Identification Number
3508	5PW1-538
3508B	5KW1-1372
3512	6WW1-688
3512B	6GW1-807 FDE1-161
3516	8TW1-465
3516B	8NW1-556 FDX1-228

PARTS NEEDED

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Qty	Part Number	Description
1	2441225	Shaft

ACTION REQUIRED

See the attached Rework Procedure.

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
0-4000 hrs	100%	8.0	0	0	0	0
4001-6000 hrs	50.0%	4.0	0	0	50%	4.0
NOTE: This is an 8.0?hr job.

PARTS DISPOSITION

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

Attach. (1-Rework Procedure)

Rework Procedure

Undo the fan retaining bolt and remove the fan. A suitable fan puller should be used to do this. Care must be taken not to damage the fan during this operation.
Remove any guarding around the belts.
Loosen tensioner and remove the belts.
Fit lifting gear to fan cowl and carefully take the slack on the chains loosen and remove the fasteners securing the fan cowl assembly and supporting legs from the frame chassis.
Remove Idler As. by loosening all bolts.
Remove the Fan Drive Taperlock As.
Loosen and remove the bearing fasteners and discard. Remove the bearing and Fanshaft As. from the bearing plate.
Degrease and clean bearing plate.

Fitting the new fan drive assembly

Fit the new fan side bearing with the new spacer and packer. The embossed writing on the casting and the inner race collar should face towards the engine.
Fit the new bolts and washers and temporally tighten.

NOTE: This is not the final torque.

Fit the main shaft and shrunk fit bearing onto the bearing plate and insert the shaft into the fan bearing.
Fit packers and square bearings onto bearing plate.
Fan side bearing. Align the dimpels in the shaft with the grub screw holes in the inner bearing.
Insert grub screws and hand tighten.
Fit bearing bolts and temporally tighten, ensure assembly is aligned.
Fit fan to shaft and insert key into keyway then fit fan retaining washer and bolt.
Torque bolt to 120 N.m.
Check fan clearance all the way round, clearance should be 6 mm +/- 2 mm.
Removing or adding packers obtain fan clearance.
Moving the bearing from side to side can do horizontal adjustment.
Ensure the pulley is square and perpendicular to the genset frame/chassis. Also, check the fan pulley is level by using a spirit level.
Once all this is complete torque all bolts as follows:

Fan bearing bolts M16 = 118 N.m

Drive bearing bolts M20 = 225 N.m

Grub screw bolts on fan bearing side. Remove grubscrews and add loctite 243 then torque screws to 17 N.m.
Remove grub screws from pulley side and add loctite 243 to thread and tighten to a torque 30 N.m.
Confirm free rotation of fan drive.
Refit fan belts and grease connecting pipes. Refit all previously removed guarding.