PRODUCT SUPPORT PROGRAM FOR REPLACING THE VARIABLE PITCH FAN ROTARY UNION KIT ON CERTAIN 538/548/558/568 EXCAVATORS AND 521B/522B TRACK FELLER BUNCHERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE VARIABLE PITCH FAN ROTARY UNION KIT ON CERTAIN 538/548/558/568 EXCAVATORS AND 521B/522B TRACK FELLER BUNCHERS

Usage:

TEBE8445-02

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14Dec2018

(Revised 25Apr2019)

U-716

A-519

D-632

O-628

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After Failure Only	PRODUCT SUPPORT PROGRAM FOR REPLACING THE VARIABLE PITCH FAN ROTARY UNION KIT ON CERTAIN 538/548/558/568 EXCAVATORS AND 521B/522B TRACK FELLER BUNCHERS
1356 1360		PS53938

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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 "PS53938" 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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NOTE:	This Revised Service Letter replaces the 14Dec2018 (Revised 25Mar2019) Service Letter. Changes have been made to the Action Required and new instructions have been added to the Rework Procedure.

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TERMINATION DATE

31Dec2020

PROBLEM

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The existing variable pitch fan rotary union kit can fail on certain 538/548/558/568 Excavators and 521B/522B Track Feller Bunchers. If the existing rotary union kit fails, it can result in an oil leak or erratic electrical operation of the fan.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
521B	F7B00276-00431
522B	F7C00251-00381

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*****Group 2*****
538 GF	GMY00100-00103 HBS00135-00220, 401-415
538 LL	JEY00128-00242, 401-417 KBJ00200
548 GF	SFZ00100-00135
548 LL	WRA00200-00239
558 GF	F5G00125-00145
558 LL	F5L00200-00265 LRT00250-00275
568 GF	GF800225-00241 YJX00124-00150
568 LL	BRB00324-00401 L6800250-00322

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
6	3S2093	STRAP-CABLE
1	5631391	UNION KT-ROTARY
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 5% 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	7K1181	STRAP-CABLE
3	1772215	STRAP-CBL DUAL
1	5631392	UNION KT-ROTARY
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 5% 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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- For 538/548/558/568 Excavators, replace the existing 434-3999 Rotary Union Kit and 363-9878 Fan Harness Assembly with a new 563-1392 Rotary Union Kit. Refer to Image1.

- For 521B/522B Track Feller Bunchers, replace the existing 434-3999 Rotary Union Kit and 396-1595 Fan Harness Assembly with a new 563-1391 Rotary Union Kit. Refer to Image2. Follow the attached machine harness Rework Procedure that applies to Track Feller Bunchers only.

Note: Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. Refer to the Operation and Maintenance Manual "Safety Section".

Refer to the Service Manual if/as necessary.

1. Remove the existing rotary union kit and fan harness assembly.

2. Remove the existing P-clips and cable straps along the hose.

3. Install the new rotary union kit.

4. Reinstall P-clips and cable straps in locations shown in Images1 and 2. Cable strap in the same weld links across the back of the cooler as shown in Image2.

Note: The new rotary union kit has a longer pitch sensor lead wire that connects directly to the main machine harness. Refer to Images1 and 2.

Note: The new rotary union kits incorporate longer lead wiring from the rotary union kits pitch sensor, which plugs directly into the electrical connector on the machine harness where the fan harness assembly was previously installed.

IMPORTANT: It is important to route and clip the lead wiring of the new rotary union kit as shown in Images1 and 2 in order to gain the entire benefit of the reliability improvement of the new part. The new rotary union kits also contain oil sealing improvements as well.

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Image1

Image2

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*****
0-4000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
4001-6000 hrs, 25-36 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 8.0-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*****
0-4000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
4001-6000 hrs, 25-36 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 4.0-hour job for Group 2

PARTS DISPOSITION

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

Rework Procedure

IMPORTANT: The following harness Rework Procedure is only needed if the Track Feller Buncher has a 434-3999 Rotary Union Kit that is being replaced by a 563-1391 Rotary Union Kit.

1. Remove each of the three wires (G834, P880, and P882) from the 155-2267 Connector Plug Assembly (connector 21) on the machine harness. Refer to Image1.2.1.

Image1.2.1

2. Insert wire P880 in socket A of the 155-2267 Connector Plug Assembly. Tug on the wire with approximately 10 lbs of force to ensure the contact is locked into the connector. Refer to Image1.3.1.

3. Insert wire P882 in socket B of the 155-2267 Connector Plug Assembly. Tug on the wire with approximately 10 lbs of force to ensure the contact is locked into the connector.

4. Insert wire G834 in socket C of the 155-2267 Connector Plug Assembly. Tug on the wire with approximately 10 lbs of force to ensure the contact is locked into the connector.

Image1.3.1

5. Insert the 155-2267 Connector Plug Assembly into the mating 3E-3370 Connector Receptacle Assembly of the 563-1391 Rotary Kit pitch sensor lead wire. Tug on the connector to verify that the two connector halves are securely latched. Refer to Image1.4.1.

Image1.4.1

6. Use the machine's IQAN display monitor to verify that the proportional fan pitch feedback signal is within the normal range.

Note: When the 563-1391 Rotary Kit is installed, the lead wire on the fan pitch sensor should be routed to the mating connection at the main machine harness and secured with cable straps. The existing 396-1595 Sensor Harness Assembly on the machine should no longer be used.