PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FAN GUARD ON CERTAIN 3456 GENERATOR SETS(60HZ) Caterpillar


PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FAN GUARD ON CERTAIN 3456 GENERATOR SETS(60HZ)

Usage:

REBE1449-01

08Mar2007
(Revised 24Apr2007)


U-89
A-75
D-74
O-83

 
Safety
  
  

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FAN GUARD ON CERTAIN 3456 GENERATOR SETS(60HZ)

1360 7155 1381 7150 1353
PI10581
NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10581" 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 "PI10581" 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 March 8, 2007 Service Letter. Changes have been made to the Affected Product.



PROBLEM

The Fan guard needs to be reworked on 3456 Generator Sets (60Hz). Ribs can fracture at welded joints and become detached from the guard assembly interfering with normal operations or resulting in damage to the fan. Undesireable loose or detached component parts may also result in personal injury or death.

AFFECTED PRODUCT

Model Identification Number
*******Group  1*******
3456 C1G00584, 646, 799, 823, 892, 959, 963, 980, 990, 1130, 1133, 1284

C3G00125-00126, 128-129, 131, 134-141, 145, 149-155, 157-164, 170-171, 175-176, 178-181, 183, 186-193, 195-197, 199-205, 210, 214, 216-221, 224-254, 257-266, 271-274, 276-292, 294-296, 298-299, 301-304, 308-311, 313-320, 327-331, 336, 338, 341-351, 354, 359, 363-364, 366-367, 372-392, 394-413, 416-417, 419, 422-427, 429-436, 438, 440, 443-449, 451, 454-458, 460-461, 464, 467-472, 474-477, 479-488, 491-505, 507-508, 511-520, 522-526, 530-536, 541-543, 545-546, 548, 550, 552-560, 562-565, 572-575, 583-585, 587-589, 593, 596-597, 600, 605-606, 608-611, 617-619, 621, 627, 631-639, 641-646, 649, 652-653, 655-664, 666-667, 670, 675, 677-681, 684-685, 687-688, 690, 692, 701-702, 725, 732, 738-741, 743-745, 768, 787-788, 797, 813-814, 823, 884-885, 897-899, 986, 994-995, 1013-1014, 1018, 1022, 1052, 1058, 1061, 1169-1172, 1174-1179, 1201-1203, 1209-1212, 1216-1217, 1221-1224, 1227-1229, 1240-1264, 1270-1272, 1274-1280, 1282-1285, 1287-1288, 1290-1292, 1295, 1298-1299, 1302-1304, 1307-1308, 1315, 1317

C4G00126, 129-150, 155-158, 163-167, 170-181, 184-188, 191-203, 205-211, 213-219, 229-234, 236-238, 241-269, 272-291, 296-330, 333-334, 351, 358-367, 369-379, 381, 383-386, 388-390, 392, 397, 401, 403, 406, 408, 457, 468, 470-472, 474, 478, 482, 485, 487-488, 496-497, 500, 502, 504, 506-507, 514, 516-517, 519-522, 524-526, 528, 530-531, 533, 535-536, 538-545, 548, 550-551, 553-554, 558-565, 567-573, 575-584, 587-590, 592-594, 597-604, 606-607, 609, 611-615, 618, 620, 622-627, 629, 631-633, 635-636, 639-647, 649, 651-673, 675-677, 679-685, 688-693, 697-698, 703-704, 708-711, 715-716, 718-719, 722-726, 732, 734, 742, 748, 750-755, 757-760, 765, 771-944, 947-985, 988-989, 991-993
*******Group  2*******
3456  7WG02900, 3215, 3218, 3223, 3244, 3250, 3256, 3283, 3294, 3296, 3320, 3322, 3328, 3343, 3351, 3767, 3778, 3782, 3784, 3845, 4115, 4145, 4152, 4162, 4171, 4174, 4179, 4185-4186, 4200, 4213, 4287, 4319, 4350, 4493, 4498-4499, 4526, 4539, 4603, 4607, 4646, 4648, 4656, 4728, 4840, 4843-4844, 4846-4847, 4849, 4851-4852, 4889, 4901, 4904-4905, 4913, 4920, 4922, 4928, 4930, 4933, 4935, 4939, 4943, 4950, 4963, 4970, 4972, 4983, 5039, 5043, 5046-5047, 5055, 5164

PARTS NEEDED

Qty

Part Number Description
*******Group 1*******
1 2968033 GUARD AS-FAN
1 2968034 GUARD AS-FAN
*******Group 2*******
1 2968033 GUARD AS-FAN
1 2968034 GUARD AS-FAN

ACTION REQUIRED

Replace the current P/N 208-8464 with P/N 296-8033 (Bottom Guard). Replace current P/N 208-9636 with P/N 296-8034 (Top Guard).

OWNER NOTIFICATION

U.S. and Canadian owners will receive the attached Owner Notification.

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

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


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.
 
 
 
COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FAN GUARD ON CERTAIN 3456 GENERATOR SETS(60HZ)

MODELS INVOLVED - Certain C1G, C3G, & C4G Generator Sets

Dear Caterpillar Product Owner:

The Fan guard needs to be reworked on 3456 Generator Sets (60Hz). Ribs can fracture at welded joints and become detached from the guard assembly interfering with normal operations or resulting in damage to the fan. Undesireable loose or detached component parts may also result in personal injury or death.

You will not be charged for the service performed.

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

Please refer the dealer to their Service Letter dated 08Mar2007 when scheduling this service.

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



Caterpillar Inc.

Identification #(s)



Attached to 08Mar2007 Service Letter


Rework Procedure


 
Instructions

1. Reference SEBU7829 Operation & Maintenance Manual

2. Switch off generator set.

3. Refer to Image 1.1.1, which shows the fan guard, fuel cooler, and radiator assembly on a 3456 generator set.
Image1.1.1
 
4. Refer to Image 1.2.1 and Image 1.2.2. These show the current and new improved design of fan guard for the 3456 generator set.

Note: That the fan guard assembly has a top and bottom half. The top half incorporates the mounting holes for the fuel cooler.
Image1.2.1
Image1.2.2
 
5. Refer to Image 1.3.1. This shows the fuel cooler attached to the top half of the fan guard assembly. Note the number and order of nuts used. Unscrew the bolts, nuts, and washers at the three locations where the fuel cooler is attached to the fan guard. Retain the bolts, nuts, and washers.
Image1.3.1
 
6. Remove the fuel cooler from the fan guard. Allow it to gently hang on its fuel supply and return hoses.

7. Refer to Image 1.4.1., Image 1.4.2. and Image 1.4.3. Unscrew the bolts and washers securing the fan guard top and bottom halves to the radiator cowl at the eight locations. Retain the bolts and washers.
Image1.4.1
Image1.4.2
Image1.4.3
 
8. Remove the fan guard top and bottom halves from the radiator assembly.

9. Locate in place the new improved, replacement fan guard top and bottom halves. The amount of space between the radiator assembly and the fan pulley guards is small. Therefore this may be achieved more easily by sliding in both top and bottom guards while orientated vertically, then rotating them through 90 degrees into the correct position.

10. Replace the bolts and washers at the eight locations securing the fan guard top and bottom halves to the radiator cowl. Tighten these securely.

11. Locate in place the fuel cooler on the left hand side of the top half of the new improved fan guard (same position as on the old fan guard).

12. Replace the bolts, nuts, and washers at the three locations securing the fuel cooler assembly to the new improved radiator fan guard. Tighten these securely.

13. Run the generator set and ensure that none of these components are loose or have leaks (as applicable).
 
 

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