PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE RADIATOR FAN GUARD ON CERTAIN C27 GENERATOR SETS Caterpillar


PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE RADIATOR FAN GUARD ON CERTAIN C27 GENERATOR SETS

Usage:

TEBE2531-00

21Jan2015


A-17

 

Safety

  
  

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE RADIATOR FAN GUARD ON CERTAIN C27 GENERATOR SETS

1356 1353 1063
PI11004
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 "PI11004" 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 "PI11004" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.



PROBLEM

The radiator fan guard needs to be replaced on certain C27 Generator Sets. The wire that forms the existing radiator fan guard may break and come loose. A flying object hazard may result if the loose pieces contact the radiator fan during operation.

AFFECTED PRODUCT

Model Identification Number
C27  GDS00639-00642

PARTS NEEDED

Qty

Part Number Description
12 8T4121 WASHER-HARD
4 8T4195 BOLT-HEX HEAD
2 1862002 HOSE-HUMP
2 4506010 GUARD AS
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 in order 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 or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

WARNING: The generator set must be isolated electrically before and while the rework is performed. Follow the proper lockout tag out procedures to protect against the unexpected energizing or 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.

REPAIR ACTION REQUIRED

Replace the existing 379-0103 Fan Guard (1) with 450-6010 Fan Guard (2). Refer to Image1 and Image2.

The 2 lower hoses (1 on each side) that connect the charge air pipes to the charge air cooler will need to be replaced with 186-2002 Hose (3) (Image 3). These longer hoses are needed to allow proper alignment on the opposite end of the pipe that connects to the turbocharger.

Refer to the attached Rework Procedure.
Image1
Image2
Image3

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 2.5-hour job


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 REPLACING THE RADIATOR FAN GUARD ON CERTAIN C27 GENERATOR SETS

MODELS INVOLVED - C27

Dear Cat Product Owner:

The radiator fan guard needs to be replaced on the products listed below. The wires that form the existing radiator fan guard can break and come loose. A flying object hazard may result if the loose pieces contact the radiator fan during operation. This flying object hazard 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 SAFETY.CAT.COM website and click on the Product Safety page for more information. Please refer the dealer to their Service Letter dated 21Jan2015 when scheduling this service.

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



Caterpillar Inc.

Identification #(s)



Attached to 21Jan2015 Service Letter


Rework Procedure


 
Remove the existing fan guard (1). Remove 8 bolts (2) that connect the halves together. Save these since they will be used to install the new fan guard. The washers will not be needed.

Remove 8 bolts that connect the fan guard to the shroud (3). Save these bolts and washers since they will be used to install the new fan guard. For re-assembly, tighten to 55 +/- 10 N-m. Refer to Image1.1.1.
Image1.1.1
 
Install new 450-6010 Fan Guard using some of the original fastening hardware and additional quantities ordered. Use quantity 12 of 8T-4195 Bolts and quantity 12 of 8T-4121 Washers to attach the fan guard to the shroud (4).

Use quantity 8 of the original 8T-4195 Bolts and quantity 8 of the new 8T-4121 Washers to attach the fan guard halves together (5). Tighten all hardware to 55 +/- 10 N-m. Refer to Image1.2.1. Some minor radiator position adjustment may be needed to fit the new fan guard. Adjustments can be made at the radiator mounting feet. Refer to Image1.2.2. Re-tighten to 55 +/- 10 N-m.
Image1.2.1
Image1.2.2
 
Install total quantity 2 (1 on each side) of 186-2002 hoses (6). These are the lower hoses that connect the charge air pipes to the charge air cooler. These longer hoses are needed to allow proper alignment on the opposite end of the pipe that connects to the turbocharger (7), after the radiator position is adjusted to allow fit-up of the new fan guard. Refer to Image1.3.1 and Image1.3.2.
Image1.3.1
Image1.3.2
 
Run generator set and verify proper operation.
 
 

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