PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE GENERATOR HAVING MISALIGNED MOUNTING FEET ON CERTAIN C4.4 AND C6.6 GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE GENERATOR HAVING MISALIGNED MOUNTING FEET ON CERTAIN C4.4 AND C6.6 GENERATOR SETS

Usage:

REBE6459-00

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20Sep2010

U-378

A-299

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE GENERATOR HAVING MISALIGNED MOUNTING FEET ON CERTAIN C4.4 AND C6.6 GENERATOR SETS
4450		PI31803

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31803" 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 "PI31803" 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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COMPLETION DATE	TERMINATION DATE
31Mar2011	30Sep2011

PROBLEM

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The existing generator installed on certain C4.4 and C6.6 series generator sets potentially have mounting feet incorrectly welded in place. An incorrectly positioned generator mounting feet assembly results in the generator feet not being parallel to the center line of the coupling disk causing the anti-vibration mounts (AVM) being unevenly loaded. This can in turn induce unnecessary vibration levels, premature AVM failure and generator coupling misalignment.

AFFECTED PRODUCT

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Model	Identification Number
C4.4	D4B01439, 1452-1453, 1458, 1464, 1466-1467, 1472-1473, 1475-1477, 1485-1490, 1492, 1495, 1500-1501, 1602-1604, 1606, 1608, 1610, 1613, 1617, 1624, 1628, 1630-1631, 1635, 1640-1642, 1646, 1651, 1654, 1656 GLD00437-00440, 442-445, 454, 457-461 GLE00759, 780-781, 785
C6.6	N6D01526, 1543, 1549, 1554, 1558, 1560, 1569, 1571, 1575, 1577, 1588, 1598, 1600-1603, 1634, 1839, 1841, 1859, 1891

PARTS NEEDED

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Qty	Part Number	Description
1	2652661	GENERATOR AR-PWR (DO NOT ORDER - SEE REWORK)
1	2652663	GENERATOR AR-PWR (DO NOT ORDER - SEE REWORK)
1	2652667	GENERATOR AR-PWR (DO NOT ORDER - SEE REWORK)
1	2652669	GENERATOR AR-PWR (DO NOT ORDER - SEE REWORK)
1	2679912	GENERATOR AR PWR (DO NOT ORDER - SEE REWORK)
1	2679913	GENERATOR AR-PWR (DO NOT ORDER - SEE REWORK)
1	2679914	GENERATOR AR-PWR (DO NOT ORDER - SEE REWORK)
1	2679915	GENERATOR AR-PWR (DO NOT ORDER - SEE REWORK)
1	2679916	GENERATOR AR-PWR (DO NOT ORDER - SEE REWORK)
1	2679917	GENERATOR AR-PWR (DO NOT ORDER - SEE REWORK)
1	2679921	GENERATOR AR-PWR (DO NOT ORDER - SEE REWORK)
1	2683596	GENERATOR AR-PWR (DO NOT ORDER - SEE REWORK)
1	2683598	GENERATOR AR-PWR (DO NOT ORDER - SEE REWORK)
1	2683599	GENERATOR AR-PWR (DO NOT ORDER - SEE REWORK)
1	2704826	GENERATOR AR-PWR (DO NOT ORDER - SEE REWORK)
1	2739590	GENERATOR AR-PWR (DO NOT ORDER - SEE REWORK)
1	2779091	GENERATOR AR-PWR (DO NOT ORDER - SEE REWORK)
1	2915394	GENERATOR AR-PWR (DO NOT ORDER - SEE REWORK)
1	2915395	GENERATOR AR-PWR (DO NOT ORDER - SEE REWORK)
1	2915396	GENERATOR AR-PWR (DO NOT ORDER - SEE REWORK)
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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1. Contact Leroy Somer to arrange shipment of new replacement generator.

2. Remove the existing generator and replace with new generator with properly aligned mounting feet.

3. Return removed generator to Leroy Somer following proper shipping method.

Refer the to attached Rework Procedure for details.

NOTE: Generator will be shipped directly from supplier, Leroy Somer. Do not order through Caterpillar Parts System.

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OWNER NOTIFICATION

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

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 9.0-hour job
Generator assembly being issued to dealer at no cost by Caterpillar supplier. No Freight Charges allowed. Caterpillar supplier providing all logistic transportion for delivery and return shipment of generators.

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PARTS DISPOSITION

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The Caterpillar dealership is to arrange for the removed generators to be shipped back to the following address via generator supplier arranged freight. The generators should be sufficiently re-packaged to prevent damage on the same shipping skid from which the replacement generator was received. The removed generator is to be returned with hardware and panels as replacement generator was received.

Leroy Somer
Attn: Russ Ramer
669 Natchez Trace Dr.
Lexington, TN 38351
(731) 967-3147
Email: russ.ramer@emerson.com

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

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE GENERATOR HAVING MISALIGNED MOUNTING FEET

MODELS INVOLVED - C4.4 and C6.6 Generator Sets

Dear Caterpillar Product Owner:

The generator needs to be replaced on the products listed below. The existing generator has mounting feet incorrectly welded in place. An incorrectly positioned generator assembly can cause premature failure of the anti-vibration mounts, unnecessary vibration levels, and generator coupling misalignment. 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 20Sep2010 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 20Sep2010 Service Letter

Rework Procedure

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The appropriate Caterpillar dealership representative working this service program is to contact the following Leroy Somer Product representative in order to receive appropriate instructions regarding delivery coordination of the replacement generator and return shipment information of original generator:

Leroy Somer
Attn: Russ Ramer
669 Natchez Trace Dr.
Lexington, TN 38351
(731) 967-3147
Email: russ.ramer@emerson.com

The correct replacement generator part number for a given generator set serial number, can be identified utilizing the Caterpillar TMI database. For additional detailed information refer to Caterpillar service publications:

SEBU8134 - C4.4 Operations Maintenance Manual
SEBU8139 - C6.6 Operations Maintenance Manual
RENR9703 - Disassembly & Assembly Manual
SENR3130 - Torque Specifications

Ensure all health and safety requirements are adhered to at all times. Also, ensure proper Lock Out-Tag Out procedures are followed at all times while work is being performed on the machine. Lock out generator before commencing any type of work.

Only qualified repair personnel should service this equipment.

1. Isolate the Genset before commencing any work on the unit, open generator set breaker, activate Emergency Stop, and disconnect battery cables.

2. Use RENR9703 as reference, detach the existing generator from the engine and then remove the generator from the enclosure.

NOTES:
a. Document the wiring configuration of the generator lead, and the voltage sensing and the current sensing conductors before disconnecting them.
b. Retain all hardware, couplings, and anti-vibration mounts for reuse when installing the replacement generator.

3. Properly repackage the removed generator in the same container in which the new generator was received. The Caterpillar dealership is to arrange for the removed generators to be shipped back to the following address via generator supplier arranged freight. The generators should be sufficiently re-packaged to prevent damage on the same shipping skid the replacement generator was received. The removed generator is to be returned with hardware and panels as the replacement generator was received.

Leroy Somer
Attn: Russ Ramer
669 Natchez Trace Dr.
Lexington, TN 38351
(731) 967-3147
Email: russ.ramer@emerson.com

6. Use RENR9703 as reference, place the new generator in the enclosure, secure the new generator to the engine.

- Ensure that the generator drive plates contact the engine flywheel and the flywheel housing halves match up.

- Confirm the alignment of the generator drive plates to the flywheel.

- Confirm that the generator is properly aligned; manually rotate the generator shaft approximately 180 degrees. While rotating the generator shaft, there will be a distinctive audible "metal snapping" sound. This audible noise confirms the proper positioning of the generator drive plates.

7. Connect the generator leads, the voltage sensing and the current sensing conductors and all other associated ancillary devices.

NOTE: Utilize the wiring configuration document created in Step 2 as reference to ensure that the generator leads, voltage sensing and current sensing conductors are connected correctly.

8. Perform functional test of generator set to reaffirm assembly process. Refer to SEBU8134 and SEBU8139.

9. Restore the generator set to its proper operational condition.