PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE COUPLING PLATE BOLTS ON CERTAIN C32 GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE COUPLING PLATE BOLTS ON CERTAIN C32 GENERATOR SETS

Usage:

TEBE8507-00

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30Nov2018

D-592

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Safety	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE COUPLING PLATE BOLTS ON CERTAIN C32 GENERATOR SETS
4456		PI11186

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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 must be administered as soon as possible. When reporting the repair, use "PI11186" 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 "PI11186" 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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PROBLEM

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The 7X-0346 Bolts used to fasten the generator coupling plate to the engine flywheel need to be replaced on certain C32 Generator Sets. Depending on the flywheel manufacturing batch and corresponding thread depth, the coupling bolts may not seat properly. This could result in a loose joint and possibly broken bolts. If the bolts break, a flying object hazard may result. This flying object hazard may, in conjunction with other factors or circumstances, result in a risk of personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
C32	K7C00796-00875

PARTS NEEDED

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Qty	Part Number	Description
6	8T4122	WASHER-HARD
6	8T9393	BOLT-HEX HEAD
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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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 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 and the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

WARNING: The generator set must be isolated mechanically and electrically before and while the rework is being performed. Follow the proper lock out tag out procedures to protect against unintended operation, unexpected movement, 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 and local and remote controls before you perform any service to the machine.

REPAIR ACTION REQUIRED

Inspect the Generator Fan Screen, Generator Fan, Coupling Plate, and Flywheel for resultant damage. If no resultant damage is found, replace the current 7X-0346 Bolts (qty 6) with 8T-9393 Bolts (qty 6). Also, replace the 8T-4122 Washers (qty 6) used in the joint stack. Refer to Image1 and Image2.

If resultant damage is found, have the Dealer Technical Communicator (TC) submit a report to CPI number 361118 through CPI Feedback within the Service Information Management System (SIMSi). Provide the inspection information and pictures in this report.

Refer to the attached Rework Procedure.

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Image1

Image2

OWNER NOTIFICATION

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Owners in the following countries will receive the attached Owner Notification:
US
Canada
Australia
New Zealand

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 2.0-hour job

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PARTS DISPOSITION

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

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

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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE COUPLING PLATE BOLTS

MODELS INVOLVED - CERTAIN C32 GENERATOR SETS

Dear Cat Product Owner:

The bolts used to fasten the generator coupling plate to the engine flywheel need to be replaced on the products listed below. These bolts may be too long for the application and result in a loose joint and possibly broken bolts. If the bolts break, a flying object hazard may result. 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 CAT.COM/SAFETY website and click on SUPPORT, then SAFETY SERVICES for more information. Please refer the dealer to their Service Letter dated 30Nov2018 when scheduling this service.

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

Caterpillar Inc.

Identification #(s)

Attached to 30Nov2018 Service Letter

Rework Procedure

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Remove and inspect the generator fan screen for any signs of resultant damage due to contact with broken bolts. Refer to Images1.1.1 and Image1.1.2.

Image1.1.1

Image1.1.2

Inspect the generator fan for resultant damage due to contact with broken bolts. Refer to Image1.2.1.

Image1.2.1

Inspect all coupling plate/flywheel joint bolts for proper fit.
Inspect the coupling plate for resultant damage. The coupling plate is considered damaged if the mounting hole diameter is greater than +0.2 mm of the original 18 mm hole diameter. Refer to Image1.3.1 and Image1.3.2.

Image1.3.1

Image1.3.2

Inspect the flywheel for broken bolts or damaged threads. Refer to Image1.4.1 and Image1.4.2.

Image1.4.1

Image1.4.2

If no resultant damage is found, replace the current 7X-0346 Bolts (qty 6) with 8T-9393 Bolts (qty 6). Also, replace the 8T-4122 Washers (qty 6)) used in the joint stack. REPLACE THE HARDWARE ONE SET AT A TIME TO MAINTAIN PROPER ALIGNMENT. Tighten fasteners to 215 +/- 40 NM.

After inspection and hardware replacement, run the unit and check for proper operation.

If resultant damage is found, have the Dealer Technical Communicator (TC) submit a report to CPI number 361118 through CPI Feedback within the Service Information Management System (SIMSi). Provide the inspection information and pictures in this report.