Rework Procedure for Generator Sets with the 262-8196 Generator Arrangement {4450} Caterpillar

Engine

3512B (S/N: LY81-UP; YBB1-UP; YAM1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

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Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.

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Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.

Reference Section

Reference: Special Instruction, REHS1841, General Welding Procedures

Reference: Special Instruction, SEHS7259, Alignment of Single-Bearing Generators

Rework Procedure

Note: Do NOT remove the engine and generator from the rail.

1. Disconnect the main connectors from all electronic components: EMCP, ECM, RTD module, and so forth.
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   Illustration 1	g06337345

2. Block off generator electrical parts.

3. Remove the paint. Apply dye penetrant to find full extent of crack (optional).

4. Grind the original square/butt weld and replace with a bevel weld at lower right-hand corner where the crack initiates. Grind a minimum of 50% of the bar thickness.

5. Grind out length of crack with 45 degrees to 90 degrees V-groove.

   Note: The bottom opening of the V-groove should be 3 mm (0.12 inch) wide.

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   Illustration 2	g06337359
   (1) Adhesive tape (2) Ceramic backing bar

6. Attach ceramic backing bar (2) to the V-groove that was ground into the generator housing.

7. Use 70 ksi welding wire and begin the weld at the lowest point on vertical leg.

8. Weld the entire gap and grind flush with the original outer surface.

9. Control distortion, avoid excessive heat build-up, and allow sufficient time to cool off.
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   Illustration 3	g06337380

10. Weld a 6 mm (0.24 inch) V-groove weld on the sides and bottom of the plate and fillet weld on the top.

11. Repaint the area to prevent corrosion.

Plate Fabrication

Note: Use 3/8 inch A36 steel plate.

Note: All chamfers are 45 degrees.

Illustration 4	g06335120
Flat Pattern (D1) 9.40 mm (0.37 inch) (D2) 225.55 mm (8.88 inch) (D3) 132.59 mm (5.22 inch) (D4) 12.70 mm (0.50 inch) Radius (D5) 25.40 mm (1.00 inch) (D6) 25.40 mm (1.00 inch)

Illustration 5	g06335126
Formed View (D7) 1022.60 mm (40.26 inch) Diameter