Product Support Program For Replacing The Spherical Roller Bearings On 3516 Generator Sets Caterpillar

NOTE: This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS5486" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

NOTE: This Revised Service Letter replaces the August 22, 1998 (Revised September 1998) Service Letter. Changes have been made to the TERMINATION DATE.

Termination Date

Problem

Spherical roller bearings (pn 2L-4444) used in 3516, single bearing SR4 and SR4B Generators may provide shorter service life than expected. Since bearings have a finite service life, as a good practice, the generator bearing should be replaced at engine overhaul.

Affected Product
Model & Identification Number

Group 1

3516 Gen Sets (25Z1953-5823), (Generator Serial Number Prefixes; 6SA, 6AA, 2ED, 8FD), (4XF433-681), (Generator Serial Number Prefixes; 2ED, 8FD), (5SJ69-540), (Generator Serial Number Prefixes; 2RF, 8GF)

Group 2

3516 Gen Sets (25Z2161-6001), (Generator Serial Number Prefixes; 2HN, 4EN, 5WN, 5SN, 4FN, 8NN), (4XF580-732), (Generator Serial Number Prefixes; 4FN, 8NN), (5SJ313-614), (Generator Serial Number Prefixes; 4FN, 5WN, 8NN)

3516B Gen Sets (6HN112-208), (Generator Serial Number Prefixes; 4FN, 8NN), (7RN198-603), (Generator Serial Number Prefixes; 5WN, 5SN, 4FN4, 8NN)

G3516 Gen Sets (4EK537-1620), (Generator Serial Number Prefix; 4EN4)

NOTE: This Program applies to engines wihtin the serial

Parts Needed

Group 1

1 - 1543032 BEARING-BALL

1 - 1600802 BRACKET GP-M

Includes:

6 - 1A8063 BOLT

6 - 5H1504 WASHER-HARD

4 - 5M2894 WASHER-HARD

4 - 5M2894 WASHER-HARD

4 - 5M2894 WASHER-HARD

2 - 1525338 RETAINER-BAR

2 - 1525338 RETAINER-BAR

Group 2

1 - 1543032 BEARING-BALL

1 - 1525179 BRACKET GP-M

Includes:

4 - 5M2894 WASHER-HARD

2 - 5P8245 WASHER-HARD

4 - 0S1571 CAP SCREW

2 - 9S1366 BOLT

1 - 1274374 SEAL

1 - 1303654 BAR-SUPPORT

1 - 1525181 BRACKET AS-H

2 - 1525338 RETAINER-BAR

Action Required

See attached Rework Procedure.

Service Claim Allowances

NOTE: This is a 10-hour job.

Parts Disposition

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

Attach.

(1-Rework Procedure)

Rework Procedure

Group 1

Remove existing 2L-4444 spherical roller bearing, bearing bracket with sleeve, outboard seal, and bearing cap with inboard seal. Replace with 154-3032 Ball Bearing and 159-9377 Bearing Bracket with sleeve. Outboard seal should be replaced with new design double lip seal 127-4374. Bearing cap and inboard seal are not required on machines with new ball bearing. Two retainer bars 152-5338 must be added in place of cap if machine will be transported.

Group 2

Remove existing 2L-4444 spherical roller bearing, bearing bracket with sleeve, outboard seal, and bearing cap with inboard seal. Replace with 154-3032 Ball Bearing and 152-5181 Bearing Bracket with sleeve. Outboard seal should be replaced with new design double lip seal 127-4374. Bearing cap and inboard seal is not required on machines with new ball bearing. Two retainer bars 152-5338 must be added in place of cap if machine will be transported.

INSTRUCTIONS FOR BOTH GROUPS

REMOVAL OF FAILED 2L-4444 BEARING:

1) Use a 1U6415 or similar puller to remove the bearing.

2) In the event that a bearing puller is unable to remove the bearing, check to see if the rolling elements will come out of the bearing.

3) If the elements have been removed, the outer race of the bearing can be lifted off the shaft. If the elements can not be removed, the outer race must be cut free using a cutting wheel.

4) Cut the inner race to within 5mm of the generator shaft with a cutting wheel. Take care to avoid damaging the shaft.

5) Remove the bearing with a puller. It should break apart or otherwise come free.

6) If the bearing remains in place, strike into the cuts with a coal chisel to loosen the fit.

7) Repeat steps 5 and 6 until the bearing has been removed.

Caution!:Do not cut the bearing with a torch. There is too great a risk of damaging the shaft.

INSTALLING A NEW BALL BEARING

1) After cleaning the shaft for use, evenly heat the bearing to 225F (107C) with an induction heater or in an oven. Some grease may purge during heating. This is normal. Do not attempt to refill the bearing with grease. Bearings are pregreased at the factory using 2S3230. No additional greasing of the bearing is needed at installation. The bearing is double shielded. The shields must not be removed at any time as the integrity of the bearing will be damaged.

2) Slide the bearing onto the rotor shaft until it is stopped by the shoulder of the rotor.

3) Apply a generous coating of 2S-3230 grease to the inner diameter of the wear sleeve while it is bolted into the bearing bracket.

4) Re-attach the bearing bracket to the unit.

5) Complete reassembly as normal.

NOTE: When installing the 154-3032 ball bearing, a induction heater or a heater that heats the bearing across the whole mass equally is the only acceptable means of heating the bearing. Heat bearing to temperature no greater than 107° C (225° F) A TORCH MUST NOT BE USED TO HEAT THE BEARING. It is imperative that the correct heating process is used.