PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE GENERATOR ON CERTAIN 3456 AND C15 60HZ GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE GENERATOR ON CERTAIN 3456 AND C15 60HZ GENERATOR SETS

Usage:

REBE3013-03

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21Nov2007

(Revised 14Mar2008)

U-609

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE GENERATOR ON CERTAIN 3456 AND C15 60HZ GENERATOR SETS
4450 1404		PI10643

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10643" 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 "PI10643" 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:	This Revised Service Letter replaces the 21Nov2007 (Revised 09Jan2008) Service Letter. Changes have been made to the Affected Product that result in the addition of C15 in multiple areas of the Service Letter.

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PROBLEM

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The generator fan will need to be replaced on certain 3456 and C15 60Hz Generator Sets. The suspect generator fans have exhibited issues that may cause the fan blades to separate which could result in personal injury or death. The generator fan 242-3919 can not be replaced in the field, the generator will have to be replaced.

AFFECTED PRODUCT

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Model	Identification Number
3456	C4G00563-00565, 567-572, 575-583, 587-594, 596-604, 606-609, 612-615, 618-705, 707-722, 724-728, 731-741, 778-786, 788-790, 792-803, 805-835, 837-882, 884-923, 926-933, 937-944, 948-949, 952-1064, 1066-1068
C15	C5E00979, 982-984, 986-987, 990-991, 993-994, 1001-1002, 1006-1007, 1013-1014, 1019-1022, 1028-1031, 1046-1047, 1051-1052, 1055, 1062-1064, 1066-1068, 1074-1078, 1081-1085, 1088-1091, 1094-1097, 1099-1100, 1102, 1104-1105, 1109-1111, 1118, 1128-1129, 1131-1133, 1136-1138, 1148-1155, 1157-1159, 1165-1168, 1194-1197, 1200-1205, 1207-1216, 1223-1226, 1229-1231, 1235-1237, 1245-1247, 1251, 1255-1262, 1265-1267, 1271, 1273-1280

PARTS NEEDED

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No parts needed for this program

ACTION REQUIRED

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Refer to the attached Rework Procedure.

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE GENERATOR ON CERTAIN 3456 AND C15 60HZ GENERATOR SETS

MODELS INVOLVED - 3456 and C15 60HZ Generator Sets

Dear Caterpillar Product Owner:

A new generator will need to be installed because suspect generator fans have exhibited issues that may cause the fan blades to separate which could result in personal injury or death on the products listed below. 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 21Nov2007 when scheduling this service.

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

Caterpillar Inc.

Identification #(s)

Attached to 21Nov2007 Service Letter

Rework Procedure

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Replacing LC6 generator on affected Gensets.

1 NACD dealers use the NERO process to get a new generator for this rework procedure. Order new generator arrangement number 323-6297 for 3456 and 322-8927 for C15. The Electric Power North America (EPNA) Product Support Reps. will initiate the PRR (part return request) and RMA (return material authorization).
1.1 Please e-mail package serial No., old generator serial No. and new generator serial No. to EP_CUSTOMER_SERVICE@CAT.COM after you have received the generator so TMI, SIMSi can be updated and new label can be issue from the factory.

2. Reference
RENR8643 ? Disassembly and assembly generator set
SEBU7829 ? Operation and maintenance manual 3456 generators.
SAE J620 ? Flywheel standard

3. Isolate genset before commencing any work on the unit, open genset breaker, put the 4 position start switch ESC into the off position on EMCP2 or push the stop button on the EMCP3, activate emergency stop, isolate the AC auxiliary voltage for battery chargers, coolant heaters, generator space heaters and disconnect battery cable. Ensure health and safety requirements are adhered to at all times.

4. Cut the cable ties on the ladder clips on the left side of the generator terminal box and remove the ten bolts on the terminal box panel. Use an M10 socket.

Image1.1.1

5. With a Philips head screwdriver remove six screws on the base of the turret, two connected to the gland plate.

Image1.2.1

6. Cut the cable ties on the ladder clips on the right side of the generator terminal box and remove the ten bolts on the terminal box panel. Use an M10 socket Image1.3.1.

7. Disconnect the braids or cables from the generator terminals.
600A and below - Use M10 sockets to remove 16 bolts to disconnect the cables.
800A - Use M6 sockets to remove 16 bolts to disconnect the braids.
1250A and greater ? Use M10 sockets to remove 16 bolts to disconnect the braids.
Image1.3.2.

8. Disconnect the earth cables in the generator terminal box, use an M17 socket Image1.3.3.

Image1.3.1

Image1.3.2

Image1.3.3

9. If a Droop CT is fitted, cut the cable ties around the braids or cables and let the CT sit on the generator terminal Image 1.4.1. and Image 1.4.2.

10. If an earth fault core balance CT is fitted remove the CT also Image 1.4.3.

Image1.4.1

Image1.4.2

Image1.4.3

11. Remove the top of the terminal box - six bolts use an M6 socket Image 1.5.1.

12. Move the braids and cables on top of the Power center Image 1.5.2.

13. If the unit has an SA enclosure, remove the top rear air inlet duct. Remove four M18 bolts, so the braids and cables can be set on top of the control panel Image1.5.3 and Image1.5.4

Image1.5.1

Image1.5.2

Image1.5.3

Image1.5.4

14. Remove the front and rear of the generator terminal box. Three M17 bolts in front and two M17 bolt in rear. Keep the rear panel with the 17 PIN No Image1.6.1.

15. Remove lifting eye covers on the generator, M17 bolt head and M16 nut then the generator fan guard using 10mm socket.

16. Place a 4?x4? block of wood under the generator barrel and a 4?x4? block of wood under the engine flywheel housing. Cut two wood blocks 6 ?? and 4 x ?? shims to position the engine block Image1.6.2. and Image1.6.3.

17. Remove terminal box on NEW generator following steps 4, 6 & 11.Image1.6.4

Image1.6.1

Image1.6.2

Image1.6.3

Image1.6.4

18. If a CDVR option is fitted on the old generator remove this and re-install on the new generator. Removing the R448 standard regulator from the new generator. 10mm and 13mm sockets required. Reference 254-1260.

19. If a 3 Phase sensing unit option is fitted on the old generator remove this and re-install on the new generator. Reference 244-5866.

20. If an RFI Kit option is fitted on the old generator, remove and re-install on the new generator. Connection D is series wye & connection A is parallel wye Image1.7.1.

21. If a spare heater is fitted on the old generator (standard on premium generator), remove and re-install on the new generator (not required for premium generator.

Image1.7.1

22. If a PMG option is fitted on the old generator (standard on premium generator) remove and re-install on the new generator (Not required for premium generator)
The components are:
- A shaft adapter (to position the rotor on the alternator shaft).
- An M16 tie rod and nut for assembling the rotor on the shaft.
- A rotor with 16 magnets.
- An assembly of frame wound stator+plastic connection sheath+plastic ferrules.
- The housing end plate (4 CBLXS M5 screws).
- 4 HM6 screws (for fixing the housing to the NDE shield).
If mounting in kit form, follow the instructions below.
22.1 - Remove the PMG cover [297] and the alternator NDE shield seal (71).
22.2 - Mount the PMG housing assembly [290] on the shield using the 4 HM6 screws.
22.3 - Apply anti-vibration adhesive to the tie rod [295] and tighten it in the alternator shaft extension tapped hole to a torque of 30 Nm.
22.4 - Mount the magnetized rotor on the shaft adapter, then using 2 M10 threaded rods screwed into the rotor, slide the assembly onto the tie rod.
22.5 - Once the rotor is in position, remove the 2 M10 rods.
22.6 - Install the cable gland washer [296].
22.7 - Lock the assembly with the M16 nut (torque of 116 Nm).
22.8 - Close the PMG with the cover [297].
22.9 - Remove the plastic plug on the NDE panel and fit the plastic sheath and its ferrule.
22.10 - Connect the PMG to the AVR see section 16 for CDVR or section 17 for R448
Image1.8.1.

23. If the old generator is connected parallel wye reconnect the new generator from series wye to parallel wye.
Connection D is Series wye & connection A is parallel wye. Image1.8.2.

24. If an enclosure is fitted remove the last two panels on the roof. A 17mm socket is needed to remove 24 bolts and wipe silicon off the panel edges. Image1.8.3. and Image1.8.4.

25. Remove M20 bolts between generator foot and cross beam Image 1.8.5.

26. A 10,000 ? 12,000lb, lifting crane is required for the generator. The generator sized lifting rings are for handling the generator alone. They must not be used to lift the genset. Choose a hoisting system, which respects the positioning of the rings. Install lifting harness Image1.8.6.

27. Start decoupling the generator from the engine 1/2? and 7/16? sockets required Image1.8.7.

Image1.8.1

Image1.8.2

Image1.8.3

Image1.8.4

Image1.8.5

Image1.8.6

Image1.8.7

28. Move generator away from the engine and place a strap around the generator to secure the rotor in position during lifting Image1.9.1.

29. Lift the old generator away from the package. During lifting, the generator should be horizontal, and then remove lifting harness.

30. Remove bracket to hold in the rotor from the new generator Image1.9.2.

31. Check that the engine and generator are compatible by checking the dimensions of the flywheel and its housing, the flange, coupling discs and offset. Check that the number of shims is 6. Image1.9.3. Reference SAE J620.

32. Check endplay on the engine reference RENR8643 record valve.

33. Place location Pin at 12 o?clock in the engine flywheel Image1.9.4.

Image1.9.1

Image1.9.2

Image1.9.3

Image1.9.4

34. Place strap around the new generator to secure the rotor in position during lifting. Follow steps 24 and 27 again. Move the new generator into position.

35. Move generator assembly into position using locating pins as a guide. Align with flywheel; insert 12 X 7/16"-14 bolts and 12 X 7/16" plain washers around the generator housing and torque to 70Nm then, insert 8 X 1/2"-13 bolts and 8 X 1/2" plain washers into the flywheel and torque to 105Nm.

36. Insert 2 X M20 bolts, 2 X M20 plain washers through the generator feet, remove wooden support from underneath the engine and lower the coupled engine and generator into position on the Vib Mounts fitted to the generator cross beam.

37. To complete the assembly use 2 X M20 plain washers and 2 X M20 plain nuts and torque all 4 mounts to 460 Nm.

38. Check endplay on the package reference RENR8643 record value.

39. Re-fit generator fan guard using 2 fasteners supplied.

40. Fit 2 X lifting eye covers to generator lifting points use sockets for a M17 bolt head and M16 nuts.

41. Reconnect the front and rear generator terminal panels using the old generator rear panel with the 17 PIN. See step 12.

42. Reinstall the lid on top of the generator see section 11.

43. Check braids or cables for any damage replace if damaged.

44. Reconnect any options CT?s see 9 and 10

45. Reconnect power braids or cables see section 7.

46. Reconnect the earth cables, see section 8

47. If standard R448 is fitted check the regulator is setup for the correct voltage and frequency. Reference 239-57454.

45. Re-install the generator terminal panels and cable tie the harness to the ladder clips section 4 & 6.

48. Re-install the turret see section 5

49. If the unit has SA enclosure re-install the top rear air inlet duct see section 13.

50. If the unit has an enclosure re-install the top two panels ? position all bolts before tightening the panels down. Seal between the panels using silicon Image1.10.1. and Image1.10.2.

Image1.10.1

Image1.10.2

51. Re-install generator terminal box on the old generator and get it ready to return to the following and please include RMA and PRR documentation.

Address
Attention Jeff Barker
Leroy Somer
669 Natchez Trace drive
Lexington TN. 38351

52. Clear area of all materials and reconnect batteries +ve lead first then ?ve lead.

53. Reconnect the AC auxiliary voltage for battery chargers, coolant heaters, generator space heaters. Check voltage on battery charger and check the heaters at operating.

54. When coolant temperature is at 70 deg C, Reset the E-Stop button.
Genset with an EMCP2 controller cycle the four-position switch to reset the Engine ECM. Genset with an EMCP3 reset faults by holding down the acknowledgement button.

55. Connect CAT ET to unit. Start unit with 0 load, run for 10 minutes checking voltage, frequency and phase rotation of the unit. Check engine is running OK. Stop genset to check the generator fan slows down naturally. Record data log information on ET please add to warranty report.

56. If the genset check out OK at no load, put the controller into auto, request the customer to remote start the genset, run the genset with site load for 10 minutes. Checking voltage, frequency, current and phase rotation of the unit. Record data log information on ET please add to warranty report. Remote stop the genset check again that the generator fan slows down naturally

57. When this is complete add the new genset label to the barrel of the generator Image 1.11.1.