PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING A 296-8050 HIGH INERTIA COUPLING GROUP ON CERTAIN G3520C GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING A 296-8050 HIGH INERTIA COUPLING GROUP ON CERTAIN G3520C GENERATOR SETS

Usage:

REBE1406-01

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29Nov2006

(Revised 10Jul2007)

D-706

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING A 296-8050 HIGH INERTIA COUPLING GROUP ON CERTAIN G3520C GENERATOR SETS
4456 3252 4450		PI31193

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31193" 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 "PI31193" 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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NOTE:	This Revised Service Letter replaces the November 29, 2006 Service Letter. Changes have been made to the Parts Required.

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COMPLETION DATE	TERMINATION DATE
31May2007	30Nov2007

PROBLEM

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The coupling needs to be replaced on certain G3520C generator sets. The existing coupling can experience excessive torsional vibration levels.

AFFECTED PRODUCT

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Model	Identification Number
G3520C	GZN00240, 247-248, 272-278, 280, 283, 285, 288, 292-293, 296, 298, 301, 304, 307-310, 312, 315, 317, 321-322, 324, 326, 329-330, 338, 340, 342, 344, 346, 348, 350, 353, 355, 357, 360, 362, 364-365, 367, 369-378, 381, 383, 409-411, 413-415

PARTS NEEDED

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Qty	Part Number	Description
8	4M6953	WASHER-HARD
12	8D7942	BOLT-12 POINT HD
8	9X2119	BOLT-12 POINT HD

ACTION REQUIRED

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Replace the old coupling with a 296-8050 High Inertia Coupling. See attached Rework Procedure.

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Image1

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 5.0-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

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING HIGH INERTIA COUPLING GROUP

MODELS INVOLVED - CERTAIN G3520C GENERATOR SETS

Dear Caterpillar Product Owner:

A new Coupling Group needs to be installed on the products listed below. The existing coupling can experience excessive torsional vibration levels. 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 29Nov2006 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 29Nov2006 Service Letter

Rework Procedure

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Instructions for replacing the Caterpillar coupling with a new high inertia coupling.

0. 249-0059 rubber coupling element and 296-8049 outer coupling ring provided by the factory.

1. Refer to the appropriate Service Manuals for safety instructions and additional details. Reference SEBU7681, RENR5980, and REHS0177.

2. Remove the generator set from operation by locking out the circuit breaker(s) and by removing battery power from the controls and the starter motor(s).

3. Make sure that the power cables and control wires connected to the generator have sufficient slack to allow the generator to be moved back from the engine. In most cases it will not be necessary to disconnect anything.

4. Unbolt the rubber boot retaining ring.

5. Remove the rubber boots.

6. Unbolt the generator from the rails and the engine flywheel housing.

7. Slide the generator back approximately 40 cm from the engine to gain access to the coupling components. Take care not to damage or mix up the shims under the generator feet.

8. Unbolt and remove the outer coupling element from the flywheel. Discard.

9. Unbolt and remove the inner element from the generator hub. Discard.

10. Clean any grease or dirt from the flywheel.

11. Install the new rubber element, 249-0059, on the generator hub using the 9X2119 bolts & 4M6953 washers. Rotate the rubber element to line it up for insertion with the coupling ring. Tighten the bolts in a clockwise opposing pattern before using the same pattern to torque the bolts to 620 Nm (+/- 80 Nm).

12. Install the new coupling ring, 296-8049, on the flywheel. Use the new washers supplied with the coupling and the 8D7942 bolts. Tighten the bolts in a clockwise opposing pattern before using the same pattern to torque the bolts to 215 Nm (+/- 40 Nm)

13. Slide the generator forward inserting the rubber element into the coupling ring.

14. Insert the original stack of shims at each generator mounting foot.

15. Align the generator set. If the generator set was properly aligned before starting on the coupling replacement only minor adjustments, if any, will be needed.

16. Check engine crankshaft deflection.