PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING THE CHARGING ALTERNATOR ON CERTAIN C15 GENERATOR SETS.
Usage:
REBE2521-00
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| 12Dec2007 |
A-519
D-520
O-556
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| Priority | PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING THE CHARGING ALTERNATOR ON CERTAIN C15 GENERATOR SETS. |
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| 1406 1405 1154 | PI31411 |
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| NOTE: | This Program must be administered as soon as possible. When reporting the repair, use "PI31411" 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 "PI31411" 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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COMPLETION DATE |
TERMINATION DATE |
| 30Jun2008 | 31Dec2008 |
PROBLEM
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| The charging alternator needs to be installed on certain C15 Generator Sets. The ordering system change did not reflect on the price list. |
AFFECTED PRODUCT
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| Model | Identification Number |
| C15 | C5H00277, 294-295, 297, 304-308, 437-438, 450-453 C5L00246, 251-252, 255-260, 262-265, 271-276, 302-303, 306-308, 310, 313-314, 316-317, 319-320, 323-329, 348-350, 352, 480, 482-484, 486-487, 489-490, 493-496, 500-501, 503-504, 522, 530, 533, 538, 540-541, 552-553, 555, 557, 560, 578, 585, 587, 589-590, 592, 603-605, 613, 617-624, 628, 630-631, 634, 638, 644-645, 649-650, 652-657, 661, 664, 666-668, 670-680, 682-685, 687-688, 690-692, 694, 697-698, 700-702, 704-708, 710-714, 716-718, 720-740, 742-750, 755, 757, 759-760, 762-770, 773, 782-784, 787, 794-795, 800, 803, 807, 809-810, 812-813, 816, 819, 823-826, 828-829, 833-834, 836-837, 841, 843, 913, 919-920, 928, 931, 936, 938, 997, 1032, 1034, 1049, 1079, 1088, 1122, 1128 STG00102 |
PARTS NEEDED
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Qty |
Part Number | Description |
| 1 | 1W1456 | PULLEY-ALT |
| 2 | 4L6454 | BOLT |
| 1 | 4N8216 | V-BELT |
| 1 | 5N5692 | ALTERNATOR GP -B |
| 1 | 5P2566 | BOLT |
| 1 | 6L5874 | ROD-PULLEY ADJ |
| 1 | 6V8188 | NUT-FULL |
| 2 | 6V8801 | NUT |
| 1 | 7X0340 | BOLT |
| 2 | 7X3374 | NUT-FULL |
| 1 | 8S5383 | BLOCK |
| 6 | 8T4223 | WASHER-HARD |
| 1 | 8T4835 | BOLT |
| 2 | 8T4896 | WASHER-HARD |
| 2 | 1061792 | STUD-TAPERLOCK |
| 1 | 2326561 | BLOCK |
| 1 | 2326579 | BRACKET |
| 1 | 3104512 | GUARD |
| In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% of dealership population. This is an inital 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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| 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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| NOTE: This is a 4.0-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 THE CHARGING ALTERNATOR ON CERTAIN C15 GENERATOR SETS. MODELS INVOLVED - C15 GENERATOR SETS. Dear Caterpillar Product Owner: The charging alternator needs to be installed 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 12Dec2007 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 12Dec2007 Service Letter |
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| References: RENR8643 Disassembly and Assembly SENR9928 Testing and adjusting REHS0354 Charging System Troubleshooting 1.Isolate Genset before commencing any work on the unit, activate Emergency stop, open Genset breaker and disconnect battery cables. Ensure health and safety requirements are adhered to at all times. |
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| Image1.1.1 |
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| Image1.1.2 |
| 2.Remove bolts (1). Remove fan guard (2). |
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| Image1.2.1 |
| 3.Remove bolts (3). Remove fan guard (4). |
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| Image1.3.1 |
| 4.Loosen 4 retaining bolts on the fan pulley head. Slacken the fan belts by adjusting the tensioning bolt on the top of the pulley head shown above. Once sufficiently slack, remove all the belts. Fit the V-belt for the charging alternator loosely to the inner most, largest pulley, on the bottom arrangement. |
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| Image1.4.1 |
| 5.Install the alternator pulley and nut (10). Tighten nut (10) to a torque of 102 +/- 7 N.m (75 +/- 5 lb ft). 6.Position bracket (8) in position on the studs. Apply Tooling (A) to the threads of the studs. Install nuts (7) and tighten nuts (7) to a torque of 70 +/- 5 N.m (52 +/- 4 lb ft). 7.Put alternator (3) in position on bracket (8) and install bolt (9). 8.Put adjustment rod (13) in position on alternator (3). Install bolt (11) and tighten bolt (11) to a torque of 88.4 +/- 6.8 N.m (65 +/- 5 lb ft). 9.Install the V-belt. Tighten the V-belt. Refer to Testing and Adjusting, "Belt Tension Chart". 10.Tighten nuts (12) to a torque of 30 +/- 15 N.m (22 +/- 11 lb ft). |
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| Image1.5.1 |
| 11.Connect harness assembly (6) on alternator (3) . Tighten nut (5) to a torque of 6.2 +/- 0.6 N.m (55 +/- 5 lb in). Tighten bolt (4) to a torque of 2.25 +/- 0.25 N.m (20 +/- 2 lb in). (see image 1.5.1) |
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| Image1.6.1 |
| 10.Install fan guard (4). Install bolts (3). |
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| Image1.7.1 |
| 11.Install fan guard (2). Install bolts (1). |
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| Image1.8.1 |
| 12.Position guard (2) and install bolts (1). 13.Clear generator area, reconnect batteries, and release emergency stop. 14.Run functional No load test on Genset. |
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