PRODUCT SUPPORT PROGRAM FOR INSTALLING THE CHARGING ALTERNATOR ON CERTAIN C15 GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING THE CHARGING ALTERNATOR ON CERTAIN C15 GENERATOR SETS

Usage:

REBE5116-00

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28Apr2009

A-139

D-135

O-144

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR INSTALLING THE CHARGING ALTERNATOR ON CERTAIN C15 GENERATOR SETS
1154 1405 1406		PS42919

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NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS42919" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "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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TERMINATION DATE

30Apr2011

PROBLEM

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Certain C15 Gensets were shipped without charging alternators.

AFFECTED PRODUCT

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Model	Identification Number
C15	C5L02111-02165, 2168-2170, 2173-2175, 2178, 2180, 2182-2183, 2186, 2188-2201, 2203, 2207, 2247-2249, 2260-2261, 2264, 2266

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 9% of dealership population. This is an initial 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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Install the charging alternator on the Affected Product.

Refer to the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-1000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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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.

Rework Procedure

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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.

Image1.1.1

Image1.1.2

2. Remove bolts (1). Remove fan guard (2).

Image1.2.1

3. Remove bolts (3). Remove fan guard (4).

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 in Image1.3.1. 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.

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).

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)

Image1.6.1

12. Install fan guard (4). Install bolts (3).

Image1.7.1

13. Install fan guard (2). Install bolts (1).

Image1.8.1

14. Position guard (2) and install bolts (1).

15. Clear generator area, reconnect batteries, and release emergency stop.

16. Run functional No Load test on Genset.