PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE SUPPORT LACING ON THE MAIN ROTORS ON CERTAIN 3516B, 3516C, 3516C HD, AND C175-16 GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE SUPPORT LACING ON THE MAIN ROTORS ON CERTAIN 3516B, 3516C, 3516C HD, AND C175-16 GENERATOR SETS

Usage:

REBE8150-01

Show/hide table

28Mar2012

(Revised 23Jul2012)

U-167

A-140

D-151

O-161

Show/hide table

*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE SUPPORT LACING ON THE MAIN ROTORS ON CERTAIN 3516B, 3516C, 3516C HD, AND C175-16 GENERATOR SETS
4457 1408		PI32010

Show/hide table

NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32010" 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 "PI32010" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

Show/hide table

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.

Show/hide table


NOTE:	This Revised Service Letter replaces the 28Mar2012 Service Letter. Changes have been made to Action Required, Service Claims Allowances, and added a Rework Procedure.

Show/hide table

COMPLETION DATE	TERMINATION DATE
30Sep2012	31Mar2013

PROBLEM

Show/hide table

The main rotor on certain 3516B, 3516C, 3516C HD, and C175-16 Generator Sets that are equipped with SR5, 3000 frame generators need to be inspected for the presence of proper support lacing. If proper lacing is not present, the main rotor winding leads could loosen and make contact with the main stator which may cause a failure of the generator.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
3516B	PBR00667-00668
3516C	SBK00900-00901, 903, 945, 947, 949, 951, 953, 995, 997-1006, 1012-1015, 1027, 1030, 1032-1039, 1043, 1125-1126
3516C HD	SCK00115
C175-16	WYB00136, 138, 142-143, 145-150, 159, 170-172, 175-177, 186, 189-191, 193-196, 201-202, 204-210, 212-215, 217, 221, 231-251, 253-254, 256, 258, 260-261, 263, 267, 271, 274, 284, 286, 288-292, 294, 296, 299-300, 306, 308, 312-320, 324-325, 327-329, 334, 336, 338, 340, 344, 346-349, 355-357, 359-362, 364-365, 371, 375-377, 379, 401, 416-419, 428, 440, 490-491 WYC00123

PARTS NEEDED

Show/hide table

No parts needed for this program

ACTION REQUIRED

Show/hide table

1. Isolate the Generator Set before commencing any work on the unit, activate Emergency stop, open Generator Set breaker, and disconnect battery cables. Wait five minutes to insure any capacitive components in the system have de-energized before performing next steps. Ensure health and safety requirements are adhered to at all times.

2. Remove the exciter cover on generator. A metric Allen wrench set will be required for this task. Refer to Image1.

3. After the cover is removed, you should be able to view all the poles and poles leads through the bearing bracket openings.

4. Use a flashlight to inspect the rotor leads on each pole to ensure the lacing strap is present in all the poles.

5. The lacing strap with the concern is the one that secures the pole lead that cross from the top to the bottom of the coil on each individual pole. Use the following examples as a guideline for the inspection. Refer to Image2, Image3, Image4, and Image5.

Note: The main rotor lead connections with lacing is located only on non-drive end of main rotor poles.

6. Take pictures of the individual poles showing the way the rotor pole leads are secured and keep those in the Generator Set history file.

7. If the lacing strap is found present on all the poles, no further action is required. If there are any questions about the lacing strap or it is confirmed the lacing strap is missing in one or more poles the rotor will need to be reworked in the field, please have your dealer Technical Communicator submit a Global Dealer Solution Network (GDSN) Service Technical request for further instructions.
The request must include the generator set service hours, pictures of the rotor lacing, and a detailed summary that describes the rotor lacing. If review of information confirms need for repair, the repair instructions will be provided by GDSN.

Refer to the attached Rework Procedure.

Show/hide table

Image1

Image2

Image3

Image4

Image5

OWNER NOTIFICATION

Show/hide table

U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

Show/hide table

Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

Show/hide table

NOTE: This is a 1.0-hour job
If, after review of GDSN Service Technical support request inspection information, a repair is confirmed to be required, an additional repair allowance applys. One additional travel to unit and up to an additional $5000 expense for labor and materials will be allowed to make repairs as instructed by GDSN.

Show/hide table

PARTS DISPOSITION

Show/hide table

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Show/hide table

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR CONFIRMATION OF PROPER SUPPORT LACING ON MAIN ROTORS FOR CERTAIN SR5, 3000 FRAME GENERATORS

MODELS INVOLVED - 3516B, 3516C, 3516C HD, C175-16

Dear Caterpillar Product Owner:

The generator rotor needs to be inspected on the products listed below. The existing generator rotor can suffer failure if proper factory assembly did not occur. 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 28Mar2012 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 28Mar2012 Service Letter

Rework Procedure

Show/hide table

Upon receiving a GDSN Service Technical request as outlined in the inspection part of this service letter, the Tier 2 support representative will review the information to confirm need of repair, and if repair is determined to be necessary, a repair instruction will be forwarded through the GDSN.

After the repair has been completed, the following information is applicable before starting the engine.

NOTICE
For initial start-up of a new or rebuilt engine, and for start-up of an engine that has been serviced, make provision to shut the engine off should an overspeed occur. This may be accomplished by shutting off the air and/or fuel supply to the engine.

Engine exhaust contains products of combustion which may be harmful to your health. Always start and operate the engine in a well ventilated area and, if in an enclosed area, vent the exhaust to the outside.

Inspect the engine for potential hazards.

- Do not start the engine or move any of the controls if there is a "DO NOT OPERATE" warning tag or similar warning tag attached to the start switch or to the controls.

- Before starting the engine, ensure that no one is on, underneath, or close to the engine. Ensure that the area is free of personnel.

- If equipped, ensure that the lighting system for the engine is suitable for the conditions. Ensure that all lights work properly, if equipped.

- All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures. To help prevent an accident that is caused by parts in rotation, work around the parts carefully.

- Do not bypass the automatic shutoff circuits. Do not disable the automatic shutoff circuits. The circuits are provided in order to help prevent personal injury. The circuits are also provided in order to help prevent engine damage.

- See the Service Manual for repairs and for adjustments.