PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE GENERATOR BEARING AND SLEEVE ASSEMBLY ON CERTAIN 3512B GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE GENERATOR BEARING AND SLEEVE ASSEMBLY ON CERTAIN 3512B GENERATOR SETS

Usage:

REBE8637-00

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08Aug2012

O-380

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE GENERATOR BEARING AND SLEEVE ASSEMBLY ON CERTAIN 3512B GENERATOR SETS
4457 4471		PI32076

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32076" 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 "PI32076" 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
28Feb2013	31Aug2013

PROBLEM

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The existing generator bearing and sleeve assembly, located in the rear bracket of the generator, may become loose causing the bearing to rotate within its sleeve. The root cause is the bearing rotating within its sleeve at a slow RPM. The movement of these two components causes the sleeve to wear on the inside diameter at the 'six o'clock' position. This wear results in misalignment of the main rotor shaft within the exciter stator, main stator and PMG stator, causing these components to make contact during genset operation. The end result is catastrophic failure. The reason for the rotation of the bearing within the inside diameter of the sleeve is most likely related to the poor application of a friction enhancing agent, branded 'Perfect Seal'. This substance is a preferred addition by the generator supplier, not a bearing supplier recommendation. The role of the 'Perfect Seal' is to improve the adherence between the outside diameter of the external bearing race and the inside diameter of the sleeve, while still allowing axial movement of the floating bearing assembly within the rear alternator housing.

AFFECTED PRODUCT

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Model	Identification Number
3512B	YAY00442-00444, 446, 448-454, 456-459, 462, 464-465, 489-495, 508-512

PARTS NEEDED

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Qty	Part Number	Description
1	2539777	RING-O
1	2539789	BEARING-BALL
1	3173717	SLEEVE-BEARING
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 17% 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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The Action Required consists of 3 phases.

The first phase is preparatory work required to remove the control panel, circuit breaker and associated assemblies surrounding the generator, this is to be conducted by the dealership.

The second phase will be conducted by the generator supplier's local representative and involves the replacement of the bearing and sleeve assembly.

The final phase, phase three is the reassembly of the circuit breaker, control panel and associated assemblies surrounding the generator. This work is to be carried out by the dealership.

Further detail of the action required is listed below.

1. Isolate the generator set before commencing any work on the unit, open generator set breaker, activate Emergency Stop, disconnect the battery cables and either disconnect or open the control circuit breaker for the AC power supply to the battery charger. Ensure all health and safety requirements are adhered to at all times. Also, ensure proper Lock Out-Tag Out procedures are followed at all times while work is being performed on the machine. Lock out generator operation and disconnect/lockout all power sources before commencing any work.

2. This repair can be completed within the genset container however to aid the rework process the EMCP control panel housing and main AC breaker must be removed to allow access to the rear of the generator.
Refer to KENR5284 for SR5 disassembly and assembly.
instructions.

3. The bearing and sleeve replacement will be carried out by the below representative. All work must be coordinated with the below contact

Latif Madampara
ARABIAN QUDRA CO.
EXIT 13, RABWA,
KHURAIS ROAD,
RIYADH, KSA.
TEL. 00966 1 4934557 X 227
FAX 00966 1 4934556
MOB. 00966 503105742

4. Reinstall the EMCP control panel housing and main AC breaker and verify proper operation. Refer to KENR5284 for SR5 disassembly and assembly instructions.

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