PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS Caterpillar


PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS

Usage:

Information for equipment:


GENERATORS
GENERATOR GP

Identification SR4 GENERATOR MOUNTED CONTROL PANEL
Abbreviations & Symbols SR4 GENERATOR MOUNTED CONTROL PANEL
How To Read Control Panel DC Schematics SR4 GENERATOR MOUNTED CONTROL PANEL
Components SR4 GENERATOR MOUNTED CONTROL PANEL
Introduction SR4 GENERATOR MOUNTED CONTROL PANEL
Automatic Start/Stop Control Panel SR4 GENERATOR MOUNTED CONTROL PANEL
Manual Start/Stop Control Panel SR4 GENERATOR MOUNTED CONTROL PANEL
Operation FLOOR-STANDING SWITCHGEAR
Automatic Start-Stop FLOOR-STANDING SWITCHGEAR
Alternating Current Components Troubleshooting FLOOR-STANDING SWITCHGEAR
Automatic Start-Stop Troubleshooting FLOOR-STANDING SWITCHGEAR

Make Sure that the Generator Set Is Stored Properly {1021, 1404, 7002} 2009/06/01
Generator Maintenance and Protective Relays Benefit the Service Life of Generator on Certain Cat<SUP>&reg;</SUP> Products {4450} 2012/09/11
A Slave Relay Should be Used for Customer Connections to EMCP 4 On Certain Generator Sets {1422, 4493} A Slave Relay Should be Used for Customer Connections to EMCP 4 On Certain Generator Sets {1422, 4493}

Rotating Rectifier - Check 3500 Generator Sets
Generator Set Vibration - Test/Record 3500 Generator Sets
Generator Bearing - Lubricate 3500 Generator Sets
Generator Bearing - Replace 3500 Generator Sets
Generator Bearing Temperature - Test/Record 3500 Generator Sets
Generator Set Alignment - Check 3500 Generator Sets
Generator Bearing - Inspect 3500 Generator Sets
Generator Operation 3500 Generator Sets
Varistor - Inspect 3500 Generator Sets
Varistor - Check 3500 Generator Sets
Stator Winding Temperature - Test 3500 Generator Sets
Rotating Rectifier - Check 3500 Generator Sets
Generator Winding - Test 3500 Generator Sets
Generator Winding Insulation - Test 3500 Generator Sets
Rotating Rectifier - Inspect/Test 3500 Generator Sets

Grounding Design Guide for Electric Power Generation Products {4450, 4459} Grounding Design Guide for Electric Power Generation Products {4450, 4459}
Winding Insulation Maintenance and Cleaning and Drying of the Generators {4450} Winding Insulation Maintenance and Cleaning and Drying of the Generators {4450}
Generator Bearing Service {4457} Generator Bearing Service {4457}

PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS

PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS

PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS

PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS

PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS

Electrical Wiring Connection Modification for 1400 Frame Generator Space Heater{1408, 4450, 7274} Electrical Wiring Connection Modification for 1400 Frame Generator Space Heater{1408, 4450, 7274}
Exciter Rotor Is Loosening on Certain 3512, and C32 Generator Sets{4454} Exciter Rotor Is Loosening on Certain 3512, and C32 Generator Sets{4454}

PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS

PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS

Systems Operation ELECTRONIC MODULAR CONTROL PANEL (EMCP)
Systems Operation SR4 GENERATOR
Systems Operation SR4 GENERATOR
General Information SR5 Electric Power Generation
Component Descriptions SR5 Electric Power Generation
Generator Operation SR5 Electric Power Generation
Glossary SR5 Electric Power Generation

REMAN GENERATOR PRODUCT LINE EXPANDED REMAN GENERATOR PRODUCT LINE EXPANDED

PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS

Testing And Adjusting ELECTRONIC MODULAR CONTROL PANEL (EMCP)
Testing And Adjusting SR4 GENERATOR
General Information SR5 Electric Power Generation
Troubleshooting SR5 Electric Power Generation
Generator Set - Test SR5 Electric Power Generation
Varistor - Test SR5 Electric Power Generation
Rotating Rectifier - Test SR5 Electric Power Generation
Winding - Test SR5 Electric Power Generation
Insulation - Test SR5 Electric Power Generation
Resistor - Test SR5 Electric Power Generation
Generator - Dry SR5 Electric Power Generation
Exciter Field - Flash SR5 Electric Power Generation
Rotating Rectifier - Test - Discrete Diode Test SR5 Electric Power Generation
Rotating Rectifier - Inspect/Test SR5 Electric Power Generation
Space Heater - Test SR5 Electric Power Generation

Control Panel SR4 GENERATOR
Generator Bearing<BR> (Outside Bearing Type RFA) SR4 GENERATOR
Generator Bearing (Inside Bearing Type RFA) SR4 GENERATOR
Generator Removal SR4 GENERATOR
Alignment Of Single-Bearing Generators<BR> (Typical) SR4 GENERATOR
Rotor Assembly SR4 GENERATOR
Stator Assembly SR4 GENERATOR
Rotor - Remove and Install SR5 Electric Power Generation
Generator - Remove SR5 Electric Power Generation
Generator - Install SR5 Electric Power Generation
Generator - Align SR5 Electric Power Generation
Coupling - Remove SR5 Electric Power Generation
Coupling - Install SR5 Electric Power Generation
Bearing - Remove and Install SR5 Electric Power Generation
Generator Fan - Remove and Install SR5 Electric Power Generation
Bus Bar - Remove and Install SR5 Electric Power Generation
Diode Assembly - Remove and Install SR5 Electric Power Generation
Terminal Box - Remove and Install SR5 Electric Power Generation
Exciter - Remove and Install SR5 Electric Power Generation
End Bracket - Remove SR5 Electric Power Generation
End Bracket - Install SR5 Electric Power Generation
Front Bracket - Remove and Install SR5 Electric Power Generation


REBE9042-04

05Nov2012
(Revised 08Apr2014)


O-541

 

After Failure Only

  
  

PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512, AND 3512B GENERATOR SETS

4457
PS52328
NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS52328" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

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.

 
NOTE:

This Revised Service Letter replaces the 05Nov2012 (Revised 20Mar2013) Service Letter. Changes have been made to the Affected Product, and Action Required.


TERMINATION DATE

30Nov2014

PROBLEM

The existing 253-9802 Exciter Rotor may become loose on the rotor shaft on certain 3512, and 3512B Generator Sets with SR5 1400 frame generators. If the existing exciter rotor becomes loose, resultant damage to the generator and its components may occur. Rework of the exciter rotor and/or rotor assembly will be required if the exciter rotor becomes loose.

AFFECTED PRODUCT

Model Identification Number
3512  YAK00181, 183, 222-224, 261-263, 265-266, 280-281, 284, 286, 299-300, 315-316, 331-332, 346-347, 373, 377-378, 390-391, 393-394, 414, 418, 440, 464, 505-507, 510, 522, 530, 552
3512B  YAM00193-00196, 208-215, 231-232, 244-247, 260, 274-275, 277-279, 283-284, 322-324, 334, 336-337, 348, 427-430, 447-449, 454-456, 500-501, 506, 509, 520-521, 577, 592-594, 615

PARTS NEEDED

No parts needed for this program

ACTION REQUIRED

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. If there is evidence that the exciter rotor is loose, remove generator. Refer to Disassembly and Assembly, KENR5284 for SR5 instructions. The symptoms of a loose exciter rotor may include the following conditions: damaged main rotor lead cables and/or lugs, excessive vibration, abnormal noise. Please include service history with the claim.

3. Send generator to the Leroy Somer Service Center in Dubai, UAE for repair. See below for contact information.

Intersel Dowding & Mills
General Manager
Jebel Ali Free zone
P.O. Box 10892
Dubai
UAE
TEL +971 (0)4 8833661
FAX +971 (0)4 8833662

4. Reinstall generator and verify proper operation. Refer to Disassembly and Assembly, KENR5284 for SR5 instructions.

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
0-20000 hrs,
0-60 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 36.0-hour job



PARTS DISPOSITION

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

Caterpillar Information System:

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