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

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

Usage:

TEBE2488-00

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26Jan2015

V461
V462

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After Failure Only (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXCITER ROTOR ON CERTAIN 3512 GENERATOR SETS
4457 4450 4454		PS52863

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NOTE:	Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.
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 "PS52863" 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.

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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

31Jan2016

PROBLEM

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The existing 2539802/">253-9802 Exciter Rotor may become loose on the rotor shaft on certain 3512 Generator Sets with SR5 1400 frame generators. If the existing exciter rotor becomes loose, and is not repaired, resultant damage to the generator and its components may occur. Rework of the exciter rotor and/or rotor assembly will be required to address exciter rotor loosening.

AFFECTED PRODUCT

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Model	Identification Number
3512	YAK00408, 410, 412-413, 460, 465-467, 469-480, 485, 502, 519-521, 571-575

PARTS NEEDED

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Qty	Part Number	Description
1	2539777	RING-O
1	2539778	WASHER-SHOW
1	2539789	BEARING-BALL
1	2539802	ROTOR - EXCITER
1	3173717	SLEEVE-BEARING
1	COMPOUND	COMPOUND (SEE REWORK PROCEDURE)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 4% 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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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 disassembly and assembly 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.

3. Send generator to a qualified generator repair (rewind) shop with the capability to repair the main rotor shaft and to balance the entire rotor assembly.

4. Refer to the attached Rework Procedure for instructions on rotor assembly repair.

5. Reinstall generator and verify proper operation. Refer to KENR5284 for SR5 disassembly and assembly instructions.

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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%
0-20000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 36.0-hour job
Repair of this particular failure mode requires the services of a qualified generator repair (rewind) shop with the capability to repair the main rotor shaft and to balance the entire rotor assembly. Include all outside expenses at cost. Retain a copy of all invoices for outside expenses in the product history folder for audit purposes.

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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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COMPOUND K1501600 PERFECT SEAL ORDERING INFORMATION

If not previously supplied, the appropriate Caterpillar dealership representative working this service program is to contact the following Leroy Somer Product representative to order Perfect Seal (anti-fretting compound). Refer to Leroy Somer part number K1501600. Note that one tube of Perfect Seal is a sufficient amount to rework approximately 20 rotors.

Debra Wood
Debra.wood@emerson.com
P (731) 967-3062
F (731) 967-3114

Refer to KENR5284 for SR5 disassembly and assembly of rotor assembly. The following steps will need to be taken in addition to what is specified in KENR5284.

1. During exciter rotor removal, record pressure required to remove exciter rotor.

2. Inspect components for possible damage during disassembly.

3. Record exciter rotor shaft dimension. The exciter rotor shaft cannot be used without repair if the diameter is less than 140.015 mm. If the shaft is found to be below this limit, repair of the shaft and keyway will be necessary. If a new keyway is required, cut 180 degrees from original keyway. See Image 1.3.1 and 1.3.2 for exciter rotor shaft dimensions.

4. Record bearing shaft dimension. The bearing shaft cannot be used without repair if the diameter is less than 100.003 mm. If the shaft is found to below this limit, repair of the shaft will be necessary. See Image 1.3.1 for bearing shaft dimensions.

5. Before installing new exciter rotor, record exciter rotor shaft dimension and new exciter rotor ID dimension.

6. Measure and record main stator, PM stator, main rotor, and exciter rotor insulation resistance values and compare to test limits.

7. Replace any defective components.

Image1.3.1

Image1.3.2

8. Reassemble rotor assembly components per KENR5284.

9. Note that the exciter rotor should be heated to 110 degrees C for 24 minutes to aid installation. Before heating exciter rotor, remove leads from diodes, remove four screws from glastic plate to diode support, and lift up. See Image 1.4.1.

10. Clean new bearing sleeve and bearing outside diameter (outer ring). Apply Perfect Seal to the surface of the outer ring of bearing. See Image 1.4.2 for Perfect Seal application method.

11. When preparing NDE bracket for installation, apply small amount of Perfect Seal in bottom of bracket and install load spring and O-ring. Perfect Seal is used to hold the spring and O-ring in place during installation.

12. Reconnect main rotor leads and diodes and balance main rotor assembly. Balance main rotor assembly to 5 grams or less.