PRODUCT SUPPORT PROGRAM FOR REPLACING THE GENERATOR ON CERTAIN C2.2 (XQ20) GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE GENERATOR ON CERTAIN C2.2 (XQ20) GENERATOR SETS

Usage:

TEBE3153-02

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02Jun2015

(Revised 07Jun2016)

U-274

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Before/After	PRODUCT SUPPORT PROGRAM FOR REPLACING THE GENERATOR ON CERTAIN C2.2 (XQ20) GENERATOR SETS
4450		PS44759

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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 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 "PS44759" 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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NOTE:	This Revised Service Letter replaces the 02Jun2015 (Revised 04Jun2015) Service Letter. A change has been made to the Rework Procedure.

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TERMINATION DATE

30Jun2017

PROBLEM

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The existing generator may experience contact between the rotor and stator on certain C2.2 (XQ20) Generator Sets. If the existing generator fails it will affect the ability of the generator sets output.

AFFECTED PRODUCT

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Model	Identification Number
C2.2	GBE01836-01837, 1839, 1841, 1843, 1845, 1847-1849, 1901, 1910-1911, 1913, 1915, 1917-1918, 1921, 1928, 1930-1931, 1935, 1939, 1941

PARTS NEEDED

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Qty	Part Number	Description
1	CAULK	Clear Silicone
3	CONNECTOR	Butt Connector 22-18 GA
1	GENERATOR	Generator AR (see Rework Procedure)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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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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%
0-4000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 8.0-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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Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction, on the product, and in this product's Operation and Maintenance Manual (OMM). If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication, the warnings that are on the product, and the warnings that are in the OMM are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, the user must ensure that it is safe for the user and for other people to use.

The user should ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

WARNING: The generator set must be isolated electrically before and while the rework is performed. Follow the proper lockout tag out procedures to protect against the unexpected energizing or startup of the generator. Failure to follow these warnings could result in injury to personnel during service. Attach a "Do Not Operate" warning tag to the machine start switch or the controls before you perform any service to the machine.

Note: Send an email to David Roberson at the Roberson_David_A@cat.com with your current serial number and address for shipping the new generator. Tracking information will be provided once the replacement generator has been shipped.

DISASSEMBLY INSTRUCTIONS -

Note:
Retain and organize all hardware during disassembly. All existing hardware can be utilized during reassembly of generator set.

Review all steps listed in this rework procedure prior to beginning rework of generator set. This document outlines the disassembly, flywheel run out verification, and final assembly.

1) Remove quantity of 6 bolts from power distribution panel and lower panel. Remove wires from remote initiate terminals(A).

Image1.2.1

Image1.2.2

2) Remove seals (A) from left and right panels, remove quantity of 6 bolts from left and right panel. Remove both panels from enclosure and remove any silicon adhesive.

Image1.3.1

Image1.3.2

3) Remove connector (A) from bottom left of control panel box and disconnect two wires (B) for rupture basin switch by cutting splices at different lengths.

Image1.4.1

Image1.4.2

4) Remove terminal cover (A) from generator, then remove all leads from terminal strip (B) and ground from alternator barrel. These leads need to be

Image1.5.1

Image1.5.2

Image1.5.3

5) Remove bolts securing cover to voltage selector box.

Image1.6.1

6) Open instrument panel (A) and remove connections for field (B), jacket water heater and alternator space heater (C). Pull wires through rear of control box.

Image1.7.1

Image1.7.2

Image1.7.3

Image1.7.4

7) Unbolt control box and slide to right. Open access panel (A) and remove fuel sender (B) for rupture basin.

Image1.8.1

Image1.8.2

8) Remove control box from enclosure by slightly lifting on roof panel.

9) Remove fan guard from left and right of generator barrel by removing Phillips screw.

Image1.9.1

10) Secure lifting device to alternator and remove 2 M12 bolts (A) from mounting feet. Lift rear of generator slightly and place supports under rear housing.

Image1.10.1

Image1.10.2

11) Remove quantity of 8, 5/16" bolts (B) and quantity of 10, 3/8" bolts (A) that secure alternator to engine. Uncouple alternator from engine and remove from generator set.

Image1.11.1

FLYWHEEL RUN OUT VERIFICATION -

Note:

Read entire procedure before beginning measurements for flywheel run out. Failure to perform the test exactly as described will produce inaccurate data. The final results need to be in metric (mm) format. If a standard (in) dial indicator is used the values need to be converted. Make sure to note which format the measurements are in when documenting data.

Images 1.12.1 and 1.12.2 are provided for reference. The special fixture that allows measurement of the bore and face of the flywheel housing together is not a requirement. The measurements can be taken with a single indicator by making two revolutions. The measurements for bore and face should begin at the 6 o' clock position and rotate clockwise per the following instructions.

1) Using dial indicator record the measurements for the bore and face of the flywheel housing. Reference the following images.

2) Start the measurements at 6 o' clock location by pushing in on the flywheel to remove crankshaft end play and setting the dial indicator to zero.

3) Rotate the engine clockwise, stopping at 9 o' clock; push in on the flywheel to remove crankshaft end play and record measurement on dial indicator.

4) Rotate the engine clockwise, stopping at 12 o' clock; push in on the flywheel to remove crankshaft end play and record measurement on dial indicator.

5) Rotate the engine clockwise, stopping at 3 o' clock; push in on the flywheel to remove crankshaft end play and record measurement on dial indicator.

6) Rotate the engine clockwise, stopping at 6 o' clock; push in on the flywheel to remove crankshaft end play and record measurement on dial indicator.

7) Perform this process for both measurements of the flywheel bore and face.

8) While dial indicator is positioned for measuring bore, after completing initial measurements rotate to 12 o? clock. Zero dial indicator and utilize device for pivot point and utilize pry bar to measure flywheel lift.

Note:

Excessive pressure is not needed during this step. Apply smooth gradual force until measurement is stable on dial indicator. Do not utilize the flywheel housing as the pivot during this measurement.

9) Record all measurements in the format referenced in Image 1.12.3. Make sure to provide details if the measurements are metric (mm) or standard (in)format and need to be converted.

10) Email results to David Roberson for review at Roberson_David_A@cat.com. Results will be reviewed and feedback provided via return email correspondence.

Image1.12.1

Image1.12.2

Image1.12.3

ASSEMBLY INSTRUCTIONS -

1) With the new generator unpackaged, inspect for damage, proceed with removing all shipping material and covers.

2) Remove 4 bolts and end cover (A) from old generator to reveal space heater (B). Remove heater and install on new alternator prior to proceeding with installation.

Image1.13.1

Image1.13.2

3) Record the new alternator details from the data tag for updating package information.

Image1.14.1

4) Remove terminal cover (A) and disconnect all leads from terminal strip (B) and ground from generator barrel. Leads will be utilized from package for ease of installation. Pull wires for field through conduit for assembly later.

Image1.15.1

Image1.15.2

Image1.15.3

5) Install pins to aid in installation at locations in image.

Image1.16.1

Image1.16.2

6) Secure appropriate lifting device to alternator and couple to rear of engine. Note: Engine and alternator should be as close as possible to horizontal position during coupling. During coupling there is no need to apply excessive force by prying or pulling the alternator into the flywheel housing. Do not use bolts to close gap between housings.

7) Install quantity of 10 3/8" bolts and washers (A) to secure alternator housing to flywheel housing. Tighten to 47 N-m in a crisscross pattern. Reference diagram 1 in Image1.17.2.

8) Install quantity of 8 5/16" bolts and washers (B) to secure rotor to flywheel. Tighten to 25 N-m in a crisscross pattern. Reference diagram 1 in Image1.17.2.

Image1.17.1

Image1.17.2

9) Remove supports from under flywheel housing and lower alternator onto feet. Secure to base using 2 M12 bolts, washers and nuts (A) through alternator feet and beam. Tighten to 100 N-m.

Image1.18.1

Image1.18.2

10) Install fan guards to left and right of generator with Phillips screws.

Image1.19.1

11) Lift control box and place on base. Slide the control box slightly to the right. Open access panel (A) and install fuel level sender (B) before proceeding. Push wires through access hole in rear of control box for later.

Image1.20.1

Image1.20.2

12) Slide control box back into position and secure to base. Note: Do not tighten bolts securing roof to control box in this step.

13) Pull two wires for field through conduit and route to control box terminal strips.

14) Install leads T1-T12 to terminal strip (B) according to the appropriate configuration of machine. Install ground wire to barrel location and install cover (A) with Phillips screws.

Image1.21.1

Image1.21.2

Image1.21.3

15) Route wiring for the jacket water heater and alternator heater to control box.

16) Open instrument panel (A) and land connections for field (B), jacket water heater and alternator space heater (C).

Image1.22.1

Image1.22.2

Image1.22.3

Image1.22.4

17) Install cover over voltage selector switch J-box. Install quantity of 6 bolts and tighten.

Image1.23.1

18) Connect wiring harness to terminal at lower left of control box (A). Locate wiring for fuel level sender (B). Remove old splice connectors and splice wires together with new terminals. Verify proper installation of splice by performing pull test.