PRODUCT SUPPORT PROGRAM FOR REPLACING THE RECTIFIER ASSEMBLY ON CERTAIN 3516C, AND C175-16 GENERATOR SETS EQUIPPED WITH A SR5 3000 FRAME GENERATOR Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE RECTIFIER ASSEMBLY ON CERTAIN 3516C, AND C175-16 GENERATOR SETS EQUIPPED WITH A SR5 3000 FRAME GENERATOR

Usage:

TEBE0329-02

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06Sep2013

(Revised 04Nov2013)

B020
B044
B170
B330
B334
B360
B370
D070
D090
D485
D530
E140
E481
E508
G224
H160
H161
H335
N020
N050
Z75F

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Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING THE RECTIFIER ASSEMBLY ON CERTAIN 3516C, AND C175-16 GENERATOR SETS EQUIPPED WITH A SR5 3000 FRAME GENERATOR
4457		PS44012

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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 "PS44012" 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 06Sep2013 (Revised 10Oct2013) Service Letter. Changes have been made to the Service Claim Allowances.

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TERMINATION DATE

30Sep2015

PROBLEM

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The existing rectifier assembly may create adverse voltage spikes during commutation, potentially creating a negative stress in the exciter rotor windings, when operating SR5 3000 frame generators.

AFFECTED PRODUCT

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Model	Identification Number
3516C	SBK01303-01306
3516C HD	SEK00226-00228
C175-16	WYB00186, 213-215, 274, 284, 286, 288, 290, 299-300, 351-352, 357, 360-361, 364-365, 371, 375-377, 379, 434, 436-439, 442, 445, 448-450, 452, 456-462, 464-465, 467, 469, 472, 474, 476, 479, 481, 484, 486, 489, 492-493, 499, 502, 506, 508, 511, 514, 518, 520, 522-523, 525, 528, 532-534, 538, 540-541, 544, 548, 555, 557, 560, 563-565, 567, 569, 571, 574, 580-581, 586, 589, 592, 597, 601, 603, 605, 607, 611, 615, 618, 624, 667-668, 671-673, 675-677, 682, 1014-1015, 1017, 1022, 1051, 1070, 1074, 1102, 1132, 1135, 1138, 1140, 1142-1148, 1150, 1152-1153, 1156, 1158-1160, 1162, 1164, 1166, 1169-1172, 1179-1180, 1183-1184, 1187, 1190, 1194, 1196, 1198, 1201, 1204-1205, 1207, 1209-1210, 1213, 1215, 1217, 1221-1225, 1227, 1229-1230, 1329

PARTS NEEDED

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Qty	Part Number	Description
1	KIT	Rectifier Kit
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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Leroy Somer will ship the repair kit including the new rectifier assembly to the affected dealers (see image 1 for reference of the kit content).

If you need more information please contact Roberto Vivas of Caterpillar.
Telephone: (770) 233-5704
Email: Vivas_Roberto@cat.com

Make sure the following tools are available before commencing any job (see Image 2 as a reference for the required tools).

Propane Torch
Crimper
Heat gun
Scissors
Wire Cutters
Loctite
Torque wrenches and sockets
Solder (use "Johnson Mfg # 465 alloy OR120, 0.125" Dia Sn 97.0 / Sb 0.8 / Cu 2.0 / Ag 0.2 11 AWG (1/8") for wiring solder Rosin Core "Lead Free" Solder? or similar)

Refer to the attached Rework Procedure.

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Image1

Image2

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 2.5-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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Rectifier Replacement Procedure:

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.

1. Remove existing rectifier assembly (see image 1.1.1).

2. Cut lugs off exciter rotor lead. Cut shortest lead back from other two leads, approximately 1.5". This will stagger the crimped splices, for easier installation of the rectifier assembly (see image 1.1.2).

3. Strip exciter rotor leads (see image 1.2.3).

Image1.1.1

Image1.1.2

Image1.1.3

4. Crimp the splice on exciter rotor leads (see image 1.2.1).

5. Cut 3 pieces (#6 awg wire) six inches, and strip one end (see image 1.2.2).

6. Crimp wires to the splices, on exciter rotor leads (see image 1.2.2).

Image1.2.1

Image1.2.2

7. Solder the splices on exciter rotor leads (see image 1.3.1).

8. Wrap the splices, with rubber silicone tape, extending 1" on each side of the splice overlapping 1/2 wrap on exciter rotor leads (see image 1.3.2).

9. Cut heat shrink sleeving and install over the taped splices on the exciter rotor leads (see image 1.3.3).

Image1.3.1

Image1.3.2

Image1.3.3

10. Cut sleeve insulation to cover and overlap existing main rotor leads (see image 1.4.1).

11. Install leads through rectifier assembly, careful not to trap insulation between rectifier assembly and shaft. Ensure pins align in rectifier assembly (see image 1.4.2).

12. Pull exciter rotor sleeving, to extend 2" from lead opening (see image 1.4.3).

Image1.4.1

Image1.4.2

Image1.4.3

13. Rotate rectifier, so that field leads are facing + and ? terminals (see image 1.5.1).
Note: If the main rotor leads are not long enough to reach the + and ? terminals, loosing the main rotor clamp and pulling the main rotor leads may give you the required length (see image 1.5.2). Secure the clamp making sure the sleeve remains in place to avoid damage to the leads. If the leads are still too short after loosing the clamp please contact Roberto Vivas for more information. Refer to the Action Required for contact information.

14. Install rectifier assembly screws and tighten to 23 foot lbs, using cross-pattern tightening sequence (see image 1.5.3 and image 1.5.4).

15. Cut exciter rotor leads, by positioning leads to terminal connection to determine length to cut (see image 1.5.4).

Image1.5.1

Image1.5.2

Image1.5.3

Image1.5.4

16. Strip exciter rotor leads (see image 1.6.1).

17. Crimp terminals to exciter rotor leads (see image 1.6.2)

18. Secure leads with nylon tie (see image 1.6.3)

Image1.6.1

Image1.6.2

Image1.6.3

19. Remove nut and small washer on rectifier terminals and the + and - terminals (see image 1.7.1)

20. Connect exciter rotor leads to rectifier terminals and main rotor leads to the + and - terminal, install small washer and locking nut (see image 1.7.2).

21. Tighten the terminals to 13 foot pounds (see image 1.7.3).