PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 5N-3765 GENERATOR SET COUPLING WITH A 247-0308 COUPLING ON CERTAIN G3520C GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 5N-3765 GENERATOR SET COUPLING WITH A 247-0308 COUPLING ON CERTAIN G3520C GENERATOR SETS

Usage:

REBE3187-02

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10Apr2008

(Revised 18Sep2008)

U-188

A-151

D-144

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 5N-3765 GENERATOR SET COUPLING WITH A 247-0308 COUPLING ON CERTAIN G3520C GENERATOR SETS
4456 5569 3252 4450		PI31482

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31482" 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 "PI31482" 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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NOTE:	This Revised Service Letter replaces the June 10, 2008 Service Letter. Changes have been made to Action Required. Damper inspection has been removed.

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COMPLETION DATE	TERMINATION DATE
31Oct2008	30Apr2009

PROBLEM

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The 5N-3765 Generator Set Coupling needs to be replaced with a 247-0308 Generator Set Coupling on certain G3520C 1800rpm Generator Sets. The existing generator set coupling can get damaged because of excessive torsional vibration levels. To help with vibration from the engine a dual damper is also being installed during the coupling change.

AFFECTED PRODUCT

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Model	Identification Number
G3520C	CWY00100-00104, 200-221 GZM00131-00176

PARTS NEEDED

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Qty	Part Number	Description
8	4M6953	WASHER-HARD
6	5P8250	WASHER-HARD
12	8D7942	BOLT-12 POINT HD
8	9X2119	BOLT-12 POINT HD
1	1599591	ADAPTER
6	1627459	BOLT
1	1627462	GUARD AS-DAMPER
2	2444508	DAMPER GP
1	2447191	COUPLING-OUTER
12	2482432	WASHER
1	2490059	COUPLING-INNER
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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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Prior to performing this update, isolate the genset before commencing any work on the unit, activate emergency stop, open genset breaker, and disconnect battery cables. Ensure health and safety requirements are adhered to at all times.

Replace the 5N-3765 Coupling with a 247-0308 Coupling and replace the single vibration damper with a new dual vibration damper. Refer to attached rework procedure.

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OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 32.0-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.

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 5N-3765 GENERATOR SET COUPLING WITH A 247-0308 COUPLING

MODELS INVOLVED - G3520C GENERATOR SETS

Dear Caterpillar Product Owner:

The 5N-3765 Generator Set Coupling needs to be replaced with a 247-0308 Generator Set Coupling on the products listed below. The existing generator set coupling can get damaged because of excessive tortional vibration levels. A dual damper will also be added to the front of the engine to help eliminate vibration in the engine. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

Please refer the dealer to their Service Letter dated 10Apr2008 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 10Apr2008 Service Letter

Rework Procedure

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Instructions for replacing the Caterpillar coupling with a new high inertia coupling.

1. Refer to the appropriate Service Manuals for safety instructions and additional details. Reference SEBU7681, RENR5980, & REHS0177.

2. Remove the generator set from operation by locking out the circuit breaker(s) and by removing battery power from the controls and the starter motor(s).

3. Make sure that the power cables and control wires connected to the generator have sufficient slack to allow the generator to be moved back from the engine. In most cases it will not be necessary to disconnect anything.

4. Unbolt the rubber boot retaining ring.

5. Remove the rubber boots.

6. Unbolt the generator from the rails and the engine flywheel housing.

7. Slide the generator back approximately 40 cm from the engine to gain access to the coupling components. Take care not to damage or mix up the shims under the generator feet. Due to the length of some generator bases, it may be necessary to block up the rear of the generator to get access to the coupling components.

8. Unbolt and remove the outer coupling element from the flywheel, and discard.

9. Unbolt and remove the inner element from the generator hub, and discard.

10. Clean any grease or dirt from the flywheel.

11. Install the new rubber element on the generator hub using the 9X-2119 Bolts with 4M6953 Washers. Rotate the rubber element to line it up for insertion with the coupling ring. Tighten the bolts in a clockwise opposing pattern before using the same pattern to tighten the bolts to a torque of 620 +/- 80 Nm (457 +/- 59 lb ft).

12. Install the new coupling ring on the flywheel. Use the new washers supplied with the coupling ring and the 8D7942 bolts. Tighten the bolts in a clockwise opposing pattern before using the same pattern to tighten the bolts to a torque of 215 +/- 40 Nm (159 +/- 30 lb ft).

13. Slide the generator forward inserting the rubber element into the coupling ring.

14. Insert the original stack of shims at each generator mounting foot.

15. Align the generator set. If the generator set was properly aligned before starting on the coupling replacement only minor adjustments, if any, will be needed.

16. Check engine crankshaft deflection.

Procedures for removal of single damper and installation of dual damper.

Required Tools 138-7573 Link Bracket

Image1.2.1

1. Remove the eight bolts and guard (1).
2. Remove two bolts (2).
3. Install Tool (A) and attach a suitable lifting device.
4. Remove two bolts (3).
5. Install two 1"-14 NF x 11" (280 mm) guide bolts (4).
6. Remove the remaining bolts (3).
7. Remove vibration damper (5). The damper weighs approximately 91 kg (200 lb).
8. Remove remaining bolts (2) and remove the adapter from vibration damper (5), if necessary. The adapter weighs approximately 34 kg (75 lb).

Damper Installation Process

NOTICE
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. If the 1N-3482 adapter was removed, install this adapter and install two guide pins to help position and hold damper in place until bolts can be installed.
2. The bolted ends of the dampers will be facing toward the front of the engine on both dampers. The 159-9591 adapter will be placed between both dampers. By placing two bolts in the damper assembly it will help to keep the dampers together.
3. Attach a suitable lifting device or if lifting devise is not availed or unable to get in confined space, use a floor jack to lift dual dampers into place.
4. Apply 4C-5593 Anti-Seize Compound to the threads of the bolts.
5. Remove the two guide bolts.
6. Install two remaining bolts. Tighten the bolts to a torque of 1125 +/- 100 N.m (830 +/- 75 lb ft).

Note: Refer to the Specifications Module, "Vibration Damper" for more information.

7. Install new guard (162-7462) and eight bolts. Tighten the bolts to a torque of 15 +/- 3 N.m (11 +/- 2 lb ft).

When finished with coupling change and new dual damper installation. Clear generator area, reconnect batteries, clear emergency stop, and clear emergency stop fault code.

Run functional no load test on generator set.