PRODUCT SUPPORT PROGRAM FOR UPDATING THE DAMPER AND DRIVE COUPLING ON G3520E 1500 RPM ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR UPDATING THE DAMPER AND DRIVE COUPLING ON G3520E 1500 RPM ENGINES

Usage:

REBE4419-00

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07Oct2008

L120
L403
L240

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Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR UPDATING THE DAMPER AND DRIVE COUPLING ON G3520E 1500 RPM ENGINES
1205 3252		PS42802

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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 "PS42802" 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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TERMINATION DATE

31Oct2010

PROBLEM

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G3520E 1500rpm Gensets experience high levels of torsional vibration.

AFFECTED PRODUCT

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Model	Identification Number
G3520E	GZH00111, 113-128, 130-132 HAL00100-00102

PARTS NEEDED

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Qty	Part Number	Description
1	0S1595	BOLT
17	1A1460	BOLT
1	1T0132	SEAL-O RING
1	3B8453	SEAL-O-RING
10	3E6916	NUT-FULL
1	3J7354	SEAL-O-RING
1	3P0654	SEAL-O-RING
4	3P0657	SEAL-O-RING
2	4J5477	SEAL-O-RING
1	4K1388	SEAL-O-RING
8	4M6953	WASHER-HARD
3	4N1320	GASKET-ADAPTER
2	5H6734	SEAL-O RING
3	5P0840	SEAL-O-RING
2	5P3456	SEAL-O-RING
10	5P8245	WASHER-HARD
16	5P8247	WASHER-HARD
6	5P8250	WASHER-HARD
3	5R7136	WASHER-SEALING
4	5R7137	WASHER-SEALING
4	6V1454	SEAL-O RING
8	6V1903	SEAL-O-RING
3	6V3348	SEAL-O-RING
4	6V3603	SEAL-O-RING
8	6V3631	NUT-FULL
1	6V3908	SEAL-O-RING
1	6V4589	SEAL-O-RING
8	6V4605	LOCKNUT-TEMP
6	6V5066	SEAL-O RING
1	6V5101	SEAL-O-RING
4	6V5103	SEAL-O-RING
4	6V5134	SEAL-O-RING
2	6V5778	SEAL-O-RING
1	6V6609	SEAL-O-RING
1	6V6809	SEAL-O RING
12	6V9746	SEAL-O RING
6	7B8363	BOLT
6	7D1649	WASHER-HARD
2	7E2326	SEAL-RING
4	7L6443	BOLT-HEX HEAD
1	7N3049	GASKET
4	7N3368	GASKET
1	7N4945	GASKET
3	7X4805	SEAL-O-RING
2	8C0624	SEAL-O-RING
30	8C8491	WASHER
12	8D7942	BOLT-12 POINT HD
2	8L9241	SEAL-O-RING
2	8M5255	SEAL-O RING
2	8N9885	GASKET-DRIVE HSG
4	8T1919	SEAL-O-RING
1	9F8127	GASKET
10	9L7373	BOLT-HIGH TEMP
24	9M1974	WASHER-HARD
4	9X2068	BOLT-HIGH TEMP
8	9X2119	BOLT-12 POINT HD
2	9X7562	SEAL-O-RING
2	9Y6893	GASKET
1	9Y8069	GASKET
2	1078505	GASKET
1	1115822	GASKET-EXHAUST
1	1138432	SEAL-CRANKSHAFT
1	1178801	SEAL-O-RING
1	1313718	SEAL-O-RING
8	1412456	BOLT-HEX HEAD
1	1520111	GASKET
5	1547477	SEAL
24	1562603	BOLT-HEX HEAD
8	1626466	BOLT-12 POINT HD
2	1743357	SEAL-O-RING
2	2006410	SEAL-O-RING
4	2083786	CONNECTOR-O-RING
2	2267485	GASKET
3	2353546	SEAL-O-RING
4	2353548	SEAL-O-RING
1	2447191	COUPLING-OUTER
12	2482432	WASHER
1	2490059	COUPLING-INNER
4	2624568	SEAL
2	2733967	GASKET
1	2986387	SEAL-O-RING
8	3053447	SEAL
1	3152616	DAMPER GP-BASIC
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% 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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Update engine with 319-8494 Damper Gp and 247-0308 Coupling Gp.

To perform this update, the front of the crankshaft will need to be drilled for engine oil supply and engine oil return holes. This drilling procedure will be performed by In-Place Machinery Co. of Wisconsin, USA. Prior to scheduling this update with the customer, you will need to contact In-Place to coordinate scheduling of the crankshaft drilling. See contact information below.

In-Place Machinery Co.
3811 N. Holton St.
Milwaukee, WI 53212
414-562-2000
www.inplace.com
Ref: Procedure 52425

Note: In-Place should be contacted a minimum of 4 weeks prior to when the update is desired to begin.

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%
0-40000 hrs	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 108.0-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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1) Contact In-Place Machinery Co. to schedule crankshaft drilling.

2) Remove any site installation related equipment from the front of the engine to allow access for removal of engine front housing and access to front of crankshaft.

Note: Use the G3520E D&A manual, RENR5980 and G3520E Specifications Manual, RENR5977 for reference.

3) Remove turbochargers and related plumbing from the engine.

4) Remove exhaust elbows and related mounting brackets to gain access for front housing removal.

5) Remove the vibration damper.

6) Remove the engine oil pump, oil cooler and related plumbing.

7) Remove engine driven water pumps, if installed.

8) Remove front housing and gear train.

9) Remove the #1 main bearing cap.

Note: The engine should now look like image 1.1.1

Image1.1.1

10) Cover the exposed section of the oil pan and seal with tape. This is to keep debris from entering the pan during drilling.

Note: See image 1.2.1 for an example of a shield to keep out debris.

Image1.2.1

11) In-Place Machinery will perform the crankshaft drilling procedure with dealer assistance.

Note: In-Place Machinery has a detailed procedure and tool kit specifically developed in conjunction with Caterpillar to perform this rework.

12) Ensure that the crankshaft drillings and engine oil pan have been flushed/cleaned throughly.

13) Install the #1 main cap and bearing.

14) Install the front housing and gear train.

15) Install water pumps, if required.

16) Install engine oil pump, oil cooler and related plumbing.

17) Install the 315-2616 damper gp. The alignment (dash) mark on damper must be aligned with alignment (dash) mark on crankshaft. Ensure that the 117-8801 and 324-2702 o-rings stay in-place during installation of the damper. Coat the 7B-8363 damper bolts with moly lubricant and torque to 1150 +/- 60 N-m (850 +/- 45 lb. ft).

18) Install exhaust components and related mounting brackets.

19) Install turbos and related lines.

20) Reinstall any site installation related equipment in front of the engine.

Note: For removing the drive coupling, 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.

22) Unbolt the rubber boot retaining ring.

23) Remove the rubber boots.

24) Unbolt the generator from the rails and the engine flywheel housing.

25) 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.

26) Unbolt and remove the outer coupling element from the flywheel. Discard.

27) Unbolt and remove the inner element from the generator hub. Discard.

28) Clean any grease or dirt from the flywheel.

29) Install the new rubber element on the generator hub using the 9X-2119 bolts with 4M-6953 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 torque the bolts to 620 +/- 80 Nm (460 +/- 63 lb. ft).

30) Install the new coupling ring on the flywheel. Use the new washers supplied with the coupling ring and the 8D-7942 bolts. Tighten the bolts in a clockwise opposing pattern before using the same pattern to torque the bolts to 215 +/- 40 Nm (160 +/- 29 lb. ft).

31) Slide the generator forward inserting the rubber element into the coupling ring.

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

33) 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.

34) Torque the generator to the flywheel housing.

35) Check engine crankshaft deflection.

36) Restart the engine and inspect for any leaks.

37) Run the engine at full load and monitor for 1 hour.

38) Take a SOS sample within 10 hrs of restarting.