PRODUCT IMPROVEMENT PROGRAM FOR REWORKING DRIVELINE ON CERTAIN C-18 GENERATOR SETS WITH LC6 GENERATORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING DRIVELINE ON CERTAIN C-18 GENERATOR SETS WITH LC6 GENERATORS

Usage:

REBE1184-01

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31Oct2006

(Revised 03May2007)

U-705

O-687

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING DRIVELINE ON CERTAIN C-18 GENERATOR SETS WITH LC6 GENERATORS
1202 1021 1404 4456 3252		PI31174

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31174" 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 "PI31174" 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 31 October, 2006 Service Letter. Changes have been made to the Action Required section and to include a Note in the Service Claims Allowance section.

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COMPLETION DATE	TERMINATION DATE
30Apr2007	31Oct2007

PROBLEM

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The driveline needs to be reworked on certain C-18 generator sets. Six shims were inserted between the flex plates and the hub of the generators resulting in zero crankshaft endplay. This could result in engine and generator bearing failure.

AFFECTED PRODUCT

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Model	Identification Number
C18	STD00125-00127, 158 STM00128-00136, 139-141, 144-146, 149-151, 154-156, 159-161, 164-166, 171-173, 178-180, 185-187, 192-194, 199-201, 206-207, 255, 262, 315-316, 318, 321, 325, 327-328, 330-333, 338, 343-354, 359-360, 370-378, 381, 385-387, 391-405, 409, 412, 414-418, 421-426, 430-433, 440-442, 451-462, 468, 472-473, 500-506, 510, 512-514, 518-520

PARTS NEEDED

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Qty	Part Number	Description
1	2414597	RING
1	2414622	RING-RUBBER O
1	2435220	BEARING
1	2513489	DISC-COUPLING

ACTION REQUIRED

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Inspect the generator to determine if shims were used between the flex plates and the generator hub. Remove all shims if any are present. Verify the distance from the mating surface of the generator bracket to the front of the flex plates per SAE 0/18 in relation to value G, table 1 in the SAE J620 standard. Add shims as necessary to bring the distance to the SAE standard. If 6 shims were used, NERO (New Engine replacement order) the Engine and rework generator according to the rework procedure. If replacement engines are invoiced to the EAME territory dealer, the invoice cost needs to be included on the warranty claim.

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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 40.0-hour job
NOTE: The invoice cost of replacement engines invoiced to dealers in EAME need to be included in the warranty claim against this program. Replacement engines for North America need to be procured through the NERO process.

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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 REWORKING DRIVELINE ON CERTAIN C-18 GENERATOR SETS WITH LC6 GENERATORS

MODELS INVOLVED - CERTAIN C-18 GENERATOR SETS WITH LC6 GENERATORS

Dear Caterpillar Product Owner:

The driveline needs to be reworked on certain C-18 generator sets. Six shims were inserted between the flex plates and the hub of the generators resulting in zero crankshaft endplay. This could result in engine and generator bearing failure. 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 31Oct2006 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 31Oct2006 Service Letter

Rework Procedure

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Rework Procedure
Reference Prints:

LC6 Generators:
LC6124K 2424994
LC6114G 2476121
LC6114F 2476119

C18 Engines:
241-2417
269-1770

Rework Material:

LC6 Alternator:
1 of 251-3489 Coupling Discs
1 of 243-5220 Bearing (Rear of Alt)
1 of 241-4597 Shim-Borelly (Rear Bearing)
1 of 241-4622 Rubber O-Ring

Instructions

1. Reference.
RENR8643 Disassembly & Assembly C18 Generator set.
SEBU7898 Operation & Maintenance manual C18 Generator

2. Check the Generator model is LC6 only continue if the marked LC6.

3. Isolate 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.

4. Remove generator guard. Part No. 242-3924 (Image 1.2.1 Item 33)

5. Use a flashlight to examine and determine the number of shims between the generator fan and the coupling discs. See Image 1.1.1

Image1.1.1

6. If 0-2 shims are on the generator the Genset go to Item 10.

7. If 6 shims are to be found on the generator decouple engine and generator. Record the Number of shims in the standard warranty claim with the Generator & Package serial No.

8. On the front of the LC6, remove coupling discs (do not reuse these) and the shims. On the rear remove and replace the bearing, rubber o-ring and the Borelly ring.

Image1.2.1

Image1.2.2

9- Replacing the bearing
Tool required.

To fully dismantle the machine, we recommend using the
tools listed below:
- 1 ratchet spanner + extension
- 1 torque wrench
- 1 set of flat spanners: 8 mm, 10 mm, 18 mm
- 1 socket set: 8, 10, 13, 16, 18, 21, 24, 30 mm
- 1 socket with male ferrule: 5 mm
- 1 puller

Screw tightening torque Image 1.2.2

9.1 Remove the air intake grille 242-3924

9.2 Remove the lid of the protective cover (48) and the side panels (366) and (367).

9.3 Remove the hook (21) and the cover rear panel (365).

9.4 Replace the hook (21) in order to manipulate the flange.

9.5 Disconnect the exciter wires (5+,6-).

9.6 Remove the bearing thrust screws (78).

9.7 Remove all 5 screws (37).

9.8 Remove the shield (36).

9.9 Take out the antifriction bearing (70) using a puller with a central screw (Image 1.3.1).

9.10 Check the Exciter end shield (Bracket)for damage using a Magnaflux replace if required Item 36

9.11 Fit the new antifriction bearing onto the shaft after heating it by induction to approximately 80 ?C.

9.12 Mount the new preloading (wavy) washer (79) + the new ?O? ring seal (349) in the shield (36).

9.13 Screw a threaded rod into the thrust bearing (78).

9.14 Refit the end shield on the machine using a dowel and nut in the shaft extension See image 1.3.2.

Image1.3.1

Image1.3.2

10. At the front of the LC6, bolt up the new coupling disc with 0 shims. Measure, with a dial indicator the end play of the maximum and minimum distances between the front of the coupling disc pack to the face of the flange that mates to the engine flywheel housing Gp. See image 1.4.1.

Image1.4.1

11. The values recorded for dimension Y must be within 15.7mm ?2mm. If recorded values fall outside this range use shims to adjust to the value of 15.7mm ?2mm.

12. NERO (New Engine Replacement Order)the Engine and replace the Engine.
Take end play reading on Engine before reassembly to package record Engine end play on the warranty claim.
References:
RENR8643 Disassembly & Assembly.
SEBU7898 Operation & Maintenance manual C18 Generator

13. Reassemble reworked generator to the new engine.
After reassembly take reading of the packageend play & record on the warranty claim.

14. Clear generator area, reconnect batteries, and release emergency stop and clear emergency stop fault code.

15. Run functional No load test on Genset
References:
SEBU7898 Operation & Maintenance manual C18 Generator