Usage:
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.
NOTE: This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4298" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
Termination Date
December 31, 1998Problem
The drive plate bolt in certain generators packaged into Larne sourced generator sets and powered by 3306B and 3406C Engines may not be tightened to the proper torque value.
Affected Product
Model & Identification Number
3406C (8FS480, 8FS482, 8FS484, 8FS486, 8FS488-490, 8FS492, 8FS493, 8FS499, 8FS500, 8FS502 , 8FS505, 8FS507, 8FS511, 8FS512, 8FS514, 8FS518, 8FS519, 8FS521-523, 8FS525 , 8FS526, 8FS529, 8FS532, 8FS533, 8FS536-538, 8FS540-543, 8FS546-562, 8FS566-568 , 8FS571, 8FS573-579, 8FS581-585, 8FS587-590, 8FS592-594, 8FS596 , 8FS598-617, 8FS619-625, 8FS627-640, 8FS642-647, 8FS649-655, 8FS657 , 8FS659, 8FS662-668, 8FS670-677, 8FS679, 8FS681, 8FS682, 8FS684, 8FS686-693 , 8FS695-699, 8FS701-708, 8FS710, 8FS713, 8FS714, 8FS716, 8FS717, 8FS719 , 8FS722, 8FS723, 8FS727-730, 8FS732-737, 8FS739-740, 8FS744, 8FS746, 8FS748 , 8FS750, 8FS752, 8FS753, 8FS758, 8FS760-765, 8FS767, 8FS770, 8FS771, 8FS773-776 , 8FS778, 8FS780-788, 8FS794-797, 8FS799-814, 8FS819-821, 8FS823 , 8FS841, 8FS844-849, 8FS851, 8FS852, 8FS858, 8FS859, 8FS861, 8FS862, 8FS864 , 8FS865, 8FS868-870, 8FS873-875, 8FS877-880, 8FS883-885, 8FS888, 8FS891 , 8FS892, 8FS894, 8FS896, 8FS900, 8FS904, 8FS919, 8FS923, 8FS941-943, 8FS949 , 8FS951, 8FS953-957, 8FS960, 8FS961, 8FS972-974 8FS3306B9DS322-325, 9DS330-333, 9DS336, 9DS342, 9DS345, 9DS378, 9DS381, 9DS382, 9DS387 , 9DS390-395, 9DS397, 9DS398, 9DS401-403, 9DS407-411, 9DS413, 9DS414 , 9DS417, 9DS418, 9DS420, 9DS421, 9DS424-446, 9DS448-454, 9DS456-460 , 9DS464, 9DS466-469, 9DS471-474, 9DS477, 9DS479-489, 9DS491-495 , 9DS499-504, 9DS506, 9DS509-513, 9DS516-525, 9DS530, 9DS532-535 , 9DS540, 9DS544, 9DS545, 9DS549-553, 9DS555, 9DS556, 9DS558-560 , 9DS562, 9DS568, 9DS574-577, 9DS580-590, 9DS593, 9DS595, 9DS597 , 9DS599, 9DS600, 9DS602, 9DS604-606, 9DS611, 9DS612, 9DS615, 9DS618-619 , 9DS621, 9DS623, 9DS624, 9DS626, 9DS627, 9DS629-633, 9DS666, 9DS673-692 , 9DS696, 9DS697, 9DS699, 9DS703, 9DS705, 9DS706, 9DS708, 9DS709, 9DS713 , 9DS717, 9DS719-721, 9DS724-728, 9DS730, 9DS732-734, 9DS739, 9DS741 , 9DS745-748, 9DS750, 9DS752-756, 9DS758-766, 9DS768, 9DS778, 9DS780-782 , 9DS784-786, 9DS791, 9DS793, 9DS797, 9DS804, 9DS805, 9DS807, 9DS808 , 9DS811, 9DS812, 9DS814, 9DS815, 9DS826-828, 9DS831, 9DS837, 9DS840-846 , 9DS849, 9DS851, 9DS858, 9DS864, 9DS866)
To make sure the Generator Set Package being considered for this Program is eligible, refer to the Generator Set Serial Number Film located on the Generator barrel. The engine Serial Number, located at the bottom of this film, must appear on the list published in this Program. Also, check to see if this package has been reworked. If there is an "F1" stamped on the engine cylinder block, at the left rear of the 3306 and the right rear of the 3406, this package has already been reworked and this program does not apply. If it is not on the list, this Program does not apply. If it is listed, check the Generator Serial Number on the Film. The Generator Serial Number appears about halfway on the film. Record the Generator Serial Number from the Film on the work order and on the warranty claim even if it does not agree with the Generator Serial Number listed for the Engine Serial Number published in this program.
Parts Needed
No parts are needed for this program.
Action Required
See the attached rework procedure.
NOTE: When the reworked has been completed, stamp "F1" on the engine cylinder block at the left rear of the 3306 and the right rear of the 3406.
Service Claim Allowances
NOTE: Record the Generator Serial Number for the package in the story of the Service Claim.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.
- (1-Rework Procedure)
Rework Procedure
Generator Drive Plate Bolt Torque
NOTE: This Procedure requires moving the engine and radiator forward approximately 150 mm for a packaged Gen Set without an enclosure. This Procedure requires moving the generator backwards approximately 150 mm for a packaged Gen Set with either a sound attenuated or a weather proof enclosure. Therefore, all pipe work and wiring not shown in this procedure must be given adequate slack or be disconnected.
For Gen Set Packages Without Enclosures:
Disassembly of engine from generator
1. Cut the tywraps which secure the wiring harnesses on both sides of the generator.
2. Remove the right hand terminal box side cover and remove the tywraps attaching the wiring harnesses to the central cross member inside the terminal box. This will give enough slack in the wiring harnesses to allow the engine to move forward.
3. Remove the Battery hold-down clamps, the Battery Drip Tray and the Batteries and tie the cables out of the way. Remove the fuel supply and return hoses at the base connections and tie them out of the way (cap all openings).
4. Remove the bottom rear Radiator Support to Engine Support Bolt from each side. (Clean the threads in the bolt hole.) Place a lifting device into the hole the bolt was removed from and secure to the supports.
5. Remove the Generator Drip Cover and Screen.
6. Loosen the Terminal Box lower front cover and slide it down in it's slots to allow the Generator to move about on the mounts. Loosen the engine vibration mount bolts removing the nuts and washers but leaving the bolts in position.
7. Turn the engine over to TDC before removing the flywheel housing to generator housing bolts. Support the Generator with wood blocks in front of and behind the generator crossbeam to keep the generator positioned for re-assembly. Using an overhead crane with a spreader bar, fit hooks through the each of the Radiator/Engine Support lifting devices (Reference Step 4) and sling under the engine flywheel housing and take up enough slack to support the weight of the engine. Remove the top flywheel housing to generator housing bolt and install a guide bolt. Remove the remaining flywheel housing to generator housing bolts and the drive plate to flywheel bolts and slide the engine forward to allow access to the generator drive plate bolts but not too far to put tension on the wiring harnesses.
Inspecting and retightening of the generator drive plate to generator hub bolts
1. Fit a bar across the generator drive plate and the generator housing to prevent the rotor from turning during tightening.
2. Inspect the 12 bolts holding the drive plate to the generator hub. This is the smallest diameter bolt pattern on the drive plate. In the unlikely event that bolts are missing or broken, replace with OS1587 Bolt and 5P8245 Washer.
3. Tighten all 12 bolts to the standard torque of 105 N·m.
Reassemble
1. All contact surfaces of the engine, the coupling, and the generator must be completely clean.
2. Place a guide bolt in the engine flywheel and move the engine backwards until the guide bolt is aligned with the hole in the drive plate. Lower the engine and move it backwards to engage the flywheel guide bolt with the drive plate. Engage the generator shaft in the flywheel bore, this may require moving the wood blocks from under the generator to get proper alignment. Make sure the flywheel housing to generator housing guide bolt is engaged before removing the wood blocks. Completely engage the generator housing into the engine flywheel housing bore.
3. Install the flywheel housing to generator housing bolts after removing the guide bolt and apply standard torque, 105N·m.
4. Install the drive plate to flywheel bolts after removing the guide bolt and apply a standard torque of 7O N·m.
5. Raise the engine slightly to engage the front vibration mount bolts. Install the nuts and washers and tighten to a torque of 37O Nm using a 1-" Universal Socket.
NOTE: This is a critical torque.
6. Install the batteries, the battery drip tray, and the battery hold-down clamps, and reconnect the cables.
7. Install the generator rain cap and screen.
8. Return the wiring harnesses to their original positions and ty-wrap them in place at the original locations.
9. Install the terminal box side cover and the terminal box front lower cover.
NOTE: Refer to the SR4B Generator Service Manual, SENR5359 for additional detail and pictures.
For Gen Set Packages With Enclosures:
Preparation prior to Disassembly:
1. Loosen two bolts on the air intake box. There are two bolts inside the enclosure, one on each side of the side seam between the rear enclosure section and the main enclosure section, located about 6 inches down from the roof of the enclosure. This will allow the air intake section of the enclosure to be moved slightly rearward so that the roof section indicated in Step 2 can be easily removed.
2. Remove the roof section of the enclosure above the control panel. This will require removing the 22 nuts or bolts that connect this panel from the mating panels of the enclosure. There are 6 nuts or bolts on each of the sides of this panel that have to be removed. There are 5 nuts or bolts on the front and rear sides of this panel that have to be removed. The sound attenuating foam will be covering most of the nuts or bolts, move the foam only enough to remove the nuts or bolts.
3. Remove the circuit breaker box cover, the gland plate, and the marshaling box cover.
4. Remove the lower RHS air Inlet Grill to the Generator from the terminal box. Loosen the circuit breaker box to allow removal of the grill, and re-tighten.
5. Remove the lower LHS air inlet grill to the Generator.
6. Remove the Terminal Box lower rear cover.
7. Cut the ty-wraps on the wiring harness in the terminal box.
8. Loosen the bolts on the lower front terminal box cover and drop to the bottom of the slots including the ones at the engine relay box mounting bracket.
9. Cut the ty-wraps on the engine to starter wiring harness and jacket water heater if so equipped.
Disassembly of Generator from Engine
1. Remove the Generator Drip Cover and Screen.
2. Remove the Terminal box to base bolts. Remove the earth bolt from the pad on the base.
3. Turn the engine over to TDC and remove the top flywheel to generator drive plate bolt and install a guide bolt. Remove the remaining flywheel to generator drive plate bolts.
4. Remove the fuel supply and return hoses at the base connections and tie them out of the way (cap all openings).
5. Remove plugs in the fuel tank base beneath the flywheel housing. (The engine flywheel housing will need to be supported when the generator is removed, and the plugs should not be used to support anything.) Remove the jacket water heater mounting brackets and move the heater out of the line of the generator to engine joint without disconnecting the hoses or wiring. This will provide easier access to the flywheel housing.
7. Fit a sling around the underside of the generator just in front of the feet. Move the terminal box rearward to clear the sling.
8. Place a box beam support under the generator barrel behind the feet long enough to put slings on each side making sure to clear the control panel and circuit breaker box, thus supporting the generator with 3 points. Ensure that all three points lift evenly and that the control panel is protected from damage.
9. Remove the flywheel housing bolts and take up the weight of the generator using the slings. The generator can now be guided away from the engine making sure that the terminal box moves with the generator.
Inspecting and retightening of the generator drive plate to generator hub bolts
1. Fit a bar across the generator drive plate and the generator housing to prevent the roter from turning during tightening.
2. Inspect the 12 bolts holding the drive plate and the generator housing to prevent the rotor from turning during tightening.
3. Tighten all 12 bolts to a standard torque of 105 N·m.
Reassemble
1. All contact surfaces of the engine, the coupling, and the generator must be completely clean.
2. Move the generator gently towards the engine until the guide bolt engages the TDC hole in the drive plate and fan, raising the generator to center the generator rotor and continue to gently move the generator toward the engine completely engage the generator housing into the engine flywheel housing bore.
3. Install the flywheel housing to generator housing bolts and tighten after assuring there is no gap between the housings before final tightening to a torque of 70 N·m.
4. Install the drive plate to flywheel bolts after removing the guide bolt and apply a standard torque of 105 N·m.
5. Remove the slings and lower the jacks under the flywheel housing and insert the generator foot bolts. Check to make sure that the generator feet are aligned properly with the mounting holes and that the front mounts have free movement. Install the nuts and washers and tighten to a torque of 370 N·m using a 1-" Universal Socket.
NOTE: This is a critical torque.
6. Remove the jacks under the flywheel housing. Install the batter tray and batteries and reconnect the cables. Re-position the jacket water heater and mounting bracks and bolt in place. Install the Generator Drip Cover and Screen. Install the Jacket Water Heater Bracket, if equipped. Install 2 plugs in the base beneath the flywheel housing. Relocate the terminal box to it's original location bolt in place. Install the earth bolt to the pad on the base. Install the lower RHS air Inlet Grill of the Generator to the terminal box and tighten the circuit breaker box bolts. Install the lower LHS air inlet grill of the Generator to the terminal box. Install the circuit breaker box cover, the gland plate, and the marshalling box duct cover. Re-position the lower front terminal box cover and tighten the bolts including the two on the engine relay box mounting bracket. Return the wiring harnesses inside the terminal box to their original positions and ty-wrap them in place at the original locations. Install the terminal box side cover the terminal box rear lower cover. Return the wiring harnesses alongside the engine to their original positions and ty-wrap them in place at the original locations. Tighten the two bolts on the sides of the air intake box . Replace the rear roof section of the canopy above the control panel and seal the joints with clear silicon sealer.
