CYL GP-0075 4389991 - Caterpillar

PARTS NEEDED
No parts needed for this program
ACTION REQUIRED
Refer to the attached Rework Procedure.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-1600 hrs,
0-48 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 12.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
1. Open and lockout the generator set circuit breaker.
2. Follow the Disassembly and Assembly Manual to remove the generator.
3. Lift the generator, remove terminal box and mounting feet
4. Place generator on a flat and level surface.
5. Seal all uncovered bolt holes with heat resistant tapes, as shown in Image1.5.1.
Image1.5.1
6. Find the 2 original welding points (A) near to the mounting brackets. Move from A by 60 +/- 3mm towards the flywheel end to locate their corresponding new welding points (B) and mark them, as shown in Image1.6.1.
Image1.6.1
7. Find the 2 original welding points (A) near to the terminal box. Move from A clockwise (view from flywheel end) by 77 +/- 3mm to locate their corresponding new welding points (B) and mark them, as shown in Image1.7.1.
Image1.7.1
8. Cover all openings of the generator with fire retardant fabric to prevent welding slag, spatter, and sparks entering generator, as shown in Image1.8.1.
Image1.8.1
9. Hit the new welding point with center punch. Drill hole with 5mm twist drill, ream the hole with 10mm twist drill, and then ream the hole with 10mm flat head drill. The hole depth should be between 5mm and 7mm. Repeat this step to drill hole at every new welding point and clean the metal debris.
Image1.9.1
10. Weld the stator core at the drilled holes. Use CO2 gas shielded arc welding with current between 170A - 190A. After welding, confirm that the hole is filled and there is no visible welding defect.
Repeat this procedure for all 4 welding points. Make sure the generator rotor shaft is horizontal and the hole being welded is in vertical direction during welding to assure sufficient fusion.
Image1.10.1