KIT-BASE 5487541 - Caterpillar

This is a 4.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS
XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999
PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING THE CHARGING ALTERNATOR ON CERTAIN C15 GENERATOR SETS.
MODELS INVOLVED - C15 GENERATOR SETS.
Dear Caterpillar Product Owner:
The charging alternator needs to be installed on the products listed below. 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 12Dec2007 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 12Dec2007 Service Letter
Rework Procedure
References:
RENR8643 Disassembly and Assembly
SENR9928 Testing and adjusting
REHS0354 Charging System Troubleshooting
1.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.
Image1.1.1
Image1.1.2
2.Remove bolts (1). Remove fan guard (2).
Image1.2.1
3.Remove bolts (3). Remove fan guard (4).
Image1.3.1
4.Loosen 4 retaining bolts on the fan pulley head. Slacken the fan belts by adjusting the tensioning bolt on the top of the pulley head shown above. Once sufficiently slack, remove all the belts. Fit the V-belt for the charging alternator loosely to the inner most, largest pulley, on the bottom arrangement.
Image1.4.1
5.Install the alternator pulley and nut (10). Tighten nut (10) to a torque of 102 +/- 7 N.m (75 +/- 5 lb ft).
6.Position bracket (8) in position on the studs. Apply Tooling (A) to the threads of the studs. Install nuts (7) and tighten nuts (7) to a torque of 70 +/- 5 N.m (52 +/- 4 lb ft).
7.Put alternator (3) in position on bracket (8) and install bolt (9).
8.Put adjustment rod (13) in position on alternator (3). Install bolt (11) and tighten bolt (11) to a torque of 88.4 +/- 6.8 N.m (65 +/- 5 lb ft).
9.Install the V-belt. Tighten the V-belt. Refer to Testing and Adjusting, "Belt Tension Chart".
10.Tighten nuts (12) to a torque of 30 +/- 15 N.m (22 +/- 11 lb ft).
Image1.5.1
11.Connect harness assembly (6) on alternator (3) . Tighten nut (5) to a torque of 6.2 +/- 0.6 N.m (55 +/- 5 lb in). Tighten bolt (4) to a torque of 2.25 +/- 0.25 N.m (20 +/- 2 lb in). (see image 1.5.1)
Image1.6.1
10.Install fan guard (4). Install bolts (3).
Image1.7.1
11.Install fan guard (2). Install bolts (1).
Image1.8.1
12.Position guard (2) and install bolts (1).
13.Clear generator area, reconnect batteries, and release emergency stop.
14.Run functional No load test on Genset.