We recceived some calls about generators failing on T500's. After some research we found that the cause was improper installation of the replacement generator. Here is an outline of the Tech bulletin on the subject.
Bulletin Number: TB068 Type of Bulletin: Service Products Affected: AT5000103, AT5000104, AT5000106, and AT5000108 Dates Manufactured: All Machines Date of Notification: November 2009 Description of Bulletin This bulletin describes the proper procedure for installing the generator in a TracStar 500. Reason for Bulletin Improper installation of generator can lead to damage of the generator, the engine and other components related to the generator. Action Required • Clean all interfacing surfaces on front of flywheel and flywheel housing – Use Brake Cleaner to clean surfaces • Clean all interfacing surfaces on Tapered Stub Shaft, Adapter Flange, and Generator – Use Brake Cleaner to clean surfaces • Make sure bolts holding flywheel to crank shaft are tight – If they are loose tighten bolts in a STAR pattern and in STAGES using Torque Wrench and 9/16” Socket • Stage 1: Tighten to 20 ft*lbs • Stage 2: Tighten to 40 ft*lbs • Slide Tapered Stub Shaft onto flywheel – Make sure Stub Shaft is pressed flush against flywheel Press flush against flywheel Crank shaft bolts Clean Clean Technical Bulletin: #TB068 2 11/18/09 TracStar 500 Generator Mounting Assembly Procedure TB068 • Use (6) 5/16”-18NC x 3/4” Lg HHCS and (6) 5/16” Split Lock Washer to secure Tapered Stub Shaft to flywheel – Confirm that Stub Shaft is flush against flywheel – Tighten bolts in a STAR pattern using Torque Wrench and 1/2” Socket to 15 ft*lbs (180 in*lbs) • Slide Adaptor Flange onto flywheel housing – Make sure date stamp, on back of Adaptor Flange, is at the TOP of the Adaptor Flange when installed • See picture for details – Make sure Adaptor Flange is pressed flush against flywheel housing • Use (8) 3/8-16NC x 1-1/4” Lg HHCS, (8) 3/8”Flat Washer, and (8) 3/8” Lock Washers to secure Adaptor Flange to flyweel housing – Lock Washer should be closest to the bolt head, followed by the Flat Washer – Tighten bolts in a STAR pattern using Torque Wrench and 9/16” Socket to 30 ft*lbs (360 in*lbs) Date stamp Press flush against flywheel housing Torque bolts to 30 ft*lbs (360 in*lbs) Torque bolts to 15 ft*lbs (180 in*lbs) Technical Bulletin: #TB068 3 11/18/09 TracStar 500 Generator Mounting Assembly Procedure TB068 • Confirm Adaptor Flange is pressed flush against flywheel housing – Use .003” Feeler Gauge to confirm there are NO gaps, .003” or larger, between Adaptor Flange and flywheel housing – If a gap is found, loosen all bolts, adjust Flange, and retighten as discussed above. Once adjusted and retightened, confirm rearranged Flange is flush with flywheel housing • Apply medium Strength Thread Locker (Loctite #242 or Equivalent) to short end of (4) provided Studs – See picture for orientation • Thread short end of (4) Studs into threaded stud holes in Adapter Flange – See picture for orientation – Make sure all threads are engaged in Adapter Flange – Tighten by hand • Slide Generator (T5016004) onto (4) previously installed Studs – Make sure Generator is installed with wire on top of Generator Wires on top .003” Feeler Gauge Short end of Stud Apply Thread Locker Studs Technical Bulletin: #TB068 4 11/18/09 TracStar 500 Generator Mounting Assembly Procedure TB068 • Use (4) 5/16”-24NF Hex Nuts, (4) 5/16” Flat Washer, and (4) 5/16” Lock Washers to secure Generator to Adaptor Flange – Lock Washer should be closest to the Nut, followed by the Flat Washer • Use Torque Wrench and 1/2” Socket to tighten nuts as follows: – Tighten 1, 2, 3,4 to 4 ft*lbs (48 in*lbs) • See picture for orientation – Retighten 5 and 6 to 4 ft*lbs (48 in*lbs) • See picture for orientation • Confirm Generator is pressed flush against Adaptor Flange – Use .003” Feeler Gauge to confirm there are NO gaps, .003” or larger, between Generator and Adaptor Flange – If a gap is found, loosen all bolts, adjust Generator, and retighten as discussed above. Once adjusted and retightened, confirm rearranged Generator is flush with Adaptor Flange • Remove Generator End Cover – Use Philips Head Screw Driver to remove cover 1, 5 4 3 2, 6 Nut, Lock Washer, and Flat Washer .003” Feeler Gauge End Cover Technical Bulletin: #TB068 5 11/18/09 TracStar 500 Generator Mounting Assembly Procedure TB068 • Remove Transit Bolt and Washer and discard – Use 9/16” Wrench to remove Bolt • Place Center Stud in Table Vise • Install (1) 5/16”-24NF nut to (1) end of Center Stud – Tighten to 15 ft*lbs (180 in*lbs) using 5/16” Socket and Torque Wrench Transit Bolt Torque nut to 15 ft*lbs (180 in*lbs) Center Stud Technical Bulletin: #TB068 6 11/18/09 TracStar 500 Generator Mounting Assembly Procedure TB068 • Apply medium Strength Thread Locker (Loctite #242 or Equivalent) opposite end of Center Stud • Slide Center Stud into Generator shaft and into Tapered Stub Shaft – Tighten to 15 ft*lbs (180 in*lbs) using 5/16” Socket and Torque Wrench – See picture for details • Replace Generator End Cover – Use Philips Head Screw Driver to replace cover
|