CMPAK-ZONG (0193-LARKANA)

FLYWHEEL HOUSING DAMAGE

Equipment Details:
Genset Model C28D5 Genset Sr. No G18R144156 Engine Model X2.5-G2 Engine Sr. No. H20416 Engine Hours 1999.0

Complain:
Customer complains that genset flywheel housing found damage once again.

Site History:
As per service team observation on site @ June 30 2019 (engine hours: 1701), flywheel housing found cracked from multiple points
initially it is difficult to find out the reason behind that failure. We cannibalize the part from OES Yard (ESN: J95466) to rectify the issue
on site and the issue resolved, but unfortunately on September 10, 2019 (engine hours: 1999.0) customer complains that genset flywheel
housing damage once again along with oil leakages. Complete case reported to TSD for analysis and as the new modified flywheel housing
is not available in stock (TSB190123) Service team once again cannibalize the flywheel housing (0104-2117) from OES Yard (J94624) and
visit to the site on (October 12, 2019) measure all the readings which consider mandatory and replace flywheel housing once again.

Troubleshooting:
September 25, 2019
Service team reached to the site and found that flywheel housing damage once again. Taken pictures to root cause failure identification
October 12, 2019
As per our diagnosis previously, service team cannibalize the Flywheel housing (0104-2117) from OES Yard (C22D5; X2.5-G2 / J94624)
on October 11, 2019 (FSR #: 097677) and move with part on the next date to the effected site.

Reached at site remove old flywheel housing and inspect it (completely cracked). Install new cannibalized flywheel housing (0104-2117)
on October 12, 2019 and then run the genset on load, everything found normal and there is no additional abnormality observe on that
time.

Measure the readings as per TSB190123, record vibration data (off-load and on-load) and all dimensions which required at the time of
flywheel housing.

Conclusion:
A TSB is launched from CUMMINS “TSB190123, Date: August 20, 2019” as some modification recommended by CUMMINS. A complete
kit modified flywheel housing (0104-2117) and Allen Screw (Plate, Adaptor – A044Y202)] is required to resolve the issue as per TSB.

Vibration Measurement Locations:

Point No. Locations Point No. Locations

1 Engine Cylinder Block Top- Flywheel Side 5 Engine Alternator Coupling Adaptor top location
2 Engine Cylinder Block Top- Radiator Side 6 Alternator Non-Drive End
3 Engine Mounting Bracket 7 Not Applicable
4 Not Applicable 8 Alternator Mounting Bracket

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FLYWHEEL HOUSING DAMAGE
Location 1 & 2

Location 3: Location 5:

Location 6: Location 8:

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FLYWHEEL HOUSING DAMAGE

At 50% load At No Load

Vibration Vibration
Position Position
Velocity (mm/s) Velocity (mm/s)
1 19.0 1 17.0
2 22.0 2 14.0
LHS: 18.0 LHS: 20.0
3 3
RHS: 20.0 RHS: 18.0
5 16.0 5 16.0
6 55.0 6 54.0
LHS: 29.0 LHS: 26.0
8 8
RHS: 29.0 RHS: 30.0

Flywheel Housing measurement:

FACE TIR OF FLYWHEEL HOUSING: FACE TIR OF FLYYWHEEL:
S No. Locations mm S No. Locations Mm
1. Location 12 o’clock 0.0 1. Location 12 o’clock 0.0
1. Location 03 o’clock 0.10 2. Location 03 o’clock 0.19
2. Location 06 o’clock 0.60 3. Location 06 o’clock 0.48
3. Location 09 o’clock 0.36 4. Location 09 o’clock 0.23
4. Minimum Observed 0.0 5. Minimum Observed 0.0
5. Maximum Observed 0.60 6. Maximum Observed 0.48

AVM MOUNTING SUBBASE PAD HEIGHTS AVM Compressed Height

S No. Locations mm S No. Locations Mm
1. AVM mounting Pad Height - Engine Right 30.0 1. Engine AVM Right Side 67.0
2. AVM mounting Pad Height - Engine Left 30.0 2. Engine AVM Left Side 66.0
3. AVM mounting Pad Height - Alternator Right 30.0 3. Alternator AVM Right Side 65.0
4. AVM mounting Pad Height - Alternator Left 30.0 4. Alternator AVM Left Side 65.5

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FLYWHEEL HOUSING DAMAGE
Supporting Pictures:
October 12, 2019

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FLYWHEEL HOUSING DAMAGE

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FLYWHEEL HOUSING DAMAGE

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