Product Support Program For Replacing The Alternator On Certain D20D And D250D Articulated Trucks Caterpillar

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 "PS8102" 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

Problem

The alternator on some D20D and D250D Articulated Trucks may not have sufficient output to keep the batteries charged in the application the trucks are used in. In addition, some may have current leakage causing the hour meter to run with the engine shut off.

Affected Product
Model & Identification Number

D20D (9MG1-118)

D250D (6NG1-231)

Parts Needed

1 - 3T4692 Terminal

1 - 0R3667 Alternator

Action Required

Replace the existing 5N5692 Alternator with a 0R3667 Alternator.

NOTE: Removal of the turbocharger air inlet tube and the 90° rubber hose will make the installation of the new alternator easier.

The terminal at the positive post on the alternator needs to be modified to fit the larger stud. This can be done by either of the following two methods:

A) Remove the existing terminal and replace it with a 3T4692 Terminal.

B) Drill the existing terminal to fit the .437" diameter stud. Use several increasingly larger drill bits to prevent damage to the terminal.

Service Claim Allowances

NOTE: This is a 1.5-hour job.

Parts Disposition

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.