Failures of the 5N-5692 Charging Alternator Gp on Certain 3500 Electric Power Generation (EPG) Engines{1405} Caterpillar

Electric Power Generation:

3512 (S/N: ZAF1-UP)

3512B (S/N: ZAJ1-UP)

3516C (S/N: SBK1-UP)

Engine:

3508 (S/N: ZAB1-UP)

3512 (S/N: YBA1-UP; YAK1-UP; 6WW1-UP; YAX1-UP; JM21-UP)

3512B (S/N: YBB1-UP; YBC1-UP; BLF1-UP; YAM1-UP; YAN1-UP; YAY1-UP; YAZ1-UP; JM31-UP)

3512C (S/N: YBD1-UP; SBG1-UP)

3516 (S/N: YAL1-UP; ZBL1-UP)

3516B (S/N: JCH1-UP; JCN1-UP; YAP1-UP; ZBP1-UP; PBR1-UP; YAR1-UP; ZAR1-UP; ZBR1-UP; YAW1-UP; 8NW1-UP)

3516C (S/N: SBJ1-UP; SFJ1-UP; SEK1-UP)

Introduction

The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.

Problem

Engine vibration on EPG applications contributes to early hour failures of the 5N-5692 Charging Alternator Gp .

Solution

Replace the 5N-5692 Charging Alternator Gp with a 169-3345 Charging Alternator Gp if a failure is experienced. Refer to the procedure below to install the 169-3345 Charging Alternator Gp .

Safety Section

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Personal injury can result from failure to disconnect the battery. First, disconnect the negative battery cable. Then, disconnect the positive battery cable. A positive power lead can cause sparks if the battery is not disconnected. Sparks can possibly result in battery explosion or fire.

Replacement Procedure

1. Disconnect the wiring, remove the belt from the pulley, and remove the current 5N-5692 Charging Alternator Gp .

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Illustration 1	g03862118
(1) Existing spacers (2) 268-5727 Plate As

2. Retain the belt, belt guard, and mounting fasteners for reinstallation. Remove the plate assembly (2) and spacers (1) and discard.

3. Install two 9V-4924 Spacers in place of spacers (1) .

4. Install the 7E-4839 Pulley onto the new 169-3345 Charging Alternator Gp .

   Note: Do not attempt to install the 7E-4839 Pulley with a hammer. Refer to Testing and Adjusting, RENR9363, "Alternator Regulator" for pulley tightening information.

   Using a M8 allen head tool to hold the alternator shaft, torque for pulley nut to ... 127 ± 10 N·m (94 ± 7 lb ft)

5. Install the new 169-3345 Charging Alternator Gp using the retained belt, belt guard, and mounting fasteners.

   ReferenceRefer to Operation and Maintenance Manual, SEBU8479 for the correct belt tension.

6. Replace the current "Battery +" terminal end on the harness with the provided 3T-4692 Ring Terminal for a 6 gauge wire or the 3T-4688 Ring Terminal for a 4 gauge wire.

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Illustration 2	g03862141
(3) "Ground -" terminal (4) "Battery +" terminal

7. Install the new "Battery +" terminal end onto the positive post on the alternator. Refer to Illustration 2.

   Torque for the "Battery +" terminal nut ... 18.2 ± 2.4 N·m (13.5 ± 1.75 lb ft)

8. Replace the current "Ground -" terminal end on the harness with the provided 2L-8050 Ring Terminal .

9. Install the new "Ground -" terminal end onto the ground post on the alternator. Refer to Illustration 2.

   Torque for the "Ground -" terminal nut ... 4.4 ± 1 N·m (39 ± 9 lb in)