PRODUCT SUPPORT PROGRAM FOR REWORKING THE 299-5886 SUPPORT PLATE FOR THE VOLTAGE REGULATOR ON CERTAIN C2.2, C3.3, C4.4, AND C6.6 POWERED GENSETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE 299-5886 SUPPORT PLATE FOR THE VOLTAGE REGULATOR ON CERTAIN C2.2, C3.3, C4.4, AND C6.6 POWERED GENSETS

Usage:

REBE6203-00

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27Oct2010

U-433

A-352

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE 2995886/">299-5886 SUPPORT PLATE FOR THE VOLTAGE REGULATOR ON CERTAIN C2.2, C3.3, C4.4, AND C6.6 POWERED GENSETS
4467		PS43181

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NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS43181" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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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.

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TERMINATION DATE

31Oct2011

PROBLEM

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The existing 2995886/">299-5886 Support Plate for the R438 Voltage Regulator can rub against the internal wiring on generators on certain C2.2, C3.3, C4.4, and C6.6 powered gensets. The position of the existing 2995886/">299-5886 Support Plate can cause it to rub through the insulation of the generator windings and cause them to short out.

AFFECTED PRODUCT

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Model	Identification Number
C3.3	N3C00514, 527-528, 538, 546, 575, 581-582
C4.4	D4B00412, 415, 418, 420, 423, 426, 431, 448, 458, 462-463, 465-466, 468-470, 472, 474-476, 481-482, 487, 490, 510, 512, 521, 523-524, 532, 536, 539, 554, 557-558, 560, 562-563, 567-568, 571, 577, 583-584, 597, 601, 606, 609, 667, 669, 671, 673-676, 690, 693, 696-697, 700, 706-709, 712, 715, 719, 729-730, 737, 744-745, 754, 762-765, 767, 769, 771-773, 777-780, 783, 785-786, 789-790, 798, 800, 802-803, 805-806, 808-811, 814, 819, 821-823, 825, 830-834, 837-838, 841, 843, 850, 852-856, 858, 861-862, 865, 867-876, 880-888, 890, 892-895, 898-899, 903-904, 907-908, 911-912, 914-915, 918, 924-925, 927, 932-933, 936, 942, 945, 947, 953, 956-958, 980-982, 984, 988, 991-994, 998-1000, 1005, 1007-1008, 1010-1013, 1016, 1018, 1025, 1028-1029, 1033, 1035, 1039-1040, 1042-1043, 1051, 1053, 1064-1065, 1068-1069, 1072-1074, 1076, 1080, 1084, 1088-1089, 1092-1093, 1097, 1102, 1106-1109, 1116-1118, 1124, 1130-1131, 1133, 1137-1139, 1149-1150, 1156, 1158-1159, 1162-1164, 1170, 1172, 1180, 1186-1188, 1192, 1198-1199, 1318-1320, 1322, 1325, 1327-1328, 1330, 1343, 1345-1346, 1356, 1363, 1371, 1383-1384, 1392, 1395, 1399, 1402-1403, 1405-1409, 1413, 1416, 1509, 1513, 1520, 1523, 1535-1538, 1574-1575, 1580-1581, 1588, 1593, 1599 GLD00134, 141, 143-144, 147-148, 151-167, 170-173, 180-181, 185, 189, 193-194, 197-198, 204, 211, 216, 221, 227-231, 235, 237-239, 293-294, 308, 311, 313-314, 323-324, 330-332, 338, 343-344, 346-349, 355, 362, 376-377, 380, 384, 387-388, 391-392, 396-397, 402, 405, 408-410 N4D00730-00734, 736-738, 740, 1002-1004, 1007, 1010-1011, 1029, 1035, 1052-1054, 1060, 1063-1064, 1067, 1070-1073, 1088-1089, 1091, 1094-1095, 1116, 1141, 1145, 1161-1162
C6.6	N6D00277-00278, 281, 290, 293-294, 296, 402, 415, 418, 424-425, 428, 430, 433-435, 438, 440, 442, 445-447, 454, 457, 461, 464, 466, 472-473, 481-483, 487, 491, 493, 495-496, 600-602, 604-607, 610, 617, 625, 627, 632-633, 635-637, 639, 643, 645, 650, 657-659, 663, 686-687, 691-693, 695-698, 702, 704, 710, 712-713, 715-716, 718, 722, 724-725, 730, 735-736, 743-744, 746, 749, 755, 763, 771, 776-777, 782-784, 791-794, 796, 805, 810-811, 813-814, 821-825, 830-831, 833, 835, 838, 845, 849-851, 853-854, 859-861, 866-867, 881, 885, 887-888, 890, 893, 902, 905, 909, 919-921, 928, 947, 949-950, 953, 958-961, 970, 976, 982, 984, 992-993, 995-997, 1005, 1007, 1009, 1013, 1019, 1030, 1033, 1035, 1037, 1039, 1041-1045, 1053, 1057-1058, 1061, 1065, 1071, 1074, 1083-1084, 1100, 1106, 1111-1112, 1114, 1117-1119, 1137, 1147, 1149-1150, 1152, 1160-1162, 1164, 1168-1169, 1171, 1173-1174, 1176, 1178-1179, 1186-1188, 1190, 1195, 1199-1200, 1214, 1222, 1227-1228, 1230-1234, 1236, 1239, 1241, 1246, 1254, 1256, 1262, 1269, 1272, 1275, 1287, 1305-1306, 1309, 1316, 1326, 1351, 1368, 1371-1373, 1376, 1383-1384, 1386, 1398, 1410-1413, 1420, 1422, 1435-1437, 1447, 1455, 1468, 1475-1477, 1480, 1493, 1499

PARTS NEEDED

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Qty	Part Number	Description
1	2995886	PLATE-SUPPORT
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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Replace the existing 2995886/">299-5886 Support Plate for the voltage regulator with the latest revision, 2995886/">299-5886 01. Revision 01 has a different bend angle that will move the support plate away from the generator windings, and remove the risk of damage to the windings and potential failure of the generator.

Refer to the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-1000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 0.5-hour job

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PARTS DISPOSITION

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

Rework Procedure

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1. Isolate Genset before commencing any work on the unit, open Genset breaker, activate Emergency Stop, disconnect the auxiliary power supply for battery charger and heaters, and disconnect battery cables. Ensure health and safety requirements are adhered to at all times. Also, ensure proper Lock Out-Tag Out procedures are followed at all times while work is being performed on the machine. Lock out generator before commencing any type of work.

2. Disconnect the sensing (1) and volts adjust (2) wiring from the voltage regulator terminals as indicated in Image1.1.1. Take particular note of the terminal to which wire 3 is connected to for later reconnection.

Image1.1.1

3. Remove the voltage regulator support plate (1) from the generator, by removing the two M6 bolts (2) shown in Image1.2.1. Retain the fasteners for later use.

Image1.2.1

4. Remove the voltage regulator (1) from the support plate (2) as shown in Image1.3.1, by unbolting the four M5 bolts. Retain the fasteners for later use.

Image1.3.1

5. Secure the voltage regulator (1) to the replacement 2995886/">299-5886 01 Support Plate (2) shown in Image1.4.1, using the four M5 bolts washers and nuts (3) removed in Step 4. Ensure that the heads of the bolts are to the rear of the bracket.

Image1.4.1

6. Locate the voltage regulator support plate assembly (1) on the original position on the alternator as shown in Image1.5.1 and secure using the two M6 bolts (2) removed in Step 3.

Image1.5.1

7. Reconnect the sensing and voltage adjust (if fitted) wiring as shown in Image1.6.1. Wire 3 should be reconnected to the terminal noted in Step 2.

Image1.6.1

8. Reconnect the auxiliary power supply for battery charger and heaters, and reconnect battery cables. Run the genset and check for correct operation of AVR and speed adjust if fitted.