PROBLEM

AFFECTED PRODUCT

PARTS NEEDED

ACTION REQUIRED

OWNER NOTIFICATION

SERVICE CLAIM ALLOWANCES

PARTS DISPOSITION

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach. (1-Owner Notification)
        (2-Rework Procedure)

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE ALTERNATOR

MODELS INVOLVED - CERTAIN 3116 AND 3126E TRUCK ENGINES

Dear Caterpillar Product Owner:

A new rotor in the alternator needs to be installed on the products listed below. The current alternator rotor may fail, resulting in loss of battery charging. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated August 30, 2004 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Identification #(s)

Attached to August 30, 2004 Service Letter

Improved alternators can be recognized by the additional "P" letter stamped after the manufacturing date code. Alternators that do not show this "P" should have their rotor replaced.

1. Loosen alternator belts; remove them from alternator pulley.
2. Loosen alternator pulley nut using an impact air gun and holding the fan by gloved hand. Do not introduce any device inside the alternator to prevent it from spinning.
3. Remove electrical connectors behind the alternator.
4. Remove suspect alternator.
5. Replace its rotor and bearing with 258-5148 kit according to the procedure below.

Alternator Disassembly

6. Hold the shaft with a hex-wrench. Remove the shaft nut, pulley or paper tube, and fan.

 

 



Illustration 2      Illustration 3

7. Remove four bolts.

 

 



Illustration 4
 

8. Remove drive-end assembly. Brushed will spring loose from brush holder.

 

 



Illustration 5
 

9. Remove brush assemblies from holder. Wipe the assemblies clean and set aside for re-assembly.




Illustration 6
 

10. Press rotor out of drive-end frame and dispose of the rotor.

 

 



Illustration 7
 

11. Remove three bearing retainer plate screws and retainer plate from drive-end frame. Replacement parts are included in case of loss or damage.




Illustration 8
 

12. Remove bearing from drive-end frame. Light press force may be required. Dispose of bearing.




Illustration 9

Drive-End Assembly

13. Assemble NEW BEARING into drive-end frame (not oriented). Light press force (ON OUTER RACE ONLY) may be required.

 

 



Illustration 10
 

14. Assemble bearing retainer plate and three screws. Torque the screws to 4.5-5.7 Nm (40-50 lb in).




Illustration 11
 

15. Press NEW ROTOR into bearing.


NOTE: Bearing inner race must be supported and end of shaft protected.



Illustration 12        Illustration 13

Brush Assembly

16. Insert lowest brush assembly into brush holder and hold in place.

 

 



Illustration 14         Illustration 15
 

17. Insert a pin into hole in brush just far enough to hold in place.




Illustration 16         Illustration 17
 

18. Insert second brush into upper hole.

 

 



Illustration 18
 

19. Push pin in to retain second pin.

 

 



Illustration 19

Alternator Assembly

20. Align drive-end assembly with rectifier-end assembly and carefully insert rotor shaft into rectifier-end bearing.


NOTE: Align drive-end non-threaded mounting lug hole with rectifier-end frame hole without threads.



Illustration 20
 

21. Insert four bolts. Check alignment of drive-end and using a crossing pattern, as shown in picture, tighten bolts in two steps. Torque bolts to 6-7 Nm (53-62 lb in) the first pass and the second time to 10.7-11.9 Nm (95-105 lb in).




Illustration 21
 

22. Install the fan, paper tube or pulley, and nut. Hand tighten nut for a paper tube. Torque to 95-108 Nm (70-80 lb ft) if it has a pulley.

 

 



Illustration 22
 

23. Remove the pin to allow brushes to contact slip ring.




Illustration 23
 

24. Insert brush pin until it contacts the brush.
25. Being sure that the pin stays n contact with brush, apply 12 volts, from a power supply or a battery, across the alternator negative (-) terminal and the brush pin for about 2 seconds.




Illustration 24
 

26. Remove the brush pin.
27. Place reworked alternator on engine, engage bolts (3) & (6) but do not tight yet.
28. Stamp the letter "P" on the name tag after the date code with a letter stamp. This will identify alternators that have a new rotor. The date code (year, month and day) will look similar to this example (03E22P).
29. Place original alternator pulley on and tighten with impact air gun to 102 +/- 7 Nm. Hold the fan with gloved hand. Do not introduce any device inside the alternator to prevent it from spinning.
30. Place V-belts back. Place electric connectors back according to Liaz instructions and wiring diagram attached.
31. Tighten V-belts according to operation and maintenance manual.
32. Tighten bolts (3) & (6) to 105 +/- 20 Nm.

Illustration 25

Illustration 26