PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE ROTOR IN THE ALTERNATOR ON CERTAIN 3116 AND 3126E TRUCK ENGINES Caterpillar


PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE ROTOR IN THE ALTERNATOR ON CERTAIN 3116 AND 3126E TRUCK ENGINES

Usage:

Information for equipment:


ELECTRICAL AND STARTING SYSTEM
ALTERNATOR GP-CHARGING

Brushless Alternators May Not Charge In Certain Conditions 1986/07/01
New Alternator Now Used{1405,7168} 1997/05/27
Repair Parts Available for Alternator R-Terminal {1405} 2000/12/01
Harness Repair of Alternator R-Terminal Connector {1405} 2000/12/01
223-9296 Alternators are Being Replaced. {1405} 2004/04/01
A New Alternator Is Now Used. {1405} 2008/10/01

Upgrading Alternators To Include An Integrated Circuit Regulator{1405, 1410} Upgrading Alternators To Include An Integrated Circuit Regulator{1405, 1410}
Charging System Troubleshooting {1406} Charging System Troubleshooting {1406}

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE ROTOR IN THE ALTERNATOR ON CERTAIN 3116 AND 3126E TRUCK ENGINES PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE ROTOR IN THE ALTERNATOR ON CERTAIN 3116 AND 3126E TRUCK ENGINES

Some 9X-7803 Alternators Were Mislabeled As 8C-6163 Some 9X-7803 Alternators Were Mislabeled As 8C-6163

Alternator<BR> 9X6796 3114 & 3116 DIESEL TRUCK ENGINES
Regulator 3114 & 3116 DIESEL TRUCK ENGINES
Alternator 30SI Series and 34SI Series Alternator
Alternator Alternator - Delco 21SI
Alternator HDB Series and M1 Series Heavy Duty Brushless Alternators
Alternator N3 Series Brushless Alternators
Alternator Alternator - Delco 27SI

General Information 30SI Series and 34SI Series Alternator
Normal Operation 30SI Series and 34SI Series Alternator
Component Description 30SI Series and 34SI Series Alternator
General Information Alternator - Delco 21SI
Component Description Alternator - Delco 21SI
Normal Operation Alternator - Delco 21SI
General Information HDB Series and M1 Series Heavy Duty Brushless Alternators
Normal Operation HDB Series and M1 Series Heavy Duty Brushless Alternators
Component Description HDB Series and M1 Series Heavy Duty Brushless Alternators
General Information N3 Series Brushless Alternators
Component Description N3 Series Brushless Alternators
Normal Operation N3 Series Brushless Alternators
General Information Alternator - Delco 27SI
Normal Operation Alternator - Delco 27SI
Component Description Alternator - Delco 27SI

REMANUFACTURED HEAVY DUTY BRUSHLESS ALTERNATORS REMANUFACTURED HEAVY DUTY BRUSHLESS ALTERNATORS

T1 Alternator Output - Test 30SI Series and 34SI Series Alternator
T2 Electrical System Current - Test 30SI Series and 34SI Series Alternator
T3 Charging System - Test 30SI Series and 34SI Series Alternator
T4 Alternator Drive System - Check 30SI Series and 34SI Series Alternator
T5 Alternator Current - Test 30SI Series and 34SI Series Alternator
T6 Residual Magnetism Restoration 30SI Series and 34SI Series Alternator
T7 Identifying Source of Current Draw - Test 30SI Series and 34SI Series Alternator
T8 Alternator Overcharging - Test 30SI Series and 34SI Series Alternator
General Information 30SI Series and 34SI Series Alternator
Initial Troubleshooting Procedure 30SI Series and 34SI Series Alternator
Component - Test 30SI Series and 34SI Series Alternator
Capacitor - Test Alternator - Delco 21SI
Diode Assembly - Test Alternator - Delco 21SI
Brush Length - Check Alternator - Delco 27SI
Field Winding - Test Alternator - Delco 21SI
Insulated Screw - Check Alternator - Delco 21SI
Rectifier - Test Alternator - Delco 21SI
Regulator - Test Alternator - Delco 21SI
Stator - Test Alternator - Delco 21SI
Residual Magnetism - Restore Alternator - Delco 21SI
Field Winding - Test HDB Series and M1 Series Heavy Duty Brushless Alternators
Capacitor - Test HDB Series and M1 Series Heavy Duty Brushless Alternators
Stator - Test HDB Series and M1 Series Heavy Duty Brushless Alternators
Rectifier - Test HDB Series and M1 Series Heavy Duty Brushless Alternators
Residual Magnetism - Restore HDB Series and M1 Series Heavy Duty Brushless Alternators
Regulator - Test HDB Series and M1 Series Heavy Duty Brushless Alternators
Field Winding - Test N3 Series Brushless Alternators
Capacitor - Test N3 Series Brushless Alternators
Rectifier - Test N3 Series Brushless Alternators
Stator - Test N3 Series Brushless Alternators
Regulator - Test N3 Series Brushless Alternators
Regulator - Test Alternator - Delco 27SI
Field Winding - Test Alternator - Delco 27SI
Stator - Test Alternator - Delco 27SI
Diode Assembly - Test Alternator - Delco 27SI
Rectifier - Test Alternator - Delco 27SI
Insulated Screw - Check Alternator - Delco 27SI
Residual Magnetism - Restore Alternator - Delco 27SI
Capacitor - Test Alternator - Delco 27SI

Alternator Charge Rate Is High 3114, 3116 and 3126 Engines
Alternator Charge Rate Is Low 3114, 3116 and 3126 Engines
Alternator Will Not Charge 3114, 3116 and 3126 Engines
Alternator Noise 3114, 3116 and 3126 Engines
General Information HDB Series and M1 Series Heavy Duty Brushless Alternators
Charging System Alternator - Delco 27SI
Charging System HDB Series and M1 Series Heavy Duty Brushless Alternators
General Information Alternator - Delco 27SI
Alternator Alternator - Delco 27SI

Alternator 3114 AND 3116 DIESEL TRUCK ENGINES
Alternator V-Belts 3114 AND 3116 DIESEL TRUCK ENGINES
Alternator - Disassemble 30SI Series and 34SI Series Alternator
Alternator - Assemble 30SI Series and 34SI Series Alternator
Alternator - Disassemble Alternator - Delco 21SI
Alternator - Assemble Alternator - Delco 21SI
Alternator - Disassemble - M1 Series Alternator (35 Amp) HDB Series and M1 Series Heavy Duty Brushless Alternators
Alternator - Assemble - M1 Series Alternator (35 Amp) HDB Series and M1 Series Heavy Duty Brushless Alternators
Alternator - Assemble - HDB Series Alternator HDB Series and M1 Series Heavy Duty Brushless Alternators
Alternator - Disassemble - HDB Series Alternator HDB Series and M1 Series Heavy Duty Brushless Alternators
Alternator - Assemble N3 Series Brushless Alternators
Alternator - Disassemble N3 Series Brushless Alternators
Alternator - Disassemble Alternator - Delco 27SI
Alternator - Assemble Alternator - Delco 27SI

New Regulator And Field Coil Assemblies Used{1410,1405} 1981/11/23
Voltage Regulator Cross Reference Chart{1410,1405} 1985/07/01
Identification Of External Terminals On Alternators{1405,1406,1400} 1987/03/23
Alternator &quot;R&quot; Terminal Wire Assembly Available For Wiring Harness Repair{1408} 1987/05/04
Alternator/Generator Output Test On The Engine{1401,1404,1405,1406} 1987/05/04
Check Alternator Output Connection Prior To Machine Delivery{1405} 1987/05/18
Remanufactured Heavy-Duty Starters And High-Amp Alternators{1405,1453} 1987/05/25
Correct Torque Value For Alternator Drive Pulley Retaining Nut Is Important{1405} 1987/11/23
8T5314 Socket Adapter Available To Correctly Install Alternator Pulley Nut {0601} 1988/01/25
New 35-Ampere Alternator Used On Some Engines In Caterpillar Equipment{1405,1406} 1979/08/13
Voltage Regulator Can Cause Variable Ammeter Indications{1410,1401,1405,1406,7467} 1979/10/22
Improved Alternator Groups Now Available{1405} 1998/05/04
Repair Parts Available for Alternator R-Terminal {1405} 2000/10/02
Harness Repair of Alternator R-Terminal Connector {1405, 1408, 7553} 2000/10/02


SEBE8891-01

August 30, 2004
(Revised September 2004)
O-217


 
Priority

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE ROTOR IN THE ALTERNATOR ON CERTAIN 3116 AND 3126E TRUCK ENGINES

1405
PI30647
NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30647" as the Part number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI30647" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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 Revised Service Letter replaces the August 30, 2004 Service Letter. Chages have been made to remove mail code TT.

COMPLETION DATE

TERMINATION DATE

February 28, 2005 August 31, 2005

PROBLEM

The rotor in the alternator needs to be replaced on certain 3116 and 3126E Truck engines. The current alternator rotor may failure, resulting in loss of battery charging.

AFFECTED PRODUCT

Model Identification Number
3116 7JL3022-3025, 3027-3029, 3031-3032, 3034-3036, 3038-3041, 3043, 3045-3048, 3050-3052, 3054-3055, 3057-3060, 3062-3064, 3066-3068, 3070-3075, 3077-3086, 3088-3092, 3094-3096, 3098, 3100-3102, 3104, 3106-3107, 3109-3112, 3114-3115, 3117-3119, 3121, 3123, 3125-3127, 3130-3132, 3136, 3138-3139, 3141-3143, 3145, 3147-3152, 3154-3157, 3159-3161, 3163-3165, 3167, 3169-3172, 3174-3197, 3199-3200, 3202-3212, 3214-3224, 3226-3228, 3230-3231, 3233-3234, 3236-3237, 3239-3240, 3242-3244, 3246-3247, 3249-3250, 3252-3253, 3255-3257, 3259-3261, 3263-3264, 3266-3267, 3269-3270, 3272-3273, 3276, 3278-3279, 3281-3282, 3284-3285, 3287-3301, 3305-3315, 3317-3320, 3323-3326, 3329-3334, 3336-3341, 3343, 3345-3369, 3373, 3376, 3378, 3380-3382, 3385-3388, 3390-3392, 3394-3395, 3397-3423, 3425-3430, 3432-3436, 3438-3442, 3444-3449, 3451-3452, 3454-3458, 3460-3465, 3467-3482, 3484-3496, 3498-3515, 3517-3524, 3526-3543, 3545-3548, 3550-3552, 3554-3558, 3560, 3562-3563, 3565-3583, 3585-3586, 3588-3614, 3616-3644, 3646-3648, 3650-3683, 3685, 3687
3126 G3E230-258, 260, 262-264, 267-271, 274, 276-280, 282, 284-289, 291-296, 299-306, 308-314, 316-317, 319-337, 339-341, 343-344, 346-350, 356, 358-363, 365-374, 376-379, 382, 386-388, 390-402, 404, 407-408, 412, 415-416, 420-421, 423, 426-427, 429-432, 434-438, 440, 442-450, 452-453, 455-456, 458-486, 488-489, 491-496

PARTS NEEDED

Qty

Part Number Description
1
2585148 ALTERNATOR KIT

ACTION REQUIRED

See the attached Rework Procedure.

OWNER NOTIFICATION

U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

Caterpillar
Dealer Suggested
Customer Suggested
Parts
Labor Hrs.
Parts
Labor Hrs.
Parts
Labor Hrs.
100%
1.0
0
0
0
0
NOTE: This is a 1.0-hour job.

NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report

PARTS DISPOSITION

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

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

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.

Caterpillar Inc.

Identification #(s)

Attached to August 30, 2004 Service Letter

Rework Procedure

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.

Illustration 1

  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.
  6. Alternator Disassembly

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

  8.  

     

    Illustration 2      Illustration 3

  9. Remove four bolts.

  10.  

     

    Illustration 4
     

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

  12.  

     

    Illustration 5
     

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

  14. Illustration 6
     

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

  16.  

     

    Illustration 7
     

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

  18. Illustration 8
     

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

  20. Illustration 9

    Drive-End Assembly

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

  22.  

     

    Illustration 10
     

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

  24. Illustration 11
     

  25. Press NEW ROTOR into bearing.

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

    Illustration 12        Illustration 13

    Brush Assembly

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

  28.  

     

    Illustration 14         Illustration 15
     

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

  30. Illustration 16         Illustration 17
     

  31. Insert second brush into upper hole.

  32.  

     

    Illustration 18
     

  33. Push pin in to retain second pin.

  34.  

     

    Illustration 19

    Alternator Assembly

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

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

    Illustration 20
     

  37. 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).

  38. Illustration 21
     

  39. 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.

  40.  

     

    Illustration 22
     

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

  42. Illustration 23
     

  43. Insert brush pin until it contacts the brush.
  44. 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.

  45. Illustration 24
     

  46. Remove the brush pin.
  47. Place reworked alternator on engine, engage bolts (3) & (6) but do not tight yet.
  48. 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).
  49. 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.
  50. Place V-belts back. Place electric connectors back according to Liaz instructions and wiring diagram attached.
  51. Tighten V-belts according to operation and maintenance manual.
  52. Tighten bolts (3) & (6) to 105 +/- 20 Nm.

Illustration 25

Illustration 26

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