Reman Alternator Failures {1405} Caterpillar

Landfill Compactor:

816F (S/N:: BMR1-UP)

836G (S/N:: BRL1-UP; 7MZ1-UP)

Soil Compactor:

815F (S/N:: BKL1-UP)

Engine:

3126B (S/N:: BEJ1-UP; DCS1-UP)

3408 (S/N:: 67U1-11134)

3408B (S/N:: 67U11135-16070)

3408C (S/N:: 67U16071-UP)

C-10 (S/N:: BCX1-UP)

C-12 (S/N:: BDL1-UP)

C-9 (S/N:: CLJ1-UP)

Excavator:

325C (S/N:: CRB1-UP)

330B (S/N:: 3YR1-UP)

345B (S/N:: 7KS1-UP)

350L (S/N:: 9FL1-UP)

365B Series II (S/N:: JMB1-UP; PEG1-UP; DER1-UP)

365B (S/N:: CTY1-UP; 9PZ1-UP)

365BL (S/N:: 9TZ1-UP)

Integrated Toolcarrier:

IT38G (S/N:: 7BS1-UP)

IT62G (S/N:: AKP1-UP)

Track-Type Loader:

953B (S/N:: 5MK1-UP)

953C (S/N:: 2ZN1-UP)

963B (S/N:: 9BL1-UP)

963C (S/N:: 2DS1-UP)

973 (S/N:: 86G1-UP)

973C (S/N:: 3RZ1-UP)

Track-Type Tractor:

D11R (S/N:: AAF1-UP; 7PZ1-UP)

D5M (S/N:: 6GN1-UP; 3CR1-UP; 4BR1-UP; 5ES1-UP)

D5N (S/N:: AKD1-UP; AGG1-UP; CFH1-UP)

D6M (S/N:: 2RN1-UP; 3WN1-UP; 4JN1-UP; 5WR1-UP; 6LR1-UP; 4HS1-UP)

D6N (S/N:: CBF1-UP; ALH1-UP; CBJ1-UP; CCK1-UP; AKM1-UP; ALR1-UP; ALY1-UP)

D6R Series II (S/N:: ADE1-UP; AFM1-UP; AAX1-UP; BMY1-UP)

D6R (S/N:: 8TM1-UP; 9BM1-UP; 4MN1-UP; 5LN1-UP; 8LN1-UP; 9PN1-UP; 4TR1-UP; 5RR1-UP)

D7R (S/N:: ABJ1-UP; AGN1-UP; 2EN1-UP; 5MR1-UP)

D8R (S/N:: 9EM1-UP)

D9R (S/N:: ABK1-UP; ACL1-UP)

Underground Articulated Truck:

AD55 (S/N:: ANW1-UP; DNW1-UP)

Wheel Dozer:

834G (S/N:: BPC1-UP; 6GZ1-UP)

Wheel Loader:

938G (S/N:: 4YS1-UP; 6WS1-UP)

950G Series II (S/N:: AYL1-UP; AXX1-UP)

950G (S/N:: 2JS1-UP; 4BS1-UP; 3JW1-UP; 5FW1-UP; 5MW1-UP)

962G (S/N:: 3BS1-UP; 4PW1-UP; 7BW1-UP)

966F Series II (S/N:: 9YJ1-UP; 1SL1-UP)

966G Series II (S/N:: AXJ1-UP; AWY1-UP)

966G (S/N:: 3ZS1-UP; 9RS1-UP; 3PW1-UP; 3SW1-UP)

970F (S/N:: 7SK1-UP)

972G Series II (S/N:: AXC1-UP; AXN1-UP)

972G (S/N:: 7LS1-UP; AAW1-UP; 1EW1-UP; 4WW1-UP)

980F Series II (S/N:: 4RN1-UP; 8JN1-UP)

980F (S/N:: 3HK1-UP)

980G Series II (S/N:: AWH1-UP)

980G (S/N:: 9CM1-UP; 2KR1-UP; 2SR1-UP)

988G (S/N:: BNH1-UP; 2TW1-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

The Reman alternators that are used in various Caterpillar Machines and Engines have an unacceptable rate of early hour failures. Dealers are reporting the following problems with the alternators:

• No charging

• Undercharging

• Stopped charging

A project team is involved with Project 40979, 56062 and 94246. The project team has been working with the supplier in order to further investigate the root causes of the alternator failures. Also, the teams are working in order to identify the responsibilities of Caterpillar and the supplier for the failures.

Once the responsibilities are determined, the corrective actions will be taken. These corrective actions are being identified, and the corrective actions are being documented in the supplier's processes. This will ensure that the future parts show a significant improvement in quality.

Table 1 shows the alternators that are experiencing early hour failure.

Illustration 1	g01229495
Identification tag for Reman alternators (1) Date code

Check the date code on the identification plate for the proper replacement of the faulty alternator. See the list below.

• The Reman date code for the improved 21SI alternators is 05 D01.

• The Reman date code for the improved 26SI alternators start at 05 J 01

• The Reman date code for the improved 34SI alternators is 04 M 01.

The 05 represents 2005. The J represents the month A-M (minus I). The 01 is the day of manufacture. For example, 05J-01 is 01September 2005.

Solution

Replace the failed alternator.