Product Support Program For Resolving Inefficient Alternator Performance On Certain 928G Wheel Loaders And It28G Toolcarriers Caterpillar

NOTE: This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4627" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

Termination Date

Problem

Alternator performance may be inefficient on certain 928G Wheel Loaders and IT28G Toolcarriers. Machines that operate in conditions of continued use at low idle can have repetitive problems with discharged batteries due to very low alternator output. This is more prevalent on machines equipped with secondary steering (machines in Groups 1 and 2). In addition, some machines may also experience the air conditioner compressor belt loosening and/or coming off (machines in Group 2 only).

Affected Product
Model & Identification Number

Group 1

928G (7SR128-132, 7SR138, 7SR142-144, 7SR150-151, 7SR154, 7SR156, 7SR159, 7SR166, 7SR169, 7SR170, 7SR174-178, 7SR180, 7SR181, 7SR183-188, 7SR190, 7SR192-195, 7SR203-205, 7SR208, 7SR209, 7SR211, 7SR215-230, 7SR232-237, 7SR240-244, 7SR249-258, 7SR261, 7SR262, 7SR264-268, 7SR272-279, 7SR282-285, 7SR288, 7SR290-297, 7SR300-303, 7SR305-308, 7SR310-318, 7SR321, 7SR313-325, 7SR327-340, 7SR342-347, 7SR349, 7SR350, 7SR352, 7SR354-356, 7SR358, 7SR359, 7SR361, 7SR363-365, 7SR367, 7SR369, 7SR370, 7SR372, 7SR373, 7SR375, 7SR377, 7SR379, 7SR380, 7SR385, 7SR387-409, 7SR411-413, 7SR425, 7SR430, 7SR434, 7SR439-442, 7SR448, 7SR451-453, 7SR455, 7SR456, 7SR458, 7SR459, 7SR461, 7SR463, 7SR464, 7SR473, 7SR475-477, 7SR483, 7SR484, 7SR488-490, 7SR493, 7SR497, 7SR499, 7SR500, 7SR502, 7SR505, 7SR507, 7SR509-512, 7SR514, 7SR515, 7SR518, 7SR520, 7SR522-529, 7SR531, 7SR534-536, 7SR538-541, 7SR543-546, 7SR548, 7SR549, 7SR551, 7SR552, 7SR555, 7SR557-560, 7SR562, 7SR563, 7SR565, 7SR569, 7SR570, 7SR572, 7SR573, 7SR576, 7SR579, 7SR581, 7SR584, 7SR587, 7SR590, 7SR591, 7SR593, 7SR594, 7SR596-598, 7SR602, 7SR604-606, 7SR608, 7SR610, 7SR615-618, 7SR621, 7SR626, 7SR630, 7SR631, 7SR633, 7SR634, 7SR636-640, 7SR643, 7SR644, 7SR646-649, 7SR652)

IT28G (9AR137, 9AR138, 9AR142, 9AR145, 9AR146, 9AR154, 9AR155, 9AR157, 9AR158, 9AR174, 9AR179-181, 9AR183, 9AR185, 9AR186, 9AR192, 9AR194, 9AR196, 9AR198, 9AR200, 9AR202-204, 9AR207, 9AR211-213, 9AR216-226, 9AR228, 9AR230, 9AR234, 9AR235, 9AR239, 9AR242, 9AR243, 9AR246, 9AR248, 9AR249, 9AR252-257, 9AR259-266, 9AR269-279, 9AR276, 9AR279, 9AR283, 9AR285, 9AR287, 9AR288, 9AR291, 9AR294-298, 9AR300, 9AR302, 9AR310, 9AR312, 9AR319-322, 9AR324-327, 9AR330, 9AR333-335, 9AR337, 9AR338, 9AR345-348, 9AR352, 9AR353, 9AR355, 9AR356 )

Group 2

928G (7SR133-135, 7SR139-141, 7SR145-149, 7SR152, 7SR153, 7SR155, 7SR157, 7SR158, 7SR160-165, 7SR167, 7SR168, 7SR171-173, 7SR179, 7SR182, 7SR189, 7SR1917SR196-202, 7SR206, 7SR207, 7SR210, 7SR212-214, 7SR231, 7SR238, 7SR239, 7SR245-248, 7SR259, 7SR260, 7SR263, 7SR269-271, 7SR280, 7SR281, 7SR286, 7SR287, 7SR289, 7SR298, 7SR299, 7SR304, 7SR309, 7SR319, 7SR320, 7SR322, 7SR326, 7SR341, 7SR348, 7SR351, 7SR353, 7SR357, 7SR360, 7SR362, 7SR366, 7SR368, 7SR371, 7SR374, 7SR376, 7SR378, 7SR381-384, 7SR386, 7SR410, 7SR414-424, 7SR426-429, 7SR431-433, 7SR435-438, 7SR444-447, 7SR449, 7SR450, 7SR454, 7SR457, 7SR460, 7SR462, 7SR465-472, 7SR474, 7SR478-482, 7SR485-487, 7SR492, 7SR494-496, 7SR498, 7SR501, 7SR503, 7SR504, 7SR506, 7SR508, 7SR513, 7SR516, 7SR533, 7SR537, 7SR542, 7SR547, 7SR550, 7SR553, 7SR554, 7SR556, 7SR561, 7SR564, 7SR566-568, 7SR571, 7SR574, 7SR5757SR577, 7SR578, 7SR580, 7SR582, 7SR583, 7SR585, 7SR586, 7SR588, 7SR589, 7SR592, 7SR595, 7SR599-601, 7SR603, 7SR607, 7SR612-614, 7SR619, 7SR620, 7SR622-625, 7SR627-629, 7SR632, 7SR635, 7SR641, 7SR642, 7SR645, 7SR650, 7SR651, 7SR653)

IT28G (9AR139-141, 9AR143, 9AR144, 9AR147-153, 9AR156, 9AR159-173, 9AR175-178, 9AR182, 9AR184, 9AR187-191, 9AR193, 9AR195, 9AR197, 9AR199, 9AR201, 9AR205, 9AR206, 9AR208-210, 9AR214, 9AR215, 9AR227, 9AR229, 9AR231, 9AR233, 9AR236-238, 9AR240, 9AR241, 9AR244, 9AR245, 9AR247, 9AR250, 9AR251, 9AR258, 9AR267, 9AR268, 9AR271-275, 9AR277, 9AR278, 9AR280-282, 9AR284, 9AR286, 9AR289, 9AR290, 9AR292, 9AR293, 9AR299, 9AR301, 9AR303-309, 9AR311, 9AR313-318, 9AR323, 9AR328, 9AR329, 9AR331, 9AR332, 9AR336, 9AR339-344, 9AR349-351, 9AR354, 9AR357-360)

Parts Needed

Parts Needed for machines in both Group 1 and 2

1 - 7C5567 Pulley

1 - 2K4823 Washer

1 - 4N8771 Belt Set - Vee

8 - 6V5839 Washer - Hard

8 - 6V7981 Bolt

2 - 9X6485 Stud - Taper

1 - 1314748 Pulley - Crank

1 - 1478190 Collar

Additional Parts Needed for machines in Group 2 only

1 - 3E8028 Bolt - Socket

4 - 9M1974 Washer - Hard

2 - 8T4121 Washer - Plate

1 - 8T4133 Nut

2 - 6V5196 Bolt - Socket

1 - 1530689 Bracket Assembly

Action Required

See the attached Rework Procedure.

Service Claim Allowances

Parts Disposition

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

Attach.

(1-Rework Procedure)

Rework Procedure

Tools Required:

24 mm socket

16 mm socket

Torque wrench suitable for 50-55 N·m

Belt tension gauge.

Rework Procedure:

1. Switch off machine at isolator switch.

2. Loosen alternator pulley retention nut.

3. Remove alternator from mountings (do not disconnect electrical connections). Rest alternator on side of engine. Remove and discard existing Vee belt.

4. Remove and discard existing alternator pulley. Retain existing washer-spacer.

5. Fit additional 2K4823 Washer - Spacer and new 7C5567 Pulley to alternator. Tighten pulle locknut to 50 ± 5 N·m (37 ± 3.5 ft lbs).

NOTE: A drive key is not required in the pulley shaft.

6. Remove 8 bolts from damper assembly on engine. Remove existing alternator drive pulley and existing damper assembly.

7. Install two 9X6485 Locating Studs, diagonally opposite, for assistance in new pulley and damper location - using 2-3 threads only, of standard thread end.

8. Install new 1314748 Pulley, existing 7C1631 Damper Assembly and new 1478190 Collar, using six new 6V7981 Bolts and six 6V5839 Washers. Do not tighten bolts.

9. Remove the two locating studs and discard.

10. Fit the remaining two 6V7981 Bolts and 6V5839 Washers, and tighten all 8 bolts to 55 ± 10 N·m (40 ± 7 ft lbs) in sequence.

11. Reinstall alternator to mounting. Install new 4N8771 Vee-belt set and tension belts to 120 ± 5 lbs (534 ± 22 N), and tighten alternator mounting bolts to 55 ± 10 N·m (40 ± 7 ft lbs).

12. Recheck alternator pulley retention locknut torque: 50 ± 5 N·m (37 ± 3.5 ft lbs)

Additional rework for machines in Group 2 only

Tools Required:

6 mm hex socket wrench

8 mm hex socket wrench

16 mm socket wrench

Torque wrench suitable for 28 N·m and 55 N·m

Vee belt tension gauge

Sharp knife

Rework Procedure:

1. Switch off machine at isolator switch.

2. Loosen air conditioner compressor from mounting. keep original Vee-belt.

3. On machines equipped with sound suppression remove suppression material from engine valve cover. Remove compressor bottom (long) mounting bolt and hardware and discard.

4. Remove the appropriate two inlet manifold hex bolts and washers and discard. Install 1530689 Bracket Assembly at the two hole mounting face using two 6V5196 Hex Socket Head Bolts and four 9M1974 Washers (two washers under each bolt head). do not fully tighten bolts. If engine sound suppression is fitted, reinstall after making cut-outs in the insulation material to clear the bracket and mountings.

5. Install the longer 3E8028 Hex Socket Head Bolt first through the boss mounting end of 1530689 Bracket, then through the compressor mounting lugs, and through the existing cast mounting bracket with one 8T4121 Washer under bolt head and then install one 8T4121 Washer and 8T4133 Nut. Do not fully tighten.

6. Tighten the two 6V5196 Bracket Mounting Bolts to 28 ± 7 N·m (21 ± 5 ft lbs).

7. Reinstall existing compressor vee belt and tension this "used" belt to 445 ± 44 N (100 ± 10 lb).

NOTE: Should it be found necessary to replace the Vee belt at this time, when installing the new 1W9693 Belt - tension to 712 ± 22 N (160 ± 5 lb).

8. Tighten all compressor mounting bolts and nuts to 55 ± 10 N·m (40 ± 7 ft lbs).