PSP FOR INSTALLING A NEW 7C7557 VOLTAGE REGULATOR ON CERTAIN 3114, 3116, 3208, 3306, AND 3406 GENERATOR SET ENGINES (BSSB) EQU IPPED WITH A SR4 GENERATOR - PS4538 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA

PSP FOR INSTALLING A NEW 7C7557 VOLTAGE REGULATOR ON CERTAIN 3114, 3116, 3208, 3306, AND 3406 GENERATOR SET ENGINES (BSSB) EQU IPPED WITH A SR4 GENERATOR - PS4538 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA - REVISED 01/91

Usage:

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Caterpillar: Confidential Yellow

PSP FOR INSTALLING A NEW 7C7557 VOLTAGE REGULATOR ON CERTAIN 3114, 3116, 3208, 3306, AND 3406 GENERATOR SET ENGINES (BSSB) EQU IPPED WITH A SR4 GENERATOR - PS4538 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA - REVISED 01/91

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.


(Revised January 1991)
U-248
A-171
AU-157
E-152
O-190
4467   PS4538
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 "PS4538"
as Part Number, "7755" as Group Number, and "96" as Description
Code.
NOTE: This Revised Service Letter replaces the December 14, 1990
Service Letter. Changes have been made to the Action Required.

Termination Date

December 31, 1991

Problem

The 7C7557 Voltage Regulator (VR4 Type) on certain 3114, 3116, 3208, 3306,
and 3406 Generator Set Engines (BSSB) equipped with a SR4 Generator may fail
if there is not enough clearance between the resistor and potting epoxy.

Affected Product

Model Identification Number
3114* 6AF1-Up
3116* 2SG1-Up
3208* 5YF1-Up
3306* 2AJ1-Up
3406B* 4RG1-Up
* If equipped with a SR4 Generator having a 7C7557 Voltage Regulator with an
identification number between 600,000 and 603590.

Parts Needed

1 - 7C7557 Voltage Regulator

Action Required

Make a gauge from a strip of wood such as a tongue depressor. See
Illustration 1.
Use the gauge as shown in Illustration 2 to check the amount of clearance
between the epoxy and the resistor body.
If the gauge will not fit between the resistor body and the epoxy, follow the
procedures in the Service Manual to remove the existing regulator from the
generator and install a new one.
****** IMAGE: SEBE4469.01001.001
CAPTION: Dimensions For Wood Gauge
****** IMAGE: SEBE4469.01001.002
CAPTION: Epoxy Clear Of The Resistor Body
Do Not Replace The 7C7557 Voltage Regulator
****** IMAGE: SEBE4469.01001.003
CAPTION: Epoxy In Contact With The Resistor Body
Replace The 7C7557 Voltage Regulator

Service Claim Allowances

Product Caterpillar Dealer Suggested Customer Suggested
smu Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
(C/L) (Sell)
0-5000 100% 1 0 0 0 0
NOTE: This is a 1-hour job.

Parts Disposition

Any parts removed (with the exception of cores used for Caterpillar
Remanufactured parts) can be rendered useless and scrapped immediately upon
completion of the repair.