Product support program to replace generator voltage regulators producing no voltage, that are subject to high humidity on 3406C, 3456, and C18 Generator Sets. Caterpillar


Product support program to replace generator voltage regulators producing no voltage, that are subject to high humidity on 3406C, 3456, and C18 Generator Sets.

Usage:

REBE1035-01

15Sep2006
(Revised 12Dec2006)


U-633
A-618
D-601
O-615

 
Before/After
  
  

PRODUCT SUPPORT PROGRAM TO REPLACE GENERATOR VOLTAGE REGULATORS PRODUCING NO VOLTAGE, THAT ARE SUBJECT TO HIGH HUMIDITY ON 3406C, 3456, AND C18 GENERATOR SETS.

4450 4467 1410
PS42255
NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS42255" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "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 September 15, 2006 Service Letter. Changes have been made to population.


TERMINATION DATE

30Sep2007

PROBLEM

R448 voltage regulators are failing due to failure mode of high humidity/heavy fog causing no output voltage or erratic voltage. This is due to condensation/moisture settling on the AVR which is mounted at an angle near to horizontal, with condensation gathering and providing a current path between the uninsulated links on the printed circuit board and the terminals on the long side of the AVR.

AFFECTED PRODUCT

Model Identification Number
3406C C2G00127, 134-135, 137, 144, 171-173, 175, 178, 183, 185, 188, 203, 211, 215, 220, 225-227, 282-284, 286, 293-294, 300-301, 308, 333, 335-337, 339, 342, 344, 347-348, 359, 361, 373-374, 380, 382, 397, 399, 439, 458-459, 463, 539, 542-546, 548-549, 562, 564, 614, 652, 686-696, 699, 756-757, 761, 781, 813, 822, 1133, 1136-1137, 1146, 1153, 1158, 1172-1174, 1176, 1190, 1206, 1210-1211, 1215, 1218, 1226, 1230, 1251-1253, 1279, 1281-1282, 1284, 1287, 1291, 1301-1303, 1305, 1313, 1317, 1319, 1321, 1344-1345, 1348, 1350, 1352-1353, 1356-1357, 1364, 1369, 1371-1372, 1376, 1407, 1431, 1719, 1964, 2061, 2211, 2213, 2217-2218, 2221, 2369-2372, 2406, 2423-2426, 2430, 2434, 2458-2460, 2493

C5G00588-00589, 679-681, 684-691, 693-699, 703-716
3456  C1G00139, 149, 152, 166, 194, 240, 242, 292, 294, 303, 318, 338, 361, 365, 426, 464, 495, 512, 514, 561, 564, 924
C-18  G4C00119-00121, 131-132, 135, 231, 240, 243, 276-277, 284, 415, 557, 568, 581, 599, 601, 609, 611, 613, 617, 686, 696, 783, 859, 864, 1055, 1065, 1079, 1088, 1096, 1101

PARTS NEEDED

Qty

Part Number Description
1 2894769 REGULATOR-AUTO V

ACTION REQUIRED

Please refer to the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
0-6000 hrs,
0-24 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 1.0-hour job



PARTS DISPOSITION

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


Rework Procedure


 
1. Record Generator serial No. in standard warranty claim.

2. Isolate Genset before being any work starts on the unit, activate emergency stop, open Genset breaker and disconnect battery cables.

3. Tools & Equipment.
a. Socket driver
b. 10mm socket
c. 5/16? socket

4. Check Generator plate for Generator model. Only continue if the Generator model is LC6. Record the Generator Serial Number. see Image 1.1.1
Image1.1.1
 
5. Remove AVR access plate on the right hand side of the generator terminal box Image 1.2.1 using the 10mm socket & driver.
Image1.2.1
 
6. Check if the AVR is 242-3958. 242-3958 has no insulation on the links

7. New AVR 289-4769 has insulation on the links see Image 1.3.1.
Image1.3.1
 
8. Disconnect cables from voltage regulator 242-3958 and remove 4 mounting bolts using 5/16? socket and driver.

9. Use the 4 mounting bolts to mount new voltage regulator 289-4769 in the same position.

10. Use Schematic 239-5745 to reconnect cable to new voltage regulator 289-4769. If a 3 phase sensing unit is fitted use Schematic 244-5866 instead.

11. Set up new voltage regulator 289-4769 for correct frequency note A on Schematic. Cut link ST9 if PMG kit is fitted. Cut link ST1 if a 3 phase sensing unit is fitted.

12. Clear generator area, reconnect batteries, and release emergency stop and clear emergency stop fault code.

13. Start up Genset and setup new voltage regulator 289-4769 for correct voltage using volts adjusts pot P2.

14. Isolate Genset and reinstall AVR access plate.
 
 

Caterpillar Information System:

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