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

Usage:

SEBE8891-01

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

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*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.

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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

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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

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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

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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

Loosen alternator belts; remove them from alternator pulley.
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.
Remove electrical connectors behind the alternator.
Remove suspect alternator.
Replace its rotor and bearing with 258-5148 kit according to the procedure below.

Alternator Disassembly

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

Illustration 2 Illustration 3

Remove four bolts.

Illustration 4

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

Illustration 5

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

Illustration 6

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

Illustration 7

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

Illustration 8

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

Illustration 9

Drive-End Assembly

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

Illustration 10

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

Illustration 11

Press NEW ROTOR into bearing.

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

Illustration 12 Illustration 13

Brush Assembly

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

Illustration 14 Illustration 15

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

Illustration 16 Illustration 17

Insert second brush into upper hole.

Illustration 18

Push pin in to retain second pin.

Illustration 19

Alternator Assembly

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

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

Illustration 20

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).

Illustration 21

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.

Illustration 22

Remove the pin to allow brushes to contact slip ring.

Illustration 23

Insert brush pin until it contacts the brush.
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.

Illustration 24

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