MULTIPLE CYLINDER HEAD 6V8032 - Caterpillar

Electric Power Generation:
G3520C (S/N: CWW1-UP; CWY1-UP)
SR4 (S/N: 5KA1-UP; 5NA1-UP; 6AA1-UP; 6FA1-UP; 9AB1-UP)
Engine:
3208 (S/N: 29A1-UP; 30A1-UP; 5YF1-UP)
3304 (S/N: 5CA1-UP; 83Z1-UP)
3304B (S/N: DED1-UP; 2KK1-UP; 9HK1-UP)
3306 (S/N: 85Z1-UP)
3306B (S/N: EFA1-UP; B8D1-UP; 1CZ1-UP; 2AJ1-UP; 8JJ1-UP; 8NS1-UP; 9DS1-UP; 9NR1-UP)
3406 (S/N: 75Z1-UP)
3406B (S/N: 2WB1-11475; 4JK1-98; 4PM1-UP; 4RG1-1501)
3406C (S/N: KPS1-UP; PFH1-UP; 1DZ1-UP; 1LS1-UP; 2WB11476-UP; 4JK99-UP; 4RG1502-UP; 4ZR1-UP; 8FS1-UP; 9ES1-UP)
3406E (S/N: 8AZ1-UP; 9NN1-UP)
3408 (S/N: 78Z1-1143)
3408B (S/N: 2BG1-UP; 78Z1144-UP)
3412 (S/N: 1EZ1-UP; 2WJ1-UP; 3FZ1-UP; 4BZ1-UP; 81Z1-14500)
3412C (S/N: BAK1-UP; BAX1-UP; BCW1-UP; 2SZ1-UP; 5FL1-UP; 81Z14501-UP; 9EP1-UP)
3456 (S/N: BGA1-UP; CAH1-UP; CBX1-UP; CCB1-UP; EPE1-UP; GHJ1-UP)
3508 (S/N: CAW1-UP; CNF1-UP; PTK1-UP; 1JZ1-UP; 1ZF1-UP; 23Z1-UP; 3LS1-UP; 5XM1-UP; 5PW1-UP; 70Z1-UP)
3508B (S/N: BGX1-UP; CNB1-UP; PTN1-UP; 1FZ1-UP; 2HW1-UP; 4GM1-UP; 5KW1-UP; 6PN1-UP)
3512 (S/N: CMJ1-UP; FDR1-UP; PTG1-UP; PTH1-UP; 1KZ1-UP; 24Z1-UP; 3MS1-UP; 3WS1-UP; 3YF1-UP; 6PM1-UP; 6WW1-UP; 67Z1-UP)
3512B (S/N: BLF1-UP; BRK1-UP; CMC1-UP; FDE1-UP; PTF1-UP; PTM1-UP; 1GZ1-UP; 4AW1-UP; 5AW1-UP; 6GW1-UP; 6WN1-UP; 8RM1-UP)
3516 (S/N: CAL1-UP; CMD1-UP; 1LZ1-UP; 2TS1-UP; 25Z1-UP; 3JS1-UP; 3NS1-UP; 4XF1-UP; 5SJ1-UP; 6CL1-UP; 7KM1-UP; 73Z1-UP; 8TW1-UP)
3516B (S/N: BMB1-UP; BPJ1-UP; CPA1-UP; FDN1-UP; FDX1-UP; PPS1-UP; 1HZ1-UP; 1NW1-UP; 2JW1-UP; 6HN1-UP; 7RN1-UP; 8NW1-UP)
G3306 (S/N: CNR1-UP)
G3406 (S/N: KAR1-UP)
G3412 (S/N: KAP1-UP)
G3508 (S/N: CPJ1-UP; CPS1-UP; CPY1-UP)
G3512 (S/N: CRN1-UP; CSP1-UP)
G3516 (S/N: CSZ1-UP)
G3516B (S/N: CEY1-UP; CME1-UP; CSC1-UP)
G3520B (S/N: BGW1-UP; CWD1-UP)
Power Module:
PM3412 (S/N: CAJ1-UP)
PM3456 (S/N: B3G1-UP)
PM3508 (S/N: BLM1-UP)
PM3512 (S/N: BNR1-UP; BRF1-UP)
PM3516 (S/N: BPD1-UP; CAC1-UP)
PMG3516 (S/N: CFD1-UP)
Illustration 1 g01025538
Problem Description
An intermittent voltage sensing or an intermittent voltage adjust circuit can lead to above-normal generator output voltage and VR3 voltage regulator failure. An intermittent circuit can be caused by the following:
Loose terminations
Improper terminal crimps
Poor solder jointsImprovement Actions
Terminations
A secure termination can be better assured by placing one 5H-6555 Lockwasher beneath every wire terminal that is used for your specific application. The 5H-6555 Lockwasher must be placed between the voltage regulator terminal pad and the wire terminal. Do NOT place the 5H-6555 Lockwasher directly under the screw. Refer to Illustration 1.Terminal Crimps
Insulated crimp-on wire terminals should be inspected for proper installation. Visually confirm that the wire insulation is properly stripped and that the crimp is made around bare wire only. No wire insulation should be seen within the crimp area. A gentle pull test will confirm that the terminal is effectively crimped on the wire. Refer to Illustration 1.Replace the terminal if the terminal is improperly crimped, discolored, or corroded. If the terminal is discolored or corroded, determine and eliminate the root cause of the discoloration or corrosion. To replace the terminal, use a crimp tool and follow the installation process recommended by the terminal manufacturer. Note: If the wire is found to be damaged, replace the entire wire from termination to termination. In-line splices are NOT recommended.Use only locking-fork terminals or ring-style terminals. Size the terminals according to the wires on which they will be installed and the size of the screws that will be used. When possible, use non-insulated terminals. Non-insulated terminals give the technician an opportunity to visually inspect the crimp. Use heat shrink tubing to provide insulation and additional strain relief to the termination. When insulating with heat shrink tubing, perform the following steps.
Use properly-sized heat shrink tubing.
Place the heat shrink tubing on the wire before crimping the terminal. The heat shrink tubing