PLATE 9V4484 - Caterpillar

Caterpillar: Confidential Yellow
This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS5474" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
This Revised Service Letter replaces the August 7, 1998 Service Letter. Changes have been made to the TERMINATION DATE and Parts Needed.
Termination Date
August 31, 2003Problem
Some stators used in SR4 generators operating in EPG packages with 3516 Gas Engines may provide shorter service life than expected. Premature wear of the stator end turn winding insulation may occur.
Affected Product
Model & Identification Number
G3516 (3RC380, 3RC443, 3RC621, 3RC622, 3RC634, 3RC636, 3RC637, 3RC639, 3RC645, 3RC714, 3RC738, 3RC753, 3RC755, 3RC760, 3RC761, 3RC766-774, 3RC776, 3RC778-781, 3RC791, 3RC793-795, 3RC801, 3RC805, 3RC810, 3RC831-834, 3RC836, 3RC837, 3RC839, 3RC843-844, 3RC875, 3RC877, 3RC883, 3RC887, 3RC897, 3RC972, 3RC993, 3RC1010-1012, 3RC1033, 3RC1042-1044, 3RC1066-1067, 3RC1079, 3RC1088, 3RC1093, 3RC1108-1109, 3RC1112-1113, 3RC1116, 3RC1120-1123, 3RC1127-1130, 3RC1133, 3RC1135-1138, 3RC1140-1142, )
G3516 (4EK14-025, 4EK31, 4EK35-49, 4EK51-55, 4EK57, 4EK59, 4EK61-62, 4EK64-65, 4EK80, 4EK87-88, 4EK101, 4EK111-112, 4EK114, 4EK116-117, 4EK120, 4EK139, 4EK141-142, 4EK147, 4EK149, 4EK153, 4EK155, 4EK158-163, 4EK165-168, 4EK170-174, 4EK182, 4EK190, 4EK195, 4EK197, 4EK203, 4EK205-208, 4EK231, 4EK236-2374EK240, 4EK245, 4EK 248, 4EK253, 4EK258-2594EK263, 4EK267, 4EK269, 4EK271, 4EK277-2784EK281, 4EK302-3064EK319, 4EK321-3224EK324, 4EK326, 4EK335, 4EK338-339, 4EK344, 4EK347-348 4EK353-3564EK358, 4EK364, 4EK366, 4EK370-3714EK373-3744EK377-379, 4EK382-383, 4EK385-386, 4EK390, 4EK392, 4EK404, 4EK406, 4EK410, 4EK412, 4EK420-421, 4EK423, 4EK443 , 4EK446, 4EK448, 4EK450-451, 4EK458, 4EK471-473, 4EK485-487, 4EK489, 4EK503-509, 4EK511, 4EK517, 4EK521, 4EK532, 4EK534, 4EK538-539, 4EK542-543, 4EK549, 4EK559, 4EK571-572, 4EK574, 4EK576, 4EK581-582, 4EK586, 4EK616, 4EK621, 4EK701-703, 4EK712, 4EK739, 4EK742, 4EK750, 4EK753, 4EK758, 4EK767, 4EK769, 4EK780, 4EK782-783, 4EK789, 4EK791)
Parts Needed
1 - 1712104 Stator As.Action Required
This program only applies to generator stator end turn failures as described below. If the stator failure does not meet this description, this program does not apply. Also, thisprogram does not apply to any generator that has been rewound.
Failure Description: The failure originates in the end turns of the main stator windings.The most significant damage, a void probably in the shape of a cup, is usually centered on the end turn, midway between the end of the tape wrapped around the bundle of individual wires and the end of the slot that the wire bundle comes out of. A failure destroys the actual location of the failure, but the center of the damage can typically be approximated. There will be additional damage in other locations. Due to the high current at the time of failure, windings in the slot are occasionally vaporized.Secondary winding failures may also occur at other end turns of the same coil, but the damage is significantly less in those locations.
Replace the stator assembly using SENR3985 as a guide. Remove the generator rotor assembly and install into new stator assembly. Install rotor assembly and connect generator connections according to service manual procedures. Perform generator alignment on unit as referenced in Service Manual SENR3985. Reference materials include, Special Instructions SMHS7259 and SEHS7654.
Service Claim Allowances
This is a 18-hour job.
Record generator serial number