86310 Mercury SPRING, RETURN - LEVER AND ARM SCREW

26Mar2009
U-124
A-110
O-107
Before/After
PRODUCT SUPPORT PROGRAM FOR REWORKING THE CHARGING ALTERNATOR, B+ OUTPUT, HARNESS TERMINAL ON CERTAIN C6.6 ENGINES
1405 PS42904
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 "PS42904" as the Part Numberand "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.
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.
TERMINATION DATE
31Mar2011
PROBLEM
The factory removes the nut from the alternator B+ terminal stud during installation of the harness terminal on the stud. The spacer that is located below the nut may become improperly seated during harness installation and result in a poor connection between the regulator and the plate to which the B+ stud is connected. Image1 shows an improperly seated spacer.
The B+ assembly requires proper seating of the spacer in order to maintain a good connection between the regulator and plate to which the B+ stud is connected. Loosening of the B+ nut can result in a poor connection between the regulator and the plate to which the B+ stud is connected.
A poor connection between the regulator and the plate to which the B+ stud is connected can result in intermittent, high, low, or NO output from the battery charging alternator and further result in a discharged battery.
AFFECTED PRODUCT
Model Identification Number
C6.6 N6D00100-00106, 108-126, 128-157, 159-160, 162-229, 231, 233, 236-302, 304-395, 397-655, 657-677, 679-700, 801-814, 817, 820, 822-825, 827, 830-833, 835-855, 857-860, 862-867, 869-871, 873-874, 877-879, 881, 885, 887
SDA00109-00114, 117-119, 121-134, 139-159, 161-162, 165-253, 262-294, 296-332, 341-380, 384-387, 393-396, 400-402, 407-423, 426-435, 465-549, 564-566, 570-571, 582-593, 595-601, 608-609
PARTS NEEDED
Qty
Part Number Description
1 5C2890 NUT-HEX (As Required)
1 9R1968 SPACER (As Required)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
Refer to the appropriate service manual as necessary.
1. Remove nut from B+ terminal stud and remove B+ harness terminal from stud.
2. Verify spacer is located on terminal stud. If the spacer is on the terminal stud, proceed to step 3. If the spacer is missing, install a 9R-1968 Spacer.
3. Make sure the spacer is properly seated.
4. Reinstall B+ nut onto the spacer and tighten to a torque of 18.2 +/- 2.4 N.m (13 +/- 2 lb ft). Refer to Image2.
5. Install B+ harness terminal on top of the 1st nut and secure the harness terminal on the stud with 5C-8290 Nut. Tighten the nut on the terminal to a torque of 18.2 +/- 2.4 N.m (13 +/- 2 lb ft).
6. Test charging system to verify proper charging alternator output.
Image1
Image2
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first