PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING NEW SOFTWARE AND POSSIBLY PRELUBRICATION PUMPS ON CERTAIN C175-16 GENERATOR SETS OPERATING IN STAND-BY APPLICATIONS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING NEW SOFTWARE AND POSSIBLY PRELUBRICATION PUMPS ON CERTAIN C175-16 GENERATOR SETS OPERATING IN STAND-BY APPLICATIONS

Usage:

REBE6025-01

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04Nov2010

(Revised 19Apr2011)

U-445

A-364

D-389

O-388

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING NEW SOFTWARE AND POSSIBLY PRELUBRICATION PUMPS ON CERTAIN C175-16 GENERATOR SETS OPERATING IN STAND-BY APPLICATIONS
1319 1901 1920		PI31817

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31817" 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 "PI31817" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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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.

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NOTE:	This Revised Service Letter replaces the 04Nov2010 Service Letter. Changes have been made to the Parts Required.

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COMPLETION DATE	TERMINATION DATE
31May2011	30Nov2011

PROBLEM

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The lubrication to the high pressure fuel pump may be insufficient during start up on certain C175-16 generator sets operating in standby applications and could result in a high pressure fuel pump failure.

Installation of the latest software available on certain C175-16 generator sets, and a prelubrication pump and latest software on certain C175-16 generator sets, will provide additional lubrication to the high pressure fuel pump.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C175-16	WYB00234-00300

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*****Group 2*****
C175-16	WYB00136, 142-143, 145-150, 170-172, 175-177, 189-191, 194, 196, 201-202, 206-210, 213-215, 232-233

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*****Group 3*****
C175-16	WYB00139-00141, 144, 151-158, 160-168, 178-185, 187-188, 192, 197-200, 203, 220, 223-230

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	SOFTWARE	UNKNOWN
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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.
*****Group 2*****
2	2L9653	CLIP
1	2W0694	ELBOW AS-VALVE
6	2Y5829	NUT-HEX
2	3E4353	WASHER-HARD
8	4P8134	CLIP-LADDER
4	4S1962	CLIP
1	4W9774	ELBOW
2	5P4115	WASHER-HARD
1	5P5846	SEAL-O-RING
10	5P8245	WASHER-HARD
2	5P8347	BOLT-HEX HEAD
1	5P9757	SEAL-O-RING
1	6V3822	BOLT
4	6V3940	BOLT
2	6V4248	BOLT
2	6V5100	SEAL-O-RING
2	6V5221	BOLT
10	6V5684	BOLT-HEX HEAD
20	6V5839	WASHER-HARD
4	6V5842	BOLT-HEX HEAD
2	6V7357	BOLT-HEX HEAD
6	6V7981	BOLT
8	6V8149	NUT-HEX
1	6V8734	ADAPTER-STR
1	6V9006	ADAPTER-ELBOW
1	6V9832	CAP AS
8	7D1649	WASHER-HARD
16	7K1181	STRAP-CABLE
1	7X0605	WASHER-HARD
2	7X2619	BOLT-HEX HEAD
1	7X7731	PLUG-NPTF
2	8C3398	LOCKWASHER
1	8M2769	CLIP
1	8T4121	WASHER-HARD
4	8T4133	NUT
4	8T4136	BOLT
1	8T4191	BOLT
1	8T6356	TEE-O-RING PORT
8	9M1974	WASHER-HARD
1	9M4494	NUT-SPANNER
4	9X8256	WASHER
1	1123540	SEAL-O-RING
2	1126646	LOCKNUT
1	1236574	BUSHING
4	1325789	CLIP-LADDER
8	1343196	WASHER-SNUBBING
2	1413983	SPACER
1	1480757	SWITCH AS-MAGC
4	1682067	MOUNT AS
1	2154639	SEAL-O-RING-STOR
1	2270066	ADAPTER-STR
3	2287093	SEAL-O-RING-ORFS
2	2287094	SEAL-O-RING-ORFS
2	2287096	SEAL-O-RING-STOR
2	2287108	SEAL-O-RING-STOR
1	2636735	FITTING-CABLE
1	2787292	BRACKET AS
2	2787339	MOUNT-SHOCK
1	2957551	TUBE AS
1	2960014	PUMP GP-BASIC
1	2971148	BRACKET AS
2	2971149	BRACKET AS
1	2972370	BRACKET
1	3096499	HOSE AS
1	3132647	VALVE-BALL
1	3139606	ELBOW
1	3183200	HOSE AS
1	3196189	CONNECTOR-STOR
1	3223434	HARNESS AS
1	SOFTWARE	UNKNOWN
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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.
*****Group 3*****
2	2L9653	CLIP
1	2W0694	ELBOW AS-VALVE
6	2Y5829	NUT-HEX
2	3E4353	WASHER-HARD
2	3L6008	SPACER
1	4P7429	CLIP-LADDER
2	4P7581	CLIP-LADDER
8	4P8134	CLIP-LADDER
4	4S1962	CLIP
1	4W9774	ELBOW
2	5P4115	WASHER-HARD
1	5P5846	SEAL-O-RING
10	5P8245	WASHER-HARD
2	5P8347	BOLT-HEX HEAD
1	5P9757	SEAL-O-RING
4	6V3940	BOLT
2	6V4248	BOLT
2	6V5100	SEAL-O-RING
2	6V5221	BOLT
10	6V5684	BOLT-HEX HEAD
20	6V5839	WASHER-HARD
4	6V5842	BOLT-HEX HEAD
2	6V7357	BOLT-HEX HEAD
6	6V7981	BOLT
8	6V8149	NUT-HEX
1	6V8734	ADAPTER-STR
1	6V9006	ADAPTER-ELBOW
1	6V9832	CAP AS
8	7D1649	WASHER-HARD
16	7K1181	STRAP-CABLE
1	7X0605	WASHER-HARD
2	7X2619	BOLT-HEX HEAD
1	7X7731	PLUG-NPTF
2	8C3398	LOCKWASHER
1	8M2769	CLIP
1	8T4121	WASHER-HARD
4	8T4133	NUT
4	8T4136	BOLT
1	8T4139	BOLT
1	8T4191	BOLT
2	8T4223	WASHER-HARD
1	8T4244	NUT-HEX
1	8T6356	TEE-O-RING PORT
8	9M1974	WASHER-HARD
1	9M4494	NUT-SPANNER
4	9X8256	WASHER
1	1123540	SEAL-O-RING
2	1126646	LOCKNUT
1	1236574	BUSHING
4	1325789	CLIP-LADDER
8	1343196	WASHER-SNUBBING
1	1480757	SWITCH AS-MAGC
4	1682067	MOUNT AS
1	2154639	SEAL-O-RING-STOR
1	2270066	ADAPTER-STR
3	2287093	SEAL-O-RING-ORFS
2	2287094	SEAL-O-RING-ORFS
2	2287096	SEAL-O-RING-STOR
2	2287108	SEAL-O-RING-STOR
1	2636735	FITTING-CABLE
1	2787292	BRACKET AS
2	2787339	MOUNT-SHOCK
1	2957548	BRACKET AS
1	2957549	BRACKET
1	2957550	BRACKET
1	2957551	TUBE AS
1	2960014	PUMP GP-BASIC
1	3096499	HOSE AS
1	3132647	VALVE-BALL
1	3139606	ELBOW
1	3183200	HOSE AS
1	3196189	CONNECTOR-STOR
1	3223434	HARNESS AS
1	SOFTWARE	UNKNOWN
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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

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Group 1:
Update the engine ECM with the latest software available for download in SIS or TMI. Follow instructions in Steps 2 through 4.

NOTE: Group 1 does not require installation of a prelubrication pump.

Group 2 and Group 3:

Engines in Group 2 (3000 Frame Size Generators) and Group 3 (1800 Frame Size Generators) require installation of a prelubrication pump and flashing the appropriate software in the engine ECM.

NOTE: If an engine in Group 2 or Group 3 is already equipped with a prelubrication pump, the only rework required is the software update in Steps 2 through 4.

Rework Procedure:

1. Refer to REHS4741, Special Instruction, "Procedure for Installing the 296-0014 Prelubrication Oil Pump Gp on C175 Generator Sets", for details on the prelubrication pump installation procedure.

2. Install the latest software available for download in SIS or TMI using Caterpillar ET.

NOTE: The parameter for cool down speed in the configuration menu for the Electronic Control Module (ECM) must be set to 1800 RPM for 60Hz gensets and 1500 RPM for 50Hz gensets prior to installation of the new software. If the cool down speed is not set correctly, a 1111-2 code "Programmable Parameter Fault Data Intermittent" will be displayed on the EMCP Panel and a 268-2 code "Programmed Parameter Fault : Erratic, Intermittent, or Incorrect diagnostic code" will be generated in the ECM when the software is installed.

3. Program the prelubrication parameters as shown in Image1.

NOTE: Certain versions of ET do not initially accept the 1400 value for the 'Engine Continuous Pre-Lube Interval'. If this occurs, it is recommended to try inputing in a number other than the recommended 1440, attempt a number like 5000 and see if that value is accepted. This should change the prelube interval setting to 5000; once this is verified, try going back to 1440 and it should now accept that value

4. Perform a power cycle on the ECM to trigger the first prelube cycle.

- Prelube pump should start at the same time the next day. If the engine is power cycled or started it will reset the timer and change the time the prelube pump will start.

NOTE: This update is ONLY for C175-16 generator sets operating in stand by applications that require the unit to start up immediately, upon request, in the event of an outage. The prelube settings for generator sets operating in prime and continuous applications do not require any changes.

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Image1

OWNER NOTIFICATION

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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%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 1.0-hour job for Group 1

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 1.0-hour job for Group 2
A maximum of 12 hours will be allowed for units that require installation of a prelubrication pump

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 3*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 1.0-hour job for Group 3
A maximum of 12 hours will be allowed for units that require installation of a prelubrication pump

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.

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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING NEW SOFTWARE AND POSSIBLY PRELUBRICATION PUMPS ON CERTAIN GENERATOR SETS OPERATING IN STAND-BY APPLICATIONS

MODELS INVOLVED - C175-16 Generator Sets

Dear Caterpillar Product Owner:

The lubrication to the high pressure fuel pump may be insufficient during start up on certain C175-16 generator sets operating in standby applications and could result in a high pressure fuel pump failure.

New software, or a prelubrication pump and new software, needs to be installed on the products listed below. This rework will provide additional lubrication for the high pressure fuel pump and will not hinder immediate start up of the unit in the event of a power outage. 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 04Nov2010 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 04Nov2010 Service Letter