PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE DEF HEATER RELAY ON CERTAIN 3516C, AND C175-16 GENERATOR SETS, AND C175-20 LOCOMOTIVE ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE DEF HEATER RELAY ON CERTAIN 3516C, AND C175-16 GENERATOR SETS, AND C175-20 LOCOMOTIVE ENGINES

Usage:

TEBE5120-00

Show/hide table

26Oct2016

U-564

Show/hide table

Priority	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE DEF HEATER RELAY ON CERTAIN 3516C, AND C175-16 GENERATOR SETS, AND C175-20 LOCOMOTIVE ENGINES
108D 1091 7499 4493		PI32695

Show/hide table

NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32695" 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 "PI32695" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

Show/hide table

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.

Show/hide table

COMPLETION DATE	TERMINATION DATE
30Apr2017	31Oct2017

PROBLEM

Show/hide table

The DEF Heater relay needs to be replaced on certain 3516C, and C175-16 Generator Sets, and C175-20 Locomotive Engines. The existing DEF heater relay can leak AC voltage to the case.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
*****Group 1*****
3516C	SCJ00112-00114, 1000-1001
3516C HD	SCK00114-00123 SFK00101-00128 SKC00101-00130
C175-16	WYC00123-00126, 1000-1012, 2000-2009

Show/hide table

*****Group 2*****
C175-20	R4F00101

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
*****Group 1*****
3	7K1181	STRAP-CABLE
40	8T1487	WIRE-ELECTRICAL
2	1093038	WIRE END
2	1108714	END-WIRE
25	1257874	TUBE-BULK
2	1364877	SPLICE-WIRE
1	2048659	RAIL-BULK
2	3149101	BRACKET-END
1	4476618	RELAY-SGL POLE
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*****
3	7K1181	STRAP-CABLE
2	0910081	SPACER
2	0996418	NUT-HEX FLANGE
2	1093038	WIRE END
2	1108714	END-WIRE
1	2048659	RAIL-BULK
2	3149101	BRACKET-END
1	4476618	RELAY-SGL POLE
2	4744545	BOLT-FLANGE HEAD
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.

ACTION REQUIRED

Show/hide table

Refer to the attached Rework Procedure.

Show/hide table

OWNER NOTIFICATION

Show/hide table

Owners in the following countries will receive the attached Owner Notification:
US
Canada

SERVICE CLAIM ALLOWANCES

Show/hide table

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 2.0-hour job for Group 1

Show/hide table

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 2.0-hour job for Group 2

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.

Show/hide table

EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE DEF HEATER RELAY

MODELS INVOLVED - CERTAIN 3516C, AND C175-16 GENERATOR SETS, AND C175-20 LOCOMOTIVE ENGINES

Dear Cat Product Owner:

The DEF Heater Relay needs to be replaced on the products listed below. The existing DEF Heater Relay can leak AC voltage to the case of the relay. You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated. Please refer the dealer to their Service Letter dated 26Oct2016 when scheduling this service.

We regret the inconvenience this may cause you, and urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 26Oct2016 Service Letter

Rework Procedure

Group Number 1

Make sure you have read and understood all of this document before beginning work.

Isolate the generator set before commencing any work on the unit, open generator set breaker, activate Emergency Stop, disconnect the battery cables and either disconnect or open the control circuit breaker for the AC power supply to the battery charger. Ensure all health and safety requirements are adhered to at all times. Also, ensure proper Lock Out-Tag Out procedures are followed at all times while work is being performed on or around the machine. Lock out generator operation and disconnect/lockout all power sources to the Generator Set and Dosing Cabinet before commencing any work.

1 - Remove the side access cover to gain access to the dosing cabinet heater relay.
Reference Image 1.2.1

Image1.2.1

2 - Remove the rubber boots and wiring from the relay and then remove the relay from the mounting bracket. Cut the existing terminals off of each wire.
Install a 109-3038 ferrule onto each of the DC wires.
Cut 3" of the 8T-1487 wire and splice onto the existing AC wires using a 136-4877 splice and 125-7874 shrink wrap. Once the appropriate length of wire is spliced onto the existing wires install a 110-8714 ferrule onto each of the AC wires.
Reference Images 1.3.1 and 1.3.2

Image1.3.1

Image1.3.2

3 - Cut the 204-8659 Din rail to 87 mm length. Install the Din rail onto the existing mounting bracket using the original Isolation shock mounts and bolts.

Install the 447-6618 relay and 314-9101 end caps onto the Din rail and insert wires as shown in the schematic.
Reference Images 1.4.1, 1.4.2, and 1.4.3

Image1.4.1

Image1.4.2

Image1.4.3

4 - After all rework has been completed, perform the "DEF Manifold Heater Override" to check for proper operation of the DEF heater.

Re-install the Dosing Cabinet side access covers.

Group Number 2

1 - Remove the side access cover to gain access to the dosing cabinet heater relay.
Reference Image 2.2.1

Image2.2.1

Image2.3.1

3 - Drill two new 7 mm holes into the existing 481-1334 rear panel
Reference Images 2.4.1 and 2.4.2

Image2.4.1

Image2.4.2

4 - Cut the 204-8659 Din rail to 87 mm length. Install the Din rail onto the newly drilled 7 mm holes in the 481-1334 rear panel using (2) 474-4545 bolts, (2) 099-6418 nuts and (2) 091-0081 spacers.
Reference Images 2.5.1 and 2.5.2

Image2.5.1

Image2.5.2

5 - Install the 447-6618 relay and 314-9101 end caps onto the Din rail and insert wires as shown in the schematic. Tie strap wires to the ladder clip.
Reference Images 2.6.1 and 2.6.2

Image2.6.1

Image2.6.2

6 - After all rework has been completed, perform the "DEF Manifold Heater Override" to check for proper operation of the DEF heater.

Re-install the Dosing Cabinet side access covers.