PRODUCT SUPPORT PROGRAM FOR RECTIFYING PRELUBE RELAY FAILURES ON CERTAIN SOLUTIONS 3512B AND 3516B GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR RECTIFYING PRELUBE RELAY FAILURES ON CERTAIN SOLUTIONS 3512B AND 3516B GENERATOR SETS

Usage:

TEBE5779-00

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06Feb2017

L120
M61T
M638
M63T

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Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR RECTIFYING PRELUBE RELAY FAILURES ON CERTAIN SOLUTIONS 3512B AND 3516B GENERATOR SETS
7620 4459		PS45380

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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 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 "PS45380" as the Part Number and "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.

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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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TERMINATION DATE

28Feb2019

PROBLEM

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An issue with prelube relays failing on multiple has occurred on certain Solutions 3512B and 3516B Generator Sets. The prelube relay is located inside the DC Distribution box on the engine. The standard prelube option is not installed on these affected generator sets, therefore the standard prelube pump and pressure switch are not installed, although the wiring and relay is present for the prelube option as standard on these engines. These affected generator sets do have a higher spec prelube pump installed in the container, but this prelube pump is AC powered and controlled completely separate to the standard prelube control system,
engine/control panel wiring harnesses and associated control logic. The prelube relay is being inadvertently energized for prolonged periods of time when a shutdown event is active (e.g. Emergency Stop) due to a configuration issue of the EMCP4.2 controller which can cause the relay coil to fail.

AFFECTED PRODUCT

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Model	Identification Number
3512B	YAY01157, 1159, 1223, 1227
3516B HD	YAR00526, 535-536, 540, 547, 552-553, 555, 576, 578, 588, 591, 593-594, 598, 603-604, 608-610, 612, 616-617, 619, 622, 624, 789, 793-794, 800, 802, 804-806, 812, 814, 824, 826, 828, 830-831, 834, 838-840, 845-854

PARTS NEEDED

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Qty	Part Number	Description
1	9X8124	SWITCH AS-MAGC
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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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Complete the following Rework Procedure.

Note: Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. Refer to the Operation and Maintenance Manual "Safety Section".

Refer to the Service Manual if/as necessary.

1. Disable Relay Output #3 in the EMCP4.2. Refer to Image1.

Relay Output #3 in the EMCP4.2 control panel can be disabled through the control panel without using the Cat ET service software and will not require a password.

Navigate through the menus on the screen of the EMCP4.2 controller to the Relay Output #3 configuration as follows:

Main Menu > Configure > Inputs & Outputs > Relay Outputs > Output #3
Change the setting for 'Relay Output #3 Usage Type' to 'Disabled'.

2. Inspect the prelube relay and replace if required using the same part number 9X-8124 Switch Assembly.

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Image1

SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-1000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%