PRODUCT SUPPORT PROGRAM FOR RELOCATING THE PRELUBE PUMP ON CERTAIN PMG3516C POWER MODULES (XQ1475G POWER MODULES) Caterpillar

PRODUCT SUPPORT PROGRAM FOR RELOCATING THE PRELUBE PUMP ON CERTAIN PMG3516C POWER MODULES (XQ1475G POWER MODULES)

Usage:

TEBE2416-03

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04Dec2014

(Revised 02Mar2015)

B26B
B94N
D35P
J520

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Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR RELOCATING THE PRELUBE PUMP ON CERTAIN PMG3516C POWER MODULES (XQ1475G POWER MODULES)
1408 1469 1319		PS44586

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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 "PS44586" 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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NOTE:	This Revised Service Letter replaces the 04Dec2014 (Revised 03Feb2015) Service Letter. Changes have been made to the Affected Product.

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TERMINATION DATE

31Dec2016

PROBLEM

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The existing prelube pump mounting bracket can fail on certain PMG351C Power Modules (XQ1475G Power Modules). To prevent bracket failure, the prelube pump needs to be relocated from the engine to the floor of the container.

AFFECTED PRODUCT

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Model	Identification Number
PMG3516C	JKK00100-00118, 120-122, 124-126, 128-129, 131, 133, 135, 138-139, 145-147, 150-156, 158-160, 163-171, 173-179, 181-186, 188-189, 194, 210

PARTS NEEDED

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Qty	Part Number	Description
4	0S1618	BOLT
1	2109599	HOSE AS
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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Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident
occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction, on the product, and in this product's Operation and Maintenance Manual (OMM). If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication, the warnings that are on the product, and the warnings that are in the OMM are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, the user must ensure that it is safe for the user and for other people to use.

The user should ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

WARNING: The generator set must be isolated electrically before and while the rework is performed. Follow the proper lockout tag out procedures to protect against the unexpected energizing or startup of the generator set. Failure to follow these warnings could result in injury to personnel during service. Attach a "Do Not Operate" warning tag to the machine start switch or the controls before you perform any service to the machine.

Rework Action Required

The 276-2910 Prelube Pump Assembly needs to be relocated from the engine to the container floor location directly below existing mounting location. This will require fabrication of one new hose assembly. Refer to the Hydraulic Information System (HIS) for information on building the 210-9599 Hose Assembly. The existing 241-0117 Hose Assembly will be re-used. Wiring and conduit lengths are sufficient. Drilling and tapping of addition mounting holes will be required. Refer to Image1 and Image2.

Refer to the attached Rework Procedure.

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Image1

Image2

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%
0-20000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 6.0-hour job

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PARTS DISPOSITION

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Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

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Remove the pump assembly from engine. Rotate the pump assembly 180 degrees from the original position and place it on floor using the original spacers under the mounting bracket. Refer to Image1.1.1.

Image1.1.1

Rotate the elbow down 15 to 45 degrees to allow fit-up of the existing hose. Refer to Image1.2.1.

Image1.2.1

Turn the elbow adapters on pump upwards with pump assembly resting flat on the pump mounting bracket. Fit new 210-9599 Hose Assembly (1) and existing 241-0117 Hose Assembly(2). Position pump to prevent hose rubbing (3). Once the best positioning is determined, use bracket bolt holes (4) as a template to mark the mounting bolt hole pattern. Refer to Image1.3.1.

Image1.3.1

Drill and tap 5/16-18 THD mounting holes and mount pump to floor. Maximum hole depth should not exceed 12 mm depth to avoid penetration of spill containment area. Also, hole depth must be approximately 10 mm deep to prevent bottoming of bolts (thread engagement is approximately 8 mm). Use existing spacers with new 0S-1618 Bolts (4 total) to mount the pump to the floor. Original bolts will not be used. Verify bolts are not hitting the bottom of the hole. Refer to Image1.4.1.

Image1.4.1

Mount the relay box to the floor. Remove cover from relay box, and use the three mounting holes in the box as a template to mark mounting holes. Drill and tap holes in the floor and mount the relay box. Refer to Image1.5.1 and Image1.5.2.

Image1.5.1

Image1.5.2

Tighten all hose connections and verify that all hoses and conduit are routed and secured to prevent rubbing. Refer to Image 1.6.1. Run the generator set and verify proper operation.