PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE PRELUBE PUMP RELAY ON CERTAIN CG170-16, G3516H, AND G3520H GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE PRELUBE PUMP RELAY ON CERTAIN CG170-16, G3516H, AND G3520H GENERATOR SETS

Usage:

TEBE5851-02

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24May2017

(Revised 16Oct2017)

U-283

A-187

D-224

O-229

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Priority	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE PRELUBE PUMP RELAY ON CERTAIN CG170-16, G3516H, AND G3520H GENERATOR SETS
1469 4493 1319		PI32769

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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 as soon as possible. When reporting the repair, use "PI32769" 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 "PI32769" 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 24May2017 (Revised 06Jun2017) Service Letter. Changes have been made to the Action Required.

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COMPLETION DATE	TERMINATION DATE
30Nov2017	31May2018

PROBLEM

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The engine prelube pump relay needs to be replaced on certain CG170-16, G3516H, and G3520H Generator Sets. The existing relay can fail to close under normal conditions. If the relay fails to close the prelube pump motor will not run.

AFFECTED PRODUCT

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Model	Identification Number
CG170-16	KSJ00162-00167
G3516H	NWH00100-00108, 113-121
G3516H HD	GLM00116-00117, 123-124, 132-136, 139, 141-149, 153-157, 161-163, 172-176, 184-188 GLN00116-00127, 132-134, 136-138
G3520H HD	GFP00116-00117, 119-121, 124-136, 138-144, 146, 148-153 GFR00115-00178

PARTS NEEDED

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Qty	Part Number	Description
4	5P4571	TERMINAL
4	7N7221	TERMINAL-BLADE
2	0977234	TERMINAL
2	1606365	SCREW
1	5165815	RELAY AS-SS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 37% 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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Before completing any rework, review the engine and equipment Operation and Maintenance Manual and follow all safety information and safe work practices.

Replace the current prelube pump 222-4533 Relay with the new 516-5815 Relay.

Follow the steps outlined below for replacing the relay.

Note: The new relay must be wired as shown in Image 3. Do not use the details shown on the face of the relay.

Step 1. Locate the prelube relay assembly.

Step 2. Remove the junction box cover.

Step 3. Remove the old 222-4533 Relay.

Step 4. Install the new 516-5815 Relay with 160-6365 Screws (A).

Step 5. Clip off stud terminals (B) wires, install new 5P-4571 Blade Terminals. (7N-7221 Blade Terminals for 18 AWG) These wires will be connected to the prelube pump motor.

Step 6. Clip off stud terminals (C) wires, install new 5P-4571 Blade Terminals. (7N-7221 terminals for 18 AWG) These wires will be connected to the AC voltage source.

Step 7. Clip off stud terminals (D) wires, install new 097-7234 Blade Terminals. These wires are for the coil side of the relay and should be connected to the 24 VDC signal wires from ECM.

Step 8. Reinstall junction box cover.

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Image1

Image2

Image3

OWNER NOTIFICATION

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

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 2.0-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.

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE PRELUBE PUMP RELAY

MODELS INVOLVED - CERTAIN CG170-16, G3516H, AND G3520H GENERATOR SETS

Dear Cat Product Owner:

The engine prelube pump relay needs to be replaced on the products listed below. The existing relay can fail to close under normal conditions. If the relay fails to close the prelube pump motor will not run. 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 24May2017 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 24May2017 Service Letter