A New Relay Assembly is Now Used on Certain G3500 Engines {1307, 1319, 4493} Caterpillar

Engine

G3512E (S/N: NWC1-108)

G3516C (S/N: GSB1-124; TJB1-106; GZC1-259; NWD1-1; G7E1-102; F6M1-166; GZZ1-362)

G3516E (S/N: GAS1-280)

G3516H (S/N: NWH1-121; GLM1-188; GLN1-138)

G3520C (S/N: GZA1-316; GZB1-286; GZJ1-716; GZK1-183; GZL1-148; GZM1-221; GZN1-893; RLP1-277; LGS1-198; HAT1-208; CWW1-277; CWY1-221)

G3520E (S/N: GZE1-407; GZH1-162; SXY1-102)

G3520H (S/N: GFP1-153; GFR1-178)

Generator Set

CG170-16 (S/N: KSJ1-167)

Power Module

PMG3516 (S/N: JKK1-327)

Description Of Change: The new relay assembly enables the use of higher voltage to operate properly. The new relay assembly will enable the pre-lube pump to start.

Adaptable To: The following changes are adaptable to the products within the listed serial numbers, and are effective with all products after the listed serial numbers.

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

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Working with electrical circuits can be hazardous. Bodily contact with electrical potential can cause personal injury or death. Ensure that personnel are trained in proper operating procedures in order to ensure safe operation.

Table 1 contains the required parts for this change.

1. Locate the pre-lube relay assembly.

2. Disconnect the power supply connected to the relay assembly.
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   Illustration 1	g06348654
   (A) Junction Box Cover

3. Remove junction box cover (A).

4. Remove the old 222-4533 Relay As.
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   Illustration 2	g06348644
   (1) 516-5815 Relay As. (2) 160-6365 Screw (B) Stud Terminals (C) Stud Terminals (D) Stud Terminals

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   Illustration 3	g06348672

5. Install new relay assembly (1) with screws (2).

   Note: Disregard the diagram displayed on the relay, follow the wiring diagram provided in illustration 3.

6. Clip off stud terminals (B) wires. Install the new 5P-4571 Blade Terminals for the 16-14 AWG ( 7N-7221 Blade Terminals for 18 AWG). These wires will be connected to the pre-lube pump motor.

7. Clip off stud terminals (C) wires. Install the new 5P-4571 Blade Terminals for the 16-14 AWG ( 7N-7221 Blade Terminals for 18 AWG). These wires will be connected to the AC voltage source.

8. 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 the ECM.

9. Reinstall junction box cover (A).

10. Reconnect the power supply to the pre-lube relay assembly.