PRODUCT IMPROVEMENT PROGRAM FOR REPLACING A FUEL HEATER HOSE AND UPDATING SOFTWARE ON CERTAIN G3500B ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING A FUEL HEATER HOSE AND UPDATING SOFTWARE ON CERTAIN G3500B ENGINES

Usage:

REBE7935-00

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15Feb2012

U-76

A-64

D-65

O-72

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING A FUEL HEATER HOSE AND UPDATING SOFTWARE ON CERTAIN G3500B ENGINES
1380 1920 1901		PI10886

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10886" 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 "PI10886" 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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PROBLEM

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The fuel heater hose needs to be replaced. The existing fuel heater hose can fail due to high exhaust heat, causing coolant to spray on the exhaust which may cause a fire hazard and, in conjunction with other conditions and circumstances, result in personal injury or death. In addition to the fuel heater hose change, the software on the engine will be updated.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
G3512B	JHH00100-00102, 1001-1012

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*****Group 2*****
G3508B	RBK00101-00109, 1001-1109

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*****Group 3*****
G3516B	JEF00101-00189, 1001-1440

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*****Group 4*****
G3520B	TPC00101, 103-146, 1001

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*****Group 5*****
G3520B	GLF00103-00126

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
3	6V3265	CLIP
2	1214345	SEAL-O-RING-ORFS
1	3821407	HOSE AS
1	3891926	SOFTWARE GP-ELEK (as needed)
1	3908615	SFWR GP-A4008
1	3913098	SOFTWARE GP-ELEK (as needed)
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	6V3265	CLIP
2	1214345	SEAL-O-RING-ORFS
1	3821407	HOSE AS
1	3887224	SOFTWARE GP-ELEK (as needed)
1	3908615	SFWR GP-A4008
1	3913083	SOFTWARE GP-ELEK (as needed)
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 3*****
3	6V3265	CLIP
2	1214345	SEAL-O-RING-ORFS
1	3821407	HOSE AS
1	3908615	SFWR GP-A4008
1	3909075	SOFTWARE GP-ELEK (as needed)
1	3909077	SOFTWARE GP-ELEK (as needed)
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 4*****
3	6V3265	CLIP
2	1214345	SEAL-O-RING-ORFS
1	3821407	HOSE AS
1	3907468	SOFTWARE GP-ELEK (as needed)
1	3907469	SOFTWARE GP-ELEK (as needed)
1	3908615	SFWR GP-A4008
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 5*****
3	6V3265	CLIP
2	1214345	SEAL-O-RING-ORFS
1	3821407	HOSE AS
1	3908615	SFWR GP-A4008
1	3909271	SOFTWARE GP-ELEK (as needed)
1	3909272	SOFTWARE GP-ELEK (as needed)
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

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Replace the existing fuel heater hose with the 382-1407 Hose that is steel braided. Update the ECM and Advisor software with new software. Refer to the attached Rework Procedure for the appropriate Group for the Affected Product.

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OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

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 2.5-hour job for Group 1

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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 2.5-hour job for Group 2

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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 2.5-hour job for Group 3

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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 2.5-hour job for Group 4

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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 2.5-hour job for Group 5

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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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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING A FUEL HEATER HOSE AND UPDATING SOFTWARE ON CERTAIN G3500B ENGINES

MODELS INVOLVED - G3508B, G3512B, G3516B, G3520B

Dear Caterpillar Product Owner:

The fuel heater hose needs to be replaced. The existing fuel heater hose can fail due to high exhaust heat, causing coolant to spray on the exhaust which may cause a fire hazard and, in conjunction with other conditions and circumstances, result in personal injury or death. In addition to the fuel heater hose change, the software on your engine will be updated. You will not be charged for the service performed.

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

Please refer the dealer to their Service Letter dated 15Feb2012 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 15Feb2012 Service Letter

Rework Procedure

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Group Number 1

Refer to the Service Manual if/as necessary.

Drain the coolant from the engine.

Loosen the connections of the existing 339-3177 Fuel Heater Hose (11) in Image1.1.1 and remove the hose and the hose clips. Install the new 382-1407 Hose and 121-4345 O-ring seals using the new 6V-3265 Hose Clips.

Refill the engine with coolant.

Image1.1.1

Update the engine software.

Update the G3500 Advisor with 390-8615 Software.

For 1.0 G NOx Feedback, update the engine ECM with 391-3098 Software.

For 0.5 G NOx Feedback, update the engine ECM with 389-1926 Software.

Group Number 2

Refer to the Service Manual if/as necessary.

Drain the coolant from the engine.

Loosen the connections of the existing 339-3177 Fuel Heater Hose (11) in Image2.1.1 and remove the hose and the hose clips. Install the new 382-1407 Hose and 121-4345 O-ring seals using the new 6V-3265 Hose Clips.

Refill the engine with coolant.

Image2.1.1

Update the engine software.

Update the G3500 Advisor with 390-8615 Software.

For 1.0 G NOx Feedback, update the engine ECM with 391-3083 Software.

For 0.5 G NOx Feedback, update the engine ECM with 388-7224 Software.

Group Number 3

Refer to the Service Manual if/as necessary.

Drain the coolant from the engine.

Loosen the connections of the existing 339-3177 Fuel Heater Hose (11) in Image3.1.1 and remove the hose and the hose clips. Install the new 382-1407 Hose and 121-4345 O-ring seals using the new 6V-3265 Hose Clips.

Refill the engine with coolant.

Image3.1.1

Update the engine software.

Update the G3500 Advisor with 390-8615 Software.

For 1.0 G NOx Feedback, update the engine ECM with 390-9077 Software.

For 0.5 G NOx Feedback, update the engine ECM with 390-9075 Software.

Group Number 4

Refer to the Service Manual if/as necessary.

Drain the coolant from the engine.

Loosen the connections of the existing 339-3177 Fuel Heater Hose (11) in Image4.1.1 and remove the hose and the hose clips. Install the new 382-1407 Hose and 121-4345 O-ring seals using the new 6V-3265 Hose Clips.

Refill the engine with coolant.

Image4.1.1

Update the engine software.

Update the G3500 Advisor with 390-8615 Software.

For 1.0 G NOx Feedback, update the engine ECM with 390-7468 Software.

For 0.5 G NOx Feedback, update the engine ECM with 390-7469 Software.

Group Number 5

Refer to the Service Manual if/as necessary.

Drain the coolant from the engine.

Loosen the connections of the existing 339-3177 Fuel Heater Hose (11) in Image5.1.1 and remove the hose and the hose clips. Install the new 382-1407 Hose and 121-4345 O-ring seals using the new 6V-3265 Hose Clips.

Refill the engine with coolant.

Image5.1.1

Update the engine software.

Update the G3500 Advisor with 390-8615 Software.

For 1.0 G NOx Feedback, update the engine ECM with 390-9271 Software.

For 0.5 G NOx Feedback, update the engine ECM with 390-9272 Software.