PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL METERING VALVE INLET TUBE ON CERTAIN G3520H GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL METERING VALVE INLET TUBE ON CERTAIN G3520H GENERATOR SETS

Usage:

TEBE5772-00

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09May2017

U-258

A-174

D-205

O-210

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Safety	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL METERING VALVE INLET TUBE ON CERTAIN G3520H GENERATOR SETS
1274		PI11115

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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 "PI11115" 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 "PI11115" 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 flange to tube joint on the existing fuel inlet tube 3963184 can develop a crack on certain G3520H Generator Sets. If the existing fuel inlet pipe cracks it can leak. This may, in conjunction with other factors or circumstances, result in a risk of personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
G3520H HD	GFP00010, 116-152 GFR00115-00177

PARTS NEEDED

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Qty	Part Number	Description
2	1684987	GASKET
1	5049951	TUBE
1	5225084	BRACKET
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 fuel inlet tube 3963184 with new cast aluminum tube 5049951 and replace bracket 4314145 with a new support bracket 5225084. During reassembly use a 1684987 gasket on each side. Refer to the attached Rework Procedure and the Disassembly and Assembly manual for repair instructions.

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Image1

OWNER NOTIFICATION

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

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 4.0-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

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL METERING VALVE INLET TUBE

MODELS INVOLVED - CERTAIN G3520H GENERATOR SETS

Dear Cat Product Owner:

The fuel metering valve inlet tube needs to be replaced on the products listed above. The existing fuel metering valve inlet tube can crack causing gas leak to atmosphere. This may, in conjunction with other factors or circumstance, result in a risk of personal injury or death. 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.

You may now search for open Safety Service Letters by entering your product serial number(s). Visit the CAT.COM/SAFETY website and click on SUPPORT, then SAFETY SERVICES for more information. Please refer the dealer to their Service Letter dated 09May2017 when scheduling this service.

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

Caterpillar Inc.

Identification #(s)

Attached to 09May2017 Service Letter

Rework Procedure

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When installing the new fuel tube 504-9951 check for the tube orientation. The flow direction arrow needs to be pointing to engine fuel metering valve.

The flex pipe 450-2401 on the inlet side of the fuel inlet pipe is a raised face flange. The tightening process for joints with a raised face flange has 4 steps. These steps must be followed when tightening a raised face flange joint.

Refer to Image 1.1.1. During each step the bolts should be tightened in this sequence.

Step 1: Hand Tighten
Step 2: 25% Torque 40 Nm (30 ft.lb.)
Step 3: 50% Torque 80 Nm (60 ft.lb.)
Step 4: 100% Torque 160 Nm (120 ft.lb.)