PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE FUEL HEATER ON CERTAIN 3516C GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE FUEL HEATER ON CERTAIN 3516C GENERATOR SETS

Usage:

TEBE8862-00

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11Mar2019

U-117

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Safety	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE FUEL HEATER ON CERTAIN 3516C GENERATOR SETS
1296		PI11204

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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 "PI11204" 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 "PI11204" 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 needs to be reworked on certain 3516C Generator Sets. The existing fuel heater can leak diesel fuel into the electrical connection box. The fuel from the fuel heater leaking into the electrical connection housing can cause an explosion or fire which 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
3516C	SBK02063, 2090-2091, 2093, 2095-2096, 2104-2105, 2108-2109, 2656, 2660, 2667, 2674 SFJ00846-00847, 851-852, 856-857, 859, 861-864, 866-867, 870-872, 875, 877, 880-882, 892, 910, 912-918

PARTS NEEDED

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Qty	Part Number	Description
2	CAP	PIPE CAP - SEE ACTION REQUIRED
1	PUMP	FUEL PUMP - SEE ACTION REQUIRED
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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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 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 and the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

WARNING: The generator set must be isolated mechanically and electrically before and while the rework is being performed. Follow the proper lock out tag out procedures to protect against unintended operation, unexpected movement, 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 and local and remote controls before you perform any service to the machine.

Order the required fuel pump, part number 20000-12609, through the Olympian Parts System.

The Gasoila Soft Set Thread Sealant w/PTFE and the 1" F-NPT 150 lb PVC Flat Threaded Pipe Caps required should have already been provided to the dealer. If a dealer does not have the parts, have the Dealer Technical Communicator (TC) submit a request for the parts to CPI number 436073 through CPI Feedback within the Service Information Management System (SIMSi).

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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 3.0-hour job
An additional 1.0 hour is allotted if the fuel flow switch, check valve, and/or fuel pump motor wiring needs to be corrected.

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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 REWORKING THE FUEL HEATER

MODELS INVOLVED - CERTAIN 3516C GENERATOR SETS

MODELS INVOLVED - 3516C

Dear Cat Product Owner:

The fuel heater needs to be reworked on the products listed below. The existing fuel heater can leak diesel fuel into the electrical connection box. The fuel from the fuel heater leaking into the electrical connection housing can cause an explosion or fire which may, in conjunction with other factors or circumstances, 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 11Mar2019 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 11Mar2019 Service Letter

Rework Procedure

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1. Disable the fuel heater. If the fuel heater has already been disabled, proceed to step 4.

2. Shut off the power at the panelboards for the fuel heater and the fuel pump.
a. Open 277/480V panel to gain access to fuel heater circuit breaker.
b. Open the fuel heater circuit breaker, 15A CB# 7-9-11. Refer to Image1.1.1.
c. Open the 120/208V panel to gain access to the fuel heater pump circuit breaker.
d. Open the fuel heater pump circuit breaker, 20A CB#19. Refer to Image1.1.2.

3. Lock out / Tag out these circuit breakers until the fuel heater has been reworked.

4. Remove the fuse from the fuel control box to remove DC power from the panel. Refer to Image1.1.3, Image 1.1.4, and Image 1.1.5.

5. Open the fuel heater electrical enclosure at the cap to gain access to the electrical connections. Refer to Image1.1.6.

6. Use a suitable device to verify the power is off the heater terminals. Disconnect 480V power wiring from the heating element leads.

7. Remove the wiring from the thermocouple in the heater head.

8. Disconnect the wiring to the RTD sensor, and pull wiring back up through the conduit and through the heater electrical housing. Refer to Image1.1.7.

9. Install the cap back on the fuel heater electrical housing.

10. Disconnect one fuel line at the lowest point in the system and drain the fuel from the heater housing and lines making sure to avoid any fuel spills.

11. Disconnect the inlet and outlet hoses to the fuel heater. Refer to Image1.1.8.

12. Remove the fuel heater from the mounting plate by removing the 3/8" bolts from the rear of the mounting plate. Retain all hardware for re-use.

13. Remove the flow sensor and all pipe fittings from the inlet and outlet of the fuel heater. Retain for reinstall on the reworked heater. Ensure that there is no residual fuel in the interior of the fuel heater. Install the provided 1" F-NPT 150lb PVC Flat Threaded Pipe Cap to the supply and return hose until the rework is complete.

14. Have the Dealer Technical Communicator (TC) submit a request for further fuel heater repair instructions to CPI number 436073 through CPI Feedback within the Service Information Management System (SIMSi).

Image1.1.1

Image1.1.2

Image1.1.3

Image1.1.4

Image1.1.5

Image1.1.6

Image1.1.7

Image1.1.8

Installation Note: In all steps below, where the threaded NPT connector installation is required, apply appropriate amount of Gasoila Soft Set Thread Sealant w/PTFE thread sealant to the fitting and torque the fitting per SENR3130.

15. Inspect the direction of the fuel heater and fuel polisher supply check valves. Both check valves should have an arrow indicating the fuel flow direction in the upward direction. If incorrect, disconnect and reinstall in the correct direction. Refer to Image1.2.1.

16. Inspect the direction of the fuel heater and fuel polisher return check valves. Both check valves should have an arrow indicating the fuel flow direction in the downward direction. If incorrect, disconnect and reinstall in the correct direction. Refer to Image1.2.2.

17. Inspect the direction of the fuel flow sensor at the outlet of the heater. The "IN" stamp should be on the right and the "OUT" stamp should be on the left when looking at the heater from inside the enclosure. If incorrect, reinstall in the proper direction when during the install of the repaired fuel heater. Refer to Image1.2.3.

18. Inspect the polarity of the power wiring to the fuel pump motor. Correct the wiring if necessary. Refer to Image1.2.4.

Image1.2.1

Image1.2.2

Image1.2.3

Image1.2.4

19. Disassemble the hosing connections and fittings to the fuel pump outlet and retain for connection later. Refer to Image1.3.1.

20. Remove the pump from the motor housing. Install the replacement pump on the motor housing, and ensure that the inlet port is pointed upwards, and the outlet port is pointed down. Refer to Image1.3.2.

21. Install the original adapter fittings to the new pump inlet & outlet. Connect the original fuel pump supply hose to the pump inlet.

Image1.3.1

Image1.3.2

22. On the repaired fuel heater, install the pipe fittings from the original assembly onto the heater inlet and outlet ports. The inlet includes the hose adapter and a 3/8? x 1? reducer. The outlet includes an elbow fitting, and the flow sensor tee-fitting. Ensure that the flow direction of the flow sensor is correct, with the "IN" port on the left and the "OUT" port on the right. Refer to Image1.4.1.

24. Install the repaired fuel heater with inlet & outlet fittings attached onto the panel mount locations using 3/8x1? SS bolts & washers. Ensure that inlet and outlet connections are pointed upward.

25. Connect the hosing between the pump outlet and the fuel heater inlet.

26. Connect the hose between the fuel heater outlet and the lower wye fitting on the tank return port. Verify that the check valve on the tank return port is pointed in the correct direction (into the tank).

Image1.4.1

27. Re-connect wiring to the heater unit, including the 480V power wiring for the heating element, as well as the wiring for the thermocouple in the heater, the RTD in the top of the tank, and the flow sensor on the heater outlet.

28. Re-install the cap on the NEMA4 enclosure on the fuel heater.

29. Re-insert the 3A fuse inside the fuel control panel to return power to the sensors.

30. Remove the lock out tags from the 480V and the 120/208V panelboards, and close the breakers for the fuel heater and fuel pump respectively.