Usage:
January 20, 1991
(Revised July 2001)
U-11
TT-1.1
Safety
Parts stock action needed |
PRODUCT IMPROVEMENT PROGRAM FOR UPDATING THE GOVERNORS ON CERTAIN 3116 TRUCK ENGINES |
|
1264 |
PI1155
|
NOTE: This Revised Service Letter replaces the January 20, 1991 (Revised March 1991) Service Letter. Replace identified governors with newer models resulting in no rework required. Governors that have already been reworked under this service letter, DO NOT require any further attention. Changes have been made to the Parts Needed, Action Required, Service Claim Allowances, and Parts Disposition sections.
NOTE: No additional rework is required on any of the 3116 Truck Engines that have already been reworked under this program. Engines that were not reworked because the governor serial number was above 0029011 and / or because the letter "K" was stamped in the "LOT" space on the governor serial number plate may need to be reworked.
NOTE: Those governors already reworked DO NOT require any further rework or replacement.
PROBLEM
The governor on certain 3116 Truck Engines may fail to control engine speed because of an improperly tightened governor riser lever bolt, or an improperly installed governor control lever spring.The normal driver shut-down system for the engine is not affected by either problem, and can be used to shut the engine off.
AFFECTED PRODUCT
- Model Identification Number
3116 7SF1-4014, 4016-4173, 4175-4347, 4349-4644, 4646-4665, 4667-5166, 5168-6355, 6357-6367, 6369-6373, 6375-6385, 6387-6392, 6394-6410, 6412-7247, 7253-8441, 8443-8455, 8457, 8458, 8460-8515, 8518-8535, 8537-8587, 8589-8597, 8599-8665, 8667-8672, 8674-8677, 8680, 8682, 8684, 8686, 8691, 8699-8719, 8723-8745, 8747, 8748, 8750, 8752, 8754-8786, 8788-8810, 8812-8817, 8820, 8823-8830, 8832-8863, 8865-8893, 8895-8903, 8905-8963, 8966-9012, 9015-9040, 9042-9098, 9100-9103, 9105-9108, 9110-9118, 9120, 9121, 9123-9143, 9145-9190, 9192-9197, 9199-9201, 9203-9208, 9210-9254, 9256-9285, 9287, 9289-9292, 9294-9330, 9333-9349, 9353, 9354, 9357, 9361, 9365-9375, 9377-9397, 9399-9423, 9425-9428, 9430-9434, 9441, 9449-9481, 9483, 9484, 9486-9501, 9503, 9505-9511, 9514, 9522, 9526, 9530, 9531, 9534-9538, 9540, 9542, 9545, 9547-9560, 9563, 9569-9582, 9584, 9586-9589, 9591-9600, 9604, 9610, 9615-9635, 9637-9647, 9650, 9653, 9658, 9660, 9663, 9667, 9672, 9674, 9684-9687, 9698, 9700, 9701, 9704-9706, 9708, 9709, 9711-9713, 9715-9718, 9720, 9722-9728, 9732, 9735, 9736, 9740, 9743, 9744, 9748, 9750, 9751, 9753, 9755, 9757, 9758, 9760, 9767, 9773, 9775-9778, 9780-9783, 9785-9796, 9798-9804, 9807, 9808, 9811, 9812, 9815, 9817, 9818, 9821, 9822, 9826, 9834, 9838-9842, 9845, 9846, 9849, 9853, 9859-9865, 9867-9873, 9875-9879, 9883, 9884, 9887, 9889, 9891, 9892, 9897-9899, 9904, 9905, 9909, 9913, 9917, 9924, 9928, 9929, 9932, 9937, 9941, 9942, 9944-9946, 9948-9951, 9953, 9955-9964, 9966, 9968-9970, 9978, 9985, 9988, 9994, 9995, 9997, 10001, 10009, 10014-10016, 10018, 10019, 10021-10024, 10026, 10028-10040, 10043-10046, 10048, 10049, 10051-10081, 10084-10086, 10093, 10097, 10101, 10104-10106, 10109, 10111-10118, 10120, 10122-10126, 10128, 10131-10136, 10139, 10141, 10144, 10148, 10151, 10155, 10156, 10161, 10163, 10167, 10172, 10177, 10179, 10180, 10182-10186, 10188-10194, 10196-10199, 10201, 10202, 10204, 10206, 10208, 10211, 10214, 10217, 10220, 10221, 10223, 10225, 10226, 10228-10230, 10233-10235, 10237, 10241-10246, 10249, 10250, 10254, 10260, 10264, 10266-10269, 10271-10273, 10277-10280, 10283, 10284, 10289-10291, 10293, 10294, 10296, 10298, 10300-10304, 10309, 10323, 10332, 10337, 10341, 10342, 10345, 10349-10351, 10356, 10357, 10360-10362, 10364, 10365, 10369, 10371, 10373, 10376-10378, 10380-10389, 10392, 10401, 10403-10405, 10415, 10419, 10422-10426, 10428, 10429, 10431-10435, 10438, 10443, 10444, 10455, 10457, 10460, 10477, 10483, 10490, 10496, 10499, 10502, 10507, 10509, 10523, 10525, 10526, 10535, 10537, 10544, 10561, 10573, 10578, 10580, 10584, 10590, 10592, 10594-10597, 10601, 10602, 10604-10609, 10612, 10613, 10616, 10620, 10624, 10635, 10638, 10642, 10646, 10650, 10652, 10653, 10656, 10659, 10663, 10667, 10674, 10677, 10678, 10682, 10684-10691, 10695, 10699, 10700, 10702, 10706, 10712, 10717, 10735, 10737, 10739, 10740, 10743, 10753, 10756, 10759, 10763, 10764, 10766, 10767, 10771, 10772, 10775, 10779, 10780, 10785-10789, 10792, 10793, 10795, 10797, 10803, 10807, 10810, 10811, 10815-10817, 10819-10821, 10823, 10824, 10827, 10831, 10837, 10839-10842, 10844, 10846, 10848, 10849, 10851-10854, 10857-10859, 10861, 10862, 10864, 10867, 10869, 10872, 10873, 10883, 10887, 10888, 10890, 10891, 10894, 10895, 10900, 10903-10906, 10909, 10910, 10916, 10918, 10920, 10923, 10924, 10928-10931, 10933-10935, 10937, 10938, 10940-10942, 10944, 10947, 10948, 10959, 10972, 10975-10977, 10981, 10990, 10991, 10994, 10996, 10997, 10999, 11001, 11002, 11004, 11006, 11007, 11010, 11013, 11015, 11018, 11030, 11141, 11046, 11048, 11052, 11054, 11055, 11061, 11063, 11065, 11066, 11068, 11073, 11081, 11084, 11085, 11095, 11100, 11105, 11108, 11116, 11117, 11120-11124, 11128, 11132, 11135, 11137, 11143-11150, 11155-11175, 11177, 11180, 11196, 11197, 11202-11206, 11208, 11209, 11222, 11230, 11231, 11233-11235, 11238-11244, 11246, 11248, 11250-11257, 11262, 11265, 11267, 11271, 11276, 11286, 11288, 11290, 11295-11299, 11301, 11307, 11309, 11323, 11329, 11330, 11332, 11334, 11349, 11355, 11358, 11360, 11365, 11371, 11377, 11378, 11382, 11397, 11404, 11408, 11411, 11412, 11414, 11427, 11433, 11446, 11455, 11456, 11460, 11462, 11464, 11474, 11485, 11488, 11490, 11493, 11495-11497, 11501, 11502, 11504, 11508, 11510, 11512, 11516, 11526, 11527, 11529, 11531, 11532, 11535, 11537-11543, 11547, 11551, 11553, 11555, 11557, 11559, 11563, 11570, 11573, 11575, 11578, 11581, 11583-11585, 11592, 11597, 11600, 11601, 11604, 11605, 11608, 11610, 11612, 11617, 11618, 11620, 11621, 11625-11628, 11630, 11632-11634, 11636, 11637, 11640, 11642-11644, 11648, 11650, 11651, 11655, 11657, 11659, 11660, 11662-11668, 11670-11674, 11676, 11680, 11682-11684, 11686-11688, 11693, 11696, 11698-11700, 11702, 11706, 11707, 11709-11719, 11721, 11726, 11728, 11732, 11735, 11738, 11742-11745, 11747, 11750-11754, 11757-11767, 11769, 11770, 11772, 11776, 11777, 11779, 11785-11791, 11793-11795, 11797, 11798, 11801, 11802, 11804-11812, 11815-11823, 11829-14388
PARTS NEEDED
Order the required parts in chart below from the parts department for this program. If the engine meets the criteria within this Service Letter, parts and labor can be claimed within the normal warranty process. Reference this service letter when processing.TopKick / Kodiak dealers should order parts
from their local Caterpillar Distributor in accordance with chart below.
Caterpillar dealers should note, that when installing the new governor,
it may be necessary to upgrade the throttle cable from non-adjustable to
adjustable. The new adjustable throttle cable assembly is GM part number
15996199 and can be obtained through any Top Kick or Kodiak dealer. Previously,
updated governors were provided at no charge on an exchange basis. This
is no longer the process. Order a replacement governor and other related
parts as outlined in the chart below.
|
|
|
165 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
- Additional Hardware: (order with each governor, return unused for credit)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
ACTION REQUIRED
Remove all new 4P2557, 7C4176, 7E0001, 7E0002, 9Y2675, and 9Y7899 Governor Groups from parts stock that have governor serial numbers below 0031637.
***** Affected Product *****
Caterpillar will notify in writing all users of trucks (vehicles) with the affected engines. Notification letters will be mailed to users within 30 days of this Service Letter (copy attached). The letter will request users to call their local TopKick/Kodiak dealer or Caterpillar dealer with the following information:
-Engine arrangement
-Engine horsepower rating
-Governor serial number
-Governor Group Number
-Governor "LOT" block information
-Vehicle mileage
-Automatic / manual transmission
-Vehicle Identification Number (VIN)
Schedule the truck engine for installation of an updated governor if both the following conditions apply:
- The engine serial number is within the affected product range
- The governor must be one of the former ones listed in chart
- No "H" is stamped in the governor serial number plate LOT block.
- (a "K" in the "Lot" block of the governor plate indicates that the basic update has been completed)
- (a "H" indicates the governor has an improved riser shaft installed)
USE THE FOLLOWING PROCEDURE TO INSTALL THE UPDATED GOVERNORS:
- Check the engine serial number against the affected product list to confirm that replacement is necessary. Also check the governor serial number plate for the governor serial number and for the letter "H" stamped in the LOT space.
If the engine serial number is listed above, there is no "H" stamped in the LOT space on the governor, and the governor serial number is 0031636 or below, installation of an updated governor is necessary.
- CAT distributors and TopKick / Kodiak dealers should obtain the required components as outlined in chart under Parts Needed Section. In addition to the Governor group and governor serial number, the engine serial number is needed when processing the warranty claim.
- When new replacement components have arrived, remove the original governor and replace with new governor group as shown in chart below. NOTE: additional items are listed to ensure all required hardware is updated for every possible engine configuration. There are differences in required associated hardware items with newer model governors. Replace in accordance with normal procedures. Return unused component/s for credit.
- If adjustable cable assembly is required, follow these steps:
- Install 15996199 Throttle Cable Assembly
- Depress (push) foot feed/pedal to the floor and move the governor control lever (with springs attached) to the MAXIMUM break over position (past high idle position)
- Push down button on throttle cable, which locks the cable sheath. This assures the foot pedal will move the governor lever to the high idle position.
- Check the fitting(s) at the fuel transfer pump outlet, and compare with the fitting(s) on the new replacement governor. If they are different, exchange the fitting(s) from the original governor to the new replacement governor. Take care not to disturb the small check valve in the housing under the fitting. The type with two fittings was replaced with a single shorter fitting and a longer fuel line. The original fuel line to the filter can be used by exchanging the fittings, if needed.
- Transfer the 7E0155 fuel-inlet screen (if equipped) from original governor, and install it in the new governor.
- Install the new replacement governor in the reverse order.
- After the governor is installed, check the fuel setting as described in the 3116 Diesel Truck Service Manual. Refer to the section titled "Fuel Setting" on page 3-10.
- Check low idle (750 +/- 10 rpm) and high idle engine speed (listed on engine information plate) and confirm that a governor seal has been installed in the high idle adjusting screw. Use a 6V3121 Multitach or 1U6602 Phototach, or an industry-equivalent photo-tachometer with accuracy of +/- 1 rpm.
OWNER NOTIFICATION
U.S. and Canadian owners have already received the attached Owner Notification.SERVICE CLAIM ALLOWANCES
Submit one claim, at dealer net price, for required replacement components listed in the Action Required section of this letter.
***** Affected Product *****
|
|
|
|||
|
|
|
|
|
|
|
|
|
|
|
|
*
The dealer will be reimbursed for the parts in
accordance with this service letter at the Dealer Net rate. |
PARTS DISPOSITION
No return of used governor is required. Ensure claims follow the guidelines established within this notification. After receiving claim payment, replaced (used) governors MUST BE SCRAPPED. Affected governors MUST NOT be placed back in service.MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
(2 - Canadian Owner Notification)
COPY OF OWNER NOTIFICATION FOR U.S. OWNERS
XYZ Corporation3240 Arrow Drive
Anywhere, YZ 99999
Dear Caterpillar Product Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Caterpillar Inc. has determined that a defect that relates to the motor vehicle safety exists in a small number of Caterpillar 3116 Truck Engines.
The engine governor may fail to control engine speed. If you or your driver, experience the inability to control engine speed before repairs can be made, the engine should be immediately shut off and the vehicle parked in gear (or other proper "Park" position) to prevent possible engine damage.
Our records indicate that your 3116 Truck Engine, listed below, may be affected. In the interest of safety and satisfaction with your vehicle, we want to emphasize the importance of having this service performed.
Please follow the instructions listed on the next page. If the governor on your engine is affected, the dealer will repair or replace the governor with an updated one at no charge to you.
To avoid inconvenience and unnecessary downtime, please:
- Complete the information on the attached "Engine/Vehicle Information Sheet" for each engine and have it available.
- Then, with this information, contact a GMC TopKick/Chevrolet Kodiak or Caterpillar Dealer. The dealer will determine if an updated governor is needed.
- Be sure to have the vehicle at the dealership when scheduled. You can expect the repair time to be four (4) hours, or less.
If eligible, the dealer will schedule a
date to install an updated governor. Allow at least two (2) business days
for the dealer to obtain an updated governor of the correct part number
for your engine.
P.O. Box 610
Mossville, Illinois 61552-0610
ATTN: Engine Division Marketing
Telephone: 1-309-578-2084 If you are still unable to have the problem corrected without charge, you may wish to report that fact to:
National Highway Traffic Safety Administration
400 7th Street S.W.
Washington, D.C. 20590
Telephone: 1-800-424-9393 (In Washington D.C; 366-0123)
Caterpillar Inc.
Identification #(s)
Attach. (1-Engine and Vehicle Information)
Attached to July 20, 1991 Service Letter
ENGINE AND VEHICLE INFORMATION
The dealer needs the information below to determine if the governor on your 3116 Truck Engine is eligible for the rework. For each engine, copy the information exactly as it appears on the engine data plates.
ENGINE INFORMATION: (Found on data plate on top of the engine valve cover)(a representation of the plate is shown below)
- Engine Serial Number (SER. NO.): _ _ _ _ _
- Engine Arrangement Number (AR. NO.): _____________
- Engine Power (HP) (circle one) 165 170 185 215 250
- Governor Serial Number (S/N): _____________________
- Governor Group Number (GP) (circle one)
- "LOT" Number Information: _________________________
- What is the current odometer reading? __________Miles/Km
- Is the vehicle equipped with an automatic transmission?
- What is the Vehicle Identification Number (VIN)? ____________________________________
9Y2675 4P2557 9Y7899 7C4176 7E0002 7E0001
(All numbers and letters)
VEHICLE INFORMATION:
(circle one) YES NO
(only the last 8 letters/numbers are needed for GMC/Chevrolet vehicles, such as LJ123456).
COPY OF OWNER NOTIFICATION FOR CANADIAN OWNERS
XYZ Corporation3240 Arrow Drive
Anywhere, YZ 99999
Dear Caterpillar Product Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Caterpillar Inc. has determined that a defect which relates to the motor vehicle safety exists in a small number of Caterpillar 3116 Truck Engines.
The engine governor may fail to control engine speed. If you or your driver, experience the inability to control engine speed before repairs can be made, the engine should be immediately shut off and the vehicle parked in gear (or other proper "Park" position) to prevent possible engine damage.
Our records indicate that your 3116 Truck Engine, listed below, may be affected. In the interest of safety and satisfaction with your vehicle, we want to emphasize the importance of having this service performed.
Please follow the instructions listed on the next page. If the governor on your engine is affected, the dealer will repair or replace the governor with an updated one at no charge to you.
To avoid inconvenience and unnecessary downtime, please:
- Complete the information on the attached "Engine/Vehicle Information Sheet" for each engine and have it available.
- Then, with this information, contact a GMC TopKick/Chevrolet Kodiak or Caterpillar Dealer. The dealer will determine if an updated governor is needed.
- Be sure to have the vehicle at the dealership when scheduled. You can expect the repair time to be four (4) hours, or less.
If eligible, the dealer will schedule a
date to install an updated governor. Allow at least two (2) business days
for the dealer to obtain an updated governor of the correct part number
for your engine.
P.O. Box 610
Mossville, Illinois 61552-0610
ATTN: Engine Division Marketing
Telephone: 1-309-578-2084 Or
Customer Service Center
1908 Colonel Same Drive
Oshawa, On, L1H8P7
1-800-263-3777
Caterpillar Inc.
Identification #(s)
Attach. (1-Engine and Vehicle Information)
Attached to July 20, 1991 Service Letter
ENGINE AND VEHICLE INFORMATION
The dealer needs the information below to determine if the governor on your 3116 Truck Engine is eligible for the rework. For each engine, copy the information exactly as it appears on the engine data plates.
ENGINE INFORMATION: (Found on data plate on top of the engine valve cover)
- Engine Serial Number (SER. NO.): _ _ _ _ _
- Engine Arrangement Number (AR. NO.): _____________
- Engine Power (HP) (circle one) 165 170 185 215 250
- Governor Serial Number (S/N): _____________________
- Governor Group Number (GP) (circle one)
- "LOT" Number Information: _________________________
- What is the current odometer reading? __________Miles/Km
- Is the vehicle equipped with an automatic transmission?
- What is the Vehicle Identification Number (VIN)? ____________________________________
GOVERNOR INFORMATION: (Found on data
plate on top of governor)
9Y2675 4P2557 9Y7899 7C4176 7E0002 7E0001
(All numbers and letters)
VEHICLE
INFORMATION:
(circle one) YES NO
(only the last 8 letters/numbers are needed for GMC/Chevrolet vehicles, such as LJ123456).