PRODUCT IMPROVEMENT PROGRAM FOR REPLACIING THE 7N5378 MUI FUEL LEVER ON CERTAIN 3508, 3512, AND 3516 INDUSTRIAL, MARINE, AND GENERATOR SET ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACIING THE 7N5378 MUI FUEL LEVER ON CERTAIN 3508, 3512, AND 3516 INDUSTRIAL, MARINE, AND GENERATOR SET ENGINES

Usage:

SEBE8062

July 15, 2002
U-165
A-119
AU-123
S-123
H-121
O-140
TM-4

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*Priority* *Parts stock action needed*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACIING THE 7N5378 MUI FUEL LEVER ON CERTAIN 3508, 3512, AND 3516 INDUSTRIAL, MARINE, AND GENERATOR SET ENGINES
1265		PI30327

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30327" 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 "PI30327" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

NOTE: The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.

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COMPLETION DATE	TERMINATION DATE
January 31, 2003	July 31, 2003

PROBLEM

The 7N5378 MUI Fuel Lever may fail on certain 3508, 3512, and 3516 Industrial, Marine, and Generator Set Engines. The levers produced after November 1, 2001 may have reduced durability and need to be replaced.

AFFECTED PRODUCT

Note: (Group 1 is engines built after November 1, 2001 with remote 2301 governors utilizing hydraulic actuators.)
(Group 2 is engines built after November 1, 2001 with mechanical governors, 3161 or UG8)

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Model	Identification Number
*** Group 1 ***
3508	23Z7905-7908, 7910, 7911, 7913
3512	24Z10103-10115
3516	25Z7076-7078
3508	4ZL901
3512	51Y850
3508	5PW466, 467, 469
3512	65Z1046
3512	67Z1996-1998
3508	68Z1201
3512	6WW569, 571-589
3516	73Z956, 957
3516	8TW450-453
3508	95Y1166, 1169
3516	CMD216-231
3512	CMJ289-340, 343
3508	CNF282-299
3512	PTG124-136

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Model	Identification Number
*** Group 2 ***
3508	23Z7909, 7912
3508	95Y1167, 1168, 1170
3508	96Y2005-2013
3508	68Z1202-1206
3512	49Y992-996
3512	50Y1769-1770
3512	65Z1047-1048, 1055, 1056
3512	66Z917-922
3516	71Z381-388
3516	72Z564
3516	29Z1370-1371

PARTS NEEDED

Dealers will need to order parts for this Program.

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Quantity	Part Number	Description
*** Group 1 ***
1	8N1996	GASKET
2	8N9885	GASKET-DRIVE
1	5P1275	WIRE-LOCK
1	8S8158	SEAL-WIRE
2	2207173	LEVER AS

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Quantity	Part Number	Description
*** Group 2 ***
1	8C5197	SEAL-0-RING
1	8N1996	GASKET
2	8N9885	GASKET-DRIVE
1	5P1275	WIRE-LOCK
1	8S8158	SEAL-WIRE
1	3P0647	SEAL-0-RING
2	2207173	LEVER AS

ACTION REQUIRED

***** Parts Stock *****

Remove all 7N5378 Fuel Levers from dealer parts stock.

***** Affected Product *****

***** Group 1 and Group 2 *****

Refer to the Service Manual and the attached photos to replace the existing 7N5378 Lever with the new 220-7173 Lever.

NOTE: The D&A Manual indicates front housing removal is required to service the fuel control linkage. However the 5N5378 lever can be replaced with the 220-7173 lever without removing the front housing.

OWNER NOTIFICATION

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

SERVICE CLAIM ALLOWANCES

***** Parts Stock *****

Submit one claim for all 7N5378 Fuel Levers removed from dealer parts stock.

***** Affected Product *****

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
*** Group 1 ***
100%	2.5	0	0	0	0
NOTE: This is a 2.5-hour job.
NOTE: U.S. and Canadian Dealers Only - This Program does not qualify for a Type 2 SIMS Report.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
*** Group 2 ***
100%	3.5	0	0	0	0
NOTE: This is a 3.5-hour job.
NOTE: U.S. and Canadian Dealers Only - This Program does not qualify for a Type 2 SIMS Report.

PARTS DISPOSITION

***** Parts Stock *****

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

***** Affected Product *****

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach. (1-Owner Notification)
(2-Rework Procedure)

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACIING THE 7N5378 MUI FUEL LEVER ON CERTAIN 3508, 3512, AND 3516 INDUSTRIAL, MARINE, AND GENERATOR SET ENGINES

MODELS INVOLVED - 3508, 3512, AND 3516 ENGINES

Dear Caterpillar Product Owner:

The 7N5378 MUI Fuel Lever may fail on the product listed below. The levers produced after November 1, 2001 may have reduce durability and need to be replaced.

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 July 15, 2002 when scheduling this service. You will not be charged for the service performed.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)
Attached to July 15, 2002 Service Letter