PRODUCT IMPROVEMENT PROGRAM FOR REPAIRING THE ACTUATOR GROUP ON CERTAIN G3516B, G3606, G3608, G3612, AND G3616 GAS ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPAIRING THE ACTUATOR GROUP ON CERTAIN G3516B, G3606, G3608, G3612, AND G3616 GAS ENGINES

Usage:

SEBE8503

September 11, 2003
U-247
D-178
O-207

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPAIRING THE ACTUATOR GROUP ON CERTAIN G3516B, G3606, G3608, G3612, AND G3616 GAS ENGINES
7550		PI30529

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30529" 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 "PI30529" 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
March 31, 2003	September 30, 2004

PROBLEM

The Actuator Gp, 2118175, needs to be repaired on certain G3516B, G3520B, G3606, G3608, G3612, and G3616 Gas Engines. Some SI Actuators were assembled incorrectly within the piston assembly process causing oil loss. Loss of oil may cause engine to run erratic, to stop, or not to start at all.

AFFECTED PRODUCT

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Model	Identification Number
* Group 1 *
G3516B	CEY160-164 CSC117-223
* Group 2 *
G3606	4ZS302, 305-321
G3608	BEN218-225
G3612	BKE213-225
G3616	BLB187-205

PARTS NEEDED

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Qty	Part Number	Description
* Group 1 *
1	2118177	PISTON AS
* Group 2 *
3	2118177	PISTON AS

ACTION REQUIRED

Shutdown the engine.
Repair only the hydrax actuators with the serial numbers from 02500000088 through 0322000492 inclusive. On G3500 engines there is one hydrax actuator for throttle control. On G3600 engines there are three: throttle, waste-gate and choke control. Locate the serial number below the part number on each actuator, see Illustration 1. Removal of the actuator may be required, action item 3, in order to complete this task. Paint may obstruct the part/serial number therefore removing the paint by scraping that area may be necessary.

Illustration 1

Drain the hydrax oil from the individual actuators. Do not drain the hydrax system. Remove the actuators as specified in the appropriate D&A manuals, SENR4259 or SENR5535.
Remove the existing piston assembly and replace it with a new piston assembly 2118177 according to the above D&A Manuals.
Restart the engine.

OWNER NOTIFICATION

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.
* Group 1 *
100%	3.0	0	0	0	0
* Group 2 *
100%	5.0	0	0	0	0
NOTE: This is at most a 5.0-hour job. NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report

PARTS DISPOSITION

NOTE: All dealers are to make sure the outside of the shipping container is marked PI30529. ***** U.S. and Canadian Dealers *****

Return all that are removed from parts stock and a copy of the claim to:

Catepillar Inc.
Attn: Matt Daugherty/Supplier Recovery PI30529
Service Claims Room
8201 N. University Street
Peoria, IL 61615

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

Attach. (1-Owner Notification)

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPAIRING THE ACTUATOR GROUP

MODELS INVOLVED ? CERTAIN G3516B, G3606, G3608, G3612, AND G3616 GAS ENGINES

Dear Caterpillar Product Owner:

The Actuator Gp needs to be repaired on the products listed below. Oil leaks may cause the engine to run erratic, to stop, or not to start at all. 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 September 11, 2003 when scheduling this service.

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 date Service Letter