PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REWORKING THE FUEL METERING VALVE ON CERTAIN G3516B, G3516C, G3516E, G3520B, G3520C, AND G3520E ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REWORKING THE FUEL METERING VALVE ON CERTAIN G3516B, G3516C, G3516E, G3520B, G3520C, AND G3520E ENGINES

Usage:

REBE4625-01

Show/hide table

26Jan2009

(Revised 02Apr2009)

U-28

A-26

D-23

O-24

Show/hide table

*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REWORKING THE FUEL METERING VALVE ON CERTAIN G3516B, G3516C, G3516E, G3520B, G3520C, AND G3520E ENGINES
1250 1741 1254		PI31618

Show/hide table

NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31618" 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 "PI31618" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

Show/hide table

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.

Show/hide table

NOTE:

Show/hide table


NOTE:	This Revised Service Letter replaces the 26Jan2009 Service Letter. Changes have been made to contact information in Action Required.

Show/hide table

COMPLETION DATE	TERMINATION DATE
31Jul2009	31Jan2010

PROBLEM

Show/hide table

The fuel metering valve needs to be inspected and possibly reworked on certain G3516B, G3516C, G3516E, G3520B, G3520C, and G3520E engines. Some of the existing fuel metering valve main circuit boards contain a light conformal coating resulting in a valve failure and engine shutdown.

The light conformal coating is not sufficient to dampen vibration from ferrites on the main circuit board. When the ferrites vibrate, the electrical connection is fatigued until it breaks. When this occurs, the engine shuts down and the fuel control valve must be replaced.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
G3516B	ZBC00145-00186
G3516C	GSB00114-00119 GZZ00164-00165, 170-173, 180-268
G3516E	GAS00136-00265
G3520B	GLF00103-00112 GZP00116-00127 TPC00101, 103-107
G3520C	GZJ00203-00388 GZK00167-00183 GZL00141-00145 GZM00144-00204 GZN00241-00251, 253-254, 257, 261-451, 454-685 LGS00150-00154 RLP00150-00180
G3520E	GZG00111 GZH00123-00139

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
1	2476020	SEAL-FUEL SYSTEM
1	3299891	SEAL-O-RING
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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

Show/hide table

This program is to be applied before a fuel metering valve failure has been experienced. In preparation for reworking the fuel metering valve, procure 84045 Conformal Coating with Applicator from Chemtool Inc. using the contact information below.

Erin Levin
Phone: 262-723-6590
elevin@chemtool.com

Inspect the hour meter on the engine. If more than 15,000 hours have been accumulated, there is no further rework required. File a SIMS entry to state the number of engine hours.

If the engine has less than 15,000 hours, rework the fuel metering valve. Refer to the attached Rework Procedure.

Show/hide table

OWNER NOTIFICATION

Show/hide table

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

SERVICE CLAIM ALLOWANCES

Show/hide table

Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

Show/hide table

NOTE: This is a 1.0-hour job
1.0 hour will be allowed for the hour meter inspection and Sims entry. An additional 1.0 hour will be allowed for the fuel metering valve rework.

Show/hide table

PARTS DISPOSITION

Show/hide table

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

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

Show/hide table

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

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REWORKING THE FUEL METERING VALVE ON CERTAIN G3516B, G3516C, G3516E, G3520B, G3520C, AND G3520E ENGINES

MODELS INVOLVED - G3516B, G3516E, G3520B, G3520C, and G3520E Engines

Dear Caterpillar Product Owner:

The fuel metering valve needs to be inspected and possibly reworked on the products listed below. The existing fuel metering valve main circuit board may fail leading to an engine shutdown. 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 26Jan2009 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 26Jan2009 Service Letter

Rework Procedure

Show/hide table

This rework procedure applies to 185-5310, 204-3508, and 236-1123 Fuel Metering Valves.

Refer to appropriate Service Manual as necessary. Follow all safety shutdown and lockout procedures.

1. Disconnect the harness assembly from the fuel control valve.

2. Use a 1/4" wrench to remove the 4 screws/washers attaching the cover to the connector, and the 18 screws/washers along the perimeter of the cover. Remove the cover.

3. After the cover has been removed, verify the location of the Ferrite Beads that require extra Conformal Coating (see Image 1.1.1 for details).

Image1.1.1

4. Use the Chemtool 84045 syringe to apply a small amount of Conformal Coating around each Ferrite Bead, and then across the top, as shown in Images 1.2.1 & 1.2.2. Each fuel control valve rework will take approximately 3 cc of Conformal Coating.

NOTE:
-Safety Glasses are required.
-Rubber Gloves are recommended while handling material.
-Material should be handled with adequate ventilation.

Image1.2.1

Image1.2.2

5. Inspect components to verify the proper fillet has been achieved (Images 1.3.1 & 1.3.2).

Image1.3.1

Image1.3.2

6. Allow 20 minutes to dry before installing the Cover.

7. Prior to attaching the cover, inspect o-rings for contamination, and lubricate with petroleum jelly as necessary.

8. Install cover and secure by hand with the 18 screws/washers, finger tight. Install the 4 screws/washers in the holes around the connector. Tighten all screws to a torque of 28 +/-3 lb-inches, in a crossing pattern.

9. Reconnect the harness assembly.

10. Discard the remaining conformal coating.
- Dispose of remaining conformal coating properly as it is a flammable substance. Local disposal laws may apply.