Product Improvement Program for adding vibration dampers to Air Shut Offs on certain 3500 diesel engines Caterpillar

Product Improvement Program for adding vibration dampers to Air Shut Offs on certain 3500 diesel engines

Usage:

REBE1061-01

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27Jul2006

(Revised 04Oct2006)

U-574

A-562

D-555

O-559

TM-505

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR ADDING VIBRATION DAMPERS TO AIR SHUT OFFS ON CERTAIN 3500 DIESEL ENGINES
1078 1435		PI31122

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31122" 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 "PI31122" 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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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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NOTE:	This Revised Service Letter replaces the 24 July 2006 Service Letter. Changes have been made to Affected Product and rework procedure.

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COMPLETION DATE	TERMINATION DATE
31Jan2007	31Jul2007

PROBLEM

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Relative motion between the air shutoff gate and the housing may cause a wear-step in the housing. This wear can prevent the gate from closing and can lead to engine damage if the engine is operated with one gate opened and one gate closed.

AFFECTED PRODUCT

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Model	Identification Number
3508B	2HW00237, 239, 335-381 3DM00332, 334, 355, 358-359, 511-521 3DW00189 CBB00444-00537 S2A00123, 127 S2B00254, 258-260, 264, 269-270, 290-292, 305-309
3508C	LLC00103-00116 LLE00101-00123
3512B	1PW00447 2AF00487-00488, 503-504, 545-562 4AW00174, 176-182, 200-201, 263, 269, 271, 275, 295, 307-310, 315, 317, 319, 439, 468-469, 472, 476, 478, 563, 590-593, 598-604, 606-608, 666-667, 670, 687-688, 696, 701, 733-737, 740-741, 744, 748, 750-752, 754-755, 757, 762, 767, 769, 773-774, 788, 790-791, 862, 1264-1663 8EM00267-00268, 272, 293, 520, 522-523, 532-533, 536-537, 554-555 PTF00170-00172, 175-180 S2H00195, 197-198, 208-209, 218, 221-223, 225-236 S2J00298, 301-302, 304, 334, 341-350 S2M00151-00154
3512C	LLA00103-00150, 152-310 LLF00100-00133
3516B	2FW00391-00394 9AN00197, 219, 339, 341-343, 397-400, 403-405 CBN00381-00440 LEK00127-00130 S2R00187-00188, 190-196, 216-230 S2S00227-00230 S2W00106 S2X00364-00365, 395-396, 419, 449, 463-482 S2Y00109-00110
3516B HD	S2Z00106-00123

PARTS NEEDED

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Qty	Part Number	Description
2	1790133	FILM-AIR SHUTOFF
2	2898498	DAMPER AS

ACTION REQUIRED

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Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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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%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 1.0-hour job

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR ADDING VIBRATION DAMPERS TO AIR SHUT OFFS

MODELS INVOLVED - CERTAIN 3500 DIESEL ENGINES

Dear Caterpillar Product Owner:
New vibration dampers need to be installed on the products listed. 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.

It is VERY IMPORTANT that your Air Shut Offs be tested every 500 operating hours and the vibration dampers installed on the ASOs need to be inspected/serviced every 6000 operating hours. Please contact your Caterpillar Dealer for a copy of Caterpillar Special Instruction REHS3005, which details this procedure. A COPY OF THIS DOCUMENT SHOULD BE PLACED IN THE APPLICABLE Operating and Maintenance Manuals.

Please refer the dealer to their Service Letter dated 27Jul2006 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 27Jul2006 Service Letter

Rework Procedure

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1. Remove existing plug from bottom of each Air Shut Off (ASO) housing, Image 1.1.1

Image1.1.1

2. Install new Vibration Damper P/N 289-8498 into the hole as shown in image 1.2.1, insuring that the threads are coated with Thread lock P/N 9S-3263 or 4C-4030 and torque the damper to 16 (+/- 2)Nm.

Image1.2.1

3. Install information labels over existing labels on the electrically actuated ASO solenoids as shown in image 1.3.1 or on hydraulically actuated ASO valve covers as shown in image 1.3.2.
Labels in languages other than English are available under the following Part Numbers:
-Arabic 297-2613
-French 297-2614
-German 297-2615
-Spanish 297-2616
-Portuguese 297-2617
-Russian 297-2618