PRODUCT IMPROVEMENT PROGRAM REPLACING THE FUEL FILTER BASE ON CERTAIN 3508, 3508B, 3512, 3512B, 3516 AND 3516B ENGINES

Usage:

SEBE8792-01

May 19, 2004
(Revised May 2004)
U-164
A-112
D-125
O-135
TM-8

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*Priority*	PRODUCT IMPROVEMENT PROGRAM REPLACING THE FUEL FILTER BASE ON CERTAIN 3508, 3508B, 3512, 3512B, 3516 AND 3516B ENGINES
1261		PI30666

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30666" 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 "PI30666" 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.

NOTE: This Revised Service Letter replaces the May 19, 2004 Service Letter. Changes have been made to the Rework Procedure.

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COMPLETION DATE	TERMINATION DATE
November 30, 2004	May 31, 2005

PROBLEM

AFFECTED PRODUCT

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Model	Identification Number
3508	CNF440-445, 457, 459, 460, 464-477, 479, 480 95Y1216, 1218-1230 96Y2056, 2058-2067 68Z1251, 1252 70Z1077
3508B	CBB186-197 CNB817, 800, 820, 821, 823-825, 829-835, 837, 845, 847, 850, 854, 855, 860-868, 872-876, 885, 888, 889, 891-892, 897-905, 909, 910, 914, 915, 917, 919-922 3DM445, 458-460, 465 7SM910, 912, 917, 927-932, 935, 936 6PN845-850, 853-867, 870-873 5PS317, 318 1TW343, 344, 347 2HW248-257, 261, 262 BGX116, 117 BPX98
3512	FDR319, 320 49Y1017-1024, 1028, 1029, 1031, 1032, 1035, 1036, 1038 50Y1806, 1807 51Y862 24Z10151, 10152 65Z1130-11346 66Z939-943, 946, 947 67Z2039-2041, 2044-2058, 2060-2067
3512B	CMC801, 804, 808, 810-813, 819, 823, 828, 829, 838, 840-845, 851-854, 862, 871, 874, 875, 877-880, 882, 884, 887, 889-891, 906, 909 2AF362-368, 373-378 PWG110-113 CMJ653-657, 661, 666, 667, 676, 692-694, 696-699, 704, 705, 708-714, 716-720, 726-728, 741, 742, 744-746, 750, 752, 754, 755, 757-771, 773, 776, 777, 779-781 BRK231-232, 239-246 7HM261 BRN190, 191 4TN782, 783, 789, 790, 792, 805, 806, 810 2GW395, 397, 399-402, 404, 406, 407 3ZW449-455, 459-461, 464, 465, 482-498, 500, 501, 503, 504 4AW823-826, 835 2EZ324-327
3512B M/	1PW427, 429, 430, 434
3516	CMD359, 360, 362-389, 392, 394, 396-399, 401-404 27Z851
3516B	CDE312 BPJ427-429, 431-439 BCK274-281 CAL159-161 CBN312-315 FDN1201, 1219-1221, 1223-1225, 1227-1231, 1235, 1237, 1238, 1241, 1242, 1244-1247, 1251-1258, 1262, 1263, 1266-1274, 1277, 1278, 1280-1283, 1289, 1291, 1297, 1300-1302, 1305, 1311 8KN565, 566, 570 2FW333-337 3CW253 4BW536, 537, 546, 547, 553, 554, 559, 562-564 S2X106

PARTS NEEDED

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Qty	Part Number	Description
1	8H2778	Seal - Ring 8H-2778
1	9M2342	Screen Assembly
1	1W0531	Base ? Fuel Filter

ACTION REQUIRED

See the attached Rework Procedure.

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
100%	1	0	0	0	0
NOTE: This is a 1-hour job.

PARTS DISPOSITION

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 - The Fuel Filter Base Needs To Be Replaced

MODELS INVOLVED - 3508, 3508B, 3512, 3512B, 3516 and 3516B Engines

Dear Caterpillar Product Owner:

The fuel filter base needs to be inspected and possibly replaced on certain 3508, 3508B, 3512, 3512B, 3516 and 3516B Engines. An incorrectly manufactured fuel filter base could have been installed on certain Caterpillar packaged generator sets. This filter base misdirects fuel flow through the filter and could cause the filter or other fuel system components to fail. The fuel filter base needs to be inspected on the products listed below. A new fuel filter base needs to be installed on the products found having the incorrectly manufactured base. 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 May 19, 2004 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 May 19, 2004 Service Letter

Rework Procedure

Turn off all supply power, prevent the engine from starting and lock out the equipment before working on the equipment or inside equipment. Only qualified Caterpillar technicians must service this equipment. Always use the properly rated voltage-sensing device in order to confirm power is off. Replace all devices, doors, and covers before turning power on to this equipment.
Isolate the 8N6435 Primary Fuel Filter Group from the engine and the fuel supply by closing the appropriate isolation valves.
Remove the 8H7202 Case and 9M2342 Element Assemblies from the Filter Base by loosening the 7N1628 Nut on top of the base. See Illustration 1.

Illustration 1

Fuel Filter Group Configuration (w/ Correct Base)

Look at the bottom side of the 1W0531 Filter Base where the element and case assemble. Refer to Illustration 2 to determine if the Filter Base is cast correctly.

Illustration 2 ? 1W0531 Filter Base Configurations

If it is determined that the Filter Base is correctly cast, proceed to Step 10.
If it is determined that the Filter Base is incorrectly cast, it must be replaced with a new 1W0531 Filter Base.
Disconnect any hoses connected to the Filter Base.
Remove the incorrect Filter Base from the system and replace with a correctly cast base.
Reconnect all hoses to the Filter Base.
Install a new 8H2778 Gasket in the location shown in Illustration 1.
If the Element Assembly previously removed is not damaged, reassemble it with the Case Assembly and the Filter Base. If it is damaged it should be replaced with a new 9M2342 Element Assembly. Tighten the nut previously removed to 25 N.m. Refer to Illustration 1.
Open all isolation valves and inspect the system for leaks. If no leaks are present, this program is complete and the system may be operated according to the Operation and Maintenance Manual.