PRODUCT IMPROVEMENT PROGRAM FOR UPDATING THE GOVERNORS ON CERTAIN 3116 TRUCK ENGINES

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Caterpillar: Confidential Yellow

PRODUCT IMPROVEMENT PROGRAM FOR UPDATING THE GOVERNORS ON CERTAIN 3116 TRUCK ENGINES

SEBE4495-02

January 20, 1991
(Revised July 2001)
U-11
TT-1.1

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*Safety* *Parts stock action needed*	PRODUCT IMPROVEMENT PROGRAM FOR UPDATING THE GOVERNORS ON CERTAIN 3116 TRUCK ENGINES
1264		PI1155

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI1155" 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 "PI1155" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

NOTE: This Revised Service Letter replaces the January 20, 1991 (Revised March 1991) Service Letter. Replace identified governors with newer models resulting in no rework required. Governors that have already been reworked under this service letter, DO NOT require any further attention. Changes have been made to the Parts Needed, Action Required, Service Claim Allowances, and Parts Disposition sections.

NOTE: No additional rework is required on any of the 3116 Truck Engines that have already been reworked under this program. Engines that were not reworked because the governor serial number was above 0029011 and / or because the letter "K" was stamped in the "LOT" space on the governor serial number plate may need to be reworked.

NOTE: Those governors already reworked DO NOT require any further rework or replacement.

PROBLEM

The governor on certain 3116 Truck Engines may fail to control engine speed because of an improperly tightened governor riser lever bolt, or an improperly installed governor control lever spring.

The normal driver shut-down system for the engine is not affected by either problem, and can be used to shut the engine off.

AFFECTED PRODUCT

NOTE: In addition to various other vehicles that use the engines listed below, most 1990 model and some 1991 model TopKick/Kodiak Trucks are affected. Check the engine serial number and compare it to the list that follows.

Model Identification Number

3116 7SF1-4014, 4016-4173, 4175-4347, 4349-4644, 4646-4665, 4667-5166, 5168-6355, 6357-6367, 6369-6373, 6375-6385, 6387-6392, 6394-6410, 6412-7247, 7253-8441, 8443-8455, 8457, 8458, 8460-8515, 8518-8535, 8537-8587, 8589-8597, 8599-8665, 8667-8672, 8674-8677, 8680, 8682, 8684, 8686, 8691, 8699-8719, 8723-8745, 8747, 8748, 8750, 8752, 8754-8786, 8788-8810, 8812-8817, 8820, 8823-8830, 8832-8863, 8865-8893, 8895-8903, 8905-8963, 8966-9012, 9015-9040, 9042-9098, 9100-9103, 9105-9108, 9110-9118, 9120, 9121, 9123-9143, 9145-9190, 9192-9197, 9199-9201, 9203-9208, 9210-9254, 9256-9285, 9287, 9289-9292, 9294-9330, 9333-9349, 9353, 9354, 9357, 9361, 9365-9375, 9377-9397, 9399-9423, 9425-9428, 9430-9434, 9441, 9449-9481, 9483, 9484, 9486-9501, 9503, 9505-9511, 9514, 9522, 9526, 9530, 9531, 9534-9538, 9540, 9542, 9545, 9547-9560, 9563, 9569-9582, 9584, 9586-9589, 9591-9600, 9604, 9610, 9615-9635, 9637-9647, 9650, 9653, 9658, 9660, 9663, 9667, 9672, 9674, 9684-9687, 9698, 9700, 9701, 9704-9706, 9708, 9709, 9711-9713, 9715-9718, 9720, 9722-9728, 9732, 9735, 9736, 9740, 9743, 9744, 9748, 9750, 9751, 9753, 9755, 9757, 9758, 9760, 9767, 9773, 9775-9778, 9780-9783, 9785-9796, 9798-9804, 9807, 9808, 9811, 9812, 9815, 9817, 9818, 9821, 9822, 9826, 9834, 9838-9842, 9845, 9846, 9849, 9853, 9859-9865, 9867-9873, 9875-9879, 9883, 9884, 9887, 9889, 9891, 9892, 9897-9899, 9904, 9905, 9909, 9913, 9917, 9924, 9928, 9929, 9932, 9937, 9941, 9942, 9944-9946, 9948-9951, 9953, 9955-9964, 9966, 9968-9970, 9978, 9985, 9988, 9994, 9995, 9997, 10001, 10009, 10014-10016, 10018, 10019, 10021-10024, 10026, 10028-10040, 10043-10046, 10048, 10049, 10051-10081, 10084-10086, 10093, 10097, 10101, 10104-10106, 10109, 10111-10118, 10120, 10122-10126, 10128, 10131-10136, 10139, 10141, 10144, 10148, 10151, 10155, 10156, 10161, 10163, 10167, 10172, 10177, 10179, 10180, 10182-10186, 10188-10194, 10196-10199, 10201, 10202, 10204, 10206, 10208, 10211, 10214, 10217, 10220, 10221, 10223, 10225, 10226, 10228-10230, 10233-10235, 10237, 10241-10246, 10249, 10250, 10254, 10260, 10264, 10266-10269, 10271-10273, 10277-10280, 10283, 10284, 10289-10291, 10293, 10294, 10296, 10298, 10300-10304, 10309, 10323, 10332, 10337, 10341, 10342, 10345, 10349-10351, 10356, 10357, 10360-10362, 10364, 10365, 10369, 10371, 10373, 10376-10378, 10380-10389, 10392, 10401, 10403-10405, 10415, 10419, 10422-10426, 10428, 10429, 10431-10435, 10438, 10443, 10444, 10455, 10457, 10460, 10477, 10483, 10490, 10496, 10499, 10502, 10507, 10509, 10523, 10525, 10526, 10535, 10537, 10544, 10561, 10573, 10578, 10580, 10584, 10590, 10592, 10594-10597, 10601, 10602, 10604-10609, 10612, 10613, 10616, 10620, 10624, 10635, 10638, 10642, 10646, 10650, 10652, 10653, 10656, 10659, 10663, 10667, 10674, 10677, 10678, 10682, 10684-10691, 10695, 10699, 10700, 10702, 10706, 10712, 10717, 10735, 10737, 10739, 10740, 10743, 10753, 10756, 10759, 10763, 10764, 10766, 10767, 10771, 10772, 10775, 10779, 10780, 10785-10789, 10792, 10793, 10795, 10797, 10803, 10807, 10810, 10811, 10815-10817, 10819-10821, 10823, 10824, 10827, 10831, 10837, 10839-10842, 10844, 10846, 10848, 10849, 10851-10854, 10857-10859, 10861, 10862, 10864, 10867, 10869, 10872, 10873, 10883, 10887, 10888, 10890, 10891, 10894, 10895, 10900, 10903-10906, 10909, 10910, 10916, 10918, 10920, 10923, 10924, 10928-10931, 10933-10935, 10937, 10938, 10940-10942, 10944, 10947, 10948, 10959, 10972, 10975-10977, 10981, 10990, 10991, 10994, 10996, 10997, 10999, 11001, 11002, 11004, 11006, 11007, 11010, 11013, 11015, 11018, 11030, 11141, 11046, 11048, 11052, 11054, 11055, 11061, 11063, 11065, 11066, 11068, 11073, 11081, 11084, 11085, 11095, 11100, 11105, 11108, 11116, 11117, 11120-11124, 11128, 11132, 11135, 11137, 11143-11150, 11155-11175, 11177, 11180, 11196, 11197, 11202-11206, 11208, 11209, 11222, 11230, 11231, 11233-11235, 11238-11244, 11246, 11248, 11250-11257, 11262, 11265, 11267, 11271, 11276, 11286, 11288, 11290, 11295-11299, 11301, 11307, 11309, 11323, 11329, 11330, 11332, 11334, 11349, 11355, 11358, 11360, 11365, 11371, 11377, 11378, 11382, 11397, 11404, 11408, 11411, 11412, 11414, 11427, 11433, 11446, 11455, 11456, 11460, 11462, 11464, 11474, 11485, 11488, 11490, 11493, 11495-11497, 11501, 11502, 11504, 11508, 11510, 11512, 11516, 11526, 11527, 11529, 11531, 11532, 11535, 11537-11543, 11547, 11551, 11553, 11555, 11557, 11559, 11563, 11570, 11573, 11575, 11578, 11581, 11583-11585, 11592, 11597, 11600, 11601, 11604, 11605, 11608, 11610, 11612, 11617, 11618, 11620, 11621, 11625-11628, 11630, 11632-11634, 11636, 11637, 11640, 11642-11644, 11648, 11650, 11651, 11655, 11657, 11659, 11660, 11662-11668, 11670-11674, 11676, 11680, 11682-11684, 11686-11688, 11693, 11696, 11698-11700, 11702, 11706, 11707, 11709-11719, 11721, 11726, 11728, 11732, 11735, 11738, 11742-11745, 11747, 11750-11754, 11757-11767, 11769, 11770, 11772, 11776, 11777, 11779, 11785-11791, 11793-11795, 11797, 11798, 11801, 11802, 11804-11812, 11815-11823, 11829-14388

PARTS NEEDED

Order the required parts in chart below from the parts department for this program. If the engine meets the criteria within this Service Letter, parts and labor can be claimed within the normal warranty process. Reference this service letter when processing.

TopKick / Kodiak dealers should order parts from their local Caterpillar Distributor in accordance with chart below. Caterpillar dealers should note, that when installing the new governor, it may be necessary to upgrade the throttle cable from non-adjustable to adjustable. The new adjustable throttle cable assembly is GM part number 15996199 and can be obtained through any Top Kick or Kodiak dealer. Previously, updated governors were provided at no charge on an exchange basis. This is no longer the process. Order a replacement governor and other related parts as outlined in the chart below.

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Engine Horsepower	Former Governor Group	New Replacement Governor
165	9Y2675	4P5506
170	4P2557	4P5506
185 w/automatic trans.	7C4176	4P5507
185 w/manual trans.	9Y7899	4P5508
215	7E0002	4P5509
250	7E0001	4P5510

Additional Hardware: (order with each governor, return unused for credit)

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Quantity	Part Number	Description
1	7X0457	Bolt
1	7X2537	Bolt
2	7X0579	Washer
2	9M1974	Washer
1	4P8150	Bracket
1	4P0683	Lever Assembly
1	4P2987	Spacer
1	4P9161	Lever
1	6I0484	Lever Assembly
2	6I0483	Spring
1	6I0482	Lever Assembly
1	5C9553	Bolt
1	6V7646	Washer
1	8T2228	Washer
1	8C8451	Bolt

ACTION REQUIRED

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

Remove all new 4P2557, 7C4176, 7E0001, 7E0002, 9Y2675, and 9Y7899 Governor Groups from parts stock that have governor serial numbers below 0031637.

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

Caterpillar will notify in writing all users of trucks (vehicles) with the affected engines. Notification letters will be mailed to users within 30 days of this Service Letter (copy attached). The letter will request users to call their local TopKick/Kodiak dealer or Caterpillar dealer with the following information:

-Engine serial number
-Engine arrangement
-Engine horsepower rating
-Governor serial number
-Governor Group Number
-Governor "LOT" block information
-Vehicle mileage
-Automatic / manual transmission
-Vehicle Identification Number (VIN) It would be most convenient to copy the "Engine and Vehicle Information" page from the owner letter and have it available to fill in when the owner calls with his vehicle information.

Schedule the truck engine for installation of an updated governor if both the following conditions apply:

The engine serial number is within the affected product range
The governor must be one of the former ones listed in chart
No "H" is stamped in the governor serial number plate LOT block.

(a "K" in the "Lot" block of the governor plate indicates that the basic update has been completed)
(a "H" indicates the governor has an improved riser shaft installed)

Engines which previously received updated governors, are NOT ELIGIBLE

TopKick / Kodiak dealers are requested to acquire the new replacement parts from their local Caterpillar distributors. File claims in accordance with normal warranty procedures. No return of problem hardware is required.

USE THE FOLLOWING PROCEDURE TO INSTALL THE UPDATED GOVERNORS:

Check the engine serial number against the affected product list to confirm that replacement is necessary. Also check the governor serial number plate for the governor serial number and for the letter "H" stamped in the LOT space.

NOTE: If the letter "H" has already been stamped in the lot space on the governor serial number plate, or if the governor serial number is above 0031636, an updated governor is not needed.

If the engine serial number is listed above, there is no "H" stamped in the LOT space on the governor, and the governor serial number is 0031636 or below, installation of an updated governor is necessary.

CAT distributors and TopKick / Kodiak dealers should obtain the required components as outlined in chart under Parts Needed Section. In addition to the Governor group and governor serial number, the engine serial number is needed when processing the warranty claim.
When new replacement components have arrived, remove the original governor and replace with new governor group as shown in chart below. NOTE: additional items are listed to ensure all required hardware is updated for every possible engine configuration. There are differences in required associated hardware items with newer model governors. Replace in accordance with normal procedures. Return unused component/s for credit.
If adjustable cable assembly is required, follow these steps:

Install 15996199 Throttle Cable Assembly
Depress (push) foot feed/pedal to the floor and move the governor control lever (with springs attached) to the MAXIMUM break over position (past high idle position)
Push down button on throttle cable, which locks the cable sheath. This assures the foot pedal will move the governor lever to the high idle position.

Transfer the 7E0155 fuel-inlet screen (if equipped) from original governor, and install it in the new governor.
Install the new replacement governor in the reverse order.
After the governor is installed, check the fuel setting as described in the 3116 Diesel Truck Service Manual. Refer to the section titled "Fuel Setting" on page 3-10.

Check low idle (750 +/- 10 rpm) and high idle engine speed (listed on engine information plate) and confirm that a governor seal has been installed in the high idle adjusting screw. Use a 6V3121 Multitach or 1U6602 Phototach, or an industry-equivalent photo-tachometer with accuracy of +/- 1 rpm.

OWNER NOTIFICATION

U.S. and Canadian owners have already received the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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

Submit one claim, at dealer net price, for required replacement components listed in the Action Required section of this letter.

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

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
*	3.3	0	0	0	0
* The dealer will be reimbursed for the parts in accordance with this service letter at the Dealer Net rate. NOTE: This is a 3.3- hour job. This labor hour allowance will cover the removal of the old governor, installation of the new governor, verification of fuel settings and exchange of the GM throttle cable (as required). List 3.3 hours labor at your selling rate.

PARTS DISPOSITION

No return of used governor is required. Ensure claims follow the guidelines established within this notification. After receiving claim payment, replaced (used) governors MUST BE SCRAPPED. Affected governors MUST NOT be placed back in service.

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

Attach. (1 - U.S. Owner Notification)
(2 - Canadian Owner Notification)

COPY OF OWNER NOTIFICATION FOR U.S. OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

Dear Caterpillar Product Owner:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Caterpillar Inc. has determined that a defect that relates to the motor vehicle safety exists in a small number of Caterpillar 3116 Truck Engines.

The engine governor may fail to control engine speed. If you or your driver, experience the inability to control engine speed before repairs can be made, the engine should be immediately shut off and the vehicle parked in gear (or other proper "Park" position) to prevent possible engine damage.

Our records indicate that your 3116 Truck Engine, listed below, may be affected. In the interest of safety and satisfaction with your vehicle, we want to emphasize the importance of having this service performed.

Please follow the instructions listed on the next page. If the governor on your engine is affected, the dealer will repair or replace the governor with an updated one at no charge to you.

To avoid inconvenience and unnecessary downtime, please:

Complete the information on the attached "Engine/Vehicle Information Sheet" for each engine and have it available.
Then, with this information, contact a GMC TopKick/Chevrolet Kodiak or Caterpillar Dealer. The dealer will determine if an updated governor is needed.

If eligible, the dealer will schedule a date to install an updated governor. Allow at least two (2) business days for the dealer to obtain an updated governor of the correct part number for your engine.

Be sure to have the vehicle at the dealership when scheduled. You can expect the repair time to be four (4) hours, or less.

If the dealer is unable to have these repairs made within 60 days and without charge, please contact:

Caterpillar Inc.

If you are still unable to have the problem corrected without charge, you may wish to report that fact to:

Administrator

^th

Caterpillar Inc.

Identification #(s)

Attach. (1-Engine and Vehicle Information)

Attached to July 20, 1991 Service Letter

ENGINE AND VEHICLE INFORMATION

The dealer needs the information below to determine if the governor on your 3116 Truck Engine is eligible for the rework. For each engine, copy the information exactly as it appears on the engine data plates.

ENGINE INFORMATION: (Found on data plate on top of the engine valve cover)(a representation of the plate is shown below)

Engine Serial Number (SER. NO.): _ _ _ _ _
Engine Arrangement Number (AR. NO.): _____________
Engine Power (HP) (circle one) 165 170 185 215 250

GOVERNOR INFORMATION: (Found on data plate on top of governor)(a representation of the plate is shown below)

Governor Serial Number (S/N): _____________________
Governor Group Number (GP) (circle one)

9Y2675 4P2557 9Y7899 7C4176 7E0002 7E0001

"LOT" Number Information: _________________________

(All numbers and letters)

VEHICLE INFORMATION:

What is the current odometer reading? __________Miles/Km
Is the vehicle equipped with an automatic transmission?

(circle one) YES NO

What is the Vehicle Identification Number (VIN)? ____________________________________

(only the last 8 letters/numbers are needed for GMC/Chevrolet vehicles, such as LJ123456).

COPY OF OWNER NOTIFICATION FOR CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

Dear Caterpillar Product Owner:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Caterpillar Inc. has determined that a defect which relates to the motor vehicle safety exists in a small number of Caterpillar 3116 Truck Engines.

Please follow the instructions listed on the next page. If the governor on your engine is affected, the dealer will repair or replace the governor with an updated one at no charge to you.

To avoid inconvenience and unnecessary downtime, please:

Complete the information on the attached "Engine/Vehicle Information Sheet" for each engine and have it available.
Then, with this information, contact a GMC TopKick/Chevrolet Kodiak or Caterpillar Dealer. The dealer will determine if an updated governor is needed.