PRODUCT IMPROVEMENT PROGRAM FOR REPLACING FUEL LINES ON CERTAIN 3516B HD LOCOMOTIVE ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING FUEL LINES ON CERTAIN 3516B HD LOCOMOTIVE ENGINES

Usage:

REBE1213-01

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17Oct2006

(Revised 11Dec2006)

O-664

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING FUEL LINES ON CERTAIN 3516B HD LOCOMOTIVE ENGINES
1252		PI31166

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31166" 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 "PI31166" 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 October 17, 2006 Service Letter. Changes have been made to the Parts Needed section.

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COMPLETION DATE	TERMINATION DATE
30Apr2007	31Oct2007

PROBLEM

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Some engines have experienced fuel leaks at connections to the fuel manifold. This change improves the reliability and durability of the fuel system by reducing the stress at these connection points.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
3516B	BCK00229-00238, 240-241, 244-245, 247-250, 253-282, 285-310

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*****Group 2*****
3516B	BCK00239, 242-243, 246, 251-252, 283-284, 311

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
3	0307949	ELBOW
1	0307972	ELBOW
1	0618284	TEE-SWIVEL
1	0L1352	BOLT
1	0S1595	BOLT
2	1849404	CLIP
1	1F7958	NUT-FULL
1	1S0994	CLIP
1	2929262	HOSE AS.
1	2929263	HOSE AS.
1	2929264	HOSE AS.
2	5M2894	WASHER-HARD
2	5P8245	WASHER-HARD
3	6D1641	CLIP-LOOP
3	6V4589	SEAL-O-RING
1	9S8752	NUT-FULL
*****Group 2*****
3	0307949	ELBOW
2	0307972	ELBOW
1	0618284	TEE-SWIVEL
1	0L2070	BOLT
1	0S1594	BOLT
1	1790469	SPACER
2	2006345	MOUNT-SWIVEL
2	2042281	TIE-WRAP
1	2929262	HOSE AS.
1	2929263	HOSE AS.
1	2929264	HOSE AS.
3	5M2894	WASHER-HARD
2	6D1641	CLIP-LOOP
1	6M7476	ELBOW
2	6V4589	SEAL-O-RING
1	8S0948	CLIP
1	9S8752	NUT-FULL
1	9Y9194	BRACKET

ACTION REQUIRED

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Please 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%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 4.0-hour job for Group 1

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 4.0-hour job for Group 2

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.

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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 REPLACING FUEL LINES

MODELS INVOLVED - CERTAIN 3516B HD LOCOMOTIVE ENGINES

Dear Caterpillar Product Owner:

New Flexible Fuel Lines should be installed to prevent potential fuel leaks.
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 17Oct2006 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 17Oct2006 Service Letter

Rework Procedure

Group Number 1

***Note: GROUP NUMBER 1 is for engines with remote (off-engine) mounted jacket water temperature regulators.

1. Remove tube assemblies 111-3388, 111-3389 and 8N-6327 from lines group 101-1246. Remove clamps, brackets and associated hardware used for the mounting of the tube assemblies.

2. Remove the 252-7778 Bracket and 2-piece clamp used to mount the 8N-6327 tube from the 155-2559 Connection Group-Water. See Image 1.2.1

Image1.2.1

3. Drill a 10.5 mm clearance hole through the existing 3/8-16 threaded hole in the 155-2558 bracket as shown in Image 1.3.1. This will allow clearance for a through-bolt and additional hose clamp as shown in Image 1.3.1.

Image1.3.1

4. Replace existing rigid fuel lines with new flex lines consistent with the parts list and per the attached images, 1.4.1 through 1.4.6.

Image1.4.1

Image1.4.2

Image1.4.3

Image1.4.4

Image1.4.5

Image1.4.6

5. Insure that all flexible fuel lines are securely mounted in accordance with the previous images. The new flexible fuel lines should not rub or contact other lines or components.

6. Operate the engine after completion and check for leaks and repair as necessary.

Group Number 2

***Note: GROUP NUMBER 2 is for engines with engine-mounted jacket water temperature regulators.

1. Remove tube assemblies 111-3388, 111-3389 and 8N-6327 from lines group 101-1246. Remove clamps, brackets and associated hardware used for the mounting of the tube assemblies.

2. Remove the 252-7778 Bracket and 2-piece clamp used to mount the 8N-6327 tube from the 155-2559 Connection Group-Water. See Image 2.2.1

Image2.2.1

3. Replace existing rigid fuel lines with new flex lines consistent with the parts list and per the attached images, 2.3.1 through 2.3.4.

Image2.3.1

Image2.3.2

Image2.3.3

Image2.3.4

4. Insure that all flexible fuel lines are securely mounted in accordance with the previous images. The new flexible fuel lines should not rub or contact other lines or components.

5. Operate the engine after completion and check for leaks and repair as necessary.