21475509 Volvo.Penta Relay

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.
This Program must be administered as soon as possible. When reporting the repair, use "PI3629" as the Part Number, "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 "PI3629"as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
This Service Letter replaces the terminated Service Letter dated December 31, 1991 - PI3545.
Completion Date
August 31, 1993Termination Date
February 28, 1994Problem
Certain 1991 model year 3176 Truck Engines need to be updated with an inlet air temperature sensor, control module, certification label, boost line, and miscellaneous installation hardware to comply with Federal, California, and Canadian emissions standards.
Affected Product
Model & Identification Number
3176(7LG739, 7LG743, 7LG745, 7LG747, 7LG754, 7LG756, 7LG757, 7LG759, 7LG761, 7LG762, 7LG765, 7LG767, 7LG773, 7LG774, 7LG778-780, 7LG790, 7LG792, 7LG797, 7LG799-800, 7LG803, 7LG810, 7LG811, 7LG813, 7LG817, 7LG820, 7LG823, 7LG828, 7LG832, 7LG837, 7LG842, 7LG844, 7LG847, 7LG852-854, 7LG859, 7LG872, 7LG875, 7LG878, 7LG879, 7LG883-886, 7LG888, 7LG895, 7LG896, 7LG903, 7LG910, 7LG911, 7LG913, 7LG917-922, 7LG926, 7LG930-932, 7LG934-937, 7LG943-945, 7LG948-950, 7LG959, 7LG964, 7LG965, 7LG974, 7LG975, 7LG978, 7LG982, 7LG983, 7LG986, 7LG987, 7LG993, 7LG995, 7LG999, 7LG1004, 7LG1006, 7LG1015, 7LG1026, 7LG1036, 7LG1057, 7LG1059, 7LG1060, 7LG1062, 7LG1065, 7LG1067, 7LG1072, 7LG1088, 7LG1089, 7LG1093, 7LG1095-1097, 7LG1104, 7LG1115-1117, 7LG1120, 7LG1121, 7LG1124, 7LG1125, 7LG1127, 7LG1133, 7LG1136, 7LG1143-1148, 7LG1154, 7LG1156, 7LG1160, 7LG1166, 7LG1171, 7LG1177, 7LG1178, 7LG1180, 7LG1183-1186, 7LG1189, 7LG1191, 7LG1196-1198, 7LG1205, 7LG1212, 7LG1213, 7LG1216, 7LG1224, 7LG1229, 7LG1232, 7LG1240, 7LG1243, 7LG1244, 7LG1253, 7LG1256-1258, 7LG1261, 7LG1262, 7LG1264, 7LG1268, 7LG1271, 7LG1278, 7LG1280, 7LG1281, 7LG1282, 7LG1286, 7LG1295, 7LG1302, 7LG1304, 7LG1308, 7LG1311, 7LG1315, 7LG1328, 7LG1333, 7LG1337, 7LG1345, 7LG1350, 7LG1352, 7LG1354, 7LG1359, 7LG1377, 7LG1378, 7LG1380, 7LG1381, 7LG1384, 7LG1386, 7LG1389-1392, 7LG1396, 7LG1399, 7LG1400, 7LG1402, 7LG1403, 7LG1405, 7LG1406, 7LG1409, 7LG1417, 7LG1419, 7LG1423, 7LG1457, 7LG1463, 7LG1482, 7LG1488, 7LG1490, 7LG1494, 7LG1496, 7LG1499, 7LG1505, 7LG1508, 7LG1513, 7LG1520, 7LG1521, 7LG1528, 7LG1529, 7LG1538, 7LG1541, 7LG1545, 7LG1546, 7LG1548, 7LG1555, 7LG1574-1576, 7LG1579, 7LG1584, 7LG1587, 7LG1590, 7LG1592, 7LG1593, 7LG1595, 7LG1600, 7LG1601, 7LG1609, 7LG1610, 7LG1612-1614, 7LG1616-1618, 7LG1624, 7LG1630, 7LG1633, 7LG1635, 7LG1656, 7LG1657, 7LG1665-1668, 7LG1680, 7LG1684, 7LG1686, 7LG1691, 7LG1694, 7LG1698, 7LG1707, 7LG1710, 7LG1714, 7LG1719, 7LG1723, 7LG1725, 7LG1732, 7LG1740, 7LG1748, 7LG1753, 7LG1795, 7LG1798, 7LG1799, 7LG1804, 7LG1813, 7LG1815, 7LG1831, 7LG1837, 7LG1840, 7LG1863, 7LG1873, 7LG1879, 7LG1885-1887, 7LG1900, 7LG1905, 7LG1911, 7LG1912, 7LG1918, 7LG1924, 7LG1925, 7LG1927, 7LG1930, 7LG1933, 7LG1936, 7LG1939, 7LG1940, 7LG1942, 7LG1944, 7LG1947, 7LG1950, 7LG1952-1956, 7LG1969, 7LG1970, 7LG1973, 7LG1978, 7LG1980, 7LG1983, 7LG1985, 7LG1988, 7LG1996, 7LG2008, 7LG2017, 7LG2020, 7LG2022, 7LG2025, 7LG2052, 7LG2053-2056, 7LG2058, 7LG2068, 7LG2069, 7LG2077, 7LG2079, 7LG2080, 7LG2084, 7LG2095, 7LG2096, 7LG2098, 7LG2101, 7LG2107, 7LG2108, 7LG2129, 7LG2132, 7LG2156, 7LG2160, 7LG2167, 7LG2188, 7LG2195, 7LG2199, 7LG2211, 7LG2215, 7LG2218, 7LG2229, 7LG2232, 7LG2246, 7LG2252, 7LG2253, 7LG2257, 7LG2258, 7LG2296, 7LG2299, 7LG2301, 7LG2305, 7LG2365, 7LG2382, 7LG2677, 7LG2747, 7LG2786, 7LG2796, 7LG2799, 7LG2801, 7LG2805, 7LG3307, 7LG3316, 7LG3319, 7LG3328)
Parts Needed
Dealers will need to order parts for this Program.
All parts are common between engine models except the 6I1527, 6I1528, 6I1529, and 6I1530 Control Group Kits.
1 - 6I1527 Control Group Kit (250 HP)1 - 6I1528 Control Group Kit (275 HP)1 - 6I1529 Control Group Kit (300 HP)1 - 6I1530 Control Group Kit (325 HP)1 - 3J1907 O-Ring Seal1 - 3J7355 Union1 - 9L8493 Cap1 - 4P9612 Extension Harness4 - 3S2093 Tie1 - 9S4182 Plug1 - 2V3216 Clip1 - 6V5048 O-Ring Seal1 - 4W5140 Plate3 - 7W5164 Gasket1 - 9X3271 Adapter1 - 9X5370 Control Group1 - 9Y6139 Hose1 - 9Y6186 Gasket1 - 016449 AdapterAction Required
See the attached procedure.
Owner Notification
U.S. and Canadian owners will receive the attached Owner Notification.
Service Claim Allowances
This is a 4-hour job. No other labor operation segments are required, such as steam cleaning, troubleshooting, test after repair, travel time, or mileage.
Parts Disposition
U.S. And Canadian Dealers
Transfer the protective cover from the new personality module to the old personality module to protect the electronics during shipment.
Return all control groups (personality modules) and a copy of a completed core credit reguest packing list to:
Caterpillar Inc.
Attn: 3176 Engine - Program PI3629
Warehouse #4 Docks 7 thru 10
8201 N. University
Peoria, IL 61615
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE
Attach:
(1-Owner's Notification)(2-Rework Procedure)Copy Of Owner Notification For U.S. And Canadian Owners
Rework Procedure
1. Connect ECAP and clear any logged diagnostic code 37 " Fuel Pressure Sensor Fault" or diagnostic code 63 " Low Fuel Pressure Warning ". Repair any current fuel pressure problems.2. Program new Full Load Setting (FLS) and Full Torque Setting (FTS) numbers using ECAP (factory passwords necessary). Get current FLS\FTS settings from Engine Information Plate on valve cover. See table 1 for new FLS\FTS settings.Table 1 If current FLS\FTS settings are not listed above refer to the attached Additional FLS\FTS Settings List.
Refer to SEHS9349 Tool Operating Manual "Using the NEXG4522 Truck Engine Functions Dual Service Program Module " - Read\Change System Configuration Parameters (pages 23-24) to program new FLS\FTS settings.
3. Remove inlet manifold from engine.4. Locate and drill an 18 mm (.718") hole in the inlet manifold. Use a square to accurately locate the 75 mm (2.95 ") dimension. Center punch and pre-drill using a 6.35 mm (.25 ") drill bit. See Illustration 1. Location of drilled hole is critical.
5. Tap the drilled hole to "-14 NPTF using a 2P5534 Tapered Pipe Tap. Tap approximately 15 turns to allow full thread depth of the 9X3271 Adapter. Clean all chips and burrs from inside of inlet manifold.6. Install 9X3271 Adapter into the tapped hole using 8T9011 Solvent Cleaner, 6V1541 Quick Cure Primer, and 7M7456 Bearing Mount. Install adapter and tighten to 60 N m (45 lb ft). See Illustration 1.
Illustration 1 - Install 9X3271 Adapter7. Remove the plug on top of the inlet manifold and install the 016449 Adapter. See Illustration 2.8. Plug the boost line connector on the end of the inlet manifold with the 9L8493 Cap. See Illustration 2.
Illustration 2 - Top View9. Install inlet manifold using (3) 7W5164 Gaskets.10. Remove the boost line from the transducer module and check for presence of water or corrosion. Clear any restriction and remove water from