PRODUCT SUPPORT PROGRAM FOR INSTALLING CUFFED CYLINDER SYSTEM COMPONENTS ON CERTAIN 3512B GENERATOR SETS, PM3512 POWER MODULES, 3516B GENERATOR SETS, AND PM3516 POWER MODULES Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING CUFFED CYLINDER SYSTEM COMPONENTS ON CERTAIN 3512B GENERATOR SETS, PM3512 POWER MODULES, 3516B GENERATOR SETS, AND PM3516 POWER MODULES

Usage:

TEBE3938-05

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10Feb2016

(Revised 07Sep2017)

U-71

A-54

D-62

O-58

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After Failure Only	PRODUCT SUPPORT PROGRAM FOR INSTALLING CUFFED CYLINDER SYSTEM COMPONENTS ON CERTAIN 3512B GENERATOR SETS, PM3512 POWER MODULES, 3516B GENERATOR SETS, AND PM3516 POWER MODULES
1218 1216 7555		PS53140

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NOTE:	Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.
NOTE:	This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS53140" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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 10Feb2016 (Revised 22May2017) Service Letter. Changes have been made to the Affected Product and Action Required.

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TERMINATION DATE

28Feb2018

PROBLEM

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In high load conditions, certain single piece forged steel piston used in the Single Piece Cylinder System may develop hard deposits at the top land of the piston.

If severe enough, deposits may wear the liner crosshatch, compromising oil control and contributing to additional deposit formation, wear, and blowby.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
3516B	JCH00100-00107 YAP00213-00214, 255-342, 344-378, 380-478, 480-540, 542-682, 685-718, 720-757, 761, 764, 795-812 YAT00120-00962 YBT00101-00585, 587-606 ZBP00101-00306
PM3516	NBR00100-00232, 235-242, 245-255, 260-264, 266-267, 269-270, 273, 275-279, 285-288, 290, 316, 353, 360-361, 377, 416, 425-436, 438, 440-443, 446, 460-469, 472, 474, 496-503, 509, 511-522, 525-531, 534, 542-652, 674-678, 695-721, 730-754, 759-760, 762-779, 782-790, 792-813, 815, 820-947

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*****Group 2*****
3512B	JM300100-00106 YAM00115-00997 YAY00126, 326-405, 407-408, 411-459, 461-466, 475-663, 671-722, 725-925, 1026-1078, 1081-1133, 1135-1141, 1344-1414, 1416-1430, 1432, 1434-1438, 1440 YBB00111, 113-123, 125-184, 186-204, 206-270, 272-322, 324-362, 364-473, 476-498
PM3512	TC800100-00102, 104, 106-243, 247, 278

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
16	1H9696	SEAL-O-RING
4	1S4810	GASKET-OIL DRAIN
4	2W0752	GASKET
3	3P0655	SEAL-O-RING
1	3P6061	GASKET
2	4N1320	GASKET-ADAPTER
16	4S5898	SEAL-O-RING
32	5P0840	SEAL-O-RING
1	5P7818	SEAL-O-RING
8	5P9890	SEAL-O-RING
2	6V1454	SEAL-O-RING
5	6V5066	SEAL-O-RING
16	6V5101	SEAL-O-RING
16	6V9769	SEAL-O-RING
48	7N2046	SEAL-O-RING
1	7N4932	GASKET
1	7N4945	GASKET
16	7N5080	GASKET-MANIFOLD
16	7W8145	GASKET-EXH MANF
4	0336031	SEAL-O-RING
16	1077330	BEARING-CONN ROD
6	1092332	SEAL-O-RING
16	1106991	GASKET-HEAD
1	1111349	GASKET
2	1228856	GASKET AS
16	1272176	SEAL-INTEGRAL
16	1445692	GASKET-PLATE
16	1989926	TUBE AS-OIL JET
16	2236361	RING-PISTON
1	2315128	COVER-VALVE
16	2407032	SEAL-PIP
16	2688154	KIT-GASKET-SFI
16	2720759	SEAL-PIP
16	2720760	SEAL
1	2986387	SEAL-O-RING
64	4200652	SEAL AS-WATER
64	4200653	SEAL AS-WATER
16	4483650	RING-PISTON
16	4483651	RING-PISTON
16	4549920	LINER-CYLINDER
16	4587071	SLEEVE
16	4807093	SEAL-LINER
16	4815615	PISTON AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 2*****
12	1H9696	SEAL-O-RING
4	1S4810	GASKET-OIL DRAIN
4	2W0752	GASKET
3	3P0655	SEAL-O-RING
1	3P6061	GASKET
2	4N1320	GASKET-ADAPTER
12	4S5898	SEAL-O-RING
24	5P0840	SEAL-O-RING
1	5P7818	SEAL-O-RING
8	5P9890	SEAL-O-RING
2	6V1454	SEAL-O-RING
5	6V5066	SEAL-O-RING
12	6V5101	SEAL-O-RING
12	6V9769	SEAL-O-RING
36	7N2046	SEAL-O-RING
1	7N4932	GASKET
1	7N4945	GASKET
12	7N5080	GASKET-MANIFOLD
12	7W8145	GASKET-EXH MANF
4	0336031	SEAL-O-RING
12	1077330	BEARING-CONN ROD
6	1092332	SEAL-O-RING
12	1106991	GASKET-HEAD
1	1111349	GASKET
2	1228856	GASKET AS
12	1272176	SEAL-INTEGRAL
12	1445692	GASKET-PLATE
12	1989926	TUBE AS-OIL JET
12	2236361	RING-PISTON
12	2407032	SEAL-PIP
1	2456770	COVER
12	2688154	KIT-GASKET-SFI
12	2720759	SEAL-PIP
12	2720760	SEAL
1	2986387	SEAL-O-RING
48	4200652	SEAL AS-WATER
48	4200653	SEAL AS-WATER
12	4483650	RING-PISTON
12	4483651	RING-PISTON
12	4549920	LINER-CYLINDER
12	4587071	SLEEVE
12	4807093	SEAL-LINER
12	4815615	PISTON AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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This Service Letter provides support for replacing the Single Piece Cylinder System components with the Cuff Liner and Piston Components System, provided each of the following conditions is met.

1. Verify Oil Consumption exceeds limits listed in LEKQ7390 from the Electronic Media Center (emc.cat.com).

2. Verify Excessive Crankcase Blowby according to the procedure in SEHS8984. Some amount of blowby is generated by every engine and the amount of blowby will typically increase with age as parts wear. The repairing dealer must compare the results to the TMI engine specific Blowby data called out in the Performance Data.

Special Note: For a Generator Set that is currently "Out-of-Service" and placed in storage, the exception to Crankcase Blowby verification would be to provide photo documentation of the cylinder liner, either by cylinder liner bore scope or the removal of the cylinder head. Document these special cases with a Product Health Service Request (SR) with the details and reference this publication in the description of the SR prior to submitting to Caterpillar.

3. Verify that the engine is seeing an increase in the Nitration and Oxidation levels in three SOS reports at or greater than the guidelines listed below for approximately the same hour interval.
- Nitration 12 UFM
- Oxidation 24 UFM

If all of these conditions are met, this Service Letter can be applied.

Note: DO NOT mix single piece forged steel pistons designed for the Single Piece Cylinder System with single piece forged steel pistons designed for the Cuffed Cylinder System. Rotating masses and system dynamics are different between the designs and are not compatible within the same engine.

Note: Connecting Rod and Piston Pins are highly reusable. For this reason, the Parts Needed tables do not list these parts. Refer to Image 1 for the ring compressor and installation tools required.

Refer to Disassembly and Assembly, UENR5578 for repair info.

Note: Install High Flow Piston Spray Jets and an Oil Pump Pressure Regulator cover to increase the engine oil pressure. Because of this update, also increase the oil filter pressure differential warning alarm set point. For 3516B, and PM3516, only reset the Oil Filter Pressure Differential warning set point from 105KPA/15PSI to 138KPA/20PSI. 3512B, and PM3512 set points remain 105KPA/15PSI.

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Image1

SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
0-8000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
8001-10000 hrs, 25-37 mo	75.0%	75.0%	0.0%	0.0%	25.0%	25.0%
10001-12000 hrs, 38-50 mo	50.0%	50.0%	0.0%	0.0%	50.0%	50.0%
12001-16000 hrs, 51-60 mo	25.0%	25.0%	0.0%	0.0%	75.0%	75.0%

NOTE: This is a 95.0-hour job for Group 1

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
0-8000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
8001-10000 hrs, 25-37 mo	75.0%	75.0%	0.0%	0.0%	25.0%	25.0%
10001-12000 hrs, 38-50 mo	50.0%	50.0%	0.0%	0.0%	50.0%	50.0%
12001-16000 hrs, 51-60 mo	25.0%	25.0%	0.0%	0.0%	75.0%	75.0%