PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING TURBOCHARGER SHIELDS ON CERTAIN 3516C GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING TURBOCHARGER SHIELDS ON CERTAIN 3516C GENERATOR SETS

Usage:

TEBE8168-01

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31Aug2018

(Revised 05Oct2018)

U-516

A-378

D-454

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Safety	PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING TURBOCHARGER SHIELDS ON CERTAIN 3516C GENERATOR SETS
1073		PI11163

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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 must be administered as soon as possible. When reporting the repair, use "PI11163" 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 "PI11163" 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:	This Revised Service Letter replaces the 31Aug2018 Service Letter. Changes have been made to the Affected Product, Parts Needed, and Service Claim Allowances.

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PROBLEM

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On certain 3516C Generator Sets, the existing turbocharger can become unbalanced and may, in conjunction with other factors or circumstances, result in a risk of personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
3516C	LYM00105-00113, 115-123

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*******Group 2*******

3516C

SBK02483, 2488-2491, 2493-2497, 2500, 2503, 2505, 2508-2509, 2511-2512, 2514-2517, 2519, 2522-2527, 2529-2532, 2539-2552, 2554-2555, 2558-2559, 2563, 2571, 2582-2583, 2586, 2589, 2591-2595, 2597, 2600, 2604, 2606-2612, 2614-2616, 2618-2619, 2621-2626, 2628-2629, 2631-2633, 2635, 2637-2656, 2658-2672, 2674-2675, 2677-2683, 2685-2695, 2697-2701, 2703-2721, 2723-2724, 2727-2728, 2731-2734, 2736-2737, 2739, 2741, 2743, 2745-2750, 2752-2755, 2761, 2763, 2765-2792

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*****Group 3*****
3516C	GBZ00110-00113, 117

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
16	3K6060	LOCKNUT
16	4L6459	BOLT
16	5S7382	BOLT-HEX HEAD
16	6V8801	NUT
4	7X0732	WASHER-HARD
12	8T2502	BOLT
8	8T4224	WASHER-HARD
68	8T4896	WASHER-HARD
8	8T9043	BOLT
4	2453512	GASKET-EXHAUST
4	PLATE1	PLATE 1 - DEALER FABRICATED OR LOCALLY FABRICATED
6	PLATE2	PLATE 2 - DEALER FABRICATED OR LOCALLY FABRICATED
4	PLATE3	PLATE 3 - DEALER FABRICATED OR LOCALLY FABRICATED
4	PLATE4	PLATE 4 - DEALER FABRICATED OR LOCALLY FABRICATED
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 35% 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*****
16	3K6060	LOCKNUT
16	4L6459	BOLT
16	5S7382	BOLT-HEX HEAD
16	6V8801	NUT
4	7X0732	WASHER-HARD
12	8T2502	BOLT
8	8T4224	WASHER-HARD
68	8T4896	WASHER-HARD
8	8T9043	BOLT
4	2453512	GASKET-EXHAUST
4	PLATE1	PLATE 1 - DEALER FABRICATED OR LOCALLY FABRICATED
6	PLATE2	PLATE 2 - DEALER FABRICATED OR LOCALLY FABRICATED
4	PLATE3	PLATE 3 - DEALER FABRICATED OR LOCALLY FABRICATED
4	PLATE4	PLATE 4 - DEALER FABRICATED OR LOCALLY FABRICATED
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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 3*****
16	3K6060	LOCKNUT
16	4L6459	BOLT
16	5S7382	BOLT-HEX HEAD
16	6V8801	NUT
4	7X0732	WASHER-HARD
12	8T2502	BOLT
8	8T4224	WASHER-HARD
68	8T4896	WASHER-HARD
8	8T9043	BOLT
4	2453512	GASKET-EXHAUST
4	PLATE1	PLATE 1 - DEALER FABRICATED OR LOCALLY FABRICATED
6	PLATE2	PLATE 2 - DEALER FABRICATED OR LOCALLY FABRICATED
4	PLATE3	PLATE 3 - DEALER FABRICATED OR LOCALLY FABRICATED
4	PLATE4	PLATE 4 - DEALER FABRICATED OR LOCALLY FABRICATED
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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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Before completing the shield installation procedure, review the safety actions in the Operation and Maintenance Manual.

Install shielding around exhaust collection elbow to contain debris from exiting the housing in the event of a turbo failure. Refer to Special Instruction, M0097759 for installation procedures.

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OWNER NOTIFICATION

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Owners in the following countries will receive the attached Owner Notification:
US
Canada
Australia
New Zealand

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 8.0-hour job for Group 1
Up to $3000 is allowed to make/procure the plates that are dealer fabricated or locally fabricated.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 8.0-hour job for Group 2
Up to $3000 is allowed to make/procure the plates that are dealer fabricated or locally fabricated.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 8.0-hour job for Group 3
Up to $3000 is allowed to make/procure the plates that are dealer fabricated or locally fabricated.

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PARTS DISPOSITION

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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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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING TURBOCHARGER SHIELDS

MODELS INVOLVED - CERTAIN 3516C GENERATOR SETS

Dear Cat Product Owner:

The existing turbocharger may become unbalanced on the products listed below. If the existing turbocharger becomes unbalanced, it may in conjunction with other factors or circumstances, result in a risk of personal injury or death. You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated.

You may now search for open Safety Service Letters by entering your product serial number(s). Visit the CAT.COM/SAFETY website and click on SUPPORT, then SAFETY SERVICES for more information. Please refer the dealer to their Service Letter dated 31Aug2018 when scheduling this service.

We regret the inconvenience this may cause you, and urge you to have this service performed for your safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 31Aug2018 Service Letter