PRODUCT IMPROVEMENT PROGRAM FOR REPLACING TURBOCHARGERS ON CERTAIN 3516C GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING TURBOCHARGERS ON CERTAIN 3516C GENERATOR SETS

Usage:

TEBE8225-01

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14Nov2018

(Revised 18Mar2019)

U-633

A-460

D-552

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Safety	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING TURBOCHARGERS ON CERTAIN 3516C GENERATOR SETS
1052		PI11181

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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 "PI11181" 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 "PI11181" 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 14Nov2018 Service Letter. Changes have been made to the Parts Needed.

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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, 131, 133, 137-138

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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, 2618-2626, 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*****
2	1D4538	BOLT
4	1S4810	GASKET-OIL DRAIN
4	1S6595	GASKET
8	2K4973	LOCKNUT
16	2N2765	BOLT-HEX FLG HD
16	2N2766	LOCKNUT
2	2W0752	GASKET
2	5S0003	NUT-FULL
8	6V3917	SEAL-O-RING
4	9N0869	WASHER-HARD
8	9X6458	WASHER-HARD
4	9Y0047	CLAMP
4	1003237	GROMMET
1	1092332	SEAL-O-RING
1	1113820	RING - RETAINER
8	1123540	SEAL-O-RING
4	1215736	GASKET-TURBO
4	1236979	CLAMP-V-BAND
8	1356261	CLAMP-T'BOLT
4	2010751	COUPLING-ELBOW
16	2162211	CLAMP-T'BOLT
2	2258574	TUBE AS
2	2453512	GASKET-EXHAUST
4	2684743	HOSE-HUMP
1	2697885	SEAL-O-RING
3	2720758	SEAL
2	2723198	TUBE
2	2723476	BRACKET
2	2773601	TUBE AS
1	2829917	TUBE
1	2829918	TUBE
4	2870421	TURBO GP-BASIC
1	2934879	TUBE AS-OIL
2	2934880	TUBE AS-OIL
1	2934881	TUBE AS-OIL
2	3668500	HOSE - HUMP
4	4529342	CLAMP AS
4	4589587	PAINT-YELLOW CAT
4	4773333	HOSE AS-OIL
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 2*****
2	1D4538	BOLT
4	1S4810	GASKET-OIL DRAIN
4	1S6595	GASKET
8	2K4973	LOCKNUT
16	2N2765	BOLT-HEX FLG HD
16	2N2766	LOCKNUT
1	2W0752	GASKET
2	5S0003	NUT-FULL
8	6V3917	SEAL-O-RING
4	8N5254	HOSE-REDUCER
16	9N0869	WASHER-HARD
8	9X6458	WASHER-HARD
4	9Y0047	CLAMP
4	1003237	GROMMET
1	1092332	SEAL-O-RING
1	1113820	RING - RETAINER
8	1123540	SEAL-O-RING
4	1215736	GASKET-TURBO
4	1236979	CLAMP-V-BAND
8	1356261	CLAMP-T'BOLT
4	2010751	COUPLING-ELBOW
2	2094451	HOSE-HUMP
16	2162211	CLAMP-T'BOLT
4	2177088	HOSE-HUMP
2	2258574	TUBE AS
2	2453512	GASKET-EXHAUST
1	2697885	SEAL-O-RING
2	2720758	SEAL
2	2723198	TUBE
2	2723476	BRACKET
2	2773601	TUBE AS
1	2829917	TUBE
1	2829918	TUBE
4	2870421	TURBO GP-BASIC
1	2934879	TUBE AS-OIL
2	2934880	TUBE AS-OIL
1	2934881	TUBE AS-OIL
2	3668500	HOSE - HUMP
4	4529342	CLAMP AS
4	4589587	PAINT-YELLOW CAT
4	4773333	HOSE AS-OIL
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*****
4	1S4810	GASKET-OIL DRAIN
4	1S6595	GASKET
8	2K4973	LOCKNUT
2	2W0752	GASKET
8	6V3917	SEAL-O-RING
7	9X6458	WASHER-HARD
4	9Y0047	CLAMP
4	1003237	GROMMET
1	1092332	SEAL-O-RING
1	1113820	RING - RETAINER
8	1123540	SEAL-O-RING
4	1215736	GASKET-TURBO
4	1236979	CLAMP-V-BAND
8	1356261	CLAMP-T'BOLT
16	1732090	SPACER
4	2010751	COUPLING-ELBOW
16	2162211	CLAMP-T'BOLT
2	2258574	TUBE AS
2	2453512	GASKET-EXHAUST
4	2684743	HOSE-HUMP
1	2697885	SEAL-O-RING
3	2720758	SEAL
2	2723198	TUBE
2	2723476	BRACKET
2	2773601	TUBE AS
4	2870421	TURBO GP-BASIC
1	2934879	TUBE AS-OIL
2	2934880	TUBE AS-OIL
1	2934881	TUBE AS-OIL
2	3668500	HOSE - HUMP
16	3767739	BOLT-HEX HEAD
16	3912167	LOCKNUT-FLANGED
4	4529342	CLAMP AS
4	4589587	PAINT-YELLOW CAT
4	4773333	HOSE AS-OIL
2	5268723	TUBE AS
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 turbocharger replacement procedure, review the safety actions in the Operation and Maintenance Manual.

Please refer to Special Instruction, M0098837 for installation procedures.

If a product improvement program for installing turbocharger shields has been done and are installed on a specific generator set, the turbocharger shields must not be installed with the new turbochargers for this program.

There is currently a limited supply of parts available for this program. The parts are frozen and allocation will be manually prioritized until sufficient quantities are available. Include the engine SN when placing the parts order with Morton.

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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 30.0-hour job for Group 1

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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 30.0-hour job for Group 2

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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 30.0-hour job for Group 3

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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 REPLACING TURBOCHARGERS

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 14Nov2018 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 14Nov2018 Service Letter