PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING TURBOCHARGER SHIELDS ON CERTAIN G3520C 1200RPM LANDFILL GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING TURBOCHARGER SHIELDS ON CERTAIN G3520C 1200RPM LANDFILL GENERATOR SETS

Usage:

TEBE2394-01

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18Dec2014

(Revised 06Dec2016)

U-770

A-570

D-677

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Safety	PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING TURBOCHARGER SHIELDS ON CERTAIN G3520C 1200RPM LANDFILL GENERATOR SETS
1052 1053 1307 1067		PI11001

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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 "PI11001" 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 "PI11001" 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 18Dec2014 Service Letter. Changes have been made to the Affected Product, Parts Needed, Action Required, and Service Claim Allowances.

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PROBLEM

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Damage to the turbine wheel or turbine nozzle ring can unevenly load the turbine wheel leading to failure, 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*****
G3520C	GZJ00161-00169, 174-181, 183-186, 188, 196-198, 201, 204-210, 215, 219-233, 236, 243-246, 266, 268, 270-271, 273-275, 277-283, 288-293, 310, 313

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*****Group 2*****
G3520C	GZJ00234-00235, 257, 259-260, 262, 265, 267, 284, 294-307, 311, 314-319, 321-363, 369-381, 385-409, 411-421, 424-428 HAT00102, 200-205, 207, 209-211

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*****Group 3*****
G3520C	GZJ00429-00473, 476, 478-491, 493-495, 498-553, 600-620, 624-665

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*****Group 4*****
G3520C	GZJ00666-00712

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
6	0S1594	BOLT
8	0S1595	BOLT
6	1A1460	BOLT
2	1A5822	BOLT
6	1F7958	NUT-FULL
6	3E4353	WASHER-HARD
4	3E6916	NUT-FULL
4	3H5825	BOLT
12	4H7655	CLIP
12	5M2894	WASHER-HARD
2	5P3456	SEAL-O-RING
4	5P7128	BOLT-HEX HEAD
18	5P8245	WASHER-HARD
6	6V1820	BOLT
2	6V3631	NUT-FULL
4	7X0818	BOLT-HEX HEAD
12	8C8491	WASHER
4	8T4224	WASHER-HARD
6	9S8752	NUT-FULL
2	0307949	ADAPTER-ELBOW
6	1003237	GROMMET
2	1115822	GASKET-EXHAUST
10	1302321	WASHER
2	2266575	WASHER - SST
2	2385081	SEAL-O-RING-STOR
2	3113212	TUBE AS
1	3188420	HOSE AS
1	3188421	HOSE AS
1	3321462	SEAL
1	3449432	SHIELD AS-TURBO
1	3449433	SHIELD AS-TURBO
1	3449434	SHIELD AS-TURBO
1	4153125	SHIELD AS
1	4153127	SHIELD AS
2	4176722	PLATE
1	4235408	BRACKET
1	4235409	BRACKET
1	4455974	GRID AS
12	FASTENER	FASTENER (as/if needed)
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*****
6	0S1594	BOLT
8	0S1595	BOLT
2	1A5822	BOLT
4	3E6916	NUT-FULL
4	3H5825	BOLT
12	4H7655	CLIP
12	5M2894	WASHER-HARD
2	5P3456	SEAL-O-RING
4	5P7128	BOLT-HEX HEAD
2	6V3631	NUT-FULL
4	7X0818	BOLT-HEX HEAD
12	8C8491	WASHER
4	8T4224	WASHER-HARD
6	9S8752	NUT-FULL
2	0307949	ADAPTER-ELBOW
6	1003237	GROMMET
2	1115822	GASKET-EXHAUST
10	1302321	WASHER
2	2266575	WASHER - SST
2	2385081	SEAL-O-RING-STOR
2	3113212	TUBE AS
1	3188420	HOSE AS
1	3188421	HOSE AS
1	3321462	SEAL
1	3449432	SHIELD AS-TURBO
1	3449433	SHIELD AS-TURBO
1	3449434	SHIELD AS-TURBO
1	4153125	SHIELD AS
1	4153127	SHIELD AS
2	4176722	PLATE
1	4455974	GRID AS
12	FASTENER	FASTENER (as/if needed)
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*****
8	0S1595	BOLT
2	1A5822	BOLT
4	3E6916	NUT-FULL
4	3H5825	BOLT
4	5P7128	BOLT-HEX HEAD
2	6V3631	NUT-FULL
12	8C8491	WASHER
2	1115822	GASKET-EXHAUST
10	1302321	WASHER
2	2266575	WASHER - SST
1	3321462	SEAL
1	4153125	SHIELD AS
1	4153127	SHIELD AS
2	4176722	PLATE
1	4455974	GRID AS
12	FASTENER	FASTENER (as/if needed)
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 4*****
2	1115822	GASKET-EXHAUST
1	4455974	GRID AS
12	FASTENER	FASTENER (as/if needed)
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 engine Operation and Maintenance Manual.

Install shielding around exhaust collection elbow (flowerpot) to contain debris from exiting the housing in the event of a turbo failure. All engines listed in this service letter should have the shields installed. Refer to Special Instruction, REHS9669 for installation procedures.

Note: Some of the coolant lines around the turbocharger may need to be removed for easier installation of the shields. This will require draining of the engine jacket water system down to below turbocharger level. The coolant should be saved and reused.

The installation of the 4455974 Grid As and one additional exhaust gasket will add 7.5mm thickness to this joint. Ensure the exhaust fasteners are capable of this additional thickness.

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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 10.0-hour job for Group 1
$50 is allowed for the longer exhaust fasteners (as/if needed) as described in the Action Required.

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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 10.0-hour job for Group 2
$50 is allowed for the longer exhaust fasteners (as/if needed) as described in the Action Required.

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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
$50 is allowed for the longer exhaust fasteners (as/if needed) as described in the Action Required.

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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 4.0-hour job for Group 4
$50 is allowed for the longer exhaust fasteners (as/if needed) as described in the Action Required.

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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 ON CERTAIN G3520C 1200RPM LANDFILL GENERATOR SETS

MODELS INVOLVED - G3520C 1200RPM Landfill Generator Sets

Dear Cat Product Owner:

Damage to the turbine wheel or turbine nozzle ring can unevenly load the turbine wheel leading to failure. This failure 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 SAFETY.CAT.COM website and click on the Product Safety page for more information. Please refer the dealer to their Service Letter dated 18Dec2014 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 18Dec2014 Service Letter