PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 341-8736 WATERLINES, 328-2635 EXHAUST MANIFOLD, AND 339-3788 EXHAUST SHIELDING ON CERTAIN 3516, AND G3516B PETROLEUM ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 341-8736 WATERLINES, 328-2635 EXHAUST MANIFOLD, AND 339-3788 EXHAUST SHIELDING ON CERTAIN 3516, AND G3516B PETROLEUM ENGINES

Usage:

REBE9534-02

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23Jul2013

(Revised 21Nov2013)

U-327

A-226

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 341-8736 WATERLINES, 328-2635 EXHAUST MANIFOLD, AND 339-3788 EXHAUST SHIELDING ON CERTAIN 3516, AND G3516B PETROLEUM ENGINES
1050 1059 1061 1380		PI32203

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32203" 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 "PI32203" 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:

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 23Jul2013 (Revised 23Sep2013) Service Letter. Changes have been made to the Affected Product.

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COMPLETION DATE	TERMINATION DATE
31Jan2014	31Jul2014

PROBLEM

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The existing waterlines for the exhaust bypass valve do not provide adequate cooling. Gaps in the current exhaust shielding can also increase the temperature around the exhaust bypass valve. The current exhaust bellows that connect the exhaust manifold adapter elbows to the turbochargers can fail due to misalignment.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
G3516	3RC00080, 988 4EK01671, 1699, 1726, 1757, 3056, 3231, 3581, 3655, 3668, 3720-3721, 3758, 3768, 3831-3832, 3862-3863, 3906, 3909-3910, 3924, 4025, 4233, 4481, 4593, 4609, 4625, 4897, 4907, 4915 8LD00077 WPW00397, 429, 449, 670, 682, 888, 926, 967, 1590, 1966, 2017, 2610, 2692
G3516B	JEF00101-00104, 106-107, 109, 112, 115-116, 122, 129-130, 150, 155-157, 159, 170, 174, 181-182, 184, 186-189, 1005, 1010, 1013, 1019, 1024, 1029-1030

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

G3516B

JEF01038, 1044, 1046-1048, 1058, 1080-1081, 1085, 1091, 1094-1095, 1097-1098, 1100, 1112, 1115-1116, 1129-1131, 1133, 1139, 1141, 1150, 1155-1158, 1160, 1162-1163, 1165, 1167-1168, 1184, 1186, 1188, 1190, 1192-1193, 1195, 1198-1199, 1202-1205, 1211, 1215-1216, 1219, 1223, 1232, 1238, 1253-1257, 1287-1288, 1292, 1294, 1297, 1300, 1326, 1333, 1338-1342, 1344, 1353, 1355, 1357-1358, 1360-1361, 1364-1369, 1372, 1374, 1377, 1379, 1381-1383, 1385, 1387, 1389, 1392, 1400, 1403, 1407

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*******Group 3*******

G3516B

JEF01412-01413, 1425-1426, 1428-1429, 1437, 1454, 1473, 1479, 1482, 1487-1488, 1491, 1507-1509, 1514-1515, 1517-1521, 1523, 1525-1527, 1539-1545, 1551, 1570-1575, 1578, 1581-1584, 1591, 1593-1595, 1598, 1607, 1612-1619, 1621-1624, 1626-1630, 1632, 1635, 1638, 1640, 1643-1648, 1651, 1653-1655, 1665, 1667-1668, 1673-1678, 1680, 1683, 1686-1687, 1689-1691, 1693, 1696, 1698-1699, 1702-1704, 1707-1708, 1713, 1715, 1718-1719, 1721, 1726-1729, 1731-1732, 1735, 1737-1738, 1743-1744

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*****Group 4*****
G3516B	JEF01747, 1749, 1753, 1755-1760, 1771, 1776-1778, 1787, 1796-1797, 1799, 1807, 1812, 1815-1816, 1818-1819, 1821, 1824, 1827, 1831, 1839-1840, 1844, 1851-1852, 1857, 1862-1867, 1874, 1876, 1881-1884, 1889, 1892, 1896, 1900, 1918-1919, 1922-1925, 1927, 1930, 1932-1936, 1939-1940, 1943-1944, 1946, 1948-1953, 1960, 1962-1969, 1971-1972, 1974

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	0L1351	BOLT
1	0L1352	BOLT
3	0S0509	BOLT
1	0S1591	BOLT
1	0S1594	BOLT
1	1A5183	BOLT
1	1B2578	NUT-JAM
4	1F7958	NUT-FULL
5	1W2430	CLAMP-V-BAND
2	2P4437	CLIP
1	2T2396	ADAPTER-ELBOW
5	3B4504	LOCKWASHER
16	3E6916	NUT-FULL
2	3S5849	GASKET
1	3S7189	BRACKET
3	4B0418	CLIP-LOOP
2	4B9302	CLIP-LOOP
1	4J5477	SEAL-O-RING-ORFS
36	4M0061	BOLT
1	4P7233	GROMMET
1	5G1442	GASKET
4	5G3676	GROMMET
8	5K0906	BOLT
1	5K6438	CLIP-LOOP
2	5M1198	CLIP
16	5M2894	WASHER-HARD
1	5M8429	CLIP
2	5N2126	CONNECTOR
44	5P4116	WASHER-HARD
16	5P7128	BOLT-HEX HEAD
1	5P8196	PLUG-O-RING
4	5P8245	WASHER-HARD
1	5P9297	CLIP-LOOP
1	6V3251	SEAL-O-RING
8	6V3630	BOLT-HIGH TEMP
8	6V3631	NUT-FULL
3	6V5064	SEAL-O-RING
6	6V5138	SEAL-O-RING
4	6V6609	SEAL-O-RING
2	6V8556	NUT-SWIVEL
1	6V8625	ADAPTER-ELBOW
1	6V8789	ADAPTER-TEE
2	6V8939	REDUCER
1	6V8942	REDUCER-O-RING
2	6V9746	SEAL-O-RING-ORFS
2	6V9769	SEAL-O-RING
1	6V9810	ADAPTER-ELBOW
1	6V9830	CAP-ORFS
1	6V9837	ADAPTER-TEE
4	6V9851	ADAPTER-ELBOW
1	6W2928	BOSS
2	7C3920	SEAL-EXHAUST
2	7C3921	RING-EX SEAL
1	7C9710	GASKET
5	7C9721	MACHINE SCREW
8	7L6443	BOLT-HEX HEAD
4	7S3916	CLIP
4	7S3919	CLIP
3	8C6871	ADAPTER-STR
1	8C7563	ADAPTER-ELBOW
1	8C8989	ADAPTER-ELBOW
1	8T1685	TEE-SPL
1	8T1715	ADAPTER-STR
2	8T6765	PLUG-NPTF
3	9C5336	SPACER
3	9S8752	NUT-FULL
1	9X2539	ELBOW-90 DEG
2	9X6458	WASHER-HARD
1	9X7712	SEAL-O-RING
4	9X8873	BOLT
1	0054362	ADAPTER-ELBOW
1	0321268	ADAPTER-ELBOW
5	0532294	BOLT-12 POINT HD
32	1108314	WASHER
1	1131572	DIAPHRAGM
1	1145277	ELBOW
4	1271958	SPACER
4	1381490	SPACER
1	1507158	CONNECTOR
1	1572348	ADAPTER-ELBOW
1	1623122	ADAPTER-ELBOW
2	1683349	PLUG-NPTF
4	1687800	LOCKNUT HEX
1	1730064	ADAPTER-ELBOW
18	1808424	SEAL-O-RING
1	1986067	SEAL-INTEGRAL
6	2295333	SEAL
5	2502343	SEAL-O-RING
1	2877261	TEE-SWIVEL
2	3369259	BELLOWS AS
1	3424813	SHIELD AS
1	3424814	SHIELD AS
1	3424815	SHIELD AS
1	3424816	SHIELD AS
12	3424817	BRACKET
1	3537956	GROMMET
1	3612216	HOSE AS
1	3826091	ELBOW
1	3826095	ELBOW
1	3832303	SHIELD AS
1	3832304	SHIELD AS
1	3832305	SHIELD AS
1	3832306	SHIELD AS
1	3832307	SHIELD AS
1	3832308	SHIELD AS
1	3832309	SHIELD AS
1	3832310	SHIELD AS
1	3832311	SHIELD AS
1	3832312	SHIELD AS
1	3832313	SHIELD AS
1	3832314	SHIELD AS
1	3832315	SHIELD AS
1	3832316	SHIELD AS
1	3832318	SHIELD AS
1	3832319	SHIELD AS
1	3949753	TUBE AS
1	3949928	TUBE AS
1	3950272	TUBE AS
1	3950274	TUBE AS
1	3950326	TUBE AS
1	3950330	TUBE AS
2	3960994	BRACKET AS
1	3960995	BRACKET
1	4160058	PLATE
1	4161326	HOSE AS
1	4178520	SHIELD 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.
*****Group 2*****
2	0L1351	BOLT
1	0L1352	BOLT
4	0S0509	BOLT
1	0S1591	BOLT
1	0S1594	BOLT
1	1A5183	BOLT
1	1B2578	NUT-JAM
4	1F7958	NUT-FULL
5	1W2430	CLAMP-V-BAND
2	2P4437	CLIP
1	2T2396	ADAPTER-ELBOW
5	3B4504	LOCKWASHER
16	3E6916	NUT-FULL
2	3S5849	GASKET
1	3S7189	BRACKET
3	4B0418	CLIP-LOOP
2	4B9302	CLIP-LOOP
1	4J5477	SEAL-O-RING-ORFS
1	4P7233	GROMMET
1	5G1442	GASKET
4	5G3676	GROMMET
1	5K6438	CLIP-LOOP
2	5M1198	CLIP
16	5M2894	WASHER-HARD
1	5M8429	CLIP
2	5N2126	CONNECTOR
44	5P4116	WASHER-HARD
16	5P7128	BOLT-HEX HEAD
1	5P8196	PLUG-O-RING
4	5P8245	WASHER-HARD
1	5P9297	CLIP-LOOP
1	6V3251	SEAL-O-RING
8	6V3630	BOLT-HIGH TEMP
8	6V3631	NUT-FULL
3	6V5064	SEAL-O-RING
6	6V5138	SEAL-O-RING
4	6V6609	SEAL-O-RING
2	6V8556	NUT-SWIVEL
1	6V8625	ADAPTER-ELBOW
1	6V8789	ADAPTER-TEE
2	6V8939	REDUCER
1	6V8942	REDUCER-O-RING
2	6V9746	SEAL-O-RING-ORFS
2	6V9769	SEAL-O-RING
4	6V9810	ADAPTER-ELBOW
1	6V9830	CAP-ORFS
1	6V9837	ADAPTER-TEE
4	6V9851	ADAPTER-ELBOW
1	6W2928	BOSS
2	7C3920	SEAL-EXHAUST
2	7C3921	RING-EX SEAL
1	7C9710	GASKET
5	7C9721	MACHINE SCREW
8	7L6443	BOLT-HEX HEAD
4	7S3916	CLIP
4	7S3919	CLIP
3	8C6871	ADAPTER-STR
1	8C7563	ADAPTER-ELBOW
1	8C8989	ADAPTER-ELBOW
1	8T1685	TEE-SPL
1	8T1715	ADAPTER-STR
2	8T6765	PLUG-NPTF
3	9C5336	SPACER
3	9S8752	NUT-FULL
1	9X2539	ELBOW-90 DEG
2	9X6458	WASHER-HARD
1	9X7712	SEAL-O-RING
4	9X8873	BOLT
1	0054362	ADAPTER-ELBOW
1	0321268	ADAPTER-ELBOW
5	0532294	BOLT-12 POINT HD
32	1108314	WASHER
1	1131572	DIAPHRAGM
1	1145277	ELBOW
4	1271958	SPACER
4	1381490	SPACER
1	1507158	CONNECTOR
1	1572348	ADAPTER-ELBOW
2	1683349	PLUG-NPTF
4	1687800	LOCKNUT HEX
1	1730064	ADAPTER-ELBOW
18	1808424	SEAL-O-RING
1	1986067	SEAL-INTEGRAL
6	2295333	SEAL
5	2502343	SEAL-O-RING
1	2877261	TEE-SWIVEL
2	3369259	BELLOWS AS
1	3537956	GROMMET
1	3612216	HOSE AS
1	3826091	ELBOW
1	3826095	ELBOW
1	3832303	SHIELD AS
1	3832304	SHIELD AS
1	3832305	SHIELD AS
1	3832306	SHIELD AS
1	3832307	SHIELD AS
1	3832308	SHIELD AS
1	3832309	SHIELD AS
1	3832310	SHIELD AS
1	3832311	SHIELD AS
1	3832312	SHIELD AS
1	3832313	SHIELD AS
1	3832314	SHIELD AS
1	3832315	SHIELD AS
1	3832316	SHIELD AS
1	3949753	TUBE AS
1	3949928	TUBE AS
1	3950272	TUBE AS
1	3950274	TUBE AS
1	3950326	TUBE AS
1	3950330	TUBE AS
2	3960994	BRACKET AS
1	3960995	BRACKET
1	4160058	PLATE
1	4161326	HOSE AS
1	4178520	SHIELD 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.
*****Group 3*****
2	0L1351	BOLT
1	0L1352	BOLT
3	0S0509	BOLT
1	0S1591	BOLT
1	0S1594	BOLT
1	1A5183	BOLT
1	1B2578	NUT-JAM
4	1F7958	NUT-FULL
5	1W2430	CLAMP-V-BAND
2	2P4437	CLIP
1	2T2396	ADAPTER-ELBOW
5	3B4504	LOCKWASHER
16	3E6916	NUT-FULL
2	3S5849	GASKET
1	3S7189	BRACKET
3	4B0418	CLIP-LOOP
2	4B9302	CLIP-LOOP
1	4J5477	SEAL-O-RING-ORFS
1	4P7233	GROMMET
1	5G1442	GASKET
4	5G3676	GROMMET
1	5K6438	CLIP-LOOP
2	5M1198	CLIP
16	5M2894	WASHER-HARD
1	5M8429	CLIP
2	5N2126	CONNECTOR
16	5P7128	BOLT-HEX HEAD
1	5P8196	PLUG-O-RING
2	5P8245	WASHER-HARD
1	5P9297	CLIP-LOOP
1	6V3251	SEAL-O-RING
8	6V3630	BOLT-HIGH TEMP
8	6V3631	NUT-FULL
3	6V5064	SEAL-O-RING
4	6V5138	SEAL-O-RING
4	6V6609	SEAL-O-RING
2	6V8556	NUT-SWIVEL
1	6V8625	ADAPTER-ELBOW
1	6V8789	ADAPTER-TEE
2	6V8939	REDUCER
1	6V8942	REDUCER-O-RING
2	6V9746	SEAL-O-RING-ORFS
2	6V9769	SEAL-O-RING
1	6V9830	CAP-ORFS
1	6V9837	ADAPTER-TEE
4	6V9851	ADAPTER-ELBOW
1	6W2928	BOSS
2	7C3920	SEAL-EXHAUST
2	7C3921	RING-EX SEAL
1	7C9710	GASKET
5	7C9721	MACHINE SCREW
8	7L6443	BOLT-HEX HEAD
4	7S3916	CLIP
4	7S3919	CLIP
3	8C6871	ADAPTER-STR
1	8C7563	ADAPTER-ELBOW
1	8C8989	ADAPTER-ELBOW
1	8T1685	TEE-SPL
1	8T1715	ADAPTER-STR
2	8T6765	PLUG-NPTF
3	9C5336	SPACER
3	9S8752	NUT-FULL
1	9X2539	ELBOW-90 DEG
2	9X6458	WASHER-HARD
1	9X7712	SEAL-O-RING
4	9X8873	BOLT
1	0054362	ADAPTER-ELBOW
1	0321268	ADAPTER-ELBOW
5	0532294	BOLT-12 POINT HD
32	1108314	WASHER
1	1131572	DIAPHRAGM
1	1145277	ELBOW
4	1271958	SPACER
4	1381490	SPACER
1	1507158	CONNECTOR
1	1572348	ADAPTER-ELBOW
2	1683349	PLUG-NPTF
4	1687800	LOCKNUT HEX
1	1730064	ADAPTER-ELBOW
18	1808424	SEAL-O-RING
1	1986067	SEAL-INTEGRAL
6	2295333	SEAL
5	2502343	SEAL-O-RING
1	2877261	TEE-SWIVEL
2	3369259	BELLOWS AS
1	3537956	GROMMET
1	3826091	ELBOW
1	3826095	ELBOW
1	3949753	TUBE AS
1	3949928	TUBE AS
1	3950272	TUBE AS
1	3950274	TUBE AS
1	3950326	TUBE AS
1	3950330	TUBE AS
2	3960994	BRACKET AS
1	3960995	BRACKET
1	4160058	PLATE
1	4161326	HOSE AS
1	4178520	SHIELD 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.
*****Group 4*****
2	0L1351	BOLT
1	0L1352	BOLT
1	0S1591	BOLT
1	0S1594	BOLT
1	1A5183	BOLT
1	1B2578	NUT-JAM
4	1F7958	NUT-FULL
5	1W2430	CLAMP-V-BAND
2	2P4437	CLIP
1	2T2396	ADAPTER-ELBOW
5	3B4504	LOCKWASHER
2	3S5849	GASKET
1	3S7189	BRACKET
3	4B0418	CLIP-LOOP
2	4B9302	CLIP-LOOP
1	4J5477	SEAL-O-RING-ORFS
1	4P7233	GROMMET
1	5G1442	GASKET
4	5G3676	GROMMET
1	5K6438	CLIP-LOOP
2	5M1198	CLIP
11	5M2894	WASHER-HARD
1	5M8429	CLIP
1	5P8196	PLUG-O-RING
2	5P8245	WASHER-HARD
1	5P9297	CLIP-LOOP
1	6V3251	SEAL-O-RING
3	6V5064	SEAL-O-RING
6	6V5138	SEAL-O-RING
4	6V6609	SEAL-O-RING
2	6V8556	NUT-SWIVEL
1	6V8625	ADAPTER-ELBOW
1	6V8789	ADAPTER-TEE
2	6V8939	REDUCER
1	6V8942	REDUCER-O-RING
2	6V9746	SEAL-O-RING-ORFS
2	6V9769	SEAL-O-RING
1	6V9830	CAP-ORFS
1	6V9837	ADAPTER-TEE
4	6V9851	ADAPTER-ELBOW
1	6W2928	BOSS
2	7C3920	SEAL-EXHAUST
2	7C3921	RING-EX SEAL
1	7C9710	GASKET
5	7C9721	MACHINE SCREW
4	7S3916	CLIP
4	7S3919	CLIP
3	8C6871	ADAPTER-STR
1	8C7563	ADAPTER-ELBOW
1	8C8989	ADAPTER-ELBOW
1	8T1685	TEE-SPL
1	8T1715	ADAPTER-STR
2	8T6765	PLUG-NPTF
3	9C5336	SPACER
3	9S8752	NUT-FULL
1	9X2539	ELBOW-90 DEG
2	9X6458	WASHER-HARD
1	9X7712	SEAL-O-RING
4	9X8873	BOLT
1	0054362	ADAPTER-ELBOW
1	0321268	ADAPTER-ELBOW
5	0532294	BOLT-12 POINT HD
1	1131572	DIAPHRAGM
1	1145277	ELBOW
4	1271958	SPACER
4	1381490	SPACER
1	1507158	CONNECTOR
1	1572348	ADAPTER-ELBOW
2	1683349	PLUG-NPTF
4	1687800	LOCKNUT HEX
1	1730064	ADAPTER-ELBOW
18	1808424	SEAL-O-RING
1	1986067	SEAL-INTEGRAL
5	2502343	SEAL-O-RING
1	2877261	TEE-SWIVEL
1	3537956	GROMMET
1	3949753	TUBE AS
1	3949928	TUBE AS
1	3950272	TUBE AS
1	3950274	TUBE AS
1	3950326	TUBE AS
1	3950330	TUBE AS
2	3960994	BRACKET AS
1	3960995	BRACKET
1	4160058	PLATE
1	4161326	HOSE AS
1	4178520	SHIELD 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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This service letter does not need to be implemented if 09Nov2012 Service Letter, PS43754, has already been completed.

Update the waterlines, exhaust bellows, exhaust elbows, exhaust bypass, and exhaust shields.

Refer to Special Instruction, REHS7132.

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OWNER NOTIFICATION

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

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 17.0-hour job for Group 1

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 16.0-hour job for Group 2

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 3*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 12.0-hour job for Group 3

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 4*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 9.0-hour job for Group 4

PARTS DISPOSITION

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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PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 341-8736 WATERLINES, 328-2635 EXHAUST MANIFOLD, AND 339-3788 EXHAUST SHIELDING ON CERTAIN 3516, AND G3516B PETROLEUM ENGINES

MODELS INVOLVED - G3516, G3516B

Dear Cat Product Owner:

Certain waterline and exhaust system components need to be replaced on the products listed below. The existing waterlines can leak coolant and exhaust system components can leak exhaust. 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.

Please refer the dealer to their Service Letter dated 23Jul2013 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 23Jul2013 Service Letter