PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING NEW ENGINE WIRING HARNESSES ON SERVICE REPLACEMENT 3516B ENGINES IN DEALER PARTS STOCK AND DEALER EXCHANGE INVENTORY Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING NEW ENGINE WIRING HARNESSES ON SERVICE REPLACEMENT 3516B ENGINES IN DEALER PARTS STOCK AND DEALER EXCHANGE INVENTORY

Usage:

REBE7792-00

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13Apr2012

U-209

A-167

D-175

O-191

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*Parts stock action only*	PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING NEW ENGINE WIRING HARNESSES ON SERVICE REPLACEMENT 3516B ENGINES IN DEALER PARTS STOCK AND DEALER EXCHANGE INVENTORY
7750		PI70434

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NOTE:

When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7751" as the Group Number, "56" as the 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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TERMINATION DATE

31Jul2012

PROBLEM

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Due to the harness size, and the heat and vibration seen in this application, the standard saddle clips break. This allows the harness to rub at various places causing abrasion and short circuits. Harness is difficult to troubleshoot and repair due to large size/number of conductors. It also fails at kinks in the internal wires and at factory splice connections. Current connector clip design is not robust in cold weather climates or against the dirty environment. Ladder clips do not adequately support the harness. The pin connectors on the alternator power leads are undersized and break. The harness breakout lengths are too long at some locations, causing them to be secured in bundles, leading to failure when bent too tight.

ACTION REQUIRED

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Rework the following engines in dealer parts stock and/or dealer exchange inventory:

373-9863, 235-0300, 288-4348 with an 8WM prefix. Rework the following engines 8WM00105-02936.

10R-2852 with an MSK prefix. Rework the following engines MSK00200-00377.

Replace the current engine harness with a newly designed engine harness. Refer to REHS7483, Special Instructions, "Installation of the 364-9117 Engine Wiring Gp on 793D Off-Highway Truck Engines" and SEPD1273, Service Magazine, "A New Oil Level Sensor Is Used for 793D Off-Highway Trucks" for installation instructions.

Parts Needed

Qty Part No. Description
7 0L1143 Bolt
14 0L2070 Bolt
13 0S0509 Bolt
2 0S1571 Bolt
1 0S1587 Bolt
2 0S1588 Bolt
10 0S1590 Bolt
4 0S1591 Bolt
10 0S1594 Bolt
2 0S1619 Bolt
1 0S1620 Bolt
1 0S1621 Bolt
1 1F4111 Bolt
1 1K4649 Spacer
14 1V6645 Spacer
1 2H3855 Bolt
2 3A3692 Clip
1 3E4352 Washer-Hard
1 3H7654 Washer-Hard
2 3K0360 Seal-O-Ring
4 4B2043 Nut
1 4P7429 Clip-Ladder
16 4P7581 Clip-Ladder
28 4P8134 Clip-Ladder
68 5M2894 Washer-Hard
1 5P3108 Seal-O-Ring
3 5P7464 Clip
3 5P7465 Clip
1 5P7466 Clip
1 5P7467 Clip
14 5P7468 Clip
14 5P7469 Clip
1 5P8112 Grommet
3 5P8245 Washer-Hard
3 6V0826 Grommet
3 6V1249 Grommet
1 6V3922 Seal-O-Ring
8 6V4349 Grommet
1 6V4589 Seal-O-Ring
11 6V5048 Seal-O-Ring
5 8T1889 Clip-2 Piece
5 8T1890 Clip-2 Piece
13 8T1893 Clip
13 8T1894 Clip
1 8T2525 Grommet
3 8T7087 Grommet
2 8T9518 Grommet
3 9S8752 Nut-Full
4 9X0262 Adapter-STR
52 9X6772 Strap-Cable
8 9X8486 Screw-Machine
1 0307941 Adapter-Elbow
12 0966166 Washer-Hard
17 1153069 Clip As-Connect
6 1155579 Clip As-Connect
1 1170067 Adapter-Elbow
2 1241479 Clip-Loop
1 1474348 Spacer
4 2042281 Tie-Wrap
5 2048000 Mount-Tie Wrap
14 2049734 Spacer
2 2065017 Spacer
1 2147568 Seal-O-Ring-Stor
2 2616847 Adapter
2 2777637 Bracket
2 2809910 Sensor Gp-Temp
1 3080875 Hose As
1 3309321 Sensor Gp-Level
2 3537954 Grommet
6 3537956 Grommet
7 3537957 Grommet
1 3649118 Harness As
1 3649119 Bracket
1 3649120 Harness As
1 3649121 Harness As
1 3649123 Harness As
1 3649124 Harness As

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SERVICE CLAIM ALLOWANCES

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Submit one claim for all engines reworked in dealer parts stock and/or dealer exchange inventory. The parts listed in the Parts Needed will be allowed for each engine that is reworked. 40 hours labor will be allowed for engine that is reworked. Include the engine serial numbers and arrangement numbers in the service claim story.