The Electronic Ignition System (EIS) Control Module Needs To Be Replaced On Certain G3508, G3512, And G3516 Engines Caterpillar

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.

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI3814" as the Part Number, "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 "PI3814" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

NOTE: This Revised Service Letter replaces the November 2, 1995 (Revised April 1996) Service Letter. Changes have been made to the COMPLETION DATE and TERMINATION DATE.

Completion Date

Termination Date

Problem

The G3500 Electronic Ignition System (EIS) Control Module has been upgraded to provide improvements in detonation detection, timing, and shutdown control strategies. The existing field units shipped prior to production effectivity of the new configuration will be replaced with remanufactured units for improved ignition system control and reliability.

Affected Product
Model & Identification Number

G3508 (9TG12-47)

G3512 (5JD12-19)

G3512 (7NJ12-95)

G3516 (4EK12-456)

G3516 (8LD12-27)

Parts Needed

The remanufactured modules are not available through the parts system and therefore will be provided by the Caterpillar Gas Engine Customer Service Department. They will be shipped directly to the appropriate dealers according to a predetermined Priority schedule.

Action Required

See the attached procedure.

Owner Notification

U.S. and Canadian owners will receive the attached Owner Notification.

Service Claim Allowances

NOTE: As the parts are not available through the parts system, dealers may claim $100.00 USD for the parts on this rework.

NOTE: This is a 2-hour job.

NOTE: Return shipping will be paid by Caterpillar, Inc.

Parts Disposition

All control modules removed from an engine, along with the engine data sheet should be returned to:

NOTE: MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach.

(1-Owner Notification)

(2-Rework Procedure)

Copy Of Owner Notification For U.S. And Canadian Owners

Rework Procedure

Before a module is replaced on and engine, the following should be thoroughly reviewed:

The upgrade unit is intended to replace the EIS Control Module currently installed on a running engine. Complete the Electronic Troubleshooting Guide Self Test, P-518, on the existing engine module prior to replacement with the upgrade unit. If the existing module fails a self-test, it should NOT be replaced with an upgrade unit. It should be replaced through warranty, if applicable. If not warrantable, the customer should pay the cost of a new 1244565 Module. If the existing module passes the self test procedure, it can then be replaced and returned per this program.

If the engine has been previously updated with a 1244565 Control Group, it is NOT a candidate for this program. The engine serial number, customer, and dealer contact person information should be faxed to Ralph Munguia at fax number (317) 448-5985. An electronic mail note to MUNGUR will also be acceptable. Information about engines that have been previously updated with a 1244565 Control Group will be helpful in documenting the efforts of this field program.

This program is NOT intended to resolve false detonation, unexplained fault code generation, wiring problems, or problems resulting from ignition noise. If any problems or concerns exist, they should be resolved prior to implementing this program. If a module is diagnosed as the possible root cause of a problem, it should be self tested, per SENR6413, Electronic Troubleshooting Guide.

NOTE: If the module currently installed on the engine fails a self test, DO NOT use this program to make the repair. The failed module should then be replaced through standard warranty procedures, if applicable. If not warrantable, the customer must purchase a new 1244565 Control Group through normal channels. If this is a warrantable repair, then the module should be returned through the normal warranty parts return procedures. Engine information about this type of conversion should be sent to Ralph Munguia, per the above mentioned method.

The upgrade control module part number is 1235101. It can only be obtained through this program, and is serviced by 1244565 Control Group.

After the information above has been thoroughly reviewed, and the target engine control module has passed a self test, then an upgrade module should be installed and the removed module returned per this program. The following procedure can be followed to successfully complete a module replacement.

NOTE: The removal and programming procedures defined in SENR6413, G3500 Electronic Troubleshooting should be used. Refer to P-202 Programming The EIS Control Module, and P-203 Speed/Timing Sensor Calibration to properly complete the module replacement.

1. Follow the procedures outlined in SENR6413 Electronic Troubleshooting P-202 and P-203 (pages 2-8 through 2-16). A copy of the worksheet is provided with the control module.

2. The cooling lines to the EIS Module must be removed to complete the replacement. Insure that coolant will not drain from the system prior to disconnecting the lines at the control module fittings.

3. Complete the engine data sheet provided with the new module.

4. Properly package the removed control module, along with the completed engine data sheet, and return per the parts disposition instructions of the program.

NOTE: In order to successfully complete this EIS Control Module upgrade program, it is very important that the module being returned has successfully passed the self test procedure outlined in SENR6413, Electronic Trouble Shooting Guide. Promptly return this module to the address provided in this letter.

All modules returned to the factory will be tested to insure that they can successfully pass the self test procedure outlined in the trouble shooting guide. If a returned module fails the self test, then the dealer who returned the part will be billed for the cost of a new 1244565 Control Group.

All questions related to this program should be directed to: