PRODUCT IMPROVEMENT PROGRAM FOR INSPECTION AND REPAIR OF ELECTRICAL WIRING ADJACENT TO FERRITE BEAD, INSTALLATION OF SHRINK TUBING AROUND BEAD, AND FLASHING NEW SOFTWARE ON CERTAIN 3508B, 3512B, 3512C, 3516B HD, AND 3516C MARINE ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTION AND REPAIR OF ELECTRICAL WIRING ADJACENT TO FERRITE BEAD, INSTALLATION OF SHRINK TUBING AROUND BEAD, AND FLASHING NEW SOFTWARE ON CERTAIN 3508B, 3512B, 3512C, 3516B HD, AND 3516C MARINE ENGINES

Usage:

REBE2082-01

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27Sep2007

(Revised 09Jan2008)

U-494

A-405

D-396

O-427

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTION AND REPAIR OF ELECTRICAL WIRING ADJACENT TO FERRITE BEAD, INSTALLATION OF SHRINK TUBING AROUND BEAD, AND FLASHING NEW SOFTWARE ON CERTAIN 3508B, 3512B, 3512C, 3516B HD, AND 3516C MARINE ENGINES
1408 1403 1901 1902 7620		PI31361

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31361" 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 "PI31361" 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 27Sep2007 Service Letter. Changes have been made to identify the correct engine software flash files corresponding to the marine propulsion engines.

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COMPLETION DATE	TERMINATION DATE
31Mar2008	30Sep2008

PROBLEM

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1) The 7X-1608 Ferrite Bead on the power/ground wires to the ECM may wear into the wire insulation inside the primary and secondary ECM connector covers on certain 3500B Marine Engines. If the wiring routed through the ferrite bead and/or the wiring that surrounds the ferrite bead experience chaffing or wear, this can lead to electrical opens and shorts and cause fault codes and possibly lead to unexpected engine shutdowns.

2) There are new flashfiles for the marine propulsion engines. The new flash files are available on SISWeb and should be installed during this service call. Reference SISWeb to identify and download the correct flash files for the engine being serviced.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
3508B	S2B00148-00149, 196-199, 204-210, 215-219, 223-224, 232-235, 245-248, 255-270, 273-289, 293-366
3512B	S2G00100-00102, 108-116 S2H00100-00103, 131-132, 187-193, 201-203, 208-214, 218-273
3512C	TTF00200 TTG00200-00202
3516B	S2P00106, 108-118 S2R00152-00157, 166-169, 187-189, 197-311 S2T00101-00103
3516B HD	S2Z00110-00140
3516C	TTD00200-00201 TTH00200-00201 TTJ00200

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*****Group 2*****
3508B	S2D00144-00151, 156-209 S2E00158-00161, 177-178, 186-188, 230-232, 240-241, 247-250, 291-294, 309-310, 326-327, 356-359, 366-367, 371-375, 384-389, 404-418, 421-424, 435-446, 458-470, 473-512, 518-626 S2F00102-00105, 111, 117-119

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

3512B

MKH00206-00208, 214-223

S2J00112-00113, 119-120, 139-140, 161-163, 168-169, 204-205, 237-245, 254-256, 261-262, 271-273, 276-282, 287-291, 296-302, 312-325, 328-414, 416-450

S2K00122-00123, 129-130, 152-153, 167-168, 187-215, 221-267

S2L00134-00137, 149-152, 162-165, 194-196, 210-214, 222-223, 232-236, 267-270, 299-300, 322-323, 327-333, 342-343, 356-357, 362-369, 381-382, 397-399, 407-433, 436-644

S2M00104-00105, 111-124, 130-133, 153-164

S2N00100-00106, 109-113, 117-123

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*****Group 4*****
3516B	S2S00130-00138, 144-147, 157-162, 177-182, 186-188, 194-211, 214-217, 222-276 S2W00106-00120 S2X00102-00103, 107-108, 183-187, 196-197, 204-205, 211-212, 266-268, 271-276, 283-284, 290-292, 309-318, 329-332, 335-337, 341-348, 353-384, 387-652 S2Y00104-00105, 109-110

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	2108958	TUBE-HEAT SHRINK
2	3097564	BEAD-FERRITE
2	3117510	ADAPTER
2	3117511	ADAPTER
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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*****
1	2108958	TUBE-HEAT SHRINK
2	3097564	BEAD-FERRITE
2	3117510	ADAPTER
2	3117511	ADAPTER
1	3129002	SOFTWARE GP-ELEK
1	3129003	SOFTWARE GP-ELEK
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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*****
1	2108958	TUBE-HEAT SHRINK
2	3097564	BEAD-FERRITE
2	3117510	ADAPTER
2	3117511	ADAPTER
1	3128981	SOFTWARE GP-ELEK
1	3128982	SOFTWARE GP-ELEK
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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*****
1	2108958	TUBE-HEAT SHRINK
2	3097564	BEAD-FERRITE
2	3117510	ADAPTER
2	3117511	ADAPTER
1	3128961	SOFTWARE GP-ELEK
1	3128962	SOFTWARE GP-ELEK
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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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The ferrite bead, and the conduit adapters, installed on these engines should be replaced. Based on the extent of chaffing or wear, certain wires may also require replacement.

Replace software on marine propulsion engines with new software flash files during this service call. The new software flash files are available on SISWeb. Reference SISWeb to identify and download the correct flash files for the engine being serviced.

Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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

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 4.0-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 4.0-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 4.0-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 4.0-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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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTION AND REPAIR OF ELECTRICAL WIRING ADJACENT TO FERRITE BEAD, SHRINK TUBING INSTALLATION AROUND THE BEAD AND FLASHING NEW SOFTWARE ON CERTAIN 3508B, 3512B, 3512C, 3516B HD, AND 3516C MARINE ENGINES

MODELS INVOLVED - Certain 3508B, 3512B, 3512C, 3516B HD,and 3516C Marine Engines

Dear Caterpillar Product Owner:

The wiring needs to be inspected, ferrite bead needs replaced, shrink tubing installed, and software replaced on the products listed below. The existing wiring can short out. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete 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.

Please refer the dealer to their Service Letter dated 27Sep2007 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 27Sep2007 Service Letter

Rework Procedure

Ferrite Bead Rework:
1. Remove the ECM J1 connector on the primary ECM (and also on the secondary ECM if a marine propulsion engine).

2. Remove the wires (four tan) running through the ferrite bead (J1 pin # 52, 53, 63, and 65).

3. Remove the existing 7X-1608 Ferrite Bead.

4. Inspect all wires for damage to determine the level of rework required.
a. If there is wear on the wire insulation where more than 50 percent of the insulation thickness has been removed, but copper wire is not visible, then apply heat shrink to the wire.
b. If any copper is exposed, then pull a new replacement wire through the conduit and splice in the harness rail.

5. Install new 309-7564 Ferrite Bead onto the wires (four tan). Locate the bead as close to the end of the conduit as possible.

6. Install new 210-8958 Heat Shrink over the ferrite bead. The heat shrink must cover the entire bead and capture the four wires at either end of the bead. Do not heat the heat shrink at this time, as the wires will bind up when inserting into the connector.

7. Install the wires (four tan) into the correct connector pin locations (J1 pin #52, 53, 63, and 65).

8. Heat the shrink tube to hold the bead in place.

9. Replace the existing 237-4356 Adapter at the conduit opening with the new 311-7510 Adapter.

10. Install the ECM J1 connector on the primary ECM (and also on the secondary ECM if a marine propulsion engine).

11. Remove the ECM J2 connector on the primary ECM (and also on the secondary ECM if a marine propulsion engine).

12. Replace the existing 237-4357 Adapter at the conduit opening with the new 311-7511 Adapter.

13. Install the ECM J2 connector on the primary ECM (and also on the secondary ECM if a marine propulsion engine).

14. Verify that the original function is maintained after the re-work:
a. Verify that panel start/stop switch is in the "OFF" position and that all breakers are in "ON" position.
b.Verify that no breakers have tripped.
c. Place the panel start/stop switch in the "STOP" position.
d. Verify that no breakers have tripped and the instrument panel powers up.
e. Verify that the engine starts and runs normally.

Software Rework:
1. For the marine propulsion engines included in this service letter, flash the engines with the latest production Flash File available on SISWeb. Reference SISWeb to identify and download the correct flash files for the engine being serviced.