PRODUCT SUPPORT PROGRAM FOR REPAIR OF ELECTRICAL WIRING ADJACENT TO FERRITE BEAD, INSTALLATION OF SHRINK TUBING AROUND BEAD, AND FLASHING OF NEW SOFTWARE Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPAIR OF ELECTRICAL WIRING ADJACENT TO FERRITE BEAD, INSTALLATION OF SHRINK TUBING AROUND BEAD, AND FLASHING OF NEW SOFTWARE

Usage:

REBE2083-01

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27Sep2007

(Revised 09Jan2008)

U-493

A-404

D-395

O-425

TM-19

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REPAIR OF ELECTRICAL WIRING ADJACENT TO FERRITE BEAD, INSTALLATION OF SHRINK TUBING AROUND BEAD, AND FLASHING OF NEW SOFTWARE
1408 1403 1901 1902 7620		PS51362

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS51362" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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 correct the Title, update the software part number information corresponding to the marine propulsion engines, and add product B5G identification numbers.

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TERMINATION DATE

30Sep2009

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	S2A00100-00127 S2B00100-00147, 150-195, 200-203, 211-214, 220-222, 225-231, 236-244, 249-254, 271-272, 290-292
3512B	MRG00100-00103 S2G00103-00107 S2H00104-00130, 133-186, 194-200, 204-207, 215-217
3516B	B5G00100-00101 PAG00100-00179 S2P00100-00105, 107 S2R00100-00151, 158-165, 170-186, 190-196 S2T00100
3516B HD	S2Z00100-00109
3516C	PES00200-00201

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*****Group 2*****
3508B	S2D00100-00143, 152-155 S2E00100-00157, 162-176, 179-185, 189-229, 233-239, 242-246, 251-290, 295-298, 300-308, 311-325, 328-355, 360-365, 368-370, 376-383, 390-403, 419-420, 425-434, 447-457, 471-472, 513-517 S2F00100-00101, 106-110, 112-116

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

3512B

MKH00200-00205, 209-213

S2J00100-00111, 114-118, 121-138, 141-160, 164-167, 170-203, 206-236, 246-253, 257-260, 263-270, 274-275, 283-286, 292-295, 303-311, 326-327

S2K00100-00121, 124-128, 131-151, 154-166, 169-186, 216-220

S2L00100-00133, 138-148, 153-161, 166-193, 197-209, 215-221, 224-231, 237-266, 271-298, 301-321, 324-326, 334-341, 344-355, 358-361, 370-380, 383-396, 400-406, 434-435

S2M00100-00103, 106-110, 125-129, 134-152

S2N00107-00108, 114-116

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*****Group 4*****
3516B	S2S00100-00129, 139-143, 148-156, 163-176, 183-185, 189-193, 212-213, 218-221 S2W00100-00105 S2X00100-00101, 104-106, 109-182, 188-195, 198-203, 206-210, 213-265, 269-270, 277-282, 285-289, 293-308, 319-328, 333-334, 338-340, 349-352, 385-386 S2Y00100-00103, 106-108

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 3% 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 3% 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 3% 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 3% 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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If the wiring routed through the ferrite bead and/or the wiring that surrounds the ferrite bead experience chaffing or wear, the ferrite bead and the conduit adapters should be replaced. Based on the extent of the damage, certain wires may also require replacement.

Replace marine propulsion engine software with new 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 attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
0-1000 hrs, 0-4 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
1001-6000 hrs, 5-12 mo	100.0%	75.0%	0.0%	0.0%	0.0%	25.0%
6001-12000 hrs, 13-24 mo	100.0%	33.0%	0.0%	0.0%	0.0%	67.0%

NOTE: This is a 4.0-hour job for Group 1

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
0-1000 hrs, 0-4 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
1001-6000 hrs, 5-12 mo	100.0%	75.0%	0.0%	0.0%	0.0%	25.0%
6001-12000 hrs, 13-24 mo	100.0%	33.0%	0.0%	0.0%	0.0%	67.0%

NOTE: This is a 4.0-hour job for Group 2

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 3*****
0-1000 hrs, 0-4 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
1001-6000 hrs, 5-12 mo	100.0%	75.0%	0.0%	0.0%	0.0%	25.0%
6001-12000 hrs, 13-24 mo	100.0%	33.0%	0.0%	0.0%	0.0%	67.0%

NOTE: This is a 4.0-hour job for Group 3

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 4*****
0-1000 hrs, 0-4 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
1001-6000 hrs, 5-12 mo	100.0%	75.0%	0.0%	0.0%	0.0%	25.0%
6001-12000 hrs, 13-24 mo	100.0%	33.0%	0.0%	0.0%	0.0%	67.0%

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.

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 219-8958 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.