PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE COMMUNICATION ELECTRONICS GROUP WIRING HARNESS ON CERTAIN G3508B, G3512B, G3516B, AND G3520B ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE COMMUNICATION ELECTRONICS GROUP WIRING HARNESS ON CERTAIN G3508B, G3512B, G3516B, AND G3520B ENGINES

Usage:

TEBE4519-01

Show/hide table

13Apr2016

(Revised 15Sep2016)

U-179

A-137

D-160

O-154

Show/hide table

Priority	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE COMMUNICATION ELECTRONICS GROUP WIRING HARNESS ON CERTAIN G3508B, G3512B, G3516B, AND G3520B ENGINES
1408 1130 5510		PI32617

Show/hide table

NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32617" 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 "PI32617" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

Show/hide table

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.

Show/hide table


NOTE:	This Revised Service Letter replaces the 13Apr2016 Service Letter. Changes have been made to the Affected Product, Parts Needed, Action Required, and Service Claim Allowances.

Show/hide table

COMPLETION DATE	TERMINATION DATE
31Oct2016	30Apr2017

PROBLEM

Show/hide table

The 423-0848 Communication Electronics Wiring Harness needs to be reworked on certain G3508B, G3512B, G3516B, and G3520B Engines. Failure to rework the existing harness can cause the 463-1128 or 463-1129 Compressor By-Pass Valve to not function properly or fail, resulting in logged 1720-12 or 1720-9 turbocharger compressor bypass valve actuator failure code. Once rework is done compressor by-pass valve will not fail with above codes.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
*****Group 1*****
G3516B	JEF02661-03427 N6E00100-00399
G3520B	GLF00108-00126, 1100-1112 TPC01140-01190

Show/hide table

*****Group 2*****
G3508B	N8C00100-00123 RBK01400-01627
G3512B	JHH01028-01047 N2S00100-00102

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
*****Group 1*****
1	3S2093	STRAP-CABLE (Before Failure Only)
2	7K1181	STRAP-CABLE (Before Failure Only)
2	8T8737	PLUG-SEAL (Before Failure Only)
1	20R6711	ACTUATOR GP -C (After Failure Only)
2	1058180	GASKET (After Failure Only)
2	1274230	GASKET (After Failure Only)
1	1552270	PLUG KIT-CONN (Before Failure Only)
1	3747463	CAP-SEAL (Before Failure Only)
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*****
1	3S2093	STRAP-CABLE (Before Failure Only)
2	7K1181	STRAP-CABLE (Before Failure Only)
2	8T8737	PLUG-SEAL (Before Failure Only)
1	20R6712	ACTUATOR GP -C (After Failure Only)
2	1058180	GASKET (After Failure Only)
2	1274230	GASKET (After Failure Only)
1	1552270	PLUG KIT-CONN (Before Failure Only)
1	3747463	CAP-SEAL (Before Failure Only)
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

Show/hide table

If the Compressor By-Pass Valve has failed and has logged 1720-9 or 1720-12 codes, please replace with the new Reman compressor by-pass valve, it is not necessary to preform the before failure wiring harness rework if compressor by-pass valve is replaced.

Note: Refer to disassembly and assembly manual for effected model on procedure for remove and installation of compressor by-pass valve.

Note: For failed compressor by-pass valve claims only, the product status report must be uploaded and saved to SIMSI prior to claims submittal to warranty.

Before Failure Only Perform the Rework Below.

Note: If valve is functioning and no codes are present there is no need to change the valve proactively just preform the rework listed below.

Note: Product Link can get information from the CDL or CAN. Unplugging the two CAN wires will not effect or change the Product Link functionality.

1. Locate 417-4722 or 459-0786 Product Link Control GP (1). Image 1

2. Remove both 7K-1181 Cable Straps (2). Image 2

3. Remove 126-1774 Connector Cover (3) with a flat blade screw driver. Image 3

4. Use a 151-6320 Pin Removal Tool (4) to remove pins 34 and 50 from the 70 pin harness connector. Image 4 and Image 5

5. Install 8T-8737 Plug Seals (5) in both 34 and 50 locations. Image 6

6. Take both wires from locations 34 (6) and 50 (7) and install 155-2270 2 Pin Connector Plug Kit (8). Image 7 and Image 8

7. Install 374-7463 Cap Seal (9) on the 2 pin connector kit and secure with 3S-2093 Cable Strap (10) back to main harness. Image 9

8. Reinstall Connector Cover (3) with new 7K-1181 Cable Straps (2). Image 10

Show/hide table

Image1

Image2

Image3

Image4

Image5

Image6

Image7

Image8

Image9

Image10

OWNER NOTIFICATION

Show/hide table

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

SERVICE CLAIM ALLOWANCES

Show/hide table

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 1.0-hour job for Group 1
An additional 3 hours is allowed for after failure compressor by-pass valve replacement.

Show/hide table

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 1.0-hour job for Group 2
An additional 3 hours is allowed for after failure compressor by-pass valve replacement.

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.

Show/hide table

EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE COMMUNICATION ELECTRONICS GROUP WIRING HARNESS

MODELS INVOLVED - CERTAIN G3508B, G3512B, G3516B, AND G3520B ENGINES

Dear Cat Product Owner:

The 423-0848 Communication Electronics Wiring Harness needs to be reworked on certain G3508B, G3512B, G3516B, and G3520B Engines. Failure to rework the existing harness can cause the 463-1128 or 463-1129 Compressor By-Pass Valve to not function properly or fail, resulting in logged 1720-12 or 1720-9 turbocharger compressor bypass valve actuator failure code. 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 13Apr2016 when scheduling this service.

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

Caterpillar Inc.

Identification #(s)

Attached to 13Apr2016 Service Letter