Product support program for reworking the Power Distribution Panel Harness Assembly on certain 3500B Series II Marine Propulsion engines Caterpillar

Product support program for reworking the Power Distribution Panel Harness Assembly on certain 3500B Series II Marine Propulsion engines

Usage:

REBE1287-00

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16Oct2006

U-679

A-657

D-641

O-661

TM-513

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*Priority*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE POWER DISTRIBUTION PANEL HARNESS ASSEMBLY ON CERTAIN 3500B SERIES II MARINE PROPULSION ENGINES
1408 1426		PI31164

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31164" 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 "PI31164" 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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COMPLETION DATE	TERMINATION DATE
30Apr2007	31Oct2007

PROBLEM

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The Power Distribution Box Harness does not connect the return circuit of the SMMS to Pin 7 on the J2 Connector of the Primary ECM. This results in a 444-5 Start Relay Open Circuit diagnostic.

AFFECTED PRODUCT

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Model	Identification Number
3508B	S2D00113-00181 S2E00145-00579 S2F00104-00118
3512B	S2J00135-00369 S2K00108-00253 S2L00160-00547 S2M00110-00162 S2N00107-00121
3516B	S2S00140-00243 S2T00100-00101 S2W00102-00111 S2X00178-00547 S2Y00106-00109

PARTS NEEDED

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Qty	Part Number	Description
1	1364877	SPLICE-WIRE
1	2339226	PIN
1	2339227	SOCKET-CONNECTOR
1	5P5623	WIRE-ELECTRICAL

ACTION REQUIRED

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Please 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%
100%	100%	0%	0%	0%	0%

NOTE: This is a 1.0-hour job

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 SUPPORT PROGRAM FOR REWORKING THE POWER DISTRIBUTION PANEL HARNESS ASSEMBLY

MODELS INVOLVED - CERTAIN 3500B SERIES II MARINE PROPULSION ENGINES

Dear Caterpillar Product Owner:

The Power Distribution Box Harness needs to be reworked on the products listed below. 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.

Please refer the dealer to their Service Letter dated 16Oct2006 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 16Oct2006 Service Letter

Rework Procedure

Some 3500B Marine Propulsion Engines will log a false 444-5 Start Relay Open diagnostic code. The 231-9867 Panel Harness As is assembled incorrectly. The primary Electronic Control Module (ECM) monitors pin 7 on the J2 Connector for return current from the starter relay coil. Wire G229-P17-BK-18 is connected to − battery. This results in a 444-5 Start Relay Open diagnostic code due to the open circuit on pin 7 of the J2 connector. This wire must be connected to pin 7 on the J2 connector.

Image1.1.1

Refer to Electrical Schematic, RENR5010 for more information.

1. Remove wire (A) in the illustration above. The illustration above shows the Starting Motor Magnetic Start (SMMS) is connected to the primary ADEM breaker. Wire (A) is connected to − battery on the 231-9867 Panel Harness As. This will cause a 444-5 Start Relay Open diagnostic code.

Image1.2.1

2. Install wire (B) in the illustration above. The illustration above shows the correct connections for the ground circuit of the relay coil. Wire (B) needs to be rewired in order to connect to pin 7 on the J2 connector for the primary ECM. Once wire (B) is rewired, a path is provided for the return circuit of the SMMS to go back to the circuit for the starter drive. This will alleviate the false 444-5 Start Relay Open diagnostic code.