PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE CUSTOMER E-STOP WIRING FOR CERTAIN 3500B MARINE PROPULSION ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE CUSTOMER E-STOP WIRING FOR CERTAIN 3500B MARINE PROPULSION ENGINES

Usage:

REBE1327-00

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10Oct2006

U-673

A-652

D-636

O-655

TM-511

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE CUSTOMER E-STOP WIRING FOR CERTAIN 3500B MARINE PROPULSION ENGINES
7418 1408 7332		PI10541

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10541" 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 "PI10541" 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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PROBLEM

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The customer E-stop wiring needs to be reworked on certain 3500B marine propulsion engines. If the wiring is not reworked it can lead to an engine shutdown if power to the primary ECM opens or is inadvertently disconnected. Loss of engine power may impact the ability to control a vessel, which may result in personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
3508B	S2D00100-00176 S2E00100-00565 S2F00100-00119
3512B	MKH00100-00103, 200-217 MRG00100-00103 S2J00100-00359 S2K00100-00248 S2L00100-00527 S2M00100-00160 S2N00100-00121
3512C	TTG00200-00202
3516B	PAG00100-00154 S2S00100-00238 S2T00100-00101 S2W00100-00110 S2X00100-00523 S2Y00100-00110
3516C	TTD00200-00201 TTH00200-00201

PARTS NEEDED

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No parts needed for this program

ACTION REQUIRED

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Refer to 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%

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NOTE: This is a 1.0-hour job

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PARTS DISPOSITION

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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

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE CUSTOMER E-STOP WIRING

MODELS INVOLVED - CERTAIN 3500B MARINE PROPULSION ENGINES

Dear Caterpillar Product Owner:

The customer E-stop wiring needs to be reworked on the products listed below. If the existing customer E-stop wiring is not corrected it can lead to an engine shutdown if power to the primary ECM opens or is inadvertently disconnected. Loss of engine power may impact the ability to control a vessel, which may result in personal injury or death. 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 10Oct2006 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 10Oct2006 Service Letter

Rework Procedure

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1. The marine propulsion wiring diagram in the 3500B Series II Marine Engines A&I Guide, LEBM7301-02 (10-03) and prior show the redundant customer E-stop wiring as follows:

a. Pin U, Engine Shutdown ?C? (Wire Code F715), is wired to Pin P, General Purpose Digital Reference ?A? (Wire Code CD998)

.b. Pin T, Engine Shutdown ?D? (Wire Code F719), is wired to Pin R, General Purpose Digital Reference ?B? (Wire Code CB998).

2. LEBM7301-03 (3-06) is the latest version of the 3500B Series II Marine Engines A&I Guide and it supersedes all prior versions. The marine propulsion wiring diagram in LEBM7301-03 is not identical to prior versions, it shows the redundant customer E-stop wiring as follows:

a. Pin U, Engine Shutdown ?C? (Wire Code F715) is now wired to Pin W, Secondary ADEM Digital Reference (Wire Code SF998)

.b. Pin T, Engine Shutdown ?D? (Wire Code F719), remains wired to Pin R, General Purpose Digital Reference ?B? (Wire Code CB998).

3. The customer E-stop wiring on 3500B marine propulsion engines must be checked and if necessary reworked to match LEBM7301-03 as shown in the attached wiring diagrams. The first diagram shows typical customer E-stop wiring without an optional customer interface box. For these applications, the wiring will be corrected at the customer connector on the left side rigid rail. The second diagram shows typical customer E-stop wiring with an optional customer interface box. For these applications, the wiring will be corrected at the interface box.

Note: If there are no remote customer E-stop switches installed, the jumper on the customer connector must still be modified so pin U is wired directly to pin W.

4. Check the E-stop wiring after the rework is completed as follows:

a. Start the engine.

b. Open the primary ECM circuit breaker at the power distribution box. The secondary ECM will become active and the engine will continue running.

c. To validate the wiring changes, shut the engine down by pressing a remote customer E-stop switch. If no remote E-stop switches are installed, press the E-stop switch on the MPD panel.

Note: This is a change to the customer connector wiring only. No changes are required to the factory-supplied engine mounted wiring harness.Note: The 272-2343 Wire Removal Tool is required for 16 gauge wires.

Note: Refer to the 3500B Marine Propulsion Series II A&I Guide, LEBM7301-03, for details of all customer connector wiring. This publication is available for download through the Electronic Media Center.