ENCLOSURE GP 1117622 - Caterpillar

Product Support Program For Installing Wiring Imporvements On Certain 3116 Marine Engines
SMCS - 1408 PS4678
1467
January 8, 1992
U-8
AU-6.1
E-7
O-8
TM-1 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.
This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4678" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96 " as the Warranty Claim Description Code and use "Z " as the SIMS Description Code.
Although this Program is to be administered as described above on the Affected Product, engines in dealer stock should be reworked as soon as possible.
Some of the Affected Product fall into more than one group. Do all applicable portions of this Program at one time.
Termination Date
January 31, 1993Program
Group 1
Two wires in the junction box may be too long on certain 3116 TA Marine Engines causing the wires to chafe on the bushing in the junction box.
Group 2
Also, certain 3116 TA Marine Engines equipped with latching fuel solenoids (energize to start and energize to shut down) may not be wired correctly at the starter motor.
Affected Product
Model & Identification Number
Group 1
3116 TA (4KG107-755*
*When equipped with factory installed wiring junction box.Group 2
3116 TA (4KG128-147,4KG149-152,4KG156,4KG157,4KG160-163,4KG174,4KG175,4KG190,4KG191,4KG196,4KG197,4KG200-214,4KG219,4KG224-229,4KG234-239,4KG263-290,4KG295-298,4KG325,4KG326,4KG329,4KG330,4KG339,4KG340,4KG347,4KG348,4KG357-360,4KG367-384,4KG395,4KG396,4KG415,4KG416,4KG421,4KG422,4KG441,4KG442,4KG453-456,4KG463,4KG473,4KG477-480,4KG487-492,4KG497-500,4KG507-513,4KG517-523,4KG535,4KG536,4KG539-541,4KG555-557,4KG580-589,4KG591-596,4KG601-632,4KG635-638,4KG642-655,4KG662-665,4KG677-725,4KG727-730,4KG737-746,4KG763-794,4KG797,4KG799-805,4KG807,4KG824,4KG826-828)
Parts Needed
Group 1
1 - 9G4343 Terminal1 - 5P3454 Terminal1 - 3S2093 StrapGroup 2
No parts needed.
Action Required
Group 1
Open junction box on rear of engine, if equipped, and check for a cable strap on the wire harness entering the junction box. If a nylon cable strap is already installed on the harness this portion of the repair has been completed.
If there is no cable strap on the harness remove wire numbers 050T264 and 052T056 from their connections in the junction box. Remove (cut) 70mm (2.75 in) from both wires. Install terminal 9G4343 on wire number 050T264. Install terminal 5P3454 on wire number 052T056. Install cable strap 3S2093 on harness inside junction box as close to the bushing as possible. Cinch the strap tightly and trim excess. Reconnect wire 052T056 to the starting motor magnetic switch. Reconnect wire 050T264 to the circuit breaker.
Group 2
If the engine has the latching fuel solenoid (energize to start and energize to shut down) installed, check the location of wire number 073T943 on the starter motor. If the wire is connected to the battery terminal on the starter motor remove it and connect it to the motor terminal on the starter motor.
Service Claim Allowances
This is a 2.5-hour job.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.