811881 Mercruiser NUT

November 28, 2004
(Revised February 2005)
U-348
A-248
D-269
O-301
Afterfailure only PRODUCT SUPPORT PROGRAM FOR ADDING A WIRETO THE ENGINE WIRING HARNESS FOR THE ALTERNATOR ON CERTAIN 938G SERIESII AND IT38G SERIES II MACHINES
1403,1405 PS50850
This Program can only be administeredafter a failure occurs. The decision whether to apply the Program is madeby the dealer. When reporting the repair, use "PS50850" as the Part numberand "7755" as the Group Number. Use "96" as the Warranty Claim DescriptionCode and use "Z" as the SIMS Description Code. The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst. This Revised Service Letter replacesthe November 28, 2004 (Revised January 2005) Service Letter. Changes havebeen made to the Affected Product and Action Required.TERMINATION DATE
November 30, 2005PROBLEM
The standard alternator (9W-3043) on certain machinesmay not turn on if the machine has not been started for a few weeks. Awire can be added to the engine harness to provide a turn on voltage forthe alternator.AFFECTED PRODUCT
Model Identification Number
938G II CRD273-291, 293-298,300-304, 306-310, 312-322, 324-358, 361-397, 399-456, 458-468, 471-480,482-502, 504-506, 509-518, 520-530, 532-533, 535-537, 542, 544-548, 550-553,557-580, 582, 584-586, 588, 590, 595, 597-598, 600-606, 608-617, 623-626,628, 631-635, 637-642, 644-651, 653-659, 661-662, 664-683, 685-686, 694-696,698, 700-711, 713-718, 720-732, 734-735, 738-741, 745-751, 753-754, 756-757,760-784, 786-790, 794-795, 797-798, 800, 802-804, 806-812, 814-818, 820-822,824-825, 827-839, 841-844, 846-856, 858-861, 863-870, 873-875, 877-881,885-891, 893, 895, 899-918, 920, 922-925, 927, 929-936, 938-946, 950-951,953-955, 957-963, 965, 967, 970-971, 975-976, 978, 980, 982, 985, 987,989-1008, 1010, 1013-1019, 1022-1039, 1041-1055, 1058, 1060-1061, 1068,1071, 1073-1095, 1100-1103, 1105-1106, 1108-1111, 1113, 1115, 1117-1120,1122-1123, 1125-1126, 1128-1136, 1139, 1144-1152, 1154, 1156-1160, 1162-1165,1167-1172, 1174, 1176-1178, 1181, 1183-1185, 1187, 1189-1193, 1195-1198,1200-1201, 1204, 1207-1209, 1211-1236
938G II PHN273-279, 281-300,302, 304-307, 309-317, 320-322, 325, 327-328, 330-333, 335, 338, 340, 342-361,364-365, 367-370, 372-375, 379-383, 385-397, 399-413, 415-417, 419-421,423-433, 435-437, 439, 442-449, 451, 453, 455-457, 459-468, 470, 472, 474-491,493-513, 515-517, 519-520, 522-527, 529-530, 532, 534, 536-553, 555-565,568-569, 571-585, 588-600, 602-604, 607-610, 614-618, 620-632, 635-655,658, 661-663, 665-670, 672, 674, 676-685, 687-691, 693-703, 705-708, 710-712,716-724, 726-729, 731-736, 738-750, 753-755, 757, 759-765, 767-769, 771-782,784, 786, 788-790, 792-805, 807-808, 810-815, 817-824, 826-827, 829-837,841-846, 848-849, 852, 856-857, 863-875, 878-880, 882-883, 885, 887-890,896, 900-902, 905-906, 908-909, 911, 913-915, 918-920, 922, 924-926, 928-929,931, 933, 935-985, 987-999, 1002, 1005-1014, 1016-1023, 1025-1044, 1046-1048,1050-1056, 1058-1066, 1068-1089, 1091-1117, 1119-1148, 1150, 1153, 1156-1195,1197-1199, 1201-1208, 1210-1213, 1215-1217, 1220, 1222, 1224-1225, 1228,1230-1231, 1233-1236, 1238-1249, 1251-1257, 1259, 1262-1265, 1267-1283,1286-1289, 1291-1293, 1295-1305, 1307-1340, 1342-1351, 1353, 1355, 1357-1358,1360-1365, 1367-1369, 1371, 1373-1374, 1376, 1378-1382, 1387-1388, 1390-1394,1396-1399, 1401-1402, 1404-1408, 1410-1411, 1413-1414, 1417-1422, 1424,1426-1428, 1430-1435RTB278-282, 285-291, 293-300, 302-303, 306-340,342-344, 347-350, 352-371, 373-392, 394-407, 409, 414, 417-464, 466-483,485-501, 503-507, 509, 511-519, 521-551, 553, 556-557, 559-589, 591-651,653, 655-657, 659-660, 662-663, 665-670, 672, 675, 677-691, 728-733, 735-753,755-768B9Y110-165, 167-189, 191-211, 213-229, 231-237,239-262, 264-265
IT38G II CSX305, 310-314, 317-353,355-374, 378-389, 391, 393-398, 400, 403-495, 498-518, 521-525, 527-540,542-545, 547-561, 564-573, 575-602, 604-621, 623-626, 628-629, 631-655PARTS NEEDED
Qty
Part Number
Description
12 7K1181 STRAP-CABLE
1 2511233 HARNESS AS.ACTION REQUIRED
Open the battery disconnect switch.
Remove the 123-WH wire from the 2 pin DT connectoron the 2023244 or 2353501 engine harness (123-WH wire is in pin 1 and G454-PKwire is in pin 2).
This 2 pin DT connector is locatednear the intake air heater. Insert the 123-WH wire (that was just removed)into the 1158109 jiffy splice on the 2511233 service harness. Insert theother 123-WH wire on the 2511233 service harness (a single wire with a8T8730 DT pin) into the 2 PIN DT connector on the 2023244 or 2353501 engineharness.
Route the 2511233 service harness as shown inthe diagram and secure it with the 7K1181 ty straps.
Illustration 1
Illustration 2
Illustration 3
Connect the C444-YL wire to the D+ terminal onthe alternator.
Close the battery disconnect switch, start themachine and confirm proper operation of the alternator.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
0-4000
0-24 mo.