- Engines:
- G3606 (S/N: 3XF)
- G3608 (S/N: 4WF)
- G3612 (S/N: 1YG)
- G3616 (S/N: 4CG)
A significant number of failures of the control modules for the CIS have been analyzed. The investigations indicate that most of the failures were avoidable. The control modules that were analyzed follow: the 172-0060 CIS Programming Control, the 172-0061 CIS Programming Control, the 172-0062 CIS Programming Control and the 172-0063 CIS Programming Control. Proper techniques for handling and maintenance will help prevent problems. Proper techniques for handling and maintenance will also result in improved reliability. The conditions that follow can be controlled in most situations.
Water Entry
The cover for the latest CIS Programming Controls has proven to be water tight. When the cover is correctly installed, the cover will not leak. Illustration 1 shows the locations of the clamps (B) for the cover (A).
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| Illustration 1 | g00872819 |
This illustration shows the locations of some of the components of the CIS Programming Controls. (A) Cover (B) 173-1021 Clamp (C) 173-1022 Screw (D) 173-1020 Gasket | |
Firmly tighten and evenly tighten the screws (C) that secure the clamps (B) in a cross pattern. When the cover is correctly installed, the gasket (D) for the cover will provide adequate sealing against the entry of water. After maintenance is performed on the CIS Programming Controls do the following steps:
- Inspect the gasket (D) for the cover (A). Replace the seal if the seal is damaged.
- Correctly install the cover and tighten the clamps (B) .
Lost Communication With The Display Module
If the electrical power is applied, an electrical chip in the CIS Programming Controls can be damaged when the wiring harness between the CIS Programming Controls and the display module is connected or disconnected. The damage can occur if either of the conditions that follow occur:
- The Positive wire from the power supply is connected before the Negative wire from the power supply.
- The Negative wire from the power supply is disconnected before the Positive wire from the power supply.
The recommendations that follow will help prevent the loss of communications:
- The engine control switch is in the OFF/RESET position before the display module for the CIS is installed.
- Install a toggle switch in the positive circuit of the wiring harness for the power supply. This toggle switch should be in the OPEN position while the wiring harness is installed between the control for the CIS and the display module. After the wiring harness is installed, move the toggle switch to the CLOSED position. Move the toggle switch to the OPEN position before disconnecting the wiring harness from the display module or the CIS.
- Permanently mount the display module for the CIS in a convenient location. While the engine control switch is in the OFF/RESET position, connect the wiring harness between the CIS and the display module. This will allow the Mode Control Switch (MCS) to control the power to the module.
Note: If the control module for the CIS loses the ability to communicate with the display module, the control module will continue to operate normally in all other aspects. The control module for the CIS must be replaced in order to restore communication with the display module.
Failed Internal Electrical Circuits
Always isolate the electronic components of the engine before welding on the engine or near the engine. Welding can result in excessive current flow through the display module for the CIS. This can result in a failure of internal circuits of the display module. Be sure that the transformer and the wiring harness are in good operating condition. A faulty transformer and/or a electrical short in the wiring can result in excessive loads on the internal circuits. Multiple failures of a display module for the CIS may be an indication of a faulty transformer or an electrical short in a wiring harness.
Excessive Vibration
The CIS Programming Control is mounted on the engine with four 188-3288 Shock Mounts. These shock mounts are designed to reduce the amount of vibration that is transmitted from the engine to the CIS Programming Control. Illustration 2 shows the locations of the shock mounts.
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| Illustration 2 | g00873155 |
This illustration shows the location of the shock mounts on a CIS Programming Controls. (E) 8T-5391 Bolt (F) 8T-4224 Hard Washer (G) 188-3288 Shock Mount (H) 6V-8189 Nut | |
The bolts (E) and the nuts (H) fasten the shock mounts (G) to the engine and the CIS Programming Controls. Tighten the bolts (E) and the nuts (H) to a torque of 25 ± 6 N·m (18 ± 4 lb ft). If these bolts or nuts are tightened excessively, the rubber material in the shock mount may be damaged. This could result in the transmission of excessive vibrations to the CIS Programming Controls.
Note: Replace the 188-3288 Shock Mount if the shock mount is damaged in any way.