PRODUCT IMPROVEMENT PROGRAM FOR ADDING AN ADAPTER TO CERTAIN G3606, G3608, G3612, AND G3616 GAS ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR ADDING AN ADAPTER TO CERTAIN G3606, G3608, G3612, AND G3616 GAS ENGINES

Usage:

SEBE8546

October 14, 2003
U-289
D-215
O-244

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR ADDING AN ADAPTER TO CERTAIN G3606, G3608, G3612, AND G3616 GAS ENGINES
7550		PI30539

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30539" 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 "PI30539" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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
April 30, 2004	October 31, 2004

PROBLEM

An adapter assembly needs to be added to certain G3606, G3608, G3612, and G3616 Gas Engines. Interference at the Integrated Combustion Sensing Modules (ICSM) connector may cause loose connections.

AFFECTED PRODUCT

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Model	Identification Number
* Group 1 *
G3606	4ZS281-302
* Group 2 *
G3608	BEN208-217
* Group 3 *
G3612	BKE192-212 1YG22, 62, 63, 240, 241, 245
* Group 4 *
G3616	BLB163-186 4CG74-76, 97, 98

PARTS NEEDED

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Qty	Part Number	Description
* Group 1 *
1	5P6029	WIRE-LOCK
6	2389395	ADAPTER AS
* Group 2 *
1	5P6029	WIRE-LOCK
8	2389395	ADAPTER AS
* Group 3 *
1	5P6029	WIRE-LOCK
12	2389395	ADAPTER AS
* Group 4 *
1	5P6029	WIRE-LOCK
16	2389395	ADAPTER AS

ACTION REQUIRED

See the attached Rework Procedure.

OWNER NOTIFICATION

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.
* G3606 and G3608 *
100%	2.0	0	0	0	0
* G3612 and G3616 *
100%	3.0	0	0	0	0
NOTE: This is at most a 3.0- hour job. NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report

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.

Attach. (1-Owner Notification)
(2-Rework Procedure)

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR ADDING AN ADAPTER

MODELS INVOLVED - CERTAIN G3606, G3608, G3612, AND G3616 GAS ENGINES

Dear Caterpillar Product Owner:

New adapters need to be installed on the products listed below. Integrated Combustion Sensing Modules (ICSM) may have cable connector interference at the ICSM connector. 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 October 14, 2003 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 date October 14, 2003 Service Letter

Rework Procedure

Adapter As. - Connector Action Plan

NOTE: This Action Plan provides the procedures necessary to add adapter assembly to the Integrated Combustion Sensing Module (ICSM). Do not perform any procedure that is outlined in this Action Plan until the entire Action Plan has been read and understood.

Remove the power from the system.
Remove cover plate over the ICSM.
Disconnect one combustion cable from the top of the ICSM. (Remove only one combustion cable at a time so that you know which connector on the ICSM it connects to.) See Illustration 1.

Illustration 1

Install one adapter assembly (2389395) to the connector on the top of the ICSM that you just removed the combustion cable from. Tighten the adapter assembly to a torque of 3.3 +/- 0.3 Nm (29.0 +/- 3.0 lb in). See Illustration 2.

Illustration 2

Connect the Combustion cable that is loose to the top of the adapter assembly. Tighten the combustion cable to a torque of 3.3 +/- 0.3 Nm (29.0 +/- 3.0 lb in). See Illustration 3.

Illustration 3

Install lock wire (5P6029) from the harness plug fastening nut to the harness plug?s endbell in the clockwise direction. See Illustration 4.

Illustration 4

Install 2nd lock wire from the adapter assembly fastening nut to the harness plug fastening nut in the clockwise direction. See Illustration 5.

Illustration 5

Repeat steps 3 through 7 for the rest of the combustion cables on the ICSM.
Reassemble the cover plate over the ICSM.
If this is a Vee engine, repeat steps 2 through 9 for the other ICSM.
Power up the system. You are now ready to start your engine.
Once the engine is started, verify that your burn times are reading correctly before going into combustion feedback.