PRODUCT SUPPORT PROGRAM FOR REWORKING THE COOLANT LEVEL SENSORS ON CERTAIN G3406 AND G3412 GAS GENSETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE COOLANT LEVEL SENSORS ON CERTAIN G3406 AND G3412 GAS GENSETS

Usage:

SEBE8632

January 28, 2004
U-17
A-12
D-13
O-15

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*before or* *after failure*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE COOLANT LEVEL SENSORS ON CERTAIN G3406 AND G3412 GAS GENSETS
1353		PS41498

NOTE: This Program can be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS41498" 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.

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.

TERMINATION DATE

January 31, 2006

PROBLEM

The jacket water coolant and the aftercooler coolant level sensors are connected in parallel by one wiring harness. When low coolant is detected by one sensor, the output signal of that sensor changes from grounded to 4.75 VDC and creates a nuisance annunciation of CID 111 FMI 03 or CID 269 FMI 04. A failed sensor is also a possible result.

AFFECTED PRODUCT

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Model	Identification Number
* Group 1 *
G3412	KAP146, 154, 155, 158, 179, 180, 182, 184?190, 192, 193, 195, 196, 210, 213, 214, 217, 219, 221
* Group 2 *
G3406	KAR127-133, 139, 143-145, 147-152, 162, 163, 166, 167, 169-172, 174-177, 180, 181, 183-193, 195, 197-201, 203, 205, 206, 209-213, 215-217, 233-241, 244-248, 251-255, 261, 262 R7E101, 102
G3412	KAP107-109, 111-113, 117-120, 124-127, 129-136, 141, 143-145, 147, 150, 151, 160, 161, 165, 167-170, 172-176, 183, 191, 194, 198, 199, 201-203, 205, 208, 211, 212, 218, 222

PARTS NEEDED

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Qty	Part Number	Description
* Group 1 *
1	1L5620	ADAPTER
1	6L2282	PLUG-PIPE SO
1	2127246	SWITCH AS-TE
1	2490605	HARNESS AS.
* Group 2 *
1	6L2282	PLUG-PIPE SO

ACTION REQUIRED

See the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
0-24 mos	100%	1.0	0	0	0	0
NOTE: This is a 1.0?hr job.

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Attach. (1-Rework Procedure)

Rework Procedure

*** Group 1 ***

Disconnect and discard the 2080947 or 2080949 wiring harness located between both coolant level sensors and the three-wire branch of the main engine wiring harness.

NOTE: This branch of the wiring harness is designated for the coolant level sensor.

Remove the 1656634 coolant level sensor from the aftercooler side of the radiator and replace it with a 6L2282 plug.
Extend and connect the three-wire branch of the engine wiring harness to the remaining 1656634 coolant level sensor located on the jacket water side of the radiator.
Preassemble the 2127246 temperature switch to the 1L5620 adapter.
Remove the 8T6762 plug from the aftercooler housing. Refer to Illustration 1.

Illustration 1

Install the adapter and temperature switch assembly into the aftercooler housing using an appropriate pipe thread sealant. Refer to Illustration 2.

Illustration 2

Connect the temperature switch to the two wire branch on the main engine wiring harness with the 2490605 wiring harness. Refer to Illustration 2 and 3.

NOTE: This two wire branch on the main engine harness is designated only for the HIATS.

Illustration 3

*** Group 2 ***

Disconnect and discard the 2080947 or 2080949 wiring harness located between both coolant level sensors and the three-wire branch of the main engine wiring harness.

NOTE: This branch of the wiring harness is designated for the coolant level sensor.

Remove the 1656634 coolant level sensor from the after-cooler side of the radiator and replace it with a 6L-2282 plug.
Extend and connect the three-wire branch of the engine wiring harness to the remaining 1656634 coolant level sensor located on the jacket water side of the radiator.