PRODUCT IMPROVEMENT PROGRAM REPLACING THE SPARK PLUG WIRE ON CERTAIN G3408 AND G3412 GAS ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM REPLACING THE SPARK PLUG WIRE ON CERTAIN G3408 AND G3412 GAS ENGINES

Usage:

SEBE8728

April 4, 2004
U-103
A-68
D-81
O-84

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*Priority*	PRODUCT IMPROVEMENT PROGRAM REPLACING THE SPARK PLUG WIRE ON CERTAIN G3408 AND G3412 GAS ENGINES
1558		PI30626

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30626" 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 "PI30626" 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
October 31, 2004	April 30, 2005

PROBLEM

The spark plug wire needs to be removed and replaced on certain G3408 and G3412 gas engines. During the spark plug terminal end crimping process the wire conductor is elongated sufficiently to break. The break will no longer allow current to flow sufficiently, thus cause a misfire.

AFFECTED PRODUCT

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Model	Identification Number
* Group 1 *
G3412	KAP160-162, 165-170, 172-176, 183, 191, 194, 197-199, 201-203, 205, 208, 209, 211, 212, 215, 216, 218, 222-224, 226, 227 7DB1783, 1788, 1790-1795, 1800, 1801, 1803, 1805, 1806, 1815, 1819-1822
* Group 2 *
G3408	6NB2547-2550, 2554-2557, 2561, 2564, 2568-2570, 2572 6RJ97

PARTS NEEDED

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Qty	Part Number	Description
* Group 1 *
12	2502149	Wire Assembly
* Group 2 *
8	2502149	Wire Assembly

ACTION REQUIRED

Shut down the engine. Remove existing 2175922 Wire Assembly on all cylinders and replace with 2502149 Wire Assembly. Return engine to service.

OWNER NOTIFICATION

U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

***** Affected Product *****

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
100%	1.0	0	0	0	0
NOTE: This is a 1.0- hour job.

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)

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM REPLACING THE SPARK PLUG WIRE

MODELS INVOLVED - CERTAIN G3408 AND G3412 GAS ENGINES

Dear Caterpillar Product Owner:

New spark plug wires need to be installed on the products listed below. During the spark plug terminal end crimping process the wire conductor is elongated sufficiently to break. The break will no longer allow current to flow sufficiently, thus cause a misfire. 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 April 4, 2004 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 April 4, 2004 Service Letter