PRODUCT SUPPORT PROGRAM FOR REPLACING THE 162-7512 COMBUSTION SENSOR ON CERTAIN G3612, AND G3616 ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE 162-7512 COMBUSTION SENSOR ON CERTAIN G3612, AND G3616 ENGINES

Usage:

REBE8193-01

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22Mar2012

(Revised 16Apr2012)

U-153

A-128

D-138

O-148

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE 1627512/">162-7512 COMBUSTION SENSOR ON CERTAIN G3612, AND G3616 ENGINES
1563		PS52197

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS52197" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

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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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NOTE:	This Revised Service Letter replaces the 22Mar2012 Service Letter. Changes have been made to the Affected Product.

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TERMINATION DATE

31Mar2014

PROBLEM

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The 1627512/">162-7512 Combustion Sensors with a date code of PR07 and PT07 that are used in G3600 High Compression Generator Set Engines with the Engine Supervisory System (ESS) control system could fail. These sensors could have been assembled without the sillment installed at the steel/ceramic interface. This will allow the sensor to fail and the center electrode to be pushed up into the cylinder head cavity area where it can damage the 1364605/">136-4605 extender and/or the 1884926/">188-4926 connector. In rare instances the center electrode can fall into the cylinder and cause damage to the turbocharger.

AFFECTED PRODUCT

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Model	Identification Number
G3612	1YG00030-00033, 36-45, 48, 56-57, 60, 66-67, 70, 76-77, 79-82, 96, 105-106, 135, 142-143, 154, 176-178, 192
G3616	4CG00025-00034, 37, 39, 41-48, 50-52, 57, 62-63, 65-67, 77-78, 82, 87-90, 121, 125-127, 135, 137, 144-145, 148-149, 152-154, 159-165, 174-187, 192-193, 196-199, 209-212, 217-224, 226, 244-245

PARTS NEEDED

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Qty	Part Number	Description
1	1115720	TURBO GP-BASIC (if needed)
1	1364605	EXTENSION AS
1	1627512	SENSOR-COMB
1	1884926	CONNECTOR AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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Remove the 1884926/">188-4926 Connector, 1364605/">136-4605 Extender, and the 1627512/">162-7512 Sensor.

Clean out any debris from the cylinder head cavity and replace the damaged parts with new as needed. Tighten the sensor to 38 +/- 2 Nm (28 +/- 2 lb ft). Tighten the connector to 35 +/- 2 Nm (26 +/- 2 lb ft).

If all or part of the center electrode is missing inspect the turbocharger nozzle ring and turbine wheel for damage and repair if needed.

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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%
0-8000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 1.0-hour job If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
If sensor parts have damaged the turbocharger, an additional 11 hours labor will be allowed. Photos and documentation of the damaged turbocharger parts must be provided in the claims report.

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