PRODUCT SUPPORT PROGRAM FOR REMOVING THE 110-1168 JACKET WATER PRESSURE SWITCH ON CERTAIN G3516C, G3516E, G3520C, AND G3520E GENERATOR SETS, G3606, G3608, G3612, AND G3616 ENGINES
Usage:
REBE9102-00
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| 14Dec2012 |
U-679
A-533
D-575
O-618
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| After Failure Only | PRODUCT SUPPORT PROGRAM FOR REMOVING THE 110-1168 JACKET WATER PRESSURE SWITCH ON CERTAIN G3516C, G3516E, G3520C, AND G3520E GENERATOR SETS, G3606, G3608, G3612, AND G3616 ENGINES |
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| 1000 7400 1408 | PS52363 |
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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 "PS52363" 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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TERMINATION DATE |
| 31Dec2014 |
PROBLEM
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| The existing 110-1168 Jacket Water Pressure Switch can fail on certain G3516C, G3516E, G3520C, and G3520E Generator Sets, G3606, G3608, G3612, and G3616 Engines. If the existing 110-1168 Jacket Water Pressure Switch fails, it can leak coolant on and around the engine. A switch malfunction may also cause an engine shutdown. Internal open/short of switch contacts and switch body fractures at location of metal face seal are the two primary causes for failure. |
AFFECTED PRODUCT
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| Model | Identification Number |
| *******Group 1******* | |
| G3606 | 3XF00018-00021, 25, 27, 34, 36, 38, 40, 45, 52, 56-61, 65-69, 73, 84, 86, 91-94, 97, 99-102, 105, 111, 114-117, 121-123, 130, 134-135, 138, 141-144, 148-149, 156-157, 159, 162, 165, 167, 178-180, 183-186, 193-195, 197, 199-202, 205, 207-208, 210, 223, 225, 231-232, 235-238, 240-243, 245, 247, 250, 252-255, 261-262, 264, 269, 271-273, 281, 289, 299-301, 304-305, 308-317, 319, 321, 327-328, 331, 333, 335-338, 341, 344, 349, 363, 365 4ZS00281-01680 |
| G3608 | 4WF00024-00025, 27-33, 39-40, 43, 47-48, 51-52, 54, 56-63, 66-70, 76-79, 85-89, 91-93, 102, 106, 109, 111-112, 115-117, 125-126, 129-130, 134-135, 141-142, 144, 147-151, 157-158, 164, 166, 176, 181, 183, 195-197, 201-205, 208-217, 220, 222, 228-230, 242-243, 248 BEN00208-00577, 579-789 |
| G3612 | 1YG00021-00023, 27-29, 34, 38, 46-47, 49-50, 52-53, 58-59, 62-65, 68-70, 72-74, 76-77, 81-84, 92-93, 97, 100, 104, 107, 111-113, 116, 118-119, 122-123, 127, 130, 132, 137-138, 141, 147, 150, 153, 155-156, 158, 161-163, 165-167, 171-173, 181-182, 185, 188, 190, 193-199, 204, 209-221, 224-225, 229, 231-232, 234-235, 238-242, 245, 249, 253-255, 259 BKE00192-00619 |
| G3616 | 4CG00023-00024, 35-38, 42-44, 60-61, 64, 74, 76, 83-86, 91-98, 117-121, 146-147, 150-151, 162, 166, 206-208, 213-215, 221-222, 224-226, 234, 236, 238-240 BLB00163-00555, 557-800 |
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| *******Group 2******* | |
| G3520C | B9P00101-00104, 200-213 CWW00100-00131, 200-301 CWY00100-00104, 200-221 GZA00191-00237 GZB00201-00231, 233-243 GZJ00161-00553, 600-613 GZK00151-00183 GZL00141-00146 GZM00131-00212 GZN00211-00251, 253-254, 257, 261-451, 454-868 HAT00102, 200-211 HEA00101-00102 HEB00103-00104 LGS00150-00176 MAD00101-00102, 200-201 RLP00150-00261 |
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| *******Group 3******* | |
| G3516E | GAS00111-00280 SLY00106-00109 |
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| *******Group 4******* | |
| G3520E | GZE00110-00195 GZG00111 GZH00111-00167 HAL00100-00102 SXY00100-00102 |
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| *******Group 5******* | |
| G3516C | GSB00113-00127 GZC00211-00249, 251-252, 254-259 GZZ00114-00173, 180-362 TJB00101-00109 TJC00817-00819 |
PARTS NEEDED
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Qty |
Part Number | Description |
| *******Group 1******* | ||
| 1 | 1U5804 | CRIMP TOOL |
| 1 | 5M6213 | PLUG-NPTF |
| 10 | 5P5623 | WIRE-ELECTRICAL |
| 2 | 8T8730 | SOCKET-CONNECTOR |
| 1 | 8T8731 | PLUG-CONNECTOR |
| 1 | 8T8737 | PLUG-SEAL |
| 1 | 3393778 | COOLANT |
| In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% 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. | ||
| *******Group 2******* | ||
| 1 | 1U5804 | CRIMP TOOL |
| 1 | 5M6213 | PLUG-NPTF |
| 10 | 5P5623 | WIRE-ELECTRICAL |
| 2 | 8T8730 | SOCKET-CONNECTOR |
| 1 | 8T8731 | PLUG-CONNECTOR |
| 1 | 8T8737 | PLUG-SEAL |
| 1 | 3393778 | COOLANT |
| In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% 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. | ||
| *******Group 3******* | ||
| 1 | 1U5804 | CRIMP TOOL |
| 1 | 5M6213 | PLUG-NPTF |
| 10 | 5P5623 | WIRE-ELECTRICAL |
| 2 | 8T8730 | SOCKET-CONNECTOR |
| 1 | 8T8731 | PLUG-CONNECTOR |
| 1 | 8T8737 | PLUG-SEAL |
| 1 | 3393778 | COOLANT |
| In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 5% 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. | ||
| *******Group 4******* | ||
| 1 | 1U5804 | CRIMP TOOL |
| 1 | 5M6213 | PLUG-NPTF |
| 10 | 5P5623 | WIRE-ELECTRICAL |
| 2 | 8T8730 | SOCKET-CONNECTOR |
| 1 | 8T8731 | PLUG-CONNECTOR |
| 1 | 8T8737 | PLUG-SEAL |
| 1 | 3393778 | COOLANT |
| In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 5% 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. | ||
| *******Group 5******* | ||
| 1 | 1U5804 | CRIMP TOOL |
| 1 | 5M6213 | PLUG-NPTF |
| 10 | 5P5623 | WIRE-ELECTRICAL |
| 2 | 8T8730 | SOCKET-CONNECTOR |
| 1 | 8T8731 | PLUG-CONNECTOR |
| 1 | 8T8737 | PLUG-SEAL |
| 1 | 3393778 | COOLANT |
| In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 5% 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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| 1. Drain the engine coolant into a suitable container to a level below the 110-1168 Jacket Water Pressure Switch. 2. Remove the pressure switch. Install the 5M-6213 Pipe Plug in place of the switch. 3. Crimp an 8T-8730 Connector Socket on to each end of 5P-5623 Wire to be used as jumper. Connect the jumper wire to terminals "B" and "C" on the harness end of the 8T-8731 Connector Plug in order to create a closed circuit. 4. Install the 8T-8737 Seal Plug into terminal "A" on the harness end of the 8T-8731 Connector Plug. 5. Connect the 8T-8731 Connector Plug to the harness breakout that was previously connected to the jacket water pressure switch. Use a tie strap to secure the breakout harness to the main engine harness. |
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SERVICE CLAIM ALLOWANCES
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