SEAL-O-RING 3107255 - Caterpillar

SEBE8632 January 28, 2004
U-17
A-12
D-13
O-15
beforeor
after failure PRODUCT SUPPORT PROGRAM FOR REWORKINGTHE COOLANT LEVEL SENSORS ON CERTAIN G3406 AND G3412 GAS GENSETS
1353 PS41498
This Program can be administered eitherbefore or after failure. In either case the decision whether to apply theProgram is made by the dealer. When reporting the repair, use "PS41498"as the Part number and "7755" as the Group Number. If administered beforefailure, use "56" as the Warranty Claim Description Code and use "T" asthe SIMS Description Code. If administered after failure, use "96" as theWarranty Claim Description Code and use "Z" as the SIMS Description Code. The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst.TERMINATION DATE
January 31, 2006
PROBLEM
The jacket water coolant and the aftercooler coolantlevel sensors are connected in parallel by one wiring harness. When lowcoolant is detected by one sensor, the output signal of that sensor changesfrom grounded to 4.75 VDC and creates a nuisance annunciation of CID 111FMI 03 or CID 269 FMI 04. A failed sensor is also a possible result.AFFECTED PRODUCT
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, 261,262R7E101, 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, 222PARTS NEEDED
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 SOACTION REQUIRED
See the attached Rework Procedure.SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
0-24 mos 100% 1.0 0 0 0 0
This is a 1.0?hr job.PARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.Attach. (1-Rework Procedure)Rework Procedure*** Group 1 ***
Disconnect and discard the 2080947 or 2080949wiring harness located between both coolant level sensors and the three-wirebranch of the main engine wiring harness.
This branch of the wiring harness isdesignated for the coolant level sensor.
Remove the 1656634 coolant level sensor from theaftercooler side of the radiator and replace it with a 6L2282 plug.
Extend and connect the three-wire branch of theengine wiring harness to the remaining 1656634 coolant level sensor locatedon the jacket water side of the radiator.
Preassemble the 2127246 temperature switch tothe 1L5620 adapter.
Remove the 8T6762 plug from the aftercooler housing.Refer to Illustration 1.
Illustration 1
Install the adapter and temperature switch assemblyinto the aftercooler housing using an appropriate pipe thread sealant.Refer to Illustration 2.
Illustration 2
Connect the temperature switch to the two wirebranch on the main engine wiring harness with the 2490605 wiring harness.Refer to Illustration 2 and 3.
This two wire branch on the main engineharness is designated only for the HIATS. Illustration 3*** Group 2 ***
Disconnect and discard the 2080947 or 2080949wiring harness located between both coolant level sensors and the three-wirebranch of the main engine wiring harness.
This branch of the wiring harness isdesignated for the coolant level sensor.
Remove the 1656634 coolant level