Failure of the Bulkhead Ignition Harness Connector on Certain G3508B Engines{1408, 4460, 7426} Caterpillar

Engine:

G3508B (S/N: RBK1-UP)

G3512B (S/N: JHH1-UP)

G3516B (S/N: JEF1-UP)

G3520B (S/N: GLF1-UP)

Petroleum Engine:

G3520B PETROLEUM (S/N: TPC1-UP)

Introduction

The problem that is identified does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.

Problem

Some G3500B Engines with the following harnesses have had problems with the ignition harness connector at the engine bulkhead.

• 329-4533 Panel Harness As

• 334-1583 Panel Harness As

• 334-1589 Panel Harness As

• 245-8347 Panel Harness As

• 245-8345 Wiring Harness

Some sockets in the harness connectors have been pushed back into the connectors by the pins in the bulkhead connectors.

The loose connections or no connections between the pins and the sockets result in ignition failures.

Solution

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Illustration 1	g02750977

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Illustration 2	g02750996

1. Disconnect the ignition harness from the J2 connector (1) on the engine Electronic Control Module (ECM). Remove the cable ties from the wiring.

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Illustration 3	g02756698

2. At the bulkhead, first loosen outer nut (2) from the harness connector in order to separate the pieces of the connector. Then loosen the nut that connects the harness to the bulkhead and disconnect the harness.

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Illustration 4	g02761116

3. Push the wire bundle through the aperture in the control box in order to provide some slack for the wire at the opposite end.

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Illustration 5	g02756716

4. Pull some slack wire through the connector end of the harness. Determine which socket is pushed back in the connector. Use needle-nosed pliers and pull the socket out of the connector.

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Illustration 6	g02756717

5. Lubricate the outer diameter of the socket with isopropyl alcohol and install the socket back into the connector. push the wiring slack back into the harness cover and pull the slack back into the control box.

6. Using hand pressure, reconnect the harness to the bulkhead connector until the connector is finger-tight. Then disconnect the connector and inspect the sockets.

7. If the socket is pushed into the connector again, repeat Steps 3 through 6.

   If the socket is retained in the connector, reconnect the harness and resume operation.

   If the socket is pushed back into the connector again, install a new harness.

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Illustration 7	g02750977

8. Pull any slack wiring back into the control box. Connect the ignition harness to the J2 connector (1) on the engine Electronic Control Module (ECM). Install new cable ties onto the wiring.