Product Support Program For Updating The Software On Certain G3606, G3608, G3612, And G3616 Engines Equipped With CMS Caterpillar

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.

NOTE: This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS8729" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

Termination Date

Problem

New software has been developed that provides improved diagnostics on CMS equipped engines. The new diagnostics incorporate improved accuracy and include some diagnostics which were not available on the original software.

Affected Product
Model & Identification Number

G3606 (3XF17, 3XF18, 3XF21-59)

G3608 (4WF16-43)

G3612 (1YG20-92)

G3616 (4CG24-56)

Parts Needed

NOTE: Only one film is required for each engine.

1 - 1179691 FILM-CONTROL

1 - 1180374 FILM-CONTROL

1 - 1182403 FILM-CONTROL

1 - 1182404 FILM CONTROL

1 - 1182405 FILM-CONTROL

1 - 1182411 FILM-CONTROL

1 - 1182413 FILM-CONTROL

Action Required

See the attached rework procedure.

Service Claim Allowances

NOTE: This is a 4-hour job.

NOTE: The servicing dealer will be allowed to claim $105.00 as a handling fee for the personality module.

Parts Disposition

Return the personality modules to:

Attach.

(1-Rework Procedure)

Rework Procedure

Complete the attached questionnaire for each engine to be updated. Send the questionnaire to Caterpillar in Lafayette, Indiana. After the questionnaire has been received, Caterpillar Large Engine Center will ship the personality module. When the new personality module is received, use the attached installation procedure to install the new module. Install the desired Engine Supervisory System (ESS) panel film selected from the following chart:

Update customer service manual with SENR6510-03 Troubleshooting on both inline and vee engines. For inline engines upgrade, order SENR4258-03 Systems Operation, Testing and Adjusting. For vee engines upgrade, order SENR5528-03 Systems Operation, JTesting and Adjusting.

Engine Supervisory System Panel Films

ECM and Personality Module

Standard Mounting of Gas Shut Off Valve

Improved Diagnostic Software For G3600 Series Engines

Installation Instructions

NOTE: Read the instructions completely before installing.

NOTE: The Diagnostic Display Tool (DDT) must have software version 1.6 installed to acquire the information needed to complete the table below. To check the software version, power up the DDT and advance to screen 00 (zero zero).

Step 1 With the engine stopped and the mode control switch in the STOP position, record the following:

Step 2 Rotate the mode control switch to the OFF/RESET position.After the panel has completely powered down, install the new personality module.

Step 3 Rotate the mode control switch to the STOP position.The mode control switch must remain in the STOP position for five minutes.The prelube switch (screen 65 on the DDT) must be de-energized for this five minute interval.

Step 4 Read the intake manifold pressure on CMS gage #4.If the value is within 2 kPa, or .29 psi of the original value recorded above, proceed to the next step after the five minute interval has elapsed.If the value is different by more than 2 kPa, recalibrate the air pressure module (see Systems Operation Testing and Adjustment, SENR5528-03, Pressure Module Calibration).

Step 5 Start the engine but do not add load to the engine.Allow the engine to stabilize for one minute.

Step 6 Record all displayed diagnostic codes.

Step 7 Clear all diagnostic codes.Do not increase the load on the engine. Rotate the mode control switch to the STOP position.

Step 8 Allow the engine to come to a complete stop and post lube to complete.

Start the engine.

Increase the speed to rated.

Adjust choke trim (DDT Screen 33) to provide the most stable operation.

Apply load to the engine.

Adjust governor (DDT Screens 70 through 72) and wastegate (DDT Screens 80 through 82) for stable operation.

Start at original values as recorded.

The engine is now ready for normal service.

Troubleshooting

If the engine is unstable or cannot maintain idle speed, check choke trim. The engine is operating either too rich or too lean. Adjust choke trim until the engine speed is stable.

If the CMS oil pressure display is blank, the sensor did not complete calibration. See SENR5528 "Oil Pressure Sensor Calibration".

If 023-02, 525-02, or 526-02 is displayed, check the linkage and feedback signals. SENR5528 for actuator linkage adjustments. See SENR6510 for additional troubleshooting instructions.

If 023-07 is displayed, see SENR6510 "Fuel Actuator Not Responding Properly".

Complete the following questionaire and fax to:

or mail to: