PRODUCT SUPPORT PROGRAM FOR UPDATING SOFTWARE ON CERTAIN G3606, G3608, G3612, AND G3616 GAS ENGINES

Usage:

SEBE8723

March 31, 2004
U-98
A-65
D-77
O-80

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*before or* *after failure*	PRODUCT SUPPORT PROGRAM FOR UPDATING SOFTWARE ON CERTAIN G3606, G3608, G3612, AND G3616 GAS ENGINES
7550		PS41578

NOTE: This Program can be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS41578" 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.

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.

TERMINATION DATE

March 31, 2006

PROBLEM

The software needs to be updated on certain G3606, G3608, G3612, and G3616 gas engines. Under certain conditions the hydrax pressure switch may open during cranking and prevent the engine from starting.

AFFECTED PRODUCT

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Model	Identification Number
G3606	4ZS281-344, 349-357 3XF18, 52, 114, 134, 311, 312
G3608	BEN208-242 4WF59, 63, 66, 68, 78, 88, 157, 158
G3612	BKE192-235 1YG22, 62, 63, 93, 123, 137, 193-197, 204, 240, 241, 245
G3616	BLB163-214 4CG64, 74, 76, 97, 98, 119, 151

PARTS NEEDED

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New Software	IC	Previous software	Previous Software	BKW	BHP	RPM
* G3606 *
2472862-01	1	2428560	2303112	1324	1775	1000
2472863	3	2428562	2360998	1191	1597	900
2472864	4	2428563	2408992	1242	1665	1000
2472865	5 FP req?d	2428561	----	1344	1803	1000
2360995	6	----	----	1367	1833	1000
* G3608 *
2472866	1	2428564	2303114	1767	2370	1000
2472867	3	2428566	2335267	1851	2482	1000
2472868	5	2428567	2364247	1767	2370	1000
2472869	6	2428568	2378254	1650	2212	900
* G3612 *
2472870	1	2428569	2265557	2647	3550	1000
2472871	2	2428570	2308814	2822	3785	1000
2472872	3	2428571	2322666	2822	3785	1000
2472873	4	----	----	2488	3335	900
2501195	5	2428565	----	2333	3127	1000
2501196	6	----	----	2488	3335	900
* G3616 *
2472874	1	2428572	2303116	3531	4735	1000
2472875	3	2428574	2308818	3315	4445	1000
2472876	4	2428575	2308820	3201	4293	900
2472877	5	2428576	2320335	3176	4259	1000
2472878	6	2428577	2330717	3807	5105	1000
2472879	7	2428578	2338100	3788	5080	1000
2498569	8	2428579	2364245	3531	4735	1000
2472881-01	9	2428580	2380971	3753	5032	1000
2501386	14	----	----	3979	5336	1000
2472882	10	2428581	----	3531	4735	1000
2472883	11	2428582	2403687	3389	4544	1000
2472884	12	2428583	2395243	3762	5045	1000
2428573	13	----	----	3570	4786	900
2501197	15	----	----	3762	5045	1000

ACTION REQUIRED

See the attached Rework Procedure.

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
0-24 mos	100%	2.0	0	0	0	0
NOTE: This is a 2.0?hr job.

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Attach. (1-Rework Procedure)

Rework Procedure

The basic operating data should be recorded before flashing the new software. Check the version of software, if the ECM has the current version of software, there is no need to proceed.
Record load, speed, manifold pressure, and fuel correction factor.
The engine must be shut down before installing the software.
Shut the engine down by placing the Engine Control Switch (ECS) in the OFF/RESET position.
After the engine shuts down, connect the COM II adapter and laptop computer with Caterpillar ET installed.
Reference System Operation Test and Adjusting (SENR5908).
Turn the ESC to the stop position and follow the ET installation procedure for Win Flash to install the software.
It is recommended that the flash file be downloaded onto the PC hard drive and then flashed to the ECM.
Do not flash software from a floppy disk to the ECM.
After the flashing procedure is completed, return the ECS to the OFF/RESET position.
The engine may now be restarted.
The operating parameters should be noted and compared to the original data that was recorded earlier.