Installation of the 324-7875 Control Box Gp for G3600 Engines {1917, 1924, 4460, 7426} Caterpillar

Engine

G3606 (S/N: 4ZS1-UP)

G3608 (S/N: BEN1-UP)

G3612 (S/N: BKE1-UP)

G3616 (S/N: BLB1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you read and understand the information.

The 324-7875 Control Box Gp replaces the canceled 242-8988 Electronic Control Gp.

This Special Instruction describes removal of the 242-8988 Electronic Control Gp and installation of the 324-7875 Control Box Gp.

Note: Because the 324-7875 Control Box Gp is thicker than the 242-8988 Electronic Control Gp, the scaffolding for engine work may require modification in some cases.

Required Parts

In-Line Engines

Vee Engines

Required Tools

Procedure for In-Line Engines

Remove the 242-8988 Electronic Control Gp from In-Line Engines

1. Turn the engine control switch to the OFF/RESET position.

2. Open the 6 A and 15 A circuit breakers inside the engine terminal box.

3. Remove the cover from the box for the control group.
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   Illustration 1	g02728146
   (1) Bolt for bracket (5) ( 2) Cable strap (3) Nut (4) Ground wire (5) Bracket

4. Remove bolt (1) and the washer from bracket (5). Keep the bolt and washer for reuse.

5. Cut cable straps (2).

6. Disconnect all of the harnesses and cables from the module. Also disconnect ground wire (4) from the mounting bracket.

7. Remove four nuts (3) that hold the box to the shock mounts and remove the box.

8. Remove bracket (5). Keep the bracket for reuse.

Install the 324-7875 Control Box Gp on In-Line Engines

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Illustration 2	g02728564
(1) 213-6302 Bracket (2) 0L-2070 Bolt (3) 3V-3308 Hard Washer (4) 0T-0102 Bolt (5) 4P-8134 Clip (6) 0S-1594 Bolt (7) 9S-8752 Full Nut (8) 3S-2093 Cable Strap (9) 324-7881 Bracket As (10) 3B-1915 Bolt (11) 9X-6458 Hard Washer

1. Remove four bolts from the cylinder block cover: two bolts from the second holes down in the cover and two bolts from the lowest holes in the cover. Refer to callouts (10) in Illustration 2.

2. Remove two of the upper bolts in the camshaft cover. Refer to callout (2) in Illustration 2.

3. Loosely install two bolts (10) and washers (3) in the second holes down in the cylinder block cover. Slide bracket (9) onto the bolts and snug the bolts.

4. Secure the bottom of bracket (9) with two bolts and washers (10) and (11).

5. Install bracket (1) onto the camshaft cover with two bolts and washers (2) and (3).

6. Attach bracket (1) to bracket (9) with one bolt and washer (4) and (3) that were removed previously and kept for reuse.

7. Make sure that all of the bolts are tightened.

8. Install the control box onto bracket (9) with four bolts and washers (6) and (3).

9. Attach two clips (5) to the ears at the top of the control box with bolts (6), washers (3) and nuts (7).

10. Connect the harness for the thermocouples to the connector at the top of the control box.

11. Connect the engine harness to the connector at the bottom of the control box.

12. Connect the cables for the combustion probes to the connectors on both sides of the control box.

13. Use straps (8) to secure the cables for the combustion probes to clips (5).

    Note: For information on connecting to the service tool connector and for information on flash programming, refer to the engine Troubleshooting manual.

14. Connect a personal computer that has Cat Electronic Technician (ET) to the engine service tool connector.

15. Close the 6 A and 15 A circuit breakers inside the engine terminal box.

16. Turn the engine control switch to the STOP position.

17. Establish communication between Cat Electronic Technician (ET) and the electronic control module in the control box.

18. Flash the 381-8821 Software into the electronic control module in the control box.

19. After the software has been successfully flashed, turn the engine control switch to the OFF/RESET position for at least 10 seconds.

20. Return the engine to service.

Procedure for Vee Engines

Perform this procedure for the modules on each side of the engine.

Remove the 242-8988 Electronic Control Gp from Vee Engines

1. Turn the engine control switch to the OFF/RESET position.

2. Open the 6 A and 15 A circuit breakers inside the engine terminal box.

3. Remove the cover from the box for the control group.
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   Illustration 3	g02728284
   (1) Cable strap (2) Bolt that holds the control box to the shock mounts (4) Bolt that holds mounting bracket (4) to the engine (4) Mounting bracket

4. Cut cable straps (1).

5. Disconnect all of the harnesses and cables from the module. Also disconnect the ground wire from the mounting bracket.

6. Remove four bolts (2) that hold the box to the shock mounts and remove the box.

7. Remove four bolts (3) and remove mounting bracket (4).

Install the 324-7875 Control Box Gp on Vee Engines

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Illustration 4	g02730342
(1) 0T-0573 Bolt (2) 3V-3308 Hard Washer (3) 324-7883 Bracket As (4) 324-7886 Bracket

1. Attach the top of bracket (3) to the camshaft cover with two bolts (1) and washers (2).

2. Attach the bottom of bracket (3) to the cylinder block with two 0S-1571 Bolts and 3V-3308 Hard Washers.

3. Attach bracket (4) to the cylinder block with two 0S-1594 Bolts and 9X-6458 Hard Washers.
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   Illustration 5	g02730434
   (5) 324-7875 Control Box Gp (6) 324-7887 Bracket (7) 0S-1591 Bolt (8) 3V-3308 Hard Washer (9) 9S-8752 Full Nut

4. Attach bracket (6) to the cylinder block with a 0S-1594 Bolt and a 9X-6458 Hard Washer.

5. Attach control box (5) to the top mounting bracket with two 0S-1594 Bolts and 3V-3308 Hard Washers.

6. Attach control box (5) to lower brackets (4) and (6) with two bolts (7), four washers (8) and two nuts (9).
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   Illustration 6	g02730496
   (2) 3V-3308 Hard Washer (9) 9S-8752 Full Nut (10) 4P-8134 Clip (11) 0S-1594 Bolt

7. Attach two clips (10) to the ears at the top of the control box with bolts (11), washers (2) and nuts (9).

8. Make sure that all of the bolts are tightened.

9. Connect the harness for the thermocouples to the connector at the top of the control box.

10. Connect the engine harness to the connector at the bottom of the control box.

11. Connect the cables for the combustion probes to the connectors on both sides of the control box.

12. Use 3S-2093 Cable Straps to secure the cables for the combustion probes to clips (10).

    Note: For information on connecting to the service tool connector and for information on flash programming, refer to the engine Troubleshooting manual.

13. Connect a personal computer that has Cat Electronic Technician (ET) to the engine service tool connector.

14. Close the 6 A and 15 A circuit breakers inside the engine terminal box.

15. Turn the engine control switch to the STOP position.

16. Establish communication between Cat Electronic Technician (ET) and the electronic control module in the control box.

17. Flash the 381-8821 Software into the electronic control module in the control box.

18. After the software has been successfully flashed, turn the engine control switch to the OFF/RESET position for at least 10 seconds.

19. Return the engine to service.