PRODUCT SUPPORT PROGRAM FOR UPDATING THE ENGINE SOFTWARE AND ADDING A SENSOR ON CERTAIN C32 PETROLEUM ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR UPDATING THE ENGINE SOFTWARE AND ADDING A SENSOR ON CERTAIN C32 PETROLEUM ENGINES

Usage:

TEBE0622-02

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26Nov2013

(Revised 15Jan2014)

U-582

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR UPDATING THE ENGINE SOFTWARE AND ADDING A SENSOR ON CERTAIN C32 PETROLEUM ENGINES
1920 1923 1917 1408		PS44097

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NOTE:

This Program must 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 "PS44097" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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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.

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NOTE:	This Revised Service Letter replaces the 26Nov2013 (Revised 06Dec2013) Service Letter. Changes have been made to Affected Product, and Parts Needed. Added Part Number 2287101 to the PSA

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TERMINATION DATE

30Nov2015

PROBLEM

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Certain C32 Petroleum Engines operating with software 423-9652 and 424-8935 or earlier versions can allow ice to accumulate in the intake manifold, during extended idle times in a extremely cold climate. If the existing fails it can/will cause a potential engine hydraulic lock condition and/or Diesel Oxidation Catalyst failures.

AFFECTED PRODUCT

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Model	Identification Number
C32	SDK00101-00244

PARTS NEEDED

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Qty	Part Number	Description
5	7K1181	STRAP-CABLE
1	2287101	SEAL-O-RING-STOR
1	3203061	SENSOR GP-PRESS
1	4460464	HARNESS AS-WRG
1	4479764	SFWR GP-A1000
1	4502463	SFWR GP-A1000
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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The engine software needs to be updated and a new sensor installed on certain C32 Petroleum Engines.

Replace 423-9652 Software or earlier versions with 447-9764 and 424-8935 software or earlier versions with 450-2463 following the attached rework procedure.

The new software features improved cold mode strategy for idling in extreme cold weather applications and an automated engine shut down feature if icing becomes excessive, in extreme cold weather conditions.

This will be identified by:
Event Code:
EID 1045-3, Engine Intake Manifold Pressure Low
SPN 102-1, Engine Intake Manifold Pressure Low
NOTE:
When shut down has occurred cycling key switch will clear the event, event will be logged in history.
The following restart procedure will need to be performed when code is present.
1) Inspect mixing manifold for ice accumulations
a. inspect with bore scope thru ether port
b. remove ATAAC hump hose for inspection
2) If ice is present remove ice by
a. removing manifold to dislodge ice
b. Bring ambient temp of engine/manifold above freezing point to allow
ice obstruction to melt
3) Ensure free rotation of engine by either:
a. manually rotating engine 360 degrees
b. bore scope all cylinders to ensure no water and or ice is present,
that would create hydro-lock condition
4) If engine will not rotate 360 degrees or ice/water has been
Identified:
a. If ice is present, ambient engine temperature will need to be
brought above freezing point to allow ice to dissipate. If water is
present and or ice has melted refer to Troubleshooting, C27 and C32 Industrial and Petroleum Engines' "Hydraulic Cylinder Lock", to address hydraulic cylinder lock conditions.
5) Refer to machine's Operation and Maintenance Manual for proper starting procedure
6) If water is present in oil refer to C27 and C32 Troubleshooting publications.

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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%
0-16000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 4.0-hour job

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PARTS DISPOSITION

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

Rework Procedure

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Gain access to front left corner of engine.

Sufficient room will be required to run jumper harness 446-0464 from ECM to right hand side air plenum.

Image1.1.1

Remove existing 241-6170 plug.

Install 320-3061 sensor.

Connect 446-0464 harness to 320-3061 sensor.

Image1.2.1

Image1.2.2

Route harness along side existing engine harness.

Loosely install 5 7K-1181 straps at location denoted by arrows.

Remove cover at 120 pin connector.

Image1.3.1

Make appropriate connection to 120 pin connector
Pin 41 = C822-EG2
Pin 80 = G826-EG100
Pin 93 = G827-EG4

Re-install 120 pin cover.

Route and adjust 446-0464 harness.

Secure straps.

Image1.4.1

Image1.4.2

Update Software
Software 447-9764 Replaces 423-9652 or earlier software for engines with a single CEM
Software 450-2463 Replaces 424-8935 or earlier software for engines with a dual CEM

To enable the cold weather protection strategy pin 46 located at J1/P1 must be grounded to a chassis ground or to pin 18 at J1/P1. None of the new features will be active until pin 46 is grounded.

Note: Grounding Pin 46 at J1/P1 will mean that the OEM accepts the speed control concessions required for elevated engine speed and cylinder cutout required for the cold weather protection strategy.