Procedure for Replacing the Software for the Electronic Ignition System (EIS){1902} Caterpillar

Engines:

G3508 (S/N: 9TG130-UP; 4WD15-UP)

G3512 (S/N: 5JD30-UP; 7NJ359-UP)

G3516 (S/N: 4EK1241-UP; 8LD36-UP)

Introduction

Do not perform any procedure in this Special Instruction until the entire Special Instruction has been read and understood.

This Special Instruction provides the procedure for replacing the software for the the EIS control module for G3500 Engines.

Required Tools

Replacement Procedure

1. Perform this procedure in a low humidity environment.

2. Remove the power from the system. Remove the EIS control module from the engine.

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Illustration 1	g00557424
Typical example of the control module for the EIS (1) Access Cover (A) Connector

3. Thoroughly clean the software access cover and the surrounding areas prior to disassembly. Refer to Illustration 1.

4. Perform this procedure on a flat surface. Point the connector away from you.

5. Remove the security wire from the access cover. Remove access cover (1) .

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Illustration 2	g00557426
(2) Chip (3) Tie-wrap (4) Ends of tie-wrap (A) Connector

6. Carefully cut the existing chip's tie-wrap (3) at both ends (4) with a side cutter. Do not damage any components on the circuit board. Do not attempt to remove the tie-wrap that is beneath the chip's socket.

7. Mark chip (2) with a permanent marker in order to help ensure that the chip does not get reinserted into the EIS.

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Illustration 3	g00557437
The notch in the chip must be to the left. (5) Notch (6) Position for the puller (A) Connector

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Illustration 4	g00557441
(2) Chip (5) Notch (6) Position for the puller (7) Puller (8) Circuit board (9) Socket

8. Note the direction of the notch on chip (2). Refer to Illustration 3. Remove the chip with puller (7). Grasp the chip at notch (5) and opposite side (6). Be careful to grab only the chip. Do not grasp socket (9) that is beneath the chip. Gently rock the chip in order to remove the chip from the socket.

9. Immediately after you remove chip (2), bend the pins. Dispose of the chip.

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Illustration 5	g00557442
(10) Plunger (11) Setscrew (12) Body

10. Adjust the installer to the depth that is shown in Illustration 5. This is done by adjusting setscrew (11) that is on the bottom of the installer.

11. The chip is very sensitive to static electricity. In order to eliminate the hazard of electrostatic discharge (ESD), momentarily touch an unpainted grounded metal object prior to handling a chip.

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Illustration 6	g00557443
(2) Chip (10) Plunger (13) Installer (B) Correct position for the installer (C) Incorrect position for the installer

12. Remove chip (2) from the packaging. Place the chip on a surface that is clean, hard, and flat. The pins should face downward. Hold body (12) of the installer while you carefully push the installer over the chip. Do not hold the plunger. Be careful not to bend any of the pins. Make sure that the chip is centered in the installer. Refer to Illustration 6.

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Illustration 7	g00557448
The notch on the chip must be to the left. (A) Connector

13. Ensure that connector (A) on the control module for the EIS is pointed away from you. Refer to Illustration 7. When you install new chip (2), point the notch in the chip to the left.

    Note: There is one hole in socket (9) for every pin on chip (2). An empty hole in the socket or a pin that is not inserted in the socket indicates improper alignment of the chip.

14. With chip (2) in installer (13), line up the chip with socket (9). Ensure that all of the pins on the chip are lined up with all of the holes in the socket. Verify proper orientation. Refer to Illustration 7. Gently push down on plunger (10) of the installer until the plunger stops. Remove the installer.

15. Inspect chip (2) and socket (9). Ensure that all of the pins on the chip are properly inserted into all the holes in the socket.. If any empty holes are visible on the socket, remove the chip. Refer to Step 8. Visually inspect the chip for damaged pins. If the pins are damaged, discard the chip. Acquire a new chip. Return to Step 11.

16. If all the pins on the chip are properly inserted into all the holes in the socket, the chip is inserted correctly. Gently push down on the chip with your finger in order to finish seating the chip in the socket.

    Note: A new tie-wrap will not be installed.

17. Thoroughly clean the software access cover (1) and the surrounding areas on the EIS control module. Refer to Illustration 1. Do not allow debris to enter the EIS control module through the access hole.

18. Remove the old O-ring seal from access cover (1). Clean the O-ring groove. Lubricate the new O-ring seal that is provided with glycerin or a similar lubricant. Do not use a petroleum based lubricant. Place the new O-ring seal in the O-ring groove on the access cover. Place the access cover on the EIS control module. Verify that the O-ring seal remains in the groove. Do not allow the O-ring seal to be pinched between the access cover and the EIS control housing.

19. Install new bolts. Tighten the bolts to a torque of 2.25 ± 0.25 N·m (20 ± 2 lb in). Install the two security seals on each end of the cover.

20. Engrave the month and the year of the new software on the control module in the area of the part number. If the EIS control module is equipped with the June 1998 version of software, engrave "w/JUN98 SW" on the EIS control module.

21. Reinstall the EIS control module on the engine. Power up the system. Scroll through the Digital Diagnostic Tool (DDT). Ensure that the DDT behaves normally. If the DDT is working normally, the engine is ready to start.

22. If the DDT will not scroll to the proper screen, run a self test on the EIS control module. If the EIS control module passes the self test, refer to Troubleshooting, SENR6413 for additional troubleshooting methods.

    Note: Do not return an EIS control module that has passed the self test.

    If the EIS control module fails the self test, send the EIS control module and an explanation of the problem to the following address:

    Caterpillar Inc.
    Customer Service
    3701 State Road 26 East
    Lafayette, Indiana 47905