PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING NEW MACHINE AND ENGINE SOFTWARE AS WELL AS INSPECTING THE AIR SYSTEM PIPING ON CERTAIN D8T TRACK-TYPE TRACTORS

PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING NEW MACHINE AND ENGINE SOFTWARE AS WELL AS INSPECTING THE AIR SYSTEM PIPING ON CERTAIN D8T TRACK-TYPE TRACTORS - MULTIPLE REPAIRS

Usage:

REBE7667-02

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09Nov2011

(Revised 17Sep2012)

U-494

A-394

D-426

O-438

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING NEW MACHINE AND ENGINE SOFTWARE AS WELL AS INSPECTING THE AIR SYSTEM PIPING ON CERTAIN D8T TRACK-TYPE TRACTORS - MULTIPLE REPAIRS
1071 7610 5701 7620 4808 4800 7490 7601 7603		PI31946

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31946" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. Exception: If the repair is done after failure, use "PI31946" as the Part Number, "7751" as the Group Number, "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 09Nov2011 (Revised 19Dec2011) Service Letter. Changes have been made to the Mail Codes.

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COMPLETION DATE	TERMINATION DATE
31May2012	30Nov2012

PROBLEM

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The current version of engine software is being updated to provide improved engine and DPF regeneration performance in cold weather as well as resolve a number of diagnostic code related issues and other general issues with the software. Machine software is being updated to include the latest features and improvements. The air piping needs inspected for potential dirt ingestion due to clamp misalignment.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
D8T	FCT00114, 116-126, 128, 130, 132, 134, 136-155, 157, 159-160, 162-163, 165-166, 168, 172-184, 186-188, 190-208, 216, 218-228, 230-242, 248-253, 257, 264, 266 MLN00301-00353, 356, 359-360, 363, 365-367, 369-371, 374-377, 379-380

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*****Group 2*****
D8T	FCT00115, 127, 129, 131, 133, 135, 156, 158, 161, 164, 167, 169, 171, 185, 189, 211, 213, 262, 269-271

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	4W9160	CLAMP-V-BAND
1	8C3089	SEAL-O-RING
1	3756546	SFWR GP-A2000
1	3756547	SFWR GP-A5000
1	3775561	SFWR GP-A4017
1	3858109	SOFTWARE GP-ELEK
1	3858154	SFWR GP-A4008
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 39% 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.
*****Group 2*****
1	4W9160	CLAMP-V-BAND
1	8C3089	SEAL-O-RING
1	3756546	SFWR GP-A2000
1	3756547	SFWR GP-A5000
1	3775561	SFWR GP-A4017
1	3858154	SFWR GP-A4008
1	3863186	SOFTWARE GP-ELEK
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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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Refer to the attached Rework Procedure.

No customer notification letter will be sent out with this program.

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SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 2.0-hour job for Group 1

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 2.0-hour job for Group 2

PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Rework Procedure

Software Update

1. For D8T Track-Type Tractors in Group 1, the machine software along with the engine software must be updated. The ECM's must be flashed with their corresponding software part number in the order shown below:

Group 1
Engine ECM: 385-8109
Powertrain ECM: 375-6547
Implement ECM: 375-6546
Indication Module: 377-5561
Advisor: 385-8154

NOTE: After flashing the Advisor, install the product I.D. Number (Machine serial number) in the Advisor. Cycle the key switch for 1 min and reconnect to the advisor and verify that the Machine ID is present.

For D8T Track-Type Tractors in Group 2, the machine software along with
the engine software must be updated. The ECM's must be flashed with
their corresponding software part number in the order shown below:

Group 2
Engine ECM: 386-3186
Powertrain ECM: 375-6547
Implement ECM: 375-6546
Indication Module: 377-5561
Advisor: 385-8154

NOTE: After flashing the Advisor, install the product I.D. Number (Machine serial number) in the Advisor. Cycle the key switch for 1 min and reconnect to the advisor and verify that the Machine ID is present.

After flashing the engine software and reconnecting to Cat ET, a message
will appear stating that Cat ET is unable to find an exact match for the
engine and machine software version found in the ECM. This message is
present due to an incompatibility between the new engine software and
Cat ET2011C and older. When ET2012A becomes available, this message will
not be present. There are no performance or functionality related issues
with the engine or Cat ET with this message. See Image1.2.1 for example
of this message.

Image1.2.1

Air Piping Inspection

1. Remove elbow from outlet of turbo compressor to where it connects to
the hose that connects to the air pipe going to the ATAAC.

Image1.4.1

2. Inspect the inner diameter of the hose that is still connected to the
ATAAC pipe for accumulations of dirt. Look closely in the corrugated
section of the hose for dirt build up.

Image1.5.1

3. If the hose is clean, re-install the elbow. Use a new 8C-3089 O-ring
at the connection to the turbo.

4. Inspect the air elbow connection at the turbo
compressor inlet. See Image1.7.1. Make sure elbow is piloted properly
in the compressor housing. Install new 4W-9160 Clamp. Tighten the clamp to 8.5 Nm.
Lightly tap around the clamp as much as possible and tighten the clamp again to 8.5 Nm.

If dirt is found in the ATAAC pipe or the elbow connection at the turbo
compressor inlet, take an SOS sample from the engine. Please have the dealer Technical Communicator submit a request to the GDSN Service Technical. Request to escalate to Base Engine Tier 2 for further direction on what potential additional repairs that may be needed for the engine. Please include photographs of the air piping that is showing dirt ingestion in the Service Request.