New Engine Software Is Available for Certain Tier 4 Interim C9.3 Through C15 Machine Engines and C9.3 Through C18 Industrial Engines {1920} Caterpillar

Articulated Truck:

735B (S/N: T4P1-UP)

740B (S/N: T4R1-UP; E4S1-UP)

740B EJECTOR (S/N: T4S1-UP)

Electric Power Generation:

C13 (S/N: X3M1-UP)

C15 (S/N: LWR1-UP)

Generator Set:

C15 (S/N: T4A1-UP; X5M1-UP)

Industrial Engine:

C9.3 (S/N: C9N1-UP)

C13 (S/N: KWJ1-UP)

C15 (S/N: LDN1-UP)

C18 (S/N: BDN1-UP)

Excavator:

336E (S/N: KED1-UP; YCE1-UP; TEG1-UP; FJH1-UP; GTJ1-UP; YEP1-UP; CMR1-UP; BZY1-UP; TMZ1-UP)

349E (S/N: DGE1-UP; SPG1-UP; TFG1-UP; RGH1-UP; KCN1-UP; MZW1-UP; KFX1-UP; MPZ1-UP; WHZ1-UP)

568 (S/N: BRB1-UP; YJX1-UP)

Motor Grader:

12M Series 2 (S/N: F9B1-UP; F9M1-UP; R9P1-UP; R9S1-UP)

140M Series 2 (S/N: M9D1-UP; R9G1-UP; M9J1-UP; R9M1-UP)

160M Series 2 (S/N: M9E1-UP; M9K1-UP; R9L1-UP; R9T1-UP)

Mobile Hydraulic Power Unit:

336E MHPU (S/N: DSZ1-UP; T3Z1-UP)

349E MHPU (S/N: S3P1-UP)

Track-Type Tractor:

D6T (S/N: KSB1-UP; ZJB1-UP; DTD1-UP; EJJ1-UP; SLJ1-UP; GMK1-UP; RRK1-UP; TSM1-UP; WLM1-UP; PLR1-UP; JRW1-UP; RCW1-UP)

D7E (S/N: TJA1-UP; TAN1-UP)

D8T (S/N: MLN1-UP; FCT1-UP)

Wheel Loader:

966K (S/N: PBG1-UP; TFS1-UP; NGX1-UP)

972K (S/N: PEM1-UP; Z4W1-UP)

980K (S/N: W7K1-UP; GTZ1-UP)

Wheel Tractor-Scraper:

621H (S/N: DBK1-UP; HKK1-UP)

623H (S/N: DBF1-UP)

627H (S/N: DBW1-UP)

Introduction

New engine software has been released to add new features and correct a number of issues in the current versions of engine software. The new part numbers and the related applications can be found below. Do not perform any procedure in this Special Instruction until you read this information and you understand this information.

Required Parts

Changes Implemented in Flash Files

The following changes are being implemented in the above listed flash files:

Issue

"Fuel System Functional Test" may provide false positive results when ran on engine with no faults or performance issues.

Resolution

Parameters of "Fuel System Functional Test" were modified to reduce the number of false positives and non-faulty parts replaced.

Issue

E539 High Intake Manifold Air Temperature event codes and associated protective de-rates can be cleared if the charge air cooler outlet temperature sensor fails and generates 3372-3 Engine Charge Air Cooler #1 Outlet Temperature Sensor: Voltage Above Normal or 33724 Engine Charge Air Cooler #1 Outlet Temperature Sensor: Voltage Below Normal codes. This condition can create the possibility of severe engine damage.

Resolution

The diagnostic strategy was updated so that a low voltage diagnostic would not enable the high temperature event to reset.

Issue

Low ambient temperatures can keep the engine coolant temperature from warming up and prevent necessary regenerations from being performed. This condition creates high soot loads and excessive troubleshooting.

Resolution

An E1300 Aftertreatment Regeneration Cannot Start Due To Low Engine Temperature event code has been added to identify when a regeneration cannot be completed due to coolant temperature being too low.

Issue

Currently when a Diesel particulate filter (DPF) Ash Service is performed, the engine ash model is reset along with the DPF soot load percentage. If the DPF soot load is not at 0% when this service is performed, the possibility exists to damage the DPF during the next regeneration.

Resolution

The software was updated to reset the engine ash model following a DPF Ash Service and not the DPF soot load percent.

Issue

In cold ambient conditions, the CRS intake pressure line may become plugged from frozen condensation which can trip an E1170 Low Aftertreatment #1 Secondary Air Pressure code and disable regenerations.

Resolution

With an E1170 Low Aftertreatment #1 Secondary Air Pressure code is active, the software will use and estimated value for this parameter. Only low speed regenerations will be allowed when this fault is active. High speed regenerations will not occur until the fault is cleared.

Issue

Rapid soot gauge increases and decreases have been observed during Hydrocarbon (HC) evaporation regenerations.

Resolution

The soot load percent gauge is frozen when an HC evaporation regeneration is active.

Issue

If only the low-pressure side of the DPF differential pressure sensor is obstructed, the sensor could trip a 2458-2 DPF #1 Differential Pressure Sensor: Erratic, Intermittent, or Incorrect code and falsely indicate a high-pressure condition. The Electronic Control Module (ECM) will interpret this as high soot load in the DPF which can cause temporary or permanent lockouts.

Resolution

The strategy will reset the fault counter at key on. This reset will allow for warm-up time to thaw a frozen pressure sensor line in cold ambient conditions.

Issue

CRS air valve wear was causing high speed regeneration to fail and logging E1025(2) Aftertreatment #1 Failed to Ignite event codes.

Resolution

A strategy was implemented in the software to recalibrate the Cat^® Regeneration System (CRS) air valve to allow for acceptable valve wear. The strategy will also generate a 2489-13 Aftertreatment #1 Air Pressure Control: Out of Calibration if the valve has exceeded the calibration limits and a failed regeneration has occurred.

Issue

Engine is unable to maintain desired coolant temperature required to perform regeneration when ambient temperatures are cold and the machine is left to idle unattended.

Resolution

The elevated idle strategy was modified to elevate the engine speed up to 1600 rpm to achieve the desired temperature. Once the desired temperature is achieved, the elevated engine speed will decrease.

Note: For D6T, max engine speed is 1200 rpm. For D7E max engine speed is 1400. For D8T max engine speed is 1600 rpm. For all other models listed in this procedure, max engine speed is 1600 rpm

Issue

The current strategy does not allow for sufficient time to save a DPF from replacement when high soot loading occurs. Hard shutdown occurs at 140%, which is also when the DPF needs replaced.

Resolution

A shutdown at 116% plus 10 minutes was implemented into the strategy to allow a dealer time to resolve issues and regenerate the DPF prior to required replacement.

Issue

Certain high load industrial applications such as blenders require idle fuel quantities that prevent a low speed regeneration from occurring. Unmanned extended idle periods can lead to 140% soot loads and DPF replacement.

Resolution

The low speed regeneration fuel threshold was increased to allow a low speed regeneration to take place in these applications.

Issue

Certain high speed, high load industrial applications such as air compressors can have issues initiating a high speed regeneration. These applications can produce exhaust temperatures that are too high for the regeneration system to initiate ignition without creating DPF temperature overshoots

Resolution

The regeneration strategy was modified to allow these industrial applications to bypass the DPF pre-heat when certain exhaust conditions are met.

Issue

High occurrences of false E1051(2) High Aftertreatment #1 Fuel Pressure #2 event codes are falsely and intermittently tripping. This code requires a dealer service visit and can lead to unnecessary part replacement trying to troubleshoot the issue.

Resolution

The diagnostic strategy was updated to detect gross fuel leaks in the ARD fuel system and reduce the occurrences of false events.

Issue

E1052 (2) Low Aftertreatment #1 Fuel Pressure #1 event codes are being tripped and can lead to unnecessary part replacement trying to troubleshoot the issue. This condition is due the diagnostics not being sufficiently robust to CRS fuel pumps operating across the entire performance specification range.

Resolution

The diagnostic specifications were updated to reduce the occurrence of false E1052 (2) event codes due to CRS fuel pumps operating at the low end of the acceptable specifications.

Issue

Machines that use the engine ECM as the sync clock master do not allow the engine hours to be set lower than the current hours.

Resolution

The software was updated to allow for the engine hours to be lowered with factory passwords.

Issue

The "ARD Nozzle Heater Circuit Test" displays an incorrect amount of time a technician must wait to start the test after a regeneration completes.

Resolution

The time displayed in Cat^® Electronic Technician (Cat ET) Service Tool now includes the nozzle heater cool down time along with the regeneration shutdown time

Issue

An air inlet temperature sensor calibration test in Cat ET will show that a successful calibration after the flow test is skipped.

Resolution

The ECM will verify that the calibration values have been updated and are within the acceptable range prior to determining if the test was successful.

Issue

Certain parameters viewed in "Snapshot" files are not configured to display properly. For example, Aftertreatment Regeneration Device Regeneration Status will show 0 or 1 instead of Active or Inactive.

Resolution

The software was corrected to convert these channels into viewable data in "Snapshot" files.

Issue

The electric priming pump shuts off after the fuel diverter valve is closed. This condition can create pressure spikes in the CRS fuel system, which has an impact on pump reliability and temporarily forces open the CRS fuel valves.

Resolution

A delay timer was added to keep the diverter valve from closing until the pump has shutdown. The timer is not active if a regeneration is desiring fuel.

Issue

The high speed regeneration and low speed regeneration status channels are not viewable in Snapshot files for industrial engines.

Resolution

These channels were added to the "Snapshot" files for industrial engines.

Issue

The DiagnosticTroubleshooting Code (DTC) auto-clear feature was clearing some logged critical codes while not clearing some logged non-critical codes.

Resolution

The DTC auto-clear list was updated with the correct critical and non-critical codes.

Issue

A 261-13 Engine Timing Calibration: Calibration Required code can trip following an ECM replacement. This condition is due to the ECM not properly storing the timing calibration offsets in the ECM replacement file.

Resolution

The software was corrected to allow the storage of timing calibration values during ECM replacement file creation.

Issue

Idle fuel is not accurately being communicated in Cat ET. Currently, the idle fuel is calculated based off engine idle speed however, some machines may be idling, but not at the programmed low idle speed, as in "Cold Engine Elevated Idle".

Resolution

The machine ECM will communicate to the engine ECM when a machine is at an idle state and calculate fuel burn at these conditions.

Issue

If an ECM is replaced and a replacement file is not used or unavailable, the DPF soot loading is reset to 0%. If the soot load was previously high, the DPF Ash Service Regeneration following the ECM replacement can damage the DPF.

Resolution

The ECM now changes the DPF soot level to a high soot level prior to the Ash Service Regeneration. This condition allows the ECM to utilize a more conservative regeneration profile, which is sufficient for cleaning soot from the DPF while protecting a DPF from varying initial soot loads.

Issue

Engine overspeed histogram information has misleading labeling and can create confusion.

Resolution

The labeling was updated to "Accumulated Time vs. High Engine Speed."

Issue

Currently, voltage faults on the ARD main fuel pressure sensor 2497-3 ARD Fuel Pressure #2 Sensor: Voltage Above Normal, 2497-4 ARD Fuel Pressure #2 Sensor Voltage Below Normal will turn on the amber lamp and be displayed on the monitor but do not disable regenerations. Conversely, voltage faults on the ARD pilot fuel pressure sensor 2460-3 ARD Fuel Pressure #1 Sensor: Voltage Above Normal, 2460-4ARD Fuel Pressure #1 Sensor: Voltage Below Normal will not turn on the amber lamp nor be displayed on the monitor but will disable regenerations. This result can create confusion for the operator and dealer technicians.

Resolution

The diagnostic logic was updated to turn on the amber lamp and monitor display for voltage faults on the ARD pilot fuel pressure sensor and not for the ARD main fuel pressure sensor.

Issue

There is an excessive amount of time required to trip an E593(2) Aftertreatment Insufficient Temperature to Complete Regeneration event code when desired and actual DPF temperatures do not align, which can potentially cause the DPF to fail.

Resolution

The diagnostic strategy for this event code was modified to respond proportionally to the difference between desired and actual DPF temperatures instead of a requiring a set amount of time regardless of the temperature differential.

Issue

Injector #-7 Cylinder # Injector: Not Responding Properly diagnostic troubleshooting codes are tripping prematurely. This premature tripping is due to a strategy in software which measures the valve opening time of the injector to report a fault after so many occurrences of the valve opening time being out of an allowable range.

Resolution

The diagnostic strategy was updated to allow more occurrences of the valve opening time out of range before tripping the -7 fault code. This strategy will provide more accuracy as to when an injector is faulty versus false reporting a good injector.