PRODUCT SUPPORT PROGRAM FOR REPLACING THE COOLANT FLOW SWITCH ON CERTAIN 3524 ENGINES INSTALLED IN 797 AND 797B OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE COOLANT FLOW SWITCH ON CERTAIN 3524 ENGINES INSTALLED IN 797 AND 797B OFF-HIGHWAY TRUCKS

Usage:

REBE6475-03

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07Dec2010

(Revised 18Jan2011)

U-487

A-400

D-427

O-427

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE COOLANT FLOW SWITCH ON CERTAIN 3524 ENGINES INSTALLED IN 797 AND 797B OFF-HIGHWAY TRUCKS
1408 7601 7620 1439		PS43199

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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 "PS43199" 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 07Dec2010 (Revised 13Jan2011) Service Letter. A change was made to the Cat ET note in the Rework Procedure.

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TERMINATION DATE

31Dec2012

PROBLEM

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The existing coolant flow switch can fail on certain 3524 Engines installed in 797 AND 797B Off-Highwy Trucks. If the existing coolant flow switch fails, it can cause a false alarm/indicator when the truck is running.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
797	5YW00194-00232, 234, 236-257, 260-276

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*****Group 2*****
797	5YW00233, 235, 258-259

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*****Group 3*****
797B	JSM00123-00124, 127-131, 134-136, 139-149, 151-213, 216-287, 292-332, 334-367, 369-488

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*****Group 4*****
797	5YW00277
797B	JSM00125-00126, 132-133, 137-138, 150, 214-215, 288-291, 333, 368

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
2	0S1617	BOLT
1	3E7448	CONNECTOR
10	3S2093	STRAP-CABLE
1	4N3841	GASKET
1	6V9027	SEAL-O-RING
2	8T8737	PLUG-SEAL
2	9M1974	WASHER-HARD
20	9X6772	STRAP-CABLE
1	1028802	RECEPTACLE KIT
1	2054821	COVER
1	2183840	SENSOR GP-PRESS
1	3626391	HARNESS AS (LAA)
1	3673823	SOFTWARE GP-ELEK (797 MASTER ECM)
1	3673824	SOFTWARE GP-ELEK (797 SLAVE ECM)
1	3715185	SFWR GP-A4003 (VIMS)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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*****
2	0S1617	BOLT
1	3E7448	CONNECTOR
10	3S2093	STRAP-CABLE
1	4N3841	GASKET
1	6V9027	SEAL-O-RING
2	8T8737	PLUG-SEAL
2	9M1974	WASHER-HARD
20	9X6772	STRAP-CABLE
1	1028802	RECEPTACLE KIT
1	2054821	COVER
1	2183840	SENSOR GP-PRESS
1	3666058	HARNESS AS (HAA)
1	3673823	SOFTWARE GP-ELEK (797 MASTER ECM)
1	3673824	SOFTWARE GP-ELEK (797 SLAVE ECM)
1	3715185	SFWR GP-A4003 (VIMS)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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 3*****
2	0S1617	BOLT
1	3E7448	CONNECTOR
10	3S2093	STRAP-CABLE
1	4N3841	GASKET
1	6V9027	SEAL-O-RING
2	8T8737	PLUG-SEAL
2	9M1974	WASHER-HARD
20	9X6772	STRAP-CABLE
1	1028802	RECEPTACLE KIT
1	2054821	COVER
1	2183840	SENSOR GP-PRESS
1	3626391	HARNESS AS (LAA)
1	3660534	SFWR GP-A4003 (VIMS)
1	3673819	SOFTWARE GP-ELEK (797B LAA MASTER ECM)
1	3673820	SOFTWARE GP-ELEK (797B LAA SLAVE ECM)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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 4*****
2	0S1617	BOLT
1	3E7448	CONNECTOR
10	3S2093	STRAP-CABLE
1	4N3841	GASKET
1	6V9027	SEAL-O-RING
2	8T8737	PLUG-SEAL
2	9M1974	WASHER-HARD
20	9X6772	STRAP-CABLE
1	1028802	RECEPTACLE KIT
1	2054821	COVER
1	2183840	SENSOR GP-PRESS
1	3660534	SFWR GP-A4003 (VIMS)
1	3666058	HARNESS AS (HAA)
1	3673821	SOFTWARE GP-ELEK (797B HAA MASTER ECM)
1	3673822	SOFTWARE GP-ELEK (797B HAA SLAVE ECM)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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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Install the 218-3840 Coolant Pressure Sensor and remove the existing coolant flow switch.

Update the engine and VIMS software.

Refer to the attached Rework Procedure.

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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%
*****Group 1*****
0-99999 hrs, 0-200 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 3.0-hour job for Group 1

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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%
*****Group 2*****
0-99999 hrs, 0-200 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 3.0-hour job for Group 2

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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%
*****Group 3*****
0-99999 hrs, 0-200 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 3.0-hour job for Group 3

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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%
*****Group 4*****
0-99999 hrs, 0-200 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 3.0-hour job for Group 4

PARTS DISPOSITION

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

Rework Procedure

1. Drain the coolant. Remove the pipe plug from the coolant pressure sensor port and install the 3E-7448 Adapter, 6V-9027 O-ring Seal, and new 218-3840 Sensor at the location shown in Image 1.1.1.

Image1.1.1

2. Disconnect the turbo outlet pressure sensor connector of the engine harness(located on the rear LH side of the front engine, behind the Master ECM, Image 1.2.1) and install the appropriate new sensor harness to integrate the new coolant pressure sensor.
a. Connect PC-C1 of new sensor harness to the connector of the turbo outlet pressure sensor.
b. Connect PC-C2 of new sensor harness to the turbo outlet pressure sensor connector on the main engine harness.
Refer to Image 1.2.1

Image1.2.1

Image1.2.2

3. Connect the PC-C3 connector on 362-6391 Harness Assembly to the coolant pressure sensor connector.

4. Route the coolant pressure wiring harness (blue single braided wire) along the current engine wiring harness to the Master ECM, strap it to the engine wiring harness with the 9X-6772 Tie Straps. At the ECM, connect this single braided blue wire to J2 pin 8 of the Master ECM.

5. Disconnect the coolant flow switch harness connection from the switch and provide an appropriate means of protecting the harness connector from damage and exposure to the elements. Refer to Image 1.5.1 for coolant flow switch location.

6. Remove the existing coolant flow switch and guard and install the 205-4821 Cover, 4N-3841 Gasket, 0S-1617 Bolts, and 9M-1974 Washers in its place at location shown in Image 1.5.1. Use the 3E-3364 Receptacle and 3E-3365 Wedge, from 102-8802 Receptacle Kit, and the two 8T-8737 Seal Plugs in order to cap the harness plug that was attached to the coolant flow switch. Securely tie strap the capped off coolant flow switch breakout to the main body of the engine wiring harness.

Image1.6.1

7. Engine software update

Important: Prior to flashing the software, go to the logged Events screen in Cat ET and clear all logged events on BOTH SLAVE ECMs.

Both Master and Slave ECMs will need to be updated with new software. Use the WinFlash utility of Cat ET to install the following software. Both slave ECMs are programmed with the same software:
a. Master ECM: flash appropriate software
b. Slave ECMs: flash appropriate software

NOTE: Cat ET 2010C or later is required for this update.

8. VIMS Software Update
Use the WinFlash Utility of CAT ET to update the software on the VIMS unit.

NOTE: After VIMS software update the payload may need to be calibrated.

9. After installing the software, activate the Coolant Pressure Sensing feature of the Master ECM. Go to the configuration screen and configure it to 'Installed'.

IMPORTANT: ONCE THE COOLANT PRESSURE SENSOR HAS BEEN SET TO INSTALLED, THE TRUCK MUST BE KEYED OFF FOR 10 SECONDS AND THEN BACK ON BEFORE IT WILL WORK PROPERLY.