PRODUCT IMPROVEMENT PROGRAM FOR REFLASHING ENGINE SOFTWARE ON CERTAIN 924G, 928G, 930G WHEEL LOADERS, IT28G INTEGRATED TOOL CARRIERS, TH220B, TH330B, TH340B, TH350B, TH355B, TH360B, TH460B, TH560B, TH580B TELEHANDLERS, M313C, M315C, M316C, M318C, M32 Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REFLASHING ENGINE SOFTWARE ON CERTAIN 924G, 928G, 930G WHEEL LOADERS, IT28G INTEGRATED TOOL CARRIERS, TH220B, TH330B, TH340B, TH350B, TH355B, TH360B, TH460B, TH560B, TH580B TELEHANDLERS, M313C, M315C, M316C, M318C, M32

Usage:

SEBE9201-03

May 31, 2005
(Revised September 2005)
U-175
A-133
D-144
O-149

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REFLASHING ENGINE SOFTWARE ON CERTAIN 924G, 928G, 930G WHEEL LOADERS, IT28G INTEGRATED TOOL CARRIERS, TH220B, TH330B, TH340B, TH350B, TH355B, TH360B, TH460B, TH560B, TH580B TELEHANDLERS, M313C, M315C, M316C, M318C, M322C WHEELED EXCAVATORS, 315C EXCAVATOR, AP-655C ASPHALT PAVERS, CP-563E, CP-573E, CP-663E, CS-563E, CS-573E, CS-583E, CS-663E, AND CS-683E COMPACTORS
7620		PI10388

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI10388" 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 "PI10388" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

NOTE: This Revised Service Letter replaces the (Revised July 2005) Service Letter. Changes have been made to the Title, Affected Product, Customer Notification Letter, and Rework Procedure.

PROBLEM

A potential fault within the 221-1018 Engine Control Module, which manages many of the key operating functions of engine may occur. The occurrence of this fault could result in loss of engine speed control (throttle response) and the inability to switch the engine off via the normal key switch shut down process and may possibly cause serious injury or death.

AFFECTED PRODUCT

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924G	RBB465-473, 475-485, 487-490, 492-518, 520-529, 531-572, 576, 578-585, 587-597, 599-616, 618-622, 624, 635, 637-663, 665-677, 679-683, 686-695, 697, 698, 703, 705 RTA177, 178, 180, 181, 185-238, 240, 242-262, 285-296, 298-301, 305-314 WGX515, 517-519, 521-527, 530-534, 537-541, 543-546, 548-579, 581, 582, 623-627, 629, 630, 632-640, 642, 647-663, 665, 666, 669-673, 675-691, 693-700, 705-708, 710, 713, 778 WMB507, 546-548, 551, 553, 554, 557-567, 569, 572-606, 610, 611, 643-645, 647-649, 651-657, 659-678, 680-708, 710-712, 714, 718-720, 723-727, 729, 731, 732, 737 DDA915-917, 922, 956, 985, 988, 989, 991, 996, 998, 1001, 1009, 1012-1018, 1021-1181, 1183-1191, 1193-1214, 1216-1224, 1226-1237, 1239-1321, 1323-1558, 1560-1579, 1581, 1582, 1584, 1586-1591, 1593-1623, 1628, 1630, 1634-1636, 1641, 1642, 1650, 1653-1656, 1660, 1661, 1663, 1665, 1763 DFZ520, 522, 533, 539, 544-557, 559-563
928G	WLG449, 450, 453-461, 463, 464, 468-473, 475-491, 493-514, 516-522, 569-571, 574-579, 585-592, 594-616, 623-628, 630-638, 640-645 DJD911, 916-918, 923, 924, 928, 929, 931, 939, 946, 949, 952-954, 967, 969, 976, 978-1013, 1015-1029, 1031-1179, 1181-1386, 1388-1411, 1425-1479, 1481-1513, 1515-1522, 1755
930G	TWR233, 234, 235, 236, 237
IT28G	WAC406, 410-414, 417-423, 428-459, 461, 462, 483-486, 488-490, 492-517, 520, 521, 524, 547, 548 DBT1012, 1017, 1018, 1021, 1025, 1026, 1030, 1044, 1047, 1053, 1066, 1069, 1071, 1073, 1075-1110, 1112-1124, 1126-1144, 1146-1179, 1181-1489, 1491-1493, 1495-1498, 1500-1509, 1518, 1521-1523, 1525-1658 EWF244-246, 252, 257, 259-262, 264-289, 293-352, 354
TH220B	SLA389, 393, 394, 396, 398, 421, 433, 469, 470, 504, 518, 520, 526, 533, 542, 551
TH330B	SLB362, 376, 387, 399, 407, 422, 432, 434, 438, 449, 477, 478, 486, 491, 496, 498, 499, 501, 503, 520, 528, 533, 575, 594, 608, 647, 648, 699, 712, 721, 796, 814, 816, 835, 848, 851, 854, 871, 888, 890, 930
TH340B	SLC269, 281, 286, 287, 298, 308, 309, 335, 341
TH350B	SLD602, 603, 611, 619, 625, 629, 630, 654, 664, 677, 707
TH355B	JRK127, 139-141, 143, 144, 146-148, 150, 151, 165, 453, 462, 464, 469, 478, 489-491
TH360B	SLE1353, 1361, 1364, 1372, 1379, 1381-1383, 1385, 1386, 1395, 1396, 1411, 1414, 1416, 1424, 1425, 1436, 1451, 1456, 1458, 1486, 1514, 1524, 1537, 1634, 1642, 1647, 1687, 1718, 1719, 1728, 1797, 1808, 1809, 1815, 1816, 1819-1822, 1825, 1844, 1847, 3009, 3031, 3042, 3125, 3126, 3131, 3140, 3147, 3156, 3170, 3172, 3179, 3188, 3189, 3197, 3363
TH460B	SLF915-917, 925, 940, 943, 945, 954-956, 965, 982, 985, 998, 1007, 1067, 1071, 1075, 1095, 1104, 1118, 1126, 1130, 1136, 1138, 1148, 1163, 1177, 1178, 1214, 1217, 1224, 1228, 1234, 1238, 1253, 1254, 1258, 1265, 1312
TH560B	SLG470, 472, 485, 488, 490, 491, 520, 526, 529, 539, 557, 569, 579, 603, 632, 636, 644, 656, 660, 683, 686, 690, 739, 724, 749, 757, 775, 777 SLH255, 258, 281, 286, 304, 305, 309
M313C	BDR458, 493, 499, 503-505, 509, 513, 525, 530, 567, 574, 577, 581, 599, 600, 604, 620, 624, 625, 629, 632, 667, 691, 701, 703, 710, 714-716, 721, 722
M315C	BDM579, 581, 586, 589, 591, 594, 596-600, 602, 603, 606, 623, 629, 630, 634, 650, 656, 659, 667, 694, 702, 704, 746, 765, 767, 772-774, 777, 780, 781, 784-789, 798-803, 812, 817, 853
M316C	BDX616-618, 621, 627, 629-739, 741-826, 829-831, 833, 851-892, 894-899, 901-920, 926, 929, 938, 616-618, 621, 627, 629-739, 741-826, 829-831, 833, 851-892, 894-899, 901-920, 926, 929, 938, 2001
M318C	BCZ673, 674, 679-682, 687-722, 724-944, 947, 949, 951-953, 960-1026, 1028-1043, 1045-1048, 1054-1056, 1060, 2001, 2002, 2003, 2037 BEB223-227, 229-270
M322C	BDK305, 309-407, 413-416, 420-425, 427, 429-442, 444, 452, 2001 BDY314, 315, 318-347, 349-366, 368-382, 2001
315C	ANF346, 353, 357, 359, 364, 365, 367, 368, 371, 380, 399, 410, 411, 444, 453, 455, 456, 458
AP-655C	AYP200-203, 205-209, 211, 213-219, 228, 231, 235 CDG300, 301, 307, 309, 311-315, 318-331, 333-339, 341,342
CP-563E	CNT343, 402, 413, 424, 428, 430, 432-440, 442-458, 460, 462, 463, 465-468, 470-490, 492-542, 544-551, 553-563, 565-580, 582-607, 609-633, 636, 639-641, 643, 645-656, 662, 663, 668-671, 673-691, 695, 722, 757 BWE237-249, 251-258, 263, 269, 276, 283, 286
CP-573E	ASY108, 109, 110, 111 ASZ202-205
CP-663E	ASF204, 206, 207 DAF208-218
CS-563E	CNG455, 457, 479, 502, 505, 506, 508-511, 513, 515, 517-638, 640-693, 695-720, 722-778, 782-792, 794-796, 798, 800-802, 809-811, 813, 815, 817, 821-829, 831, 833-836, 838-843, 849, 852, 853, 859, 861-893, 897, 900, 902, 904, 906, 910, 915, 918, 926-928, 932, 933, 935, 939, 965, 966, 992, 994,1004 ASA420-422, 424-429, 431, 435-446, 448-478, 480-555, 557-609, 612, 614, 615, 617-626, 670, 679, 686, 693, 695, 731
CS-573E	CNN206-218, 220, 223, 224 CEB201-210
CS-583E	CNX311-321, 323-328, 330, 331 DAJ313, 357-390, 392-395, 397-402, 414, 431
CS-663E	ASB101-104, 106-112 DAG363, 365-370, 372-416, 420, 431
CS-683E	ASG303-309, 312 DAD329, 331-340, 342-361

PARTS NEEDED

See the cross-reference of the machine model number against the new flash file part number.

ACTION REQUIRED

See rework procedure

OWNER NOTIFICATION

U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
100%	.75	0	0	0	0
NOTE: This is a .75 hour job. NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report

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.

Attach. (1-Owner Notification)
(2-Rework Procedure)

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REFLASHING ENGINE SOFTWARE

MODELS INVOLVED - CERTAIN 924G, 928G, 930G WHEEL LOADERS, IT28G INTEGRATED TOOL CARRIERS, TH220B, TH330B, TH340B, TH350B, TH355B, TH360B, TH460B, TH560B, TH580B TELEHANDLERS, M313C, M315C, M316C, M318C, M322C WHEELED EXCAVATORS, 315C EXCAVATOR, AP-655C ASPHALT PAVERS, CP-563E, CP-573E, CP-663E, CS-563E, CS-573E, CS-583E, CS-663E, AND CS-683E COMPACTORS

Dear Caterpillar Product Owner:

A potential fault within the Engine Control Module (ECM), which manages many of the key operating functions of engine, may occur on the above machine. The occurrence of this fault could result in loss of engine speed control (throttle response) and the inability to switch the engine off via the normal key switch shut down process and may possibly cause serious injury or death. New software needs to be installed in the engine ECM. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated May 31, 2005 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to May 31, 2005 Service Letter

Rework Procedure

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Model	Engine Arrangement	Identification Number	New Flash File
924G	206-2744	RBB465-473, 475-485, 487-490, 492-518, 520-529, 531-572, 576, 578-585, 587-597, 599-616, 618-622, 624, 635, 637-663, 665-677, 679-683, 686-695, 697, 698, 703, 705	260330400
	206-2744	RTA177, 178, 180, 181, 185-238, 240, 242-262, 285-296, 298-301, 305-314	260330400
	206-2744	WGX00515, 517-519, 521-527, 530-534, 537-541, 543-546, 548-579, 581, 582, 623-627, 629, 630, 632-640, 642, 647-663, 665, 666, 669-673, 675-691, 693-700, 705-708, 710, 713, 778	260330400
	179-1796	WMB507, 546-548, 551, 553, 554, 557-567, 569, 572-606, 610, 611, 643-645, 647-649, 651-657, 659-678, 680-708, 710-712, 714, 718-720, 723-727, 729, 731, 732, 737	260330400
	179-1796	DDA00915-917, 922, 956, 985, 988, 989, 991, 996, 998, 1001, 1009, 1012-1018, 1021-1181, 1183-1191, 1193-1214, 1216-1224, 1226-1237, 1239-1321, 1323-1558, 1560-1579, 1581, 1582, 1584, 1586-1591, 1593-1623, 1628, 1630, 1634-1636, 1641, 1642, 1650, 1653-1656, 1660, 1661, 1663, 1665, 1763	260330400
	179-1769	DFZ00520, 522, 533, 539, 544-557, 559-563	260330400
928G	179-1797	WLG00449, 450, 453-461, 463, 464, 468-473, 475-491, 493-514, 516-522, 569-571, 574-579, 585-592, 594-616, 623-628, 630-638, 640-645	260330500
928G	179-1797	DJD00911, 916-918, 923, 924, 928, 929, 931, 939, 946, 949, 952-954, 967, 969, 976, 978-1013, 1015-1029, 1031-1179, 1181-1386, 1388-1411, 1425-1479, 1481-1513, 1515-1522, 1755	260330500
930G	179-1797	TWR00233, 234, 235, 236, 237	260330500
IT28G	179-1797	WAC00406, 410-414, 417-423, 428-459, 461, 462, 483-486, 488-490, 492-517, 520, 521, 524, 547, 548	260330500
	179-1797	DBT01012, 1017, 1018, 1021, 1025, 1026, 1030, 1044, 1047, 1053, 1066, 1069, 1071, 1073, 1075-1110, 1112-1124, 1126-1144, 1146-1179, 1181-1489, 1491-1493, 1495-1498, 1500-1509, 1518, 1521-1523, 1525-1658	260330500
	234-3543	EWF00244-246, 252, 257, 259-262, 264-289, 293-352, 354	260330700
TH220B	194-9477	SLA00389, 393, 394, 396, 398, 421, 433, 469, 470, 504, 518, 520, 526, 533, 542, 551	260330300
TH330B	194-9477	SLB00362, 376, 387, 399, 407, 422, 432, 434, 438, 449, 477, 478, 486, 491, 496, 498, 499, 501, 503, 520, 528, 533, 575, 594, 608, 647, 648, 699, 712, 721, 796, 814, 816, 835, 848, 851, 854, 871, 888, 890, 930	260330300
TH340B	176-3180	SLC00269, 281, 286, 287, 298, 308, 309, 335, 341	260330200
TH350B	176-3180	SLD00602, 603, 611, 619, 625, 629, 630, 654, 664, 677, 707	260330200
TH355B	176-3180	JRK00127, 139-141, 143, 144, 146-148, 150, 151, 165, 453, 462, 464, 469, 478, 489-491	260330200
TH360B	176-3180	SLE01353, 1361, 1364, 1372, 1379, 1381-1383, 1385, 1386, 1395, 1396, 1411, 1414, 1416, 1424, 1425, 1436, 1451, 1456, 1458, 1486, 1514, 1524, 1537, 1634, 1642, 1647, 1687, 1718, 1719, 1728, 1797, 1808, 1809, 1815, 1816, 1819-1822, 1825, 1844, 1847, 3009, 3031, 3042, 3125, 3126, 3131, 3140, 3147, 3156, 3170, 3172, 3179, 3188, 3189, 3197, 3363	260330200
TH460B	176-3180	SLF00915-917, 925, 940, 943, 945, 954-956, 965, 982, 985, 998, 1007, 1067, 1071, 1075, 1095, 1104, 1118, 1126, 1130, 1136, 1138, 1148, 1163, 1177, 1178, 1214, 1217, 1224, 1228, 1234, 1238, 1253, 1254, 1258, 1265, 1312	260330200
TH560B	194-9477	SLG00470, 472, 485, 490, 491, 520, 526, 529, 539, 557, 569, 579, 603, 636, 644, 656, 660, 683, 686, 690, 739, 749, 757, 775, 777	260330300
	176-3180	SLG00488, 632, 724	260330200
	194-9477	SLH00255, 258, 286, 304, 305, 309	260330300
	176-3180	SLH00281	260330200
M313C	188-5099	BDR00458, 493, 499, 503-505, 509, 513, 525, 530, 567, 574, 577, 581, 599, 600, 604, 620, 624, 625, 629, 632, 667, 691, 701, 703, 710, 714-716, 721, 722	260331100
M315C	188-5100	BDM00579, 581, 586, 589, 591, 594, 596-600, 602, 603, 606, 623, 629, 630, 634, 650, 656, 659, 667, 694, 702, 704, 746, 765, 767, 772-774, 777, 780, 781, 784-789, 798-803, 812, 817, 853	260331100
M316C	188-5097	BDX00616-618, 621, 627, 629-739, 741-826, 829-831, 833, 851-892, 894-899, 901-920, 926, 929, 938, 616-618, 621, 627, 629-739, 741-826, 829-831, 833, 851-892, 894-899, 901-920, 926, 929, 938, 2001	260331000
M318C	188-5096	BCZ00673, 674, 679-682, 687-722, 724-944, 947, 949, 951-953, 960-1026, 1028-1043, 1045-1048, 1054-1056, 1060, 2001, 2002, 2003, 2037	260331000
M318C	188-5096	BEB00223-227, 229-270	260331000
M322C	188-5098	BDK00305, 309-407, 413-416, 420-425, 427, 429-442, 444, 452, 2001	260331000
M322C	188-5098	BDY00314, 315, 318-347, 349-366, 368-382, 2001	260331000
315C	176-3172	ANF346, 353, 357, 359, 364, 365, 367, 368, 371, 380, 399, 410, 411, 444, 453, 455, 456, 458	260331600
AP-655C	176-3155	AYP00200-203, 205-209, 211, 213-219, 228, 231, 235	260326800
AP-655C	176-3155	CDG00300, 301, 307, 309, 311-315, 318-331, 333-339, 341,342	260326800
CP-563E	176-3165	CNT00343, 402, 413, 424, 428, 430, 432-440, 442-458, 460, 462, 463, 465-468, 470-490, 492-542, 544-551, 553-563, 565-580, 582-607, 609-633, 636, 639-641, 643, 645-656, 662, 663, 668-671, 673-691, 695, 722, 757	260330800
CP-563E	176-3165	BWE00237-249, 251-258, 263, 269, 276, 283, 286	260330800
CP-573E	176-3165	ASY00108, 109, 110, 111	260330800
CP-573E	176-3165	ASZ00202-205	260330800
CP-663E	176-3166	ASF00204, 206, 207	260330900
CP-663E	176-3166	DAF00208-218	260330900
CS-563E	176-3165	CNG00455, 457, 479, 502, 505, 506, 508-511, 513, 515, 517-638, 640-693, 695-720, 722-778, 782-792, 794-796, 798, 800-802, 809-811, 813, 815, 817, 821-829, 831, 833-836, 838-843, 849, 852, 853, 859, 861-893, 897, 900, 902, 904, 906, 910, 915, 918, 926-928, 932, 933, 935, 939, 965, 966, 992, 994,1004	260330800
CS-563E	176-3165	ASA00420-422, 424-429, 431, 435-446, 448-478, 480-555, 557-609, 612, 614, 615, 617-626, 670, 679, 686, 693, 695, 731	260330800
CS-573E	176-3165	CNN00206-218, 220, 223, 224	260330800
CS-573E	176-3165	CEB00201-210	260330800
CS-583E	176-3165	CNX00311-321, 323-328, 330, 331	260330800
CS-583E	176-3165	DAJ00313, 357-390, 392-395, 397-402, 414, 431	260330800
CS-663E	176-3166	ASB00101-104, 106-112	260330900
CS-663E	176-3166	DAG00363, 365-370, 372-416, 420, 431	260330900
CS-683E	176-3166	ASG00303-309, 312	260330900
CS-683E	176-3166	DAD00329, 331-340, 342-361	260330900

Download Flash File

Log onto SIS web

Select from Additional Service Information "Engine Technical Marketing Information ? TMI Web" as shown in Fig 1

Illustration 1

After slecting "Engine Technical Marketing Information ? TMI Web" you will see the following screen see Fig 2
Enter your full machine number into the "Reference Number" field.

Illustration 2

Select from field shown in Figure 3 second field "Serial Number" as shown

Select "Retrieve Data"

Illustration 3

You should have the following screen shown in Figure 4
From this screen select Flash File as shown in figure 4

Illustration 4

You should see the following screen Fig 5 from this screen select flash file highlighted in blue to download

10. Follow on screen instructions to download flash file

NOTE: This should be the only file you can access

Illustration 5

Flash file Programming Electronic Control Module

Connect Cat ET to the service tool connector.

Select "WinFlash" from the "Utilities" menu on Cat ET.

"WinFlash" will try to detect an ECM.
When an ECM has been detected, the "ECM Selector" window will appear. Select the appropriate ECM that needs to be flashed and press "OK".

The "Flash File Selection" window will appear.
When the window "Flash File Selection" appears locate flash files, which you previously downloaded from TMI.

A list of flash files will appear.
Select the correct file from the list of flash files. Read the "File Info" and the "Description" in order to verify that the correct file is selected. Select "OK".
Select the "Begin Flash" button in order to program the personality module.

When the flash is completed, this message will appear: "Flash Completed Successfully".
Key off the ignition for 30 seconds to reset all parameters on the ECM
Start the engine and check for proper operation.

"WinFlash" Error Messages If you receive any error messages during flash programming, click on the "Cancel" button in order to stop the process. Access the information about the "ECM Summary" under the "Information" menu. Make sure that you are flashing the correct file for your engine.