PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING NEW SOFTWARE ON CERTAIN 3516B, PM3516B, AND GS3516B ELECTRIC POWER ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING NEW SOFTWARE ON CERTAIN 3516B, PM3516B, AND GS3516B ELECTRIC POWER ENGINES

Usage:

SEBE8528-01

October 5, 2003
(Revised November 2003)
U-272
A-192
D-201
O-231

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING NEW SOFTWARE ON CERTAIN 3516B, PM3516B, AND GS3516B ELECTRIC POWER ENGINES
1064 7620		PI30566

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30566" 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 "PI30566" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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.

NOTE: This Revised Service Letter replaces the October 5, 2003 Service Letter. Changes have been made to the Affected Product, Action Required, and added Table 1.

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COMPLETION DATE	TERMINATION DATE
April 30, 2004	October 31, 2004

PROBLEM

New software needs to be installed on certain 3516B, PM3516B, and GS3516B electric power engines. Under certain operating conditions a fuel leak may develop and result in low fuel pressure. This new software will shut down the engine when low fuel pressure is diagnosed.

AFFECTED PRODUCT

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Model	Identification Number
* Group 1 *
3516B	7RN1333-1335, 1337, 1339, 1342, 1343, 1345, 1360, 1510, 1511, 1515, 1843, 1862, 1864, 1868, 1869, 1874, 1938, 1939
G3516B	FDN223, 231, 240, 243, 258, 322-324, 332, 468, 469, 491, 522, 557, 659, 660, 661, 662, 746, 747, 807, 856, 891, 920, 936-938, 945, 946, 961
* Group 2 *
3516B	7RN1030-1034, 1038, 1039, 1043-1045, 1075, 1077, 1090, 1106, 1108, 1109, 1112, 1162-1164, 1168, 1170, 1175, 1185, 1193, 1196, 1204, 1206, 1218, 1230, 1232, 1247, 1254, 1265, 1266, 1276, 1277, 1281, 1283, 1285, 1289, 1291, 1292, 1294, 1297, 1302-1305, 1308, 1312-1314, 1318, 1321, 1324, 1326, 1330, 1332, 1349, 1354, 1355, 1363, 1364, 1367, 1372, 1375, 1378, 1381, 1382,1401, 1404, 1409, 1410, 1412, 1436-1438, 1462, 1464, 1471, 1475, 1477, 1479, 1484, 1487, 1489, 1492, 1525, 1526, 1529, 1555, 1556, 1559, 1561, 1563, 1564, 1568, 1577, 1578, 1581, 1590-1592, 1602, 1607, 1608, 1611-1613, 1615, 1616, 1627, 1632, 1633, 1635, 1650, 1673, 1680, 1682, 1685, 1700, 1701, 1726, 1727, 1729, 1730, 1735, 1737, 1749, 1766, 1775, 1819, 1822, 1823, 1826, 1829-1833, 1836, 1844, 1856, 1859, 1860, 1867, 1871-1873, 1875, 1880, 1882, 1883, 1885, 1888, 1916-1923, 1935, 1937, 1941
GS3516B	FDN115, 116, 119, 120, 122, 124, 141, 144, 145, 147, 149-153, 169-172, 175, 177-180, 198, 199, 208, 213-215, 217, 220-222, 226-229, 233, 235-237, 241, 242, 245, 248, 253-256, 327, 334, 341, 352, 353, 363, 367, 382, 387, 388, 398, 404, 425, 454, 455, 465, 471, 472, 480, 482, 487, 488, 492-498, 503, 504, 506, 509-12, 515, 520, 521, 523, 534, 544, 545, 553, 570-573, 576, 579, 582, 597, 598, 626-628, 639, 654-656, 658, 666-668, 672-677, 681, 682, 694-696, 705, 714-723, 728-731, 733, 734, 754, 768, 784-787, 795-798, 805, 806, 808-810, 814-817, 823-825, 831-833, 837-839, 842-844, 847-852, 854, 855, 858-869, 874-877, 880, 881, 885, 887-890, 892-895, 908-911, 917, 918, 922-927, 932, 934, 940-942, 956, 966-968, 976
* Group 3 *
3516B	7RN1092-1097, 1099-1105, 1107, 1110, 1114, 1115, 1117, 1124, 1128, 1130, 1131, 1135, 1137, 1139, 1141, 1148, 1150, 1151, 1169, 1171, 1173, 1182, 1183, 1187, 1192, 1195, 1201-1203, 1205, 1209, 1210-1212, 1214, 1215, 1217, 1220-1224, 1226-1229, 1234-1236, 1239-1241, 1243-1246, 1248-1252, 1258, 1278, 1280, 1282, 1284, 1286-1288, 1290, 1293, 1298, 1299, 1306, 1307, 1310, 1311, 1315-1317, 1319, 1320, 1322, 1323, 1325, 1327-1329, 1331, 1353, 1361, 1402, 1411, 1413-1415, 1417-1424, 1426, 1429, 1432, 1434, 1435, 1439, 1445, 1447, 1449-1451, 1454, 1455, 1458, 1459, 1468, 1474, 1476, 1499, 1505, 1514, 1520, 1522-1524, 1527, 1541, 1554, 1557, 1558, 1562, 1565-1567, 1569, 1570, 1572, 1573, 1575, 1576, 1579, 1580, 1582-1589, 1593-1599, 1601, 1603, 1604, 1606, 1628, 1630, 1634, 1636, 1637, 1641, 1646, 1647, 1651, 1654, 1656, 1659-1661, 1676, 1677, 1687-1689, 1693-1696, 1702, 1703, 1706-1713, 1716-1718, 1720, 1723, 1731-1734, 1736, 1738-1740, 1742, 1743, 1752, 1755, 1756, 1765, 1774, 1776, 1779, 1802, 1828, 1834, 1837, 1839, 1845, 1847-1853, 1855, 1892, 1897, 1898, 1900, 1902, 1904-1907, 1934, 1936
PM3516B	BPD149, 150, 151, 155-158, 165, 167, 171, 172, 176, 178, 181-184, 186-190, 193-195, 198, 217-219, 222, 229, 232, 235, 236, 238-254, 258, 260, 263, 265-274, 282-290, 293, 305-307, 311-314, 327, 333, 334, 336, 338, 339, 341-343, 345, 346, 349, 354, 357-362, 364, 385, 388, 391, 395, 397, 403, 406, 410, 407, 413, 414, 417, 418, 420, 422, 423, 425, 428, 429, 432, 433, 435, 441, 444, 447, 448, 450, 452, 454-456, 460, 462, 468, 469, 472, 478-484, 486-488, 491-493, 499, 503-507, 514, 522, 524, 527-531, 533, 536, 541, 544, 545, 548, 550, 551, 553, 556-558, 560, 562, 563, 567, 568, 571-575, 578-581, 584, 586, 587, 589, 593-596, 600, 602-605, 608, 615, 625, 628, 631-634, 637-641, 643, 647, 649, 651, 653, 654, 656, 657, 661, 667, 673, 675, 681, 693, 700, 713, 741, 771, 772, 777, 811, 823, 844, 934, 948, 951, 956, 961, 963, 967, 968, 970, 971, 973-978, 983-985, 987, 989-992, 998, 1001, 1009-1013, 1015, 1018, 1020, 1052
GS3516B	FDN126-130, 181-194, 209, 224, 225, 230, 232, 234, 238, 239, 252, 259, 260, 264, 271, 278, 326, 400-403, 433, 441, 445-447, 467, 473-475, 536, 629, 635-638, 649, 657, 663, 664, 704, 739-741, 743-745, 761, 766, 767, 770, 846, 884, 896, 913-915, 928-931, 953-955, 960, 962, 969-972, 977, 980-984, 986
* Group 4 *
3516B	7RN1052-1054, 1057, 1062, 1063, 1080, 1084, 1086, 1088, 1098, 1113, 1138, 1142, 1255-1257, 1262, 1263, 1279, 1338, 1340, 1341, 1344, 1346, 1347, 1359, 1425, 1427, 1430, 1446, 1448, 1491, 1494, 1495, 1497, 1498, 1500, 1501, 1503, 1506, 1507, 1528, 1536, 1539, 1540, 1551, 1560, 1574, 1684, 1741, 1747, 1748, 1771, 1772, 1788, 1789, 1814-1816, 1820, 1835, 1881, 1884, 1890, 1891, 1896, 1899, 1908, 1930-1933, 1940, 1942
PM3516B	BPD845, 874, 950, 960, 995
GS3516B	FDN195, 211, 457, 470, 476-479, 490, 513, 514, 516-519, 524-527, 529, 563-568, 601, 602, 630-634, 640-647, 678-680, 683-693, 697-700, 769, 771-774, 776-783, 790-794, 802-804, 845, 882, 883, 916, 921, 948
* Group 5 *
3516B	7RN1026, 1028, 1049, 1068, 1071, 1072, 1074, 1081-1083, 1085, 1087, 1160, 1165, 1172, 1174, 1176-1179, 1184, 1186, 1295, 1296, 1300, 1309, 1356, 1369-1371, 1373, 1376, 1377, 1379, 1380, 1383, 1408, 1444, 1461, 1466, 1469, 1481, 1485, 1486, 1493, 1552, 1639, 1640, 1643, 1665, 1667, 1719, 1759-1763, 1767, 1768, 1777, 1778, 1780-1784, 1786, 1787, 1790, 1794-1796, 1799, 1800, 1803-1812, 1817, 1818, 1824, 1825, 1827, 1854, 1858, 1865, 1876-1878, 1889, 1893-1895, 1901, 1913
PM3516B	BPD936, 939-944
GS3516B	FDN111-114, 117, 118, 121, 123, 125, 131-133, 136, 138-140, 146, 148, 154-162, 164, 176, 196, 197, 200-206, 210, 216, 218, 219, 257, 261-263, 325, 389-391, 399, 449-453, 485, 486, 546-552, 554, 558-562, 569, 574, 575, 584, 585, 589, 599, 650-653, 702, 703, 706, 732, 762, 788, 789, 799, 800, 812, 826, 834-836, 840, 841, 870-873, 879, 886, 899, 900, 904-907, 912, 933, 939, 943, 944, 950-953, 973-975, 979
* Group 6 *
3516B	7RN1336, 1813, 1821, 1846, 1866, 1870, 1909-1912, 1914, 1915
GS3516B	FDN507, 508, 537, 541, 583, 588, 593, 600

PARTS NEEDED

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Qty	Part Number	Description
* Group 1 *
1	2425347	SOFTWARE
* Group 2 *
1	2425348	SOFTWARE
* Group 3 *
1	2425349	SOFTWARE
* Group 4 *
1	2425350	SOFTWARE
* Group 5 *
1	2425351	SOFTWARE
* Group 6 *
1	2425353	SOFTWARE

ACTION REQUIRED

Turn off all supply power, prevent the engine from starting and lock out the equipment before working on or inside the equipment. Only qualified personnel should service this equipment. Replace all devices, doors and covers before turning power on to this equipment. Restore all power when complete. Observe and follow all safety procedures as described in Caterpillar Inc. manuals.
Find the five digit Julian Date Code that is located on the side of the aftercooler housing below the CAT part number. See Illustration 1. Record the aftercooler core assembly Julian date code in Table 1.

Illustration 1

Power up the engine ECM.
Connect the service tool to the engine.
Check event and active diagnostic codes.
Troubleshoot and correct any open diagnostics as appropriate.
Download the following histogram data:

Load vs Time

Right Exhaust Temp. vs Time

Left Exhaust Temp vs Time

Replace previous software with appropriate new file.
Complete the attached Table 1 and E-mail histogram data and Table 1 to Craig Perez, or print the data and Table 1 and FAX to (765)448-5013 Attention: Craig Perez.

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%	2.0	0	0	0	0
NOTE: This is a 2.0-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-Table 1)

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING NEW SOFTWARE

MODELS INVOLVED - CERTAIN 3516B, PM3516B, AND GS3516B ELECTRIC POWER ENGINES

Dear Caterpillar Product Owner:

New software needs to be installed on the products listed below. Under certain operating conditions a fuel leak may develop and result in low fuel pressure. This new software will shut down the engine when low fuel pressure is diagnosed. 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 October 5, 2003 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to October 5, 2003 Service Letter