PRODUCT SUPPORT PROGRAM FOR UPDATING THE ENGINE SOFTWARE AND ADDING A INTAKE MANIFOLD ABSOLUTE PRESSURE (IMAP) SENSOR TO THE RIGHT HAND INTAKE MANIFOLD ON CERTAIN 773G, 775G, AND 777G OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR UPDATING THE ENGINE SOFTWARE AND ADDING A INTAKE MANIFOLD ABSOLUTE PRESSURE (IMAP) SENSOR TO THE RIGHT HAND INTAKE MANIFOLD ON CERTAIN 773G, 775G, AND 777G OFF-HIGHWAY TRUCKS

Usage:

TEBE0628-03

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25Nov2013

(Revised 11Jun2014)

U-580

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR UPDATING THE ENGINE SOFTWARE AND ADDING A INTAKE MANIFOLD ABSOLUTE PRESSURE (IMAP) SENSOR TO THE RIGHT HAND INTAKE MANIFOLD ON CERTAIN 773G, 775G, AND 777G OFF-HIGHWAY TRUCKS
7490		PS44095

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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 "PS44095" 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 25Nov2013 (Revised 20Dec2013) Service Letter. Changes have been made to Affected Product, Parts Needed, Action Required, and Rework Procedure.

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TERMINATION DATE

30Nov2015

PROBLEM

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Certain 773G, 775G, and 777G Off-Highway Trucks that are operating with 423-7736, 423-6575, and 423-8717 Engine Software or earlier versions may experience slobber and icing within the air intake during extended idle times, while in extreme cold climate.

AFFECTED PRODUCT

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Model	Identification Number
773G	JWS00162-00248
773G OEM	T5T00101-00103
775G	MJS00273-00397
775G OEM	T5F00101-00102
777G	RDR00102-00296
777G OEM	T5A00100-00117

PARTS NEEDED

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Qty	Part Number	Description
5	7K1181	STRAP-CABLE
1	2287101	SEAL-O-RING-STOR
1	3203061	SENSOR GP-PRESS
1	4460464	HARNESS AS-WRG
1	4582978	ENGINE SOFTWARE (773G)
1	4583398	ENGINE SOFTWARE (775G)
1	4583399	ENGINE SOFTWARE (777G)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% 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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The engine software needs to be updated and a new sensor installed on
certain 773G, 775G, and 777G Off-Highway Trucks.

773G replace 423-7736 Software or earlier versions with 458-2978
775G replace 423-6575 Software or earlier versions with 458-3398
777G replace 423-8717 Software or earlier versions with 458-3399

Note: Perform the attached rework procedure prior to installing the new software.

The new engine software employs three strategies to protect the truck if icing occurs in the intake in extreme cold weather conditions: CAC-Out Temperature Protection (COTP), Arctic Cold Mode (ACM), and Cold Weather Shutdown. The CAC-Out Temperature Protection (COTP) uses a strategy of increasing the engine speed for five minutes increments to try to achieve a desired intake manifold absolute temperature. If after running at engine speeds of 1600 RPM, 1600 RPM, 1800 RPM, and 2000 RPM for five minutes each and the desired intake manifold absolute temperature is not achieved, the software will go into Arctic Cold Mode (ACM). Arctic Cold Mode (ACM) cuts off the fuel to the front six cylinders so the engine will only run on the rear six cylinders. This will aid in preventing accumulation of water vapor in the intake since Exhaust Gas Recirculation (EGR) is generated from the front six cylinders and brings in water vapor. If icing continues in the intake, the new software will go into Cold Weather Shutdown which will automatically shut the truck down.

Note: Automatic shutdown due to new software will only occur when the machine transmission control is in the park position.

This will be identified by :
Event Code:
1045-3, Engine Intake Manifold Pressure Low.
Fault Annunciations within Cab: "Low Intake Manifold Pressure".

NOTE:
When shut down has occurred cycling key switch will clear the event, event will be logged in history.

The following restart procedure will need to be performed when code is
present and the machine has been shut down for greater than 30 minutes.
1) Inspect the mixing manifold for ice accumulation:
a. inspect with a bore scope through the ether port
b. remove the ATAAC hump hose for inspection
2) If ice is present remove ice by:
a. removing manifold to dislodge ice
b. Bring ambient temp of engine/manifold above freezing point to allow
ice obstruction to melt
3) Ensure free rotation of engine by either:
a. manually rotating engine 360 degrees
b. bore scope all cylinders to ensure no water and or ice is present,
that would create hydro-lock condition
4) If engine will not rotate 360 degrees or ice/water has been
identified:
a. If ice is present, ambient engine temperature will need to be
brought above freezing point to allow ice to dissipate. If water is
present and or ice has melted refer to Troubleshooting, C27 and C32
Engines for Caterpillar Built Machines, "Hydraulic Cylinder Lock" to address hydraulic cylinder lock conditions.
5) Refer to machine's Operation and Maintenance Manual for proper starting procedure
6) If water is present in oil refer to C27 and C32 Troubleshooting
publications.

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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%
0-15000 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 3.0-hour job

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PARTS DISPOSITION

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

Rework Procedure

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1) Gain access to front left corner of engine. Sufficient room will be required to run 446-0464 Harness As. from ECM to right hand side air plenum.

Image1.1.1

2) Gain access to front right corner of engine. Note: Arrow denoted in Image 1.2.2 is location of the plug to be removed. Image 1.2.2 is a 777G engine, plug is located in same area for the 773G/775G.

Image1.2.1

Image1.2.2

3) For 773Gs and 775Gs only, additional clearance may be required to achieve access to intake manifold. If required, perform the following to gain additional clearance:

1 - Remove air intake tube and elbow.
2 - Remove bracket and fasteners for oil guide at oil filter head.
3 - Remove fasteners for oil filter assembly, allowing assembly to be rotated out of the way and secure assembly. Oil lines do not need to be removed.
4 - Use bungee cord or similar item to pull oil guide to the side.

4) Install 228-7101 Seal to 320-3061 Sensor Gp.

Image1.4.1

Image1.4.2

5) Remove existing 241-6170 Plug. Note: 6mm x 3/8" allen head socket, 3/8" swivel adapter, 10" 3/8" extension, and 3/8" drive will be needed if technician is unable to reach between DOC and ladder bracket.

6) Install 320-3061 Sensor Gp.

7) Connect 446-0464 Harness As. to 320-3061 Sensor Gp.

Image1.5.1

8) Route harness assembly along side of the existing engine harness. Loosely install five 7K-1181 Straps at locations denoted by arrows in Image 1.6.1.

9) Remove cover at 120 pin connector and make appropriate connections to connector:
Pin 41 = C822-EG2 / YL-16-RADXL
Pin 80 = G826-EG100 / BR-16-RADXL
Pin 93 = G827-EG4 / BU-16-RADXL

10) Re-install 120 pin cover.

11) Route and adjust 446-0464 Harness As and secure 7K-1181 Straps.

Image1.6.1

Image1.6.2

12) Re-install air intake tube and elbow (1), hardware and bracket for oil guide (2), and oil filter assembly (3), if these components were removed during installation of sensor.

13) Update machine with appropriate software:

773G replace 423-7736 Software or earlier versions with 458-2978
775G replace 423-6575 Software or earlier versions with 458-3398
777G replace 423-8717 Software or earlier versions with 458-3399