PRODUCT IMPROVEMENT PROGRAM FOR REPLACING ENGINE ELECTRONIC CONTROL MODULES ON CERTAIN C7 HIGHWAY TRUCK ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING ENGINE ELECTRONIC CONTROL MODULES ON CERTAIN C7 HIGHWAY TRUCK ENGINES

Usage:

REBE1724-01

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15May2007

(Revised 05Nov2007)

U-188

A-155

TT-13

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING ENGINE ELECTRONIC CONTROL MODULES ON CERTAIN C7 HIGHWAY TRUCK ENGINES
1901		PI10596

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10596" 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 "PI10596" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:	This Revised Service Letter replaces the 15May2007 Service Letter. Changes have been made to the Affected Product.

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PROBLEM

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This Product Improvement Program is a Safety Recall in accordance with the US National Traffic and Motor Vehicle Safety Act. The ECM may malfunction without warning and render the engine inoperable which could cause the vehicle to stall at highway speeds. Steering and braking control would not be lost. Once the engine becomes inoperable it cannot be restarted, which may result in a situation where a vehicle crash could occur. It is a violation of US Federal law for a dealer to deliver a new motor vehicle or new or used engine covered by this Safety PIP until the PIP has been completed.

AFFECTED PRODUCT

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Model	Identification Number
C7	WAX76292, 76295, 76375, 76414-76415, 76419, 76422, 76457, 76469-76470, 76482-76483, 76503, 76511, 76816, 76858, 76860, 76867, 76877-76878, 76887, 76913, 76916, 76920, 76931, 76969, 76971

PARTS NEEDED

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Qty	Part Number	Description
1	2405302	CONT GP - E
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% of dealership population. This is an inital 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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Replace ECM with service replacement part number. Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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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%	100%	0%	0%	0%	0%

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NOTE: This is a 3.2-hour job
Chassis Type______SC___MC___BU___CO 1901 010 R&I______1.7__1.3__2.1__1.5 1901 025 V3_______0.5__0.5__0.5__0.5 1901 030__________0.5__0.5__0.5__0.5 1901 591__________0.4__0.4__0.4__0.4 1901 554__________0.2__0.2__0.2__0.2

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PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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IMPORTANT: SAFETY NOTICE

SAFETY ? RECALL FOR REPLACING THE Engine ECM (Electronic Control Module)

MODELS INVOLVED - CERTAIN C7 TRUCK ENGINES

Dear Caterpillar Product Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Caterpillar has decided that a defect which relates to motor vehicle safety exists in trucks equipped with certain Caterpillar C7 engines.

The ECM may malfunction without warning and render the engine inoperable which could cause the vehicle to stall at highway speeds. Steering and braking control would not be lost. Once the engine becomes inoperable it cannot be restarted, which may result in a situation where a vehicle crash could occur. A new ECM will be installed on the engine. You will not be charged for the service performed.

If you are a lessor of these vehicles, you must forward this letter to your lessee within ten days.

If you have had your vehicle repaired prior to receipt of this notice and incurred any costs, you may be eligible for reimbursement. Please contact Caterpillar at this toll free number (800) 447-4986.

If you no longer own vehicle with this engine, please contact Caterpillar at this toll free number (800) 321-7332.

If the dealer is unable to have the repair made, please contact:

Caterpillar Inc.
PO Box 610
Mossville, IL 61552-610
Attn: Engine Products Division
Truck Engine Call Center
Telephone: (800) 447-4986

If you are unable to have the repair made within 60 days or without charge, you may submit a complaint to:

In the U.S.
Administrator
National Highway Traffic Safety Administration
400 Seventh Street, S.W.
Washington, D.C. 20590
Telephone: 1-888-327-4236 (TTY:1-800-424-9153)or go to http://www.safercar.gov

Please refer the dealer to their Service Letter dated 15May2007 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 15May2007 Service Letter

Rework Procedure

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1. Supply power to the electronic control module (ECM) by turning the vehicle keyswitch to the "ON" position. Do not start the engine.

2. Connect Electronic Technician (ET) to the data link.

3. Note the software part number in the ECM Summary screen.

4. Use the ET Copy Configuration - ECM Replacement function to load the configuration from the ECM. Make note of the name and location of the saved configuration file. Disconnect ET.

5. Turn the keyswitch to the "OFF" position.

6. Replace the ECM with the appropriate ECM service replacement.

7. Turn the keyswitch to the "ON" position.

8. Use ET to flash in the software version noted in step 3 (or later version if available).

9. Use the ET Copy Configuration to program the ECM with the previously saved configuration.