PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING A REVISED FLASH FILE ON THE ENGINE ELECTRONIC CONTROL MODULE ON CERTAIN C4.4 INDUSTRIAL ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING A REVISED FLASH FILE ON THE ENGINE ELECTRONIC CONTROL MODULE ON CERTAIN C4.4 INDUSTRIAL ENGINES

Usage:

REBE4140-00

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30Jul2008

U-393

A-320

D-322

O-357

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING A REVISED FLASH FILE ON THE ENGINE ELECTRONIC CONTROL MODULE ON CERTAIN C4.4 INDUSTRIAL ENGINES
1901		PI31539

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31539" 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 "PI31539" 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:

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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COMPLETION DATE	TERMINATION DATE
31Jan2009	31Jul2009

PROBLEM

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Affected Product have engine arrangement number 307-0433.

a) The existing flash file can lead to a long starting cycle in cold conditions.
b) The remote shutdown option within the ECM user interface is not enabled.

AFFECTED PRODUCT

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Model	Identification Number
C4.4	44400674, 743-755, 775-787, 797-809, 824-835, 841-854, 987-1006, 1011-1037, 1059-1060, 1064-1084, 1086-1105, 1130-1149, 1172-1181, 1223-1232, 1245-1254, 1257-1266, 1295-1309, 1457, 2553-2559, 2561-2563, 2566-2568, 2570, 2572, 2586, 2588-2590, 2592-2594, 2596-2597, 2600, 2602-2604, 2606-2629, 2631

PARTS NEEDED

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Qty	Part Number	Description
1	3290147	SOFTWARE GP-ELEK
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 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 listed Affected Product require a flash file update to improve performance, and installation of the user interface switch option.

NOTE: Flashing new software will require a new factory password.

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 1.0-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.

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

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING A REVISED FLASH FILE ON THE ENGINE ELECTRONIC CONTROL MODULE ON CERTAIN C4.4 INDUSTRIAL ENGINES

MODELS INVOLVED - C4.4 Industrial Engines

Dear Caterpillar Product Owner:

The electronic control module needs to have the flash file replaced and the remote shutdown option enabled on the products listed below. The existing flash file can cause longer start cycles in cold conditions and the disabled remote shutdown option prevents the customer interface from shutting down the engine in some cases, (NOTE: This issue does not prevent the engine being shutdown during normal stop and emergency stop events). 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 30Jul2008 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 30Jul2008 Service Letter

Rework Procedure

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THIS IS A TWO STAGE REWORK PROCEDURE

STAGE 1

Engine Reflash

Tools Required
PC or laptop with CAT ET installed and licensed (Version 2007A minimum)
Communication Adaptor with diagnostic connector

Flashfiles required for this engine is part no 3290147.

Process

1. Save the New Flashfiles to your local hard drive

2. Connect to ECM using Service Tool (CAT ET)

3. Make sure ECM is powered up (Check Red light on Comms adaptor is illuminated).

4. Go to ?Winflash? or ?Flash Memory?

5. CAT ET will re-connect to the ECM

6. Using the browse function in the top right hand corner, select the new flashfile, which you should have saved to your hard drive.

7. Select ?Begin Flash? (bottom right hand corner)

8. Once Flashing is complete select ?CAT ET?

9. The Personality Module Mismatch Message should appear, select the OK button. If the factory password screen appears follow steps 10 and 11 otherwise go to step 12.

10. Use https://fps.cat.com to obtain factory passwords

11. Enter Factory Passwords

12. CAT ET High Level Configuration screen should be displayed.

13. Re-flash complete.

STAGE 2

ECM Remote shutdown switch

Tools Required

PC or laptop with CAT ET installed and licensed (Version 2007A minimum)
Communication Adaptor with diagnostic connector

Process

1.Connect Diagnostic Communications Adaptor ? Switch Engine ECM on (Without engine running)

2. Connect to CAT ET

3. Select ?Service? drop down menu and then select ?Configuration? (See Image 1.1.1)

Image1.1.1

4. Select Configurable Inputs (See Image 1.2.1)

Image1.2.1

5. Select ?User Defined Switch Installation Switch Status?. Select Installed. Press OK (see Image 1.3.1)

Image1.3.1

6. To ensure user defined switch has installed correctly switch Engine ECM OFF. The ?Unable to communicate with Caterpillar Adapter? window should appear. (See Image 1.4.1)