PRODUCT SUPPORT PROGRAM FOR UPDATING SOFTWARE AND INSTALLING CRANKCASE VENTILATION PRESSURE SENSOR ON CERTAIN C7 ON-HIGHWAY TRUCK ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR UPDATING SOFTWARE AND INSTALLING CRANKCASE VENTILATION PRESSURE SENSOR ON CERTAIN C7 ON-HIGHWAY TRUCK ENGINES

Usage:

REBE4825-00

Show/hide table

26Jan2009

U-29

A-27

TT-5

Show/hide table

*Before/After*	PRODUCT SUPPORT PROGRAM FOR UPDATING SOFTWARE AND INSTALLING CRANKCASE VENTILATION PRESSURE SENSOR ON CERTAIN C7 ON-HIGHWAY TRUCK ENGINES
1916 1408 1920 1901		PS42868

Show/hide table

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 "PS42868" 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.

Show/hide table

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.

Show/hide table

TERMINATION DATE

31Jan2011

PROBLEM

Show/hide table

Updates to certain C7 truck engine hardware and software have enhanced the diagnostic reporting. This software update also increased Caterpillar Regeneration System robustness. The new software requires the addition of a Closed Crankcase Ventilation pressure sensor on early vintage engines.

AFFECTED PRODUCT

Show/hide table

Model

Identification Number

C7S00500, 514-515, 522-526, 531, 534, 536, 543, 553, 561, 563, 565, 568, 571-573, 575-576, 581, 585-587, 589, 591-592, 594-596, 599, 603-604, 607, 610, 613, 615-617, 620-622, 625, 627, 635, 637, 640, 642, 650-654, 657, 659, 661, 664, 666-667, 669, 671, 674-676, 680-681, 683, 689, 695, 697, 701, 704, 707-708, 711-712, 716, 718-719, 721, 724-725, 728-729, 732, 739, 749-750, 752, 759, 768, 770, 772-773, 775, 777, 779, 781, 783, 786, 789, 792, 797, 800, 805-807, 810-812, 815, 818-820, 824, 826, 830-831, 834, 837, 840, 842, 848, 851, 855-858, 863-865, 868, 871-872, 874, 881, 888, 897, 900-902, 904, 911-913, 916, 918, 920, 923, 926, 929, 931-932, 935-937, 941, 943, 946-947, 952-953, 955-956, 961-962, 964, 966-967, 974, 976, 978-979, 982, 984, 986-987, 992, 994-995, 998, 1000, 1002, 1005, 1009, 1014, 1016, 1018-1020, 1024-1025, 1030, 1032-1034, 1036, 1038, 1045, 1049, 1052-1057, 1059-1060, 1062-1064, 1067, 1070, 1072-1074, 1076-1077, 1079, 1085-1086, 1091, 1096, 1100, 1104, 1107-1108, 1110, 1112-1113, 1115-1116, 1119-1122, 1124-1126, 1128-1132, 1136, 1138, 1140-1141, 1145, 1148, 1152-1154, 1157, 1160, 1163, 1165, 1175-1177, 1179, 1186, 1188-1189, 1192, 1196-1198, 1201, 1204, 1206-1207, 1212, 1214, 1220, 1235-1238, 1241, 1243, 1246, 1248-1250, 1252, 1256, 1260, 1264, 1266-1267, 1271-1273, 1276, 1283, 1291, 1293-1295, 1297, 1300, 1312-1313, 1315, 1318-1319, 1322, 1324-1325, 1331, 1335-1336, 1340, 1342, 1347-1348, 1352, 1355-1356, 1358, 1362, 1364-1367, 1374-1375, 1377, 1382, 1385, 1388, 1390, 1398-1400, 1405, 1410, 1413

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
1	6V5048	SEAL-O-RING
1	6V5049	SEAL-O-RING
1	9X0261	ADAPTER
1	3056873	SENSOR GP-PRESS
1	3098611	KIT-WIRING
1	3139575	SOFTWARE GP-ELEK
1	3342353	SOFTWARE GP-ELEK
1	3342354	SOFTWARE GP-ELEK
1	3342355	SOFTWARE GP-ELEK
1	3342356	SOFTWARE GP-ELEK
1	3342357	SOFTWARE GP-ELEK
1	3342358	SOFTWARE GP-ELEK
1	3342359	SOFTWARE GP-ELEK
1	3342360	SOFTWARE GP-ELEK
1	3342361	SOFTWARE GP-ELEK
1	3342362	SOFTWARE GP-ELEK
1	3342363	SOFTWARE GP-ELEK
1	3342364	SOFTWARE GP-ELEK
1	3342365	SOFTWARE GP-ELEK
1	3342366	SOFTWARE GP-ELEK
1	3342367	SOFTWARE GP-ELEK
1	3342368	SOFTWARE GP-ELEK
1	3342369	SOFTWARE GP-ELEK
1	3342370	SOFTWARE GP-ELEK
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

Show/hide table

Install pressure sensor and update software.

Refer to attached Rework Procedure.

Show/hide table

SERVICE CLAIM ALLOWANCES

Show/hide table

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%
0-3600 hrs	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

Show/hide table

NOTE: This is a 1.5-hour job

Show/hide table

PARTS DISPOSITION

Show/hide table

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

Rework Procedure

Show/hide table

C7 Hardware Update to install Closed Crankcase Ventilation (CCV) Sensor:

Remove plug from valve cover base. The plug is located on the left side of the base, near the end of the fuel rail.

Install 9X-0261 adapter into the base with a 6V-5049 o-ring. Tighten to a torque of 12.5 lb ft (17 Nm).

Install 305-6873 pressure sensor with a 6V-5048 o-ring into the adapter previously installed. Tighten to a torque of 7.4 lb ft (10 Nm).

Refer to Image 1.1.1

Refer to Image 1.1.2

Locate the Close Crankcase Ventilation (CCV) connector on the main engine harness. This breakout will be labeled CCV sensor and is located near the location of the new sensor.

Refer to Image 1.1.3

Install jumper harness kit 309-8611 between the new pressure sensor and the CCV breakout on the main engine harness. Secure the wiring harness away from any moving parts, pinch points, or excessively hot components using the straps included in the harness kit.

Image1.1.1

Image1.1.2

Image1.1.3

"Procedure for Updating the Personality Module Part Number"

Using Caterpillar Electronic Technician (ET) 2007B or newer, connect with Dual Data Link (J1939 and ATA). If Dual Data Link is not enabled diagnostic and service test will not function properly. 2007B is required for service test to operate correctly.

Determine the ECM Personality Module Part Number. If the ECM Personality Module Part Number currently installed on the truck is not the same as the Part Number listed on SIS WEB, the truck must be flashed with the correct ECM Personality Module Part Number. After determining the correct ECM software to be flashed, download the correct Personality Module Software from SIS Web, save the software file on your service tool computer.

Using ET, connect to the engine ECM. Copy the current engine ECM Configuration. This will save the customer configuration and injector trim codes. Before taking this replacement file, make sure the dashboard display in ET is disabled or the file may not copy injector trim files correctly.

To shut the dashboard display off, toggle the dashboard display button in the lower right hand corner of the active diagnostics or ECM summary windows in ET. The service tool dashboard should be red when disabled. Disconnect ET from the engine ECM by clicking on the disconnect button at the top of the ET screen and then reconnect.

In ET, click on the "Service" drop down menu and select "Configuration" then "Copy Configuration/ECM Replacement". Save this file to be used later in the procedure.

In the "Diagnostic" drop down menu, view the "Active Diagnostic" codes. If active codes are present, use the "Reset All" button, clear all active diagnostic codes.

Connect to the ECM with "WinFlash".Select the new Personality Module Software Part Number and begin the flashing process.After the flash process is complete reconnect with ET.

Review the "Configuration" to ensure Injector trim files and other configurable parameters are correct. Also, set vehicle voltage selection under system settings to the applicable value (12V or 24V). If configuration is not correct, from the "Service" drop down menu, perform a "Copy Configuration ECM Replacement" and "Load from File".

Select the previously saved configuration file and program the file into the ECM configuration.

Note: Changes in how diagnostic codes are triggered may cause new active codes to appear after flashing the new software file. If the service letter is being performed pro-actively then the flashing and any additional repairs performed to correct new active codes caused by flashing the new software should be submitted to warranty using PD code 56.

Return truck to service.