PRODUCT IMPROVEMENT PROGRAM FOR REPROGRAMMING CUSTOMER COMMUNICATION MODULE 164-8940 FOR COMPATIBILITY WITH CERTAIN 3508B LOCOMOTIVE ENGINES WITH AN ADEM III CONTROL Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPROGRAMMING CUSTOMER COMMUNICATION MODULE 164-8940 FOR COMPATIBILITY WITH CERTAIN 3508B LOCOMOTIVE ENGINES WITH AN ADEM III CONTROL

Usage:

REBE3148-00

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04Feb2008

O-54

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPROGRAMMING CUSTOMER COMMUNICATION MODULE 164-8940 FOR COMPATIBILITY WITH CERTAIN 3508B LOCOMOTIVE ENGINES WITH AN ADEM III CONTROL
1926 1901		PI31444

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31444" 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 "PI31444" 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
31Aug2008	28Feb2009

PROBLEM

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The 164-8940 Customer Communications Module (CCM) may misinterpret data link communications with the ADEM III ECM.

AFFECTED PRODUCT

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Model	Identification Number
3508B	5PS00331, 347, 349, 351-358, 361-366, 393-424, 428-442, 465-469, 473-477, 480-483, 488-490, 492, 494-498, 511-518, 520-528, 534-540, 543-548, 554, 564-571

PARTS NEEDED

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Qty	Part Number	Description
1	SFTWARE	SOFTWARE (FIRMWARE UPDATE)
1	STICKER	CCM PART NUMBER UPDATE (188-3080 EQUIVALENT)
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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Refer to the attached Rework Procedure to update the software in the 164-8940 CCM and apply an update sticker.

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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 Updating Software

MODELS INVOLVED - 3508B Locomotive Engines

Dear Caterpillar Product Owner:

The 164-8940 Customer Communications Module (CCM) needs to be updated with software to work properly on the engines listed below. The existing 164-8940 CCM software may misinterpret messages from the Engine Electronic Control Module. 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 04Feb2008 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 04Feb2008 Service Letter

Rework Procedure

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Updating the 164-8940 CCM module with software to be equivalent to the 188-3080-02 CCM

NOTE: The CCM updating procedure does not use the same equipment or programs as normally used for flashing software in other Caterpillar electronic controls. The following procedure must be followed as documented:

Equipment Needed:
1. A computer (PC) with a Microsoft Windows based operating system. Tested operating systems are Windows 3.1, Windows 95, Windows NT 4.0, Windows 2000 and Windows XP. The PC must have an active serial port COM1.

2. A self extracting file 1883080.exe containing the IO program (io.exe) and support files: io.cfg, io.prg, encrypt.tbl, key.prg, swpn.prg including a readme file and the new update software file, 18830843.brn.

3. The new software file updating the CCM is 18830843.brn. NOTE: This is not an engine flash file and is not found on SIS and can not be used with ET Winflash.

4. A 24V DC power source for the CCM with the appropriate leads.

5. A nine pin to twenty-five pin null modem cable or its equivalent. Ref. Caterpillar 1320453 Cable.

6. The CCM module which needs this update is 164-8940.

Setup Procedure:

All repairing dealers are required to contact Caterpillar Electronics at 877-598-8920 during daytime business hours (8AM-4PM Central Standard Time) for approval prior to exercising this Program for all updates.

The repairing dealer should have the engine serial number, engine hours, the CCM part number with change level, if available, and date of installation of the CCM prior to calling Caterpillar. The necessary software will be e-mailed or mailed at that time to those dealers.

1. Execute the self-extracting file either from the hard drive or floppy disc.

2. A subdirectory will be created on your C:\ drive as \ccm and automatically write 8 files to that subdirectory. Support files are io.exe, io.cfg, io.prg, encrypt.tbl, key.prg, swpn.prg, readme.txt and the updated change level burn file, 18830843.brn.

NOTE: 18830843.brn is not considered a "flashfile" therefore will not be available on SIS.

3. Connect the CCM to the 24V DC power source using the terminals marked "+B" and "-B" and apply power to the CCM. Note the display, after power is applied, will scroll and should show n81 9600. This indicates the default baud rate of the CCM setting at 9600. If other than 9600, write down or remember the displayed value to be used later.

4. Connect the CCM to the PC COM1 serial port using the nine pin to twenty-five pin null modem cable. NOTE: COM1 port must be used.

CCM Update Procedure:

NOTE: The computer COM Port 1 must be used to connect the computer to the CCM. CCM baud rate default is 9600 therefore COM Port 1 should be set to 9600. If the CCM Baud Rate has been changed, it will be displayed at the time of power-up and should have been written down or remembered from Setup Procedure step 3. This information will be used in the following instructions.

1. Open a DOS window from within Windows, or boot to DOS. This flash program must be run from a DOS command prompt.

2. Type "c:" and press the "Enter" key. Type "CD C:\CCM" and press the "ENTER" key. If the baud rate was 9600 determined at power-up proceed to step 3. If the baud rate was other than 9600, the io.cfg file needs to be edited using a text editor such as Notepad. Open io.cfg with a text editor. Locate the "Baud Rate to use for selected ports section". The default is #5 for 9600 Baud (left column). Type the correct number corresponding to the baud rate determined at power-up. Save the file and close the text editor. Your PC hardware will require setting the COM 1 port to this same Baud value. Refer to the owner's manual for your PC to perform this task. Proceed to Step 3.

Partial Screen Image of io.cfg

* IO Module Configuration File 12JAN93
* (Note the order of items in this file can not be altered)
* Baud Rate to use for selected port
* 1 = 300 Baud
* 2 = 1200 Baud
* 3 = 2400 Baud
* 4 = 4800 Baud
* 5 = 9600 Baud
* 6 = 19200 Baud (no other baud rates can be used)

3. Type "io" and press the "ENTER" key. This starts the io.exe flash program.

4. "Main Menu" will be displayed. Type "1" to select "Flash Memory Programming".

5. "ENTER DEVICE MID" is displayed. If E00 is displayed on the CCM, Type "61" and press "ENTER". If S00 is displayed on the CCM, Type "66" and press "Enter".

NOTE: In the next few steps, do not enter the information requested, but press "enter" as instructed. The information requested is automatically accessed from the included support files.

6. "ENTER THE FILENAME TO PROGRAM" is displayed. Press "ENTER".

7. "ENTER THE KEY" is displayed. Press "ENTER".

8. "ENTER THE NEW SOFTWARE PART NUMBER" is displayed. Press "ENTER". The IO program will now generate the data files it needs for the updating process, which will be displayed on the PC screen, and may take 1 to 2 minutes before the next step.

9. "ENTER NEW INTERNAL FILE ID" is displayed. Press "ENTER". This will initiate the updating process. While updating (programming), the CCM will display "PrO" with a segment revolving in the "O", and the PC will show data scrolling down the screen for approximately 3 to 4 minutes.

10. When the CCM update procedure is complete, the CCM will display "End", and the flash program will display "PROGRAMMING SUCCESSFUL" and "Press any key".

11. Press any key to return to the main menu, and then press "8" to exit.

12. Disconnect, and then reconnect power to the CCM. It should start normally and display "E00" or "S00". If not, rerun procedure and make sure the instructions are followed.

13. The CCM update procedure is completed.

14. Apply to the top of the CCM the 188-3080-02 sticker provided with the software update.