PRODUCT SUPPORT PROGRAM FOR REPLACING THE ENGINE FLASH FILE ON CERTAIN 3054E ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE ENGINE FLASH FILE ON CERTAIN 3054E ENGINES

Usage:

REBE3888-00

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10Jun2008

U-309

A-252

D-250

O-275

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE ENGINE FLASH FILE ON CERTAIN 3054E ENGINES
1920 1901 7620		PS51505

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS51505" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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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TERMINATION DATE

30Jun2010

PROBLEM

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The existing flash file can cause the oil warning light for certain 3054E engines to remain on. If the existing flash file fails it can indicate that there is a problem with the engine when there is not.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
3054E	30400341-00342, 344-363, 395-400, 405, 407, 409-412, 433, 435, 440, 446-451, 458, 460-474, 550-568, 581-586, 604-626, 628, 674-704, 716-817, 845-864, 900-952, 979-1001, 1052-1087, 1095-1104, 1106-1115, 1122-1147, 1153-1161, 1170-1179, 1206-1242, 1244-1251, 1255-1274, 1291-1302, 1343-1344, 1359-1398, 1443-1456, 1472-1501, 1516-1525, 1555-1567, 1580-1591, 1604-1613, 1644-1688, 1691-1700, 1727-1750, 1776-1784, 1786-1820, 1855-1897, 1943-1947, 1983-1987, 1989-1992, 2004-2012, 2019-2028, 2179-2193, 2204-2211, 2238-2245, 2277-2281, 2449-2457, 2503, 2572-2581, 2613-2614, 2654-2667, 2681-2693, 2861-2886, 2974, 3016-3024, 3035-3042, 3251-3280, 3346-3360, 3588, 3606, 3608-3613, 3625, 3642-3646, 3661-3666, 3676, 3691, 3722-3733, 4012-4026, 4163-4172, 4224-4233, 4244-4245, 4361-4370, 4467-4468, 4571-4590, 4654-4680, 4928-4937, 5005-5019, 5089-5090, 5101-5110, 5121-5163

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*******Group 2*******

3054E

30400364-00373, 375-394, 844, 953-961, 968, 978, 1007, 1018-1041, 1105, 1121, 1526-1537, 1639-1643, 1721-1726, 1931-1942, 1980-1982, 2029, 2033, 2044-2064, 2069-2074, 2232-2237, 2309, 2694-2696, 2731-2735, 2776-2778, 2917-2920, 2945-2954, 3176-3189, 3587, 3607, 3614-3624, 3626-3641, 3647-3660, 3667-3675, 3705-3721, 3734-3776, 3979-3993, 4027-4046, 4173-4188, 4209-4223, 4234-4243, 4371-4385, 4394-4400, 4447-4459, 4472-4474, 4485, 4531-4570, 4591-4620, 4686-4688, 4938-4962, 5003-5004, 5020-5088, 5091-5100, 5111-5120, 5164-5244

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*******Group 3*******

3054E

30400438, 444, 459, 575-579, 587-591, 705-706, 708-710, 818-824, 967, 969-977, 1008-1017, 1048, 1050-1051, 1088-1094, 1195-1198, 1253-1254, 1327-1330, 1341-1342, 1345-1352, 1439-1442, 1538-1541, 1614-1638, 1689-1690, 1851-1854, 1929-1930, 1978-1979, 1988, 1993-2002, 2030-2032, 2034-2043, 2065-2068, 2158, 2160-2164, 2246-2250, 2310-2329, 2357-2361, 2545-2548, 2615-2618, 2626, 2836-2840, 2979-2980, 3025-3034, 3157-3161, 3166-3175, 3190-3197, 3339-3345, 3401-3405, 3908-3927

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*****Group 4*****
3054E	30400580, 640-643, 707, 711-715, 825-843, 962-966, 1002-1006, 1042-1047, 1116-1120, 1199-1202, 1205, 1312-1316, 1353-1358, 1414-1418, 2014-2018, 2110-2116, 2251-2255, 2304-2308, 2895-2897, 2996-3005, 3093-3096, 3098-3103, 3162-3165, 3219-3228

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*****Group 5*****
3054E	30400374, 437, 441-443, 2157, 2175-2178, 3125-3156

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*****Group 6*****
3054E	30401203, 1243, 2075, 2159, 2549-2550

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	3288872	SOFTWARE GP-ELEK
*****Group 2*****
1	3288238	SOFTWARE GP-ELEK
*****Group 3*****
1	3288874	SOFTWARE GP-ELEK
*****Group 4*****
1	3288876	SOFTWARE GP-ELEK
*****Group 5*****
1	3288877	SOFTWARE GP-ELEK
*****Group 6*****
1	3288878	SOFTWARE GP-ELEK

ACTION REQUIRED

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Download the appropriate flash file.
Reflash the Engine Electronic Control Module (ECM).

NOTE: A new Factory Password will be required after flashing new software.

Refer to the attached Rework Procedure.

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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%
*****Group 1*****
0-3000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 1.0-hour job for Group 1

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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%
*****Group 2*****
0-3000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 1.0-hour job for Group 2

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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%
*****Group 3*****
0-3000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 1.0-hour job for Group 3

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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%
*****Group 4*****
0-3000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 1.0-hour job for Group 4

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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%
*****Group 5*****
0-3000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 1.0-hour job for Group 5

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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%
*****Group 6*****
0-3000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 1.0-hour job for Group 6

PARTS DISPOSITION

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

Rework Procedure

Factory Password will be needed for the Engine ECM Reflash to be completed.

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

Flash Files Required:

Select the appropriate new Flash File from the group information above.

Process:

1. Download the appropriate flash file from SISWeb or TMI.
2. Save the correct Flashfile to your local hard drive.
3. Connect to the ECM using Service Tool (CAT ET)
4. Make sure the ECM is powered up (Check that Red light on Comm. Adaptor is illuminated).
5. Go to "Winflash" or "Flash Memory".
6. CAT ET re-connect to the ECM.
7. Using the browse function in the top right hand corner, select the new Flashfile, which you should have saved to your hard drive.
8. Select "Begin Flash" (bottom right hand corner).
9. Once Flashing is complete select ?CAT ET?.
10. The Personality Module Mismatch should appear, select the ok button.
11. The factory password screen should now appear.
12. Use https://fps.cat.com to obtain factory passwords.
13. Enter Factory Passwords.
14. CAT ET High Level Configuration screen should be displayed.
15. Re-flash complete.