PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE ENGINE ELECTRONIC CONTROL MODULE (ECM) ON CERTAIN 924H, 928H, 930H, AND 938H WHEEL LOADERS; M313D, M316D, AND M318 WHEELED EXCAVATORS; D6N TRACK-TYPE TRACTORS; AND C4.4 AND C6.6 INDUSTRIAL ENGINES APPLICA Caterpillar


PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE ENGINE ELECTRONIC CONTROL MODULE (ECM) ON CERTAIN 924H, 928H, 930H, AND 938H WHEEL LOADERS; M313D, M316D, AND M318 WHEELED EXCAVATORS; D6N TRACK-TYPE TRACTORS; AND C4.4 AND C6.6 INDUSTRIAL ENGINES APPLICA

Usage:

REBE5586-00

12Nov2009


U-386
D-343
O-344

 
Before/After
  
  

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE ENGINE ELECTRONIC CONTROL MODULE (ECM) ON CERTAIN 924H, 928H, 930H, AND 938H WHEEL LOADERS; M313D, M316D, AND M318 WHEELED EXCAVATORS; D6N TRACK-TYPE TRACTORS; AND C4.4 AND C6.6 INDUSTRIAL ENGINES APPLICATIONS

1901 1920
PS42983
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 "PS42983" 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.

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.


TERMINATION DATE

30Nov2010

PROBLEM

An internal ECM defect may cause the ECM to fail.

In certain conditions the engine may either not start or log diagnostic code 1779-5 (FIP solenoid current below normal).

AFFECTED PRODUCT

Model Identification Number
*******Group  1*******
C4.4 44407083, 7086-7088, 7104-7107, 7118, 7182, 7198-7199, 7262-7264, 7282, 7290-7291, 7317, 7326-7329, 7331-7333

44603573
C6.6 TIER 3  66612253, 12256-12257, 12260-12261, 12289, 12317-12319, 12344-12349, 12351-12353, 12356, 12358-12360, 12363-12367, 12376, 12379-12387, 12389-12390, 12392, 12404, 12406-12409, 12417-12431, 12433
*******Group  2*******
924H HXC01349-01350, 1358

JTM00881, 884, 887-888
924H Z  PED00750-00751, 753, 755-761, 763-765, 767-768, 770, 794
928H BYD00426-00428, 434

CXK00773-00774, 777-778, 806-810

RSB00106, 140-141, 143, 155
930H DHC01603

FTD01194-01195, 1199, 1203-1205, 1210, 1212, 1216
M313D  W3H00891, 906
M316D  W6A01167
M318D  W8P01182
*******Group  3*******
D6N LGP  GHS00239
D6N XL  MLW00120, 122
*******Group  4*******
938H LKM00580-00581, 584-586, 590-592, 594-596, 598-600, 602-603, 605-607, 623-625, 627-629, 631-632, 636, 638-639

MJC00758-00775

PARTS NEEDED

Qty

Part Number Description
*******Group 1*******
1 3317539 CONTROL GP -E
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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.
*******Group 2*******
1 3317539 CONTROL GP -E
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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.
*******Group 3*******
1 3317540 CONTROL GP -E
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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.
*******Group 4*******
1 3317539 CONTROL GP -E
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 16% 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

Replace ECM referring to appropriate Assembly & Disassembly Instruction (KENR6081) "Electronic Control Module - Remove & Install".

1. Use Caterpillar Electronic Technician(ET) to connect to the ECM in Dual Data link Mode (J1939 and CDL), download a Warranty Report from the ECM, and copy the engines current ECM Configuration. This will save the customers configuration and injector trim codes.

2. In ET, click on the Service drop down menu and select Configuration then Copy Configuration / ECM Replacement. Ensure that the Injector Trim Codes are copied. Save this file to be used later in the procedure.

3. Remove the ECM from the engine and replace it according to parts requirement.

4. Connect to the new ECM with WinFlash. Select the correct Flash file part number and begin the flashing process.

5. After the flash process is complete reconnect with ET. From the Service drop down menu, perform a Copy configuration ECM Replacement and Load from File.

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

7. Start the engine to ensure proper operation.

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-2000 hrs,
0-24 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 2.0-hour job for Group 1

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-2000 hrs,
0-24 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 2.0-hour job for Group 2

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 3*******
0-2000 hrs,
0-24 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 2.0-hour job for Group 3

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 4*******
0-2000 hrs,
0-24 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 2.0-hour job for Group 4



PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. A parts return request will be generated by Send It Back when the warranty claim is submitted.

Within NACD:
Caterpillar Inc.
Attn: Supplier Recovery
Service Claims Room
8201 N. University
Peoria, IL 61615

Outside of NACD:
Attn: Supplier Recovery
Parts Return Centre
Industrial Power Systems Division
Peterborough
PE1 5NA
United Kingdom
 
 
 

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