PRODUCT SUPPORT PROGRAM FOR FLASHING NEW ENGINE ECM SOFTWARE ON CERTAIN 630HP AND 700HP C18 INDUSTRIAL ENGINES LOCATED IN COUNTRIES WITH LOW REGULATED FUEL Caterpillar


PRODUCT SUPPORT PROGRAM FOR FLASHING NEW ENGINE ECM SOFTWARE ON CERTAIN 630HP AND 700HP C18 INDUSTRIAL ENGINES LOCATED IN COUNTRIES WITH LOW REGULATED FUEL

Usage:

Information for equipment:


ELECTRICAL AND STARTING SYSTEM
ELECTRONICS GP-ENGINE

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PRODUCT SUPPORT PROGRAM FOR FLASHING NEW ENGINE ELECTRONIC CONTROL MODULE (ECM) SOFTWARE ON CERTAIN 630HP C18 INDUSTRIAL ENGINES LOCATED IN COUNTRIES WITH LOW REGULATED FUEL PRODUCT SUPPORT PROGRAM FOR FLASHING NEW ENGINE ELECTRONIC CONTROL MODULE (ECM) SOFTWARE ON CERTAIN 630HP C18 INDUSTRIAL ENGINES LOCATED IN COUNTRIES WITH LOW REGULATED FUEL

PRODUCT SUPPORT PROGRAM FOR REFLASHING ENGINE SOFTWARE ON CERTAIN C18 INDUSTRIAL ENGINES, AD55/AD45 UNDERGROUND ARTICULATED TRUCKS, AND PM-201 COLD PLANERS PRODUCT SUPPORT PROGRAM FOR REFLASHING ENGINE SOFTWARE ON CERTAIN C18 INDUSTRIAL ENGINES, AD55/AD45 UNDERGROUND ARTICULATED TRUCKS, AND PM-201 COLD PLANERS
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PRODUCT SUPPORT PROGRAM FOR FLASHING NEW ENGINE ELECTRONIC CONTROL MODULE (ECM) SOFTWARE ON CERTAIN 630HP C18 INDUSTRIAL ENGINES LOCATED IN COUNTRIES WITH LOW REGULATED FUEL PRODUCT SUPPORT PROGRAM FOR FLASHING NEW ENGINE ELECTRONIC CONTROL MODULE (ECM) SOFTWARE ON CERTAIN 630HP C18 INDUSTRIAL ENGINES LOCATED IN COUNTRIES WITH LOW REGULATED FUEL

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PRODUCT SUPPORT PROGRAM FOR FLASHING NEW ENGINE ECM SOFTWARE ON CERTAIN 630HP AND 700HP C18 INDUSTRIAL ENGINES LOCATED IN COUNTRIES WITH LOW REGULATED FUEL PRODUCT SUPPORT PROGRAM FOR FLASHING NEW ENGINE ECM SOFTWARE ON CERTAIN 630HP AND 700HP C18 INDUSTRIAL ENGINES LOCATED IN COUNTRIES WITH LOW REGULATED FUEL
PRODUCT SUPPORT PROGRAM FOR FLASHING NEW ENGINE ELECTRONIC CONTROL MODULE (ECM) SOFTWARE ON CERTAIN 630HP C18 INDUSTRIAL ENGINES LOCATED IN COUNTRIES WITH LOW REGULATED FUEL PRODUCT SUPPORT PROGRAM FOR FLASHING NEW ENGINE ELECTRONIC CONTROL MODULE (ECM) SOFTWARE ON CERTAIN 630HP C18 INDUSTRIAL ENGINES LOCATED IN COUNTRIES WITH LOW REGULATED FUEL

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PRODUCT SUPPORT PROGRAM FOR FLASHING NEW ENGINE ELECTRONIC CONTROL MODULE (ECM) SOFTWARE ON CERTAIN 630HP C18 INDUSTRIAL ENGINES LOCATED IN COUNTRIES WITH LOW REGULATED FUEL PRODUCT SUPPORT PROGRAM FOR FLASHING NEW ENGINE ELECTRONIC CONTROL MODULE (ECM) SOFTWARE ON CERTAIN 630HP C18 INDUSTRIAL ENGINES LOCATED IN COUNTRIES WITH LOW REGULATED FUEL

PRODUCT SUPPORT PROGRAM FOR REFLASHING ENGINE SOFTWARE ON CERTAIN C18 INDUSTRIAL ENGINES, AD55/AD45 UNDERGROUND ARTICULATED TRUCKS, AND PM-201 COLD PLANERS PRODUCT SUPPORT PROGRAM FOR REFLASHING ENGINE SOFTWARE ON CERTAIN C18 INDUSTRIAL ENGINES, AD55/AD45 UNDERGROUND ARTICULATED TRUCKS, AND PM-201 COLD PLANERS
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PRODUCT SUPPORT PROGRAM FOR FLASHING NEW ENGINE ELECTRONIC CONTROL MODULE (ECM) SOFTWARE ON CERTAIN 630HP C18 INDUSTRIAL ENGINES LOCATED IN COUNTRIES WITH LOW REGULATED FUEL PRODUCT SUPPORT PROGRAM FOR FLASHING NEW ENGINE ELECTRONIC CONTROL MODULE (ECM) SOFTWARE ON CERTAIN 630HP C18 INDUSTRIAL ENGINES LOCATED IN COUNTRIES WITH LOW REGULATED FUEL

PRODUCT SUPPORT PROGRAM FOR REFLASHING ENGINE SOFTWARE ON CERTAIN C18 INDUSTRIAL ENGINES, AD55/AD45 UNDERGROUND ARTICULATED TRUCKS, AND PM-201 COLD PLANERS PRODUCT SUPPORT PROGRAM FOR REFLASHING ENGINE SOFTWARE ON CERTAIN C18 INDUSTRIAL ENGINES, AD55/AD45 UNDERGROUND ARTICULATED TRUCKS, AND PM-201 COLD PLANERS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGERS, LINES GROUP, AND SOFTWARE ON CERTAIN 237-1955, 241-0021, 308-0037, AND 316-0039 ENGINE ARRANGEMENTS INSTALLED IN TEREX O&K SHOVELS PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGERS, LINES GROUP, AND SOFTWARE ON CERTAIN 237-1955, 241-0021, 308-0037, AND 316-0039 ENGINE ARRANGEMENTS INSTALLED IN TEREX O&K SHOVELS
PRODUCT SUPPORT PROGRAM FOR FLASHING NEW ENGINE ELECTRONIC CONTROL MODULE (ECM) SOFTWARE ON CERTAIN 630HP C18 INDUSTRIAL ENGINES LOCATED IN COUNTRIES WITH LOW REGULATED FUEL PRODUCT SUPPORT PROGRAM FOR FLASHING NEW ENGINE ELECTRONIC CONTROL MODULE (ECM) SOFTWARE ON CERTAIN 630HP C18 INDUSTRIAL ENGINES LOCATED IN COUNTRIES WITH LOW REGULATED FUEL

APPEARANCE CHANGE ON REMAN SHORT BLOCKS APPEARANCE CHANGE ON REMAN SHORT BLOCKS

PRODUCT SUPPORT PROGRAM FOR REFLASHING ENGINE SOFTWARE ON CERTAIN C18 INDUSTRIAL ENGINES, AD55/AD45 UNDERGROUND ARTICULATED TRUCKS, AND PM-201 COLD PLANERS PRODUCT SUPPORT PROGRAM FOR REFLASHING ENGINE SOFTWARE ON CERTAIN C18 INDUSTRIAL ENGINES, AD55/AD45 UNDERGROUND ARTICULATED TRUCKS, AND PM-201 COLD PLANERS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGERS, LINES GROUP, AND SOFTWARE ON CERTAIN 237-1955, 241-0021, 308-0037, AND 316-0039 ENGINE ARRANGEMENTS INSTALLED IN TEREX O&K SHOVELS PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGERS, LINES GROUP, AND SOFTWARE ON CERTAIN 237-1955, 241-0021, 308-0037, AND 316-0039 ENGINE ARRANGEMENTS INSTALLED IN TEREX O&K SHOVELS
PRODUCT SUPPORT PROGRAM FOR FLASHING NEW ENGINE ELECTRONIC CONTROL MODULE (ECM) SOFTWARE ON CERTAIN 630HP C18 INDUSTRIAL ENGINES LOCATED IN COUNTRIES WITH LOW REGULATED FUEL PRODUCT SUPPORT PROGRAM FOR FLASHING NEW ENGINE ELECTRONIC CONTROL MODULE (ECM) SOFTWARE ON CERTAIN 630HP C18 INDUSTRIAL ENGINES LOCATED IN COUNTRIES WITH LOW REGULATED FUEL


REBE6172-02

30Jun2010
(Revised 24Sep2010)


O-197

 
Before/After
  
  

PRODUCT SUPPORT PROGRAM FOR FLASHING NEW ENGINE ECM SOFTWARE ON CERTAIN 630HP AND 700HP C18 INDUSTRIAL ENGINES LOCATED IN COUNTRIES WITH LOW REGULATED FUEL

1901 1920
PS43105
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 "PS43105" 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.

 
NOTE:

This Revised Service Letter replaces the 30Jun2010 (Revised 12Jul2010) Service Letter. Changes have been made to Affected Product to add serial numbers for certain 630hp and 700hp C18 engines operating in countries with low regulated fuel.


TERMINATION DATE

31Dec2010

PROBLEM

Certain C18 industrial engines installed in irrigation pumps in Saudi Arabia have experienced oil degradation resulting from the use of high sulfur fuel. Oil degradation results in a breakdown of the oil additives and may lead to multiple symptoms including sooting. The oil degradation in this region has been identified through Scheduled Oil Samples.

AFFECTED PRODUCT

Model Identification Number
*******Group  1*******
C18  WJH00288, 664, 1128, 1364, 1434, 1474, 2142, 2350, 2512, 2514-2515, 2526, 2551, 2562, 2640, 2818, 2881, 2892, 2908, 2925, 2941, 3090, 3245, 3258, 3262, 3277, 3280, 3288, 3296, 3309, 3364, 3560, 3665, 3840, 4000, 4002, 4112, 4193, 4821-4823, 4826-4827, 4963-4964, 4978, 4980, 4994-4997, 5007, 5009, 5022-5023, 5027, 5029, 5035-5036, 5039, 5041, 5059-5060, 5228, 5230, 5232, 5245-5246, 5556, 5558-5559, 5570-5571, 5573, 5618, 5630, 5635, 5637, 5640, 5647-5652, 5671, 5673-5674, 5690-5692, 5799, 5870, 5989-5991, 6179, 6230, 6262, 6369, 6374, 6486, 6497, 6763, 6768, 6770-6772, 6807, 6857, 6950, 6954, 6956, 6959-6967, 6992, 6994-6995, 7001, 7003-7005, 7027
*******Group  2*******
C18  WJH03995, 3998, 4011-4012, 4016, 4020, 4024, 4027, 4040-4041, 4077, 4505, 4528, 4532, 4538, 4548, 5115, 5119-5120, 5126-5127

PARTS NEEDED

Qty

Part Number Description
*******Group 1*******
1 3624272 SOFTWARE GP-ELEK
1 LABEL EMISSIONS LABEL (REFER TO REWORK PROC.)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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 3656497 SOFTWARE GP-ELEK
1 LABEL EMISSIONS LABEL (REFER TO REWORK PROC.)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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

A Parts Service Only (PSO) engine flash file to help address oil degradation has been developed for applications operating in lesser regulated countries related to high sulfur fuel usage.

1. Group affected units by geographical proximity.

2. Submit serial number groups for new labels.

3. Flash the engine ECM with the new software, remove the existing emissions and performance spec. label, and attach new emissions and performance spec. label.

NOTE: A Factory Password will be required when completing software update.

Refer to the attached Rework Procedure.

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*******
0-10000 hrs,
0-60 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 0.6-hour job for Group 1
The Prognostic Download must be loaded into the SIMSi ticket for verification.

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-10000 hrs,
0-60 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 0.6-hour job for Group 2



PARTS DISPOSITION

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


Rework Procedure


 
C18 INDUSTRIAL ENGINES (630HP & 700HP):

Engines to be updated to the new PSO software file are engines that operate in unregulated regions. Once units that can benefit from the gathered software update are identified, the engine serial numbers will be tabled and sent to Caterpillar to obtain new emissions labels. It is not recommended to update an engine with PSO software if the unit may travel to another emission-controlled region (Rentals).
 
PROCESS STEPS:

1. Identify the appropriate units for the updated sofware in Group 1 (362-4272) or Group 2 (365-6497). Units should be grouped by geographical location to facilitate efficiency when traveling to service site. Maximum group size for submission of replacement stickers is 20 units to be manageable.

2. Identify Customer Name, City / Region, snd Country.

3. Send the serial number list to Service Engineering; Attention of: Clive Matthews via e-mail at Matthews_Clive@perkins.com.
 
4. Service Engineering will obtain new emissions labels.

5. Service Engineering will send labels for up to 20 units at a time to Field Service Representative.

6. Field Service Rep. will coordinate installation of label on identified engines.

7. Dealer will verify the engine serial numbers are correct and remove the current engine emissions label. Dealer then documents and updates a spreasheet according to the process to re-certify the engine.

NOTE: Be sure to send the old emissions labels to the address included in the Image1.3.1.
Image1.3.1
 
Process to Re-certify an Engine (Unregulated Country)

NOTE: Engines selected for Re-Certification must be in an unregulated country. This process should be documented with a digital photo of the emissions label update. Photo can be sent with other information to Service Engineering. Dealer will collect the old emission labels and send to the Caterpillar return mailing address contact (Field Service Rep.) above.

8. When new emissions labels are delivered, proceed with flashing the PSO P/N 362-4272 (Group 1 630HP) or P/N 365-6497 (Group 2 700HP).

9. Perform a Prognostic and Histogram download after completing the software flash update. Upload the Prognostic and Histogram with the claim in SIMSi.

Histogram Download should be as follows: "Load Factor vs. Time" and "Actual Arrangement Speed vs. Time"

10. Remove old label(s) completely from the engine and save. Clean the surface with a 1:1 mixture of isopropyl alcohol (IPA) and water, and a clean, lint-free paper towel so that all dirt and adhesive are removed from the engine surface. Allow surface to dry before installing the replacement label(s).

11. If the original label is no longer on the engine and the label location cannot be determined, replacement labels may be installed on the engine valve cover, front cover, flywheel housing, or oil cooler.

12. Carefully remove the new label from the backing and immediately apply to engine. Avoid trapping air bubbles under the label material. Apply pressure to smooth entire label surface to ensure adhesion, especially at the corners and edges. Use of a hand roller or squeegee is recommended to apply pressure across the face of the film and along edges to ensure maximum adhesion.

NOTE: Do not install new label over old label. Layered labels compromise label adhesion and durability. Adhesive labels must be applied to a clean, dry, smooth-painted surface.

13. Once the label is applied, remove the clear laminate from the backing and apply over the label so that entire surface is protected. Apply pressure to smooth entire laminate surface to ensure adhesion, especially at the corners and edges.

14. Wait 60 minutes before disturbing the labels, to ensure good adhesion. Full cure time is 24 hours.

15. Return all removed emission labels to your Caterpillar Field Representative, Clive Matthews.

16. If no emission label is present on the engine; document the engine serial number and provide in the spreasheet to be sent to your Field Representative, Clive Matthews.
 
 

Caterpillar Information System:

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