PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE COOLANT FLOW SWITCH ON CERTAIN 3524 REMAN ENGINES IN DEALER PARTS STOCK, FOR 797B OFF-HIGHWAY TRUCKS Caterpillar


PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE COOLANT FLOW SWITCH ON CERTAIN 3524 REMAN ENGINES IN DEALER PARTS STOCK, FOR 797B OFF-HIGHWAY TRUCKS

Usage:

REBE6751-01

17Dec2010
(Revised 04Jan2011)


U-505
A-416
D-442

 
Parts stock action only
  
  

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE COOLANT FLOW SWITCH ON CERTAIN 3524 REMAN ENGINES IN DEALER PARTS STOCK, FOR 797B OFF-HIGHWAY TRUCKS

1408 7601 7610 7620
PI70372
NOTE:

When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7751" as the Group Number, "56" as the 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 17Dec2010 Service Letter. Changes have been made to Action Required and Rework Procedure.


TERMINATION DATE

31Mar2011

PROBLEM

The existing coolant flow switch can fail on certain 3524 Reman Engines for 797B Off-Highwy Trucks. If the existing coolant flow switch fails, it can cause a false alarm/indicator when the truck is running.

ACTION REQUIRED

Rework the listed 3524 engines in dealer stock to include updates according to the attached Rework Procedure. Based upon application the engine arrangement part number is either 10R-1676 or 10R-7929.

Engines requiring rework:
NPM00229-00230, NPM00232-00241, NPM00243-00259, NPM00261-00308, NPM00310-00311, NPM00313-00314


1. Remove the existing coolant flow switch and install the 218-3840 Coolant Pressure Sensor and associated parts.

2. Update the engine and VIMS software.

Refer to the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

3.0 hours will be allowed for each engine in dealer parts stock that is reworked according to this program.

Submit one claim for all engines reworked in dealer parts stock.

PARTS DISPOSITION

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


Rework Procedure


 
1. Refer to Image 1.1.1 for the list of parts needed.
Image1.1.1
 
2. Drain the coolant. Remove the pipe plug from the coolant pressure sensor port and install the 3E-7448 Adapter, 6V-9027 O-ring Seal, and new 218-3840 Sensor at the location shown in Image 1.2.1.
Image1.2.1
 
3. Disconnect the turbo outlet pressure sensor connector of the engine harness(located on the rear LH side of the front engine, behind the Master ECM, Image 1.3.1) and install the appropriate new sensor harness to integrate the new coolant pressure sensor.
a. Connect PC-C1 of new sensor harness to the connector of the turbo outlet pressure sensor.
b. Connect PC-C2 of new sensor harness to the turbo outlet pressure sensor connector on the main engine harness.
Refer to Image 1.3.2
Image1.3.1
Image1.3.2
 
4. Connect the PC-C3 connector on 362-6391 Harness Assembly to the coolant pressure sensor connector.
 
5. Route the coolant pressure wiring harness (blue single braided wire) along the current engine wiring harness to the Master ECM, strap it to the engine wiring harness with the 9X-6772 Tie Straps. At the ECM, connect this single braided blue wire to J2 pin 8 of the Master ECM.
 
6. Disconnect the coolant flow switch harness connection from the switch and provide an appropriate means of protecting the harness connector from damage and exposure to the elements. Refer to Image 1.6.1 for coolant flow switch location.
Image1.6.1
 
7. Remove the existing coolant flow switch and guard and install the 205-4821 Cover, 4N-3841 Gasket, 0S-1617 Bolts, and 9M-1974 Washers in its place at location shown in Image 1.6.1. Use the 3E-3364 Receptacle and 3E-3365 Wedge, from 102-8802 Receptacle Kit, and the two 8T-8737 Seal Plugs in order to cap the harness plug that was attached to the coolant flow switch. Securely tie strap the capped off coolant flow switch breakout to the main body of the engine wiring harness.
 
8. Engine software update

Important: Prior to flashing the software, go to the logged Events screen in Cat ET and clear all logged events on BOTH SLAVE ECMs.

Both Master and Slave ECMs will need to be updated with new software. Use the WinFlash utility of Cat ET to install the following software. Both slave ECMs are programmed with the same software:
a. Master ECM: flash appropriate software
b. Slave ECMs: flash appropriate software

NOTE: Cat ET 2010B or later is required for this update.
 
9. VIMS Software Update
Use the WinFlash Utility of CAT ET to update the software on the VIMS unit.

NOTE: After VIMS software update the payload may need to be calibrated.
 
10. After installing the software, activate the Coolant Pressure Sensing feature of the Master ECM. Go to the configuration screen and configure it to 'Installed'.

IMPORTANT: ONCE THE COOLANT PRESSURE SENSOR HAS BEEN SET TO INSTALLED, THE TRUCK MUST BE KEYED OFF FOR 10 SECONDS AND THEN BACK ON BEFORE IT WILL WORK PROPERLY.
 
 

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