New Engine Software Needs To Be Installed On 776D Tractors And On 777D And 793C Trucks Caterpillar

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI3069" as the Part Number, "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 "PI3069" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

Completion Date

Termination Date

Problem

The prelube system on the 776D Tractors and on 777D and 793C Trucks has no way to bypass the prelube cycle in case of the need for an emergency start of the engine. This software is also needed in combination with the low pressure turbo update at low altitude sites. Replacement engines in stock should also be updated with the new flash file.

Affected Product
Model & Identification Number

Group 1

777D (3PR1-607)

776D (5ER1-85)

3508B (2GR1-864) (Dealer Exchange)

3508B (5XS170) (Reman)

Group 2

793C (4AR1-250)

3516B (7TR1-419) (Dealer Exchange)

Parts Needed

Dealers will need to order parts for this Program.

NOTE: All NACD Dealers and all other dealers who have access to engine flash softwear from the software bulletin board or from SIS information disks should use the 151-2155 or 146-9358 Software. They should not order a 1512157/">151-2157 or 1469360 Control Group (Pers. Mod.). Only dealers who do not have access to software files can order the Control Group (Pers. Mod.) and claim it under this program.

Group 1

1 - 1512155 Software

Or

1 - 1512157 Control Group (Pers. Mod.)

Group 2

1 - 1469358 Software

Or

1 - 1469360 Control Group (Pers. Mod.)

Action Required

Obtain and install engine flash software part number 146-9358 or 151-2155 using the et flash utility. Engine flash software is obtained from the software bulletin board or from the sis information disks. Instructions for using the bulliten board and sis disks is attatched. Flash file is only obtainable from the above two sources.

See the attached procedure.

Owner Notification

U.S. and Canadian owners will receive the attached Owner Notification.

Service Claim Allowances

Dealer Exchange Units

NOTE: This is a 1-hour job per engine. Submit one claim for all dealer exchange engines reworked.

When filing a claim for a spare engine use the following serial numbers as the vehicle serial number:

NACD Dealers - 99Z21

CACO Dealers - 99Z621

COFA Dealers - 99Z121

CAPL Dealers - 99Z821

COSA Dealers - 99Z421

Affected Product

Parts Disposition

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

NOTE: MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach.

(1-Owner Notification)

(2-Rework Procedure)

Copy Of Owner Notification For U.S. And Canadian Owners

Rework Procedure

776D, 777D, AND 793C SOFTWARE UPDATE REWORK PROCEDURE.

Use Engine News SEBD9244 Dated 01/Jan/97 - Methods Of Obtaining Engine Flash Files for this update (copy below) and the April 21, 1997 Service Magazine Article "3500 Machine Engine Software Serviceability".

Currently, there are two sources from which flash files can be obtained. One source is the Caterpillar Mailbox System Bulletin Board and the other source is the SIS Setup And Tool Guide CD. The bulletin board is updated as soon as the new flash files become available. The SIS CDs are updated monthly and contain the flash files that were available on the twentieth day of the preceding month.

The following, is a description of the methods used to obtain flash files from the bulletin board and the SIS CD.

OBTAINING FLASH FILES FROM THE BULLETIN BOARD.

Obtaining flash files from the bulletin board requires the use of an error correcting modem. To download files quickly, a modem baud rate of 14.4 K baud or higher is recommended. Refer to the service literature for the modem to see if it is adequate. Use the following procedure to get access to the bulletin boards:

1. Obtain hyperaccess/5 (dos-os/ version) and install it into the PC that will be used to obtain the flash files. Hyperaccess/5 is PC communications software that can be ordered from Caterpillar (LERQ3133) or purchased from outside vendors. Hyperaccess/5 is required for flash file download from the Caterpillar Mailbox System Bulletin Board.

2. Once Hyperaccess/5 has been installed, call 1-800-HELP-EPI OR 309-675-0834 and select option No. 7. step by step instructions will be given in order to register the PC and download information into the PC, such as bulletin board telephone numbers. Multiple PC registration instructions can also be obtained by calling the numbers listed above.

Once the PC has been setup to receive flash files from the bulletin board, the following steps can be used to obtain the desired flash files:

1. From the dos prompt (usually C:>), type cd.

2. The prompt should now be C:

3. From the Hyperaccess/5 menu now displayed, type C for "call a system".

4. Type D for "data call".

5. Select flash download from the system list in the lower half of the menu.

6. The program displays a menu with three options, select Option No. 1 Receive Flash Part Number File(s).

7. Enter in the flash file name as directed. Multiple files can be downloaded by using the "wild card" character *. for example, if the flash file name 1222860/">1222860* was entered, all flash files on the bulletin board with file names from 1222860 to 1222869 would be downloaded.

8. The program then connects to the bulletin board and the file(s) are downloaded in to the flash directory in the PC. After the download is complete, the same menu mentioned in Step No. 6 appears and the user may download additional files or exit the program.

Obtaining flash files from the SIS Setup And Tool Guide CD.

This procedure requires that the PC used be equipped with a CD ROM drive.

Use the following procedure to locate the flash files contained in the SIS Setup And Tool Guide CD:

1. Insert the SIS Setup & Tool Guide CD into the CD Rom Drive. Do not start the SIS Program.

2. At this point, the user can access the flash files using file manager in windows or dos commands. The flash files are located in the flash directory. If using dos commands, at the dos prompt (c:>), type d:, then hit enter.

3. Type CD.

4. At this point, DOS commands can be used to copy the desired flash files to a floppy disc for use in another PC or the flash program can be executed by simply typing flash, this assumes that the PC is properly connected to an ECM. The SIS Setup And Tool Guide CD also contains a flash file cross reference that is identical to the one in the Find System. The file name is "Readxref.TXT" and it is also located in the flash directory of the SIS CD.

Once flash files are obtained, use the ET service tool Flash utility to flash the new software into the engine. Flashing the engine control using ET will require a communication adaptor, a 7X1425 PC cable, and either the 7X1412 ATA cable or the 139-1466 Universal cable.

CHANGING PERSONALITY MODULES:

When it is difficult to obtain flash files, it may be necessary to change the personality module instead.

The personality module is located in the back side of the Engine Control Module (ECM). Use the following procedure to change the Personality Module in the ECM.

1. Shut off the main disconnect and remove the negative battery cable.

2. Remove the two harness connectors from the ECM using a 7 mm allen wrench.

3. Remove four bolts holding the ECM to the engine.

4. Flip the ECM over and remove 4 bolts holding the cover to the personality module. Be sure area around the cover is clean and no dirt enters the ECM when the cover is removed. Take care not to loose the gasket ring under the cover plate.

5. Grasp the ends of the personality module and while squeezing , pull straight out.

6. Insert the new personality module noting that it will only insert one way. When the moule is inserted correctly a "click" will be heard as each end of the module is latched into place.

7. Replace the cover being sure to have the sealing gasket (O-ring) in the slot machined. Failure to install the gasket properly will result in moisture entry into the ECM and will result in failure of the ECM.

8. Reattach the ECM to the engine and reconnect the wiring harness. Harness connector bolts may be difficult to turn while seating the connectors. Connectors must be fully seated to prevent engine operational problems.

9. Start truck and check for faults.