PRODUCT SUPPORT PROGRAM FOR INSTALLING NEW FLASH FILES FOR CERTAIN C15 TRUCK ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING NEW FLASH FILES FOR CERTAIN C15 TRUCK ENGINES

Usage:

SEBE8950-01

October 23, 2004
(Revised November 2004)
U-303
A-213
TT-24

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*before or* *after failure*	PRODUCT SUPPORT PROGRAM FOR INSTALLING NEW FLASH FILES FOR CERTAIN C15 TRUCK ENGINES
7751		PS41700

NOTE: This Program can 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 "PS41700" as the Part number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "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 October 23, 2004 Service Letter. Changes have been made to the affected product.

TERMINATION DATE

April 30, 2005

PROBLEM

The engine RPM may increase under specific operating conditions.

AFFECTED PRODUCT

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Model

Identification Number

C15

BXS11602-12547, 12551-12565, 12570-12606, 12608-12653, 12657-12815, 12817-12907, 12909, 12910, 12912, 12913, 12915-13044, 13046-13207, 13209-13331, 13333-13336, 13338, 13339, 13343, 13345-13447, 13449, 13450, 13452, 13454, 13455, 13458-13587, 13589, 13590, 13592, 13593, 13595, 13596, 13599, 13600, 13672-13721, 13725, 13732, 13734, 13735, 13737, 13741, 13743-13858, 13860, 13861, 13875, 13876, 13878, 13880, 13884-14011, 14013-14060, 14062-14539, 14541-15556, 15558-15925, 15927-16650, 16652-17467, 17469-18951, 18953-19480, 19482-21089, 21091-21607, 21609-22870, 22872-23356, 23358-23514, 23516-23621, 23623-23735, 23737-24025, 24027-24662, 24664-25536, 25538-25718, 25720, 25722-25762, 25764-25963, 25965-26108, 26112-26314, 26316-26479, 26481-26657, 26659-26865, 26867-27099, 27101-27147, 27149-27370, 27372-27407, 27409-27498, 27500-27906, 27908-28374, 28376-28412, 28414-28546, 28549, 28561-28651, 28653-28730, 28732-28802, 28804-28853, 28855-29057, 29059, 29061-29107, 29109-29238, 29241-29660, 29662-29899, 29901-29977, 29979-30064, 30066-30135, 30137-30151, 30153-30254, 30256-30350, 30352-30445, 30447-30461, 30463-30469, 30471-30498, 30500-30504, 30506-30646, 30648, 30649, 30651-30701, 30703-30738, 30740-30787, 30789, 30790, 30793-30799, 30801-30824, 30826-30855, 30857, 30858, 30860-30865, 30867-30885, 30887-30911, 30913-30968, 30971, 30973-30980, 30982-31008, 31010-31016, 31018-31045, 31047-31107, 31109-31121, 31123-31128, 31130-31142, 31144-31181, 31183-31242, 31244-31392, 31394-31404, 31406-31474, 31476-31586, 31588-31603, 31606-31635, 31637-31796, 31799, 31801-31803, 31805-31818, 31821-31830, 31832-31881, 31883-31912, 31914-31959, 31961-31973, 31975-31977, 31979-32002, 32004-32017, 32019, 32021-32028, 32030-32068, 32071-32187, 32189-32197, 32199-32239, 32243,32245, 32246, 32248-32251, 32253-32263, 32265-32271, 32273, 32275-32281, 32283-32285, 32287-32289, 32291-32302, 32304, 32305, 32307-32314, 32316-32413, 32415-32445, 32447-32472, 32474-32483, 32485-32487, 32489-32554, 32556, 32558-32712, 32815-32869, 32871-32891, 32893-32909, 32911-32942, 32944-32946, 32948-32961, 32963-32992, 32994-33032, 33034-33036, 33038-33054, 33056-33087, 33090-33115, 33117, 33119-33126, 33128-33135, 33138-33140, 33142, 33144-33164, 33166-33168, 33170-33176, 33179-33191, 33193-33195, 33198-33211, 33213, 33215-33217, 33219, 33221-33232, 33234-33238, 33240, 33241, 33243, 33244, 33246-33253, 33255-33325, 33327-33414, 33416-33424, 33426, 33427, 33430-33436, 33438, 33439, 33442, 33444-33473, 33475, 33477-33491, 33493-33505, 33507-33527, 33529-33531, 33533-33540, 33542-33498, 33500,33551, 33553-33571, 33573-33595, 33598-33600, 33602-33618, 33630-33646, 33648-33657, 33659-33665, 33667-33674, 33676, 33677, 33679-33717, 33719-33728, 33730, 33732-33737, 33741-33763, 33765, 33767, 33768, 33770-33775, 33777-33794, 33796-33803, 33805-33814, 33817, 33818, 33820-33823, 33825-33834, 33836-33839, 33841-33844, 33846-33865, 33867-33888, 33890-33912, 33914, 33915, 33917-33933,33935-33952, 33954-33961, 33964, 33967, 33969, 33970, 33972, 33973, 33975-33977, 33979, 33981-33983, 33985-33987, 33989-33992, 33994, 33995, 33997-34000, 34002, 34005, 34007-34028, 34030-34034, 34036-34042, 34044-34048, 34051-34067, 34069-34080, 34082-34099, 34101-34103, 34105-34107, 34109, 34110, 34113-34115, 34117-34122, 34124-34135, 34137-34141, 34143-34145, 34147-34149, 34151, 34152, 34154-34156, 34158-34161, 34163-34180, 34182, 34184, 34185, 34187-34192, 34194-34200, 34203-34206, 34208-34211, 34213, 34214, 34216, 34217, 34220, 34222-34224, 34226-34228, 34230-34233, 34235-34238, 34241-34249, 34251-34254, 34256, 34257, 34259-34261, 34263-34271, 34274-34276, 34279-34284, 34286-34287, 34289, 34290, 34292, 34294-34298, 34300-34305, 34307-34309, 34311-34314, 34317, 34319, 34321, 34322, 34324, 34327-34330, 34334-34336, 34338, 34342, 34345-34347, 34350, 34351, 34353-34356, 34359, 34360, 34362, 34363, 34366-34370, 34372, 34374-34376, 34378-34382, 34384, 34385, 34391, 34392, 34399, 34401-34412, 34415, 34416, 34418, 34420-34423, 34427, 34428, 34432-34435, 34437, 34438, 34440, 34447-34454, 34456-34461, 34465, 34466, 34470-34505, 34507-34516, 34538, 34545-34549, 34553-34557, 34560-34577, 34580, 34586, 34587, 34597, 34599, 34604-34607, 34615, 34616, 34619-34621, 34630, 34633, 34635-34642, 34644, 34645, 34651-34654, 34660, 34669, 34670, 34672, 34679, 34680, 34682, 34683, 34686, 34687, 34689-34721, 34723-34728, 34730, 34731, 34733-34739, 34741-34743, 34745-34748, 34760, 34782, 34785, 34786, 34790, 34799, 34800, 34806, 34807, 34814, 34816, 34826-34828, 34831-34833, 34836, 34839, 34840, 34844-34846, 34848-34852, 34854-34856, 34858, 34861, 34862, 34864-34867, 34869-34871, 34874, 34875, 34877, 34882, 34883, 34885, 34887-34890, 34892, 34894, 34896, 34898, 34900, 34901, 34903, 34911, 34913, 34918, 34919, 34921-34925, 34927, 34929, 34931, 34934-34937, 34943, 34945-34947, 34949, 34952, 34957, 34960, 34965, 34969-34976, 34979, 34980, 34983, 34986, 34988, 34990-34993, 34995, 34998-35002, 35007, 35009-35011, 35013, 35015-35018, 35020, 35023, 35027, 35029, 35031, 35033, 35036, 35043, 35044, 35046, 35047, 35050, 35052, 35055-35065, 35067, 35069, 35070, 35076-35084, 35086-35128, 35130-35146, 35151, 35154-35171, 35173, 35194, 35197-35206, 35216, 35219, 35220, 35224, 35226-35228, 35230-35236, 35241, 35243-35246, 35248-35252, 35254-35262, 35266-35272, 35274-35277, 35279-35297, 35299-35301, 35303, 35305, 35306, 35311, 35315-35378, 35384, 35386, 35392, 35394-35340, 35410, 35417, 35422, 35426, 35433, 35435, 35437-35439, 35441, 35455-35459, 35461, 35464, 35466-35467, 35470-35474, 35478-35484, 35489-35514, 35516, 35518-35520, 35522-35530, 35532-35549, 35551-35595, 35600-35607, 35617, 35668, 35669, 35671, 35672, 35674-35677, 35682, 35684-35686, 35688-35691, 35693, 35694, 35696,35697, 35699, 35701, 35703-35707, 35709, 35714, 35716-35719, 35721, 35723-35738, 35740-35755, 35757-35760, 35762, 35765, 35767-35774, 35776-35778, 35783, 35786, 35788, 35789, 35791-35793, 35795-35798, 35800-35802, 35804, 35805, 35807, 35808, 35810-35825, 35827, 35829-35835, 35837-35840, 35842-35848, 35851-35860, 35871, 35896, 35900-35902, 35905-35907, 35913, 35929, 35933-35937, 35939, 35940, 35942-35945, 35947-35952, 35956, 35959, 35960, 35962, 35964-35967, 35973-35975, 35977-35980, 35983-35990, 35992, 35993, 35995, 35997, 36000-36002, 36007, 36012-36014, 36018, 36019, 36023, 36025, 36026, 36030, 36032-36034, 36038, 36043, 36047, 36050-36052, 36054, 36055, 36057, 36058, 36060, 36061, 36063, 36065, 36067-36072, 36074, 36077-36079, 36081, 36083, 36084, 36088-36091, 36094, 36097, 36098, 36101, 36102, 36104-36106, 36110, 36111, 36118, 36119, 36123-36126, 36128, 36130, 36131, 36137, 36140-36142, 36146, 36147, 36152-36154, 36157, 36159, 36161, 36163, 36165, 36166, 36168, 36171-36173, 36175, 36184, 36190, 36194, 36197-36200, 36202, 36206, 36208, 36209, 36215, 36217, 36221, 36223, 36224, 36228, 36230, 36232-36234, 36236, 36240, 36241, 36245, 36246, 36249, 36250, 36252, 36260, 36261, 36267, 36271, 36276, 36277, 36282, 36284, 36289, 36297, 36298, 36301, 36303, 36305, 36306, 36309, 36310, 36317, 36320-36322, 36325, 36329, 36336-36338, 36341, 36346, 36349, 36352, 36354, 36357, 36360-36362, 36364, 36365, 36368, 36369, 36371, 36373, 36380, 36381, 36384, 36386-36396, 36404, 36405, 36407, 36408, 36410, 36412, 36414-36426, 36428, 36429, 36436, 36438, 36440, 36442, 36446, 36449-36451, 36454, 36464, 36468-36471, 36474-36476, 36479-36481, 36484-36486, 36488-36499, 36503, 36506, 36510, 36511, 36513, 36514, 36516, 36572, 36587-36589, 36591, 36593, 36598, 36601, 36609-36622, 36624-36629, 36631, 36633-36637, 36642, 36643, 36645, 36646, 36653, 36654, 36656, 36657, 36660, 36665, 36667-36670, 36673, 36674, 36676, 36677, 36682, 36684, 36686, 36688, 36697, 36699, 36700, 36703, 36704, 36707, 36710-36712, 36715, 36717-36719, 36721-36723, 36725, 36727, 36735, 36739, 36740, 36742-36749, 36801, 36802, 36807, 36816, 36818, 36825, 36828, 36835, 36840, 36844, 36862, 36876, 36878, 36885, 36888, 36891, 36896, 36903, 36906, 36907, 36910, 36911, 36915, 36926, 36931, 36933, 36935, 36937, 36946, 36950, 36958, 36980, 37012, 37036, 37054, 37065, 37069, 37071, 37099, 37132, 37645, 37670, 37671, 37834, 37840-37842, 37844, 37851-37856, 37858, 37867, 37870-37872, 37875-37877, 37882, 37885, 37892-37893, 37898, 37917, 37919, 37926, 37927, 37929, 37930, 37932, 37934, 37937, 37939, 37940, 37943, 37946, 37948, 37950, 37954, 37956-37959, 37961-37964, 37966, 37968, 37970, 37974, 37979-37981, 37985, 37988, 37990, 37992, 37993, 37995, 37997, 37998, 38005-38026, 38029-38031, 38034, 38037-38039

PARTS NEEDED

The flash files listed below are available for download on SISWeb.

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Old Flash File Number	New Flash File Number	Interlock
255-4930	262-3722	48
258-6910	262-3723	60
255-4931	262-3724	44
255-4932	262-3725	45
255-1267	262-3726	54
255-4933	262-3727	40
255-4934	262-3728	41
255-4935	262-3729	50
255-4936	262-3730	46
255-4937	262-3731	47
255-4938	262-3732	42
255-4939	262-3733	51
255-1268	262-3734	55
255-4940	262-3735	49
255-4941	262-3736	52
255-1269	262-3737	56
255-4942	262-3738	43
255-4943	262-3739	53

ACTION REQUIRED

There have been a few incidents when the engine RPM increases while engine speed is below low idle with hot fuel.

If this action occurs with an engine, complete the following steps.

Inspect the engine wiring for damage under the harness end bell at the ECM J1 connector.
Inspect the ECM J1 connector for corrosion at pin 70 and confirm the connector is seated correctly.
Verify the key switch circuit is working properly using the test detailed in the Troubleshooting Guide SENR9698.

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
0-24 mos	100%	1.0	0	0	0	0
NOTE: This is a 1.0 hr job.