PRODUCT IMPROVEMENT PROGRAM FOR REPLACING ENGINE ECM�S ON CERTAIN 777D, 785C, 789C, 793C OFF HIGHWAY TRUCKS, 3508B, 3512B, 3516B ENGINES, 992G, 994D WHEEL LOADERS, D11R TRACK TYPE TRACTORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING ENGINE ECM�S ON CERTAIN 777D, 785C, 789C, 793C OFF HIGHWAY TRUCKS, 3508B, 3512B, 3516B ENGINES, 992G, 994D WHEEL LOADERS, D11R TRACK TYPE TRACTORS

Usage:

SEBE9245

July 3, 2005
U-218
A-159
D-172
O-180

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING ENGINE ECM?S ON CERTAIN 777D, 785C, 789C, 793C OFF HIGHWAY TRUCKS, 3508B, 3512B, 3516B ENGINES, 992G, 994D WHEEL LOADERS, D11R TRACK TYPE TRACTORS
7610		PI30827

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30827" as the Part number and "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 "PI30827" as the Part Number, "7751" as the Group Number, "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.

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COMPLETION DATE	TERMINATION DATE
January 31, 2006	July 31, 2006

PROBLEM

Some machines may have a defective engine ECM that could cause the engine stop running or to not start.

AFFECTED PRODUCT

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Model	Identification Number
789C	2BW786, 790-792, 794-796, 799-802, 804-805, 808-811, 814, 817-819, 821-822, 831, 834, 836, 838
994D	3TZ334-335
3508B	5KW1681-1709, 1711-1713, 1715-1720
3512B	6GW1080, 1083-1084, 1088, 1090-1102, 1104-1106, 1108-1109, 1115, 1118 6RZ449-451 PTM372-400
D11R	7PZ984, 986, 988-990, 992-1032, 1034-1056 AAF243-244, 246
3516B	8NW817, 820
777D	AGC1721, 1731-1735, 1737-1751, 1753-1777, 1779-1780, 1782-1784, 1786-1796, 1798-1807, 1809-1825, 1828-1842, 1861, 1865, 1869-1871, 1874 DCB184-195
785C	APX559, 580-581, 583-590, 592, 594-607, 609-610, 612-614, 616-625, 628-629, 633, 638, 643
793C	ATY822-823, 825, 829, 832-843, 845-846, 849-856, 858-860, 874-876
992G	AZX356-357, 359-366

PARTS NEEDED

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Qty	Part Number	Description
1	1767503	CONT GP

ACTION REQUIRED

See the attached Rework Procedure.

OWNER NOTIFICATION

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

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
100%	2.0	0	0	0	0
NOTE: This is a 2.0 hour job. NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report

PARTS DISPOSITION

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

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING ECM?S

MODELS INVOLVED - CERTAIN 777D, 785C, 789C, 793C OFF HIGHWAY TRUCKS, 3508B, 3512B, 3516B ENGINES, 992G, 994D WHEEL LOADERS, D11R TRACK TYPE TRACTORS

Dear Caterpillar Product Owner:

A new ECM needs to be installed on the products listed below. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated July 3, 2005 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to July 3, 2005 Service Letter

Rework Procedure

To identify the ECM part number, connect your computer equipped with ET2004B sp1 to engine and locate the ECM serial number in ET. If the serial number is within the range listed below the ECM must be visually validated as explained by *visual verification.

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Part Number	Serial Number Start	Serial Number End
176-7503	3384B001CD	3654B001CD
176-7503	0005B001CD	0535B001CD

Using the table above, if the value of the first four digits of the serial number is less than the value of the first four digits of Serial Number Start or if the value of the first four are larger than the Serial Number End listed above the ECM is out of range.

Example:

Part number 176-7503 s/n 3484B001CD falls with in the range.
Part number 176-7503 s/n 3184B001CD is before the range.
Part number 176-7503 s/n 0615B12CD is beyond the range.

If the serial number is outside the range, no further action is required.

*Visual Verification ? It is possible that the ECM has been corrected, even if the serial number exists within the affected range. All ECMs have the serial number engraved on the housing as shown in figure 1. If the ECM has been corrected, a letter S will be imprinted directly below the serial number. Refer to figure 2.

Serial Number Location Figure 1

3484B001CD
S
Figure 2 Corrected ECM Marking

If the ECM is within the serial number range, but does not have the ?S? indicating it has been corrected, the ECM should be replaced. Follow the steps in the troubleshooting guide for Replacing the ECM