PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING A NEW SENSOR, UPDATING SOFTWARE, AND UPDATING THE WATER LINES GROUP ON CERTAIN 789C OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING A NEW SENSOR, UPDATING SOFTWARE, AND UPDATING THE WATER LINES GROUP ON CERTAIN 789C OFF-HIGHWAY TRUCKS

Usage:

SEBE9070-01

February 20, 2005
(Revised April 2005)
U-49
A-36
D-42
O-42

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING A NEW SENSOR, UPDATING SOFTWARE, AND UPDATING THE WATER LINES GROUP ON CERTAIN 789C OFF-HIGHWAY TRUCKS
1380		PI30722

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30722" 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 "PI30722" 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.

NOTE: Some of the Affected Product fall into more than one group. Do all applicable portions of this Service Letter at the same time.

NOTE: This Revised Service Letter replaces the February 20, 2005 Service Letter. Changes have been made to the Parts Needed and Action Required.

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COMPLETION DATE	TERMINATION DATE
August 31, 2005	February 28, 2006

PROBLEM

Due to recent changes in the air induction system, a new sensor, software, and water lines group need to be installed or modified on certain 789C Off-Highway Trucks.

The changes need to be made as follows:

2BW704-2BW768 - The water lines group needs to be updated to eliminate interference between the 4W-1501 Tube and the new 249-5090 Tube. Interference between the tubes can result in a failure. See illustration below.

2BW704-2BW768 - A new software flash file needs to be installed in order to read both turbo inlet pressure sensors in the new air induction system. Some trucks were shipped from the factory without the new software; therefore these trucks will not be able to detect a plugged filter on one side.

2BW704-2BW803 - The new air induction design does not use a "balance tube" connecting the left and right air filters; therefore, two turbo inlet pressure sensors are now required. Some trucks were shipped from the factory with only one sensor; therefore these trucks will not be able to detect a plugged filter on one side.

AFFECTED PRODUCT

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Model	Identification Number
*** Group 1 ***
789C	2BW704-768

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Model	Identification Number
*** Group 2 ***
789C	2BW704-803

PARTS NEEDED

Dealers will need to order parts for this Program.

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Quantity	Part Number	Description
*** Group 1 ***
31 cm	5P1265	HOSE
1	7S8767	GASKET
1	2526369	BONNET
1	2526371	TUBE
1	2575918	SOFTWARE GP-ELEK

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Quantity	Part Number	Description
*** Group 2 ***
2	5M2894	WASHER-HARD
2	4P8134	CLIP-LADDER
2	0S0509	BOLT
2	6V5048	SEAL-O-RING
1	9X0262	ADAPTER
2	9X6772	STRAP-CABLE
1	1619926	SENSOR GP-PR

ACTION REQUIRED

Water Lines Update

Refer to the Service Manual Parts Book if/as required. Replace the existing 156-3668 Bonnet, 4W-1501 Tube, and 5P-1265 Hose(16 cm) with the new 252-6369 Bonnet, 252-6371 Tube, and 5P-1265 (31 cm). The 7S-8767 Gasket should also be replaced.

Sensor Update

Refer to the Service Manual Parts Book if/as required. Remove plug and add one 141-7132 Sensor & Mounting Gp (See "Parts Needed" Table above) to the 249-3766 Tube which is missing the sensor. The 249-3766 Tube on the right side will likely be the one missing the sensor. Connect the sensor to the additional harness provided on the front of the engine.

Software Update

Using Electronic Technician (ET), flash the new software file directly over the old file. Once the new software is installed, the ECM will need to be configured to the "dual" sensor mode (the default is "single" sensor mode). Please follow the following steps to properly configure the ECM:

...After the new engine software has been flashed into ECM, connect ET. Open the configuration screen by using the menu option Service à Configuration.

...In Configuration Group 2 there is a parameter Sec Turbo In Pres. This parameter has a default setting of "Not Installed".

...Click on this parameter and select "Installed", then click OK.

After configuring the sensor to "Installed", disconnect ET and turn the Keyswitch OFF for ~15 seconds. After turning the Keyswitch back ON, reconnect ET and verify that the Sec Turbo In Pres parameter is programmed to "Installed".

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.
*** Group 1 ***
100%	3	0	0	0	0
NOTE: This is a 3-hour job.
NOTE: U.S. and Canadian Dealers Only - This Program does not qualify for a Type 2 SIMS Report.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
*** Group 2 ***
100%	1	0	0	0	0
NOTE: This is a 1-hour job.
NOTE: U.S. and Canadian Dealers Only - This Program does not qualify for 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)

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999 PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING A NEW SENSOR, UPDATING SOFTWARE, AND UPDATING THE WATER LINES GROUP ON CERTAIN 789C OFF-HIGHWAY TRUCKS MODELS INVOLVED - 789C OFF-HIGHWAY TRUCKS

Dear Caterpillar Product Owner:

Due to recent changes in the air induction system, a new sensor, software, and water lines group need to be installed or modified on the products listed below. These changes will eliminate interference and update the system to prevent failures.

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 February 20, 2005 when scheduling this service. You will not be charged for the service performed.

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 February 20, 2005 Service Letter