PRODUCT SUPPORT PROGRAM FOR UPDATING SOFTWARE ON CERTAIN MODEL YEAR '07 C7 AND C9 ON-HIGHWAY TRUCK ENGINES
Usage:
REBE2116-01
Show/hide table
| 28Jun2007 |
| (Revised 15Aug2007) |
U-297
A-243
D-329
O-355
TT-19
Show/hide table
| Before/After | PRODUCT SUPPORT PROGRAM FOR UPDATING SOFTWARE ON CERTAIN MODEL YEAR '07 C7 AND C9 ON-HIGHWAY TRUCK ENGINES |
|
| 1902 1901 7620 | PS42447 |
|
Show/hide table
| NOTE: | This Program must 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 "PS42447" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code. |
Show/hide table
| 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. |
Show/hide table
| NOTE: | This Revised Service Letter replaces the 28Jun2007 Service Letter. Changes have been made to Affected Product, Parts Needed, and the Rework Procedure. |
Show/hide table
TERMINATION DATE |
| 30Jun2008 |
PROBLEM
Show/hide table
| Updates to certain C7 and C9 truck hardware and software have enhanced the diagnostic reporting. This software update also increased Caterpillar Regeneration System (CRS) robustness. The new software requires the addition of a Closed Crankcase Ventilation pressure sensor on early vintage engines. |
AFFECTED PRODUCT
Show/hide table
| Model | Identification Number |
| *******Group 1******* | |
| C7 | C7S00500, 514-515, 520-527, 531, 534, 536-537, 543, 548, 553, 557-1375, 1377-1379, 1382-1383, 1385, 1387-1396, 1398-1407, 1409-1413 |
Show/hide table
| *******Group 2******* | |
| C7 | C7S01414-01459, 1461-1467, 1469-1474, 1479, 1481-1483, 1485, 1487-1494, 1496-1497, 1500-1508, 1511-1566, 1568-1592, 1594-1610, 1612-1615, 1617-1944, 1946-2223, 2228, 2239, 2243, 2252, 2261-2262, 2264-2266, 2274, 2276, 2279, 2283, 2285-2286, 2289-2290, 2293, 2296, 2301-2553, 2651, 2711, 2741, 2768, 2789, 2792, 2808, 2811, 2814, 2820, 2840, 2843, 2846, 2850, 2857, 2874, 2879, 2890, 2953, 2964, 2991, 3029, 3108, 3178, 3198, 3238, 3244, 3254, 3264, 3298, 3390, 3423, 3545, 3549, 3567 |
Show/hide table
| *******Group 3******* | |
| C9 | C9S00500, 503-505 |
Show/hide table
| *******Group 4******* | |
| C9 | C9S00501-00502, 506-507 |
Show/hide table
| *******Group 5******* | |
| C9 | C9S00522-00523, 527, 531, 534-661, 664, 666, 668, 673-732 |
PARTS NEEDED
Show/hide table
Qty |
Part Number | Description |
| *******Group 1******* | ||
| 1 | 6V5048 | SEAL-O-RING |
| 1 | 6V5049 | SEAL-O-RING |
| 1 | 9X0261 | ADAPTER |
| 1 | 3056873 | SENSOR GP-PRESS |
| 1 | 3098611 | KIT-WIRING |
| 1 | 3139518 | SOFTWARE GP-ELEK |
| 1 | 3139519 | SOFTWARE GP-ELEK |
| 1 | 3139520 | SOFTWARE GP-ELEK |
| 1 | 3139521 | SOFTWARE GP-ELEK |
| 1 | 3139522 | SOFTWARE GP-ELEK |
| 1 | 3139523 | SOFTWARE GP-ELEK |
| 1 | 3139524 | SOFTWARE GP-ELEK |
| 1 | 3139525 | SOFTWARE GP-ELEK |
| 1 | 3139526 | SOFTWARE GP-ELEK |
| 1 | 3139527 | SOFTWARE GP-ELEK |
| 1 | 3139528 | SOFTWARE GP-ELEK |
| 1 | 3139529 | SOFTWARE GP-ELEK |
| 1 | 3139530 | SOFTWARE GP-ELEK |
| 1 | 3139531 | SOFTWARE GP-ELEK |
| 1 | 3139532 | SOFTWARE GP-ELEK |
| 1 | 3139533 | SOFTWARE GP-ELEK |
| *******Group 2******* | ||
| 1 | 3139518 | SOFTWARE GP-ELEK |
| 1 | 3139519 | SOFTWARE GP-ELEK |
| 1 | 3139520 | SOFTWARE GP-ELEK |
| 1 | 3139521 | SOFTWARE GP-ELEK |
| 1 | 3139522 | SOFTWARE GP-ELEK |
| 1 | 3139523 | SOFTWARE GP-ELEK |
| 1 | 3139524 | SOFTWARE GP-ELEK |
| 1 | 3139525 | SOFTWARE GP-ELEK |
| 1 | 3139526 | SOFTWARE GP-ELEK |
| 1 | 3139527 | SOFTWARE GP-ELEK |
| 1 | 3139528 | SOFTWARE GP-ELEK |
| 1 | 3139529 | SOFTWARE GP-ELEK |
| 1 | 3139530 | SOFTWARE GP-ELEK |
| 1 | 3139531 | SOFTWARE GP-ELEK |
| 1 | 3139532 | SOFTWARE GP-ELEK |
| 1 | 3139533 | SOFTWARE GP-ELEK |
| *******Group 3******* | ||
| 3 | 3S2093 | STRAP-CABLE |
| 1 | 6V5048 | SEAL-O-RING |
| 1 | 6V5049 | SEAL-O-RING |
| 1 | 9X0261 | ADAPTER |
| 1 | 3056873 | SENSOR GP-PRESS |
| 1 | 3094564 | HARNESS AS.-WRG |
| 1 | 3139569 | SOFTWARE GP-ELEK |
| 1 | 3139570 | SOFTWARE GP-ELEK |
| 1 | 3139571 | SOFTWARE GP-ELEK |
| 1 | 3139573 | SOFTWARE GP-ELEK |
| 1 | 3139575 | SOFTWARE GP-ELEK |
| 1 | 3139577 | SOFTWARE GP-ELEK |
| *******Group 4******* | ||
| 1 | 6V5048 | SEAL-O-RING |
| 1 | 6V5049 | SEAL-O-RING |
| 1 | 9X0261 | ADAPTER |
| 1 | 3056873 | SENSOR GP-PRESS |
| 1 | 3098611 | KIT-WIRING |
| 1 | 3139572 | SOFTWARE GP-ELEK |
| 1 | 3139574 | SOFTWARE GP-ELEK |
| 1 | 3139576 | SOFTWARE GP-ELEK |
| *******Group 5******* | ||
| 1 | 3139569 | SOFTWARE GP-ELEK |
| 1 | 3139570 | SOFTWARE GP-ELEK |
| 1 | 3139571 | SOFTWARE GP-ELEK |
| 1 | 3139572 | SOFTWARE GP-ELEK |
| 1 | 3139573 | SOFTWARE GP-ELEK |
| 1 | 3139574 | SOFTWARE GP-ELEK |
| 1 | 3139575 | SOFTWARE GP-ELEK |
| 1 | 3139576 | SOFTWARE GP-ELEK |
| 1 | 3139577 | SOFTWARE GP-ELEK |
ACTION REQUIRED
Show/hide table
| Group 1, Group 3, and Group 4 require a hardware and software update. Group 2 and Group 5 require a software update only. Refer to attached Rework Procedure. Note: Group 1, Group 3, and Group 4 procedure details follow Group 2 and Group 5 procedure details in the Rework Procedure. |
Show/hide table
SERVICE CLAIM ALLOWANCES
Show/hide table
| *******Group 1******* | ||||||
| NOTE: This is a 1.5-hour job for Group 1 | ||||||
Show/hide table
| *******Group 2******* | ||||||
| NOTE: This is a 0.5-hour job for Group 2 | ||||||
Show/hide table
| *******Group 3******* | ||||||
| NOTE: This is a 2.5-hour job for Group 3 | ||||||
Show/hide table
| *******Group 4******* | ||||||
| NOTE: This is a 1.5-hour job for Group 4 | ||||||
Show/hide table
| *******Group 5******* | ||||||
| NOTE: This is a 0.5-hour job for Group 5 | ||||||
PARTS DISPOSITION
| Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. |
| Group Number 2 Group Number 5 |
| "Procedure for Updating the Personality Module Part Number" Using Caterpillar Electronic Technician (ET) 2007B or newer, connect with Dual Data Link (J1939 and ATA). If Dual Data Link is not enabled diagnostic and service test will not function properly. 2007B is required for service test to operate correctly. Determine the ECM Personality Module Part Number. If the ECM Personality Module Part Number currently installed on the truck is not the same as the Part Number listed on SIS WEB, the truck must be flashed with the correct ECM Personality Module Part Number. After determining the correct ECM software to be flashed, download the correct Personality Module Software from SIS Web, save the software file on your service tool computer. Using ET, connect to the engine ECM. Copy the current engine ECM Configuration. This will save the customer configuration and injector trim codes. Before taking this replacement file, make sure the dashboard display in ET is disabled or the file may not copy injector trim files correctly. To shut the dashboard display off, toggle the dashboard display button in the lower right hand corner of the active diagnostics or ECM summary windows in ET. The service tool dashboard should be red when disabled. Disconnect ET from the engine ECM by clicking on the disconnect button at the top of the ET screen and then reconnect. In ET, click on the "Service" drop down menu and select "Configuration" then "Copy Configuration/ECM Replacement". Save this file to be used later in the procedure. In the "Diagnostic" drop down menu, view the "Active Diagnostic" codes. If active codes are present, use the "Reset All" button, clear all active diagnostic codes. Connect to the ECM with "WinFlash". Select the new Personality Module Software Part Number and begin the flashing process. After the flash process is complete reconnect with ET. Review the "Configuration" to ensure Injector trim files and other configurable parameters are correct. Also, set vehicle voltage selection under system settings to the applicable value (12V or 24V). If configuration is not correct, from the "Service" drop down menu, perform a "Copy Configuration ECM Replacement" and "Load from File". Select the previously saved configuration file and program the file into the ECM configuration. Note: Changes in how diagnostic codes are triggered may cause new active codes to appear after flashing the new software file. If the service letter is being performed pro-actively then the flashing and any additional repairs performed to correct new active codes caused by flashing the new software should be submitted to warranty using PD code 56. Return truck to service. |
| Group Number 1 |
| C7 Hardware Update to install Closed Crankcase Ventilation (CCV) Sensor: Remove plug from valve cover base. The plug is located on the left side of the base, near the end of the fuel rail. Install 9X-0261 adapter into the base with a 6V-5049 o-ring. Tighten to 12.5 lb ft (17 Nm). Install 305-6873 pressure sensor with a 6V-5048 o-ring into the adapter previously installed. Tighten to 7.4 lb ft (10 Nm). Refer to Image 2.1.1 Refer to Image 2.1.2 Locate the Close Crankcase Ventilation (CCV) connector on the main engine harness. This breakout will be labeled CCV sensor and is located near the location of the new sensor. Refer to Image 2.1.3 Install jumper harness kit 309-8611 between the new pressure sensor and the CCV breakout on the main engine harness. Secure the wiring harness away from any moving parts, pinch points, or excessively hot components using the straps included in the harness kit. Follow the "Procedure for Updating the Personality Module Part Number" included in the rework instructions for Groups 2 and 5. |
|
| Image2.1.1 |
|
| Image2.1.2 |
|
| Image2.1.3 |
| Group Number 3 |
| C9 truck hardware update to install closed crankcase ventilation (CCV) sensor. Remove plug from the cylinder head. the plug is located just above the ECM, under the cylinder head air box. Install 9X-0261 adapter into the head with a 6V-5049 o-ring. Tighten to 12.5 lb ft(17 N-m). Install 305-6873 pressure sensor with a 6V-5048 o-ring into the adapter previously installed. Tighten to 7.4 lb ft (10 N-m). Refer to image 3.1.1 Refer to image 3.1.2 Refer to image 3.1.3 Locate the closed crankcase ventilation (CCV) connector on the main engine harness. This breakout will be labeled CCV sensor and is located near the location of the new sensor. Install the 309-4564 harness between the new pressure sensor and the breakout on the main engine harness. Secure the wiring harness away from any moving parts, pinch points, or excessively hot components. Secure the harness using the 3S-2093 straps. Refer to image 3.1.4 Follow the "Procedure for Updating the Personality Module Part Number" included in the rework instructions for Groups 2 and 5. |
|
| Image3.1.1 |
|
| Image3.1.2 |
|
| Image3.1.3 |
|
| Image3.1.4 |
| Group Number 4 |
| C9 RV hardware update to install closed crankcase ventilation (CCV) sensor. Remove plug from the cylinder head. The plug is located just above the ECM, under the cylinder head air box. Install 9X-0261 adapter into the head with a 6V-5049 o-ring. Tighten to 12.5 lb ft (17 N-m). Install 305-6873 pressure sensor with a 6V-5048 o-ring into the adapter previously installed. Tighten to 7.4 lb ft (10 N-m). Refer to image 4.1.1 Refer to image 4.1.2 Refer to image 4.1.3 Locate the closed crankcase ventilation (CCV) connector on the main engine harness. This breakout will be labeled CCV sensor and is located near the location of the new sensor. Install 309-8611 harness kit between the new pressure sensor and the breakout on the main engine harness. Secure the wiring harness away from any moving parts, pinch points, or excessively hot components using the straps included in the harness kit. Refer to image 4.1.4 Follow the "Procedure for Updating the Personality Module Part Number" included in the rework instructions for Groups 2 and 5. |
|
| Image4.1.1 |
|
| Image4.1.2 |
|
| Image4.1.3 |
|
| Image4.1.4 |
Caterpillar Information System:
PRODUCT SUPPORT PROGRAM FOR THE REPLACEMENT OF THE LOW PRESSURE ACTUATORS (LPA) FOR THE INTAKE VALVE ON CERTAIN C11 AND C13 TRUCK ENGINES PRODUCT SUPPORT PROGRAM FOR THE REPLACEMENT OF THE LOW PRESSURE ACTUATORS (LPA) FOR THE INTAKE VALVE ON CERTAIN C11 AND C13 TRUCK ENGINES
PRODUCT SUPPORT PROGRAM FOR REPLACING PISTON RINGS IN CAPACITY BRAND YARD JOCKEYS WITH THE C7 ENGINE PRODUCT SUPPORT PROGRAM FOR REPLACING PISTON RINGS IN CAPACITY BRAND YARD JOCKEYS WITH THE C7 ENGINE
PRODUCT IMPROVEMENT PROGRAM FOR REMOVING CERTAIN 1R-0750 AND 1R-0751 FUEL FILTERS FROM DEALER STOCK PRODUCT IMPROVEMENT PROGRAM FOR REMOVING CERTAIN 1R-0750 AND 1R-0751 FUEL FILTERS FROM DEALER STOCK
PRODUCT SUPPORT PROGRAM FOR REPAIR OF ELECTRICAL WIRING ADJACENT TO FERRITE BEAD, INSTALLATION OF SHRINK TUBING AROUND BEAD, AND FLASHING OF NEW SOFTWARE PRODUCT SUPPORT PROGRAM FOR REPAIR OF ELECTRICAL WIRING ADJACENT TO FERRITE BEAD, INSTALLATION OF SHRINK TUBING AROUND BEAD, AND FLASHING OF NEW SOFTWARE
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTION AND REPAIR OF ELECTRICAL WIRING ADJACENT TO FERRITE BEAD, INSTALLATION OF SHRINK TUBING AROUND BEAD, AND FLASHING NEW SOFTWARE ON CERTAIN 3508B, 3512B, 3512C, 3516B HD, AND 3516C MARINE ENGINES PRODUCT IMPROVEMENT PROGRAM FOR INSPECTION AND REPAIR OF ELECTRICAL WIRING ADJACENT TO FERRITE BEAD, INSTALLATION OF SHRINK TUBING AROUND BEAD, AND FLASHING NEW SOFTWARE ON CERTAIN 3508B, 3512B, 3512C, 3516B HD, AND 3516C MARINE ENGINES
PRODUCT IMPROVEMENT PROGRAM FOR REMOVING 125-4352 WATER PUMPS FROM DEALER STOCK PRODUCT IMPROVEMENT PROGRAM FOR REMOVING 125-4352 WATER PUMPS FROM DEALER STOCK
PRODUCT SUPPORT PROGRAM FOR UPDATING SOFTWARE ON CERTAIN 07 MODEL YEAR C13 AND C15 ON-HIGHWAY TRUCK ENGINES PRODUCT SUPPORT PROGRAM FOR UPDATING SOFTWARE ON CERTAIN 07 MODEL YEAR C13 AND C15 ON-HIGHWAY TRUCK ENGINES
PRODUCT SUPPORT PROGRAM TO REPAIR CAMSHAFT LOBES AND LIFTERS IN CERTAIN 3500B SERIES MARINE ENGINES WITH A RATED SPEED OF 1600RPM PRODUCT SUPPORT PROGRAM TO REPAIR CAMSHAFT LOBES AND LIFTERS IN CERTAIN 3500B SERIES MARINE ENGINES WITH A RATED SPEED OF 1600RPM
PRODUCT SUPPORT PROGRAM TO REPAIR CAMSHAFT LOBES AND LIFTERS IN CERTAIN 3508B, 3512B, AND 3516B MARINE ENGINES WITH A RATED SPEED OF GREATER THAN 1301RPM PRODUCT SUPPORT PROGRAM TO REPAIR CAMSHAFT LOBES AND LIFTERS IN CERTAIN 3508B, 3512B, AND 3516B MARINE ENGINES WITH A RATED SPEED OF GREATER THAN 1301RPM
PRODUCT SUPPORT PROGRAM TO REPAIR CAMSHAFT LOBES AND LIFTERS IN CERTAIN 3500B SERIES MARINE ENGINES WITH A RATED SPEED OF 1200RPM PRODUCT SUPPORT PROGRAM TO REPAIR CAMSHAFT LOBES AND LIFTERS IN CERTAIN 3500B SERIES MARINE ENGINES WITH A RATED SPEED OF 1200RPM
PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE HIGH PRESSURE TURBOCHARGER ON CERTAIN C15 TRUCK ENGINES PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE HIGH PRESSURE TURBOCHARGER ON CERTAIN C15 TRUCK ENGINES
PRODUCT IMPROVEMENT PROGRAM FOR REPLACING TOP MOUNTED EXHAUST MANIFOLD ON SPECIFIED C6.6 INDUSTRIAL ENGINES PRODUCT IMPROVEMENT PROGRAM FOR REPLACING TOP MOUNTED EXHAUST MANIFOLD ON SPECIFIED C6.6 INDUSTRIAL ENGINES
PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING AN ALTERNATOR WIRING HARNESS AND CIRCUIT BREAKER ON CERTAIN 3500B AND 3500C PETROLEUM APPLICATION ENGINES PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING AN ALTERNATOR WIRING HARNESS AND CIRCUIT BREAKER ON CERTAIN 3500B AND 3500C PETROLEUM APPLICATION ENGINES
PRODUCT SUPPORT PROGRAM FOR REPLACING FAILED AFTERCOOLER CORES ON 3606 AND 3608 DIESEL MARINE ENGINES. PRODUCT SUPPORT PROGRAM FOR REPLACING FAILED AFTERCOOLER CORES ON 3606 AND 3608 DIESEL MARINE ENGINES.
PRODUCT SUPPORT PROGRAM FOR REFLASHING ENGINE SOFTWARE ON CERTAIN C18 INDUSTRIAL ENGINES, AD55/AD45 UNDERGROUND ARTICULATED TRUCKS, AND PM-201 COLD PLANERS PRODUCT SUPPORT PROGRAM FOR REFLASHING ENGINE SOFTWARE ON CERTAIN C18 INDUSTRIAL ENGINES, AD55/AD45 UNDERGROUND ARTICULATED TRUCKS, AND PM-201 COLD PLANERS
PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE PISTON ASSEMBLIES IN CERTAIN 3044CT ENGINES PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE PISTON ASSEMBLIES IN CERTAIN 3044CT ENGINES
PRODUCT SUPPORT PROGRAM FOR INSTALLING IMPROVED FUEL MANIFOLD BRACKET ON CERTAIN 2007 C15 ON-HIGHWAY TRUCK ENGINES PRODUCT SUPPORT PROGRAM FOR INSTALLING IMPROVED FUEL MANIFOLD BRACKET ON CERTAIN 2007 C15 ON-HIGHWAY TRUCK ENGINES
PRODUCT IMPROVEMENT PROGRAM FOR RE-FLASHING NEW SOFTWARE ON CERTAIN 3516B 50HZ GENERATOR SETS EQUIPPED WITH ADEM II ENGINE ELECTRONIC CONTROL MODULES (ECM) PRODUCT IMPROVEMENT PROGRAM FOR RE-FLASHING NEW SOFTWARE ON CERTAIN 3516B 50HZ GENERATOR SETS EQUIPPED WITH ADEM II ENGINE ELECTRONIC CONTROL MODULES (ECM)
PRODUCT SUPPORT PROGRAM FOR REPORTING THE USAGE OF IMPROPER FUEL ON 2007 ON-HIGHWAY TRUCK ENGINES PRODUCT SUPPORT PROGRAM FOR REPORTING THE USAGE OF IMPROPER FUEL ON 2007 ON-HIGHWAY TRUCK ENGINES
PRODUCT SUPPORT PROGRAM FOR REWORKING THE PURGE AIR PUMP CHECK VALVE ON CERTAIN C13 AND C15 ON-HIGHWAY TRUCK ENGINES. PRODUCT SUPPORT PROGRAM FOR REWORKING THE PURGE AIR PUMP CHECK VALVE ON CERTAIN C13 AND C15 ON-HIGHWAY TRUCK ENGINES.
PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING DISCRETE I/O MODULES AND/OR ITS MOUNTING GROUP ON CERTAIN 3516B AND 3516C 60HZ GENRATOR SETS PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING DISCRETE I/O MODULES AND/OR ITS MOUNTING GROUP ON CERTAIN 3516B AND 3516C 60HZ GENRATOR SETS
PRODUCT IMPROVEMENT PROGRAM FOR MISSING SHIPPED LOOSE PARTS ON MOUNT AS. (232-0536) ON CERTAIN C32 MODELS PRODUCT IMPROVEMENT PROGRAM FOR MISSING SHIPPED LOOSE PARTS ON MOUNT AS. (232-0536) ON CERTAIN C32 MODELS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL LINE SUPPORT BRACKETS AND HARDWARE ON CERTAIN 3516BHD LOCOMOTIVE ENGINES PRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL LINE SUPPORT BRACKETS AND HARDWARE ON CERTAIN 3516BHD LOCOMOTIVE ENGINES
PRODUCT SUPPORT PROGRAM FOR REWORKING THE FUEL FILTER BASE ON CERTAIN 3456 GENSETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE FUEL FILTER BASE ON CERTAIN 3456 GENSETS