PRODUCT IMPROVEMENT PROGRAM FOR FLASHING THE ENGINE ECM WITH UPDATED SOFTWARE ON CERTAIN C27 GENSETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR FLASHING THE ENGINE ECM WITH UPDATED SOFTWARE ON CERTAIN C27 GENSETS

Usage:

REBE5398-02

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15Oct2009

(Revised 11Nov2009)

U-347

A-287

D-312

O-314

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR FLASHING THE ENGINE ECM WITH UPDATED SOFTWARE ON CERTAIN C27 GENSETS
1901 1920		PI31695

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31695" 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 "PI31695" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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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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NOTE:	This Revised Service Letter replaces the 15Oct2009 (Revised 28Oct2009) Service Letter. Changes have been made to Affected Product.

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COMPLETION DATE	TERMINATION DATE
30Apr2010	31Oct2010

PROBLEM

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Under certain conditions, existing engine software may cause the engine not to achieve full output power on certain C27 gensets.

AFFECTED PRODUCT

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Model

Identification Number

C27

DWB00102-00114, 116-123, 125-142, 144-158, 160-166, 168-169, 171-191, 193-195, 197-222, 224-230, 233-240, 242-254, 256-262, 264-286, 288-290, 292-300, 303-339, 341-387, 392-397, 402-421, 423-433, 435-442, 447-448, 453-455, 458-469, 471, 475, 477-478, 490-491, 494-501, 506, 509-513, 516-520, 522-524, 530, 534-538, 544-545, 548-553, 556-564, 569-571, 579-580, 583-606, 612-662, 664-690, 693-700, 704-711, 714-718, 720-738, 742-746, 750, 757-779, 783-784, 791-792, 795, 797-804, 807-808, 812, 815, 820-831, 834-843, 851-864, 867-881, 885-895, 900, 905-912, 921-932, 935, 938, 942-951, 955-960, 969-973, 975-981, 986-989, 992-1026, 1028-1035, 1037-1064, 1072-1089, 1094-1105, 1125-1126, 1130-1135, 1137-1142, 1144-1157, 1160-1173, 1177-1181, 1183-1191, 1194-1208, 1213, 1217-1231

PARTS NEEDED

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Qty	Part Number	Description
1	3459194	SOFTWARE GP-ELEK
1	LABEL	Engine Information Label (Order On-line)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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Give careful attention to serial numbers to determine the appropriate update for each genset. Refer to the attached Rework Procedure for details on the following sections.

SECTION I: PROCEDURE FOR REPLACING THE ENGINE INFORMATION LABEL
SECTION II: ECM FLASHFILE UPDATE
SECTION III: PROCEDURE FOR CHANGING FLS AND FTS

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OWNER NOTIFICATION

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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%	100%	0%	0%	0%	0%

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NOTE: This is a 1.5-hour job

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PARTS DISPOSITION

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

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

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR FLASHING THE ENGINE ECM WITH UPDATED SOFTWARE

MODELS INVOLVED - C27 Gensets

Dear Caterpillar Product Owner:

The engine ECM needs to be updated with new software on the products listed below. The existing engine software may cause the engine not to achieve full output power. 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 15Oct2009 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 15Oct2009 Service Letter

Rework Procedure

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NOTE: Perform these sections in order.

SECTION I: PROCEDURE FOR REPLACING THE ENGINE INFORMATION LABEL

NOTE: To eliminate unnecessary travel, Section I is required to be performed first, prior to traveling, arriving at the genset and performing Sections II and III.

A new Engine Information Label will be required after flashing the engine ECM and programming the new FLS and FTS numbers.

1. Begin at the SISWeb homepage. The address is https://sis.cat.com

2. From the SISWeb homepage, select the Engine Technical Marketing Information - TMI Link.

3. Once in TMI, input the serial number of the engine into the reference number box and select "serial number" in the drop down menu.

4. Press the "Retrieve Data" button.

5. Select the "Emissions Data" link.

6. Scroll to the bottom and click the link titled, "Need emissions replacement label - Click Here!". This will direct the user to the Large Power Systems Division Homepage.

7. Click on the emission / certificate replacement link.

Image1.7.1

8. Complete the dealer name and address information.

Image1.8.1

9. Complete the remaining fields with a red asterisk.

10. Select Engine Information Label (Rating, power info) as the label type. Enter the number of this Priority Program in the field titled "Reason for the replacement label request." It is also very important to have the engine serial number field completed with the correct information and to include the engine flashfile where indicated.

Image1.10.1

Image1.10.2

11. After receiving the new Engine Information Label, remove the old label and install the new label.

Section II: ECM Flashfile Update

1. Flash the ECM using the latest version of ET (Version 2007A minimum) with the software listed in Image 1.12.1 - Table 1: C27 Flashfile

Image1.12.1

Section III: Procedure for changing FLS and FTS

1. Refer to Images 1.16.1 - 1.16.10, Table 2 through Table 11: "C27 Serial Numbers with new FLS/FTS settings" to locate the genset serial number and the corresponding FLS and FTS values.

2. Use ET, under Service Menu - (F5)Configuration and System
Settings, change the FLS and FTS to the new values found in Table
2 through Table 11. Once completed, factory passwords will be required.

3. All factory passwords for this Service Letter can be obtained by contacting your Caterpillar Dealer Technical Communicator (TC), or by directly accessing the Caterpillar Factory Password System at https://fps.cat.com.

NOTE: If your Caterpillar Dealer TC is not available, or the Caterpillar Factory Password System cannot be accessed, you can contact the Caterpillar Global On-Highway Call Center at 1-800-447-4986 or 309-578-3901 during the Caterpillar Global On-Highway Call Center normal working hours; Monday thru Friday = 7:00am Central Standard Time (CST) to 11:30pm CST. Saturday = 7:00am to 4:30 pm CST.

- If contacting the Caterpillar Global On-Highway Call Center for factory passwords, PRESS 1 for On-Highway Truck Engines when prompted.

- Requesting passwords using the Caterpillar Global On-Highway Call Center, and not through the Caterpillar Factory Password System, will incur a $25.00 charge for which your dealer will be liable.

4: The following information will be required for password generation: (examples shown in parenthesis)

Engine Serial Number followed by the Checksum: (0XX00000-AB)
Diagnostic Clock and Value Indicator: (1234 hours/miles/kilometers (H,M, or K))
Work Order number: (ABC12345)
Service Tool Serial Number: (ET123456-5-A1)
ECM Serial Number:
Total Tattletale Value: (12)
Reason Code: (1)
Current FLS: (-13)
Current FTS: (+25)
Test Spec: (2T2562)
Caterpillar Dealer Code: (D090 (Carolina Cat))
Technicians full name: (John Doe)
All Documents That Prompts for Password, ie: Service Letters, Special
Instructions, etc. (PI12345)