PRODUCT IMPROVEMENT PROGRAM FOR UPDATING THE SOFTWARE AND ADDING A SENSOR ON CERTAIN C27 LOCOMOTIVE ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR UPDATING THE SOFTWARE AND ADDING A SENSOR ON CERTAIN C27 LOCOMOTIVE ENGINES

Usage:

TEBE0740-00

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18Dec2013

O-539

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR UPDATING THE SOFTWARE AND ADDING A SENSOR ON CERTAIN C27 LOCOMOTIVE ENGINES
1920 1408 1901		PI10951

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10951" 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 "PI10951" 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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PROBLEM

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When the engine is subject to extreme cold temperatures and extended periods of engine idling with little to no load ice accumulates in the engine air intake manifold on certain C27 Locomotive Engines.

The current freeze protection strategy takes the engine to high idle with out operator notification. This can cause the vehicle to speed up in this application if left in forward/reverse.

There is a new software strategy that has been implemented to mitigate ice formations and prevent the engine from to high idle when in the forward/reverse position.

AFFECTED PRODUCT

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Model	Identification Number
C27	WJC00201-00216

PARTS NEEDED

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Qty	Part Number	Description
5	7K1181	STRAP-CABLE
1	3203061	SENSOR GP-PRESS
1	4460464	HARNESS AS-WRG
1	4503075	SFWR GP-A1000
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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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Update the software and add a new sensor.

Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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Owners in the following countries will receive the attached Owner Notification:
US
Canada
Australia
New Zealand

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 2.5-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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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR UPDATING THE SOFTWARE AND ADDING A SENSOR ON CERTAIN C27 LOCOMOTIVE ENGINES

MODELS INVOLVED - C27

Dear Cat Product Owner:

New software needs to be installed on the products listed below. The existing software can cause an uncomanded increase in engine speed. The current software has a feature that allows for the engine speed to increase in cold ambient conditions. When the conditions are met to trigger 'Arctic Cold Mode' the engine speed will increase. Engine speed will affect locomotive traction speed and an uncommanded increase in speed in conjunction with other circumstances and conditions could result in a risk of personal injury or death. You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated.

You may now search for open Safety Service Letters by entering your product serial number(s). Visit the SAFETY.CAT.COM website and click on the Product Safety page for more information. Please refer the dealer to their Service Letter dated 18Dec2013 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 18Dec2013 Service Letter

Rework Procedure

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Gain access to front left corner of engine.

Sufficient room will be required to run jumper harness 446-0464 from ECM to right hand side air plenum.

Image1.1.1

Remove existing 241-6170 plug.

Install 320-3061 sensor.

Connect 446-0464 harness to 320-3061 sensor.

Image1.2.1

Image1.2.2

Route harness along side existing engine harness.

Loosely install 5 7K-1181 straps at location denoted by arrows.

Remove cover at 120 pin connector.

Image1.3.1

Make appropriate connection to 120 pin connector
Pin 41 = C822-EG2
Pin 80 = G826-EG100
Pin 93 = G827-EG4

Re-install 120 pin cover.

Route and adjust 446-0464 harness.

Secure straps.

Image1.4.1

Image1.4.2

Install the new 4503075 software in the ECM.

To enable the new "Arctic Weather Strategy", Pin 46 on the J1/P1 connector will need to be sent to a switched ground. When Pin 46 is grounded this is acknowledging that it is deemed safe by the operator that the engine is in a Non-Work mode and the ECM has permission to take control of engine speed. When the conditions are met the engine will enter the new strategy.

2. Consult with the locomotive OEM to determine a ground signal that ensures the locomotive is in a Non-Work mode and for proper wiring diagrams. When the locomotive is placed in Neutral Pin 46 should be grounded.

The software features enabled when in this new mode are "Charge Air Cooler Out Temperature Protection" and "Arctic Cold Mode". These will only become active when Pin 46 is grounded and intake manifold temperatures are below 0C for a certain amount of time. The length of time varies between 1 to 3 hours depending on intake temperature. There are 2 requirements which allow an exit of Arctic Cold Mode. If intake manifold temperatures rise above 10C or Pin 46 is ungrounded. Meeting either one of these requirements independently will exit the Arctic Cold Mode strategy. The strategy will not start again until Pin 46 is grounded and the intake manifold temperatures are below 0C for the 1 to 3 hour timeline.