PRODUCT SUPPORT PROGRAM FOR INSTALLING REPLACING FLASH FILE AND INJECTORS ON CERTAIN 953D AND 963D TRACK LOADERS, M316D, M318D, AND M322D WHEELED EXCAVATORS, CP-563F, CP-573F, CS-573F, CS-583F, CS56, CS74, CS76 SOIL COMPACTORS, AP-655D PAVERS, AND C6 Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING REPLACING FLASH FILE AND INJECTORS ON CERTAIN 953D AND 963D TRACK LOADERS, M316D, M318D, AND M322D WHEELED EXCAVATORS, CP-563F, CP-573F, CS-573F, CS-583F, CS56, CS74, CS76 SOIL COMPACTORS, AP-655D PAVERS, AND C6.6 INDUSTRIAL ENGINES [REBE3919]

ELECTRICAL AND STARTING SYSTEM

ELECTRONICS GP-ENGINE

REBE3919-01

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19Jun2008

(Revised 01Aug2008)

U-325

A-268

D-267

O-293

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR INSTALLING REPLACING FLASH FILE AND INJECTORS ON CERTAIN 953D AND 963D TRACK LOADERS, M316D, M318D, AND M322D WHEELED EXCAVATORS, CP-563F, CP-573F, CS-573F, CS-583F, CS56, CS74, CS76 SOIL COMPACTORS, AP-655D PAVERS, AND C6.6 INDUSTRIAL ENGINES
1920 1901 7620 1252 1290 1251		PS51511

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS51511" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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 AVSpare product analyst.

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NOTE:	This Revised Service Letter replaces the 19Jun2008 Service Letter. Changes have been made to Parts Needed.

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TERMINATION DATE

30Jun2010

PROBLEM

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The existing flash file and injectorS can create an X-7 code in the ECM on certain 953D and 963D Track Loaders, M316D, M318D, and M322D Wheeled Excavators, CP-563F, CS-573F, CP-573F CS-583F, CS74, CS56, CS76 Soil Compactors AP-655D Pavers and C6.6 Industrial Engines. If the existing flash file and injectors fail it will cause an X-7 code in the ECM which cannot be removed whithout the latest flash file and injectors.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C6.6 TIER 3	66600485, 524-532, 536, 550-554, 556-564, 566-594, 596-601, 603-615, 629, 635-649, 651, 657, 661, 676-677, 679-695, 697-710, 718, 749, 813-819, 826-829, 843-862, 870-884, 895-913, 921, 938-944, 962-966, 968-986, 1014, 1041-1044, 1048-1051, 1061-1068, 1103-1104, 1107, 1109-1113, 1131-1135, 1137-1145, 1179-1182, 1224-1225, 1241-1242, 1244-1259, 1276-1281, 1305-1315, 1328, 1349-1361, 1363-1364, 1369, 1397-1398, 1419-1429, 1432-1434, 1436, 1438-1439, 1441-1442, 1453, 1467, 1471, 1493-1509, 1511-1525, 1534-1562, 1564-1565, 1568-1598, 1601-1606, 1608-1620, 1622-1634, 1636-1658, 1688, 1692, 1696-1702, 1704-1706, 1709-1735, 1737-1740, 1742-1745, 1760-1761, 1763-1767, 1769-1770, 1773-1776, 1778-1780, 1782-1783, 1787-1795, 1797-1824, 1826, 1828, 1830-1839, 1841-1844, 1846-1853, 1856-1867, 1882-1887, 1893-1894, 1898, 1903-1904, 1909-1911, 1913-1920, 1922-1926, 1930-1931, 1933-1934, 1938-1948, 1950-1956, 1958-1961, 1964, 1967-1968, 1971, 1973-1977, 1979, 1983, 1985, 1988-1989, 1991-1993, 2005-2008, 2012, 2067-2068, 2089-2094, 2099-2100, 2102, 2124-2125, 2166, 2172, 2198, 2283-2288, 2361, 2446-2448, 2483, 2506-2507, 2568, 2619-2625, 2667, 2732, 2744-2745, 2754-2756, 2760-2763, 2771, 2775-2778, 2843-2847, 2872-2873, 2930, 2947, 2983, 2985-2989, 3005-3012, 3064, 3084, 3123-3129, 3148

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*****Group 2*****
963D	LCS00211-00212, 214-219, 221, 226, 228-229, 231-232, 234-236, 238, 244-245, 259, 262, 265-266, 269, 271, 275-276, 298

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*****Group 3*****
M316D	W6A00291, 293
M318D	W8P00441
M322D	W2S00116, 118

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*******Group 4*******

C6.6 TIER 3

66600654, 656, 663, 712, 719-722, 742-748, 788-796, 806, 919-920, 923-926, 928-937, 946, 957-958, 960, 1004, 1045-1046, 1053-1060, 1070, 1076-1089, 1092, 1094-1095, 1097-1100, 1105-1106, 1146-1151, 1153-1156, 1158, 1160, 1162-1164, 1166-1169, 1171-1178, 1195, 1197-1199, 1260-1275, 1282-1288, 1290-1295, 1297-1304, 1316-1326, 1331-1341, 1343-1348, 1365, 1367-1368, 1370-1371, 1373-1376, 1394-1395, 1401-1403, 1430, 1468, 1492, 1563, 1670-1671, 1689, 1736, 1747, 1756, 1878-1881, 1888-1890, 1899-1902, 2026-2032, 2108, 2114-2122, 2137, 2139-2150, 2181-2192, 2194-2195, 2199-2206, 2211-2220, 2227-2228, 2237-2240, 2249, 2274, 2309-2310, 2409-2412, 2453-2464, 2470-2482, 2508-2509, 2585-2606, 2614-2618, 2629-2639, 2671-2675, 2709, 2736, 2741-2742, 2746, 2750-2753, 2758-2759, 2774, 2806-2815, 2849-2871, 2927-2929, 2948-2958, 2974, 2997-3004, 3013-3016, 3020-3029, 3048-3051, 3060-3061, 3063, 3065-3067, 3130-3133, 3142-3145, 3190-3192, 3225, 3238, 3341, 3369-3376, 3388-3389, 3403, 3414-3425, 3469, 3493-3494, 3530-3531, 3621, 3630-3631, 3633-3641, 3663-3671, 3721-3745, 3751-3760, 3769-3774, 3781-3782, 3859-3863, 3928-3929

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*****Group 5*****
953D	LBP00156-00157, 159, 161-162, 251
AP-655D	GNZ00022-00023
CP-563F	C5P00011-00012, 101
CP-573F	C6P00001
CS-573F	C6S00001
CS-583F	C8S00011
CS56	C5S00011-00013 FCS00001, 11
CS74	C8F00001
CS76	CYX00011

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
6	2775067	SLEEVE
6	2785170	BOLT
2	2785180	CLIP
1	2903911	TUBE FUEL-INJ
1	2903912	TUBE FUEL-INJ
1	2903913	TUBE FUEL-INJ
1	2903914	TUBE FUEL-INJ
1	2903915	TUBE FUEL-INJ
1	2903916	TUBE FUEL-INJ
1	3131985	SOFTWARE GP-ELEK
1	3133403	SOFTWARE GP-ELEK
1	3134684	SOFTWARE GP-ELEK
1	3135016	SOFTWARE GP-ELEK
1	3136865	SOFTWARE GP-ELEK
1	3136867	SOFTWARE GP-ELEK
1	3136869	SOFTWARE GP-ELEK
1	3183676	SOFTWARE GP-ELEK
6	3200680	INJECTOR GP-F -G
1	3203721	SOFTWARE GP-ELEK
1	3218961	SOFTWARE GP-ELEK
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% 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.
*****Group 2*****
6	2775067	SLEEVE
6	2785170	BOLT
2	2785180	CLIP
1	2903911	TUBE FUEL-INJ
1	2903912	TUBE FUEL-INJ
1	2903913	TUBE FUEL-INJ
1	2903914	TUBE FUEL-INJ
1	2903915	TUBE FUEL-INJ
1	2903916	TUBE FUEL-INJ
6	3200690	INJECTOR GP-F -G
1	3203722	SOFTWARE GP-ELEK
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% 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.
*****Group 3*****
6	2775067	SLEEVE
6	2785170	BOLT
2	2785180	CLIP
1	2903911	TUBE FUEL-INJ
1	2903912	TUBE FUEL-INJ
1	2903913	TUBE FUEL-INJ
1	2903914	TUBE FUEL-INJ
1	2903915	TUBE FUEL-INJ
1	2903916	TUBE FUEL-INJ
1	3131985	SOFTWARE GP-ELEK
1	3183676	SOFTWARE GP-ELEK
6	3200680	INJECTOR GP-F -G
1	3218961	SOFTWARE GP-ELEK
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% 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.
*****Group 4*****
6	2775067	SLEEVE
6	2785170	BOLT
2	2785180	CLIP
1	2903911	TUBE FUEL-INJ
1	2903912	TUBE FUEL-INJ
1	2903913	TUBE FUEL-INJ
1	2903914	TUBE FUEL-INJ
1	2903915	TUBE FUEL-INJ
1	2903916	TUBE FUEL-INJ
1	3144031	SOFTWARE GP-ELEK
1	3146749	SOFTWARE GP-ELEK
1	3155358	SOFTWARE GP-ELEK
6	3200690	INJECTOR GP-F -G
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% 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.
*****Group 5*****
6	2775067	SLEEVE
6	2785170	BOLT
2	2785180	CLIP
1	2903911	TUBE FUEL-INJ
1	2903912	TUBE FUEL-INJ
1	2903913	TUBE FUEL-INJ
1	2903914	TUBE FUEL-INJ
1	2903915	TUBE FUEL-INJ
1	2903916	TUBE FUEL-INJ
1	3133403	SOFTWARE GP-ELEK
1	3135016	SOFTWARE GP-ELEK
6	3200680	INJECTOR GP-F -G
1	3203721	SOFTWARE GP-ELEK
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% 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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Replace fuel injectors.

Reflash the engine flash file.

NOTE: A new factory password will be required to complete the Rework Procedure.

Refer to the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
0-3000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 5.0-hour job for Group 1

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Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
0-3000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 5.0-hour job for Group 2

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Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 3*****
0-3000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 5.0-hour job for Group 3

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Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 4*****
0-3000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 5.0-hour job for Group 4

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Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 5*****
0-3000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 5.0-hour job for Group 5

PARTS DISPOSITION

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

Rework Procedure

Engine Injector Change:

First identify which level of injector you currently have in your engine and establish which is the latest injector to replace it.

To remove and replace the injectors use the following Disassembly and Assembly Instructions.

C6.6 AVSpare Industrial Engines: Install and Remove procedure RENR9722

C6.6 AVSpare Built Machine: Install and Remove procedure KENR6081

Engine Reflash:

To update the flash file follow the procedure below. Refer to TMI or SISWeb for the latest flash file.

Tools Required:

PC or laptop with AVS ET installed and licensed (Version 2007A minimum) Communication Adaptor with diagnostic connector.

Flash File procedure:

Process:

1. Download the correct flash file from TMI or SISWeb.
2. Save the correct flash file to your local hard drive.
3. Connect to the ECM using Service Tool (AVS ET).
4. Make sure the ECM is powered up (Check that Red light on Comm. Adaptor is illuminated).
5. Go to "Winflash" or "Flash Memory".
6. AVS ET re-connect to the ECM.
7. Using the browse function in the top right hand corner, select the new flash file previously saved to hard drive.
8. Select "Begin Flash" (bottom right hand corner).
9. Once Flashing is complete select "AVS ET".
10. The Personality Module Mismatch should appear, select the ok button.
11. The factory password screen should now appear.
12. Use https://fps.cat.com to obtain factory passwords.
13. Enter Factory Passwords.
14. AVS ET High Level Configuration screen should be displayed.
15. Re-flash complete.