Product Improvement Program For Installing Engine Control Software and Reworking The Wastegate Line Assembly On Certain 793 793b and 793c Off-Highway Trucks

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Service Letter
PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING ENGINE CONTROL SOFTWARE AND
REWORKING THE WASTEGATE LINE ASSEMBLY ON CERTAIN 793, 793B, AND 793C OFFHIGHWAY TRUCKS
Media Number -SEBE8265-04
Publication Date -16/01/2003
Date Updated -09/05/2003
CONFIDENTIAL
SEBE82650001
SEBE8265-04
January 16, 2003

(Revised May 2003)
U-22
A-16
D-16
O-21
Priority
1057
PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING

ENGINE CONTROL SOFTWARE AND REWORKING THE
WASTEGATE LINE ASSEMBLY ON CERTAIN 793,
793B, AND 793C OFF-HIGHWAY TRUCKS
PI30413
NOTE: This Program must be administered as soon as
possible. When reporting the repair, use "PI30413" 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 "PI30413" 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
https://sisweb.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/s... 03/11/2009
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first contacting your Caterpillar product analyst.

NOTE: This Revised Service Letter replaces the
January 16, 2003 (Revised April 2003) Service Letter.
Changes have been made to the Parts Needed.
COMPLETION DATE
TERMINATION DATE
July 31, 2003
January 31, 2004
PROBLEM
New engine control software needs to be installed on certain 793,
793B, and 793C Off-Highway Trucks. The 793 engine control software
would allow the cylinder pressures to go above desired. This cylinder
pressure above desired could be aggravated with a lack of wastegate
maintenance and response.
AFFECTED PRODUCT
Model
Identification Number
793
3SJ1-56 (Converted to 3516 EUI)
793B
1HL1-524
793C
4AR1-424
4GZ1-264
ATY183-201, 203-209, 226-232, 239-242, 400-414, 484485, 516-519
NOTE: This program DOES NOT APPLY to any model of 793
truck with a 3500HD engine installed.
PARTS NEEDED
Part Number
Description
1241911
COUPLING-STR (793C only)
5P7468
CLIP (793C only)
Qty
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5P7469
CLIP (793C only)
9R3845
BOSS (793C only)
8T4139
BOLT (793C only)
8T4223
WASHER-HARD (793C only)
84"
1226875
HOSE-HYDRAUL (793C only)
1883580
VALVE GP-SOL (all 793C and any 793/793B

equipped with 3516 EUI with ECM-controlled
wastegate)
8B2664
ADAPTER (CERTAIN 793C, only 4AR and 4GZ serial

number prefix)
6V0387
PLUG (CERTAIN 793C, only 4AR and 4GZ s/n

prefix)
2D8928
HOSE ASSEMBLY (CERTAIN 793C, only 4AR and 4GZ

serial number prefix)
2301404
SOFTWARE (793C equipped with RR151

turbocharger)
2301405
SOFTWARE (793C equipped with TPS52

turbocharger)
2301406
SOFTWARE (793/793B equipped with RR151

turbocharger)
2301407
SOFTWARE (793/793B equipped with TPS52

turbocharger)
NOTE: The 1226875 hydraulic hose comes in 787-in.
rolls.
ACTION REQUIRED
1. Install the new software as per the following:
z
For all 793C truck engines equipped with RR151 low-pressure

turbochargers, install Flash File 2301404 using ET.
For all 793C truck engines equipped with TPS52 low-pressure
turbochargers, install Flash File 2301405 using ET.
For all 793B truck engines equipped with RR151 low-pressure
turbochargers, install Personality Module 2301406 (non-flashable
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ECM).
For all 793B truck engines equipped with TPS52 low-pressure
turbochargers, install Personality Module 2301407 (non-flashable
ECM).
2. This step applies to certain 793 with 3516 EUI and ECM-controlled
wastegate, certain 793B with ECM-controlled wastegate and all
793C. The wastegate air line begins at the right hand side of the
cab at port #2. In this line is an on-off solenoid that opens and
closes the air supply to the wastegate based on the position of
the key switch. Replace the current on-off solenoid with a new
1883580 Valve Group-Sol. During future maintenance, only use an
1883580 Valve Group-Sol. Do not use the previous solenoid valve.
3. This step applies to 793C only. Rotate the air tank as per the
attached rework procedure.
OWNER NOTIFICATION
U.S. and Canadian owners will receive the attached Owner
Notification.
SERVICE CLAIM ALLOWANCES

Caterpillar
Dealer Suggested
Customer Suggested
Parts
Labor Hrs.
Parts
Labor Hrs.
Parts
Labor
Hrs.
100%
NOTE: This is a 4.0-hour job.

NOTE: U.S. and Canadian Dealers Only - Eligible
dealers may enter 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)
(2-Rework Procedure)
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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 INSTALLING ENGINE CONTROL
SOFTWARE
MODELS INVOLVED - CERTAIN 793, 793B, AND 793C OFF-HIGHWAY TRUCKS
Dear Caterpillar Product Owner:
New engine control software needs to be installed and the wastegate
line assembly reworked on the products listed below. The 793 engine
control software would allow the cylinder pressures to go above
desired. This cylinder pressure above desired could be aggravated
with a lack of wastegate maintenance and response. 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
January 16, 2003 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 January 16, 2003 Service Lette
Rework Procedure
NOTE: The following rework procedure provides
instructions for reworking the wastegate air lines
group for 793C only. Do not apply the following
procedure to 793 and 793B.
1. Remove air lines to supply tank.

2. Loosen band clamps and rotate tank to new position shown in
3.
4.
5.
6.
7.
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Illustration 1. When viewed from the right hand side of truck,

tank will be rotated counterclockwise.
Tighten band clamps.
Install boss. See Illustration 2.
Assemble new air hose using 2 1241911 hose ends and 2140mm of
1226875 hose.
Install new air hose and clamps. See Illustration 3.
Move the drain to the new port on the tank. Illustration 4
applies to 793C (4AR, 4GZ serial number prefix.) Illustration 5
applies to 793C (ATY serial number prefix.)
Illustration 1
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Illustration 2
Illustration 3
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Illustration 4
Illustration 5

Product Improvement Program For Installing Engine Control Software and Reworking The Wastegate Line Assembly On Certain 793 793b and 793c Off-Highway Trucks

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Product Improvement Program For Installing Engine Control Software and Reworking The Wastegate Line Assembly On Certain 793 793b and 793c Off-Highway Trucks

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Advanced Full Text Search - SEBE8265 - PRODUCT IMPROVEMENT PROGRAM ...

Publication Date -16/01/2003

Date Updated -09/05/2003

January 16, 2003