tech tips 13 febrero 2002

February 2002 - LEVN5159

Tech TipsFebruary 13, 2002

10am CST


IndexIron/Mechanical

C-10/C-12 Engine Oil Leaks Front Housing to Block Joint 4C-10/C-12 Injector Lifter ECN 5Turbo Failure due to contaminated lube 6

Factory Password System 8

3126B/E Flywheel Housing 233126B/E Idle Gear Rattle 253116/3126/3126B/E Head Torque Procedure 263126B/E Oil Pressure 273126B/E Manuals 31

TMI Web- Certify & Rerate 33

3100 HEUI Troubleshooting 383406E & C-15 Turbo Wastegate Kit 413406E, C-15/C-16 Oil Pump 433406E, C-15, C-16 PacBrake Failures 45

Electronics

3126 Parts Service Software 48Heavy Duty Engine Software Release 49J1939 Vehicle Speed Calibrations 50Troubleshooting Guides 51

Service Tools

Cat ET2001B - Service Pack 1 54Cat Comm Adapter II 55Customizing the Function Keys 57Cat ET Websites 61PC Software Support Hotline 62

Pocket Tec� Fleet Edition 64ECNs on PowerNet 76

SIS Web - Full Text Search 82

Q&A IIBinder Info 84Broadcast Information 85Keepin� In Touch 86Electronic Controls Part # Reference 87


C-10 / C-12 Update


C-10 / C-12 Engine Oil LeaksFront Housing-to-Block joint✔ Root Cause:

■ Loss of Preload on lower bolts✔ Resolution:

■ Improve bolt load retention through increased bolt stretch and improved gasket

✔ Field Containment:■ Higher Strength Bolt (204-0712) + Higher Torque (40N-m (35 lb-ft)) -

2Q 2001■ New 211-2822 Gasket (perforated steel core with graphite material)

✔ Production Fix■ Counter bored Block - 2Q 2001■ Longer Bolts = increased Pre-load with std torque � 2Q 2001 ■ New 211-2822 Gasket � Dec 2001

✔ New Special Instruction REHS1189 is now available■ For process details, Part #�s, and serial number ranges


PROBLEM: Some C-10 and C-12 Truck Engines built within the below specified Serial Number ranges have had failures of the Injector Lifter (Roller Follower) Assembly (Part numbers 115-9393 or 179-7272).

Affected Serial Number Range:

9NS01200-03200, 1YN11800-12820, 8YS00570-01130, and 2PN06600-07200 were due to a cracked roller quality problem. 9NS12900-16100, and 8YS04600-05400 were due to a roller axle pin press fit problem.

� For Engines WITHIN the above affected serial number ranges only: On engines that experience a failure of one or more of the Unit Injector Lifter Assemblies, all 6 Injector Lifter Assemblies should be replaced and covered under warranty.

� For engines OUTSIDE the above stated serial number ranges, TIBU3179 should be followed to inspect for any possible injector lifter failures in process whenever an engine is in for repair with the cylinder head off for any reason. For these engines, only those individual lifters, which qualify as failed under the TIB, should be replaced.

C-10/C-12 Injector Lifter - ECN


Turbo Failures due to Contaminated Lube✔ PROBLEM: Turbo Failures after major engine

repair due to contaminated lube✔ Current Turbo Warranty Return Analysis shows

44% of all turbo failures are due to contaminated lube.

✔ Primary Contaminates are Aluminum Oxide (Grinding Media) and Glass Bead material.

✔ Primary Source: Airborne shop contaminates during engine repair

✔ RESOLUTION: Improve Cleanliness!■ COVER open engines and components during repair■ Where possible, isolate debris-generating processes from engine

repair area■ A team is looking at this issue to give further guidelines


Factory Password System Update


Factory Passwords

✔ Web version of Factory Password Calculator ■ Controlled rollout of system during 1st Qtr 2002■ Your �Dealer Security Coordinator� will notify you when available

■ https://login.cat.com/useridhelp.html

■ Website features ( https://FPS.cat.com )

■ Estimate rerate charge (Estimate)■ Factory Passwords (FPS)■ Feedback■ HELP

■ What is FPS?■ Frequently Asked Questions (FAQ) ■ How to send feedback■ Support Information


Who�s my Security Coordinator?


Corporate Web Security


Estimate Rerate

Click

Click � To calculate passwords


�Auto Fill� from Estimate rerate

screen

Factory Password Calculation



Product S/N from Service Tool�

NOT necessarily same as S/N from engine

block(ex. �0XX00000�

for NON - RC5 Passwords)



Rerate charge information



Summary screen with Passwords

Click � To go back to a �clear� FPS screen


Feedback

Click


Feedback


HELP !!!


HELP� What is FPS?


HELP� FAQ�s


HELP� Support Information


3116 / 3126 Update


3126B/E Flywheel Housing

✔ ECN released March, 2001✔ TIBU3378 issued July, 2001

■ Key Points:■ Get local Cat and OEM Representative involved■ Drive shafts need to be checked for balance■ Contact 3100 Product Analyst (1-800-447-4986) with information

requested per TIBU3378✔ Cat off-road heavy duty style flywheel housing

(160-5142) currently servicing (126-5874) as a containment action

■ Direct replacement ■ Is NOT Service Replacement for FWH 146-8141 ■ 146-8141 Service Part target availability 3rd QTR 2002

✔ Cat continues to work with OEM�s for drive train �system� resolution


3126B/E Flywheel Housing

✔ Warranty Reporting Criteria■ No longer need to call 3100 Product Analyst per TIBU3378■ Submit claims under standard warranty including

■ Copy of drive shaft inspection sheet (from drive line shop)■ OEM specs for drive shaft(s)■ Actual test results

■ Include in claim story:■ Truck Manufacturer and Model■ Truck VIN , Engine Serial Number■ Transmission Make and Model■ Transmission Support (Yes/No)■ Number of Drive shafts■ Axle Ratio■ Contact Name and Number

✔ Warranty Acceptance/Coverage■ Drive shaft(s) must be proven to be in balance■ Standard FWH R&I and drive shaft inspection cost


3126B/E Idle Gear Rattle

✔Problem:! Customer complaint of �noise� coming from transmission (transmission in neutral, clutch engaged)

! Noise goes away when clutch is fully disengaged

! No performance related complaints

✔Action:■ Systems issue, transmission reacting to torsional vibrations from engine firing pulses

■ Eaton has developed a �7+1� clutch driven disc to address the issue■ Helps isolate transmission from engine

■ Direct customer to 7+1 driven disc through OEM channels


3116, 3126, and 3126B/ENew Cylinder Head Torque + 90° Turn Procedure

✔ Calls regarding TRG times with new cylinder head torque procedure.

✔ Study will be conducted✔ Claims will allow an addition 0.7 hour labor time for

R&I of cylinder head.✔ Reminder � Cylinder head torque procedure should

be done with hand wrench, not an impact wrench


3126B/E Oil Pressure

✔ Reports against low oil pressure■ Cab indicator lamp■ Gauge appears to read low

✔ Follow low oil pressure troubleshooting steps outlined in �System Operation � Testing and Adjusting� guide in your 3126B & 3126E Truck Service Manuals.

✔ Minimum Oil Pressure at low idle (700 RPM)■ 6 PSI NOT 15 PSI

✔ Reference Chart in Service Manual and SIS is incorrect. Chart will be corrected to reflect 6 PSI minimum oil pressure. Please see reference charts on following pages.

✔ Have your TC call 1-800-447-4986 for further assistance.


3126B/E Oil Pressure Chart New 3126B/E Oil Pressure Reference Chart

0

100

200

300

400

500

600

700

600 1000 1400 1800 2200 2600

Engine RPM

Pres

sure

- kP

a (p

si)

Not Acceptable

Not Acceptable

Minimum Oil Pressure

Maximum Oil Pressure

Acceptable

41 (6.0) -

100 (14.5)

200 (29.0)

300 (43.5)

400 (58.0)

500 (72.5)

600 (87.0)

700 (101.5)


3126B/E Oil Pressure Chart Current/Old 3126B/E Oil Pressure Reference Chart

DO NOT USE


3126B/E OMM Guide Current/Old 3126B/E Oil Pressure Reference Chart


3126B/E Manual Releases

✔ New 3126B/E Operation and Maintenance Manual is available (December 2001 � media number SEBU7011-10

■ In-line primary fuel filter now included in PM Level 1 in maintenance section.

✔ New 3126B/E Service Manuals available (media number RENR1360

■ Product Safety (SENR2995-04)■ Torque Specifications (SENR3130-06)■ Specifications (RENR1270-07)■ System Operation Testing and Adjusting (RENR1271-06)■ Disassembly and Assembly (RENR1369-06)■ Service Bendix Air Compressor (SENR6455)■ Service Midland Air Compressor (SENR7594-03)■ Service Wabco Air Compressors (RENR2314)■ Cat ID Owners Manual (SEBU6875-05)■ Service Electronic PTO A & I (RENR1282-03)■ Schematic � Electrical System (RENR1368-04)■ Troubleshooting (RENR1367-03)


TMI Web Update


TMI Web �Certify & Rerate�

✔ Engine rerate information is available on the web for all TMI users

✔ https://TMIWEB.CAT.COM✔ Click on Certify Rerate✔ Enter engine serial number✔ Submit


Click �Certify Rerate�



Enter S/N and click �Submit�



Print certificate Engine rerated from IC 75 to IC 77

If certification not listed send Email

request



C-15 / C-16 / 3400 Update


3100 HEUI Troubleshooting

✔ Can not duplicate the problem in a high percentage of returns

✔ Pump creates flow✔ IAPCV (Control Valve) regulates flow to control

pressure✔ Properly working pump and valve (fully closed) will

create over 4000 PSI during the dead head pump test

✔ If valve is fully open, only 230 PSI can be created✔ If the pump gear is loose, tighten to 110 ± 14Nm

(81 ± 10 lb ft). If the pump spin freely, re-install and retest


3100 HUEI Troubleshooting

✔ Compare the sensor reading to a gauge✔ Verify Maintenance Interval � Oil Change may be

required✔ Only one part should be replaced for each repair✔ Quick reference procedure available under ECN

number ECN021202✔ Completed quick reference procedure will be used

in warranty analysis


3100 HUEI TroubleshootingCustomized Maintenance Interval Calculation

U.S.

____Total Miles / _____Total Fuel = ______ Overall MPG____Overall MPG X 50 X _____ (Sump Capacity in quarts) = _____ Customized Interval

Metric

____ Total Kilometers / _____ Total Liters Fuel = _____ Overall KPL____ Overall KPL x 200 x ____ (Sump Capacity in Liter) = _____ Customized Interval

Note: Shallow Sump Capacity is 22 qts. (21 L.) Deep Sump Capacity is 30 qts. (28 L.)Add on systems may increase overall system capacity.


3406E & C-15 Turbo Wastegate Kit

✔ Only for serial numbers 6NZ and 2WS with turbo part number 167-9247 or 0R7310

✔ Calibration Kit has all the tools needed _________

✔ Crimp Tool can be purchased separately _________


3406E & C-15 Wastegate Calibration Kit✔ Kit includes:

Plastic CaseCrimping ToolRegulator4-Way fittingToggle valve (2)30 PSI (1/4 PSI Resolution) liquid filled gaugeHose connection

DOES NOT INCLUDE:¼ ID hoseQuick Connector fitting

Crimp Tool


3406E, C-15, C-16 Engine Oil Pump✔ Three Pump Part Numbers used in production

■ 4N0733 ≈50 PSI pump■ 4N8734 ≈65 PSI pump■ 4N8735 ≈65 PSI pump (BrakeSaver� engines only)

✔ All three pumps used with serial numbers 5EK and 6TS00001 � 6TS12327

✔ Only 4N8734 and 4N8735 used with 1LW, 5DS, 2WS, 1MM, 6NZ, and 7CZ

✔ Retainer height ■ 4N0733 66.6mm (2.62in)■ 4N8734 57.1mm (2.25in)■ 4N8735 57.1mm (2.25in)

✔ Use the proper pump for repair


Measuring Retainer Height

Retainer Height


3406E, C-15, C-16 PacBrake� Failures✔ Caterpillar Bolt 167-0867 and Pacbrake part

number 179-4316 Break✔ Affected engine serial numbers

■ 2WS38782 � 2WS42798■ 1MM01398 �1MM01488■ 6NZ00282 � 6NZ40249■ 7CZ00417 � 7NZ02006

✔ 167-0867 bolt ■ 12 Point■ �R� on Cap


Electronics Update


Electronics

✔ Parts Service Software for 3126 (7AS) Engines

✔ Heavy Duty Engine Software Release

✔ J1939 Vehicle Speed Calibrations

✔ Troubleshooting Guides


3126 Parts Service Software

✔ Parts Service for 3126 Engines■ 7AS Serial Number Prefix■ Resolution for Hard Starting ■ Resolution for White Smoke at Altitudes above 3500 feet

✔ Available February 15, 2002

✔ Min / Max Governor Option


✔ C-10, C-12, C-15 and C-16 Clean Power Engines ■ Serial #�s 3CS23000 and up, 2KS72000 and up, 6NZ54000 and up,

7CZ02800 and up■ Production Date of February 2002 (Delayed from November 2001)■ Problem Fixes

■ Vehicle Activity Report Minimum Idle Time■ Battery Monitor Engine Control Voltage

■ New Features■ Min-Max Governor■ J1939 Switch Multiplexing■ Test ECM Feature■ J1939 ABS Vehicle Speed input■ PTO Active Output■ Maximum PTO Enable Speed

Heavy Duty Engine Software Release


J1939 Vehicle Speed Calibrations✔ Vehicle Speed Cal (J1939-Trans)

■ Based on Transmission Output Shaft revolutions per mile

■ Typical Calculations

■ Transmission Output Shaft revolutions per mile■ Transmission Speed Sensor pulse per mile

Number of Teeth on Output Shaft Chopper Wheel■ (Tire revolutions per mile) x (Axle Ratio)

✔ Vehicle Speed Cal (J1939-ABS)■ Based on Tire Revolutions Per Mile■ Typical calculation

■ ABS Assumed tire revolutions per mile = 500■ Actual Tire revolutions per mile = 400■ Vehicle Speed Cal = 400/500 = 0.800


Trouble Shooting Guides

✔ Troubleshooting 3126B and 3126E Truck Engines

Media: RENR1367-04Date: December 2001Serial Numbers:BKD1 - Up CRP1 - Up1AJ1 - UP 7AS1 - Up8YL1 - Up 8SZ1 - UpCKM1 - Up 9SZ1 - Up


Trouble Shooting Guides

✔ Troubleshooting 3406E, C-10, C-12, C-15 and C-16 Engines

Media: RENR2238-04 Date: February 2002Serial Numbers:CPD1- Up 2WS1 - Up1MM1- UP 3CS1 - Up2KS1 - Up 6NZ1 - Up7CZ1 - Up


Caterpillar Electronic Technician


Cat ET 2001B-Service Pack 1Release Information✔ Update is available�

■ InfoCast Website■ Contacting the Service System Support Center

✔ Cat ET 2001B or STW 2001B must be installed before installing Cat ET 2001B-SP1.

✔ What�s New■ Cylinder Cutout Test (3126 HEUI)

■ Automatic portion (OK/Not OK) of the Cylinder Cutout Test is available.

■ Within the Workbench, you now have the ability to print histograms.


Caterpillar Communication Adapter II✔ To prevent downtime with Cat ET when using the Caterpillar

Communication Adapter II, contact the Service System Support Center or logon to InfoCast for solutions to the following common Cat Comm Adapter II issues:

■ Error #443: The driver software and the Cat Comm Adapter II firmware are not compatible.

■ The selected file does not support the Cat Comm Adapter II hardware version.

■ Running the Cat Comm Adapter II on a PC that does not have a built in RS232 serial point.

■ Reinstalling Cat Comm Adapter II software.


Cat Comm Adapter II Website ✔ From the Cat ET website... Select Support >

Communication >

Then select Caterpillar Communication Adapter II


✔ To customize the function keys:

Customizing the Function Keys

Select Custom from the View menu, and then select Function Keys...from the sub-menu.


Customizing the Function Keys(cont.)

✔ The Customize Function Keys dialog box displays.

Default Settings:

F1: Content Sensitive Help

F2: Status

F3: Active Diagnostic Codes

F4: Logged Diagnostic Codes

F5: Configuration

F8: Connect/Disconnect

F9: Exit



F1, F8, and F9 cannot be changed.

F1: Online help information for the active Cat ET screen displays when pressing F1.

F8: Either connect or disconnect communication with the ECM.

F9: Exit Cat ET.



✔ To change the order or add a new function:

1. Select the �F� number text box.

2. Select the function from the drop-down list.

3. Press �OK.�


Caterpillar ET Websites

✔NACD Infocast: https://nacd.cat.com■ https://nacd.cat.com/infocast/frames/psfulfill/sfulfill/et/

✔CAPL APDNet: https://catasia.cat.com■ https://catasia.cat.com/infocast/frames/pss/service/et/

✔CCL APDNet: https://catchina.cat.com■ https://catchina.cat.com/infocast/frames/pss/service/et/

✔Power Net: https://engines.cat.com■ https://engines.cat.com/infocast/frames/truck/service/catet/


PC Software Support Hotline

✔ Service Systems Support Center

Voice: (800) 765-0999 or (309) 675-0999Fax: (309) 636-5823E-mail: [email protected] or

SSSC (Caterpillar Host e-mail)Serv Sys Support Ctr (Lotus Notes)

Hours: Monday through Friday6:00am to 6:00pm (Central Standard Time)


Licensing Caterpillar ET

✔ Caterpillar Media and Product Information Logistics

Voice: (800) 566-7782 or (309) 266-0942Fax: (309) 494-1348 or (309) 494-1345E-mail: [email protected] or

medial (Caterpillar Host E-mail)Media Logistics (Lotus Notes)

Hours: Monday through Friday7:30am to 4:30pm (Central Standard Time)


Pocket Tec� & Power Net Update


Pocket Tec� - Fleet Edition

✔ Fleet Edition■ Release Date

■ 1st Week of April


Pocket Tec�Fleet Edition vs. Driver Edition

Fleet Edition Features Driver Edition Features

Configuration Configuration1) (See Parameter List) 1) (See Parameter List)2) Params separated into selectable groupsStatus Status1) (See Parameter List) 1) (See Parameter list)2) Params separated into selectable groups3) User defineable groups can be built and savedDiagnostics/Codes Diagnostics/Codes1) Private Active Codes 1) Public Active Codes2) Logged Codes (read, no clearing)3) Logged Events (read, no clearing)4) Critical Events (read, no clearing)5) Save all Codes/Events in Memo pad 2) Save all Codes/Events in Memo padTotals Totals1) Lifetime Totals 1) Lifetime Totals2) Driver Trip Totals (resetable) 2) Driver Trip Totals (resetable)3) Fleet Trip Totals 3) Fleet Trip Totals4) Program Driver Ids 4) Program Driver Ids5) View segments for each Driver ID6) Save all Totals into Memo pad 5) Save all Totals into Memo padMaintenance Indicator Maintenance Indicator1) Reset PM1 1) Reset PM1Theft Deterrent Theft Deterrent1) Enable/Disable System 1) Enable/Disable System2) Configure PasswordDriver Reward1) View current scores and actual values2) View/Program targets and weighting factorsFleet Management - Data Download1) Download: Vehicle ID, Fuel Economy, % Idle, Average Driving Speed2) View downloads on Palm; sort on any category3) Save downloads to Memo Pad to be HotSynced to PC for processing


Pocket Tec� Fleet vs. DriverConfiguration Parameters

Configuration Parameters

Fleet Edition Driver EditionVehicle ID Vehicle IDEngine Serial NumberRating Type Rating TypeAdvertised Power, Rated Peak Torque,

Governed SpeedTop Engine Speed RangeECM Serial NumberSoftware Part Number/Release DateVehicle Speed LimitVSL ProtectionVehicle Speed CalibrationLow Cruise Control Speed Set LimitHigh Cruise Control Speed Set LimitSoftCruise Control SoftCruise ControlEngine Retarder/Exhaust Mode Engine Retarder/Exhaust ModeEngine Retarder Minimum VSL Type Engine Retarder Minimum VSL TypeEngine Retarder Minimum Vehicle Speed Engine Retarder Minimum Vehicle SpeedAuto Retarder in Cruise Auto Retarder in CruiseAuto Retarder in Cruise Increment Auto Retarder in Cruise IncrementFan with Engine Retarder in High Mode Fan with Engine Retarder in High ModeEngine Retarder Delay Engine Retarder DelayIdle Vehicle Speed LimitIdle RPM LimitIdle/PTO RPM Ramp Rate Idle/PTO RPM Ramp RateIdle/PTO Bump RPM Idle/PTO Bump RPMFast Idle RPM #1Fast Idle RPM #2Battery Monitor and Engine Control Voltage Battery Monitor and Engine Control VoltageBattery Monitor Low Idle Engine SpeedTop Engine LimitTop Engine Limit with DroopLow Idle Engine RPM Low Idle Engine RPMTransmission StyleEaton Top 2 Override with Cruise Switch

Fleet Edition Driver EditionGovernor TypeIdle Shutdown TimeAllow Idle Shutdown Override #1Minimum Idle Shutdown Outside TempMaximum Idle Shutdown Outside TempEngine Monitoring ModeMaintenance Indicator Mode Maintenance Indicator ModePM1 Interval PM1 IntervalEngine Oil Capacity Engine Oil CapacityFuel Correction Factor Fuel Correction FactorMinimum Idle TimeDriver Reward EnableQuick Stop Rate Quick Stop RateChange Fuel Correction FactorChange Customer ParametersPM1 Reset PM1 ResetFleet Trip ResetState SelectionTheft Deterrent System Control Theft Deterrent System Control

Theft Deterrent PasswordCustomer Password #1Customer Password #2


Pocket Tec� Fleet vs. DriverStatus Parameters

Status ParametersFleet Edition Driver EditionAccel Pedal Pos Accel Pedal PosAtmospheric PresBoost Pressure Boost PressureBrake Sw #1Brake Sw #2Clutch SwCoolant Level Coolant LevelCruise/Idle Mode Cruise/Idle ModeCruise Accel/Decel ModeCruise On/Off SwitchCruise KickoutCruise Set Speed Cruise Set SpeedDriver Bonus Driver BonusECM Batt Voltage ECM Batt VoltageEng Coolant Temp Eng Coolant TempEng Load FactorEngine Oil Pressure Engine Oil PressureExhaust Brake/Engine RetarderExhaust Brake/Engine Retarder Sw StatusEng Coolant Temp Eng Coolant TempEng Speed - Des Eng Speed - DesEst Fuel Rate Est Fuel RateFast Idle SwFuel Economy Fuel EconomyFuel Temp Fuel TempIdle KickoutIdle Shutdown StatusInjection Actuation PressureIntake Air Temp Intake Air TempMulti-TorqueNeutral SwOutside Air Temp Outside Air TempParking Brake SwResume SwSet SwStarting Aid On/Off SwStarting Aid Output Starting Aid OutputTorque Limit SwTwo Speed Axle SwVehicle Speed Vehicle SpeedVehicle Speed Limit Vehicle Speed Limit


Fleet Edition - Main Screen

✔ New Icons■ Fleet Manage■ Reward■ Connect


Fleet Edition - Config Screen

✔ Drop Down Menu■ Group Parameters


Fleet Edition - Status Screen

✔ Drop Down Menu■ Group Screens■ User Definable


Fleet Edition - Diag Screen

✔ More Codes■ Logged Codes■ Logged Events■ Critical Events


Fleet Edition - Totals Screen

✔ More Totals■ Driver■ Fleet■ Driver 1 & 2 Trip


Fleet Edition - Fleet Manage Screen

✔ Download from Truck■ View■ Save to Memo Pad■ Hot Sync Memo Pad Data

■ Place in Spreadsheet


Fleet Edition - Driver Reward Screen✔ Set Up Driver Reward


Electronic Communicator Newsletters on PowerNet



✔ https://engines.cat.com✔ CWS Password Required✔ Click �Enter�



✔ Click on �Service�



✔ Click on■ �Electronic

Communicator Newsletter (ECN)�


Electronic Communicator Newsletters on PowerNet✔ Other Useful

Information


SIS Web Update


Click

SIS Web Advanced Full Text Search


SIS Web Advanced Full Text Search


2001 Binder

✔ The binder this year is a three ring binder with dividers - one for each show.

✔ Has slotting to hold all four video tapes✔ Form # LEKQ5055


Broadcast Information✔ Update Broadcast Videos

■ LEVN4998 - �Tech Tips� Broadcast - February 14, 2001■ LEVN4999 - �Tech Tips� Broadcast - May 9, 2001■ LEVN5000 - �Tech Tips� Broadcast - August 8, 2001■ LEVN5001 - �Tech Tips� Broadcast - November 14, 2001■ LEVN5159 - �Tech Tips� Broadcast - February 13, 2002

■■ LEVN3947 LEVN3947 -- Yearly Subscription (English Tape & Handouts)Yearly Subscription (English Tape & Handouts)■■ LEVN5080 LEVN5080 -- Yearly Subscription (English Tape/Spanish Yearly Subscription (English Tape/Spanish

Handouts)Handouts)

✔ Broadcast Schedule for 2002■ May 8■ August 14■ November 13


Keepin� In Touch

EmailInternet E-Mail

[email protected]

World Wide Webhttp://www.Cat.comEngine Spec Sheets


Electronic Controls

Part Number

Reference


Form Number Booklet Description Serial Number PrefixesRENR2238-04 C-10,C-12 & 3406E 1MM,2KS,2WS,3CS, 6NZ, 7CZ,

CPDRENR1328-02 C-10,C-12 & 3406E 5DS,8YS,9NS,1LWSENR5582-06 3176B,C-10,C-12 & 3406E 5EK,9CK,1YN,2PN,6TSSENR5503-00 3406C (PEEC III) 4CKSENR3479-05 3406B (PEEC II) 2EK,5YG,8TCSENR3913-04 3176 Truck Engine 2YGSENR5112-01 3176 Truck Engine 7LGRENR1367-04 3126B Truck Engine 7AS, 8YL,8SZ,BKD, 1AJ,CKM,

CRP,9SZSENR6566-03 3100 HEUI Truck Engine 8WL,1WM,4ES,2CW, 8HW, 7LZ

Troubleshooting Guide Listing


The guidelines for HD Truck FLS/FTS changes for Re-Rates are as follows:1. FLS/FTS SHOULD be changed to values listed in JTZ101-02 FLS/FTS LOOKUP FOR RATING CHGS

screen for 3406E or GKN401-06 ENGINE TEST SPEC screen for 3176B, C-10, C-12 when:Engine is rerated outside the current rating family. Since rerating outside the current rating familyrequires a "Reason Code 5" factory password, change FLS/FTS if "Reason Code 5" factorypasswords are required. (Example: rerating a 3406E engine from a 475 Hp rating to a 550 Hp rating)

NOTE - When using either of the screens listed above (JTZ101-02 or GKN401-06) it will be necessary toenter the new "Performance Spec" number and the serial number of the engine being rerated. Afterflashing the new software file, you can find the new performance spec on the ET configuration screen.If you are rerating to a multi-torque rating, be sure to use the FLS/FTS values for the secondperformance spec listed on the configuration screen.

2. FLS/FTS SHOULD NOT be changed when:Engine is rerated within the current rating family. Since rerating within the current rating familydoes not require a "Reason Code 5" factory password, do not change FLS/FTS if "Reason Code 5�factory passwords are not required. (Example: rerating a 3406E engine from a 475 Hp, 1650 lb-ft ratingto a 475 Hp, 1750 lb-ft rating)

3. FLS/FTS SHOULD be changed to 0/0 when:Engine is rerated to a "field rerate only" rating that is not offered on engines directly from thefactory. (Example: rerating a 3406E engine from a 375 Hp rating to a 410 field rerate only rating)

Heavy Duty Truck Engine FLS/FTS Adjustment Policy


Serial Number Prefixes3116/3126

✔ 1WM 3126 HEUI■ 1995 to Current

✔ 8WL 3116 HEUI■ 1995 to Current

✔ 7AS 3126B■ 1998 thru July 31, 1999

✔ 8YL■ July 1999 to December 2000

✔ 8SZ■ 1998 thru July 31, 1999 - short eng version

✔ 9SZ■ 2001 to present

✔ CKM BKD 1AJ CRP 3126E■ 2001 to present


Serial Number Prefixes C-10, C-12 & 3176✔ 2YG 3176

■ 1988 to 1990✔ 7LG 3176

■ 1991 to December 1993✔ 9CK 3176B

■ May 1993 to March 1995✔ 2PN C-10

■ March 1995 to September 1997✔ 8YS C-10

■ September 1997 to November 1998

✔ 1YN C-12■ March 1995 to September 1997

✔ 9NS C-12■ September 1997 to November

1998✔ 3CS C-10

■ November 1998 to Current✔ 2KS C-12

■ November 1998 to Current


Serial Number Prefixes3406/C-15/C-16✔ 8TC PEEC II and PEEC II.V

■ 1987 to 1990✔ 5YG PEEC II - 460Hp Only

■ 1990✔ 2EK PEEC II and PEEC II.V

■ 1991✔ 4CK 3406C Electronic

■ August 1991 to December 1993✔ 5EK 3406E

■ May 1993 to December 1996✔ 6TS 3406E

■ January 1997 to December 1997

✔ 1LW 3406E 14.6L■ December 1997 - November

1998✔ 5DS 3406E 15.8L

■ December 1997 - November 1998

✔ 2WS 3406E 14.6L■ November 1998 to Current

✔ 1MM 3406E 15.8L■ November 1998 to Current

✔ 6NZ C-15■ November 1999 to Current

✔ 7CZ C-16■ November 1999 to Current


3126E Electronic Control and Sensors✔ ECM (3126E Basic & Full Feature) 179-4898✔ Coolant temperature Sensor - 130-9811

■ O-Ring Seal 6V6609✔ Inlet Manifold temperature Sensor - 130-9811

■ O-Ring Seal 8L2786✔ Speed/Timing Sensors - 119-4142

■ O-Ring Seal 117-1385✔ Atmospheric Pressure Sensor - 194-6722

■ O-Ring Seal 6V5049✔ Boost Pressure Sensor - 194-6723

■ O-Ring Seal 3J7354✔ Injection Actuation Pressure Sensor - 167-1708

■ O-Ring Seal 1J9671✔ Pedal Position Sensor - 204-7949✔ Injector Wiring Harness - 153-8920✔ Wire Router - 126-1774


3116 HEUI & 3126 HEUI �Electronic Parts✔ 3116 HEUI - 8WL and 3126 HEUI - 1WM

■ ECM � 145-7807■ ECM Connector Bolt Kit � 6V6703■ 40 Pin Plug Assembly � 114-4408 (includes 110-6844 Seal)■ 40 Pin Connector Seal � 110-6844

■ Speed/Timing Sensor Service Kit � 119-4142 ■ Includes 117-1385 O-Ring Seals

■ Inlet Air Temperature Sensor � 107-8618■ Requires 3K0360 Seal

■ Coolant Temperature Sensor � 106-0735■ Requires 3K0360 Seal

■ Boost Pressure Sensor � 161-9927■ Male/Male Adapter � 9X0262 & 3J7354 � Seal

■ Injection Actuation Pressure Sensor � 167-1709■ Requires 108-5803 Seal

■ Injection Actuation Pressure Control Valve � 122-5053■ Seal Kit 9X1484

■ Throttle Position Sensor � 204-7949■ Fuel Transfer Pump to Hydraulic Pump O-Ring � 004-1963■ Hydraulic Pump Dome O-Ring � 6V5656


Other 3116 HEUI & 3126 HEUI Parts

✔ Part Numbers missing for Parts Books (3116 HEUI � SEBP2271 and 3126 HEUI SEBP2355)

■ 123-1199 Seal for Injector and IAPCV Connectors■ 118-8622 Service Replacement Harness

■ 40 pin to Injectors■ 122-8840 Service Replacement Harness

■ 40 pin to Speed/Timing Sensor■ 122-8842 Service Replacement Harness

■ 40 pin to IAPCV■ 122-8839 Service Replacement Harness

■ 40 pin to all other sensors■ 141-7060 Injector Wiring Harness Connector Repair Kit■ 143-8325 Injection Actuation Pressure Sensor Guard


C-10, C-12, 3176B & 3406E Pre-�99 Current Parts✔ C-10 - 2PN & 8YS, C-12 - 1YN & 9NS, 3176B - 9CK &

3406E - 5EK & 6TS, 1LW, 5DS■ Electronic Control Module (ECM) � 212-9450

■ ECM with J1939 Data Link Option � 212-9459■ Speed/Timing Sensor

■ 3406E � 129-6628 Sensor ■ 126-8481 Shim (0.020�)

■ C-10, C-12 & 3176B � 129-6628 Sensor No Shim■ Coolant/Fuel Temperature Sensor - 102-2240■ Air Inlet Temperature Sensor - 107-8618■ Boost Sensor - CRB 161-9927■ Atmospheric Pressure Sensor 111-8125■ Oil Pressure Sensor - CRB 161-9930■ Pedal Mounted Throttle Position Sensor - CRB176-1602


3176 �2YG Current Parts

✔ 3176 - 2YG■ ECM - 9X9529 0R6149

■ ECM FORD - 9X9528 / 0R6148■ Transducer module - 9X8226 / 0R6132■ Harness - 7E8421■ Speed/Timing Sensor - 102-9029■ Fuel Pressure Sensor - 107-7142■ Coolant Temperature Sensor - 9X5370■ Vehicle Speed Buffer - 3E0020■ Remote Mounted Throttle position Sensor - 9X9647

■ Remote Mounted Throttle Position Sensor - FORD - 9X9648■ Pedal Mounted Throttle Position Sensor - 161-8906


C-10, C-12, C-15, C-16 & 3406E�99 Model Year to Current

✔ C-10 - 3CS, C-12 - 2KS, & 3406E - 2WS (14L) - 1MM (16L), C-15 - 6NZ, C-16 - 7CZ

■ Electronic Control Module (ECM) - 179-1747■ Speed/Timing Sensor

■ C-10, C12 Cam Sensor � 189-9801■ 3406E Cam Sensor � 189-9267■ C-10, C-12 & 3406E Crank Sensor � 189-9266

■ Coolant/Fuel/Inlet Air Manifold Temperature Sensor - 130-9811■ Boost Pressure Sensor - 161-9929■ Atmospheric Pressure Sensor 194-6722■ Oil Pressure Sensor - 161-9931■ Pedal Mounted Throttle Position Sensor

■ Long Pig Tail - 3E-7700■ Short Pig Tail - 121-0231


3176 � 7LG Current Parts

✔ 3176 7LG■ ECM - 3E5293■ Transducer Module - 9X8226 / 0R6132

■ Altitude Retrofit - 3E8644 / 0R6470■ Speed Timing Sensor - 102-9029■ Oil Pressure Sensor

■ �DT� Connector 7LG08721 and Up � 161-9930■ �HD� Connector 7LG07500 to 7LG08720 � 163-8516

■ Coolant / Inlet Air Temperature Sensors■ Full Range - 7LG07500 and Up � 102-2240■ Limited Rage - 7LG00001 to 7LG07499 � 9X5370

■ Vehicle Speed Buffer - 3E0020■ Remote Mounted Throttle position Sensor - 9X9647

■ Remote Mounted Throttle Position Sensor - FORD - 9X9648■ Pedal Mounted Throttle Position Sensor - 161-8906


3406C Electronic Current Parts

✔ 3406C - 4CK■ ECM - 9X8085■ Transducer Module - 132-4363■ Speed Sensor - 100-6619■ Rack Sensor - 9X7793■ Timing Sensor - 129-4501■ BTM - 105-2939■ Coolant Temperature Sensor - 102-2240■ Pedal Mounted Throttle Position Sensor - 161-8906■ Remote Mounted Oil Pressure Sensor Kit - 118-6256■ Vehicle Speed Buffer - 3E0020 (same for PEEC II)


PEEC II.V Current Parts

✔ PEEC - 8TC and 2EK - FORD Only■ ECM - 9X4840■ Transducer Module - 132-4363■ Speed Sensor - 100-6619■ Rack Sensor - 9X7793■ Timing Sensor - 129-4501■ BTM - 105-2939■ Throttle Position Sensor

■ Remote Mounted �Beer Can� Sensor - 9X9648■ Pedal Mounted Throttle Position Sensor - 161-8906

■ Remote Mounted Oil Pressure Sensor Kit - 122-1649■ If the engine (2EK and 5YG) has had the White Smoke Product

Support Program performed. The following parts will be installed:■ 6I2382 - Wiring Harness■ 9X5370 - Temperature


PEEC II Current Parts

✔ PEEC II - 8TC, 5YG and 2EK■ ECM - 8T8770■ Transducer Module - 132-4363■ Speed Sensor - 100-6620■ Rack Sensor - 9X7793■ Timing Sensor - 129-4501■ BTM - 105-2939■ Throttle Position Sensor

■ Remote Mounted �Beer Can� Sensor - 9X9647■ Pedal Mounted Throttle Position Sensor - 161-8906

■ Remote Mounted Oil Pressure Sensor Kit - 122-1649■ If the engine (2EK and 5YG) has had the White Smoke Product

Support Program performed. The following parts will be installed:■ 6I2382 - Wiring Harness■ 9X5370 - Temperature

Appendix A

TECH TIPS PROGRAM EVALUATION February 13, 2002

Please complete and return immediately after the show to: Caterpillar Inc.; ATTN: Ann Shea; 100 N.E. Adams Street; Peoria, IL 61629-2230 OR FAX TO: (309) 675-1796. 1.The information presented during the broadcast will make me: No More Change Effective A. C-10/C-12 Update B. Factory Password System C. 3100 Update D. TMI Web Update E. 3400/C-15/C-16 Update F. Electronics Update G. Service Tools H. Caterpillar Pocket Technician™ I. SIS Web Update 2. The handouts were of sufficient detail and easily understood? Yes No 3. If you answered "No" to #2, what improvements would you like to see? ___________ __

____________________________________________________________________________________________________________________________________________

4. I have: less than 1 year; 1-5 years; 6-10 years; 11 or more years; experience working on Caterpillar engines. (check one) 5. I watched the Tech Tips broadcast: Live "or" On Video Tape 6. The mid-broadcast break was: Too Short; Just Right; Too Long. 7. Will you watch again? Yes No Please write Legibly!! 8. Comments: ___________________________________________________________________

______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

9. Quick Tips: ___________________________________________________________________

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Name ________________________________ Title_______________________________ Dealership ____________________________ Location ___________________________ City _______________________ State/Prov. ____________________ Country ________

tech tips 13 febrero 2002

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