Tech Tips May 9, 200110:00AM Central Daylight Time May 2001 - LEVN4999 Page 1 Appendix A TECH TIPS PROGRAM EVALUATION May 9, 2001 Please complete and return immediately after the show to: Caterpillar Inc.; ATTN: Teri Matarelli; 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 Change More Effective A. Iron B. Fuels C. Engine Service Training D. Electronic Troubleshooting E. Service Tools F. Caterpillar Pocket Technician™ o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o 2. The handouts were of sufficient detail and easily understood? o Yes o No 3. If you answered "No" to #2, what improvements would you like to see? ___________ __ ______________________________________________________________________ ______________________________________________________________________ 4. I have: o less than 1 year; o 1-5 years; o 6-10 years; o 11 or more years; experience working on Caterpillar engines. (check one) 5. I watched the Tech Tips broadcast: o Live "or" o On Video Tape 6. The mid-broadcast break was: o Too Short; o Just Right; o Too Long. 7. Will you watch again? o Yes o No Please write Legibly!! 8. Comments: ___________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ 9. Quick Tips: ___________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Name ________________________________ Title_______________________________ Dealership ____________________________ Location ___________________________ City _______________________ State/Prov. ____________________ Country ________ Index MECHANICAL IRON 3126 Pushrods 3126E Catalytic Converter / Muffler Troubleshooting 3126E Flywheel Housing Failures C-10/C-12/C-15/C-16 Front Engine Accessory Drive C-10/C-12 Turbo Supply / Drain Lines C-10/C-12 Head Gasket Repair Procedure Where Does the Torque Go? Effects of Thread Lubricants Effects of Debris In Threads Clamping Force In Joint Using Torque Only Using Single Torque-Turn Procedure Using Double Torque-Turn Procedure Fire Ring & Fluid Sealing Load Distribution C-10/C-12 Truck Engine - Engine Oil SOS Cylinder Head Gasket Heli-Coil Installation Review Keepin’ In Touch 4 6 7 8 9 11 12 13 14 15 16 17 18 19 20 21 22 24 26 32 33 33 34 34 35 ELECTRONICS TROUBLESHOOTING April01 3126 Software Release Speed / Timing Sensor Kits Dash Lamps Not Illuminating 39 41 42 46 47 49 50 51 53 54 55 57 58 59 60 61 SERVICE TOOLS Caterpillar Electronic Technician 2001A Menu Location Changes Trainer “What’s New” On-Line Licensing Readme.txt PC Software Support Hotline Licensing CAT ET CATERPILLAR POCKET TECHNICIAN™ Kit Numbers Which Palm Do I Buy? What Can I Do With Pocket Tec™ Pocket Tec™ Driver Version Buystuff FUELS Biodiesel ENGINE SERVICE TRAINING Q&A II Binder Labels Broadcast Information Keepin’ In Touch Electronic Controls Part # Reference 63 64 65 66 Heavy Duty Truck Technician Program Update Engine Instructor Re-Certification Summary LEXT1044 Engine Performance Reference Truck PAR Grams Truck PAR Technician Re-Certification Engine Diagnostics Course Update APPENDIXES Q&A I Appendix A - Show Evaluation May 2001 - LEVN4999 Page 2 IRON May 2001 - LEVN4999 Page 3 3126B Pushrods Effective serial number range (8YL39000-56000) 4 Less than 30.010” Rocker mechanism noise complaint Single cylinder missing 4 Reminder….000 Miles/1100Gal/250Hr/6Months May 2001 . Inititial Valve Lash (WHICHEVER COMES FIRST) n Deep Sump n 15.000 Miles/1500 Gal/400Hr/6Months 11.000 miles 4 TIB Published March 7. 2001 4 Key factors: 4 n n n Valve Lash > 0.LEVN4999 Page 4 n Shallow Sump w/22Qts n . LEVN4999 Page 5 .3126B Pushrods Acceptable Wear Burnishing on entire ball end Unacceptable Wear Grooves in ball end and material displaced Acceptable Wear burnishing only on tip of ball end May 2001 . 3126E Catalytic Converter/Muffler Troubleshooting 4 Recall….LEVN4999 Page 6 . “Air Inlet and Exhaust System Inspect” for backpressure test procedure. 4 Refer to “System Operation. Testing and Adjusting. 4 If customer is complaining of low power/performance and converter/muffler is suspected to be the problem: Drive vehicle under load for 5-15 minutes to “clean out” converter/muffler n Install exhaust tap and measure BP @ high idle (if necessary) n Call TECC toll free 800-447-4986 if BP exceeds maximum allowable total exhaust system backpressure spec for further instructions. n May 2001 . RENR1271.CKM serial number engines are equipped with catalytic converter/mufflers and the maximum allowable total exhaust system backpressure is 60” H2O. 4 Get appropriate TEPS dealers/OEM Reps involved if drive shaft imbalance has proven to be root cause of failure.LEVN4999 Page 7 . 4 Drive shafts should be checked for balance in failed units. tractor type vehicle applications. May 2001 . 4 Any units that have failed flywheel housings in the past fitting the above description should have the drive shafts checked to avoid repeat failures. single drive shaft.3126E Flywheel Housing Failures 4 Reported cases of flywheel housings cracking on 3126E engines in single axle. results in improved belt alignment/durability Direct bolt-in Replacement for 135-2142 & 148-1974 In Effect Feb 2001 . 7CZ02166 (C-16) May 2001 .Front Engine Accessory Drive Tensioner Improvements for C-10/C-12/C-15/C-16 4 4 4 4 4 New Tensioner 190-0649 available Increased Bushing Area .2KS64385 (C-12). 6NZ42696 (C-15).results in improved belt alignment/durability Reduced Spring centerline offset.LEVN4999 Page 8 . 3CS19785 (C-10). LEVN4999 Page 9 . New Gasket Material available For Use on Field Repairs In Effect Feb 2001 on Production C-10/C-12 units May 2001 .C-10/C-12 Turbo Supply/Drain Lines 4 4 4 4 4 Improvements to C-10/C-12 turbo oil supply and drain line sealing system Longer Bolt and spacer for increased Bolt Stretch. C-10/C-12 Turbo Supply/Drain Lines Part Numbers for Field Repair of C-10 / C-12 Turbo Supply and Drain Lines Engine Model C-10 C-10 Turbo Lines Gp 136-4324 143-0819 153-7057 187-3325 115-9377 143-0820 153-9049 163-6094 165-0592 New Bolts (2) 8T-0276 Supply (4) 8T-0276 New Spacers (1) 4K-5824 (1) 9G-8661 Supply ONLY (1) 4K-5824 (1) 9G-8661 Supply (2) 9G-8661 Drain (4) 6H-7127 (1) 4K-5824 (1) 9G-8661 Supply (2) 9G-8661 Drain Drain Supply Gasket Gasket 188-6126 188-6126 8H-9788 8H-9788 C-12 C-12 (4) 6V-5218 (4) 8T-0276 188-6126 188-6126 8H-9788 8H-9788 May 2001 .LEVN4999 Page 10 . C-10/C-12 Head Gasket Repair Procedure April 2001 LEVN5101 May 2001 .LEVN4999 Page 11 . LEVN4999 Page 12 .Where Does The Torque Go? Torque 45% Underhead Friction 10% Bolt Stretch 45% Thread Friction May 2001 . Effects Of Thread Lubricants 100% 90% 80% % Clamping Force 70% 60% 50% 40% 30% 20% 10% 0% 6V4876 Molycote Paste 4C5599 High Temperature AntiSeize Engine Oil No Lube on Washer and Bolt Head Dry Threads 160 N-m (120 ft-lbs) + 90 Deg Turn May 2001 .LEVN4999 Page 13 . LEVN4999 Page 14 .Effects Of Debris In Threads 100% 90% 80% 30% 50% % Clamping Force 70% 60% 50% 40% 30% 20% 10% 0% 6V4876 Molycote Paste Debris In Threads W/6V4876 Molycote Paste 160 N-m (120 ft-lbs) + 90 Deg Turn Best Case Worst Case May 2001 . Clamping Force In Joint Using Torque Only Baseline 140% 130% % Clamping Force 120% 110% 100% 90% 80% 70% 60% 50% 40% 30% 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 49% BOLT NUMBER 1ST TORQ 292 N-m (215 FT-LB) 2ND TORQ 292 N-m (215 FT-LB) May 2001 .LEVN4999 Page 15 . 160 N-m (120 Ft-lbs) Plus 90 Deg Turn 140% 130% 120% % Clamping Force 110% 100% 90% 80% 70% 60% 50% 40% 30% 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Baseline 21% BOLT NUMBER PRETORQ 160 N-m (120 FT-LB) 90 DEG TURN May 2001 .LEVN4999 Page 16 .Using Single Torque-Turn Procedure 160 N-m (120 Ft-lbs). LEVN4999 Page 17 . 160 N-m (120 Ft-lbs) Plus 90 Deg Turn.Using Double Torque-Turn Procedure 160 N-m (120 Ft-lbs). LOOSEN BOLTS APPLY 160 N-m (120 Ft-lbs). 160 N-m (120 Ft-lbs) Plus 90 Deg Turn 140% Baseline 130% 120% % Clamping Force 21% 110% 100% 90% 80% 70% 60% 50% 40% 30% 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 May 2001 . Fire Ring And Fluid Sealing Load Distribution 100% 90% 80% 70% 2nd Torque-Turn Fire Ring Load 1st Torque-Turn Fire Ring Load JOINT LOAD 60% 50% 40% 30% 20% 10% 0% 0% 10% 20% 30% 40% 50% 25% 2nd Torque-Turn Fluid Sealing Load 1st Torque-Turn Fluid Sealing Load 60% 70% 80% 90% 100% BOLT LOAD May 2001 .LEVN4999 Page 18 . 170 Miles Hours Gallons of Fuel Miles.Na (Sodium) or K (Potassium) 200 Investigate 150 100 OK 10. Investigate IMMEDIATELY .C-10/C-12 Truck Engine Using Engine Oil SOS results to Diagnose Coolant Leak .Use Chart below to determine whether to investigate a coolant leak into oil .300 25.000 500 4.670 15.000 300 2.LEVN4999 Page 19 .If SOS results show Positive Antifreeze.000 400 3.500 20.Maximum Recommended Oil Change Interval is 25.000 200 1.000 miles or 500 hours or 4. hours or gallons of fuel on Engine Oil at time of sample May 2001 . 250 PPM .Must Test for Na (Sodium) if using Standard coolant . of fuel.Must Test for K (Potassium) if using ELC coolant .170 gals. LEVN4999 Page 20 .Cylinder Head Gasket Cylinder Head Configuration Straight Scalloped Block Configuration Straight 187-3307 187-3306 Scalloped 187-3306 187-3306 May 2001 . LEVN4999 Page 21 .Heli-Coil Installation hole using an 1U5686 (21/64) drill 4 Tap hole using 4C9732 tap 4 Use 8T2799 installation tool 4 Install 9U5604 Heil-Coil insert 4 Drill n Note: Special 32mm Grip Length May 2001 . LEVN4999 Page 22 .26 in numerical sequence to 160 ±15 N-m (120 ± 11 Ft-lb) May 2001 . Underside of Bolt Head.Review 4 Determine n cause of coolant leak 4 Determine the correct head gasket part number Reference: Truck Engine News December 2000 4 Clean all 26 bolt holes with 8T3096 (M16x2) tap 4 Vacuum all debris from bolt holes 4 Visually inspect bolts for damage n Heli-Coil damaged bolt holes 4 Check cylinder head and block flatness 4 Properly Lube Bolt Threads. and Washers with 6V-4876 Molycote 4 Tighten Bolts 1. Review 4 Tighten Bolts 1.26 Again. in numerical sequence to 160 ± 15 N-m (120 ± 11 Ft-lb).LEVN4999 Page 23 .26 in numerical sequence to 160 ± 15 N-m (120 ± 11 Ft-lb) 4 Tighten Bolts 1. 4 Turn each bolt 90° (¼ turn) 4 Loosen Bolts # 1. 4 Turn each bolt 90° (¼ turn) 4 Tighten bolts # 27 .26 n Washers should be loose under bolt head 4 Tighten Bolts 1. in numerical sequence to 160 ± 15 N-m (120 ± 11 Ft-lb).33 in numerical sequence to 28 ± 7 N-m (20 ± 5 Ft-lb) Torque May 2001 .26 Again. com n Truck Engine Call Center (TECC) (800) 447-4986 May 2001 .LEVN4999 Page 24 .Keepin’ In Touch 4 Gene n Linder Phone: (309) 578-4770 n Fax: (309) 578-2673 n E-Mail: [email protected] or Techtips@cat. LEVN4999 Page 25 .Fuels May 2001 . LEVN4999 Page 26 .Biodiesel 4 IRM Caterpillar Position on the Use of Biodiesel Fuel n Literature Number n n PELE0805 4 Biodiesel Soybean Oil. Rapeseed Oil n Waste Cooking Oil n Must be esterified n May 2001 . Biodiesel 4 Must n meet One of the following specifications Caterpillar Biofuel Specification n ASTM PS121 n DIN 51606 May 2001 - LEVN4999 Page 27 Biodiesel 4 Important n n n n Considerations Oil Change Interval SOS Do Not change the rating to compensate Less Energy n Monitor hoses and seals n Storage n n n Low ambient Temperatures Filter plugging Blending Additive Filter Plugging Water in fuel accelerates growth n n Oxidation n Microbial Growth n n May 2001 - LEVN4999 Page 28 Biodiesel 4 User n is Responsible EPA Compliance n Local regulations n Proper exemptions 4 Failures n resulting from the use of any fuel are not Caterpillar factory defects Not covered by Caterpillar Warranty May 2001 - LEVN4999 Page 29 Engine Service Training May 2001 - LEVN4999 Page 30 Engine Service Training Topics 4 Heavy Duty Truck Technician Program Update 4 Engine Instructor Re-Certification Summary 4 LEXT1044 Engine Performance Reference 4 Truck PAR Grams 4 Truck PAR Technician Re-Certification 4 Engine Diagnostics Course Update May 2001 .LEVN4999 Page 31 . pre-work and exam process Cyndie Anderson Todd Roth Ray Lott Larry Wood (309) 578-9827 (309) 494-5783 (309) 494-5994 (309) 494-5898 n If there are questions.Engine Service Training 4 Heavy n n n Duty Truck Technician Program Update Numbers of Technicians Certified by Caterpillar: Only 250 were certified as of mid-February Now 500 Technicians have passed the on-line Certified Service Exam Certified Techs will receive a brass Medallion or Belt Buckle n Please promote this Program through your organizations n Core Work book LEXV0193-01 is great for getting started n n Booklet explains nomination. contacts are: n n n n May 2001 .LEVN4999 Page 32 . May 2001 .Engine Service Training 4 Engine n Instructor Re-Certification Summary The Re-Certification of all Engine Instructors is Now Complete n 110 Engine Instructors have completed re-certification n 22 instructors scored a perfect 100% on the 40 question test! n Certification labels and a Laser Pointer are being mailed n Many thanks to all the Instructors for your continued service and commitment to the engine products and service requirements. This is a great reference to use in the classroom or to keep in your toolbox. Performance Tolerances. Fuel Density Chart.LEVN4999 Page 33 . 4 LEXT1044 n Engine Performance Reference This 15 page reference provides the latest: Useful Formulas. Diesel Fuel API Gravity Correction Chart and Horsepower Correction Factors. 4 Truck n PAR Technician Re-Certification Truck PAR Technician Re-Certification will start this summer n Packets will be mailed to your Cat Dealer PAR contact soon n Truck PAR technician re-certification now will be every two years n Technicians will be allowed to take the test one time only n More details will be included in the upcoming mailing packets May 2001 .Engine Service Training 4 Truck n PAR Grams PAR Contacts: Ray Lott & Stan Preston in Engine Training n There have not been any PAR grams sent for a while.LEVN4999 Page 34 . Engine Training maintains a database of the active PAR Technicians and PAR Instructors and will be sending new PAR grams and other information out again very soon. Engine Service Training 4 Engine n Diagnostics Course Update Engine Diagnostics course is being updated n Expected to be in the literature system around June n Will be Available in two medias: n n CD ROM in Adobe and PowerPoint formats 2” by 2” Slide form with Instructor Book The update will be published in Pre-view n An E-mail will go out to Engine Instructors when it is available n May 2001 .LEVN4999 Page 35 . LEVN4999 Page 36 .Q&A May 2001 . LEVN4999 Page 37 .ELECTRONICS May 2001 . LEVN4999 Page 38 .Electronic Troubleshooting May 2001 . LEVN4999 Page 39 .APR01 3126 Software Release 4 3126 n Parts Service Release Engine Running Output Progressive Shift Intermediate Gears Problem Fix Elevated Idle on Low Battery Voltage Engine Serial # 7AS n Key Features n n n May 2001 . APR01 3126 Software Release 4 Engine n Running Output High-side output (J1/P1:13) is activated when engine speed is above 600 RPM. and deactivated when engine speed drops below 100 RPM n Output controls relay to interrupt power to the starter motor to prevent cranking when engine is running. May 2001 .LEVN4999 Page 40 . 4 Progressive n Shift Problem Fix Intermediate Gears of Progressive Shift now functional 4 Elevated n Idle on Low Battery Voltage Feature elevates engine idle rpm when battery voltage drops below a programmed value to maintain battery charge. LEVN4999 Page 41 . check polarity of connection n Incorrect polarity of Speed/Timing sensor(s) can result in 22-11 fault.Speed/Timing Sensor Kits 4 Speed n Timing Sensor Kit Installation Be sure to install butt-splice pigtail if included in kit n Be sure polarity of pigtail is correct 4 22-11 n Cam Sensor to Crank Sensor Fault If 22-11 fault becomes active after installing kit. and inability to perform Timing Calibration May 2001 . LEVN4999 Page 42 . May 2001 . C-12. C-15. C-16 and 3406E engines with OCT00 or NOV00 software 4 Low n Oil Pressure and High Coolant Temperature Lamps may not function if: Engine Monitoring Lamps parameter is programmed to Option 1 AND the PTO Configuration parameter is programmed before the Engine Monitoring Lamps parameter.Dash Lamps Not Illuminating 4 Engines n affected: C-10. Dash Lamps Not Illuminating 4 Perform n the following steps Exactly to fix problem: Program PTO Configuration parameter to “OFF” n Program Engine Monitoring Lamps parameter to “Warning Lamp” n Wait 5-10 seconds n Program Engine Monitoring Lamps parameter back to “Option 1” n Program PTO Configuration parameter back to desired setting.LEVN4999 Page 43 . May 2001 . LEVN4999 Page 44 .Electronic Service Tools May 2001 . LEVN4999 Page 45 .Caterpillar Electronic Technician May 2001 . LEVN4999 Page 46 .Caterpillar Electronic Technician Version 2001A 4 Scheduled for delivery May 2001 4 Version name change (year of release) 2001A (Spring version) n 2001B (Fall version) n 4 Release n Information Topics: Menu location changes n Access the Comm Adapter II Toolkit n Trainer offers C-9 Industrial Engines n “What’s New” List n Licensing on the web n Be sure to read “readme.txt” May 2001 . To customize the toolbar and function keys May 2001 .LEVN4999 Page 47 .Caterpillar ET 2001A Menu location changes 4 File drop-down menu: n 4 View drop-down menu: n n n Connect or Disconnect from Cat ET Switch Data Links Select a different ECM Customize the Toolbar and Function Keys Formerly under the Settings drop-down menu. To change the size of the icons on the toolbar Formerly under the Data Link dropdown menu. Caterpillar ET 2001A Menu location changes (cont. n May 2001 .) 4 Utilities drop-down menu: n Formerly under the Settings drop-down menu.LEVN4999 Page 48 . Access the Comm Adapter II Toolkit dialog box (if installed) n Change Preferences License ET New in Cat ET 2001A. Caterpillar ET 2001A Trainer 4 C-9 Engine May 2001 .LEVN4999 Page 49 . Caterpillar ET 2001A “What’s New” 4 “What’s n New” option Views a list of new functions and major enhancements May 2001 .LEVN4999 Page 50 . LEVN4999 Page 51 .Caterpillar ET 2001A On-line Licensing 4 Licensing of Cat ET will soon be available on the internet n Select “License ET” from the Utilities drop down n Select the hyperlink hyperlink Note: You must have at least IE version 5.0 or or Netscape version 4. May 2001 .5 for proper web licensing. Press “Login.LEVN4999 Page 52 . May 2001 . follow the instructions on how to license your service tool. n The Service System Software Online Licensing screen displays.” Press the “License” push-button. Then.Caterpillar ET 2001A Online Licensing (cont.) n Your internet browser displays the Corporate Security Web page. Enter Logon ID and Password into the text boxes. Caterpillar ET 2001A Readme.txt contains important release notes about Cat ET 2001A n Hardware Requirement Changes n Windows 2000 User Permission Issues n Caterpillar Communication Adapter II Installation information May 2001 .txt 4 Readme.LEVN4999 Page 53 . LEVN4999 Page 54 .com or SSSC (Caterpillar Host e-mail) Serv Sys Support Ctr (Lotus Notes) Monday through Friday 6:00am to 6:00pm (Central Standard Time) Hours: May 2001 .PC Software Support Hotline 4 Service Voice: Fax: E-mail: Systems Support Center (800) 765-0999 or (309) 675-0999 (309) 636-5823 SSSC@cat. com or medial (Caterpillar Host E-mail) Monday through Friday 7:30am to 4:30pm (Central Standard Time) Hours: May 2001 .Licensing Caterpillar ET 4 Caterpillar Voice: Fax: E-mail: Media and Product Information Logistics (800) 566-7782 or (309) 266-0942 (309) 494-1348 or (309) 494-1345 [email protected] Page 55 . LEVN4999 Page 56 .Caterpillar Pocket Technician May 2001 . LEVN4999 Page 57 .Pocket Tec™ 4 Kit n Numbers EEKE4006 = Software/Adapter/6-pin Cable/Manual n EEKE4009 = Software/Adapter/9-pin Cable/Manual n EEKE4096 = Software/Adapter/ 6 and 9 Pin Cables/Manual n EEKE4001 = Software/Adapter/GM Cable/Manual EEKE4009 Kit May 2001 . Which Palm™ Do I Buy? 4 Any III family 4 V family needs adapter n palmdock.LEVN4999 Page 58 .com 4 Any VII family 4 Does NOT work currently with M100 Family n M500 Family n May 2001 . What Can I Do With Pocket Tec™? 4 Configuration n Read & Change 4 Status 4 Diagnostics 4 Totals Lifetime n Trip n 4 Maintenance 4 Theft Deterrent May 2001 .LEVN4999 Page 59 . read View these Status Parameters Accelerator Pedal Position Boost Pressure Coolant Level Cruise Kickout Cruise Mode Cruise Set Speed Driver Reward VSL Bonus ECM Battery Voltage ECM Serial Number Engine Coolant Temp Engine Load Factor Engine Oil Pressure Engine Speed – Actual Engine Speed .Desired Estimated Fuel Rate Fuel Economy Fuel Temp Intake (Manifold) Air Temp Outside Air Temp Starting Aid Output Vehicle Speed Vehicle Speed Limit View and Save these Lifetime Totals Fuel Economy (mpg) Distance Traveled Average Speed Fuel Consumed Running Time PTO Fuel Consumed PTO Time Idle Fuel Consumed Idle Time Load Factor % Idle View and Save this Trip Total Information Driver ID Fuel Economy (mpg) Distance Traveled Average Speed Fuel Consumed Running Time PTO Fuel Consumed PTO Time Idle Fuel Consumed Idle Time % Idle May 2001 .read SoftCruise Control – read and change Idle/PTO RPM Ramp Rate – read and change Idle/PTO Bump RPM – read and change Low Idle Engine RPM – read and change Fan with Engine Retarder-High Mode – read and change Engine Retarder Delay – read and change.read Engine Retarder Mode .read Engine Retarder Min Vehicle Speed .LEVN4999 Page 60 . lockable Battery Monitor-Engine Control Voltage – read and change Maintenance Indicator Mode – read and change PM1 Interval – read and change Engine Oil Capacity .Pocket Tec™ Driver Version Parameters/Features Access these Programmable Parameters Rating Number .read ECM Software Module Release .read Fuel Correction Factor .read Auto Retarder in Cruise .read Vehicle ID .read Dash – PM1 Reset – read and change Theft Deterrent System Control – read and change Quick Stop Rate .read Engine Serial Number – read ECM Software Module P/N .read Engine Retarder Min VSL Type .read Auto Retarder in Cruise Inc . cattruckengines.LEVN4999 Page 61 .com/buystuff 4 Palm Software 4 Chrome Parts 4 and more… 4 On Line Now! May 2001 .Buystuff 4 http://www. Q&A May 2001 .LEVN4999 Page 62 . 2001 Binder 4 The binder this year is a three ring binder with dividers .one for each show.LEVN4999 Page 63 . 4 Has slotting to hold all four video tapes 4 Form # LEKQ5055 May 2001 . May 10.February 9.November 10.Yearly Subscription to Tech Tips August 8 Nov 14 4 Broadcast Schedule for 2001 n n May 2001 .“Tech Tips” Broadcast .November 8.“Tech Tips” Broadcast .May 9. 2000 LEVN4810 .August 9.“Tech Tips” Broadcast .“Tech Tips” Broadcast . 1999 LEVN4738 .“Tech Tips” Broadcast .“Tech Tips” Broadcast . 2001 LEVN4999 .LEVN4999 Page 64 . 2000 LEVN4998 .2000 LEVN4811 . 1999 LEVN4808 .Broadcast Information 4 Update n n n n n n n n Broadcast Videos LEVN4715 .“Tech Tips” Broadcast .“Tech Tips” Broadcast . 2001 n LEVN3947. 2000 LEVN4809 .August 11.February 14. com Engine Spec Sheets May 2001 .Keepin’ In Touch Email Caterpillar E-Mail Internet E-Mail TECHTIPS [email protected] World Wide Web http://www.Cat.LEVN4999 Page 65 . LEVN4999 Page 66 .Electronic Controls Part Number Reference May 2001 . 9NS. 8SZ 8WL.Troubleshooting Guide Listing Latest Truck Engine Electronic Troubleshooting Guides: Form Number RENR2238-02 RENR1328-02 SENR5582-06 SENR5503-00 SENR3479-05 SENR3913-04 SENR5112-01 RENR1367-01 SENR6566-03 Booklet Description C-10.8TC 2YG 7LG 7AS.C-12 & 3406E C-10.C-12 & 3406E 3406C (PEEC III) 3406B (PEEC II) 3176 Truck Engine 3176 Truck Engine 3126B Truck Engine 3100 HEUI Truck Engine Serial Number Prefixes 1MM. 7CZ 5DS.2KS.8YS.2CW.2PN.1LW 5EK.1WM.LEVN4999 Page 67 .C-12 & 3406E 3176B.5YG.2WS.4ES. 8HW.1YN. 8YL. 7LZ May 2001 .3CS.6TS 4CK 2EK.C-10. 6NZ.9CK. After flashing the new software file. 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.When using either of the screens listed above (JTZ101-02 or GKN401-06) it will be necessary to enter the new "Performance Spec" number and the serial number of the engine being rerated. 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 the factory. you can find the new performance spec on the ET configuration screen.LEVN4999 Page 68 .Heavy Duty Truck Engine FLS/FTS Adjustment Policy The guidelines for HD Truck FLS/FTS changes for Re-Rates are as follows: 1. If you are rerating to a multi-torque rating. Since rerating outside the current rating family requires a "Reason Code 5" factory password. 2. 1750 lb-ft rating) 3. (Example: rerating a 3406E engine from a 475 Hp. C-12 when: Engine is rerated outside the current rating family. C-10. change FLS/FTS if "Reason Code 5" factory passwords are required. be sure to use the FLS/FTS values for the second performance spec listed on the configuration screen. FLS/FTS SHOULD NOT be changed when: Engine is rerated within the current rating family. (Example: rerating a 3406E engine from a 475 Hp rating to a 550 Hp rating) NOTE . (Example: rerating a 3406E engine from a 375 Hp rating to a 410 field rerate only rating) May 2001 . 1650 lb-ft rating to a 475 Hp. Since rerating within the current rating family does not require a "Reason Code 5" factory password. do not change FLS/FTS if "Reason Code 5” factory passwords are not required. LEVN4999 Page 69 .Serial Number Prefixes – 3116/3126 4 1WM n 3126 HEUI 3116 HEUI 1995 to Current 1995 to Current 4 8WL n 4 7AS n 3126B 1998 thru July 31. 1999 . 1999 July 1999 to December 2000 December 2000 to Current 1998 thru July 31.Short Eng Version March 2001 to Current (Catalytic Converter / Muffler) 4 8YL n 4 9SZ n 4 8SZ n 4 CKM n May 2001 . Serial Number Prefixes C-10. C-12 & 3176 4 4 4 4 4 4 2YG 3176 n 4 4 4 9NS C-12 n 1988 to 1990 1991 to December 1993 May 1993 to March 1995 March 1995 to September 1997 September 1997 to November 1998 March 1995 to September 1997 September 1997 to November 1998 November 1998 to Current November 1998 to Current 7LG 3176 n 3CS C-10 n 9CK 3176B n 2KS C-12 n 2PN C-10 n 8YS C-10 n 1YN C-12 n May 2001 .LEVN4999 Page 70 . November 1998 December 1997 .V n 2WS 3406E 14.8L n 1990 4 2EK PEEC II and PEEC II.6L n 1991 4 4CK 3406C Electronic n 1MM 3406E 15.Serial Number Prefixes .LEVN4999 Page 71 .November 1998 November 1998 to Current November 1998 to Current November 1999 to Current November 1999 to Current 5YG PEEC II .3406 4 4 4 4 4 4 8TC PEEC II and PEEC II.V n 4 1LW 3406E 14.8L n August 1991 to December 1993 4 5EK 3406E n 6NZ C-15 n May 1993 to December 1996 4 6TS 3406E n 7CZ C-16 n January 1997 to December 1997 May 2001 .6L n 1987 to 1990 4 December 1997 .460Hp Only n 5DS 3406E 15. 153-8920 Wire Router .176-1602 Injector Wiring Harness .3126E Electronic Control and Sensors 4 4 4 4 4 4 4 4 4 4 ECM (3126E Basic & Full Feature) 179-4898 Coolant temperature Sensor .161-9928 O-Ring Seal 3J7354 Injection Actuation Pressure Sensor .130-9811 O-Ring Seal 6V6609 Inlet Manifold temperature Sensor .167-1708 O-Ring Seal 1J9671 Pedal Position Sensor .130-9811 O-Ring Seal 8L2786 Speed/Timing Sensors .126-1774 May 2001 .119-4142 O-Ring Seal 117-1385 Atmospheric Pressure Sensor .LEVN4999 Page 72 .161-9925 O-Ring Seal 6V5049 Boost Pressure Sensor . 3116 HEUI & 3126 HEUI — Electronic Parts 4 3116 HEUI .1WM n ECM – 145-7807 n n n ECM Connector Bolt Kit – 6V6703 40 Pin Plug Assembly – 114-4408 (includes 110-6844 Seal) 40 Pin Connector Seal – 110-6844 Includes 117-1385 O-Ring Seals Requires 3K0360 Seal Requires 3K0360 Seal Male/Male Adapter – 9X0262 & 3J7354 – Seal Requires 108-5803 Seal Seal Kit 9X1484 n Speed/Timing Sensor Service Kit – 119-4142 n n Inlet Air Temperature Sensor – 107-8618 n n Coolant Temperature Sensor – 106-0735 n n Boost Pressure Sensor – 161-9927 n n Injection Actuation Pressure Sensor – 140-3540 n n Injection Actuation Pressure Control Valve – 122-5053 n n n n Throttle Position Sensor – 176-1602 Fuel Transfer Pump to Hydraulic Pump O-Ring – 004-1963 Hydraulic Pump Dome O-Ring – 6V5656 May 2001 .LEVN4999 Page 73 .8WL and 3126 HEUI . LEVN4999 Page 74 .Other 3116 HEUI & 3126 HEUI Parts 4 Part Numbers missing for Parts Books (3116 HEUI – SEBP2271 and 3126 HEUI SEBP2355) 123-1199 Seal for Injector and IAPCV Connectors n 118-8622 Service Replacement Harness n 40 pin to Injectors n 122-8840 Service Replacement Harness n 40 pin to Speed/Timing Sensor n 122-8842 Service Replacement Harness n 40 pin to IAPCV n 122-8839 Service Replacement Harness n 40 pin to all other sensors n 141-7060 Injector Wiring Harness Connector Repair Kit n 143-8325 Injection Actuation Pressure Sensor Guard n May 2001 . 020”) C-10.145-7806 ECM with J1939 Data Link Option . 3176B & 3406E Pre-’99 Current Parts C-10 .1YN & 9NS.CRB 161-9930 Pedal Mounted Throttle Position Sensor .9CK & 3406E . 3176B .145-7805 Speed/Timing Sensor 3406E — 129-6628 Sensor 126-8481 Shim (0.5EK & 6TS.LEVN4999 Page 75 . C-12 & 3176B — 129-6628 Sensor No Shim Coolant/Fuel Temperature Sensor .CRB176-1602 May 2001 .CRB 161-9927 Atmospheric Pressure Sensor 111-8125 Oil Pressure Sensor . 5DS Electronic Control Module (ECM) . 1LW.102-2240 Air Inlet Temperature Sensor . C-12.C-10.107-8618 Boost Sensor . C-12 .2PN & 8YS. 3E0020 n Remote Mounted Throttle position Sensor .FORD .9X9648 n Pedal Mounted Throttle Position Sensor .7E8421 n Speed/Timing Sensor .9X9529 0R6149 n ECM FORD .9X5370 n Vehicle Speed Buffer .9X9647 n Remote Mounted Throttle Position Sensor .LEVN4999 Page 76 .9X8226 / 0R6132 n Harness .110-8190 n May 2001 .3176 —2YG Current Parts 4 3176 .107-7142 n Coolant Temperature Sensor .102-9029 n Fuel Pressure Sensor .9X9528 / 0R6148 n Transducer module .2YG ECM . & 3406E .2KS. C-12 . C-15.3CS. C-16 Cam Sensor .179-1747 Speed/Timing Sensor C-10.2WS (14L) & 1MM (16L) Electronic Control Module (ECM) .Repair Kit: 194-5339 Coolant/Fuel/Inlet Air Manifold Temperature Sensor . C-16 Crank Sensor .161-9929 Atmospheric Pressure Sensor 161-9925 Oil Pressure Sensor .1309811 Boost Pressure Sensor .Repair Kit: 194-5340 3406E. C-12 & 3406E Crank Sensor .Repair Kit: 194-5341 C-10.LEVN4999 Page 77 .C-10.176-1602 Short Pig Tail . C-15.161-9931 Pedal Mounted Throttle Position Sensor Long Pig Tail .176-1604 May 2001 . C12 Cam Sensor .Repair Kit: 194-5338 3406E. C-12 & 3406E ‘99 Model Year And Up Current Parts C-10 . 020”) C-10.5EK & 6TS.C-10. 3176B . 1LW. C-12 . C-12.1YN & 9NS.161-9930 Pedal Mounted Throttle Position Sensor . 3176B & 3406E Pre-’99 Current Parts C-10 . 5DS Electronic Control Module (ECM) .176-1602 May 2001 .102-2240 Air Inlet Temperature Sensor .145-7805 Speed/Timing Sensor 3406E — 129-6628 Sensor 126-8481 Shim (0.LEVN4999 Page 78 .9CK & 3406E .145-7806 ECM with J1939 Data Link Option .107-8618 Boost Sensor .2PN & 8YS. C-12 & 3176B — 129-6628 Sensor No Shim Coolant/Fuel Temperature Sensor .161-9927 Atmospheric Pressure Sensor 111-8125 Oil Pressure Sensor . 9X9648 n Pedal Mounted Throttle Position Sensor .3E0020 n Remote Mounted Throttle position Sensor .7LG00001 to 7LG07499 — 9X5370 n Vehicle Speed Buffer .FORD .LEVN4999 Page 79 .102-9029 n Oil Pressure Sensor n “DT” Connector 7LG08721 and Up — 161-9930 n “HD” Connector 7LG07500 to 7LG08720 — 163-8516 n Coolant / Inlet Air Temperature Sensors n Full Range .3E8644 / 0R6470 n Speed Timing Sensor .9X8226 / 0R6132 n Altitude Retrofit .110-8190 n May 2001 .9X9647 n Remote Mounted Throttle Position Sensor .3176 — 7LG Current Parts 4 3176 7LG ECM .7LG07500 and Up — 102-2240 n Limited Rage .3E5293 / 0R6302 n Transducer Module . 100-6619 n Rack Sensor .110-8190 n Remote Mounted Oil Pressure Sensor Kit .9X8085 / 0R6486 n Transducer Module .9X7793 n Timing Sensor .4CK ECM .LEVN4999 Page 80 .102-2240 n Pedal Mounted Throttle Position Sensor .3E0020 (same for PEEC II) n May 2001 .3406C Electronic Current Parts 4 3406C .129-4501 n BTM .132-4363 n Speed Sensor .105-2939 n Coolant Temperature Sensor .118-6256 n Vehicle Speed Buffer . 100-6619 n Rack Sensor .Wiring Harness n 9X5370 .Temperature n May 2001 .LEVN4999 Page 81 .132-4363 n Speed Sensor .129-4501 n BTM .9X9648 n Pedal Mounted Throttle Position Sensor .105-2939 n Throttle Position Sensor n Remote Mounted “Beer Can” Sensor .122-1649 n If the engine (2EK and 5YG) has had the White Smoke Product Support Program performed.FORD Only ECM .8TC and 2EK .V Current Parts 4 PEEC .PEEC II.9X7793 n Timing Sensor . The following parts will be installed: n 6I2382 .110-8190 n Remote Mounted Oil Pressure Sensor Kit .9X4840 / 0R6081 n Transducer Module . Temperature n May 2001 .100-6620 n Rack Sensor .132-4363 n Speed Sensor .PEEC II Current Parts 4 PEEC II . 5YG and 2EK ECM .LEVN4999 Page 82 .129-4501 n BTM . The following parts will be installed: n 6I2382 .110-8190 n Remote Mounted Oil Pressure Sensor Kit .Wiring Harness n 9X5370 .9X7793 n Timing Sensor .122-1649 n If the engine (2EK and 5YG) has had the White Smoke Product Support Program performed.105-2939 n Throttle Position Sensor n Remote Mounted “Beer Can” Sensor .9X9647 n Pedal Mounted Throttle Position Sensor .8T8770 / 0R5607 n Transducer Module .8TC.