2004-02 TechTips PDF

Tech Tips
February 11, 2004

10:00am CST
February 2004 – LEVN5616

Page 1
Index
3126 / C7 Update Caterpillar Electronic Technician Update
C7 / 3126 Oil Cooler Gaskets and Seals 4-5 Cat Electronic Technician Version 2003B Service Pack 1 54
C7 Injector / Flash File Story 6-7 Transmission Torque Protection Reset 55-59
C7 Injector Table 8 Cylinder Cutout Test C7 and C9 engines with ACERT Technology 60-63
C7 Flash Files 9-10 Service Tool Reports Viewing a Report with Microsoft Excel 64-71
C7 Turbo Information Request 11 Caterpillar Electronic Technician website and contact information 72-73
DBSi Website 74
C-10 / C-12 / C11 / C13 Update PC Software Support Hotline 75
10-13L Service Letter Update 12 Licensing Caterpillar ET 76
C11 / C13 Push Tube Installation 13-14
ACERT Air Compressor Air Box 15-16 Troubleshooting Overcooling
C13 Air Compressor Vibration 17 Overcooling Troubleshooting 78
C13 AC Pressure Switch Function 18 Overcooling Engine Discussion 79-80
C13 Surge 19 Overcooling C-15 / C-16 Cooling System Circuit Discussion 81-82
C11 / C13 Vibration & White Smoke 20 Overcooling Engine Discussion 83
C-10 / C-12 / C -15 / C-16 Injector R&I 21-22 Overcooling C15 ACERT Cooling System Circuit Discussion 84
C11 / C13 Cat Brake Retrofit 23 Overcooling Troubleshooting 85-88
Overcooling Checklist (7 steps) 89
Variable Valve Actuator Diagnostics
Variable Valve Actuator Diagnostics 25-27 Pocket Tec
Fleet Edition 2.0 91
C-15 / C-16 / C15 Update Special Promotions 92
PS50667 Exhaust Rocker Arm 29
PS50740 C-15 Truck Cylinder Liner 30 Question and Answer Section 93
C15 BXS Turbo Mounting 31-33
C15 BXS Valve Actuator Wiring 34 DSN
Dealer Solution Network 94-101
Electronic Update
New Format for Multi Torque Ration 36-37 Binder Info 102
Eaton Top II 38 Broadcast Information 103
Transmission Neutral Switch 38 Keepin’ In Touch 104
Oil Well Service Files 39 Electronic Controls Part Number Reference 105-121
Air Inlet Shutoff System Control Test 39-44
Outside Temp Based Idle Shutdown 45
Flashing ECM’s 45
Blank Box 46-49
Reminders 50
Phone Analysts 51
Late Breaker 52

Page 2
3126 / C7 Update
Kevin Kempher

Page 3
C7 / 3126 Oil Cooler Gaskets and
Seals
4 New gaskets have been released to seal the joint
between the oil filter base, the oil cooler group and
the block
n New gaskets use improved material that is less
susceptible to thermal growth
n New o-ring seals made from improved material
n New gaskets should be used as a set
n All parts are available in the “Oil Cooler and Lines

Gasket kit” - part number 250-9214

Page 4
C7 / 3126 Oil Cooler Gaskets
233-7654
233-7655

Page 5
C7 Injector / Flash File Story
4 Two versions of injectors for each horsepower family
n Injector part numbers can not be mixed in an engine
n Original version is not supported in the parts system
n The factory serial number breaks for the new injectors for each
horsepower family are:
n LHP KAL07986
n MHP KAL11871
n HHP KAL12898
n When replacing injectors in engines built after the above effective
serial numbers, it is not necessary to replace complete sets
n When replacing injectors in engines with serial numbers below the
effective serial number breaks, it is necessary to replace the
complete set with the following exception:
n If the injectors have been previously replaced with the new
injector part number, only the defective injector needs to be
replaced

Page 6
C7 Injector / Flash File Story
4 Three C7 horsepower families
n LHP (low horsepower) includes 190hp through 210 hp
ratings
n MHP (mid horsepower) includes 230hp through
250_660 low torque ratings
n HHP (high horsepower) includes 250_800 high torque
through the 330 hp ratings

Page 7
C7 Injector Table
Old Injector Serviceable New Injector Serviceable
Horsepower Part Number Part Number Part Number Part Number
(on solenoid) (parts system) (on solenoid) (parts system)
Family
LHP 233-3536 236-0973 241-3238 243-4502
MHP 236-6011 238-9808 241-3239 243-4503
HHP 233-3535 236-0974 238-8091 241-3400

Page 8
C7 Flash Files
4 New Flash Files have been released for all C7
ratings
n Improved cold ambient drivability
n Revised coolant temperature set points
n Fuel histogram capability
4 Compatible with current injectors

Page 9
C7 Flash Files
4 Reminder: Select the correct flash file for the injector
part number that is in the engine.
n It is very important to select the CORRECT flash file for the
injector part number that is in the engine!!! Engines that have the
"factory installed injector p/n" can use the flash file for the s/n
range listed. However, if an engine was built with the older
injectors and has since been updated to the new injectors, it may
be necessary to obtain the correct flash file part number by
looking under the rating information in “Readxref” in SIS. The link
to “Readxref” is on the same screen used to download flash files.

Page 10
C7 Turbo Information Request
4 Limited number of C7 HHP turbo failures –
information needed to troubleshoot
n Engine serial number
n Truck model
n Truck VIN
n Miles
n Current Flash File part number
n Compressor inlet elbow part number
n Max operating altitude
4 Please fax information to (309) 578-2673

ATTN: Mike Rocke

Page 11
C-10 / C-12 / C11 / C13 Update
Brad Bowdoin

Page 12
10-13L Service Letter Update
4 PS50041 (C-10/C-12 Head Gasket Repair)
n Scheduled to Expire January 31st 2004
n Extended Until the End of May
4 PS50338 (C-10 – C-15 Injector Tip)

n Expired December 2003
n Will Not be Extended

Page 13
C11/C13 Push Tube Installation
4 Valve Push Tube Installation Problems
n CPI Issue: 55852
n Problem: Intake and Exhaust Push Tubes can be installed

incorrectly
n Ball end outside of lifter pocket

Page 14
C11/C13 Push Tube Installation
n Affected Product: All C11/C13
n Fix: Ensure Push Tubes are installed correctly during

assembly by inspection.
n Communication: TEN Article Planned 2nd Quarter 2004

Page 15
ACERT Air Compressor Air Box
4 Debris Related Failures on Air Compressor
n CPI Issue: 57620
n Problem: Carry over debris from Air Box Resulting in Air

Compressor Failure
Air Box
n C15 Air Compressor Group

Page 16
ACERT Air Compressor Air Box
n C13 Air Box
Air Box
n Affected Product: All HD ACERT Engines
n Fix: Ensure the air box is free of debris after a repair where the air
compressor incurred a core iron failure (ie. Piston failure)
n Communication: TEN Article 2 nd Quarter 2004

Page 17
C13 Air Compressor Vibration
4 BA 921 Single Cylinder Air Compressor
n CPI Issue: 54887
n Problem: The new BA-921 Single Cylinder Air Compressor

can excite engine chassis vibration
n Vibration Meter Reading 1.14 Order (1.14 x crank speed)
n Affected Product: KCB00508 – KCB01638
n Fix: New Counter Weight Gear to Reduce Air Compressor

imbalance.
n Communication: TEN Article Planned Late 1 st Quarter 2004

Page 18
C13 AC Pressure Switch Function
4 AC Pressure Switch Function
n CPI Issue: 56933
n Problem: ECM software has a non-functional Air Conditioner

Input Switch
n Fix: February Release Software
n Communication: TIB Planned for Mid February

Page 19
C13 Surge
4 C13 Surge
n CPI Issue: 56110
n Problem: Small Number of Chassis Configurations Excite the

Driveline with the C13 Engine
n Typically referred to as “violent” surge during slight acceleration
n Communication: Scheduled TIB for Early February

Page 20
C11/C13 Vibration & White Smoke
4 C11/C13 Slight Surge and White Smoke
n CPI Issue: 58741
n Problem: Complaints of Vibration and White Smoke around

1500 RPM
n Affected Product: KCB00508 – Feb 9th Start on Line
n Communication: Scheduled TIB for Early February Coupled

with “Violent” Surge

Page 21
C-10/C-12/C-15/C-16 Injector R&I
4 Slightly modified procedure for R&I injectors
n CPI Issue: 51168
n Problem: Injector hold down bolt failures after service
n Affected Product: All Heavy Duty Engines

Page 22
C-10/C-12/C-15/C-16 Injector R&I
4 Slightly modified procedure for R&I injectors
n Fix: New Remove and Install Procedure
a. Make sure to mark which cylinder unit injector, spacer, clamp, and bride
assemblies came from.
a. Reinstall these parts on the same cylinder they were removed from.
b. Inspect the hold down bolt assembly prior to disassembly.
a. If the bolt is NOT loose during disassembly, then proceed directly to
step C.
b. If the hold down bolt IS loose during disassembly:
i. Inspect the injector bore for debris
ii. Inspect the bore for wear
iii. Replace the clamp, and spacer Proceed to step C
c. NOTE: In ALL instances, replace the injector hold down bolt with a
NEW bolt
d. Do NOT reuse seals or hold down bolts.
n Communication: TEN Article Planned 1st Quarter 2004

Page 23
C11/C13 Cat Brake Retrofit
Actuator Actuator Internal Internal

Serial Assembly Assembly Harness Harness
Number Quantity 3 Quantity 3 Quantity 1 Quantity 1
(12 Volt) (24 Volt) (Front) (Rear)
KCB508 &
241-6090 242-9001 240-9996 240-9997
up
4 Future Plans to Release Retrofit Kit

n Early 2 nd Quarter 2004
n TEN Article to Announce Release

Page 24
Variable Valve Actuator
Diagnostics
Jack Maroney

Page 25
Diagnostics
4 Intake Valve Actuator Response - Test
n Used to diagnose mechanical problems only. Any electrical

fault codes (-05 or -06) must use “Intake Valve Actuator
Circuit - Test”.
n All electrical faults must be repaired before mechanical

problems can be properly diagnosed.
n Symptoms requiring this Troubleshooting Guide.

n Logged fault codes 283-07, 385-01, or 285-07-290-07.
n Intermittent engine derate.
n Intermittent check engine light.

Page 26
Diagnostics
4 Interactive Procedures
n The guide is designed to be interactive (i.e. HEUI style

troubleshooting).
n Helps the technician diagnose problems faster.
n Provides Caterpillar with the data needed to further enhance the
troubleshooting procedures.
n The technician will be asked to fill in certain information

throughout the guide.
nExample:
√ If code 385-01 returns proceed to test step 12.
If code 285-07 to 290-07 returns proceed to test step 7.
The technician would check the appropriate box.

Page 27
Diagnostics
4 Future Plans
n Return trouble shooting procedure with returned part
n If there is a VVA Housing replacement, the completed

Trouble Shooting Guide should be returned with the VVA
Housing.
n Include snapshots if available.
n Describe problem as accurately as possible.

Page 28
C-15 / C-16 / C15 Update
Roger Hudson

Page 29
PS50667 Exhaust Rocker Arms
4 Affected serial numbers
n 6NZ83126-Up
n 7CZ3834-Up
n MBN1-22118
4 Engines with Jacobs 340D Brake

4 Replace all exhaust rocker arms
4 Replace intake rocker arm on failed cylinder
4 Replace all compression brake bolts and studs
4 Set brake slave lash
n 6NZ83126-Up 0.025”
n 7CZ3834-Up 0.025”
n MBN1-22118 0.030”

Page 30
PS50740 C-15 Truck Cylinder
Liner
4 After Failure
4 Serial numbers included
n MBN12044-21022,6NZ91415-92097,C2A131-141
n 8SB3066-3067,7XC12188-12259,2MZ562-583
n 4AS665-689
4 Inspect date codes

n Replace affected liners as outlined in the service letter

Page 31
C15 BXS Turbo Mounting
4 Use Spiralock nuts only
n Part Number 168-7800
n Torque to 55 ± 5 N·m (40.6 ± 3.7 lb ft.)
4 Use Stainless Steel Studs

4 Use turbo mounting gasket
4 Nuts will spin on easily
4 No stake marks on nut
4 Over tightening can cause the stud to fail

Page 32

Page 33
238-4665 Stud
168-7800 Spiralock Nuts
Use turbo gasket 243-
6462

Page 34
C15 BXS Valve Actuator Wiring
4 Solenoid connector same as medium duty injector
4 Kit can be used for repair
n Part number 156-7106
4 Repair procedure
n REHS1809 Special Instruction
4 Less downtime for the customer
4 Keep wiring out of discharge stream of valve
actuator
n Can deflect oil causing oil mist from breather

Page 35
Electronics Update
Kevin Hampton

Page 36
Page 37
What’s New
ü Multi-Torque Rating. New format on Caterpillar ET
shows MT A, MT B, or MT C.
ü New Engine Fan Parameters.

ü Affected Engines: C11, C13, and C15
ü Cat ET 2003B or newer required
ü On/Off DC (Direct Current)
ü 3 Speed DC (Direct Current)
n Fan Special Test works same as before. No changes.

Page 38
What’s New
ü Eaton Top II
ü New Gear Fast Run Slow flash files. (GFRS)
ü On GFRS flash files the transmission style will show up as Eaton
Top II. The transmission style is not programmable with the GFRS
files.
ü Only for Eaton Top II Transmissions.
ü Change in flash file from GFRS to other flash file requires factory
passwords.
ü Changing the transmission from Eaton Top II to different
transmission will require a different flash file. Factory Passwords
are required to make this change.
ü Transmission Neutral Switch
ü Neutral Switch is located on J1/P1:62 or over the 1939 Data link.
ü Neutral Switch is now programmable for all transmission styles.
ü This can affect Fast Idle, PTO, Elevated Idle, and Cruise Control.
ü Important to check neutral switch programming and operation if

there is a complaint with Fast Idle, PTO, Elevated Idle, or Cruise
Control.
ü Caterpillar ET 2003B is required.

Page 39
What’s New
ü Oil Well Service Files (OWS)
ü New Air Inlet Shutoff Switch
ü Located on J1/P1:46
ü Designed to test the Air Inlet Shutoff System
ü 2 New Special Tests for Oil Well Service

Applications
ü Air Inlet Shutoff System Control Test
ü Allows testing of shutoff system through CAT ET.
ü Air Inlet Shutoff Output Relay
ü Allows testing of ecm output. (test lamp)

Page 40
E SPD Less Than 1400 RPM

Page 41
Page 42
Neutral Sw
In Gear

Page 43
Page 44
Page 45
Reminder
4 Outside Temperature Based Idle Shutdown
n Installation of sensor kit 185-7733 is required when the idle shutdown is
programmed to “Outside Temp Based” If this kit is not installed the idle
shutdown system may not function properly.
n The sensor kit must be mounted so an accurate measurement of the outside
ambient air temperature can be taken.
4 Flashing ECMs
n Always transfer the flash file to the hard drive of your computer.
Computers communicate faster when the file is on the hard drive.
n Also try the bypass harness. There is a lot of information on the
data link from other devices such as ABS, or transmissions. This
isolates the ECM from this noise.
n By putting the file on the hard drive and using the bypass harness
this will allow a ECM to be flashed in less time.
n ACERT flash files are too big for floppy disks. Do not download
ACERT flash files to a floppy. The flash will abort. File needs to be
on a CD or downloaded directly from SIS web to the computer you
are using to flash the ecm. Files downloaded to a CD still need to be
copied to the computers hard drive.
Page 46
Reminder
4 Blank Box
n Caterpillar ET may display the ECM as a blank box when it is
not.
n New ECMs are being used as test ECMs. The ECM is then
reflashed but aborted before the flash is complete. When Cat
ET is used it shows blank box. The ECM is then returned.
n The ECM is not blank. The application code is still in the
ECM.
n Another customer buys this ECM and flashes it. Passwords
are then required because a different file is used along with
other system parameters.
n Before allowing a ECM to be returned use your Caterpillar ET
and go to winflash. When winflash connects you will see the
ECMon the left side of the screen. Below that you will see old
software and new software. If there is a number next to the
old software text then the ECM has been previously flashed.

Page 47
Page 48
Page 49
Page 50
Reminder
4 Passwords
n Remember ECM serial numbers end with 2 alpha characters. We currently
have ECMs that end in a IK, IE, and IH. The is not a 1 or an L.
n 3126B, 3126E, and C7 engines require the Engine Serial Number, Truck
Manufacturer, and possibly the Truck Model Type to be programmed prior to
doing a copy configuration. On new ECMs the copy configuration programs
password protected parameters prior to programming the engine serial
number and truck models. These parameters need to programmed first then
the copy configuration can be completed.
4 Authorization Numbers and Coverage's
n Authorization number is only good for ECMs still under warranty.
n If not under warranty, tech can still call in for help.
n Dealer is responsible to determine if the ECM is still under warranty.
n ECM Hotline assumes ECM is under warranty.
n Authorization Number is not a Policy code. See your CAT Rep.
n If no authorization number is given or a dealer does not call in, the ECM
can still be claimed under warranty. The ECM will go through our validation
process. If ECM is no fault found the claim will be debited.
n An authorization guarantees claim payment regardless of test results.

Page 51
Phone Analysts
4 Phone Analyst Changes
n Andy Burks has left the ECM Hotline and taken a new
position at the Peoria Proving Grounds.
n Dave Morrow, Mark Shaull, and Tony King have joined the
ECM Hotline Group.
n Our hours are still the same. 7:30 AM to 10:00 PM Monday
through Friday and 7:00 AM to 5:00 PM on Saturdays.
n Changes may be made due to holidays. Any changes will be
made known through our voicemail system.
4 Thanks
n Test ECM Mode Questions have dropped significantly.
n Thanks for the hard work.

Page 52
Late Breaker
4 ACERT Heavy Duty Flash Files
n Effects C11, C13, and C15 Engines
n September 2003 Software
n Total Max Fuel is disabled
n This effects the average load factor.
n Current totals the load factor may show a negative number
n Trip segment the load factor may show data invalid
n Newer software the Max Fuel has been enabled.
n After newer software is flashed the max fuel and average

load factor will still be off.
n No way around this.
n Does not effect warranty.

Page 53
Caterpillar Electronic Technician
Susan Kiser

Page 54
Version 2003B –Service Pack 1
4 Cat ET 2003B or STW 2003B must be installed
before installing Cat ET 2003B-SP1.
4 Update is available…
n InfoCast Website
4 What’s New
n Transmission Torque Protection Reset
n Update - Cylinder Cutout Test - C7/C9 engines with ACERT™
Technology

Page 55
Transmission Torque Protection Reset

Page 56
Transmission Torque Protection
Reset
4 Purpose
n Transmission Torque Protection Reset allows you to
interactively reset the torque limit of an engine.
4 Accessing
n Select Transmission Torque Protection Reset from the
Service menu.

Page 57
Reset
4 The Transmission Torque Protection Reset screen
displays.
The Status Parameter
area lists parameters
needed for the function
and their current values
for your reference.
The Instruction area lists instructions

on using the function, usage tips, and
constraints.

Page 58
Reset
4 If the Transmission Torque Limit is active, press
the "Reset Protection" button to reset the
Transmission Torque Limit.

Page 59
Reset
4 A message box displays confirming the
Transmission Torque Limit was successfully reset.
Press “OK.”

Page 60
Cylinder Cutout Test
C7 and C9 engines with ACERT
Technology

Page 61
C7 and C9 engines
4 Injection Actuation Pressure variance increased to
+435 PSI (+3000 kPa).

Page 62
C7 and C9 engines
4 What to do if a cylinder is “Questionable.”

Page 63
C7 and C9 engines
4 For a “Questionable” injector, remove the
injector and locate the serial number stamped
on the injector.
Enter the stamped

injector serial number
in the text box.

Page 64
Service Tool Reports

Page 65
4 If you saved the report as an X-M-L file, you first
need to export it into H-T-M-L format.
1. Select Export from the File menu.

The Open dialog box displays.

Page 66
2. Select the file you want to
export.
3. Press “Open.” The Save As
dialog box displays.

Page 67
4. Press “Save.” The Export
dialog box displays.

Page 68
5. Press “Export” to
complete the
process. The
Service Tool file
was successfully
exported… dialog
box displays.
6. Press “OK.”

Page 69
4 Open the application you wish to view the report.
7. In Excel, select Open from the File

menu. The Open dialog box
displays.

Page 70
8. Select the file you
want to view.
9. Press “Open.”
Be sure *.html is selected in

the Files of type text box.

Page 71
4 The Report displays
as a spreadsheet.

Page 72
Website and Contact Information

Page 73
Caterpillar ET Websites
4 NACD Infocast: https://nacd.cat.com
n https://nacd.cat.com/infocast/frames/psfulfill/sfulfill/et/
4 APDNet: https://apd.cat.com
n https://apd.cat.com/cda/layout/0,,l-7_m-17410_x-7,00.html
4 CatAmericasNet: https://lacd.cat.com
n https://lacd.cat.com/infocast/frames/PSE/ops/servtech/et/
4 FlashNet: https://cosa.cat.com
n https://cosa.cat.com/infocast/frames/prod_supp/serv_tech/et/
4 Cat Power Net: https://truck.cat.com

n https://truck.cat.com/cda/framed/frameset/0,1263,m-261_x-7,00.html l

Page 74
DBSi Website
4 To access the DBSi website:
1. Connect to the DBSi website (https://dbsi.cat.com).

2. Enter your CWS Logon ID and Password in the text boxes.
3. Press “Login.”
4. Select “DCS Knowledge Database.”
5. Select “Search All Products.”
6. In the “Enter a description of your problem here:” textbox,
enter the error code number or a brief description of the
problem.
7. Select “Submit.”
8. Select a solution to view.

Page 75
PC Software Support Hotline
4 Dealer Channel Systems Support Center
Voice: (800) 765-0999 or (309) 675-4000
Fax: (309) 675-4080
E-mail: DCS_Support_Center@cat.com or
DCS Support Center (Lotus Notes)
Hours: Monday through Friday

6:00am to 6:00pm (Central Standard Time)

Page 76
Licensing Caterpillar ET
4 Caterpillar Media and Product Information
Logistics
Voice: (800) 566-7782 or (309) 266-0942
Fax: (309) 494-1348 or (309) 494-1345
E-mail: media_logistics@cat.com or
Media Logistics (Lotus Notes)
Hours: Monday through Friday

7:30am to 4:30pm (Central Standard Time)

Page 77
Troubleshooting Overcooling
Doug Wilson

Page 78
Overcooling Troubleshooting
4 Is this “overcooling”?

Page 79
Overcooling Engine Discussion
4 Definition: Overcooling can be defined as the condition where the
normal temperature at which an engine operates cannot be reached.
n This condition is most commonly reported as:
n Engine coolant temperature runs cool only at idle.
n Engine coolant temperature runs normal at idle, but overcools

noticeably while driving or operating in cool ambient
temperatures.
4 The recommended minimum operating temperature for diesel
engines that operate on high sulfur fuel is 80C (175F).
4 This can be achieved by elevating the idle to 1000 RPM. This results
in the engine adding more heat into the system.
n Customers operating engines with temperatures below 80C
(175F), may report several of the following complaints:
n Reduced fuel economy <OK
n White smoke <OK
n Reduced power <OK
n Reduced component life <OK

Page 80
4 6NZ C-15 “Primary source of heat into the system”

Page 81
Overcooling C-15/C-16 Cooling
System Circuit Discussion
4 C-15/C-16 Cooling System
HX1
HX2
(
Heat Into Sys
HX3
HX4
HX5
Page 82
Overcooling C-15/C-16 Cooling
4 C-15/C-16 Heat out of the system
HX1
HX2
(
HX3
HX4
HX5
Page 83
4 BXS C15 “Primary source of heat into the system”
Precooler

Page 84
Overcooling C15 ACERT Cooling
HX1
HX2
( Heat Into Sys
HX3
HX4
HX5

Page 85
4 From the Troubleshooting Guide
4 Engine Overcooling
4 Probable Cause
4 Long Idle Periods - When the engine is running with no load, only a small
quantity of fuel is burned. Therefore, the heat from the engine is removed
too fast. The check valve in the vent line may be missing, or the orifice in
the vent line may be missing. When the check valve or the orifice is
missing, too much heat is removed from the engine.
4 Very Light Load - Very light loads, a very slow speed or downhill travel
can cause overcooling. This overcooling is caused by the low heat input
of the engine. The installation of shutters helps to correct this condition.
<<“Shutters Dated”
4 Faulty Water Temperature Regulator (thermostat) - A water temperature
regulator that is stuck open can cause overcooling. Overcooling also
occurs when the water temperature regulator is stuck between the
following positions: open position and closed position. Coolant leaks that
are around the water temperature regulator can cause overcooling. An
example would be a vent line leak. <<“how do you check”
4 Thermostat leakage rate is 10cc/min per stat. Need a way to measure?

Page 86
4 First: Compare the OEM gage with the ECM.
n This step is essential to validate the complaint . If inaccuracy is
found, investigate. This is fairly common source of overcooling
complaints. Remember, “the operator sees the gage”.
n Gage sender location, OEM’s differ
n Gage accuracy versus ECM
n Gage adapters may trap air

Page 87
4 Inspect the vent line for excess leakage.
n Quick check is to plug the line and cap #4 fitting.
n Install check ball.
n ACERT engines have two vent lines. This will require an

update to the vent line recommendation. Current line
configuration is above the fitting for the check ball.
4 Truck Engine News

1999/04/01 Media Number -SEBD6710-00 Publication Date -
New Cooling System Vent Line Check Valve Helps Prevent
Over Cooling{1370}
4 Know Your Cooling System; SEBD0518 (paper)
4 Know Your Track-Type Tractor Cooling System; REHS1063

Page 88
4 Investigate thermostat or thermostat seal leakage.
n Several methods used to test.
n 1) Historically, thermostats were checked with a hot plate and
thermometer. It has since become economical to replace them if
removed. Note: this test gives thermostat performance not leak rate.
n 2) Recently the increased use of infared temperature instruments to
estimate leakage of the thermostats. The results are qestionable.
(40% of thermostats replaced are no fault found.)
n 3) Measure the leakage rate and compare to known specifications.
More accurate with results that can be documented. Criteria with this
test is pass or fail. Less invasive and conclusive.
n Specified leakage rates
n P/N 7C3095 = 10cc/min maximum. Opening Temp 190-208degF
n P/N 7W0317 = Print spec is higher Opening Temp 200-219degF
n Note total leakage rate = 20cc/min
n Fabricate tool to measure volume change. Accurate method and giv es
good results. Todd and Doug to show an example tool that was fabricated.

Page 89
Overcooling Checklist (7 Steps)
4 System Questions? Complaint begins with system.
4 1) Complaint recorded _______________________
4 2) Dash Gage reading at condition _____(F/C)
4 3) ECM temp reading at condition _____ (F/C)
4 Engine Questions?
4 4) Vent line check ball or isolated. ______(Y/N)
4 5) Thermostat leakage checked and
verified to be less than 10cc/min per stat. _____ (Y/N)
4 System Circuits?
4 6) HX Circuits identified. List Number ____________
4 7) HX circuits isolated. List root cause contributor to
overcooling. _________________________________

Page 90
Pocket Tec™ Update
Megan Ash

Page 91
Fleet Edition 2.0
ü New Configuration Features
n Ability to set PTO Parameters
n Adjust ECM Date/Time
n Added Performance/Test Spec
n Gear Down Protection
ü New Status Parameters

n Engine Coolant Diverter Solenoid
n Intake Valve Actuation System Oil Pressure Solenoid
ü Available late February 2004

n PC Doctor
n PowerNet Website
n https://truck.cat.com/cda/layout/0,,m-2001_x-7,00.html

Page 92
Special Promotions
ü Fleet Edition Kit with Palm handheld included
n Starting in March
n Over $60 Value!
n Refurbished Palm kit Includes Hot Sync serial cradle or cable
n Link to desktop support:
n http://www.palmone.com/us/support/downloads/win_desktop.html
n 30 Day warranty
n Limited Time Offer—while supplies lasts
n Palm III 6 & 9 Pin Kit Only
n - $427.20 US D/N
ü Driver Edition Kits Pricing Promo to end in Early 2004 (Palm III and
m100 kits will no longer be available)
n Palm III
n 216-2779 – 6 Pin Kit - $100US D/N
n 216-3923 – 9 Pin Kit - $100US D/N
n 216-2785 – 6 & 9 Pin Kit - $135US D/N
n 216-2782 – GM ALDL Kit - $100US D/N
n Palm m100
n 216-2788 – 6 Pin Kit - $160US D/N
n 216-2789 – 9 Pin Kit - $160US D/N
n 216-2786 – 6 & 9 Pin Kit - $195US D/N
n 216-2787 – GM ALDL Kit - $160US D/N February 2004 – LEVN5616
Page 93
Q&A

Page 94
Dealer Solutions Network (DSN)
Tim Stear

Page 95
cpi.cat.com
DSN- Dealer Solution Network

Page 96
4 TC is Dealer’s one safe source
4 Embed the CPI process in your dealership, ensure the Dealer CPI
process is in place
4 Maintain & enhance product health escalation process at your

dealership
n Technician -> Technical Communicator
n Service Manager -> Technical Communicator
4 We need your help …You are the voice of the customer!

Page 97
When is Caterpillar going to recognize
product problems faster,
fix them quicker and tell us sooner?
Right Now!
Page 98
Previous Dealer Contact Process
Dealer TC Marketing Tier I & II Product & Component Tier I & II
* Dealer TC’s have 200+
potential contacts to
sort through and mutiple
systems.
Failed Contact
Good Contact
Too many failed contacts

Page 99
CPI-DSN Process
Dealer TC DSN– Tier I Product & Component – Tier II
CPI website
CPI-DSN Phone #
Dealer Solution
Analysts
Service Engineers
Communications center with one & Product Analysts
common process, defined roles,
defined metrics, and one set of
tools to ensure global consistency

Page 100
How do I register for DSN access?
4 Request access
n Through your dealer CPI coordinator
Or
n Directly with your IT security coordinator
Solutions will be given to authorized dealer

4 Target Audience resources only. If non-authorized personnel contact
the DSN, the solution will be forwarded to one of your
n Dealer TC’s authorized users.
4 Note: If you already have access to the CPI Status

Reports in SIMSi then you may already be
authorized to contact the DSN.

Page 101
CPI-DSN Solution
Addresses Dealer Concerns
4 Communications centers with one common Clarity
process, defined roles, defined metrics, and one
set of tools to ensure global consistency, which Consistency
yields: Commitment
n Easy point of contact
n Time zone independent
Dealer TC DSN– Tier I Product & Component – Tier II
n One enterprise database for problem events
Prod Analyst / Serv Engr
n Information sharing on CPI projects with dealers www.cpidsn .cat.com
CPI-DSN Phone #
n Around-the-world support with response time targets

n Multiple levels of technical support i.e. “defined
escalation”
CPI
n Links the Dealers, marketing organizations, product / Dealer
business units, and component groups resources. Solution Network

Page 102
2004 Binder
4 The binder this year is a three ring binder with
dividers - one for each show.
4 Has slotting to hold all four video tapes
4 Form # LEKQ5055

Page 103
Broadcast Information
4 Update Broadcast Videos
n LEVN5438 – “Tech Tips” Broadcast – February 12, 2003
n LEVN5439 – “Tech Tips” Broadcast – May 14, 2003
n LEVN5440 - “Tech Tips” Broadcast - August 13, 2003
n LEVN5441 – “Tech Tips” Broadcast – November 12, 2003
n LEVN3947 - Yearly Subscription

n English Tape & Handouts
4 Broadcast Schedule for 2004
n May 12th
n August 11
th
n November 10
th

Page 104
Keepin’ In Touch
Email
Internet E-Mail
techtips@cat.com
World Wide Web

http://www.Cat.com
Engine Spec Sheets

Page 105
Electronic Controls
Part Number
Reference
Page 106
Troubleshooting Guide Listing
Form Number Booklet Description Serial Number Prefixes
RENR2238-04 C-10,C-12 & 3406E 1MM,2KS,2WS,3CS, 6NZ, 7CZ,
CPD
RENR1328-02 C-10,C-12 & 3406E 5DS,8YS,9NS,1LW
SENR5582-06 3176B,C-10,C-12 & 3406E 5EK,9CK,1YN,2PN,6TS
SENR5503-00 3406C (PEEC III) 4CK
SENR3479-05 3406B (PEEC II) 2EK,5YG,8TC
SENR3913-04 3176 2YG
SENR5112-01 3176 7LG
RENR1367-04 3126B 7AS, 8YL,8SZ,BKD, 1AJ,CKM,
CRP,9SZ
SENR6566-03 3100 HEUI 8WL,1WM,4ES,2CW, 8HW, 7LZ

Page 107
Heavy Duty FLS/FTS Adjustment
Policy
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 family
requires a "Reason Code 5" factory password, change FLS/FTS if "Reason Code 5" factory
passwords 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 to
enter the new "Performance Spec" number and the serial number of the engine being rerated. After
flashing the new software file, you can find the new perfor mance 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 second
performance 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 family
does 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 rating
to 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 the
factory. (Example: rerating a 3406E engine from a 375 Hp rating to a 410 field rerate only rating)

Page 108
Serial Number Prefixes
3116/3126
4 1WM 3126 HEUI
n 1995 to Current
4 8WL 3116 HEUI
n 1995 to Current
4 7AS 3126B
n 1998 thru July 31, 1999
4 8YL
n July 1999 to December 2000
4 8SZ
n 1998 thru July 31, 1999 - short eng version
4 9SZ
n 2001 to present
4 CKM BKD 1AJ CRP 3126E
n 2001 to present

Page 109
C-10, C-12 & 3176
4 2YG 3176 4 9NS C-12
n 1988 to 1990 n September 1997 to
4 7LG 3176 November 1998
n 1991 to December 1993
4 3CS C-10
4 9CK 3176B n November 1998 to
n May 1993 to March 1995 September 2002
4 2PN C-10
4 2KS C-12
n March 1995 to September 1997
n November 1998 to
4 8YS C-10 September 2002
n September 1997 to November
1998 4 MBJ C-10
4 1YN C-12 n October 2002 to Current
n March 1995 to September 1997
4 MBL C-12
n October 2002 to Current

Page 110
3406/C-15/C-16
4 8TC PEEC II and PEEC II.V 4 1LW 3406E 14.6L
n December 1997 - November 1998
n 1987 to 1990
4 5DS 3406E 15.8L
4 5YG PEEC II - 460Hp Only n December 1997 - November 1998
n 1990 4 2WS 3406E 14.6L
4 2EK PEEC II and PEEC II.V n November 1998 to Current
n 1991 4 1MM 3406E 15.8L

n November 1998 to Current
4 4CK 3406C Electronic 4 6NZ C-15
n August 1991 to December 1993 n November 1999 to September 2002
4 5EK 3406E 4 7CZ C-16
n November 1999 to September 2002
n May 1993 to December 1996
4 MBN C-15
4 6TS 3406E n October 2002 to Current
n January 1997 to December
1997

Page 111
3126E Electronic Control and
Sensors
4 ECM (3126E Basic & Full Feature) 179-4898
4 Coolant temperature Sensor - 130-9811
n O-Ring Seal 6V6609
4 Inlet Manifold temperature Sensor - 130-9811
n O-Ring Seal 8L2786
4 Speed/Timing Sensors - 119-4142
n O-Ring Seal 117-1385
4 Atmospheric Pressure Sensor - 194-6722
n O-Ring Seal 6V5049
4 Boost Pressure Sensor - 194-6723
n O-Ring Seal 3J7354
4 Injection Actuation Pressure Sensor - 167-1708
n O-Ring Seal 1J9671
4 Pedal Position Sensor - 204-7949
4 Injector Wiring Harness - 153-8920
4 Wire Router - 126-1774

Page 112
3116 HEUI & 3126 HEUI —
Electronic Parts
4 3116 HEUI - 8WL and 3126 HEUI - 1WM
n ECM – 145-7807
n ECM Connector Bolt Kit – 6V6703
n 40 Pin Plug Assembly – 114-4408 (includes 110-6844 Seal)
n 40 Pin Connector Seal – 110-6844
n Speed/Timing Sensor Service Kit – 119-4142
n Includes 117-1385 O-Ring Seals
n Inlet Air Temperature Sensor – 107-8618
n Requires 3K0360 Seal
n Coolant Temperature Sensor – 106-0735
n Requires 3K0360 Seal
n Boost Pressure Sensor – 161-9927
n Male/Male Adapter – 9X0262 & 3J7354 – Seal
n Injection Actuation Pressure Sensor – 167-1709
n Requires 108-5803 Seal
n Injection Actuation Pressure Control Valve – 122-5053
n Seal Kit 9X1484
n Throttle Position Sensor – 204-7949
n Fuel Transfer Pump to Hydraulic Pump O-Ring – 004-1963
n Hydraulic Pump Dome O-Ring – 6V5656

Page 113
Other 3116 HEUI & 3126 HEUI
Parts
4 Part Numbers missing for Parts Books (3116 HEUI –
SEBP2271 and 3126 HEUI SEBP2355)
n 123-1199 Seal for Injector and IAPCV Connectors
n 118-8622 Service Replacement Harness
n 40 pin to Injectors
n 40 pin to Speed/Timing Sensor
n 40 pin to IAPCV
n 40 pin to all other sensors
n 141-7060 Injector Wiring Harness Connector Repair Kit
n 143-8325 Injection Actuation Pressure Sensor Guard

Page 114
C-10, C-12, 3176B & 3406E Pre-’99
Current Parts
4 C-10 - 2PN & 8YS, C-12 - 1YN & 9NS, 3176B - 9CK & 3406E -
5EK & 6TS, 1LW, 5DS
n Electronic Control Module (ECM) – 212-9450
n ECM with J1939 Data Link Option – 212-9449
n Speed/Timing Sensor
n 3406E — 129-6628 Sensor
n 126-8481 Shim (0.020”)
n C-10, C-12 & 3176B — 129-6628 Sensor No Shim

n Coolant/Fuel Temperature Sensor - 102-2240
n Air Inlet Temperature Sensor - 107-8618
n Boost Sensor - CRB 161-9927
n Atmospheric Pressure Sensor 111-8125
n Oil Pressure Sensor - CRB 161-9930
n Pedal Mounted Throttle Position Sensor - CRB176-1602

Page 115
3176 —2YG Current Parts
4 3176 - 2YG
n ECM - 9X9529 0R6149
n ECM FORD - 9X9528 / 0R6148
n Transducer module - 9X8226 / 0R6132
n Harness - 7E8421
n Speed/Timing Sensor - 102-9029
n Fuel Pressure Sensor - 107-7142
n Coolant Temperature Sensor - 9X5370
n Vehicle Speed Buffer - 3E0020
n Remote Mounted Throttle position Sensor - 9X9647
n Remote Mounted Throttle Position Sensor - FORD - 9X9648
n Pedal Mounted Throttle Position Sensor - 161-8906

Page 116
C-10, C-12, C-15
Oct ‘02 Production
4 C-10 – MBJ, C-12 – MBL, C-15 – MBN
n Electronic Control Module (ECM) – 206-2700
n C-10, C-12 Cam Sensor – 189-9801 (194-5340 Service only)
n C-15 Cam Sensor – 188-7513 (194-5341 Service only)
n C-10, C-12 Crank Sensor – 188-7511 (194-5338 Service only)
n C-15 Crank Sensor – 189-9266 (194-5339 Service only)
n Coolant/Fuel/Inlet Air Manifold Temp Sensor – 130-9811
n Boost Pressure Sensor – 161-1704
n Atmospheric Pressure Sensor – 161-1703
n Oil Pressure Sensor – 161-1705
n Pedal Mounted Throttle Position Sensor

n 204-7949 - Short Pigtail
n 204-7950 - Long Pigtail
n Smart Wastegate Solenoid – 219-0329 (going to 228-0267)

Page 117
C-10, C-12, C-15, C-16 & 3406E
‘99 Model Year to September ‘02
4 C-10 - 3CS, C-12 - 2KS, & 3406E - 2WS (14L) - 1MM (16L), C-15
- 6NZ, C-16 - 7CZ
n Electronic Control Module (ECM)
n 6NZ70120 and Below - 179-1747 - Parts Service - 209-9587
n 7CZ03312 and Below - 179-1747 - Parts Service - 209-9587
n 3CS27824 and Below - 179-1747 - Parts Service - 209-9587
n 2KS90518 and Below - 179-1747 - Parts Service - 209-9587
n Above these Serial Numbers - 206-2700
n C-10, C12 Cam Sensor – 189-9801
n 3406E Cam Sensor – 189-9267
n C-10, C-12 & 3406E Crank Sensor – 189-9266
n Coolant/Fuel/Inlet Air Manifold Temperature Sensor - 130-9811
n Boost Pressure Sensor - 161-9929
n Atmospheric Pressure Sensor 194-6722
n Oil Pressure Sensor - 161-9931
n Pedal Mounted Throttle Position Sensor
n Long Pig Tail - 3E-7700
n Short Pig Tail - 121-0231

Page 118
3176 — 7LG Current Parts
4 3176 7LG
n ECM - 3E5293
n Transducer Module - 9X8226 / 0R6132
n Altitude Retrofit - 3E8644 / 0R6470
n Speed Timing Sensor - 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 - 7LG07500 and Up — 102-2240
n Limited Rage - 7LG00001 to 7LG07499 — 9X5370
n Vehicle Speed Buffer - 3E0020
n Remote Mounted Throttle position Sensor - 9X9647
n Remote Mounted Throttle Position Sensor - FORD - 9X9648

Page 119
3406C PEEC Electronic Current
Parts
4 3406C - 4CK
n ECM - 9X8085
n Transducer Module - 132-4363
n Speed Sensor - 100-6619
n Rack Sensor - 9X7793
n Timing Sensor - 129-4501
n BTM - 105-2939
n Coolant Temperature Sensor - 102-2240
n Remote Mounted Oil Pressure Sensor Kit - 118-6256
n Vehicle Speed Buffer - 3E0020 (same for PEEC II)

Page 120
PEEC II.V Current Parts
4 PEEC - 8TC and 2EK - FORD Only
n ECM - 9X4840
n BTM - 105-2939
n Throttle Position Sensor
n Remote Mounted “Beer Can” Sensor - 9X9648
n If the engine (2EK and 5YG) has had the White Smoke Product
Support Program performed. The following parts will be installed:
n 6I2382 - Wiring Harness
n 9X5370 - Temperature

Page 121
PEEC II Current Parts
4 PEEC II - 8TC, 5YG and 2EK
n ECM - 8T8770
n BTM - 105-2939
n Throttle Position Sensor
n Remote Mounted “Beer Can” Sensor - 9X9647
n If the engine (2EK and 5YG) has had the White Smoke Product
Support Program performed. The following parts will be installed:
n 6I2382 - Wiring Harness
n 9X5370 - Temperature

Page 122

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Tech Tips

February 11, 2004

February 2004 – LEVN5616

February 2004 – LEVN5616

February 2004 – LEVN5616

n New gaskets should be used as a set

n All parts are available in the “Oil Cooler and Lines

February 2004 – LEVN5616

February 2004 – LEVN5616

n Original version is not supported in the parts system

February 2004 – LEVN5616

February 2004 – LEVN5616

LHP 233-3536 236-0973 241-3238 243-4502

MHP 236-6011 238-9808 241-3239 243-4503

HHP 233-3535 236-0974 238-8091 241-3400

February 2004 – LEVN5616

n Fuel histogram capability

4 Compatible with current injectors

February 2004 – LEVN5616

February 2004 – LEVN5616

n Current Flash File part number

n Compressor inlet elbow part number

n Max operating altitude

4 Please fax information to (309) 578-2673

February 2004 – LEVN5616

February 2004 – LEVN5616

4 PS50338 (C-10 – C-15 Injector Tip)

February 2004 – LEVN5616

n Problem: Intake and Exhaust Push Tubes can be installed

February 2004 – LEVN5616

n Affected Product: All C11/C13

n Fix: Ensure Push Tubes are installed correctly during

n Communication: TEN Article Planned 2nd Quarter 2004

February 2004 – LEVN5616

n Problem: Carry over debris from Air Box Resulting in Air

February 2004 – LEVN5616

n Affected Product: All HD ACERT Engines

n Communication: TEN Article 2 nd Quarter 2004

February 2004 – LEVN5616

n Problem: The new BA-921 Single Cylinder Air Compressor

n Affected Product: KCB00508 – KCB01638

n Fix: New Counter Weight Gear to Reduce Air Compressor

n Communication: TEN Article Planned Late 1 st Quarter 2004

February 2004 – LEVN5616

n Problem: ECM software has a non-functional Air Conditioner

n Affected Product: KCB00891 – KCB01676

n Fix: February Release Software

n Communication: TIB Planned for Mid February

February 2004 – LEVN5616

n Problem: Small Number of Chassis Configurations Excite the

n Affected Product: KCB00508 – KCB02033

n Fix: February Release Software

n Communication: Scheduled TIB for Early February

February 2004 – LEVN5616

n Problem: Complaints of Vibration and White Smoke around

n Affected Product: KCB00508 – Feb 9th Start on Line

n Fix: February Release Software

n Communication: Scheduled TIB for Early February Coupled

February 2004 – LEVN5616

n Problem: Injector hold down bolt failures after service

n Affected Product: All Heavy Duty Engines

February 2004 – LEVN5616

n Communication: TEN Article Planned 1st Quarter 2004