Power

Connection
July 11, 2001
10AM Central Daylight Time

July 2001 – LEVN4996

Page 1
 Appendix A

POWER CONNECTION PROGRAM EVALUATION

July 11, 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 More
Change Effective
A. Commercial/Common o o o o o

B. Electronic Service Tools 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 Power Connections 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!!

7. Comments :_____________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________

Name ___________________________________ Title____________________________

Dealership ________________________________ Location ________________________

City _______________________ State/Prov. ____________________ Country ________

 Index
Commercial/Common Q&A
C-10/C-12 Head Gasket Repair Procedure 4 2001 Binder 36
Electronic Tachometers 17 Broadcast Information 37
3406E/3456/C-15/C-16 UI Rocker Arm 20 Keepin’ in Touch 38
“Banded V-Belt” for 938G, 950G, 962G & IT38G, IT62G Machines 22 Reference 39
Appendix A - Show Evaluation Form
Electronic Service Tools
CAT ET Version 2001A 24

July 2001 – LEVN4996

Page 2
Commercial/
Common
Marine/Industrial/EPG

July 2001 – LEVN4996

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C-10/C-12 Head
Gasket Repair
Procedure
April 2001
LEVN5101

July 2001 – LEVN4996

Page 4
Where Does The Torque Go?
Torque 45%
Underhead
Friction

10% Bolt Stretch

45%
Thread
Friction
July 2001 – LEVN4996
Page 5
 Effects Of Thread Lubricants
100%

90%

80%

70%
% Clamping Force

60%

50%

40%

30%

20%

10%

0%
6V4876 Molycote 4C5599 High Engine Oil No Lube on Washer Dry Threads
Paste Temperature Anti- and Bolt Head
Seize

160 N-m (120 ft-lbs) + 90 Deg Turn

July 2001 – LEVN4996

Page 6
 Effects Of Debris In Thread
100%

90% 30%
80%
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

July 2001 – LEVN4996

Page 7
 Clamping Force In Joint Using
Torque Only
Baseline
140%

130%

120%
% Clamping Force

110%
49%
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

BOLT NUMBER

1ST TORQ 292 N-m (215 FT-LB) 2ND TORQ 292 N-m (215 FT-LB)

July 2001 – LEVN4996

Page 8
Using Single Torque-Turn Procedure
160 N-m (120 Ft-lbs), 160 N-m (120 Ft-lbs) Plus 90 Deg Turn
140%
Baseline
130%
120%
110%
% Clamping Force

100%
21%
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

BOLT NUMBER

PRETORQ 160 N-m (120 FT-LB) 90 DEG TURN

July 2001 – LEVN4996

Page 9
 Using Double Torque-Turn Procedure
160 N-m (120 Ft-lbs), 160 N-m (120 Ft-lbs) Plus 90 Deg Turn, LOOSEN BOLTS
APPLY 160 N-m (120 Ft-lbs), 160 N-m (120 Ft-lbs) Plus 90 Deg Turn
140%
Baseline
130%

120%
21%
% 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

July 2001 – LEVN4996

Page 10
Fire Ring And Fluid Sealing Load
Distribution
100%

90%

80% 2nd Torque-Turn

Fire Ring Load
70% 1st Torque-Turn
JOINT LOAD

Fire Ring Load

60%
25%
50%

40%

30% 2nd Torque-Turn

Fluid Sealing Load
20%
1st Torque-Turn
10% Fluid Sealing Load

0%
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
BOLT LOAD

July 2001 – LEVN4996

Page 11
 C-10/C-12 Truck Engine
Using Engine Oil SOS results to Diagnose Coolant Leak

- If SOS results show Positive Antifreeze, Investigate IMMEDIATELY

- Must Test for Na (Sodium) if using Standard coolant
- Must Test for K (Potassium) if using ELC coolant
- Use Chart below to determine whether to investigate a coolant leak into oil
- Maximum Recommended Oil Change Interval is 25,000 miles or 500 hours or 4,170 gals. of fuel.
250
PPM - Na (Sodium) or K (Potassium)

200

Investigate
150

100

OK

10,000 15,000 20,000 25,000 Miles

200 300 400 500 Hours
1,670 2,500 3,300 4,170 Gallons of Fuel

Miles, hours or gallons of fuel on Engine Oil at time of sample

July 2001 – LEVN4996

Page 12
 Cylinder Head Gasket

Cylinder Head Configuration

Straight Scalloped

Configuration Straight 187-3307 187-3306

Block

Scalloped 187-3306 187-3306

July 2001 – LEVN4996

Page 13
 Heli-Coil Installation
• Drill hole using an 1U5686 (21/64) drill
• Tap hole using 4C9732 tap
• Use 8T2799 installation tool
• Install 9U5604 Heil-Coil insert
– Note: Special 32mm Grip Length

July 2001 – LEVN4996

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 Review
• Determine cause of coolant leak
• Determine the correct head gasket part number
– Reference: Truck Engine News December 2000
• Clean all 26 bolt holes with 8T3096 (M16x2) tap
• Vacuum all debris from bolt holes
• Visually inspect bolts for damage
– Heli-Coil damaged bolt holes
• Check cylinder head and block flatness
• Properly Lube Bolt Threads, Underside of Bolt
Head, and Washers with 6V-4876 Molycote
• Tighten Bolts 1- 26 in numerical sequence to
160 ±15 N-m (120 ± 11 Ft-lb)

July 2001 – LEVN4996

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 Review
• Tighten Bolts 1- 26 Again, in numerical sequence
to 160 ± 15 N-m (120 ± 11 Ft-lb).
• Turn each bolt 90° (¼ turn)
• Loosen Bolts # 1- 26
– Washers should be loose under bolt head
• Tighten Bolts 1- 26 in numerical sequence to
160 ± 15 N-m (120 ± 11 Ft-lb)
• Tighten Bolts 1- 26 Again, in numerical sequence
to 160 ± 15 N-m (120 ± 11 Ft-lb).
• Turn each bolt 90° (¼ turn)
• Tighten bolts # 27 - 33 in numerical sequence to
28 ± 7 N-m (20 ± 5 Ft-lb) Torque

July 2001 – LEVN4996

Page 16
 New Electronic Tachometers
• Two Tachometers now available:
– 197-7347 with backlight
– 197-7348 without backlight
• Replace 9X-1114 & 9X-1116 (with backlight)
and 9X-1117 (without backlight)
• New Tachometers require a DT connector in
the wiring harness.
• Parts to convert harness connections:
155-2274 Connecting Plug Kit, 186-3736
Connector Sockets, 8T-8737 Seal Plugs

July 2001 – LEVN4996

Page 17
 New Electronic Tachometers

Former Serviced by New Parts needed to convert

Tachometer Tachometer to DT connectors
155-2274 Connecting Plug Kit
186-3736 Connector Socket (4)
9X-1114 197-7347
8T-8737 Seal Plug (2)

155-2274 Connecting Plug Kit

186-3736 Connector Socket (4)
9X-1116 197-7347
8T-8737 Seal Plug (2)
155-2274 Connecting Plug Kit
186-3736 Connector Socket (2)
9X-1117 197-7348
8T-8737 Seal Plug (4)

July 2001 – LEVN4996

Page 18
 New Electronic Tachometers

+ -

9X-1114 197-7347

July 2001 – LEVN4996

Page 19
3406E/3456/C-15/C-16 UI Rocker Arm

• Some loose 4P4279 jam nuts have

been reported on 3406E, 3456, C-15,
& C-16 Unit Injector rocker arms.

• Effective immediately, adjusting nut

torque has been increased;
– From 81 +/- 10 N-m (60 +/- 7 Ft-lb)
– To 100 +/- 10 N-m (74 +/- 7 Ft-lb)

July 2001 – LEVN4996

Page 20
3406E/3456/C-15/C-16 UI Rocker Arm
• Affects all commercial and machine
3406E/3456/C-15/C-16 engines;
– 3406E Prime/Standby Gen Set (8AZ), 3406E Marine (9WR)
– 3406E Industrial (6BR), 3456 Industrial (3LW)
– C-15 Industrial (BEM), C-16 Industrial (BFM)
– D350E (2XW), D400E (8PS, APF), 735 (AWR), 740 (AXM)
– D8R (6YZ, 7NP, 7WP, AKA)
– 621G (ALP), 623G (ARW), 627G (AXF)
– 834G (6GZ), 836G (7MZ), 988G (2TW)
• ECN, Engine News, and Service Magazine
articles were issued June 2001.

July 2001 – LEVN4996

Page 21
 New "Banded V-Belt" for 938G, 950G,
962G and IT38G, IT62G Machines
New Banded V-Belt is similar to the 2-belt set, but has a common backing.

Former New
Belt P/N [1] Belt P/N Model [2] Description
2S2481 198-6890 938G, IT38G w/standard 55-amp
alternator

6L6557 198-6827 950G, 962G, IT62G 70-amp alternator is

and 938G, IT38G standard if equipped
w/ 70-amp alternator

[1] Certain "Low Sound" or "Waste Handler" machines currently have a different belt drive
system with a single Vee-Belt, and have the Alternator located directly above the engine valve
cover. These machines cannot use the new belts listed above.
[2] Former Vee-Belts were matched 2-belt sets (2 individual belts). The former belt p/n's are not
canceled, and remain available for other applications.

July 2001 – LEVN4996

Page 22
 Electronic
Service Tools

July 2001 – LEVN4996

Page 23
Caterpillar Electronic
Technician

July 2001 – LEVN4996

Page 24
 Cat ET 2001A-Service Pack 1
• Release Information
– Corrects the problem where Snapshot Viewer
could not be accessed off-line
– Corrects the ECM Summary information printed
at the top of a Cat ET report
– Includes Flexxaire Fan Support for a D9 Track-
Type Tractor
– Adds support for 5230B VIMS

July 2001 – LEVN4996

Page 25
 Cat ET 2001A-Service Pack 1
(cont.)
• Cat ET Integration with STW 2001A
Release Information
– Corrects Keyboard Shortcuts for screen
functions (example: “Ctrl+P” to Print).
– When using STW, connecting to an ECM is not
automatic on startup.
• Select “Connect” from the File menu
• Push the F8 key (or)
• Press the “Connect” icon on the toolbar (if default is
set)
– STW no longer sets the communication interface
device to Caterpillar Communication Adapter II
(RP1210) on an upgrade.

July 2001 – LEVN4996

Page 26
 Challenger Technician 2001B
• Release Information
– Increases reliability of Challenger Technician
Flash Download
– Error “Watchdog Problems, failure code #5002”

July 2001 – LEVN4996

Page 27
 Cat ET 2001A-Service Pack 1
Challenger Technician 2001B
• Update is available on…

– SISWeb (https://sis.cat.com)

– NACD InfoCast (https://nacd.cat.com)

– July SIS Setup and Tool Guide CD-ROM

July 2001 – LEVN4996

Page 28
 Caterpillar Electronic Technician
Now on NACD InfoCast
• To access the Cat ET page:
– Connect to NACD InfoCast (https://nacd.cat.com)

Click “Enter InfoCast.”

July 2001 – LEVN4996

Page 29
 Caterpillar Electronic Technician
Now on NACD InfoCast (cont.)
– Then…

Click “Service Click “Electronic

Fulfillment.” Technician.”

Click “Product
Support Fulfillment.”
Click “Service
Technician Workbench.”

July 2001 – LEVN4996

Page 30
 Caterpillar Electronic Technician
Now on NACD InfoCast (cont.)
– The Caterpillar Electronic Technician page
displays.

July 2001 – LEVN4996

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 Caterpillar Electronic Technician
Now on NACD InfoCast (cont.)
• Information available:
– Software downloads
• Caterpillar Electronic Technician
• Challenger Technician
• Caterpillar Communication
Adapter II
– Manuals and information on the
latest release
– Media and Part Numbers
– PC and Hardware Requirements
– Contact Information
– Support documents and
troubleshooting tips for many
common Cat ET and Cat Comm
Adapter II issues

July 2001 – LEVN4996

Page 32
 PC Software Support Hotline
• Service Systems Support Center

Voice: (800) 765-0999 or (309) 675-0999

Fax: (309) 636-5823
E-mail: SSSC@cat.com or
SSSC (Caterpillar Host e-mail)
Serv Sys Support Ctr (Lotus Notes)
Hours: Monday through Friday
6:00am to 6:00pm (Central Standard Time)

July 2001 – LEVN4996

Page 33
 Licensing Caterpillar ET
• 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
medial (Caterpillar Host E-mail)
Hours: Monday through Friday
7:30am to 4:30pm (Central Standard Time)

July 2001 – LEVN4996

Page 34
Q&A

July 2001 – LEVN4996

Page 35
 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 # LEKQ5054

July 2001 – LEVN4996

Page 36
 Broadcast Information
• Update Broadcast Videos
– LEVN4805 - “Power Connection” Broadcast – April 19, 2000
– LEVN4806 - “Power Connection” Broadcast - July 12, 2000
– LEVN4994 - “Power Connection” Broadcast - Jan. 17, 2001
– LEVN4995 - “Power Connection” Broadcast - April 18, 2001
– LEVN4996 - “Power Connection” Broadcast - July 11, 2001

– LEVN4212 - Yearly Subscription to Power

Connection
• Broadcast Schedule for 2001
– July 11
– Oct 17

July 2001 – LEVN4996

Page 37
 Keepin’ In Touch
• Email
– Caterpillar E-Mail
• PWRCONN
– Internet E-Mail
• Power_Connection@cat.com

• World Wide Web

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

July 2001 – LEVN4996

Page 38
Reference Material
Engine Serial Number Prefixes
Electronic Parts

July 2001 – LEVN4996

Page 39
 Engine Serial Number Prefixes
• EPG
– 2WJ 3412C PEEC III Electronics - 1995 to Present
– 9NN 3406E (14.6L) ADEM II Electronics 1997 to Present
• Industrial
– 1DW 3196 ADEM II Electronics - 1998 to Present
– 2AW 3176C ADEM II Electronics - 1998 to Present
– 3LW 3456 ADEM II Electronics - 1998 to Present
– 3NL 3176B ADEM II Electronics - 1995 to 1997
– 4CR 3412E ADEM II Electronics - 1996 to Present
– 6BR 3406E ADEM II Electronics - 1997 to Present
– 7PR 3408E ADEM II Electronics - 1996 to Present
– 9XM 3408C PEEC III Electronics - 1994 to Present
– 9XF 3412C PEEC II Electronics - 1994 to Present
– BDT 3412E ADEMII Electronics - 2000 to Present

July 2001 – LEVN4996

Page 40
 Engine Serial Number Prefixes
• Machine
– 43Z 3176B ADEM II Electronics - 1993 to Present
– 6AR 3196 ADEM II Electronics - 1998 to Present
– 7RC 3456 ADEM II Electronics - 1998 to Present
– 80M 3412E ADEM II Electronics - 1996 to Present
– 9AP 3406E ADEM II Electronics - 1998 to Present
– 99C 3408E ADEM II Electronics - 1996 to Present

July 2001 – LEVN4996

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 Engine Serial Number Prefixes
• Marine
– 2XR 3196 ADEM II Electronics - 1997 to Present
– 3GS 3126B ADEM III Electronics - 2000 to Present
– 3JK 3412C PEEC III Electronics - 1995 to Present
– 6BW 3176C ADEM II Electronics - 1998 to Present
– 8RG 3408C PEEC III Electronics - 1995 to Present
– 9KS 3412E ADEM II Electronics - 1999 to Present
– 9PW 3412E ADEM II Electronics - 2000 to Present
– 9WK 3176B ADEM II Electronics - 1997 to Present
– 9WR 3406E ADEM II Electronics - 1997 to Present

July 2001 – LEVN4996

Page 42
 3408E/3412E Industrial/Machine
Current Electronic Parts
• ECM 172-0802
• Speed/Timing Sensors
– Primary & Backup Cam S/T Sensor 129-6628
• Pressure Sensors
– Rail Pressure Sensor 140-3540
– Turbo Outlet Press. Sensor 161-9929
– Atmospheric Press. Sensor 161-9925
– Oil Press. Sensor 161-9931
– Fuel Pressure Sensor 161-9930
• Temperature Sensors
– Coolant Temp. Sensor 102-2240
– Engine Oil Temp. Sensor 106-0735
– Fuel Temp. Sensor 102-2240
• Coolant Flow Switch (Machine) 3E6428
• Coolant Level Sensor (Industrial) 165-6634

July 2001 – LEVN4996

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 3176C/3196/3406E Marine Current
Electronic Parts
• ECM 145-7806
w/J1939 145-7805
• Speed/Timing Sensors
– Primary & Backup Cam S/T Sensor 129-6628
– 3456 Engine Only 142-8393 & 142-8394
• Pressure Sensors
– Boost Pressure Sensor 161-9929
– Oil Pressure Sensor 161-9930
– Atmospheric Press. Sensor 161-9925
– Transmission Press. Sensor 161-9932
– Fuel Pressure Sensor 161-9930
• Temperature Sensors
– Fuel & Coolant Temp. Sensor 102-2240
– Inlet Manifold Temp. Sensor 107-8618
– Transmission Temp. Sensor 100-3055
• Coolant Level Sensor 165-6634
• Throttle Position Sensors
– Standard “Beer Can” 9X9647
– Optional “Beer Can” 9X9648
– Optional Pre-calibrated 121-7029 (161-8904 sensor only)

July 2001 – LEVN4996

Page 44
 3176C/3196/3406E/3456 Industrial
Current Electronic Parts
• ECM 145-7806
• Speed/Timing Sensors
– Primary & Backup Cam S/T Sensor 129-6628
• Pressure Sensors
– Boost Pressure Sensor 161-9927
– Oil & Fuel Press. Sensor 161-9930
– Atmospheric Press. Sensor (Std.) 161-9925
– Atm. Press. Sensor (Underground) 163-8350
– Auxiliary Press. Sensor 161-9932
• Temperature Sensors
– Fuel & Coolant Temp. Sensor 102-2240
– Inlet Manifold Temp. Sensor 107-8618
– Auxiliary Temp. Sensor 131-0427
• Coolant Level Switch 111-3794
• Throttle Position Sensor 161-8906

July 2001 – LEVN4996

Page 45
 3406E/3456 Machine Current
Electronic Parts
• ECM 145-7806
• Speed/Timing Sensors
• Cam S/T Sensor 142-8393
• Crank S/T Sensor 142-8394
• Pressure Sensors
– Boost Pressure Sensor 161-9929
– Oil Press. Sensor 161-9931
– Atmospheric Press. Sensor 161-9925
• Temperature Sensors
– Fuel & Coolant Temp. Sensor 102-2240
– Inlet Manifold Temp. Sensor 107-8618
• Coolant Flow Switch (If Equipped) 134-6054
• Throttle Position Sensor (Articulated Truck) 176-1602

July 2001 – LEVN4996

Page 46
 3176B/3196 Machine Current
Electronic Parts
• ECM 145-7806
• Speed/Timing Sensor 129-6628
• Pressure Sensors
– Boost Pressure Sensor 161-9927
– Oil/Fuel Press. Sensor 161-9930
– Atmospheric Press. Sensor 161-9925
• Temperature Sensors
– Fuel & Coolant Temp. Sensor 102-2240
– Inlet Manifold Temp. Sensor 107-8618
• Throttle Position Sensor (Challenger) 161-8906

July 2001 – LEVN4996

Page 47
 3412E Marine Electronic Parts
• ECM 156-7172
• Speed/Timing Sensors
– Primary & Backup Cam S/T Sensor 129-6628
• Pressure Sensors
– Boost Pressure Sensor 161-9929
– Oil & Fuel Press. Sensor 161-9931
– Atmospheric Press. Sensor 161-9926
– Injection Actuation Press. Sensor 167-1709
– Transmission Press. Sensor 161-9932
• Temperature Sensors
– Fuel & Coolant Temp. Sensor 102-2240
– Oil Temp. Sensor 106-0735
– Transmission Temp. Sensor 100-3055
• Coolant Level Switch 111-3794
• Throttle Position Sensors
– Standard “Beer Can” 9X9647
– Optional “Beer Can” 9X9648
– Optional Pre-calibrated 121-7029 (161-8904 sensor only)

July 2001 – LEVN4996

Page 48