Tech tips 11 11 1998

Tech Tips November 11, 1998

November 1998 LEVN4533 Page 1

Index 1999 Model Year Electronics 3126 ’99 Model Year Change ’99 MY HD ECM ECM Connectors & Tools Components & Locations Sensors & Troubleshooting Customer Parameters ET Status Screens Rating History ET Snapshot Viewer Flash Programming Service Tools Electronic Manuals Quick Tip #1 1999 Model Year HD Software Release 1999 Model Year Service Tools ET Version 2.3 ECAP Version 2.3 CAT ID Version 2.0 CAT ID Version 1.6

TOPP

3 TOPP Administration Tips 5 6 Quick Tip #2 8 12 23 37 Current Iron 39 3126 Rocker Arm Button 44 Inlet Valve Bridge Orientation 47 New Valve Seats 49 HEUI Injector Installation 56 Proper Heating of Crank Gear Head Bolt Re-Torqueing Procedure For Tool 57 3406E Unit Injector Sleeve/O-Rings 3406E Exhaust Manifold Gasket/Cylinder Head Exhaust Port Sleeve 58 3406C/E BrakeSaver Diaphragm/Spool 3406E Camshaft/Rocker Arm 3406E Crankshaft End Flange Thread Repair 59 3400 2-Piece Piston Skirt Cracks 80 81 83

84 89

90 91 92 93 94 95 96 97 98 101 103 104

November 1998 LEVN4533 Page 2

3126B ‘99MY 4 Effective with s/n 7AS36237 4 Same Ratings as ‘98MY 4 330 HP turbo used 250 HP and above 4 210 HP High Performance Rating n Unique rating n 190 HP iron with 210 HP Standard rating turbo 4 New Interlock Codes for ‘99MY

November 1998 LEVN4533 Page 3

New Full Feature ECM 4 Effective with s/n 7AS27551 4 Internally protected 4 No diode kit needed

November 1998 LEVN4533 Page 4

C-10/C-12, & 3406E 1999 Model Year ECM 4 New ECM, part number 157-3705-01 4 Not the same as 3126B n Housing identical except for the part number 4 Fuel Cooling Eliminated 4 7 pounds lighter than current production

November 1998 LEVN4533 Page 5

ECM Connectors & Tools 4 Gold terminals required 4 Same connector as 3126B Full Feature (NOT Basic, GM) Part Description Caterpillar Part Number #14 AWG Socket 126-1768 #16/#18 AWG Socket 9X-3402 Connector O-Ring Seal 159-9322 ECM Vehicle Connector P1 160-7689 ECM Engine Connector P2 160-7690 Sealing Plug #14,#16,#18 9G-3695 Terminal Removal Tool 151-6320

November 1998 LEVN4533 Page 6

13

1

23

14

31

24

47 39

40 32

70 57

58 48

C-10/C-12, & 3406E 1999 Model Year ECM ‌ Engine System ADEM III Electronic Control Module

Engine Retarder Solenoids

157-3705-01

161-9929 Boost Pressure

161-9925 Atmospheric Pressure

Coolant Temperature 130-9811

Intake Manifold Air Temperature

161-9931

Oil Pressure

160-0028 Crank Speed/Timing

Electronic Unit Injectors

130-9811

Cam Speed/Timing Fuel Temperature 130-9811 160-0030 3406E 160-0029 C-10/C-12

November 1998 LEVN4533 Page 7

1999 MY 3406E Electronic System Component Locations‌ Left Side Boost Electronic Unit Pressure Sensor Injector Connector

Intake Manifold Air Temperature Sensor Engine Ground Stud

Camshaft Position Sensor Electronic Control Module (ECM)

Fuel Temperature Sensor

OEM Vehicle Harness Connector J1/P1

Atmospheric Pressure Sensor

Crankshaft Position Sensor

Engine Harness Connector J2/P2 Engine Ground Stud Left Side View

November 1998 LEVN4533 Page 8

3406E Electronic System Component Locations… Right Side Coolant Temperature Sensor

Front View Oil Pressure Sensor Right Side View

November 1998 LEVN4533 Page 9

C-10/C-12 Electronic System Component Locations‌ Left Side Electronic Unit Injector Connector

Fuel Temperature Sensor

Atmospheric Pressure Sensor

Engine Ground Stud

Electronic Control Module (ECM)

Camshaft Position Sensor

OEM Vehicle Harness Connector J1/P1

Crankshaft Position Sensor

Engine Harness Connector J2/P2

Left Side View

Engine Ground Stud

Oil Pressure Sensor November 1998 LEVN4533 Page 10

C-10/C-12 Electronic System Component Locations‌ Right Side Coolant Temperature Sensor

Front Right Side View

Intake Manifold Air Temperature Sensor

Front Top View

Boost Pressure Sensor

Atmospheric Pressure Sensor

November 1998 LEVN4533 Page 11

Sensors 4 New n Two Speed/Timing Sensors n Boost Pressure Sensor n Oil Pressure Sensor n Atmospheric Pressure Sensor n Temperature Sensors

November 1998 LEVN4533 Page 12

New Speed/Timing Sensors 4 Passive Sensors n Two wire 4 Two Sensors n Cam Sensor n Crank Sensor 4 Engine starts and runs on one n Either sensor, provides redundancy

Crank Cam November 1998 LEVN4533 Page 13

New Speed/Timing Sensors 4 3406E Cam Sensor (160-0030) different part number than C-

10/C-12 (160-0029) 4 Crank Sensors are same part number (160-0028) 4 3126B uses different parts n

Camshaft Position Sensor

3406E

Deutsch two terminal connectors used on Heavy Duty sensors

C-10/C-12 Camshaft Position Sensor

Crankshaft Position Sensor

Crankshaft Position Sensor

November 1998 LEVN4533 Page 14

New Speed/Timing Sensors‌ Troubleshooting 4 Thoroughly inspect connector n Make sure it is latched 4 Inspect sensor bracket installation n Make sure n n

Bracket bolt is tight Sensor is not mis-aligned in hole

4 Use resistance checks n Cam sensors 600 - 1800 ohms n Crank sensor 75 - 230 ohms

November 1998 LEVN4533 Page 15

New Speed/Timing Sensors…

Troubleshooting 4 Two new diagnostic codes n 190-12 Loss of Engine Crank Sensor RPM Signal (34) n 64-12 Loss of Engine Cam Sensor RPM Signal (34) 4 DO NOT REPLACE THE SENSOR BECAUSE OF A LOGGED

FAULT n

If you can’t re-create after all connector, wiring, and resistance checks have been thoroughly performed and everything is OK

November 1998 LEVN4533 Page 16

New Speed/Timing Sensors‌ Troubleshooting 4 If replacing, make sure n Sensor is seated to the flange before bolting down n O-ring seal is in place n Tie wrap harness correctly 4 Sensors serviced individually, not as a pair n Sensor and bracket serviced together as one part 4 Timing calibration not required after sensor replacement Seat sensor to flange, BEFORE bolting down bracket

Crank Cam

O-ring must be installed November 1998 LEVN4533 Page 17

New Pressure Sensors 4 Boost (161-9929) and Oil (161-9931) n Increased range compared to current production n Troubleshooting identical to current production n

n

Follow the Troubleshooting Guide

Not compatible with current production C-10/C-12/3406E

4 Atmospheric pressure (161-9925)

November 1998 LEVN4533 Page 18

New Temperature Sensors 4 Passive Sensors (130-9811) 4 Coolant, fuel, and intake manifold air temperatures n Same part number used for each sensor n

Same part number as 3126B

November 1998 LEVN4533 Page 19

New Temperature Sensors‌ Troubleshooting 4 Thoroughly inspect connector n Make sure it is latched 4 Use open and short circuit tests n Troubleshooting identical to 3126B n

Follow the Troubleshooting Guide

November 1998 LEVN4533 Page 20

Deutsch Two Pin Connectors 4 Make sure connector is fully latched n Perform pull test 4 Watch for connector latch taking a “set”, stays in depressed

position n

Disconnect connector n

Look for connector latch mechanism not springing back up when unconnected

connector latch returns to position

connector latch taking a “set”

November 1998 LEVN4533 Page 21

C-10/C-12, & 3406E 1999 Model Year ECM … Vehicle System SAE J1587, SAE J1922, SAE J1939 Data Links

Check Engine and Ignition Warning Lamp Key Switch Input

3 PWM Inputs

Coolant Level

2 Lamp Outputs

9 Switch Inputs

Tachometer

Retarder

Speedometer

Cruise Control

4 Sensor Inputs

3 Outputs

3 Outputs Vehicle Speed

Clutch A/C High On-Off Fan Switch Pressure Switch Control Solenoid

Service Brake Switch

Accelerator Position November 1998 LEVN4533 Page 22

Customer Parameters 4 92 Customer Parameters 4 Several changes from 1998 to 1999 Model Year

C-10, C-12, and 3406E

November 1998 LEVN4533 Page 23

Customer Parameters‌ Changes n

Vehicle Speed Calibration, pulses per mile n

n

Engine Retarder Mode n

n

Default = manual (old default = coast)

Torque Limit, lb. ft n

n

Range changes to 4000 to 150,000 (old range = 4000 to 65535)

Range changes to 200 to 2500, default = 2500 (old default = 2000)

Transmission Style n

n

Changes: n Automatic Option 3 = old Auto w/ 2 Brake Sw n Automatic Option 4 = old Auto w/o 2 Brake Sw New: n Automatic Option 1 n Automatic Option 2

November 1998 LEVN4533 Page 24

Customer Parameters‌ Changes n

Fan with Engine Retarder in High Mode n

n

Coolant Level Sensor n n

n

Default = no, old default = yes Default = no, old default = yes Range changes to no, 4-Pin, old range = yes, no

Powertrain Data Link n

Default = off, old default = J1922

November 1998 LEVN4533 Page 25

Customer Parameters… Changes n

Engine Running Output n

n

Engine Shutdown Output n

n

New structure Engine Shutdown Output = None, J1/P1:10, J1/P1:12, or J1/P1:13 n Old structure = Multi-Function Output #2, Multi-Function Output #3, or MultiFunction Output #4 .

Auxiliary Brake n

n

New structure Engine Running Output = None, J1/P1:10, J1/P1:12, or J1/P1:13 n Old structure = Multi-Function Output #2, Multi-Function Output #3, or MultiFunction Output #4 .

New structure Auxiliary Brake = None, J1/P1:12 n Old structure = Multi-Function Output #2, Multi-Function Output #3, or MultiFunction Output #

Fan Control Type n n

Default = off, old default = On-Off New option = Three Speed Fan

November 1998 LEVN4533 Page 26

Customer Parameters‌ Changes n

Remote PTO Set Switch n

n

Remote PTO Resume Switch n

n

Now programmable with PTO Configuration to J1/P1:58, None default = J1/P1:58 Now programmable with PTO Configuration to J1/P1:60, None default = J1/P1:60

PTO Switch ON Lamp n

Now programmable with PTO Configuration to J1/P1:30

November 1998 LEVN4533 Page 27

Customer Parameters‌ New n

Two Speed Axle Switch n

n

Low Speed Range Axle Ratio n

n

None, J1/P1:47 (default = None)

Torque Limit Switch n

n

None, J1/P1:7, J1/P1:47, J1/P1:6, J1/P1:46 (default = None)

Ignore Brake/Clutch Switch n

n

1.00 to 9.99

Fan Override Switch n

n

1.00 to 19.99

High Speed Range Axle Ratio n

n

None, J1/P1:6 (default = None)

None, J1/P1:7 (default = None)

Diagnostic Enable n

None, J1/P1:46 (default = None)

November 1998 LEVN4533 Page 28

Customer Parameters‌ New n

Cruise Control On/Off Switch n

n

Cruise Control Set/Resume Switch n

n

J1/P1:22 (default = J1/P1:22) J1/P1:23 & 40 (default = J1/P1:23 & 40)

Service Brake Pedal Position Switch #1 n

n

(default = J1/P1:35 & 44)

Retarder Off/Low/Medium/High Switch n

n

J1/P1:35 & 44

Clutch Pedal Position Switch n

n

J1/P1:59 (default = J1/P1:59)

J1/P1:45 (default = J1/P1:45)

Accelerator Pedal Position n

J1/P1:66 (default = J1/P1:66)

November 1998 LEVN4533 Page 29

Customer Parameters‌ Input and Output Selections 4 Allows ECM n to be customized n to provide more options than input terminals n to have future expansion

November 1998 LEVN4533 Page 30

Customer Parameters‌ Input Selections 4 Programmable Option format is

ECM Connector:Terminal 4 Example: Two Speed Axle Switch is programmed to ECM Connector J1/P1 (Vehicle Harness Connector):Terminal 6

November 1998 LEVN4533 Page 31

Customer Parameters‌ Input Selections 4 Some options are available from more than one input n Fan Override Switch 4 Parameter options are the ECM terminal the feature will use 4 Some options not yet programmable Customer Programmable Input Parameter Terminal Fan Override Switch Remote PTO Set Switch Remote PTO Resume Switch Ignore Brake Clutch Sw Torque Limit Switch Two Speed Axle Switch Diagnostic Enable Service Brake Pedal Position Switch Clutch Pedal Position Switch Accelerator Pedal Position Cruise Control On/Off Switch Cruise Control Set/Resume Switch Retarder Solenoid Off/Low/Med/Hi Sw

#2 58

#3 60

#4 7 X

#5 47 X

#6 #7 #11 #18 #19 6 46 41 40 23 59 35 & 44 22 23 & 40 45 X X

66

X X X X X X X X X X X X

November 1998 LEVN4533 Page 32

Customer Parameters… Input Selections 4 Fan Override switch options

November 1998 LEVN4533 Page 33

Customer Parameters‌ Input Selections 4 ET prevents programming an input to more than one option n Example: Attempt to program Two Speed Axle Switch to J1/P1:6 when Fan Override Switch is already programmed to J1/P1:6

November 1998 LEVN4533 Page 34

Customer Parameters… Input Selections 4 ET Response:

November 1998 LEVN4533 Page 35

Customer Parameters‌ Output Selections 4 Some options are available from more than one output n Engine Running Output n Engine Shutdown Output 4 Parameter options are

the ECM terminal the feature will use

Customer Programmable Output Parameter Terminal Engine Running Output Engine Shutdown Output Auxiliary Brake PTO Switch On Lamp

#2 10 X X

#3 12 X X X

#4 13 X X

#1 30

#9 31

X

November 1998 LEVN4533 Page 36

ET Status Screens‌ Input and Output Selections 4 Programmable Input & Output Status Screens n Show status and connector and terminal using the feature 4 Example:

Torque Limit Switch is programmed to ECM Connector J1/P1 (Vehicle Harness Connector): Terminal 7 November 1998 LEVN4533 Page 37

ET Status Screens…

Engine Cooling Fan Status 4 4 4

4 4 4 4 4

All on default group 4 status screen Status parameter for fan- On or Off Status parameter for ECM output(s)- “On/Off Fan Output” On or Off A/C fan input Engine coolant temperature Engine intake manifold air temperature Fan override switch Most common fan parameters on one screen November 1998 LEVN4533 Page 38

Rating History 4 New feature coincides with 1999 Model Year Heavy Duty

Engines 4 Located in the Information History Rating menu of ET 2.3

November 1998 LEVN4533 Page 39

Rating History 4

4

ECM records and ET displays setting as the engine was built, or Original Setting Adds Present Setting when the ECM is flashed with a different rating

November 1998 LEVN4533 Page 40

Rating History 4

ECM records and ET displays Previous and Present setting

November 1998 LEVN4533 Page 41

Rating History 4

ECM records and ET displays Previous and Highest setting

November 1998 LEVN4533 Page 42

Rating History‌ Summary 4

ECM records and ET displays: n n n n

Original Setting Previous Setting Present Setting Highest Setting

4

Records: n n n n n n

Advertised Power Governed Speed Rated Peak Torque Date & Time ECM was flashed Hours of engine operation w/rating Service Tool s/n

November 1998 LEVN4533 Page 43

ET Snapshot Viewer…

4 ET snapshot viewer incorrectly describes diagnostic codes n Truncates the FMI (two digits at end of diagnostic code number) n FMI always indicates “0” n PID OK (1 to 3 digits at start of diagnostic code number) 4 Example, snapshot viewer

will incorrectly indicate n

110-0 High Coolant Temperature Warning for both the 110- 3 Coolant Temp Sensor Open Circuit and 110- 4 Coolant Temp Sensor Short Circuit codes as well as the 110-0 High Coolant Temperature Warning

November 1998 LEVN4533 Page 44

ET Snapshot Viewer…

4 ET snapshot viewer incorrectly describes diagnostic codes n But when selecting “View Data” displays the code correctly

Incorrectly indicates 110-0 High Coolant Temperature Warning

Correctly indicates 110- 3 Coolant Temp Sensor Open Circuit

November 1998 LEVN4533 Page 45

ET Snapshot Viewer…

4 ET snapshot viewer incorrectly describes diagnostic codes n Truncates the FMI (two digits at end of diagnostic code number) n FMI always indicates “0” n PID OK (1 to 3 digits at start of diagnostic code number)

November 1998 LEVN4533 Page 46

Flash Programming 4 Files 1.1 MB n Takes 12 to 20 minutes to flash program with Caterpillar communications adapter

F Significantly longer time to flash program with the Pro-Link as a communications adapter compared to the Caterpillar communications adapter

November 1998 LEVN4533 Page 47

Flash Programming 4 If flash process n Takes longer than normal on a truck OR n Aborts a couple of times on a truck n DON’T REPLACE THE ECM

✦ Use the new 167-9225 bypass harness or 135-5063 (discontinued) bypass harness

November 1998 LEVN4533 Page 48

Service Tools 4 ET 4 ECAP 4 Pro-Link 4 70 Pin Breakout 4 Bypass Cable

November 1998 LEVN4533 Page 49

Electronic Service Tools‌ ET version 2.3 4 Full service capability 4 Program all parameters 4 Service all truck engines

November 1998 LEVN4533 Page 50

Electronic Service Tools‌ ECAP version 2.3 4 Same capability as ET except... n Unable to flash program the ECM n Unable to program Input & Output Selections n No ECM replacement or fleet configuration capability n Unable to view Rating Date - Time Stamping Electron ic C on trol An alyzer Prog ra m m er

November 1998 LEVN4533 Page 51

Electronic Service Tools‌ Pro-Link Caterpillar Cartridge 4 Cartridge 1.07 has limited support n Same limitations as ECAP plus: n n n n n

Unable to view many engine display status parameters Unable to program vehicle speed calibration Unable to program Transmission Style Unable to program Fan Control Type Unable to clear Factory password protected diagnostic codes

4 Pro-Link Caterpillar Cartridge 3.0 n Not available until middle of 1999

ENTER

November 1998 LEVN4533 Page 52

Electronic Service Tool Summary The following matrix illustrates the capability of the ET, ECAP and Pro-Link to work with the heavy duty 1999 truck engines.

Feature Cat ET ECAP Pro-Link (1) (1) (3) Read / Change customer Parameters Yes Limited Limited Read / Change Factory Parameters Yes Yes No (3) Display Engine Status Yes Yes Limited (2) Display / Clear Diagnostic Codes Yes Yes Yes Calibrations and Calibrate Speed / Timing Sensor Yes Yes Yes Cylinder Cutout Yes Yes Yes Injection Signal Duration Yes Yes No Engine Retarder Special Test Yes Yes Yes (3) Cooling Fan Driver Special Test Yes Yes No (3) View Fleet Trip Data Segment Yes Yes No (3) View Driver Trip Data Segment Yes Yes No (3) View Trip Histograms Yes Yes No Custom Data Yes Yes Read Only View Maintenance Indicator Data Yes Yes Yes View / Trigger Snapshot Recorder Yes Yes No (3) Special Service Tests Yes Yes No ECM Replacement / Fleet Configuration Yes No No (4) Guided Diagnostics (On-line Troubleshooting Guide) No No No Totals and ECM Date and Time Yes Yes Yes Customer Parameter Lockout Yes Yes Read Only Rating / Date Tracking Yes No No Flash Programming Yes No No Improved Graphics & Other Enhancements Yes No No 1. "Read only" on input and output selection parameters. (See Electronic Troubleshooting Guide for details) 2. MPSI Pro-Link will not clear any critical event because it does not support factory passwords.

3. Support available mid 1999.

4. Available with ET 2.4 or on SIS by 1/99.

NOTE: Pro-Link can be used as a communication adapter for flashing new software to the ECM. '99 model year engines will experience significantly longer flash time with Pro-Link vs the Cat Communications Adapter.

November 1998 LEVN4533 Page 53

Service Tools…

140-2266 70 Pin Breakout ‘T’ 4 Not a “full” breakout n Data links, power & ground, ignition key switch to all three connectors 4 Not for use while engine is running n Use to test open circuits and short circuits 4 Universal connector allows connection to either ECM engine

or vehicle connector

November 1998 LEVN4533 Page 54

Service Tools‌ 167-9225 Bypass 4 Use when unable to communicate from cab connector 4 Data links, ignition key switch, power & ground with battery

clips 4 If a 135-5063 is already available, continue to use it n

167-9225 cable has enhancements for non-truck applications

November 1998 LEVN4533 Page 55

Electronic Manuals

Service Manual Application and Installation Guide Electronic Troubleshooting PTO Special Instruction Color W iring Diagram Operation & Maintenance Manual C-10/C-12 System Operations Test & Adjust C-10/C-12 Disassembly & Assembly 3406E System Operations Test & Adjust 3406E Disassembly & Assembly

Form Number LEBT9010 RENR2238 REHS0367 RENR2237 SEBU7186 RENR2235 RENR2236 SENR5017 SENR5016

November 1998 LEVN4533 Page 56

Quick Tip #1 4 Received from Orville W. Lawrence of Alban Engine Power

Systems, Elkridge, Maryland 4 Check fuses when diagnosing cooling fan problems

November 1998 LEVN4533 Page 57

1999 ADEM III Heavy Duty Truck Software Release 4 OCT98 Software Released for all 1999 C10, C12, and 3406E

engines C-10 Serial Number Prefix 3CS n C-12 Serial number Prefix 2KS n 3406E Serial Number Prefix 2WS (14 liter) and 1MM (16 liter) n Cat ET Version 2.3 or ECAP version 2.3 or later n C-10/C-12 and 3406E Flash File Cross References reflect the new part numbers, interlock codes and ratings available for download n

November 1998 LEVN4533 Page 58

Caterpillar Electronic Technician Version 2.3 Update 4 ET Version 2.3 will be released mid-October 1998.

4 New ET Tools n Updated ET Trainer that will allow WinFlash simulation n Communication Adapter Choices w/ RP1210 (Recommended Practice 1210A – from the Truck Maintenance Council) n Multi-Function Input/Output Programming (with J1939) Data Link Capability.

This will allow programming of a feature directly to a specific pin n Rating Date Tracking 4 New Diagnostic Tests n 3126B Automatic Cylinder Cutout Test (covered in last broadcast)

November 1998 LEVN4533 Page 59

Caterpillar Electronic Technician Version 2.3 Update 4

Updated support for: n n n n

C-10 On-Highway Truck C-12 On-Highway Truck 3406E On-Highway Truck 3126B On-Highway Truck

November 1998 LEVN4533 Page 60

Caterpillar Electronic Technician Supported Products 4

Listed here are the supported products for ET’s various subscriptions. This information can also be found in the README.TXT file in ET.

n

JERD2125 TEPS Cat Dealer & NEXG5009 TEPS Cat Customer: n

n

Includes support for the products listed in On-Highway Truck Engines

JERD2129 Full Service Dealer ET & NEXG5007 Full Service Cat Customer: n

Includes support for the products listed in On-Highway Truck Engines, Commercial Engines, and Machines

November 1998 LEVN4533 Page 61

Caterpillar Electronic Technician Supported Products On-Highway Truck Engines: 3116 HEUI Electronic Engine 3126 HEUI Electronic Engine 3176 Electronic Engine 3176B Electronic Engine 3406B Electronic Engine 3406C Electronic Engine 3406E Electronic Engine C-10 Electronic Engine C-12 Electronic Engine 3126B Basic On-Highway truck 3126B Full Feature On-Highway truck Commercial Engines: 3176 Marine/Industrial 3176B Marine/Industrial 3196 Marine/industrial 3400 PEEC Marine/Industrial 3400 Oil Well Service 3401 SCOTE 3406E Marine/Industrial 3408, 3412 HEUI - Industrial 3500/3600 PEEC Locomotive 3500B Marine/EPG 3500B Locomotive Hydrocarbon Injection Control 3600 Marine 3600 Monitoring System 3176C Marine/Industrial

Machines: M300 Wheeled Excavator 300B Hydraulic Excavator 345 Hydraulic Excavator 3176B Challenger 35/45/55 Challenger 65/75 3176 Engine/Hitch Control Challenger /85/95 3196 Engine Control H-Series Motorgraders Skid-Steer Loaders Backhoe Loaders 480 Combine 3176 Engine Control 589 Pipe Layer 69D, 73D Elphinstone 769-797 Off-Highway Trucks 810, 820, 830 Compactors D250-D400 Articulated Trucks DEUCE R1300, R1600, R1700, R2900 Track-Type Tractors: DSM, DGM, DGR, D7R, D9R,D10R,D11N, D11R, D11CD Mining Shovel: 5110, 5130, 5230 Wheel Tractor Scrapers (621-657) 953, 963, 973 Track-type Loaders Integrated tool carriers Wheel Loaders (914-994)

November 1998 LEVN4533 Page 62

Caterpillar Electronic Technician Supported Products 3126: DEUCE 3408E/12E HEUI Control: 769, 771, 773 Off-Highway Truck D9R, D10R, Track-Type Tractor 988F, 990 Wheel Loader 631 - 657 Wheel Tractor Scraper 834B, 836 Compactor 24H Motor Grader PM-565 Cold Planer 5110 Mining Shovel 3500 EUI: 777 - 793 Off-Highway Truck D11N Track-Type Tractor 5130, 5230 Mining Shove 3500B EUI: 992G, 994 Wheel Loader 776 Off-Highway Truck D11R Track-Type Tractor Scraper Control (ESTC) Auto Retarder Control: 769 - 793 Off-Highway Truck All Wheel Drive Control: H-Series Motor Graders

Transmission Control: 769 - 793 Off-Highway Truck 910 - 938 Wheel Loader 980G, 992G Wheel Loader IT12 - IT28 Integrated Tool Carrier 446 Backhoe Loader 515, 525, 535 Skidder 621 - 657 Wheel Tractor Scraper D250/D300/D350/D400 Articulated Truck 824, 825, 826 Compactor H-Series Motor Graders 953, 963, 973, Track-Type Loader DEUCE D5, D6, D7,D9, D10, D11, D11CD Track-Type Tractor Traction Aid Control: 938F Wheel Loader Machine Control: 5110, 5130, 5230 Mining Shovel Implement Control: 980G, 992G Wheel Loader 824, 825, 826 Compactor VIMS Sensor Modules: 992G Wheel Loader 784, 785, 789, 793 OHT 5130, 5230, Mining Shovel Electronic Shift Control: 924, 928, 938 Wheel Loader IT24, IT28, IT38 Integrated Tool Carrier

November 1998 LEVN4533 Page 63

Caterpillar Guided Diagnostics Supported Products List 4

The diagnostic data for ET2.3 will include the following products: n

C-10 Truck Engine 2PN 8YS

n

C-12 Truck Engine 1YN 9NS

3126 Truck Engine 4ES 7AS

n

3116 Truck Engine 2BK 2CW 2FR 5RM 7JL 7SF 8WL 9CJ 9GK 9LN 9YN

n

n

3176 Truck Engine 2YG 5XN 7LG

n

3176B Truck Engine 9CK

n

3406B Truck Engine 2EK 5YG 8TC

n

3406C Truck Engine 4CK

n

3406E Truck Engine 1LW 4AS 5DS 5EK 6TS

November 1998 LEVN4533 Page 64

Caterpillar Electronic Technician Version 2.3 Update 4 As a reminder, if you have already received Authorization for

your copy of ET, it is not necessary to Authorize again when updating to the latest version.

4 However, it is important to log the current ET serial numbers

on all of your PC's for reference at a later time.

November 1998 LEVN4533 Page 65

Multi-Function Input / Output Programming - ADEM III 4

4

Multi I/O Programming is a new feature that allows you to customize the I/O of various functions on an electronic control module. Rather than having input and output functions restricted to a certain pin on the control, Multi I/O Programming enables these inputs and outputs to be programmed to a variety of different functions on the ECM. You can also have the J1939 data link programmed as an input for monitoring.

This feature is intended to provide programming flexibility with a limited number of inputs and outputs. Each function will have an associated list of I/Os that can be programmed as seen here in the configuration screen.

November 1998 LEVN4533 Page 66

Service Tool Status Groups-ADEM III 4

4

ET will also display the status of the functions for Multi I/O. There are 4 new predefined status groups to choose from, or as always, you may choose from the available list of parameters and create your own groups.

The next few handout pages will show the pre-defined status groups for the ET & ECAP service tools.

November 1998 LEVN4533 Page 67

Service Tool Status Groups ET Ver 2.3 ADEM II

ET Ver 2.3 ADEM III

ECAP Ver 2.3 ADEM II

ECAP Ver 2.3 ADEM III

Scr e e n 1

Scr e e n 1

Scr e e n 1

Scr e e n 1

Vehicle Speed Engine Speed Throttle Position Fuel Position Boost Pressure Engine Oil Pressure Engine Coolant Temperature Engine Retarder Powertrain Status

Vehicle Speed Engine Speed Accelerator Pedal Position Fuel Position Boost Pressure Engine Oil Pressure Engine Coolant Temperature Engine Retarder Intake Manifold Air Temperature Atmospheric Pressure

Engine Speed Vehicle Speed Fuel Position Engine Brake Throttle Position Boost Pressure

Vehicle Speed Engine Speed Throttle Position Fuel Position Boost Pressure Engine Coolant Temperature Engine Brake Powertrain Status

Scr e e n 2

Scr e e n 2

Scr e e n 2

Scr e e n 2

Engine Speed Desired Engine Speed Throttle Position Fuel Position FRC Fuel Limit Rated Fuel Limit Boost Pressure

Engine Speed Desired Engine Speed Accelerator Pedal Position Fuel Position FRC Fuel Limit Rated Fuel Limit Boost Pressure Ignition Key Switch Powertrain Status

Engine Speed Desired Engine Speed Fuel Position FRC Fuel Limit Rated Fuel Limit Injection Actuation Output Injection Actuation Pressure Desired Injection Actuation Pressure

Engine Speed Fuel Position FRC Fuel Limit Injection Actuation Pressure Desired Engine Speed Rated Fuel Limit Injection Actuation Output Desired Injection Actuation Pressure Ignition Key Switch

Screen 3

Screen 3

Screen 3

Screen 3

Engine Speed Atmospheric Pressure Engine Oil Pressure Fuel Pressure Fuel Temperature Intake Manifold Air Temperature Vehicle Speed Limit Driver Incentive VSL Bonus

Engine Speed Estimated Fuel Rate Fuel Economy Fuel Temperature Intake Manifold Air Temperature Engine Oil Temperature Vehicle Speed Limit Driver Incentive VSL Bonus Ignition Key Switch ECM Battery Voltage

Engine Speed Engine Coolant Temperature Boost Pressure Atmospheric Pressure ** Not Supported ** Intake Manifold Air Temperature Estimated Fuel Rate

Engine Speed Engine Coolant Temperature Boost Pressure Atmospheric Pressure Intake Manifold Air Temperature Estimated Fuel Rate Engine Oil Pressure Engine Oil Temperature

November 1998 LEVN4533 Page 68

Service Tool Status Groups ET Ver 2.3 ADEM II

ET Ver 2.3 ADEM III

ECAP Ver 2.3 ADEM II

ECAP Ver 2.3 ADEM III

Scr e e n 4

Scr e e n 4

Scr e e n 4

Scr e e n 4

Engine Speed Estimated Fuel Rate Fuel Economy A/C Fan Input Cooling Fan Multi-Func Output #4 Engine Coolant Temperature Coolant Level

Engine Speed Cooling Fan On/Off Fan Output Three Speed Fan Slip Output Three Speed Fan Brake Output A/C Fan Input Engine Coolant Temperature Intake Manifold Air Temperature Coolant Level Fan Override Switch

Clutch Switch Brake Switch #1 Brake Switch #2 Neutral Switch Cruise/Idle Switch Set/Resume Switch Cruise/Idle Mode Accel/Decel Mode Cruise Set Speed Idle Set Speed

Engine Speed Estimated Fuel Rate Fuel Economy A/C Fan Input Cooling Fan Engine Coolant Temperature Coolant Level

Screen 5

Screen 5

Screen 5

Screen 5

Idle Shutdown Status Parking Brake Switch ** Not Supported ** Engine Retarder Switch ECM Battery Voltage Multi-Func Output #2 Multi-Func Output #3 Multi-Func Output #4 Outside Air Temperature

Engine Retarder Engine Retarder Switch Accelerator Pedal Position Vehicle Speed Cruise/Idle On-Off Switch ECM Battery Voltage Idle Shutdown Status Auxiliary Brake Service Brake Pedal Position Switch #1 Clutch Pedal Position Switch

Cruise Kickout Idle Kickout Idle Shutdown Status Fast Idle Kickout Fast Idle Switch Fast Idle RPM ECM Battery Voltage

Idle Shutdown Status Engine Brake ECM Battery Voltage

Scr e e n 6

Scr e e n 6

Scr e e n 6

Scr e e n 6

Vehicle Speed Cruise Set Speed Cruise/Idle Mode Cruise/Idle Switch Set/Resume Switch Accel/Decel Mode Cruise Kickout Brake Switch #1 Clutch Switch

Vehicle Speed Cruise Set Speed Cruise/Idle Mode Cruise/Idle On-Off Switch Cruise Control Set/Resume Switch Accel/Decel Mode Cruise Kickout Service Brake Pedal Position Switch #1 Clutch Pedal Position Switch Service Brake Pedal Position Switch #2

Engine Speed PTO Set RPM PTO Config Set/Resume Switch PTO Kickout PTO Throttle Position Multi-Func In #1 Multi-Func In #2 Multi-Func In #3

Clutch Switch Cruise/Idle Switch Set/Resume Switch Cruise Set Speed Brake Switch #1 Brake Switch #2 Cruise/Idle Mode Accel/Decel Mode Idle Set Speed Neutral Switch

November 1998 LEVN4533 Page 69

Service Tool Status Groups ET Ver 2.3 ADEM II

ET Ver 2.3 ADEM III

ECAP Ver 2.3 ADEM II

ECAP Ver 2.3 ADEM III

Screen 7

Screen 7

Screen 7

Engine Speed Idle Set Speed Cruise/Idle Mode Cruise/Idle Switch Set/Resume Switch Accel/Decel Mode Idle Kickout Brake Switch #1 Clutch Switch

Engine Speed Idle Set Speed Cruise/Idle Mode Cruise/Idle On-Off Switch Cruise Control Set/Resume Switch Accel/Decel Mode Idle Kickout Service Brake Pedal Position Switch #1 Clutch Pedal Position Switch

Cruise Kickout Idle Shutdown Status Fast Idle Switch ECM Battery Voltage Idle Kickout Fast Idle Kickout Fast Idle RPM Brake Switch #1 Brake Switch #2 Clutch Switch

Screen 8

Screen 8

Screen 8

Engine Speed PTO Set RPM PTO Config Set/Resume Switch PTO Kickout PTO Throttle Position Multi-Func In #1 Multi-Func In #2 Multi-Func In #3 PTO Shutdown Status

Engine Speed PTO Set RPM PTO Config Cruise Control Set/Resume Switch PTO Kickout PTO Accelerator Sensor PTO Shutdown Status PTO On/Off Switch Remote PTO Set Switch Remote PTO Resume Switch

PTO Config PTO Throttle Position PTO Kickout PTO Set RPM Input #1 Input #2 Input #3 Set/Resume Switch Engine Speed PTO Shutdown Status

Scr e e n 9

Scr e e n 9

Scr e e n 9

Engine Speed Percent Torque Powertrain Status TC Status TC Speed TC Torque Transmission Status Transmission Output Speed Transmission Torque ABS Status

Engine Speed Percent Torque Powertrain Status TC Status TC Speed TC Torque Transmission Status Transmission Output Speed Transmission Torque ABS Status

Engine Speed Percent Torque Powertrain Status TC Status TC Speed TC Torque Transmission Status Transmission Output Speed Transmission Torque ABS Status

November 1998 LEVN4533 Page 70

Service Tool Status Groups ET Ver 2.3 ADEM II

ET Ver 2.3 ADEM III

ECAP Ver 2.3 ADEM II

ECAP Ver 2.3 ADEM III

Scr e e n 1 0

Scr e e n 1 0

PTO On/Off Switch PTO Engine RPM Set Speed Input A PTO Engine RPM Set Speed Input B PTO Engine RPM Set Speed Input C PTO Engine RPM Set Speed Input D Fast Idle Enable Switch Ignore Brake/Clutch Switch Torque Limit Switch Diagnostic Enable Idle Shutdown Switch

Vehicle Speed Input #4 Input #5 Input #6

Scr e e n 1 1 Vehicle Speed PTO Accelerator Sensor Shutdown Switch Engine Shutdown Output Starter Aid On/Off Switch Starting Aid Output Two Speed Axle Switch Cruise/Idle On-Off Switch Cruise Control Set/Resume Switch

Scr e e n 1 2 Clutch Pedal Position Switch Retarder Off/Low/Med/High Switch Service Brake Pedal Position Switch #1 Outside Temperature Sensor A/C High Pressure Switch Service Brake Pedal Position Switch #2 Transmission Neutral Switch Accelerator Pedal Position Engine Running Output

November 1998 LEVN4533 Page 71

Service Tool Status Groups ET Ver 2.3 ADEM II

ET Ver 2.3 ADEM III

ECAP Ver 2.3 ADEM II

ECAP Ver 2.3 ADEM III

Screen 13 Auxiliary Brake PTO Switch On Lamp Vehicle Speed Ignition Key Switch On/Off Fan Output Lockout Solenoid Shift Solenoid Fast Idle Enabled Lamp Cruise/Idle On-Off Switch Clutch Pedal Position Switch

November 1998 LEVN4533 Page 72

Multi-Function I/O Special Tests ADEM III 4

ET will also allow you to perform special tests on the output functions as well.

November 1998 LEVN4533 Page 73

Multi-Function I/O Requirements ADEM III 4 To

perform the multi I/O programming function, you will need ET version 2.3 and ECM software dated 12/98 or later for the ADEM III HD On-highway trucks.

4 Note: n The number of inputs and outputs will vary with the ECM hardware n The list of available I/Os will vary for each function‌ and n ET will prevent programming a function to an input/output that is already programmed on another function.

November 1998 LEVN4533 Page 74

Caterpillar Electronic Technician Rating History - ADEM III 4

4

4

Rating History will display the history of various engine ratings.

The ECM will date stamp and record the horsepower, torque, duration, and electronic service tool serial number at the time of rating change entry.

In addition, the ECM will record a total of four different rating settings: the original, present, highest, and previous rating to be programmed.

November 1998 LEVN4533 Page 75

Caterpillar Electronic Technician Manual Updates 4 We

are doing a complete re-write of the manuals to meet field requests.

4 We will not ship a manual with the 2.3 update.

4 The manual did not make it on the Dealer Additions CD-ROM.

November 1998 LEVN4533 Page 76

Caterpillar Electronic Technician Product Brochures 4 Dealer n

ET Brochure

NEDG6013

4 Customer

ET Brochure

NEDG6015 n This brochure will provide you with available features and ordering information for Customer ET. n

November 1998 LEVN4533 Page 77

Caterpillar Electronic Technician Training 4 Included

on the Dealers Additions CD is training material put together by Service Training. n

The training material is in Adobe Acrobat Reader format.

4 The

reader is available on the CD. n

Please refer to the Dealer Additions Manual for Installation instructions

November 1998 LEVN4533 Page 78

Caterpillar Electronic Technician Training 4

Caterpillar offers an ET Training Video n

4

ET Training Video & Workbook n

4

The training video and workbook package guides you through the ET menu functions and is intended for the novice user.

NEHS0694

Additional Workbooks n

NEHS0693

November 1998 LEVN4533 Page 79

ECAP Truck SPM Version 2.3 Update 4

ECAP Truck SPM Version 2.3 has the same capability as ET Version 2.3 n

n

n

The new release of ECAP version 2.3 will support Multi-Function I/O Programming in a read only format. Meaning, that ECAP will not be able to program the parameters You will be able to monitor any of the settings and perform the special tests as show with ET version 2.3.

You will not be able to perform the 3126B Automatic Cylinder Cutout feature the was implemented in Cat ET Version 2.3

ECAP Truck SPM Version 2.3 should ship by late November 1998.

November 1998 LEVN4533 Page 80

64K Cat ID / Ver 2.0 Software New Release 4

We are expecting a release of the 64K Version of Cat ID Ver 2.0 mid 4th quarter 1998. n

4

32K & 64K Hardware look the same n

4

There is new 64K Hardware & 64K software.

The 64K Hardware will be indicated by a version number 4 on the unit

Multiple languages on on chip n

The new chips are color coded & the the 64K chips will not function in the current 32K version of Cat ID

Version 2.0 Cat ID will support: n

n

New diagnostic code support for J1939 Back Panel Unit, Eaton Top II, Cam / Crank and 5V supply You will now have the capability to view negative temperatures

November 1998 LEVN4533 Page 81

64K Cat ID / Ver 2.0 Software New Release 3 2 K M e m o r y D isplay CAT ID 1.6 OEM

CAT ID

English Spanish French CAT

ID

English Spanish French

4 4

6 4 K M e m o r y D isplay CAT ID 2.0

w/Personality Module

150-8717 150-8718 150-8719 (Personality Module) 168-7777 168-7778 168-7779

Cancelled & replaced by

English OEM

/

Spanish

CAT ID

/

French

w/chip

166-4092 CAT

ID

English / 168-7931

(Personality Module) Spanish

/

French

64K chip will support multiple languages on one chip.

ADEM III will only be completely supported by the 64K version with 2.0 software.

November 1998 LEVN4533 Page 82

32K Cat ID / Version 1.6 Software Update 4 32K Cat ID Version 1.6 is expected to be released mid-first

quarter 1999.

November 1998 LEVN4533 Page 83

New TOPP P/M Forms 4 New TOPP P/M forms are available through normal literature

channels or by using Caterpillar’s Fax Back Service at (800) 937-9629, press 1 then7 and follow instructions. Forms will be faxed to you within minutes.

November 1998 LEVN4533 Page 84

P/M 1 Filter Kit Charges 4 When TOPP customers request P/M 1 filter kits, to reduce

confusion, may need to charge the filter kits to a shop work order. Then process work order through warranty department.

November 1998 LEVN4533 Page 85

TOPP Oil Change Service Levels 4

TOPP offers 2 levels of oil change service.

1.

2.

4 4

P/M 1, Lube Oil & Filter (LOF). This service is similar to a truck stop or quick lube type service. Service includes an oil and filter change including up to 2 fuel filters, chassis lube and inspection, topping off of fluids and pays 1.5 hours labor plus parts.

P/M 1 Full Service. This service includes an oil and filter change including up to 2 fuel filters, comprehensive chassis inspection, chassis lubrication, topping off of fluids, air filters (as needed), brake and clutch adjustments, and pays 2.8 hours labor plus parts. An additional 1/2 hour labor is allowed if brake or clutch is adjusted.

Advise TOPP if air filters are used or brakes and clutch are adjusted to assure payment for these services.

During oil change services, be sure to check gear lube levels. This is required for both levels oil change service offered.

November 1998 LEVN4533 Page 86

Value of TOPP to Caterpillar Dealers 4 Since January ‘98, 550 different dealers have performed an

average of 15 service/repairs at an average of $408.00 per visit.

November 1998 LEVN4533 Page 87

New TOPP Service Representatives 4 Four new TOPP Customer Service Representatives joined

TOPP in ‘98. Combined, new reps have over 50 years experience.

4 Bruce Ballard is now processing TOPP service claims.

For claim related questions, contact Bruce at (800) 338-3428.

November 1998 LEVN4533 Page 88

Quick Tip #2 4 Received from Larry Collins, Technician from Freightliner

Arizona in Phoenix, Arizona 4 Deflating cab air bags for improved access for torqueing C-12

number 6 head bolt

November 1998 LEVN4533 Page 89

3126B HEUI Rocker Arm Buttons n n

The rocker arms buttons can be knocked off during assembly Check if they are in place before and after assembly

November 1998 LEVN4533 Page 90

3126B HEUI Inlet Valve Bridge Orientation

November 1998 LEVN4533 Page 91

NEW 3126 Valve Seat Inserts 130-9004 n

n n

n

n

Used on all 3114 and 3116 Industrial, Marine, Gen Sets, and Fire Truck Engines; all 3126 Industrial, Marine, and Truck Engines.

Designed to provide a wider seating face.

Requires more machining to maintain the same valve to cylinder head face dimension.

The valve to cylinder head face dimension must be in the current specification of 1.13 to 2.05 mm (.044 to .081 in.)

OD of the seating face on the 130-9004 Intake Valve Seat should be machined to a diameter of 47.0 mm (1.85 in.)

November 1998 LEVN4533 Page 92

3126B HEUI Injector Installation n n

n n

Evacuate fuel and oil from cylinder Install seals and backup rings with 149-2955 seal protector and 149-2956 seal installer Lubricate seals with clean engine oil and install into injector bore.

Torque shoulder bolt to 6Nm (50 lb in) then torque socket head bolt to 12Nm (108 lb in).

November 1998 LEVN4533 Page 93

Crankshaft Gear 4 Service Manuals prior to 1998 have the incorrect preheat

temperature to install the crankshaft gear 4 Proper Procedure 4 Heat gear to 410 Degrees F. (210 Degrees C) 4 Heat for NO more than 1 hour 4 Remove from oven and install 4 Procedure is in the June Truck Engine News

November 1998 LEVN4533 Page 94

Cylinder Head RetorqueTool 4 161-3440 Socket available for cylinder head retorque 4 Designed to allow torqueing of head bolt without removal of

water manifold 4 Tool MUST be perpendicular to bolt head to prevent tool breakage

November 1998 LEVN4533 Page 95

3406E Unit Injector Sleeve O-Ring 4 Problem:

Fuel in coolant/coolant in fuel due to deteriorated o-rings

4 Effective with late November ’98

production new o-rings (larger diameter) 4 For 3406E engines built before this

change, use 166-3718 o-rings in both positions. Same size as former 9X7431.

New material.

November 1998 LEVN4533 Page 96

3406E Exhaust Port Sleeve 4 Problem:

101-6706 sleeve loosens in exhaust port of head, may wear groove into manifolds.

4 In late November ‘98 production of 1 new sleeve assembly

will replace 101-6706 sleeve and 138-4611 gasket.

November 1998 LEVN4533 Page 97

3406C/E Brakesaver New Diaphragm & Spool 4 Problem:

Diaphragm wears out, tears 4 New design allows spool to rotate without applying load on diaphragm.

Spool 154-1907 n Diaphragm 158-0507 n Retainer 154-1684 n

4 See next page for installation instructions.

4 Production to begin later in November.

November 1998 LEVN4533 Page 98

Assemble BrakeSaver Control Valve w/New 2-piece Spool 4 4

4

Follow the disassembly instructions for the BrakeSaver control valve given in the 3406E Disassembly and Assembly Manual.

The following steps are for assembly of the BrakeSaver control valve. The numbering scheme in the figure is consistent with that used in the 3406E Disassembly and Assembly Manual (the same number references the corresponding part in the new assembly.)

NOTICE: When diaphragm (12) is installed on valve retainer (14) make sure the fabric side is pulled down over the valve retainer to make contact with it and the smooth (rubber coated) side is next to the valve body.

4

1. Put diaphragm (12) in position on valve retainer (14).

4

2. Align the hole in valve stop (13) with the pin in valve retainer (14) and install the stop.

4

3. Install bolt (11). Two No. 10-24 bolts installed in the stem of the retainer may be used to hold the retainer while torque is applied to the bolt. Do not damage the pilot surface on the retainer stem or the diaphragm rolling surface on the retainer while installing the bolt.

4

4. Install the thrust races (15) bearing (16) on the stem of the retainer (14)

November 1998 LEVN4533 Page 99

Assemble BrakeSaver Control Valve w/New 2-piece Spool 4

5. Insert the stem of the retainer (14) into the pilot hole on the spool (8).

4

6. Install sleeves (5) and the O-ring seals.

4

7. Put spring (7), stop (10), spring (6), and slug (9) in position in valve spool (8).

4

8. Install valve spool (8) and retainer (14) into the valve body. As the valve is installed, make sure the edge of the diaphragm makes contact all the way around with the groove in the valve body. At this time the valve retainer end must extend approximately 38.1 mm (1.50 in.) from the valve body. Push the valve spool-retainer assembly approximately 6.4 mm to 12.7 mm (.25 in. to .50 in.) father into the valve body. Make sure there are no wrinkles in the diaphragm.

4

9. Install covers (3) and (4) on the valve body.

4

10. Install three O-ring seals (1).

4

End By: a. install BrakeSaver control valve.

November 1998 LEVN4533 Page 100

3406E Camshaft/Rocker Arm 4

Description: n

n

n

n

n

Micropitting on cam lobes, rocker arm rollers New rocker arm assemblies now in production Intake/Exhaust Rocker Arm Assembly: 1629175 Unit Injector Rocker Arm Assembly: 1629174 Reman Rocker Arms Assembly: n n n

n

Intake OR9544* Exhaust OR9545* Unit Injector

OR9546

Effective with 1LW23717, 5DS00841 *Available only in:

Cam Kits OR8449 - Low HP OR8450 - Hi HP or Rocker Arm Kit OR9430

November 1998 LEVN4533 Page 101

3406E Intake/Exhaust Rocker Arm Adjusting Screw 4 Description: n Breaking of 4P4313 n

New 164-5950 Adjusting Screw (Alloy/Heat treat Change)

n

Effective with: 1LW23717, 5DS00841

November 1998 LEVN4533 Page 102

3400 Crankshaft End Flange Thread Repair 4 4 4

No more than 4 holes per flange Adjacent holes should not be repaired Repair Kit 4C8389 (5402-10) which contains inserts, drill tap and installation tool. n

NOTE: (HELI-COIL part number)

1.

2.

3.

4.

Using a 4C8480 drill, drill a 16.27mm (41/64 in) diameter hole 32.3 mm (1.27 in) deep Countersink 120° to 17.5 mm (0.69 in) dia.

Tap with 4C9701 (8193-10) Heli-coil tap. Minimum full thread depth 25.4 mm (1.00 in) Install Heli-coil standard insert 4C8439 (1191-10CN -0938) (package of 6) with Heli-coil inserting tool 8T2745 (2299-10) 5. Top of insert to be 1.25 mm (0.05 in) below face of flange

1 2

5

November 1998 LEVN4533 Page 103

3400 - 2 piece Piston Skirt Cracks 4 Another example of 3400 2-piece piston skirt cracks resulting

from impact damage to the crown Hairline Crack

Piston Pin Bore

November 1998 LEVN4533 Page 104

Electronic Controls Part Number Reference

November 1998 LEVN4533 Page 105

Serial Number Prefixes – 3116/3126 4 1WM 3126 HEUI n

1995 to Current

4 8WL 3116 HEUI n

4

1995 to Current

7AS 3126B n

1998

November 1998 LEVN4533 Page 106

Serial Number Prefixes C-10, C-12 & 3176 4

2YG 3176 n

4 4

4

November 1998 to Current

2KS C12 n

November 1998 to Current

May 1993 to March 1995 March 1995 to September 1997 September 1997 to November 1998

1YN C-12 n

4

n

8YS C-10 n

4

3CS C10

2PN C-10 n

4

1991 to December 1993

9CK 3176B n

4

1988 to 1990

7LG 3176 n

4

March 1995 to September 1997

9NS C-12 n

September 1997 to November 1998

November 1998 LEVN4533 Page 107

Serial Number Prefixes - 3406 4

8TC PEEC II and PEEC II.V n

4 4

n

4

August 1991 to December 1993

5DS 3406E 15.8L n

4

December 1997 - November 1998

2WS 3406E 14.6L n

4

December 1997 - November 1998

November 1998 to Current

1MM 3406E 15.8L n

November 1998 to Current

5EK 3406E n

4

4

1991

4CK 3406C Electronic

1LW3406E 14.6L n

1990

2EK PEEC II and PEEC II.V n

4

1987 to 1990

5YG PEEC II - 460Hp Only n

4

May 1993 to December 1996

6TS 3406E n

January 1997 to December 1997

November 1998 LEVN4533 Page 108

3126B Electronic Control and Sensors 4ECM (Full Feature) 157-3708

(Basic) 149-6989

4Coolant temperature Sensor - 130-9811 4Inlet Manifold temperature Sensor - 130-9811 4Speed/Timing Sensors - 119-4142 4Atmospheric Pressure Sensor - 141-4119 4Boost Pressure Sensor - 149-7511 4Injection Actuation Pressure Sensor - 141-4122 4Pedal Position Sensor - 3E7700 4Injector Wiring Harness - 153-8920 4Wire Router - 126-1774

November 1998 LEVN4533 Page 109

3116 HEUI & 3126 HEUI — Electronic Parts 4 3116 HEUI - 8WL and 3126 HEUI - 1WM n

ECM – 145-7807 n n n

n

Speed/Timing Sensor Service Kit – 119-4142 n

n

n n

Requires 108-5803 Seal

Injection Actuation Pressure Control Valve – 122-5053 n

n

Male/Male Adapter – 9X0262 & 3J7354 – Seal

Injection Actuation Pressure Sensor – 140-3540 n

n

Requires 3K0360 Seal

Boost Pressure Sensor – 111-2351 n

n

Requires 3K0360 Seal

Coolant Temperature Sensor – 106-0735 n

n

Includes 117-1385 O-Ring Seals

Inlet Air Temperature Sensor – 107-8618 n

n

ECM Connector Bolt Kit – 6V6703 40 Pin Plug Assembly – 114-4408 (includes 110-6844 Seal) 40 Pin Connector Seal – 110-6844

Seal Kit 9X1484

Throttle Position Sensor – 3E7700 Fuel Transfer Pump to Hydraulic Pump O-Ring – 004-1963 Hydraulic Pump Dome O-Ring – 6V5656 November 1998 LEVN4533 Page 110

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

n

n

122-8840 Service Replacement Harness n

n

40 pin to Speed/Timing Sensor

122-8842 Service Replacement Harness n

n

40 pin to Injectors

40 pin to IAPCV

122-8839 Service Replacement Harness n

40 pin to all other sensors

141-7060 Injector Wiring Harness Connector Repair Kit n 143-8325 Injection Actuation Pressure Sensor Guard n

November 1998 LEVN4533 Page 111

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) - 145-7806 n

n

ECM with J1939 Data Link Option - 145-7805

Speed/Timing Sensor n

3406E — 129-6628 Sensor n

n

n n n n n n

126-8481 Shim (0.020”)

C-10, C-12 & 3176B — 129-6628 Sensor No Shim

Coolant/Fuel Temperature Sensor - 102-2240 Air Inlet Temperature Sensor - 107-8618 Boost Sensor - 111-2351 Atmospheric Pressure Sensor 150-7673 Oil Pressure Sensor - 111-2350 Pedal Mounted Throttle Position Sensor - 3E7700

November 1998 LEVN4533 Page 112

3176 —2YG Current Parts 4 3176 - 2YG n

ECM - 9X9529 0R6149 n

ECM FORD - 9X9528 / 0R6148

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

n

n

Remote Mounted Throttle Position Sensor - FORD - 9X9648

Pedal Mounted Throttle Position Sensor - 110-8190

November 1998 LEVN4533 Page 113

C-10, C-12 & 3406E ‘99 Model Year Current Parts 4 C-10 - 3CS, C-12 - 2KS, & 3406E - 2WS (14L) & 1MM (16L)

Electronic Control Module (ECM) - 157-3705 n Speed/Timing Sensor n

n n n

C-10, C12 Cam Sensor - 160-0029 3406E Cam Sensor - 160-0030 C-10, C-12 & 3406E Crank Sensor - 160-0028

Coolant/Fuel/Inlet Air Manifold Temperature Sensor - 130-9811 n Boost Pressure Sensor - 161-9929 n Atmospheric Pressure Sensor 161-9925 n Oil Pressure Sensor - 161-9931 n Pedal Mounted Throttle Position Sensor n

n n

Long Pig Tail - 3E-7700 Short Pig Tail - 121-0231 November 1998 LEVN4533 Page 114

3176 — 7LG Current Parts 4 3176 7LG ECM - 3E5293 / 0R6302 n Transducer Module - 9X8226 / 0R6132 n

n

Altitude Retrofit - 3E8644 / 0R6470

Speed Timing Sensor - 102-9029 n Oil Pressure Sensor n

n n

n

“DT” Connector 7LG08721 and Up — 111-2350 “HD” Connector 7LG07500 to 7LG08720 — 107-7142

Coolant / Inlet Air Temperature Sensors n n

Full Range - 7LG07500 and Up — 102-2240 Limited Rage - 7LG00001 to 7LG07499 — 9X5370

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

n

n

Remote Mounted Throttle Position Sensor - FORD - 9X9648

Pedal Mounted Throttle Position Sensor - 110-8190 November 1998 LEVN4533 Page 115

3406C Electronic Current Parts 4 3406C - 4CK ECM - 9X8085 / 0R6486 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 Pedal Mounted Throttle Position Sensor - 110-8190 n

n

Remote Mounted Oil Pressure Sensor Kit - 118-6256

November 1998 LEVN4533 Page 116

PEEC II.V Current Parts 4 PEEC - 8TC and 2EK - FORD Only ECM - 9X4840 / 0R6081 n Transducer Module - 132-4363 n Speed Sensor - 100-6619 n Rack Sensor - 9X7793 n Timing Sensor - 129-4501 n BTM - 105-2939 n Throttle Position Sensor n

n n

Remote Mounted “Beer Can� Sensor - 9X9648 Pedal Mounted Throttle Position Sensor - 110-8190

Remote Mounted Oil Pressure Sensor Kit - 122-1649 n If the engine (2EK and 5YG) has had the White Smoke Product Support Program performed. The following parts will be installed: n

n n

6I2382 - Wiring Harness 9X5370 - Temperature November 1998 LEVN4533 Page 117

PEEC II Current Parts 4 PEEC II - 8TC, 5YG and 2EK ECM - 8T8770 / 0R5607 n Transducer Module - 132-4363 n Speed Sensor - 100-6620 n Rack Sensor - 9X7793 n Timing Sensor - 129-4501 n BTM - 105-2939 n Throttle Position Sensor n

n n

Remote Mounted “Beer Can� Sensor - 9X9647 Pedal Mounted Throttle Position Sensor - 110-8190

Remote Mounted Oil Pressure Sensor Kit - 122-1649 n If the engine (2EK and 5YG) has had the White Smoke Product Support Program performed. The following parts will be installed: n

n n

6I2382 - Wiring Harness 9X5370 - Temperature November 1998 LEVN4533 Page 118

Binder Labels 4 Labels for Standard Cat Binder (SENR2910) are available for

your Tech Tips Handouts SENR5100 - 1998 Truck n SENR5101 - 1998 Cat Machine Engines Commercial Engines n

November 1998 LEVN4533 Page 119

Broadcast Information 4 Update Broadcast Information n LEVN4284 - “Tech Tips” Broadcast - Feb. 11, 1998 n LEVN4384 - “Tech Tips” Broadcast - May 13, 1998 n LEVN4453 - “Tech Tips” Broadcast - August 12, 1998 n LEVN4533 - “Tech Tips” Broadcast - November 11, 1998 4 Broadcast Schedule for 1999 n Feb 10 n May 12 n Aug 11 n Nov 10

November 1998 LEVN4533 Page 120