Tech Tips 09 Mayo 2001

May 2001 - LEVN4999Page 1

Tech TipsMay 9, 2001

10:00AM Central Daylight Time

Appendix A

TECH TIPS PROGRAM EVALUATIONMay 9, 2001

Please complete and return immediately after the show to:Caterpillar Inc.; ATTN: Teri Matarelli; 100 N.E. Adams Street; Peoria, IL 61629-2230OR FAX TO: (309) 675-1796.

1.The information presented during the broadcast will make me:

No MoreChange Effective

A. Iron o o o o o

B. Fuels o o o o o

C. Engine Service Training o o o o o

D. Electronic Troubleshooting o o o o o

E. Service Tools o o o o o

F. Caterpillar Pocket Technician™ o o o o o

2. The handouts were of sufficient detail and easily understood? oYes oNo3. If you answered "No" to #2, what improvements would you like to see? ___________ __

____________________________________________________________________________________________________________________________________________

4. I have: o less than 1 year; o 1-5 years; o 6-10 years; o 11 or more years;experience working on Caterpillar engines. (check one)

5. I watched the Tech Tips broadcast: o Live "or" o On Video Tape6. The mid-broadcast break was: o Too Short; o Just Right; o Too Long.7. Will you watch again? o Yes o No

Please write Legibly!!

8. Comments: _________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

9. Quick Tips: _________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Name ________________________________ Title_______________________________

Dealership ____________________________ Location ___________________________

City _______________________ State/Prov. ____________________ Country ________


IndexMECHANICAL

IRON3126 Pushrods 43126E Catalytic Converter / Muffler Troubleshooting 63126E Flywheel Housing Failures 7C-10/C-12/C-15/C-16 Front Engine Accessory Drive 8C-10/C-12 Turbo Supply / Drain Lines 9C-10/C-12 Head Gasket Repair Procedure 11

Where Does the Torque Go? 12Effects of Thread Lubricants 13Effects of Debris In Threads 14Clamping Force In Joint Using Torque Only 15Using Single Torque-Turn Procedure 16Using Double Torque-Turn Procedure 17Fire Ring & Fluid Sealing Load Distribution 18C-10/C-12 Truck Engine - Engine Oil SOS 19Cylinder Head Gasket 20Heli-Coil Installation 21Review 22Keepin’ In Touch 24

FUELSBiodiesel 26

ENGINE SERVICE TRAININGHeavy Duty Truck Technician Program Update 32Engine Instructor Re-Certification Summary 33LEXT1044 Engine Performance Reference 33Truck PAR Grams 34Truck PAR Technician Re-Certification 34Engine Diagnostics Course Update 35

Q&A I

ELECTRONICS

TROUBLESHOOTINGApril01 3126 Software Release 39Speed / Timing Sensor Kits 41Dash Lamps Not Illuminating 42

SERVICE TOOLSCaterpillar Electronic Technician 2001A 46

Menu Location Changes 47Trainer 49“What’s New” 50On-Line Licensing 51Readme.txt 53

PC Software Support Hotline 54Licensing CAT ET 55

CATERPILLAR POCKET TECHNICIAN™Kit Numbers 57Which Palm Do I Buy? 58What Can I Do With Pocket Tec™ 59Pocket Tec™ Driver Version 60Buystuff 61

Q&A IIBinder Labels 63Broadcast Information 64Keepin’ In Touch 65Electronic Controls Part # Reference 66

APPENDIXESAppendix A - Show Evaluation


IRON


3126B Pushrods

4 Effective serial number range (8YL39000-56000)4 Less than 30,000 miles4 TIB Published March 7, 20014 Key factors:

n Valve Lash > 0.010”n Rocker mechanism noise complaintn Single cylinder missing

4 Reminder…. Inititial Valve Lash (WHICHEVERCOMES FIRST)

n Deep Sumpn 15,000 Miles/1500 Gal/400Hr/6Months

n Shallow Sump w/22Qtsn 11,000 Miles/1100Gal/250Hr/6Months


3126B Pushrods

Acceptable Wear Burnishing on entire ball end

Unacceptable Wear Grooves in ball end and material displaced

Acceptable Wear burnishing only on tip of ball end


3126E Catalytic Converter/MufflerTroubleshooting

4 Recall….CKM serial number engines are equipped withcatalytic converter/mufflers and the maximum allowabletotal exhaust system backpressure is 60” H2O.

4 Refer to “System Operation, Testing and Adjusting,RENR1271, “Air Inlet and Exhaust System Inspect” forbackpressure test procedure.

4 If customer is complaining of low power/performanceand converter/muffler is suspected to be the problem:

n Drive vehicle under load for 5-15 minutes to “clean out”converter/muffler

n Install exhaust tap and measure BP @ high idle (if necessary)n Call TECC toll free 800-447-4986 if BP exceeds maximum allowable total

exhaust system backpressure spec for further instructions.


3126E Flywheel Housing Failures

4 Reported cases of flywheel housings cracking on3126E engines in single axle, single drive shaft,tractor type vehicle applications.

4 Drive shafts should be checked for balance in failedunits.

4 Any units that have failed flywheel housings in thepast fitting the above description should have thedrive shafts checked to avoid repeat failures.

4 Get appropriate TEPS dealers/OEM Reps involved ifdrive shaft imbalance has proven to be root causeof failure.


Front Engine Accessory DriveTensioner Improvements for C-10/C-12/C-15/C-16

4 New Tensioner 190-0649 available4 Increased Bushing Area - results in

improved belt alignment/durability4 Reduced Spring centerline offset- results in

improved belt alignment/durability4 Direct bolt-in Replacement for 135-2142 &

148-19744 In Effect Feb 2001 - 2KS64385 (C-12),

3CS19785 (C-10), 6NZ42696 (C-15),7CZ02166 (C-16)


C-10/C-12 Turbo Supply/Drain Lines

4 Improvements to C-10/C-12turbo oil supply and drain linesealing system

4 Longer Bolt and spacerfor increased Bolt Stretch.

4 New Gasket Material available4 For Use on Field Repairs4 In Effect Feb 2001 on

Production C-10/C-12 units


C-10/C-12 Turbo Supply/Drain Lines

8H-9788188-6126(1) 4K-5824 (1) 9G-8661Supply

(2) 9G-8661 Drain

(4) 8T-0276143-0820153-9049163-6094165-0592

C-12

8H-9788188-6126(4) 6H-7127(4) 6V-5218115-9377C-12

8H-9788188-6126(1) 4K-5824 (1) 9G-8661Supply

(2) 9G-8661 Drain

(4) 8T-0276143-0819 153-7057187-3325

C-10

8H-9788188-6126(1) 4K-5824 (1) 9G-8661Supply ONLY

(2) 8T-0276 Supply136-4324C-10

SupplyGasket

DrainGasket

New SpacersNew BoltsTurboLines Gp

EngineModel

Part Numbers for Field Repair of C-10 / C-12Turbo Supply and Drain Lines


C-10/C-12 HeadGasket Repair

Procedure

April 2001LEVN5101


Where Does The Torque Go?

Torque 45% Underhead Friction

10% Bolt Stretch

45%

ThreadFriction


Effects Of Thread Lubricants

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

6V4876 MolycotePaste

4C5599 HighTemperature Anti-

Seize

Engine Oil No Lube on Washerand Bolt Head

Dry Threads

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

% C

lam

ping

For

ce


Effects Of Debris In Threads

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

6V4876 Molycote Paste Debris In Threads W/6V4876 Molycote Paste

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

% C

lam

ping

For

ce

30%

50%


30%

40%

50%

60%

70%

80%

90%

100%

110%

120%

130%

140%

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)

Clamping Force In Joint UsingTorque Only

% C

lam

ping

For

ce

Baseline

49%


30%

40%

50%

60%

70%

80%

90%

100%

110%

120%

130%

140%

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

Using Single Torque-Turn Procedure160 N-m (120 Ft-lbs), 160 N-m (120 Ft-lbs) Plus 90 Deg Turn

Baseline

% C

lam

ping

For

ce

21%


30%

40%

50%

60%

70%

80%

90%

100%

110%

120%

130%

140%

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

Using Double Torque-Turn Procedure160 N-m (120 Ft-lbs), 160 N-m (120 Ft-lbs) Plus 90 Deg Turn, LOOSEN BOLTSAPPLY 160 N-m (120 Ft-lbs), 160 N-m (120 Ft-lbs) Plus 90 Deg Turn

% C

lam

ping

For

ce

Baseline

21%


0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

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

BOLT LOAD

JOIN

T L

OA

D

1st Torque-TurnFluid Sealing Load

2nd Torque-TurnFluid Sealing Load

1st Torque-TurnFire Ring Load

2nd Torque-TurnFire Ring Load

Fire Ring And Fluid Sealing LoadDistribution

25%


- 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.

C-10/C-12 Truck EngineUsing Engine Oil SOS results to Diagnose Coolant Leak

100

150

200

250

PP

M -

Na

(So

diu

m) o

r K

(Po

tass

ium

)

10,000200

1,670

15,000300

2,500

20,000400

3,300

25,000500

4,170

MilesHoursGallons of Fuel

Investigate

OK

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


Cylinder Head Gasket

Cylinder Head Configuration

Straight Scalloped

Straight 187-3307 187-3306B

lock

Con

figur

atio

n

Scalloped 187-3306 187-3306


Heli-Coil Installation

4 Drill hole using an 1U5686 (21/64) drill4 Tap hole using 4C9732 tap4 Use 8T2799 installation tool4 Install 9U5604 Heil-Coil insert

n Note: Special 32mm Grip Length


Review

4 Determine cause of coolant leak4 Determine the correct head gasket part number

n Reference: Truck Engine News December 2000

4 Clean all 26 bolt holes with 8T3096 (M16x2) tap4 Vacuum all debris from bolt holes4 Visually inspect bolts for damage

n Heli-Coil damaged bolt holes

4 Check cylinder head and block flatness4 Properly Lube Bolt Threads, Underside of Bolt

Head, and Washers with 6V-4876 Molycote4 Tighten Bolts 1- 26 in numerical sequence to

160 ±15 N-m (120 ± 11 Ft-lb)


Review

4 Tighten Bolts 1- 26 Again, in numerical sequence to160 ± 15 N-m (120 ± 11 Ft-lb).

4 Turn each bolt 90° (¼ turn)4 Loosen Bolts # 1- 26

n Washers should be loose under bolt head

4 Tighten Bolts 1- 26 in numerical sequence to160 ± 15 N-m (120 ± 11 Ft-lb)

4 Tighten Bolts 1- 26 Again, in numerical sequence to160 ± 15 N-m (120 ± 11 Ft-lb).

4 Turn each bolt 90° (¼ turn)4 Tighten bolts # 27 - 33 in numerical sequence to

28 ± 7 N-m (20 ± 5 Ft-lb) Torque


Keepin’ In Touch

4 Gene Lindern Phone: (309) 578-4770n Fax: (309) 578-2673n E-Mail: [email protected]

or [email protected] Truck Engine Call Center (TECC) (800) 447-4986


Fuels


Biodiesel

4 IRMn Caterpillar Position on the Use of Biodiesel Fuel

n Literature Numbern PELE0805

4 Biodieseln Soybean Oil, Rapeseed Oiln Waste Cooking Oiln Must be esterified


Biodiesel

4 Must meet One of the following specificationsn Caterpillar Biofuel Specificationn ASTM PS121n DIN 51606


Biodiesel

4 Important Considerationsn Oil Change Interval

n SOSn Less Energy

n Do Not change the rating to compensaten Monitor hoses and sealsn Storage

n Low ambient Temperaturesn Filter pluggingn Blending

n Oxidationn Additive

n Microbial Growthn Filter Pluggingn Water in fuel accelerates growth


Biodiesel

4 User is Responsiblen EPA Compliancen Local regulationsn Proper exemptions

4 Failures resulting from the use of any fuel are notCaterpillar factory defects

n Not covered by Caterpillar Warranty


Engine ServiceTraining


Engine Service Training Topics

4 Heavy Duty Truck Technician Program Update4 Engine Instructor Re-Certification Summary4 LEXT1044 Engine Performance Reference4 Truck PAR Grams4 Truck PAR Technician Re-Certification4 Engine Diagnostics Course Update


Engine Service Training

4 Heavy Duty Truck Technician Program Updaten Numbers of Technicians Certified by Caterpillar:

n Only 250 were certified as of mid-Februaryn Now 500 Technicians have passed the on-line Certified Service Exam

n Certified Techs will receive a brass Medallion or Belt Bucklen Please promote this Program through your organizationsn Core Work book LEXV0193-01 is great for getting started

n Booklet explains nomination, pre-work and exam process

n If there are questions, contacts are:n Cyndie Anderson (309) 578-9827n Todd Roth (309) 494-5783n Ray Lott (309) 494-5994n Larry Wood (309) 494-5898



4 Engine Instructor Re-Certification Summaryn The Re-Certification of all Engine Instructors is Now Completen 110 Engine Instructors have completed re-certificationn 22 instructors scored a perfect 100% on the 40 question test!n Certification labels and a Laser Pointer are being mailedn Many thanks to all the Instructors for your continued service and

commitment to the engine products and service requirements.

4 LEXT1044 Engine Performance Referencen This 15 page reference provides the latest: Useful Formulas, Fuel

Density Chart, Performance Tolerances, Diesel Fuel API GravityCorrection Chart and Horsepower Correction Factors. This is agreat reference to use in the classroom or to keep in your toolbox.



4 Truck PAR Gramsn PAR Contacts: Ray Lott & Stan Preston in Engine Trainingn There have not been any PAR grams sent for a while. Engine

Training maintains a database of the active PAR Technicians andPAR Instructors and will be sending new PAR grams and otherinformation out again very soon.

4 Truck PAR Technician Re-Certificationn Truck PAR Technician Re-Certification will start this summern Packets will be mailed to your Cat Dealer PAR contact soonn Truck PAR technician re-certification now will be every two yearsn Technicians will be allowed to take the test one time onlyn More details will be included in the upcoming mailing packets



4 Engine Diagnostics Course Updaten Engine Diagnostics course is being updatedn Expected to be in the literature system around Junen Will be Available in two medias:

n CD ROM in Adobe and PowerPoint formatsn 2” by 2” Slide form with Instructor Book

n The update will be published in Pre-viewn An E-mail will go out to Engine Instructors when it is available


Q&A


ELECTRONICS


ElectronicTroubleshooting


APR01 3126 Software Release

4 3126 Parts Service Releasen Engine Serial # 7ASn Key Features

n Engine Running Outputn Progressive Shift Intermediate Gears Problem Fixn Elevated Idle on Low Battery Voltage


APR01 3126 Software Release

4 Engine Running Outputn High-side output (J1/P1:13) is activated when engine speed is

above 600 RPM, and deactivated when engine speed drops below100 RPM

n Output controls relay to interrupt power to the starter motor toprevent cranking when engine is running.

4 Progressive Shift Problem Fixn Intermediate Gears of Progressive Shift now functional

4 Elevated Idle on Low Battery Voltagen Feature elevates engine idle rpm when battery voltage drops below

a programmed value to maintain battery charge.


Speed/Timing Sensor Kits

4 Speed Timing Sensor Kit Installationn Be sure to install butt-splice pigtail if included in kitn Be sure polarity of pigtail is correct

4 22-11 Cam Sensor to Crank Sensor Faultn If 22-11 fault becomes active after installing kit, check polarity of

connectionn Incorrect polarity of Speed/Timing sensor(s) can result in 22-11

fault, and inability to perform Timing Calibration


4 Engines affected:n C-10, C-12, C-15, C-16 and 3406E engines with OCT00 or NOV00

software

4 Low Oil Pressure and High Coolant TemperatureLamps may not function if:

n Engine Monitoring Lamps parameter is programmed to Option 1AND the PTO Configuration parameter is programmed before theEngine Monitoring Lamps parameter.

Dash Lamps Not Illuminating


Dash Lamps Not Illuminating

4 Perform the following steps Exactly to fix problem:n Program PTO Configuration parameter to “OFF”n Program Engine Monitoring Lamps parameter to “Warning Lamp”n Wait 5-10 secondsn Program Engine Monitoring Lamps parameter back to “Option 1”n Program PTO Configuration parameter back to desired setting.


ElectronicService Tools


Caterpillar ElectronicTechnician


Caterpillar Electronic TechnicianVersion 2001A4 Scheduled for delivery May 20014 Version name change (year of release)

n 2001A (Spring version)n 2001B (Fall version)

4 Release Information Topics:n Menu location changesn Access the Comm Adapter II Toolkitn Trainer offers C-9 Industrial Enginesn “What’s New” Listn Licensing on the webn Be sure to read “readme.txt”


Formerly under theData Link drop-down menu.

Formerly underthe Settingsdrop-down menu.

To change thesize of the iconson the toolbar

To customizethe toolbar andfunction keys

Caterpillar ET 2001AMenu location changes4 File drop-down menu:

n Connect or Disconnect from CatET

n Switch Data Linksn Select a different ECM

4 View drop-down menu:n Customize the Toolbar and

Function Keys


4 Utilities drop-down menu:

n Change Preferences

n License ET

Caterpillar ET 2001AMenu location changes (cont.)

n Access the Comm Adapter II Toolkitdialog box (if installed)Formerly under

the Settingsdrop-down menu.

New in Cat ET2001A.


Caterpillar ET 2001ATrainer4 C-9 Engine


Caterpillar ET 2001A“What’s New”4 “What’s New” option

n Views a list of new functions and major enhancements


hyperlinkNote: You must have atleast IE version 5.0 oror Netscape version 4.5for proper weblicensing.

Caterpillar ET 2001AOn-line Licensing4 Licensing of Cat ET will soon be available on the

internetn Select “License ET” from the Utilities drop down

n Select the hyperlink


Enter Logon ID andPassword into thetext boxes. Press“Login.”

Press the “License” push-button.Then, follow the instructions onhow to license your service tool.

Caterpillar ET 2001AOnline Licensing (cont.)

n Your internet browser displaysthe Corporate Security Webpage.

n The Service System SoftwareOnline Licensing screendisplays.


Caterpillar ET 2001AReadme.txt4 Readme.txt contains

important release notesabout Cat ET 2001A

n Hardware Requirement Changes

n Windows 2000 User PermissionIssues

n Caterpillar CommunicationAdapter II Installationinformation


PC Software Support Hotline

4 Service Systems Support Center

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

Fax: (309) 636-5823

E-mail: [email protected] orSSSC (Caterpillar Host e-mail)

Serv Sys Support Ctr (Lotus Notes)

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


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: [email protected] ormedial (Caterpillar Host E-mail)

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


Caterpillar PocketTechnician


Pocket Tec™

4 Kit Numbersn EEKE4006 = Software/Adapter/6-pin Cable/Manualn EEKE4009 = Software/Adapter/9-pin Cable/Manualn EEKE4096 = Software/Adapter/ 6 and 9 Pin Cables/Manualn EEKE4001 = Software/Adapter/GM Cable/Manual

EEKE4009 Kit


Which Palm™ Do I Buy?

4 Any III family4 V family needs adapter

n palmdock.com

4 Any VII family4 Does NOT work currently

withn M100 Familyn M500 Family


4 Configurationn Read & Change

4 Status4 Diagnostics4 Totals

n Lifetimen Trip

4 Maintenance4 Theft Deterrent

What Can I Do With Pocket Tec™?


Access these Programmable Parameters

Rating Number - readVehicle ID - readEngine Retarder Mode - readEngine Retarder Min VSL Type - readEngine Retarder Min Vehicle Speed - readAuto Retarder in Cruise - readAuto Retarder in Cruise Inc - readSoftCruise Control – read and changeIdle/PTO RPM Ramp Rate – read and changeIdle/PTO Bump RPM – read and changeLow Idle Engine RPM – read and changeFan with Engine Retarder-High Mode – read and changeEngine Retarder Delay – read and change, lockableBattery Monitor-Engine Control Voltage – read and changeMaintenance Indicator Mode – read and changePM1 Interval – read and changeEngine Oil Capacity - readFuel Correction Factor - readDash – PM1 Reset – read and changeTheft Deterrent System Control – read and changeQuick Stop Rate - readEngine Serial Number – readECM Software Module P/N - readECM Software Module Release - read

View these Status Parameters

Accelerator Pedal PositionBoost PressureCoolant LevelCruise KickoutCruise ModeCruise Set SpeedDriver Reward VSL BonusECM Battery VoltageECM Serial NumberEngine Coolant TempEngine Load FactorEngine Oil PressureEngine Speed – ActualEngine Speed - DesiredEstimated Fuel RateFuel EconomyFuel TempIntake (Manifold) Air TempOutside Air TempStarting Aid OutputVehicle SpeedVehicle Speed Limit

View and Save these Lifetime Totals

Fuel Economy (mpg)Distance TraveledAverage SpeedFuel ConsumedRunning TimePTO Fuel ConsumedPTO TimeIdle Fuel ConsumedIdle TimeLoad Factor% Idle

View and Save this Trip Total Information

Driver IDFuel Economy (mpg)Distance TraveledAverage SpeedFuel ConsumedRunning TimePTO Fuel ConsumedPTO TimeIdle Fuel ConsumedIdle Time% Idle

Pocket Tec™ Driver VersionParameters/Features


Buystuff

4 http://www.cattruckengines.com/buystuff4 Palm Software4 Chrome Parts4 and more…

4 On Line Now!


Q&A


2001 Binder

4 The binder this year is a three ring binder withdividers - one for each show.

4 Has slotting to hold all four video tapes4 Form # LEKQ5055


Broadcast Information

4 Update Broadcast Videosn LEVN4715 - “Tech Tips” Broadcast - August 11, 1999n LEVN4738 - “Tech Tips” Broadcast - November 10, 1999n LEVN4808 - “Tech Tips” Broadcast - February 9, 2000n LEVN4809 - “Tech Tips” Broadcast - May 10, 2000n LEVN4810 - “Tech Tips” Broadcast - August 9,2000n LEVN4811 - “Tech Tips” Broadcast - November 8, 2000n LEVN4998 - “Tech Tips” Broadcast - February 14, 2001n LEVN4999 - “Tech Tips” Broadcast - May 9, 2001

nn LEVN3947- Yearly Subscription to Tech TipsLEVN3947- Yearly Subscription to Tech Tips

4 Broadcast Schedule for 2001n August 8n Nov 14


Keepin’ In Touch

EmailCaterpillar E-Mail

TECHTIPSInternet E-Mail

[email protected]

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


Electronic ControlsPart Number Reference


Latest Truck Engine Electronic Troubleshooting Guides:

Form Number Booklet Description Serial Number Prefixes

RENR2238-02 C-10,C-12 & 3406E 1MM,2KS,2WS,3CS, 6NZ, 7CZRENR1328-02 C-10,C-12 & 3406E 5DS,8YS,9NS,1LWSENR5582-06 3176B,C-10,C-12 & 3406E 5EK,9CK,1YN,2PN,6TSSENR5503-00 3406C (PEEC III) 4CKSENR3479-05 3406B (PEEC II) 2EK,5YG,8TCSENR3913-04 3176 Truck Engine 2YGSENR5112-01 3176 Truck Engine 7LGRENR1367-01 3126B Truck Engine 7AS, 8YL, 8SZSENR6566-03 3100 HEUI Truck Engine 8WL,1WM,4ES,2CW, 8HW, 7LZ

Troubleshooting Guide Listing


The guidelines for HD Truck FLS/FTS changes for Re-Rates are as follows:1. FLS/FTS SHOULD be changed to values listed in JTZ101-02 FLS/FTS LOOKUP FOR RATING CHGS screen for 3406E or GKN401-06 ENGINE TEST SPEC screen for 3176B, C-10, C-12 when: Engine is rerated outside the current rating family. Since rerating outside the current rating 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 performance spec on the ET configuration screen. If you are rerating to a multi-torque rating, be sure to use the FLS/FTS values for the 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)

Heavy Duty Truck Engine FLS/FTSAdjustment Policy


Serial Number Prefixes – 3116/3126

4 1WM 3126 HEUIn 1995 to Current

4 8WL 3116 HEUIn 1995 to Current

4 7AS 3126Bn 1998 thru July 31, 1999

4 8YLn July 1999 to December 2000

4 9SZn December 2000 to Current

4 8SZn 1998 thru July 31, 1999 - Short Eng Version

4 CKMn March 2001 to Current (Catalytic Converter / Muffler)


Serial Number PrefixesC-10, C-12 & 3176

4 2YG 3176n 1988 to 1990

4 7LG 3176n 1991 to December 1993

4 9CK 3176Bn May 1993 to March 1995

4 2PN C-10n March 1995 to September 1997

4 8YS C-10n September 1997 to November 1998

4 1YN C-12n March 1995 to September 1997

4 9NS C-12n September 1997 to November 1998

4 3CS C-10n November 1998 to Current

4 2KS C-12n November 1998 to Current


Serial Number Prefixes - 34064 8TC PEEC II and PEEC II.V

n 1987 to 1990

4 5YG PEEC II - 460Hp Onlyn 1990

4 2EK PEEC II and PEEC II.Vn 1991

4 4CK 3406C Electronicn August 1991 to December 1993

4 5EK 3406En May 1993 to December 1996

4 6TS 3406En January 1997 to December 1997

4 1LW 3406E 14.6Ln December 1997 - November 1998

4 5DS 3406E 15.8Ln December 1997 - November 1998

4 2WS 3406E 14.6Ln November 1998 to Current

4 1MM 3406E 15.8Ln November 1998 to Current

4 6NZ C-15n November 1999 to Current

4 7CZ C-16n November 1999 to Current


3126E Electronic Control andSensors

4 ECM (3126E Basic & Full Feature) 179-48984 Coolant temperature Sensor - 130-9811 O-Ring Seal 6V66094 Inlet Manifold temperature Sensor - 130-9811 O-Ring Seal 8L27864 Speed/Timing Sensors - 119-4142 O-Ring Seal 117-13854 Atmospheric Pressure Sensor - 161-9925 O-Ring Seal 6V50494 Boost Pressure Sensor - 161-9928 O-Ring Seal 3J73544 Injection Actuation Pressure Sensor - 167-1708 O-Ring Seal

1J96714 Pedal Position Sensor - 176-16024 Injector Wiring Harness - 153-89204 Wire Router - 126-1774


3116 HEUI & 3126 HEUI —Electronic Parts

4 3116 HEUI - 8WL and 3126 HEUI - 1WMn ECM – 145-7807

n ECM Connector Bolt Kit – 6V6703n 40 Pin Plug Assembly – 114-4408 (includes 110-6844 Seal)n 40 Pin Connector Seal – 110-6844

n Speed/Timing Sensor Service Kit – 119-4142n Includes 117-1385 O-Ring Seals

n Inlet Air Temperature Sensor – 107-8618n Requires 3K0360 Seal

n Coolant Temperature Sensor – 106-0735n Requires 3K0360 Seal

n Boost Pressure Sensor – 161-9927n Male/Male Adapter – 9X0262 & 3J7354 – Seal

n Injection Actuation Pressure Sensor – 140-3540n Requires 108-5803 Seal

n Injection Actuation Pressure Control Valve – 122-5053n Seal Kit 9X1484

n Throttle Position Sensor – 176-1602n Fuel Transfer Pump to Hydraulic Pump O-Ring – 004-1963n Hydraulic Pump Dome O-Ring – 6V5656


Other 3116 HEUI & 3126 HEUI Parts

4 Part Numbers missing for Parts Books (3116 HEUI – SEBP2271and 3126 HEUI SEBP2355)

n 123-1199 Seal for Injector and IAPCV Connectorsn 118-8622 Service Replacement Harness

n 40 pin to Injectorsn 122-8840 Service Replacement Harness

n 40 pin to Speed/Timing Sensorn 122-8842 Service Replacement Harness

n 40 pin to IAPCVn 122-8839 Service Replacement Harness

n 40 pin to all other sensorsn 141-7060 Injector Wiring Harness Connector Repair Kitn 143-8325 Injection Actuation Pressure Sensor Guard


C-10 - 2PN & 8YS, C-12 - 1YN & 9NS, 3176B - 9CK & 3406E - 5EK & 6TS,1LW, 5DS

Electronic Control Module (ECM) - 145-7806ECM with J1939 Data Link Option - 145-7805

Speed/Timing Sensor3406E — 129-6628 Sensor

126-8481 Shim (0.020”)C-10, C-12 & 3176B — 129-6628 Sensor No Shim

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

C-10, C-12, 3176B & 3406E Pre-’99Current Parts


3176 —2YG Current Parts

4 3176 - 2YGn ECM - 9X9529 0R6149

n ECM FORD - 9X9528 / 0R6148n Transducer module - 9X8226 / 0R6132n Harness - 7E8421n Speed/Timing Sensor - 102-9029n Fuel Pressure Sensor - 107-7142n Coolant Temperature Sensor - 9X5370n Vehicle Speed Buffer - 3E0020n Remote Mounted Throttle position Sensor - 9X9647

n Remote Mounted Throttle Position Sensor - FORD - 9X9648n Pedal Mounted Throttle Position Sensor - 110-8190


C-10 - 3CS, C-12 - 2KS, & 3406E - 2WS (14L) & 1MM (16L)Electronic Control Module (ECM) - 179-1747Speed/Timing Sensor

C-10, C12 Cam Sensor - Repair Kit: 194-53403406E, C-15, C-16 Cam Sensor - Repair Kit: 194-5341C-10, C-12 & 3406E Crank Sensor - Repair Kit: 194-53383406E, C-15, C-16 Crank Sensor - Repair Kit: 194-5339

Coolant/Fuel/Inlet Air Manifold Temperature Sensor - 130-9811

Boost Pressure Sensor - 161-9929Atmospheric Pressure Sensor 161-9925Oil Pressure Sensor - 161-9931Pedal Mounted Throttle Position Sensor

Long Pig Tail - 176-1602Short Pig Tail - 176-1604

C-10, C-12 & 3406E ‘99 Model YearAnd Up Current Parts


C-10 - 2PN & 8YS, C-12 - 1YN & 9NS, 3176B - 9CK & 3406E - 5EK& 6TS, 1LW, 5DS

Electronic Control Module (ECM) - 145-7806ECM with J1939 Data Link Option - 145-7805

Speed/Timing Sensor3406E — 129-6628 Sensor

126-8481 Shim (0.020”)C-10, C-12 & 3176B — 129-6628 Sensor No Shim

Coolant/Fuel Temperature Sensor - 102-2240Air Inlet Temperature Sensor - 107-8618Boost Sensor - 161-9927Atmospheric Pressure Sensor 111-8125Oil Pressure Sensor - 161-9930Pedal Mounted Throttle Position Sensor - 176-1602

C-10, C-12, 3176B & 3406EPre-’99 Current Parts


3176 — 7LG Current Parts

4 3176 7LGn ECM - 3E5293 / 0R6302n Transducer Module - 9X8226 / 0R6132

n Altitude Retrofit - 3E8644 / 0R6470n Speed Timing Sensor - 102-9029n Oil Pressure Sensor

n “DT” Connector 7LG08721 and Up — 161-9930n “HD” Connector 7LG07500 to 7LG08720 — 163-8516

n Coolant / Inlet Air Temperature Sensorsn Full Range - 7LG07500 and Up — 102-2240n Limited Rage - 7LG00001 to 7LG07499 — 9X5370

n Vehicle Speed Buffer - 3E0020n Remote Mounted Throttle position Sensor - 9X9647

n Remote Mounted Throttle Position Sensor - FORD - 9X9648n Pedal Mounted Throttle Position Sensor - 110-8190


3406C Electronic Current Parts

4 3406C - 4CKn ECM - 9X8085 / 0R6486n Transducer Module - 132-4363n Speed Sensor - 100-6619n Rack Sensor - 9X7793n Timing Sensor - 129-4501n BTM - 105-2939n Coolant Temperature Sensor - 102-2240n Pedal Mounted Throttle Position Sensor - 110-8190n Remote Mounted Oil Pressure Sensor Kit - 118-6256n Vehicle Speed Buffer - 3E0020 (same for PEEC II)


PEEC II.V Current Parts

4 PEEC - 8TC and 2EK - FORD Onlyn ECM - 9X4840 / 0R6081n Transducer Module - 132-4363n Speed Sensor - 100-6619n Rack Sensor - 9X7793n Timing Sensor - 129-4501n BTM - 105-2939n Throttle Position Sensor

n Remote Mounted “Beer Can” Sensor - 9X9648n Pedal Mounted Throttle Position Sensor - 110-8190

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

performed. The following parts will be installed:n 6I2382 - Wiring Harnessn 9X5370 - Temperature


PEEC II Current Parts

4 PEEC II - 8TC, 5YG and 2EKn ECM - 8T8770 / 0R5607n Transducer Module - 132-4363n Speed Sensor - 100-6620n Rack Sensor - 9X7793n Timing Sensor - 129-4501n BTM - 105-2939n Throttle Position Sensor

n Remote Mounted “Beer Can” Sensor - 9X9647n Pedal Mounted Throttle Position Sensor - 110-8190

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

performed. The following parts will be installed:n 6I2382 - Wiring Harnessn 9X5370 - Temperature

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Tech Tips 09 Mayo 2001

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