Tech Tips 10 Octubre 2007

Page 1

TechTips - CatBTVOct 10th,2007 10am CDT

October 2007 – AEVD6307 - Page 2

Program IndexRules of the Road H. p 32006 Update Roger Hudson p 5ECM Hotline & DSN H. p15Performance Tips Doug Wilson p172007 Focus Team Tim Stear p312007 HD Update Jack Maroney p36Road With Confidence H. p492007 MR Update Mike Burhoe p502007 Truck Videos H. p602007 DPF Update Matt Bober p622007 TC Conf Videos H. p712007 Electronics Andy Zich p722007 Component ID H. p82Transmission Update Dennis Myers p83Cat Training Update John Deselem p90Reman Update Marty Young p100DPF / Bio / USLD / Uprates Steve Ashburn p110Q&A Kevin Kempher p166Keepin' in Touch H. p167


DVD Subscription

For Oct 10th, 2007 BTV Broadcast only:AEVD6307 – DVD

DVD Subscription – LEVD3947Continues thru 2007Cancelled for 2008Video Clips available on Truck.Cat.com

Additional Information• Orders - Media Logistics, 1-800-566-7782• Questions – Dorothy Baker, 1-309-675-4556

2008


eEvaluations and the jacket drawings for TechTipswill be discontinued after this broadcast…we very much want to continue hearing your comments about our broadcast at: [email protected]

Our future depends on your faithful comments.Thank you…

eEvaluations

Page 5

2006 UpdateRoger Hudson


C7 Fuel Pressure Regulator

Description:Customer complaint of hard starting or low power (CPI 96375)

Root Cause:Check Valve o-ring material is getting caught in the Regulator Valve

Solution:Screen filter is being placed between the regulator valve and the Check ValvePCA implemented Feb 07Part Numbers 229-8870 and 229-8871 replaced by 294-8620 and 294-8621 respectively


C7/C9 HEUI Pump

Description:Customer complaint of hard start, no start, low power, rough running(CPI 127919)

Root Cause:Bearing misalignment due to shaft deflectionHigher pump loads resulting from relief valve setting changes for increased pump stability

Solution:ICA implemented Feb 07

Part number 10R6327Pump center shaft / bearing joint design is being validated

Scheduled for production later this year


C7/C9 Published Diagnostics

Coming Soon!!! One Safe Source to Help Eliminate DSN Involvement with HEUI Troubleshooting to Decrease Customer Downtime.Team Members From Marketing, Development, Warranty and Product Health Worked on this Procedure.Piloting Draft Being Tested in the Field Over the Last Month with Good Success.


152-1057 Injector Tool - Removal


152-1057 Injector Tool - Install


C13 Turbo Exhaust Gasket

Description:Complaint of a broken stud or blown out gasket (CPI 188773)

Root Cause:The gasket material has earlier fatigue than is acceptable

Solution:ICA Ensure that correct parts are used and the proper torque is used

New gasket material is more robust against heat stressSame material as the stud

Nickel alloy 718 “Inconel”New gasket available in Morton in Early December


C13 High Oil Consumption

Description:Customer complaint of excessive oil consumption (CPI 80136)

Root Cause:Oil Capacities / Crank dipping > blow-byInjection Timing / Carbon build-up

Solution:Software released – Hydrocarbon Reduction – w/KCB72870, 6-22-06Oil capacity changed – In prod w/KCB81305, 9-12-06

40 qts FULL standard sump (from 42 qt)34 qts. ADD mark ( from 38 qt)

PB engines built with shallow sump pan w/36 qt fill –Chg to 34 qt fillService Letter PS42351– Dipstick Calibration / replace & Reflash


C15 – Hi Press Turbo Stud Failures

Description:Turbo mounting studs break (CPI 116671)

Root CauseThermal expansion Side loading on stud

SolutionSpot Face on turbo housing • TIBU5065 issued

Check spot face on turboReplace all four stud and nutsTorque to 25Nm plus 60 degree turn

“Inconel” stud being released • Same material as C13• Better thermal expansion• Will have different torque spec

Location of Manifold to Turbo

Joint

XCurrent Stud Inconel Stud

7I8


C13/C15 VVA Not Responding

Problem• C13/C15 engines with “–07” VVA not

responding faultsFault codes 285 thru 290 –07

• Root Cause• VVA built with single piece LPA

Field Repair• 2 Piece LPA kit available – 10R7302• 2 packages of screws

Long screw C11/C13/C15 BXSShorter screws C15 MXS and NXSSpecial Instruction – REHS3814

One Piece Design Two Piece Design


• ECM Hotline:- Dave Abrams, Dave Mooney, Tony King

• DSN Support:- Nick Christian - Engine Electronics

Truck, Machine, Industrial, Gas, Genset, Marine- Mike McIntire - Machine System Electronics

• Coming Soon:- Ryan Zimmerman:

ECM Hotline and 2007 Truck Engine DSN Support

ECM Hotline and DSN


When to call the ECM Hotline

ECM Hotline (877)598-8920• Immediate assistance• General ECM and software questions• ECM Troubleshooting help• ECM Replacement Authorization

(Call prior to replacing the ECM or installing a Test ECM)• Monday – Friday 7:30AM CST to 10:00PM CST• Saturday – 7:00AM CST to 5:00PM CST• M-F 4 to 10PM and Saturdays, Hotline staff is on call only.

Please make sure to leave a message.DSN (Tier II Electronics)

• In depth, complex, new / unknown issues• Response time effected by DSN Priority

Page 17

Performance TipsDoug Wilson


LPFS Start PerformanceCPI # 162399

• Improve Low Pressure Fuel System @ System Level

• Hard Start or Start and Stall condition.Reported Condition Occurs

• Soon after engine shutdown (quick air migration)• Can be after vehicle has set for days (slow air migration)Primary Root Cause – Validated

• Air / Vapor @ Primary Fuel Filter• Air / Vapor migrates due to “2” causes

Primary Fuel Filter Base Positive Seal (ICA/PCA Seal)Air migration across media after long term (PCA Standpipe)

PCA – 2 Related• Positive Seal at PFB & Continuous Fuel Filter Improvements


s

s

s

LPFS Validation Bench

AE

AE AE

AE

AE CYL HEAD

Primary Source of Hard Starting

SFBPFB

Fuel Tank

PFB AIR BUBBLEIDENTIFIED HERESignificant LPFS Issue

Q: Secondary Air Bubble Collect?

ANS: Does not remain in filter housing.

Ideal Bleed Path


LPFS System Photos 6V-3683 O-Ring Machined Snout

CATERPILLAR P/N 280-2698

High Flow Primary Fuel Bases

REV0 & REV 1


Primary Fuel Filter & BaseHose Fitting Matrix PECP5030 Page 190

Base Size & # of ports

Base Size P/NCaterpillarFitting P/N

JIC Thread Line Size (A)

STOR Port Size (B)

Caterpillar Fitting Desc

-10 (2X)

-8 (4X) & -6 (2X)

P/N 280-2698

P/N 195-1068

030-79435P4318141-23756M7476

-8-8-10-10

-8-10-8-10

Angle 45 Deg

-8-8-10-10

-8-8-10-10

P/N 1R0781P/N 1R0769

P/N 256-8753P/N 179-2949

P/N 256-8753P/N 179-2949

Primary Fuel Filter

-10 (2X)

-8 (4X) & -6 (2X)

P/N 280-2698

P/N 195-1068

030-8027005-41731P7625149-4230

-8-10-8-10

Angle 90 Deg

-10 (2X)

-8 (4X)& -6 (2X)

P/N 280-2698

P/N 195-1068

030-8110033-5691030-42859M4584

-8-10-8-10

Straight Fitting

200 GPHYESEC 4YesP/N 195-1068

129 GPHYESEC 2NoP/N 280-2698REV1

129 GPHYESEC 2YesP/N 280-2698 REV 0

RATINGHigh FlowStandpipe Option

Stud O-Ring Required

Primary Fuel Filter Base


Pump Lift Test (T/S)Disable Engine Electronics so it will not start.

• Connect Clear Tubing to inlet of T-Pump.

Open Bleed valve 3 turns as in • (O & M Guide) < KEY

Crank engine pump should lift fuel to T-Pump inlet at 15 seconds or less.

• Returned Pumps have passedIf Pump fails to lift from floor to T-Pump inlet, verify:

• The bleed valve is open the required amount.

• No Leaks in the test line and fittings

If pump fails replace T-Pump and repeat lift test.

• Note with pump that it failed lift test. Supplier will re-test.

Fluid Lift Height

Fluid Level

Inlet


LPFS PerformanceCPI Project for LPFS System Performance

• Primary Fuel Filter and Base• Not Covered Under Standard Warranty• Claims against “non CATERPILLAR Bases”

Reports of Aeration at Elevated ERPM.• Can affect performance• May be correlated with low power complaints.

Speed Sweep with Sight Tubes are effective.• Measure Pressure Drop across PFB• Measure Inlet Restriction to T-Pump• Compare to A & I guide and TMI information


Typical Dealer LPFS TestVacuum Gauge for Inlet Restriction.

Sight Tube for Aeration.• Higher Restriction• Greater Delta P• Increased Aeration

See Video @ 2100 ERPM

2100 RPM.MPG


Allison Trouble ShootingProject to improve trouble shooting Automatics used in Vocational and RV’s. The majority of information needed is located in the I SCAAN report from Allison.

• Obtain this information before T/S beyond basics, and generating unnecessary labor hours.

• Open a DSN – Automatic Performance T/SKEY Elements to T/S

• I SCAAN – Most important informationHas Torque Converter Stall RPMHas Performance 0 to 20 MPH Performance SpecificationHas Other related Performance Information.

• Torque Converter Stall TestCompare to I SCAAN reportTests Converter and Eng Power

• 0- 20 Acceleration – Customer ComplaintsCompare to ISCANN report



Data Log Channels TC Stall

Eng Speed < KEYRated Fuel Pos < KEYFuel Pos < KEYFRC < FRCPercent Torque <FRCPower Train Status < KEYBoostThrottle PositionPresent Injection Mode (PIM) (opt)Vehicle Speed


Torque Converter Stall Example


Vehicle Acceleration Test – DATA LOG

Set Up Data Log (See next slide)Warm Engine > 80C/176FTurn - FAN ONFully Depress Throttle 100% Accelerate from standing start thru complaint area.• 1) Capture Necessary Time for Acceleration.• 2) Place in Neutral, Cool Engine• 3) Repeat – Total of 3 tests with cool down

between.• Save Data and attach to DSN.


0 to 20 MPH Example

5.5 secSCAAN ACCELERATION TEST VEHICLE NOT

LOADED IN THIS EXAMPLE

Page 31

2007 Focus Team / DSN coverageTim Stear


DSN Coverage Changes

Turn off 877-MY07CAT coverage for TEPS All Calls going back to DSN Tier 1Dealer TC supporting TEPS

Hours of operation changeStarting Oct. 1st 2007M-F 6:30-5:00 PM

DSN Tier 2Nate Hotel 3100, C7 & C9 Legacy and 2007 TruckJason Armrest C-10, C11, C-12, C13 Legacy and 2007 TruckEli Grove 3406E, C-15, C15, C-16 Legacy and 2007 Truck Rick Smock Tier 2 PlusMike Burhoe Tier 2 Plus


2007 Truck Focus Team

Team LocationBldg AC through end 2007Continue supporting DSN Tier 2Continue Field support

Rick Smock & Mike BurhoeTier 2 Plus supportRick Smock ---C15 Service EngineerMike Burhoe---2010 Serviceability Service Engineer


Product Health Re-OrgTim Stear

Product Health ServiceEngineer Supervisor

Jack MaroneyOn Highway Truck

Team Lead

Geoff Monari2010 On Highway

Truck Serviceability

Roger HudsonStandards/

Regulations/ServiceLetters

Rick SmockC15

On Highway Truck

Josh EvansC13

On Highway Truck

Kory EndressC7/C9

On Highway Truck

Mike Burhoe2010 On Highway

Truck Serviceability

Matt BoberAftertreatment

Allan SilzerCost of Repair


2007 On Highway DSN Team

Page 36

2007 HD UpdateJack Maroney


C13,C15 / ARD Head Replacement Problem: In line fuel filter fittings must be replaced when the ARD head is replaced. Additionally the purge air inline filter fitting must also be changed.Problem to the Problem: Confusion on which parts to order.Publications: Provide communication regarding serial number breaks and part number changes to these fittings. TEN release scheduled

Fuel Filter Fittings

Purge air inline fitting

Typical Example of Fuel Manifold


Excessive Idle While TroubleshootingProblem: Excessive idling while troubleshooting Caterpillar Regeneration System (CRS) may lead to DPF replacement.Symptoms: Three fault codes for excessive soot accumulation in the DPF• 3719-16 Moderate Severity• 3719-0 Most Severe• 3715-31 System Lock OutResult: If 3715-31 becomes active while troubleshooting, the DPF must be replaced.


Excessive Idle While TroubleshootingContainment Action: Check for Active EventsActive Events• If the 3719-0 is active reduce idle time while

troubleshooting.

Unnecessary Idle Time

How much time do you have?• The amount of engine idle time

that will trigger a 3715-31 cannot be defined.

• Variables such as Abnormal High CGI Flow, low boost, etc will dramatically reduce this time.


Primary Fuel FiltersProblem: Inadequate primary fuel filtration can cause early hour debris plugging of the Aftertreatment Regeneration Device Nozzle.

Root Cause: The primary fuel filter is the only filtration for the Caterpillar Regeneration System fuel.

Solution: The use of a 10 micron primary fuel filter is critical.


Sensor Identification

Problem: Sensor names on Cat ET can be confusing and can lead to troubleshooting the wrong sensor circuitCause: Cadet must display component names that are provided by the Society of Automotive Engineers (SAE). The SAE component names can be confusingFix: Two columns are being added to the code lists in the sensor troubleshooting procedures. The columns indicate the location of the sensor and the location of the sensor’s connectorExamples are on the next slide


Sensor Identification

Added Columns:

SensorLocation

ConnectorLocation

Added Pictures:The numbers in the

table match thenumbers in the picture

Code

Sensor

Connector


Heavy Duty Purge Air SystemProblem: Purge air pump is susceptible to oil ingestion due to the current air inlet supply location.

Symptoms: 3556-7 Aftertreatment #1 Fuel Injector; Not Responding Properly

Containment Action: Follow troubleshooting outlined in ARD Nozzle-Test

Purge air pump

Purge air pump filter

ARD Head

CRS Manifold 2

CRS Manifold 1

Purge Air SystemPurge Air System


Heavy Duty Purge Air System

Purge air pump


ARD Head

CRS Manifold 2

CRS Manifold 1

Oil Ingestion starts here.

Oil Passes through the Purge Air Pump

Oil gets deposited on components inside ARD

Head


If the purge air pump is damaged (verified by high dead head pressures)

• Mechanical portion of the pump must be replaced

• ARD Nozzle must be cleaned

Mechanical portion of pumpP/N 260-6800 (REHS3781)



Solution: We are quickly working to resolve this issue

• Relocate air inlet supply away from air compressor.

• Publication to be released after final validation of re-routing complete.


Purge air pump


ARD Head

CRS Manifold 2

CRS Manifold 1

Potential relocation of Purge Pump Supply away from Air Compressor

(Minimum of 12 in to Air Compressor Inlet)


Truck Engine News

Recent Articles• Repairing the fuel injector rocker arm

• Replace Injector also• Updated procedure for cleaning the nozzles in the ARD

• Details procedures and steps prior to injecting cleaner

Upcoming Articles• Replacing the combustion head for the ARD

• Refers to Special Instruction REHS3406-00 (6 line ARD Head to 5 line)

• Guidelines for replacing oil supply lines for the combustion airvalve on certain C13 Engines.• Very early production engines must service both lines


Service Letters

• Recent Service Letters Released

• PS42469 - Product Support Program for Reporting the Usage of Improper Fuel On 2007 On-Highway Truck Engines• Not to be used as an inspection Service Letter

• PS42494 - Product Support Program for Replacing the Aftertreatment Regeneration Device (ARD) Combustion Body Group Bracket Bolts on Certain C13 On-Highway Truck Engines.• Some C13 On-Highway Truck Engines have Combustion

Body Group bracket bolts that need to be replaced. Current bolts are too short and may become loose.


The Road with Confidence

Brochure PEDJ0076 (10pages)ref: 2007 C13/C15 O&MM SEBU8087

Page 50

2007 MR UpdateMike Burhoe


C7/C9 Service LettersBe sure to perform all open service letters. There are a few that apply to the C7 and C9 engines.


2007 C7/C9 Turbo Troubleshooting

Turbocharger related diagnostic codes – Follow the TSGFor the C7 RV and C9 DAVNT’s (Double Axial VariableNozzle Turbo), the actuator requires a 12V supply from the OEM. Be sure the power and ground are properly connected. (MTB will have a 24V system)TIBs: 5162 and 5128


Turbocharger Actuators (TIBU5162)

Description:The above listed engines have electronically actuated turbochargers. The actuators are non-serviceable and the actuators should not be removed or replaced. The actuators are specifically set for the individual turbocharger that is on the engine. If the actuator is removed or replaced, the turbocharger will not function properly.

Solution:If a problem with the actuator is found, the entire turbochargerneeds to be replaced.


C7/C9 Turbo Oil Leakage (TIBU5128)Description:

2007 model year C7 and C9 turbochargers are being replaced for oil that is leaking across the seals on either the exhaust side or the side of compression. The closed crankcase on the 2007 model year C7 and C9 make the turbochargers sensitive to pressure differentials. Oil that is leaking across the seal is usually anindication of another system problem. Examples of conditions that can cause oil to leak across the turbocharger are high back pressure, leakage of boost, excessive crankcase pressure, low crankcase pressure and diluted oil.

Solution:Repair the system that has caused the oil to leak across the turbocharger. Once the repair is made, the turbocharger will stop allowing oil to pass through the turbocharger. Only replace the turbocharger if other damage is present. Replace the turbocharger for excessive play in the shaft or wear marks on the housing or the wheel.


Oil Passing Through Turbo


Oil Passing Through Turbo

Check for crankcase pressure codesCheck for DPF DeltaP related codesCheck for boost leaksCheck for fuel dilution in the oilRun Air Systems Verification Test


2007 C7/C9 Oil Level

In some instances on 2007 C7 and C9 truck engines it takes a longer time for oil to drain back to the oil pan compared to legacy engines.Good practice is to wait approximately 15-20 minutes after the engine is turned off before checking the oil level.


C7/C9 High Pressure Fuel Lines

The C7 and C9 high pressure fuel lines are one time use only.All fuel line clips, high pressure and low pressure, must be installed in the proper locations. If there are clips that are removed, damaged, or mis-positioned, there is a high probability that that fuel line will break.


C7/C9 Troubleshooting Guide

The TSG for the C7 and C9 engine is making great progress. Please be sure to follow the TSG and provide input on the procedures. There are still a few holes, but they are being filled quickly.


2007 Truck Videoshttps://truck.cat.com/cda/layout?m=121186&x=7


2007 Truck Videoshttps://truck.cat.com/cda/layout?m=121186&x=7

Page 62

DPF Inspection TipsMatt Bober


DPF visual inspections

Do not rely on the tailpipe inspectionTwo ways to determine a DPF failure 1) Visual black smoke in exhaust when engine running,

indicating soot passing…Do not mistake for white or gray colored smoke

2) Inspection of the DPF outlet reveals either burnt cells or fails the “White Glove Test”

White Glove Test• Use a clean and white glove, towel, or handkerchief

to wipe the outlet side of the DPF • Analyze the white glove to determine if the substance

is soot or just rust, debris, ash, etc.


DPF visual inspections DPF visual inspections

Outlet SideOutlet Side

• This is failed• Black soot covered on outlet


DPF visual inspectionsDPF visual inspections

• This is not failed• There are weld marks on outer perimeter from manufacturing • There is also normal “staining” from operation

Outlet Side


Inlet SideInlet Side


• Can’t determine if this is failed based on the inlet side• The outlet side is the only viable criteria for determining failure




• This is not failed• There is normal “staining” from operation and also rust at the 6 o’clockposition




• This is failed• More difficult to determine at first glance• White Glove test would work well


DPF visual inspections

Outlet SideOutlet Side • This is failed

• One of the most difficult to determine

• Usually will seea couple of burnt individual cells as shown


Burnt CellBurnt Cell


• The individual burnt cells indicate internal damage to the DPF • This will cause black smoke during engine operation


2007 TC Conference Videoshttps://truck.cat.com/cda/layout?m=121186&x=7

ComingSoon…

Page 72

2007 ElectronicsAndy Zich


PACCAR Dash Display

Symptom: PACCAR dash shows Particulate Trap Outlet Temp 1 fault even though there is not a similar fault displayed in CatETCause: Any Cat engine ECM code not supported by Namux II dash software shows as the above faultWork around: Look in CatET for actual codePermanent fix:Consult PACCARDealers for softwareUpdate in mid-Oct


520192-18 CGI Mass Flow: Low

Symptom: Check engine light, 30% engine derate, and 520192-18 logged or active in CatET Cause: When does fault log: • 1. Parking lot issue (8 min) – high rpm, 0 or low vehicle

speed, low fuel but higher than 40 mm3

• 2. Highway driving (25 minutes minimum) - Continuous on throttle, off throttle operation 1450 to 1700 rpm

Work around: Cycle Key switch powerPermanent fix: Future software release


Clearing Active Events

Symptom: Can not clear active eventsCause: Attempting to clear from active diagnostics screenWork around:Open Active Events Window in CatET: Diagnostics, Events, Active EventsPermanent fix: Training! Can NOT clear codes with dashboard

Cycle Key Switch then hit Reset All


Clearing Active Events

Use Active Events screen “Reset All” button to clear active events

Use Active Diagnostics screen “Reset All” button to clear active diagnostics


Clearing Active Codes

Active Events (FMI: 0, 1, 15, 16, 17, and 18)• 3246-16 High Particulate Trap#1 Outlet Temperature(2)Active Diagnostics (All other FMI’s)• 3486-7 Aftertreatment 1 Purge Air Pressure Not

Responding• 3474-31 Aftertreatment Loss of Combustion• 3473-31 Aftertreatment Failed To Ignite• 3711-31 Particulate Trap Active Regeneration Inhibited

Due to Low Exhaust Gas Temperature• 3715-31 Particulate Trap Active Regeneration Inhibited

Due to Permanent System Lockout (3)


Add Button for Active Events


Add button for Active Events


Add button for Active Events


Adding Test Results to Warranty Report


2007 Component I.D.

TC Conference - Sept2007

Page 83

Transmission UpdateDennis Myers II


Caterpillar Automatic Transmissions

CX286 Speed

CX316 Speed

CX358 Speed

Matches C7 and C9• HP Ratings: 350hp (425 hp RV/FT)• Torque Ratings: 1250 lb-ft (1350 lb-ft RV/FT)• Weight: 595 lbs Non PTO 665/6680 lbs PTO (similar to Allison)• Production Date: Dec. 2007

Matches C13 and C15 (low torque)• HP Ratings: 500hp (Severe) / 550 hp (On/Off Highway)

600hp (Emergency Vehicles) / 625 (RV)• Torque Ratings: 1650 lb-ft (Severe) / 1770 (OH/FT)

1900 lb-ft (RV)• Weight: 910 lbs (without Retarder)• Production Date: AVAILABLE NOW

Matches C15 and some C18 applications• HP Ratings: 625hp • Torque Ratings: 2150 lb-ft • Weight: 1320 lbs (without Retarder)• Production Date: Dec. 2007


Cat CX31 Transmission Features

Trans Mounted ECM

Rear PTO Options

Clean Right Side

Remote Mountable Filter

Industry Standard PTO (1&8 o’clock)

SAE Flywheel Housing w/ Flexplate Drive

Industry Standards• Industry standard package size –

minimize vehicle changes

• J1939 / 1587 datalink compatible

• ATF Oil Compatible

• SAE STOR cooler ports Standard and Shallow Sump

Industry Standard Yokes

Externally Serviceable Controls

TC Options for Engine Matching


Yokes:1710 9C1760 8.5C1810 ISO 8667-T180SPL170 ISO 7646 – A180SPL250 RPL20

Filter’s:Spin-onCartridgeRemote

Sump’s:StandardShallow

Flexplates:C9-C13C15

TC’s:TC42531TC42731TC42833

Rear PTO DriveFIG

Input Retarder

CX31 Configuration Options


Oil & Filter Change IntervalsDexron III

Severe Applications 500 Hours or 12,000 MilesGeneral Applications 1000 Hours or 25,000 Miles

Cat AT-1 SyntheticSevere Applications 3000 Hours or 75,000 MilesGeneral Applications 4000 Hours or 150,000 Miles

CX31 Maintenance Information

Transmission Type Estimated Intial Fill Service Refill

Shallow Sump 10 US gal 4.5 US gal

Standard Sump 12 US gal 6.5 US gal

Retarder 13 US gal 7 US gal

Oil Capacity


Parts & Service Literature CX31 (Serial Number Prefix B3X)

• Parts Manual SEBP4927• OMM SEBU8192• Spec, Sys Op, T & A KENR5090• A & I Guide – Electrical REHS2884• A & I Guide – Mechanical REHS2790• Troubleshooting Guide KENR5099• Electrical Schematic KENR5109 • D & A KENR5091• Bench Test Guide REHS3184

Publications – CX31 On-Highway Transmissions Publications – CX31 On-Highway Transmissions


Spec Sheet and A&I InformationSpec Sheet and A&I Information

Page 90

Cat Training Update


DLMS Service Curriculum Available

Electrical Engine Repair Engine Performance Hydraulics Air Conditioning Hydraulic Excavator PowertrainBrakes

Over 100 hours of learning available through the DLMS

& more on it’s way


Instructor Led Course Registration







Hydraulic Curriculum

Air Conditioning Curriculum

Engine Performance Curriculum

Brakes Curriculum

Product Curriculum

Electrical Curriculum

Engine Repair Curriculum

Power Train Curriculum

Service Campus Prerequisite MapDo You want to Get Started?

•You can sign up for individual courses, but he best way is to utilize the bundled courses in the Curriculums•Register and begin courses!


Curriculum Maps

Successful Completion of the WBT & Diagnostic Exercises is Pre-requisite for ILT


Hydraulic Curriculum

Air Conditioning Curriculum

Engine Performance Curriculum

Brakes Curriculum

Product Curriculum

Power Train Curriculum

Scenario: You want to be proficient in Engine Performance. The curriculum path you would follow is:

Electrical Curriculum

Engine Repair Curriculum

This means signing up for each of the curricula in order


Certification / Gap Analysis Test2 purposes – 1 tool

• Systems Certification• Skill Gap AnalysisAccessed through DLMS

Page 100

Reman UpdateMarty Young


Reman Service Engineer Contacts

Marty Layer• Corinth/Lafayette/Purchase Finish

EnginesBlocksHeadsCrankshaftsGovernors

Mark Gasper• Nuevo Laredo/Purchase Finish

TurbosElectronicsStartersAlternatorsAir CompressorsPower Train

John “Scott” Weber• Nuevo Laredo/Purchase Finish

Fuel InjectorsFuel NozzlesIVA/VVAClean Gas Induction (CGI)Cat Regeneration System (CRS)

Marty Young• Prentiss/Purchase Finish

Pumps – fuel/oil/water/hydraulic• Oil Coolers

Hydraulic MotorsHydraulic CylindersCylinder packsCamshaftsRocker ArmsLifters


3406E / C-15 Rough Idle IssueDescription (CPI 169425):

Customer reports rough idle after a OPT overhaul with Reman injectors, cylinder heads, and cylinder packs. This occurs primarily in 3406E & C-15 truck engines.

Root Cause:In some cases the team has found that the Reman injectors are causing the rough idle complaint. In other cases, root cause includes cylinder heads, wiring, fuel filter bases, chassis issues.

Solution:Short term: Reman working w/dealers on a case-by-case study via the DSN.

Some engines are matched w/Reman injectors & problem is solved.Other engines require approval of new injectors to correct.The team is working with the dealers, through the DSN process, to resolve rough idle complaints & obtain injectors for the team to test. When needed, the CPI team is available to make dealer visits.

Long term: The team is using the 6 Sigma methodologies to find and correct the root cause(s) of the rough idle complaints.


3406E / C-15 Injector Sleeve and Cone LeaksDescription (CPI 110109):

There have been many failures related to injector sleeves and injector cone sealing on these heads.

Root Cause:Debris under sleeve.Injector sleeve bore out-of-round.Insufficient cleaning causing O-rings to tear.Injector Cone out-of-round and erosion.

Solution:Injector sleeve bores detailed at assembly line.Improved sleeve insertion process to eliminate O-ring issues and debris.Revised Head machining and welding process to allow Injector sleeve bore and cone to be re-machined to as-new dimensions.


3126B Intake Valve / Piston ContactDescription (CPI 169017):

In a number of 3126B engines w/REMAN cylinder heads, customers have complained of noise from the top end and in severe cases total engine loss caused by Inlet valves hitting the pistons and failing.

Root Cause:Incorrect Valve seats fitted (too thick).Insufficient valve depth checks on assembly. Print Structure unclear for operators

Solution:Assembly information updated.Operators retrained on the differences.Increase valve depth checks on assembly. Prints realigned to correct error.TIBU5155-01 Issued informing dealers to check Stock.Service letter being written


Description (CPI 137325):Governor adjustment generates engine black smoke.Governor causes engine to have low power symptoms, requires adjustment.Governor does not last the life of the engine.

Root Cause:Adjustment at Supplier Factory not to Caterpillar specificationsAged test stand not capable of consistently producing good partsProduction requirements drawing not current

Solution:Test stand FRC changed from transient to steady-state measurementsReplaced Dial Indicator to improve adjustment of torque cam height.Establish reuse and inspection guidelines for a remanufacturer of 1.1L GovernorsValidate solution at a Caterpillar dealer and at the CAT Corinth facilityAdd a governor serial number to monitor effectiveness of this solution.

3116 1.1L Governor Issue


Reman Component Availability

• Reman C7 – C15 Short & Long Block IRM: PELJ0806, Aug ’07• C11 & C13’s LB’s not available until late 4thQ2007

• Sept ’07 Reman News Letter, (ref. Reman.cat.com)

• Publications – contact Allison Andrews to be added to mail list

([email protected])


Reman Component Issue

Reman Flywheels:

• Report of face thickness allowing original bolts to bottom out on crankshaft holes, causing flywheel unbalanced.

• Further investigation pending, please forward any reports via normal DSN.


Reman CommunicationTechnical Supplements -• Update Project – completed by Year end• New Format - Consistent• More Details - Complete Information• Short & Long Blocks Cross Reference• Less Complicated• Look for upcoming Announcements


3406E & C15 Cyl Heads and Bridges

• Special Instructions (REHS3810) now included with Reman Head

• Change forthcoming to Head Core Acceptance Criteria – by year end.

• Additional Communication next month:IRMTruck Engine NewsService MagazineEngine News

Page 110

DPF Cleaning / Bio / USLD / UpratesSteve Ashburn


Regeneration Info

LEDT7022 - “The DPF Regeneration Lamps, Switches and Driver Tips

Did Look Like This!

Now Looks Like This!


Regeneration Info

Companion Regen Video• Truck.Cat.Com> Products> On-Highway Marketing>

Videos• Scroll to the bottom

• Public Sitehttp://ohe.cat.com/drivingtips

1 2

43


Rules

Rules• Can NOT use a DPF with more miles then on the

truck

Truck Miles = 250,000

DPF Miles must be less than 250,000


Rules

Rules• Can NOT use a DPF with more miles then on the

truck

• Ash Model Must be reset

Truck Miles = 250,000

DPF Miles must be less than 250,000


Ash Model Reset

Ash Model must be reset• Like “zeroing the scale”Best fuel economyRequires Factory Password• Requires “Nov07” Software• FPS On-line 2nd Qtr 2008Also serves as Filter Tracker


Filter Tracking

Must Ensure Filter has ≤ mileage as the truck• EPA Requirement• FPS System Captures Filter Data

S/N, Mileage at Change/Cleaning, Engine S/N, …

• FPS Screen to check usage


FPS Screen for Checking

Factory Password Checking App• Enter DPF Serial Number• Miles on the Truck• Yes/No

Page 118

Ash Cleaning Methods



Cleaning ToolClean ExchangeRemanNew

Preferred MethodPreferred Method



Cleaning Tool• Preferred Method

Off Vehicle

• Least Expensive for the Customer$500 - $700



Clean Exchange - Proposed• No Tool• Uses “Reman” Process

Core ReturnPart numbers associated with mileage

• Higher Cost to Customer2 to 3 times the cost of Cleaning



150K-199K Miles

10R-XXX2

200K-249K Miles

10R-XXX3

250K - 299K Miles

10R-XXX4

202,000 MilesOn the Truck

0-149K Miles

10R-XXX1



Reman - Pending• Upgrade to New• No Tool• Core Return• Even Higher Cost to Customer

$3,900 USD D/N - Estimated13x17 (Used on C13/C15)



New• Needed to replace Damaged Filter

Part of Collateral Damage

• Highest Cost$6,000 USD D/N - Estimated

13x17 (Used on C13/C15)

Page 125

Ash Cleaning Tool


DPF Ash Cleaning Tool

Requirements• 100 psi, 700 kPa Shop Air• 120 VAC

Size• 75”(l) x 40”(w) x 83”(h)• 1.9m(l) x 1.01m(w) x 2.1m(h)

Weight• 1100 lbs• 500 kg


DPF Ash Cleaning Tool

HEPA Filter

Accumulator Tank

Control Panel

Disposable Bucket(Behind Door)

Filters

Expansion Tank

Computer Controlled Valve

Page 128

Ash Cleaning Process



Regen DPF on the Truck• Cat ET attached• Ash Service TestLet Cool and Remove FilterPlace Filter in Tool


Adapter

Seal

Seal

DPF


•Various adaptors for the different DPF’s

•1 adaptor can be used for multiple sizes


Hand Pump Raises the bed

Seals DPF in Tool


Bed

Hydraulic Cylinders



Start Process• Push Start

Air Flow≈ 45 MinutesTotally AutomatedSounds like

disconnecting an air hose



AshCollectionArea



Remove Filter from ToolRe-install on Truck• Replace SealsHook-up Cat ET• Reset Ash Model• Interim Process - Call DSNSend the truck on its way!



Cost• Total time ≈ 4 hours labor• Consumable Costs• Tool Cost• Gaskets• Tool DepreciationCustomer Cost• $500 to $700 USD


Consumables

Five Items • HEPA Filter• Cartridge Filters (2)• Disposal Bucket• Air Dryer Desiccant• Coalescing Filter


Consumables

HEPA Filter• 319-2193• Life

500 - 1000 DPF Cleanings

• Cost$840.76 USD D/N


Consumables

Cartridge filter • 319-2194• 14 dia, 30 long• 2 filters/pack

Life15 to 100 DPF Cleanings

• Cost$ 349.45 USD D/N


Consumables

Soot in DPF dramatically shortens Cartridge Filter

life!

Soot in DPF dramatically shortens Cartridge Filter

life!

Regen beforeCleaning DPF

Regen beforebeforeCleaning DPF


Consumables

Filter Bucket• 319-1833• Life

3 or 4 per clean outClean out every 15 - 100 DPF

Cleanings



Consumables

Air Dryer Desiccant• 320-2679• Life

25 DPF CleaningsCan be oven dried and re-used



Consumables

Coalescing Filter• 320-2680• Life

500+ DPF Cleanings


Page 143

Part Numbers & Costs


Tool Part Numbers

319-2189 Cleaner Gp• Includes:

319-2187 Cleaner – DPF319-2190 Adaptor group

319-1834 Cone – 11 inch319-1835 Cone – 13 inch319-1836 Cone – 15 inch319-1838 Adaptor-lower – large319-1839 Adaptor-lower – small


*This is NOT part of the standard 319-2190 Adaptor Group, it is ordered separately!

Additional Adapters Mass Transit Bus

Use 319-2192 Adaptor-MTB*• Use with 319-1835 cone• Cost

$739.74 USD D/N


Cleaner Costs* Dealer Net

319-2189 Cleaner Gp $16,169.47

*Dealer Net prices as of 14 Sep 07

Individual Pricing319-2187 Cleaner – DPF $14,787.77319-2190 Adaptor group $2,024.87

319-1834 Cone – 11 inch - $245.12319-1835 Cone – 13 inch - $249.66319-1836 Cone – 15 inch - $256.90319-1838 Adaptor-lower – large - $747.64319-1839 Adaptor-lower – small - $750.54


Do I Buy A Tool?Do I Buy A Tool?

Yes, ONE per dealer to start• Limited availability

4th Qtr ‘07 thru 1st Qtr ‘08

• Unlimited availability After 1st Qtr ‘08

Is that a problem?Is that a problem?


Cleaning Opportunities

Page 149

Biodiesel


Biodiesel RequirementsBiodiesel blend must meet requirements for distillate diesel fuel• Biodiesel blend stock (B100) must meet Caterpillar

biodiesel specification*, ASTM D6751, or EN 14214 • Distillate diesel used for blending must meet

Caterpillar requirements, ASTM D975, or EN590Blends above B5• Complete oil analysis (Cat S.O.S. Services) is

strongly recommendedEnsure oil change intervals are appropriate

* Available at www.cat.com


Biodiesel Requirements

Refer to:• SEBU6385-07

Caterpillar On-Highway Diesel Engine Fluids Recommendations

• SEBU6251-10Caterpillar Commercial Diesel Engine Fluids Recommendations

* Available at www.cat.com


Pre-2007 Engines Biodiesel

2006 and Older:• Up to B30 blend meeting Caterpillar requirements

acceptable:ACERT Technology

C7, C9, C11, C13, C153114, 3116, 3126, 3176, 3208, 3306, C-9, C-10, C-12, 3406, C-15, C-

16


2007 On-Highway Engines Biodiesel

Status for 2007 Engines• On-Highway engines

Requirements under review


2007 On-Highway Engines Biodiesel

Proposal pending EPA approval: • Recommended allowance for 2007 On-Highway

Engines C13 / C15 - Up to B20C7 / C9 - Up to B5

• Maintenance requirementCRS cleaning fluid every oil change

Official announcement will be made as soon as approval received

PE

ND

ING

PE

ND

ING

PE

ND

ING

PE

ND

ING

Page 155

ULSD Availability


ULSD Availability

Refiners• 80/20

,00

0 B

arre

ls

9/06 3/073/07

Does Not Mean itDoes Not Mean it’’s At the Pumps At the Pump

TotalULSDLSDOff Road


ULSD Availability

Flying J• 89% (158/178) have ULSD• 61% (109/178) have Low Sulfur


ULSD Availability

Pockets of unavailability• I-75 - Atlanta to Lake City,FLUnlabeled Pumps• Labels Required

LSD or ULSD


ULSD Availability

EPA Reporting by Customer• http://www.epa.gov/compliance/complaints/index.htmlCat Dealer Reporting• Doug Wilson: 309-578-9450 or • E-mail: [email protected] - Reporting S/LREHS3796-Special Instruction

Page 160

2007 Uprateability


Injectors & Turbo

DPF

DPF, Turbo, & Injectors

DPF & Pistons

C7 Uprateability

HP Torque

210 620

210 520

190 520

HP Torque

230 660

230 620

230 560

HP Torque

250 800

250 660

HP Torque

300 860

275 800

HP Torque

350 860

330 860


Injectors & Turbo

DPF

DPF, Turbo, & Injectors

DPF & Pistons

C7 Uprateability

HP Torque

210 620

210 520

HP Torque

230 660

230 620

230 560

HP Torque

250 800

250 660

HP Torque

300 860

275 800

HP Torque

350 860

330 860C7 190 HP rating new sales discontinued September 1, 2007


DPF , Turbo, & Pre-cooler

C13 Uprateability

LEE 00001 to 05879

HP Torque

370 1450

370 1350

350 1550

350 1450

350 1350

335 1250

305 1150

HP Torque

525 1750

485 1650

470 1550/1750

470 1650

470 1550

430 1550/1750

430 1650

430 1550

410 1450/1650

410 1450/1550

410 1550

410 1450

380 1450


HP* Torque

410 1450/1650

410 1450/1550

410 1550

410 1450

380 1450

DPF

Turbo & Pre-cooler

*430/1650 PSO File Available

C13 Uprateability

LEE 05880 & Up

HP Torque

370 1450

370 1350

350 1550

350 1450

350 1350

335 1250

305 1150

HP Torque

525 1750

485 1650

470 1550/1750

470 1650

470 1550

430 1550/1750

430 1650

430 1550



Questions…

Email: [email protected] 1-877-494-4700#353707#3359391


Keepin’ in Touch

Training

Broadcast ScheduleeEvaluationeMailElectronic PNsHandoutsVideo Replays

Handouts

http

s://t

ruck

.cat

.com


Caterpillar Electronic Technician

2007C-v1.0 Available for Download Oct 12th

NACD Infocast: https://nacd.cat.comwww.truck.cat.comCAPL APDNet: https://catasia.cat.comCCL APDNet: https://catchina.cat.comDealer Distribution Services Support CenterVoice: (800) 765-0999 or (309) 675-4000Fax: (309) 675-4080E-mail: [email protected] or

DDS Support Center (Lotus Notes) Hours: Monday through Friday

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


2007 Broadcasts…

check your calendars…

Feb 14th 10am CST CatBTV BroadcastApr 11th 10am CDT WebEXJune 13th 10am CDT CatBTV Broadcast Aug 8th 10am CDT WebExOct 10th 10am CDT CatBTV BroadcastDec 12th 10am CST WebEx

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Tech Tips 10 Octubre 2007

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