TECH TIPS+11+02+1998

February 1998LEVN4284

Page 1

TRUCKTech Tips

February 11, 1998

LEVN4284


Page 2

IndexIron Electronics Software

HEUI Squeal PSP 3 3116/3126 Software Updates 55Replacement Ring Gear w/o Bolt Holes 4 Dec. '97 Software Changes 563116/3126 Side Cover Replacement Gasket 6 2300 RPM Re-Flash 58

Fumes Disposal TuBe Decals 7 Feb. '98 Software Changes 603126B Service Tool List Reference 8 Driver Incentive Features 61C-10/C-12 Cylinder Head Bolt Inspection/Re-Torque 9C-12 Jake Brake Lash Setting Change 11 Electronic Service Tools3176B/C-10/C-12 Injector Hold-Down Bolt 12 ET 2.2 Release 633406 Piston Rings 13 ET Trainer Announcement 693400 C & E Cooling Jet Part Numbers 17 Customer ET 73

600 HP Piston Skirt & Cooling Jet 18 FIS Version 3.1 76Reman Unit Injector Rocker Arm 19 SIS for Windows 80Head-To-Block Joint 20 Dealer Additions CD 823406E Flywheel Housing Gasket 21 ECAP Version 2.2 Truck SPM Release 83

3406E Fuel Priming Pump 22 New Oil Pump 23 Publications

3126B Video Version of CD-ROM Training Program 85 Quick Tip #1 24 3126B PTO Special Instruction 85

Ordering Information for 1998 Manuals 86Electronic Troubleshooting 3126 Troubleshooting Tips 26 Vehicle Speed Filter 30 Oil Pressure Sensor Leaks 33 Transmission Style Options 34 Automatic Transmission Tips 35 Accelleration Pedal Position Sensor 49

Electronics HardwareECM Connector Serviceability 50New Atmospheric Pressure Sensor 51CAT ID Version 1.5 52

Quick Tip #2 54


Page 3

3116/26 High Pitched Squeal

3100 Customer Service Group Published a product supportletter PS5384 in December 1997 that will address the highpitched squeal complaints.

Please follow PS5384 when this condition occurs.

A revision to PS5384 authorizes the addition of two O-ringSeals.

6 - 113-6303 Jumper tube seat o-ring

6 - 033-5853 Tuned fitting o-ring


Page 4

Replacement of the 7W5095 RingGearRemove Bolts and remove flywheel.

Note: To help remove flywheel, install two long bolts intoflywheel for handle

Weight of flywheel is 32kg (72 lbs).

If flywheel ring gear needs to be replaced, position flywheel onwooden block and drive ring gear off.

Note: The following steps are for the installation of theflywheel.

If ring gear was removed, heat new gear to a maximumtemperature of 204° C (400° F). Position ring gear on flywheelwith part number on the crank side. After ring gear has cooled.Tap with a soft drift, to be sure is seated against flywheelshoulder.


Page 5

Replacement of the 7W5095 RingGear

Note: If the outer bolts holes of the flywheel are to be used, it will benecessary to drill and tap the new ring gear. Use the flywheel as atemplate and drill twelve holes to a diameter of 8.2mm(0.3228 in).Thread holes with a 3/8 in - 16NC tap.

Note: Apply 9S3263 Thread Lock to threads of bolts.

Line up mark on the flywheel, indicated by arrow and the mark on thecrankshaft. Position flywheel and install bolts. Tighten bolts to a torqueof 120 +/- 20 Nm (90 +/- 15 lbs-ft).

Note: See Specification section of the Service Manual for moreinformation on flywheel runout checks.

This information can be found in the Disassembly & Assembly Manual.


Page 6

3116/3126 & 3126B New Side CoverReplacement Gasket

The new gasket 4Y9652 replaces 7W9699.

It is currently being used on all 3126B engines.

The 4Y9652 gasket can be used to replace the 7W9699 gasketon all 3100 Product.

The new 4Y9652 gasket does not require the use of anaerobicsealant.


Page 7

Location of Decal for ReportingProblems on 3126B 7AS Engines4 On S/N 7AS00430 through 7AS01437 a 154-1896 Decal will

appear on the fumes disposal tube.

4 If you are not repairing a 7AS 3126B engine with this decalplease call the 1-888-578-3126 number to report the problemsyou may encounter.


Page 8

Required 3126B Service Tool List

Injector Installer

152-1057 Installer

Injector O-Ring Installation Tooling

149-2955 Guide - Seal

149-2956 Installer - Seal

Cylinder Head Bolt Socket

152-1058 Impact Socket

Steel Sleeve Removal Tools

151-4832 Injector Sleeve Removal Tool

150-3152 Injector Sleeve InstallerExhaust Valve

149-4008 Guide Collar

149-6115 Valve Seat Installer


Page 9

C-12 Head Bolt Inspection &Re-Torque4 PIP Program for High Horsepower C-12’s

n 410 HP and Highern Apply after 125,000 miles (200,000 KM)n Includes Valve and Jake Brake Lash Adjustment

4 Procedure:


Page 10

C-12 Head Bolt Inspection &Re-Torque - Procedure4 One Bolt at a time in bolt torque sequence

4 (A) Loosen bolt 1/4 turnType 1 Full Shank Type 2 Reduced Shank

(2PN1-2376 & 1YN1-3233) (All Other serial Numbers)

n (B) Retorque to: 150 Nm (110 LB-FT) 160 Nm (120 LB-FT

+ 90 degree turn +90 degree turn

4 (C) On Left Outside Bolts #15, #17, #19, #21, #23, #25Remove bolt (rather than just loosening)Type 1 Full Shank Type 2 Reduced ShankReplace with 129-3184 Inspect & Replace if pitted

Torque new bolt to: Torque new bolt to: 160 Nm (120 LB-FT) 160 Nm (120 LB-FT) +90 Degree turn +90 Degree turn


Page 11

C-12 Jake Brake Lash SettingChange4 Jake Brake Lash Setting Change

n Serial No. Prefix 9NS Onlyn No Change to Serial No. 1YNn No Change to C-10’s

4 Change Settingn From 1.14 mm (0.045”)n To 1.02 mm (0.040”)

4 Reference Settings: Engine Model Engine Serial No.Prefix

Jacobs ExhaustBrake Model

Slave PistonClearance

9NS 1.02 mm(0.040 in)

C-121YN

312A1.14 mm(0.045 in)

8YSC-10

2PN310A

0.64 mm(0.025 in)

3176B 9CK 310/310A 0.64 mm(0.025 in)


Page 12

3176/3176B/C-10/C-12 Injector HoldDown Bolts4 Improved High Strength Hold Down Bolt Now Used

4 New Part Number: 152-3001Use on all:Engine Serial No.3176 2YG, 7LG, 9CKC-10 2PN, 8YS,C-12 1YN, 9NS

Effective in Production9CK32731

2PN070888YS008201YN124929NS02163

Use Same Special Torque 30 Nm (22 LB-FT)

Bolt


Page 13

3406E PISTON RINGS

4 THE 3406E HAS USED SEVERAL PISTON RINGCOMBINATIONS SINCE FIRST PRODUCTION.

4 WHEN REBUILDING AN E ENGINE THE RINGCOMBINATIONS SHOWN IN THE HANDOUT SHOULD BEUSED. ALSO IN THE HANDOUT IS A BRIEF DESCRIPTIONOF EACH RING FOR FUTURE REFERENCE.

RING PART NUMBERS

SERIAL NUMBER PREFIX TOP INTERMEDIATE OIL5EK & 6TS (Except EURO II) 134-3761 144-5902 7N-7078

1LW 132-6662 139-9126 7E-2990

5DS (3406E 600HP) 153-4101 139-8504 139-8505

EURO II CORE ARRANGEMENTS ARE 130-2314 143-0532


Page 14

3406E PISTON RINGSDescription of Ring Features

------------137.185 mm (5.4 inch) nominal diameter ------------------

134-3761 TOP ring is full keystone compression ring, plasma coated, barrel faced.144-5902 INTERMEDIATE ring is a full keystone compression ring, chrome coating, ID

notch on top, taper faced. It is slightly thicker than the 2P2817 ring it replaces.

7N7078 OIL ring is a slotted ring type with coil spring loading, chrome coating. The axialheight of this ring is 3.14mm (1/8 inch).

132-6662 TOP ring is a full keystone compression ring, plasma coated, offset barrelfaced.

139-9126 INTERMEDIATE ring is a rectangular compression ring, chrome coating, IDnotch on top, taper faced.

7E2990 OIL ring is a slotted ring type with coil spring loading, chrome coating. The axialheight of this ring is 4.00 mm (5/32 inch).


Page 15

3406E PISTON RINGSDescription of Ring Features

-------------139.685 (5.5 inch) nominal diameter ----------------------

153-4101 TOP ring is a full keystone compression ring, plasma coated, ID notch on top,barrel faced

139-8504 INTERMEDIATE ring is a rectangular compression ring, chrome coating, IDnotch on top, taper faced.

139-8505 OIL ring is a slotted ring type with coil spring loading, chrome coating. Theaxial height of this ring is 4.00 mm (5/32 inch).


Page 16

3406E PISTON RINGS

3406E Cylinder Packs4 0R8334 is Replaced by 0R8913 and 0R8912

4 0R8912 is for Euro II Engines ONLY with 130-2314 &

143-0532 core arrangements

4 There is no usage for 0R8912 in the U.S. or Canada


Page 17

3400 C and E Cooling JetPart Numbers

BEGINNING S /N WITH 7/16 BOLT

OIL J ET RB= REPLACED BY

OIL J ET COLOR CODE 1993 UP TYPE

3406C 3406E 3/8 INCH 7/1 6 INCH

11N16054 1LW002284N-9881 RB 7W7496 OR 7W4990

--- NONES INGLE

1LS 00459 5DS 00056 7E-8456 --- RED S INGLE

1RK00087 6BR00861

7W-4990 151-5929 NONE

S INGLE1S S 00230 6TS 25055 7W-7496 --- NONE S INGLE2AM00020 9NN004213ER02359 9WR00489 --- 158-0449 WHITE DUAL3ZJ 61824 100-3851 RB145-6860 --- WHITE DUAL

41Z08066 113-7862 RB 1192294 --- BLACK DUAL

4BM00006 119-2294 --- MED BLUE DUAL4FD01558 145-6860 151-5931 RB 158-0449 YELLOW DUAL4J K00356 155-4010 155-4011 GREEN DUAL

4TB06187 4P-2568 RB 113-7862 --- MED BLUE DUAL

4ZR03354 6I-2992 RB 155-4010 GREEN DUAL5KJ 08432 7E-3632 151-5928 VIOLET DUAL6TB176088PN12372 111-8606 BOLT90U200189AP00245 150-1156 HI FLOW 151-5925 BOLT9NN004159PL00007


Page 18

3406E 600 HP Piston Skirt andCooling Jet4 Part Numbers to Use in Repair

Serial No. Piston Skirt Cooling Jet

5 DS1-55 158-0446 145-6860 (3/8inch)

5DS56-UP 158-0446 158-0449 (7/16inch)


Page 19

3406E Re-Manufactured UnitInjector Rocker Arm4 0R4743 Arm Assembly

• Preferred Repair for Production Arm Assemblyn 137-4060n 130-0075n 126-0075n 6I-3930

• Available in March 1998


Page 20

3406E Head to Block Joint

1LW002285DS00056SERIAL NO. 1LW035035DS00187153-9653


Page 21

3406E Flywheel Housing Gasket

155-5619 Cancels/Replaces 108-5891

Effective with:

6TS26802

1LW00325

5DS00057


Page 22

3406E Fuel Priming Pump

137-5541

In production on 500 HP and Higher on the followingOEM’s:

Peterbilt Kenworth Ford Navistar

on Western Star trucks: All HP ratings

The 105-2508 fuel priming pump is still used in all othertruck applications

Effective Serial numbers:

1LW00228 5 DS00056

The 137-5541 pump is 1.3” taller than the 105-2508 pump


Page 23

3406E Oil Pump

4N8734 Replaces 4N0733 in production 3406E Engines

Higher bypass pressure

Effective with:

6TS12328 & up

1LW1 & up

5DS1 & up

Needed because of the piston/cooling jet changes in some1997 and all 1998 engines

Reman # 0R9057


Page 24

Quick Tip #13116/3126 Sleeve Removal Tool4 Submitted by Craig Stambaugh of Alban Engine in

Sterling, Virginia

4 The 143-2099 injector sleeve replacement tool is a big timesaver.

4 Details are on the following page.


Page 25

Quick Tip #1


Page 26

3126B Troubleshooting Tips

4 Symptom: Allison ATEC or WTEC Transmission huntingbetween top two gears

n Occurs ONLY when operating:n At programmed Vehicle Speed Limit and 100% Throttle Positionn While in Cruise Control

n Software update coming in March


Page 27


4 Average load factor on ET 2.1 Service Tool Status Screenn Incorrect value will be displayed- changing ECM software or ECM will not fix this!

Ignore this!


Page 28


4 Average load factor on ET 2.2 Service Tool Status Screen

ET 2.2 willreplace incorrectvalue with “Unavailable”


Page 29

4 If ECM Personality Module Date is JAN98 ornewer with Electronic Technician 2.1

Status screens and Programmed Parameters will be OK.When available, updating to ET 2.2 will eliminate thismessage and provide additional parameter options.



Page 30

117-7213 Vehicle Speed Filter

4 If ECM Serial Number ends in CJ, CG, or CBn Do NOT use 117-7213 Vehicle Speed Filter

n Misuse will load signal and possible cause more problems than it solves

n For ECMs with CJ and CG suffixn Vehicle speed circuit does NOT route through J24/P24!

ECM Part No.(Serial No. Suffix)

Use Filter(117-7213)

Vehicle Speed Routed ThroughTDC Connector J24/P24

3E-0360 (CA)108-0491 (CA)

YES YES

117-8351 (CA) NO YES

117-4017 (CG)118-7631 (CJ)145-7805 (CG)145-7806 (CJ)

NO NO

120-8974 (CD) YES NO

9X-5566 (CB)145-7807 (CB)

NO NO


Page 31

ECM Serial Number

4 ECM Serial Number available from Configuration Screenon ET


Page 32

ECM Serial Number

4 ECM Serial Number available on first screen as youconnect to ET


Page 33

Oil Pressure Sensor Leaks

4 3176B/C-10/C-12/3406E Enginesn Check o-ring seal mounted on engine

n Check for leak on to sensor

4 Sensor itself does NOT leak oil


Page 34

Transmission Style Options

4 3126B Basicn Not available or used

4 3126B Full Featuren Nine options

4 3116/3126 HEUIn Five options

4 C-10/C-12/3406En Four options


Page 35

3126B Basic Transmission Style

4 Transmission Style Parameter Not Availablen For Manual Transmissions

n Jumper for Transmission Neutral Switch to Batteryn Clutch Pedal Position Switch Required

n For Automatic Transmissionsn Jumper for Clutch Pedal Position Switch to Sensor Commonn Transmission Neutral Switch Requiredn AT/MT/HT Transmission Output Special Test always available

n ECM does not know if AT/MT/HT Transmission is installed

4 7AS- Serial Number Prefix in GM Chassis


Page 36

3126B Basic Transmission Style

4 What is affect of Jumpers Not Installed?

4 Check mark in table means feature will not function ifjumper installed as indicated

J1 = ECM Vehicle Harness ConnectorJ1-22 = ECM Connector J1, Terminal 22+B = + Battery

TransmissionIns talled

JumperIns talled

Cruis eControl

CabPTO

RemotePTO

Fas tIdle

ServiceTool S tatus

Automatic J1-22 to J1-5 OK OK OK OK Clutch = OFF

Manual J1-62 to +B OK OK OK OK Neutra l = ON

Automatic None 3 3 OK 3 Clutch = ON

Manual None OK 3 OK 3 Neutra l = OFF


Page 37

3126B Full Feature TransmissionStyle Options

Switch UsageTransmission StyleParameter Setting

AT/MT/HT TransmissionRelay Usage Service Brake #1 Service Brake #2 Clutch Transmission

Neutral

Manual 4 4

Automatic Option 1 4

Automatic Option 2 4 4

Automatic Option 3 4 4 4

Automatic Option 4 4 4

AT/MT/HT Option 1 4 4

AT/MT/HT Option 2 4 4 4

AT/MT/HT Option 3 4 4 4 4

AT/MT/HT Option 4 4 4 4

4 New with FEB98 Software and ET 2.2

4 7AS- Serial Number Prefix


Page 38

3126B Full Feature TransmissionStyle Options4 What is affect of Programming not matching hardware?4 For Allison WTEC or ATEC a check mark in table means:

n Performance problems may only occur at the programmed Vehicle SpeedLimit with 100% Throttle or, in Cruise Control

4 If AT/MT/Relay not connected or incorrectly connected, shiftpoints dramatically affected, could result in transmissiondamage

TransmissionInstalled

TransmissionStyle Programming

AT/MT/HTRelay

Performance

Allison WTEC Manual Unused 3

Allison WTEC AT/MT/HT Option 1, 2, 3, or 4 Unused 3

Allison ATEC Manual Unused 3

Allison ATEC AT/MT/HT Option 1, 2, 3, or 4 Unused 3

Allison AT/MT/HT Manual 3 3

Allison AT/MT/HT Automatic Option 1, 2, 3, or 4 3 3


Page 39

3126B Full Feature TransmissionStyle Options4 ET 2.1 will still show old Transmission Style options

n ET 2.2 will show new options

OLD PARAMETER SETTINGNEW PARAMETERSETTING Manual Auto w/2

Brk SwAuto w/o2 Brk Sw

AT/MT/HT w/ 2Brk Sw

AT/MT/HT w/ o2 Brk Sw

Manual 4

Automatic Option 1 NOT AVAILABLE

Automatic Option 2 NOT AVAILABLE



AT/MT/HT Option 1 NOT AVAILABLE

AT/MT/HT Option 2 NOT AVAILABLE

AT/MT/HT Option 3 4

AT/MT/HT Option 4 4


Page 40

3126 HEUI Transmission StyleOptions4 For 3126 HEUI engines

n 1WM-, 4ES- Serial Number Prefix



XMSNInterface

ServiceBrake #2

Clutch TransmissionNeutral

Allison WTEC Auto w/ 2 Brk Sw 3 3

Allison WTEC Auto w/o 2 Brk Sw 3

Allison ATEC Auto w/ 2 Brk Sw 3 3

Allison ATEC Auto w/o 2 Brk Sw 3

AllisonAT/MT/HT

AT/MT/HT w/ 2 Brk Sw 3 3 3

AllisonAT/MT/HT

AT/MT/HT w/o 2 Brk Sw 3 3

Manual Manual 3 3


Page 41

3126 HEUI Transmission StyleOptions

4 What is affect of Programming not matching hardware?4 For Allison WTEC or ATEC a check mark in table means:

n Performance problems may only occur at the programmed Vehicle SpeedLimit with 100% Throttle or, in Cruise Control

4 For Allison AT/MT/HT if AT/MT/Relay not connected orincorrectly connected, shift points dramatically affected, couldresult in transmission damage



AT/MT/HTRelay

Performance

Allison WTEC Manual,AT/MT/HT w/ 2 Brk Sw, orAT/MT/HT w/o 2 Brk Sw

Unused 3

Allison ATEC Manual,AT/MT/HT w/ 2 Brk Sw,

or AT/MT/HT w/o 2 Brk Sw

Unused 3

Allison AT/MT/HT Manual, Auto w/ 2 Brk Sw, orAuto w/o 2 Brk Sw

3 3


Page 42

3116 HEUI Transmission StyleOptions4 For 3116 HEUI engines

n 8WL- Serial Number Prefix

n 2nd Service Brake Switch is always installed

n Jumpers used for clutch or neutral


Page 43

3116 HEUI Transmission StyleOptions4 What is affect of Programming not matching hardware?

4 Check mark in table means feature will not function ifjumper installed as indicated


JumperInstalled

CruiseControl

CabPTO

RemotePTO

FastIdle

ServiceTool Status

Automatic J1-24 to J1-29 OK OK OK OK Clutch = OFF

Manual J1-38 to J1-29 OK OK OK OK Neutral = ON

Automatic None 3 3 OK 3 Clutch = ON

Manual None OK 3 OK 3 Neutral = OFF


Page 44

3116 HEUI Transmission StyleOptions4 What is affect of Programming not matching hardware?

4 For Allison WTEC or ATEC:n Performance problems may only occur at the programmed Vehicle Speed

Limit with 100% Throttle or, in Cruise Control

4 For Allison AT/MT/HT:n If AT/MT/Relay not connected or incorrectly connected, shift points

dramatically affected, could result in transmission damage


Page 45

3176B/C-10/C-12/3406ETransmission Style Options4 Four options

n Manual, Auto w/2 Brk Sw, Auto w/o 2 Brk Sw, and Eaton Top 2Transmission

InstalledTransmission

StyleProgramming

PowertrainData Link

ClutchPedal

Switch

ServiceBrake

Switch #2

Multi-FunctionOutput #2


AllisonWTEC

Auto w/ 2 Brk Sw

AllisonWTEC

Auto w/o 2 BrkSw

3

Allison ATEC Auto w/ 2 Brk Sw

Allison ATEC Auto w/o 2 BrkSw

3

Eaton Top 2 Manual 3 3 3

Manual Manual 3

EatonAutoShift

Manual J1939 3

EatonCEEMAT

Auto w/ 2 Brk Sw J1922 3

EatonCEEMAT

Auto w/o 2 BrkSw

J1922

SpicerAutomate 2

Manual J1922 3


Page 46

3176B/C-10/C-12/3406ETransmission Style4 Special consideration for some transmissions


TransmissionStyle

Programming

PowertrainData LinkParameter




Allison WTEC Auto w/ 2 Brk Sw

Allison WTEC Auto w/o 2 Brk Sw

Allison ATEC Auto w/ 2 Brk Sw

Allison ATEC Auto w/o 2 Brk Sw

Eaton Top 2 Eaton Top 2 3 3 3

Manual Manual

Eaton AutoShift Manual J1939

Eaton CEEMAT Auto w/ 2 Brk Sw J1922

Eaton CEEMAT Auto w/o 2 Brk Sw J1922

SpicerAutomate 2

Manual J1922


Page 47

3176B/C-10/C-12/3406ETransmission Style4 What is affect of Programming not matching hardware?


TransmissionStyle

Programming

PowertrainData LinkParameter

Result

Allison WTEC Manual Shift cycling may occur at VSLwith 100% Throttleor in Cruise Control

Allison ATEC Manual Shift cycling may occur at VSLwith 100% Throttleor in Cruise Control

Eaton Top 2 Manual Engine ECM will not shift Top 2Gears, feature disabled. StandardSuper 10 transmission function.

Eaton AutoShift J1922 Engine will not communicate withtransmission. Shifting reverts to

AutoSelect transmission.


Page 48

Automatic Transmission Tips

4 If performing a Torque Converter stall checkn Make sure VSL Protection Customer Parameter is set out of the way

n Set to the maximumn Restore original value after test

4 Vehicle Speed or Cruise Control Speed Set Limits shouldnot be set near shift points

n May result in shift cycling under some conditions


Page 49

Accelerator Pedal Position SensorTroubleshooting4 Before replacing Accelerator Pedal Position Sensor

4 Check wiring harness routingn Re-routing a new harness where the old was may result in repeat failure

n Check harness from sensor back to ECM for intermittent problem

Replacing sensor androuting harness to samelocation will resultin a repeat failure


Page 50

Servicing Engine ECM Connectors

ADEM II

40 pin connector screw serviceable with

part number 6V6703

ADEM III

70 pin connector screw is not serviceable

Replace the connector

Engine Harness Connector 133-8749

OEM Harness Connector 133-8748


Page 51

Improved Atmosphere PressureSensor - C-12/C-12/3406E4 Synthetic boot has been added to reduce moisture entry

4 New sensor part number: 150-7673


Page 52

Cat ID, Version 1.5

4 Each language will have its own EEPROM chip due tomemory limitations

4 In dash hardware - English: 150-8717Spanish: 150-8718French: 150-8719

4 Dash mounted hardware - English: 150-8720

Spanish: 150-8721French: 150-8722

4 Software - English: 150-8868Spanish: 150-8870French: 150-8869


Page 53

Cat ID, Version 1.5

4 New features include support for new Economy ModelVSL Reward feature and a realignment of driver trip,fleet trip, and lifetime totals under the “TotalsInformation” column.


Page 54

Quick Tip #2

Submitted by Wayne Tinkler of Hewitt Equipment

4 3406E Troubleshooting Guide RENR 1328-01 has anerror on page 222

4 It states the 3406E idles at 800 rpm in cold mode. This iswrong

4 The correct idle speed for the 3406 in cold mode is 600rpm


Page 55

3116/3126 Software Release

3116/3126 HEUI

Software Date NOV97

Effective Serial Numbers: 8WL06235

1WM25788

Fixes intermittent Check Engine and Inlet Air Heater lamp inthe JUN97 Release

3126B

Software Date JAN98

First software release on the bulletin board

FIND System Updated


Page 56

1998 Model Year 3406E TruckDEC97 Software Releases4 - DEC97 Software Released For 1998 3406E Trucks

4 - Serial Number Prefixes 1LW (14 liter) and 5DS (16 liter)

4 - Cat ET Version 2.1 (or later) or ECAP (w/SPM NEXG4522Version 2.1 or later)

4 - Multi-Torque Applies to the Top Four Gears UnlessOtherwise Specified

4 - 500 HP Fleet Ratings once flashed are Not Re-Flashable


Page 57

1998 Model Year 3406E TruckDEC97 Software Releases4 - New Fan-On Temp is 216°F and Monitoring Temperatures

have Increased 10°F

4 - Economy Model Vehicle Speed Limit (VSL) Reward

4 - Multi-torque Rating Display on Service Tools

4 - Support for Eaton AutoShift Transmission


Page 58

NEW 3406E TRUCK SOFTWARERELEASE(2300 RPM OFF-ROAD APPLICATION)

- Released For Field Re-Flash Only

4 - Available for 1996, 1997 and 1998n Serial Number Range Listed

4

4 - Software Allows a Higher "TEL" Intended for Off-RoadDriving Truck applications

4 - The ECM Can be set to Govern with Droop up to 2300RPM


Page 59

NEW 3406E TRUCK SOFTWARERELEASE

Serial No. Flash InterlockEngine Rating Information Range File Code

500 HP 1850 PT 1800/2100 5EK67193 & UP 150-7876 132 6TS00001 & UP

500 HP 1850 PT 1800/2100 5EK67193 & UP 150-7878 133BRAKESAVER 6TS00001 & UP550 HP 1850 PT 2100 RPM 5EK67193 & UP 150-7880 134 6TS00001 & UP

550 HP 1850 PT 2100 RPM 5EK67193 & UP 150-7882 135BRAKESAVER 6TS00001 & UP

500 HP 1850PT 1800/2100 1LW00001 & UP 156-8623 141500 HP 1850PT 1800/2100 1LW00001 & UP 156-8624 142BRAKESAVER

550 HP 1850PT 2100 RPM 1LW00001 & UP 156-8625 143

550 HP 1850PT 2100 RPM BRAKESAVER 1LW00001 & UP 156-8626 144

600 HP 2050PT 2100 RPM 5DS00001 & UP 156-8627 145

600 HP 2050PT 2100 RPM BRAKESAVER 5DS00001 & UP 156-8628 146


Page 60

H-D TRUCK SERVICE UPDATEFEB98 SOFTWARE RELEASE4 FEB98 Service Update Released for All 3406E, C-10 and

C-12 Enginesn C-10 Serial Number Prefixes 2PN, 8YS (10 liter)n C-12 Serial Number Prefixes 1YN, 9NS (12 liter)n 3406E Serial Number Prefixes 5EK,6TS,1LW (14 liter) and 5DS (16 liter)n Cat ET version 2.1 (or later) or ECAP (w/SPM NEXG4522 Version 2.1 or later)

4 Key Features provided by the FEB98 Software include:n Economy Model Vehicle Speed Limit (VSL) Rewardn Multi-torque Rating Display on Service Toolsn Support for Eaton AutoShift Transmissionn Updated Remote Message Processing - Uploading


Page 61

Economy Model VSL Reward

4 Effective with OCT97 software for C-10/C-12 and DEC97software for 3406E

4 Provides increased vehicle speed to drivers meeting orexceeding owner expectations

4 Targets, weighting factors, and bonus information

are programmable viaFIS, version 3.0


Page 62

Economy Model VSL Reward

4 Economy Model Report is also available viaFIS 3.0 or greater

4 Drivers can check in

their performance/statusvia Cat ID, Version1.5


Page 63

ET Version 2.2 Release

ET Version 2.2 is scheduled for release in March of 1998. Theupdates that will affect the “Truck World” are as follows:

•Added support for Input #4 which is programmable toTorque Limit Switch and Input #5 which isprogrammable to Ignore Brake / Clutch Switch for3126B Full Feature ADEM III in configuration &status screens.


Page 64


• There is a new Idle Quality Calibration option in theconfiguration screen.


Page 65


• ET will display a list of criteria that need to be met ifyou have not met one or more of these criteria.


Page 66


• Customer Parameter range checking. If you change avalue in configuration and the new value is out ofrange, ET will display the allowable range. Thesevalues are read directly from the ECM.


Page 67


• The Fan Driver parameter has been added to the statusscreen.


Page 68


• Also, the following features have been added forHeavy Duty and 3126B Full Feature ADEM III:

• Support has been added for Input #6, which can beprogrammed to Two-Speed Axle on/off switch.

• Once programmed, this will allow you to change the LowSpeed Range Axle Ratio & the High Speed Range Axle Ratioin Configuration.

4 File Management has also been enhanced. You can nowexport an entire file full of documents for easier transfer of agroup of files from one computer to another.


Page 69

ET Trainer Announcement

4 In addition to the new features, ET Version 2.2 will includeCat ET Trainer.

4 Simulates the major diagnostic features of an Off-highway‘777’ Truck Engine Control

4 Does not require being physically connected to an ECM or aCommunications Adapter.

4 There’s no charge for CAT ET Trainer, and authorization isnot required.

4 We plan to provide simulation of On-highway Truck Enginesin ET Version 2.3.


Page 70

ET Trainer Announcement


Page 71

ET for Technical Schools

We are also releasing a version of Cat ET designed for collegesand Technical schools.

• Allows students to connect to the school’s training engines for electronic enginetraining.

For more information, please contact:• Caterpillar Service Technology Group• Caterpillar Inc.• 1-800-542-8665 (USA)• 1-800-541-8665 (Illinois)• 1-800-523-8665 (Canada)• CSTG (Hotline E-mail)• 022 849 4036 (Geneva Phone)• 022 849 4544 (Geneva Fax)


Page 72

ET for Technical Schools

4 36CSTG (COSA E-Mail)


Page 73

Customer ET

4 Customer ET will be included in version 2.2• No access to sensitive factory and dealer password controlled functions.

• No versions of Customer ET have the ability to FLASH the Electronic ControlModule!

• The Customer version of ET will provide equipment owners with importantinformation they need to improve the operation and maintenance of their equipment.

4 Changing from full version subscription to customersubscription:

• Install ET Version 2.2 on your customer’s computer

• Call the PC Doctor @ 1-800-843-7237 and tell them you wish to transfer yourcustomer’s license to the customer version.

• They will then walk you through the license transfer process, which is very similarto the license process.


Page 74

Customer ET

For more information, please contact:•Caterpillar Service Technology Group•Caterpillar Inc.•1-800-542-8665 (USA)•1-800-541-8665 (Illinois)•1-800-523-8665 (Canada)•CSTG (Hotline E-mail)•022 849 4036 (Geneva Phone)•022 849 4544 (Geneva Fax)


Page 75

Customer ET

4 36CSTG (COSA E-Mail)


Page 76

FIS Version 3.1

4 FIS will also be upgrading late 1st quarter ’98. Some of theenhancements to Version 3.1 will include:

• On direct connections with the communications adapter, you will be able to view theATA rating description.

• You may now transfer a vehicle from one fleet to another.


Page 77

FIS Version 3.1

• FIS now has the ability to perform a backup of your data. For an effective backup,you should have the backup files copied to an area other than where your FIS data islocated, like a floppy or a network drive in your office.


Page 78

FIS Version 3.1

• There is a new report available - ‘Vehicle Ranking’. This report will allow you torank your fleet on a specific parameter and list the best or the worst according toyour selections.


Page 79

FIS Version 3.1

• The master configuration has also been updated. You now have the ability to allowone or more parameters to be specified, rather then having to program all of theavailable parameters.


Page 80

SIS for Windows

4 Caterpillar has officially announced SIS V4.0 for Windows.This version includes a search by part #’s. The next versionof SIS for Windows, which is due mid 1998, will include thefull text search and other program enhancements.

4 Caterpillar will continue to support the OS/2 version of SISwith data upgrades. However, the sale of the OS/2 versionwill only be offered until the Windows version is fullycomplete.

• The January update of SIS included a postcard that dealers should return for a FREEupgrade to the Windows platform.


Page 81

SIS for Windows

• Customers will also receive a card that will ask them to contact their dealer to upgrade tothe Windows platform.

4 As in the past, your first line of support is your on-site SISCoordinator followed by the support available from yourMarketing Subsidiary.


Page 82

Dealer Additions CD

4 Starting with ET Version 2.2, we will be releasing flash fileson a separate ‘Dealer Additions CD’. This CD will alsocontain some additional ET training material that has been puttogether by service training.


Page 83

ECAP Version 2.2 Truck SPMRelease4 The On-highway truck SPM Version 2.2 updates are expected

to be released end of 1st quarter 1998 and will contain manyof the same updates as ET, these include:

• Added support for Input #4 which is programmable to Torque Limit Switch andInput #5 which is programmable to Ignore Brake / Clutch Switch for 3126B FullFeature ADEM III in configuration & status screens.

• There is a new Idle Quality Calibration option in the configuration screen. ECAPwill display a list of criteria that need to be met if you have not met one or more ofthese criteria.

• Customer Parameter range checking. If you change a value in configuration and thenew value is out of range, ECAP will display the allowable range. These values areread directly from the ECM.


Page 84

ECAP Version 2.2 Truck SPMRelease

• Also, the following features have been added for Heavy Duty and 3126B FullFeature ADEM III:

• Support has been added for Input #6, which can be programmed to Two-Speed Axleon/off switch.

• Once programmed, this will allow you to change the Low Speed Range AxleRatio & the High Speed Range Axle Ratio in Configuration.


Page 85

3126B Service Publications

REHS0215 - PTO Installation and Application InstructionRENR1367 - Electronic Troubleshooting GuideRENR1390 - Fuel System and Electronics System Operation

and Troubleshooting (CD-ROM)LEVN4296 - Fuel System and Electronic System Operation

and Troubleshooting (Video)


Page 86

Ordering Information for 1998Manuals4 1998 Operation and Maintenance Manuals

n 3126B SEBU7011n C-10/C-12/3406E SEBU7088

4 1998 Service Manualsn 3126B RENR 1360n C-10/C-12 RENR 1320n 3406E RENR 1275

4 1998 Parts Manualsn 3126B SEBP 2744n C-10 SEBP 2725n C-12 SEBP 2697n 3406E: 1LW SEBP 2743

5DS SEBP 2741


Page 87

Electronic Controls Part NumberReference


Page 88

Serial Number Prefixes – 3116/3126

4 1WM 3126 HEUIn 1995 to Current

4 8WL 3116 HEUIn 1995 to Current

4 7AS3126Bn 1998


Page 89

Serial Number Prefixes -C-10, C-12& 31764 2YG 3176

n 1988 to 1990

4 7LG 3176n 1991 to December 1993

4 9CK 3176Bn May 1993 to Current

4 2PN C-10n March 1995 to Current

4 8YS C-10n September 1997 to Current

4 1YN C-12n March 1995 to Current

4 9NS C-12n September 1997 to current


Page 90

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 1LW3406E 14.6Ln December 1997

4 5DS 3406E 15.8Ln December 1997


Page 91

3116 HEUI & 3126 HEUI —Electronic Parts

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

n ECM Connector Bolt Kit – 6V6703

n 40 Pin Plug Assembly – 114-4408 (includes 110-6844 Seal)n 40 Pin Connector Seal – 110-6844

n Speed/Timing Sensor Service Kit – 119-4142n 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 – 111-2351n 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 – 3E7700

n Fuel Transfer Pump to Hydraulic Pump O-Ring – 004-1963

n Hydraulic Pump Dome O-Ring – 6V5656


Page 92

Other 3116 HEUI & 3126 HEUIParts4 Part Numbers missing for Parts Books (3116 HEUI –

SEBP2271 and 3126 HEUI SEBP2355)n 123-1199 Seal for Injector and IAPCV Connectors

n 118-8622 Service Replacement Harnessn 40 pin to Injectors

n 122-8840 Service Replacement Harnessn 40 pin to Speed/Timing Sensor

n 122-8842 Service Replacement Harnessn 40 pin to IAPCV

n 122-8839 Service Replacement Harnessn 40 pin to all other sensors

n 141-7060 Injector Wiring Harness Connector Repair Kit

n 143-8325 Injection Actuation Pressure Sensor Guard


Page 93

3126 Electronic Control and Sensors4ECM (Full Feature) 149-6990 (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


Page 94

C-10, C-12, 3176B & 3406E CurrentParts4 C-10 - 2PN & 8YS, C-12 - 1YN & 9YS, 3176B - 9CK &

3406E - 5EK & 6TSn Electronic Control Module (ECM) - 145-7806

n ECM with J1939 Data Link Option - 145-7805

n Speed/Timing Sensorn 3406E — 129-6628 Sensor

n 126-8481 Shim (0.020”)

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

n Coolant/Fuel Temperature Sensor - 102-2240

n Air Inlet Temperature Sensor - 107-8618

n Boost Sensor - 111-2351

n Atmospheric Pressure Sensor 150-7673

n Oil Pressure Sensor - 111-2350

n Pedal Mounted Throttle Position Sensor - 3E7700


Page 95

3176 —2YG Current Parts

4 3176 - 2YGn ECM - 9X9529 0R6149

n ECM FORD - 9X9528 / 0R6148

n Transducer module - 9X8226 / 0R6132

n Harness - 7E8421

n Speed/Timing Sensor - 102-9029

n Fuel Pressure Sensor - 107-7142

n Coolant Temperature Sensor - 9X5370

n Vehicle Speed Buffer - 3E0020

n Remote Mounted Throttle position Sensor - 9X9648n Remote Mounted Throttle Position Sensor - FORD - 9X9647

n Pedal Mounted Throttle Position Sensor - 110-8190


Page 96

3176 — 7LG Current Parts

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

n Altitude Retrofit - 3E8644 / 0R6470

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

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

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 - 9X9648

n Remote Mounted Throttle Position Sensor - FORD - 9X9647



Page 97

3406C Electronic Current Parts

4 3406C - 4CKn 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 Remote Mounted Oil Pressure Sensor Kit - 118-6256


Page 98

PEEC II.V Current Parts

4 PEEC - 8TC and 2EK - FORD Onlyn ECM - 9X4840 / 0R6081





n BTM - 105-2939

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


n If the engine (2EK and 5YG) has had the White Smoke Product SupportProgram performed. The following parts will be installed:

n 6I2382 - Wiring Harnessn 9X5370 - Temperature


Page 99

PEEC II Current Parts

4 PEEC II - 8TC, 5YG and 2EKn ECM - 8T8770 / 0R5607





n BTM - 105-2939

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


n If the engine (2EK and 5YG) has had the White Smoke Product SupportProgram performed. The following parts will be installed:

n 6I2382 - Wiring Harnessn 9X5370 - Temperature


Page 100

Binder Labels

4 Labels for Standard Cat Binder (SENR2910) are availablefor your Tech Tips Handouts

n SENR5100 - 1998 Truckn SENR5101 - 1998 Cat Machine

Engines Commercial Enginesn Available Feb. 1, 1998


Page 101

Broadcast Information

4 Update Broadcast Informationn LEVN3357 - “Tech Tips” Broadcast - Feb. 7, 1996n LEVN3377 - “Tech Tips” Broadcast - May 8, 1996n LEVN3803 - “Tech Tips” Broadcast - Aug. 21, 1996n LEVN3899 - “Tech Tips” Broadcast - Nov. 13, 1996n LEVN3975 - “Tech Tips” Broadcast - Feb. 5, 1997n LEVN4034 - “Tech Tips” Broadcast - April 23, 1997n LEVN4115 - “Tech Tips” Broadcast - Aug. 20, 1997n LEVN4194 - “Tech Tips” Broadcast - Nov. 11, 1997

4 Broadcast Schedule for 1998n February 11n May 13n Aug 12n Nov 11

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