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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
October 2007 – AEVD6307 - Page 3
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
October 2007 – AEVD6307 - Page 4
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
October 2007 – AEVD6307 - Page 6
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
October 2007 – AEVD6307 - Page 7
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
October 2007 – AEVD6307 - Page 8
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.
October 2007 – AEVD6307 - Page 9
152-1057 Injector Tool - Removal
October 2007 – AEVD6307 - Page 10
152-1057 Injector Tool - Install
October 2007 – AEVD6307 - Page 11
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
October 2007 – AEVD6307 - Page 12
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
October 2007 – AEVD6307 - Page 13
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
October 2007 – AEVD6307 - Page 14
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
October 2007 – AEVD6307 - Page 15
• 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
October 2007 – AEVD6307 - Page 16
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
October 2007 – AEVD6307 - Page 18
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
October 2007 – AEVD6307 - Page 19
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
October 2007 – AEVD6307 - Page 20
LPFS System Photos 6V-3683 O-Ring Machined Snout
CATERPILLAR P/N 280-2698
High Flow Primary Fuel Bases
REV0 & REV 1
October 2007 – AEVD6307 - Page 21
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
October 2007 – AEVD6307 - Page 22
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
October 2007 – AEVD6307 - Page 23
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
October 2007 – AEVD6307 - Page 24
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
October 2007 – AEVD6307 - Page 25
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
October 2007 – AEVD6307 - Page 26
October 2007 – AEVD6307 - Page 27
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
October 2007 – AEVD6307 - Page 28
Torque Converter Stall Example
October 2007 – AEVD6307 - Page 29
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.
October 2007 – AEVD6307 - Page 30
0 to 20 MPH Example
5.5 secSCAAN ACCELERATION TEST VEHICLE NOT
LOADED IN THIS EXAMPLE
Page 31
2007 Focus Team / DSN coverageTim Stear
October 2007 – AEVD6307 - Page 32
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
October 2007 – AEVD6307 - Page 33
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
October 2007 – AEVD6307 - Page 34
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
October 2007 – AEVD6307 - Page 35
2007 On Highway DSN Team
Page 36
2007 HD UpdateJack Maroney
October 2007 – AEVD6307 - Page 37
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
October 2007 – AEVD6307 - Page 38
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.
October 2007 – AEVD6307 - Page 39
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.
October 2007 – AEVD6307 - Page 40
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.
October 2007 – AEVD6307 - Page 41
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
October 2007 – AEVD6307 - Page 42
Sensor Identification
Added Columns:
SensorLocation
ConnectorLocation
Added Pictures:The numbers in the
table match thenumbers in the picture
Code
Sensor
Connector
October 2007 – AEVD6307 - Page 43
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
October 2007 – AEVD6307 - Page 44
Heavy Duty Purge Air System
Purge air pump
Purge air pump filter
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
October 2007 – AEVD6307 - Page 45
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)
Heavy Duty Purge Air System
October 2007 – AEVD6307 - Page 46
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.
Heavy Duty Purge Air System
Purge air pump
Purge air pump filter
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)
October 2007 – AEVD6307 - Page 47
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
October 2007 – AEVD6307 - Page 48
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.
October 2007 – AEVD6307 - Page 49
The Road with Confidence
Brochure PEDJ0076 (10pages)ref: 2007 C13/C15 O&MM SEBU8087
Page 50
2007 MR UpdateMike Burhoe
October 2007 – AEVD6307 - Page 51
C7/C9 Service LettersBe sure to perform all open service letters. There are a few that apply to the C7 and C9 engines.
October 2007 – AEVD6307 - Page 52
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
October 2007 – AEVD6307 - Page 53
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.
October 2007 – AEVD6307 - Page 54
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.
October 2007 – AEVD6307 - Page 55
Oil Passing Through Turbo
October 2007 – AEVD6307 - Page 56
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
October 2007 – AEVD6307 - Page 57
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.
October 2007 – AEVD6307 - Page 58
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.
October 2007 – AEVD6307 - Page 59
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.
October 2007 – AEVD6307 - Page 60
2007 Truck Videoshttps://truck.cat.com/cda/layout?m=121186&x=7
October 2007 – AEVD6307 - Page 61
2007 Truck Videoshttps://truck.cat.com/cda/layout?m=121186&x=7
Page 62
DPF Inspection TipsMatt Bober
October 2007 – AEVD6307 - Page 63
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.
October 2007 – AEVD6307 - Page 64
DPF visual inspections DPF visual inspections
Outlet SideOutlet Side
• This is failed• Black soot covered on outlet
October 2007 – AEVD6307 - Page 65
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
October 2007 – AEVD6307 - Page 66
Inlet SideInlet Side
DPF visual inspectionsDPF visual inspections
• Can’t determine if this is failed based on the inlet side• The outlet side is the only viable criteria for determining failure
October 2007 – AEVD6307 - Page 67
Outlet SideOutlet Side
DPF visual inspectionsDPF visual inspections
• This is not failed• There is normal “staining” from operation and also rust at the 6 o’clockposition
October 2007 – AEVD6307 - Page 68
Outlet SideOutlet Side
DPF visual inspectionsDPF visual inspections
• This is failed• More difficult to determine at first glance• White Glove test would work well
October 2007 – AEVD6307 - Page 69
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
October 2007 – AEVD6307 - Page 70
Burnt CellBurnt Cell
DPF visual inspectionsDPF visual inspections
• The individual burnt cells indicate internal damage to the DPF • This will cause black smoke during engine operation
October 2007 – AEVD6307 - Page 71
2007 TC Conference Videoshttps://truck.cat.com/cda/layout?m=121186&x=7
ComingSoon…
Page 72
2007 ElectronicsAndy Zich
October 2007 – AEVD6307 - Page 73
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
October 2007 – AEVD6307 - Page 74
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
October 2007 – AEVD6307 - Page 75
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
October 2007 – AEVD6307 - Page 76
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
October 2007 – AEVD6307 - Page 77
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)
October 2007 – AEVD6307 - Page 78
Add Button for Active Events
October 2007 – AEVD6307 - Page 79
Add button for Active Events
October 2007 – AEVD6307 - Page 80
Add button for Active Events
October 2007 – AEVD6307 - Page 81
Adding Test Results to Warranty Report
October 2007 – AEVD6307 - Page 82
2007 Component I.D.
TC Conference - Sept2007
Page 83
Transmission UpdateDennis Myers II
October 2007 – AEVD6307 - Page 84
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
October 2007 – AEVD6307 - Page 85
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
October 2007 – AEVD6307 - Page 86
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
October 2007 – AEVD6307 - Page 87
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
October 2007 – AEVD6307 - Page 88
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
October 2007 – AEVD6307 - Page 89
Spec Sheet and A&I InformationSpec Sheet and A&I Information
Page 90
Cat Training Update
October 2007 – AEVD6307 - Page 91
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
October 2007 – AEVD6307 - Page 92
Instructor Led Course Registration
October 2007 – AEVD6307 - Page 93
Instructor Led Course Registration
October 2007 – AEVD6307 - Page 94
Instructor Led Course Registration
October 2007 – AEVD6307 - Page 95
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!
October 2007 – AEVD6307 - Page 97
Curriculum Maps
Successful Completion of the WBT & Diagnostic Exercises is Pre-requisite for ILT
October 2007 – AEVD6307 - Page 98
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
October 2007 – AEVD6307 - Page 99
Certification / Gap Analysis Test2 purposes – 1 tool
• Systems Certification• Skill Gap AnalysisAccessed through DLMS
Page 100
Reman UpdateMarty Young
October 2007 – AEVD6307 - Page 101
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
October 2007 – AEVD6307 - Page 102
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.
October 2007 – AEVD6307 - Page 103
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.
October 2007 – AEVD6307 - Page 104
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
October 2007 – AEVD6307 - Page 105
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
October 2007 – AEVD6307 - Page 106
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
October 2007 – AEVD6307 - Page 107
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.
October 2007 – AEVD6307 - Page 108
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
October 2007 – AEVD6307 - Page 109
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
October 2007 – AEVD6307 - Page 111
Regeneration Info
LEDT7022 - “The DPF Regeneration Lamps, Switches and Driver Tips
Did Look Like This!
Now Looks Like This!
October 2007 – AEVD6307 - Page 112
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
October 2007 – AEVD6307 - Page 113
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
October 2007 – AEVD6307 - Page 114
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
October 2007 – AEVD6307 - Page 115
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
October 2007 – AEVD6307 - Page 116
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
October 2007 – AEVD6307 - Page 117
FPS Screen for Checking
Factory Password Checking App• Enter DPF Serial Number• Miles on the Truck• Yes/No
Page 118
Ash Cleaning Methods
October 2007 – AEVD6307 - Page 119
Ash Cleaning Methods
Cleaning ToolClean ExchangeRemanNew
Preferred MethodPreferred Method
October 2007 – AEVD6307 - Page 120
Ash Cleaning Methods
Cleaning Tool• Preferred Method
Off Vehicle
• Least Expensive for the Customer$500 - $700
October 2007 – AEVD6307 - Page 121
Ash Cleaning Methods
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
October 2007 – AEVD6307 - Page 122
Ash Cleaning Methods
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
October 2007 – AEVD6307 - Page 123
Ash Cleaning Methods
Reman - Pending• Upgrade to New• No Tool• Core Return• Even Higher Cost to Customer
$3,900 USD D/N - Estimated13x17 (Used on C13/C15)
October 2007 – AEVD6307 - Page 124
Ash Cleaning Methods
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
October 2007 – AEVD6307 - Page 126
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
October 2007 – AEVD6307 - Page 127
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
October 2007 – AEVD6307 - Page 129
Ash Cleaning Process
Regen DPF on the Truck• Cat ET attached• Ash Service TestLet Cool and Remove FilterPlace Filter in Tool
October 2007 – AEVD6307 - Page 130
Adapter
Seal
Seal
DPF
Ash Cleaning Process
•Various adaptors for the different DPF’s
•1 adaptor can be used for multiple sizes
October 2007 – AEVD6307 - Page 131
Hand Pump Raises the bed
Seals DPF in Tool
Ash Cleaning Process
Bed
Hydraulic Cylinders
October 2007 – AEVD6307 - Page 132
Ash Cleaning Process
Start Process• Push Start
Air Flow≈ 45 MinutesTotally AutomatedSounds like
disconnecting an air hose
October 2007 – AEVD6307 - Page 133
Ash Cleaning Process
AshCollectionArea
October 2007 – AEVD6307 - Page 134
Ash Cleaning Process
Remove Filter from ToolRe-install on Truck• Replace SealsHook-up Cat ET• Reset Ash Model• Interim Process - Call DSNSend the truck on its way!
October 2007 – AEVD6307 - Page 135
Ash Cleaning Process
Cost• Total time ≈ 4 hours labor• Consumable Costs• Tool Cost• Gaskets• Tool DepreciationCustomer Cost• $500 to $700 USD
October 2007 – AEVD6307 - Page 136
Consumables
Five Items • HEPA Filter• Cartridge Filters (2)• Disposal Bucket• Air Dryer Desiccant• Coalescing Filter
October 2007 – AEVD6307 - Page 137
Consumables
HEPA Filter• 319-2193• Life
500 - 1000 DPF Cleanings
• Cost$840.76 USD D/N
October 2007 – AEVD6307 - Page 138
Consumables
Cartridge filter • 319-2194• 14 dia, 30 long• 2 filters/pack
Life15 to 100 DPF Cleanings
• Cost$ 349.45 USD D/N
October 2007 – AEVD6307 - Page 139
Consumables
Soot in DPF dramatically shortens Cartridge Filter
life!
Soot in DPF dramatically shortens Cartridge Filter
life!
Regen beforeCleaning DPF
Regen beforebeforeCleaning DPF
October 2007 – AEVD6307 - Page 140
Consumables
Filter Bucket• 319-1833• Life
3 or 4 per clean outClean out every 15 - 100 DPF
Cleanings
• Cost$90.70 USD D/N
October 2007 – AEVD6307 - Page 141
Consumables
Air Dryer Desiccant• 320-2679• Life
25 DPF CleaningsCan be oven dried and re-used
• Cost$86.84 USD D/N
October 2007 – AEVD6307 - Page 142
Consumables
Coalescing Filter• 320-2680• Life
500+ DPF Cleanings
• Cost$65.91 USD D/N
Page 143
Part Numbers & Costs
October 2007 – AEVD6307 - Page 144
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
October 2007 – AEVD6307 - Page 145
*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
October 2007 – AEVD6307 - Page 146
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
October 2007 – AEVD6307 - Page 147
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?
October 2007 – AEVD6307 - Page 148
Cleaning Opportunities
Page 149
Biodiesel
October 2007 – AEVD6307 - Page 150
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
October 2007 – AEVD6307 - Page 151
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
October 2007 – AEVD6307 - Page 152
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
October 2007 – AEVD6307 - Page 153
2007 On-Highway Engines Biodiesel
Status for 2007 Engines• On-Highway engines
Requirements under review
October 2007 – AEVD6307 - Page 154
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
October 2007 – AEVD6307 - Page 156
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
October 2007 – AEVD6307 - Page 157
ULSD Availability
Flying J• 89% (158/178) have ULSD• 61% (109/178) have Low Sulfur
October 2007 – AEVD6307 - Page 158
ULSD Availability
Pockets of unavailability• I-75 - Atlanta to Lake City,FLUnlabeled Pumps• Labels Required
LSD or ULSD
October 2007 – AEVD6307 - Page 159
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
October 2007 – AEVD6307 - Page 161
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
October 2007 – AEVD6307 - Page 162
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
October 2007 – AEVD6307 - Page 163
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
October 2007 – AEVD6307 - Page 164
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
October 2007 – AEVD6307 - Page 165
October 2007 – AEVD6307 - Page 166
Questions…
Email: [email protected] 1-877-494-4700#353707#3359391
October 2007 – AEVD6307 - Page 167
Keepin’ in Touch
Training
Broadcast ScheduleeEvaluationeMailElectronic PNsHandoutsVideo Replays
Handouts
http
s://t
ruck
.cat
.com
October 2007 – AEVD6307 - Page 168
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)
October 2007 – AEVD6307 - Page 169
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