Robert FalkinghamRobert FalkinghamNational Accounts Product National Accounts Product

Support ManagerSupport ManagerOn-Highway Engine On-Highway Engine

ProductsProducts

10-13L Service Letter 10-13L Service Letter UpdateUpdate

PS50041 (C-10/C-12 Head Gasket Repair)PS50041 (C-10/C-12 Head Gasket Repair)– Scheduled to Expire January 31Scheduled to Expire January 31stst 2004 2004– Extended Until the End of MayExtended Until the End of May

PS50338 (C-10 – C-15 Injector Tip)PS50338 (C-10 – C-15 Injector Tip)– Expired December 2003Expired December 2003– Will Not be ExtendedWill Not be Extended

C11/C13 Push Tube C11/C13 Push Tube InstallationInstallation

Valve Push Tube Installation ProblemsValve Push Tube Installation Problems– CPI IssueCPI Issue: 55852: 55852

– ProblemProblem: Intake and Exhaust Push Tubes : Intake and Exhaust Push Tubes can be installed incorrectlycan be installed incorrectly• Ball end outside of lifter pocketBall end outside of lifter pocket

C11/C13 Push Tube C11/C13 Push Tube InstallationInstallation

– Affected ProductAffected Product: All C11/C13: All C11/C13

– FixFix: Ensure Push Tubes are installed : Ensure Push Tubes are installed correctly during assembly by correctly during assembly by inspection.inspection.

– CommunicationCommunication: TEN Article : TEN Article Planned 2Planned 2ndnd Quarter 2004 Quarter 2004

ACERT Air Compressor Air ACERT Air Compressor Air BoxBox

Debris Related Debris Related Failures on Air Failures on Air CompressorCompressor– CPI IssueCPI Issue: 57620: 57620

– ProblemProblem: Carry : Carry over debris from over debris from Air Box Resulting Air Box Resulting in Air Compressor in Air Compressor FailureFailure

– C15 Air C15 Air Compressor GroupCompressor Group

Air Box

ACERT Air Compressor Air ACERT Air Compressor Air BoxBox– C13 Air BoxC13 Air Box

– Affected ProductAffected Product: All HD ACERT Engines: All HD ACERT Engines

– FixFix: Ensure the air box is free of debris after a repair where the : Ensure the air box is free of debris after a repair where the air compressor incurred a core iron failure (ie. Piston failure)air compressor incurred a core iron failure (ie. Piston failure)

– CommunicationCommunication: TEN Article 2: TEN Article 2ndnd Quarter 2004 Quarter 2004

Air Box

C13 Air Compressor VibrationC13 Air Compressor Vibration BA 921 Single Cylinder Air CompressorBA 921 Single Cylinder Air Compressor

– CPI IssueCPI Issue: 54887: 54887

– ProblemProblem: The new BA-921 Single Cylinder Air : The new BA-921 Single Cylinder Air Compressor can excite engine chassis vibrationCompressor can excite engine chassis vibration• Vibration Meter Reading 1.14 Order (1.14 x Vibration Meter Reading 1.14 Order (1.14 x

crank speed)crank speed)

– Affected ProductAffected Product: KCB00508 – KCB01638 : KCB00508 – KCB01638

– FixFix: New Counter Weight Gear to Reduce Air : New Counter Weight Gear to Reduce Air Compressor imbalance. Compressor imbalance.

– CommunicationCommunication: TEN Article Planned Late 1: TEN Article Planned Late 1stst Quarter 2004Quarter 2004

C13 AC Pressure Switch C13 AC Pressure Switch FunctionFunction

AC Pressure Switch FunctionAC Pressure Switch Function– CPI IssueCPI Issue: 56933: 56933

– ProblemProblem: : ECM software has a non-ECM software has a non-functional Air Conditioner Input Switchfunctional Air Conditioner Input Switch

– Affected ProductAffected Product: KCB00891 – KCB01676: KCB00891 – KCB01676

– FixFix: February Release Software: February Release Software

– CommunicationCommunication: TIB Planned for Mid : TIB Planned for Mid FebruaryFebruary

C13 SurgeC13 Surge C13 SurgeC13 Surge

– CPI IssueCPI Issue: 56110: 56110

– ProblemProblem: Small Number of Chassis Configurations : Small Number of Chassis Configurations Excite the Driveline with the C13 EngineExcite the Driveline with the C13 Engine• Typically referred to as “violent” surge during Typically referred to as “violent” surge during

slight accelerationslight acceleration

– Affected ProductAffected Product: KCB00508 – KCB02033: KCB00508 – KCB02033

– FixFix: February Release Software: February Release Software

– CommunicationCommunication: Scheduled TIB for Early February: Scheduled TIB for Early February

C-10/C-12/C-15/C-16 C-10/C-12/C-15/C-16 Injector R&IInjector R&I

Slightly modified procedure for Slightly modified procedure for R&I injectorsR&I injectors– CPI IssueCPI Issue: 51168: 51168

– ProblemProblem: Injector hold down bolt : Injector hold down bolt failures after servicefailures after service

– Affected ProductAffected Product: All Heavy Duty : All Heavy Duty EnginesEngines

C-10/C-12/C-15/C-16 Injector C-10/C-12/C-15/C-16 Injector R&IR&I

Slightly modified procedure for R&I injectorsSlightly modified procedure for R&I injectors– FixFix: New Remove and Install Procedure: New Remove and Install Procedure

A.A. Make sure to mark which cylinderMake sure to mark which cylinder unit injector, spacer, unit injector, spacer, clamp, and bride assemblies came from.clamp, and bride assemblies came from.

i.i. Reinstall these parts on the same cylinder they were removed Reinstall these parts on the same cylinder they were removed from.from.

B.B. Inspect the hold down bolt assembly prior to disassembly.Inspect the hold down bolt assembly prior to disassembly. i.i. If the bolt is If the bolt is NOTNOT loose during disassembly, then proceed loose during disassembly, then proceed

directly to step C.directly to step C.ii.ii. If the hold down bolt If the hold down bolt ISIS loose during disassembly: loose during disassembly:

a.a. Inspect the injector bore for debrisInspect the injector bore for debrisb.b. Inspect the bore for wearInspect the bore for wearc.c. ReplaceReplace the clamp, and spacer Proceed to step C the clamp, and spacer Proceed to step C

C.C. NOTE: In NOTE: In ALLALL instances, instances, replacereplace the injector hold down the injector hold down bolt with a bolt with a NEWNEW bolt bolt

D.D. Do Do NOTNOT reuse seals or hold down bolts. reuse seals or hold down bolts.

– CommunicationCommunication: TEN Article Planned 1: TEN Article Planned 1stst Quarter 2004 Quarter 2004

PS50667 Exhaust Rocker PS50667 Exhaust Rocker ArmsArms

Affected serial numbersAffected serial numbers– 6NZ83126-Up6NZ83126-Up– 7CZ3834-Up7CZ3834-Up– MBN1-22118MBN1-22118

Engines with Jacobs 340D BrakeEngines with Jacobs 340D Brake Replace all exhaust rocker armsReplace all exhaust rocker arms Replace intake rocker arm on failed Replace intake rocker arm on failed

cylindercylinder Replace all compression brake bolts and Replace all compression brake bolts and

studs studs Set brake slave lashSet brake slave lash

– 6NZ83126-Up 0.025”6NZ83126-Up 0.025”– 7CZ3834-Up 0.025”7CZ3834-Up 0.025”– MBN1-22118 0.030”MBN1-22118 0.030”

PS50740 C-15 Truck PS50740 C-15 Truck Cylinder LinerCylinder Liner

After FailureAfter Failure Serial numbers includedSerial numbers included

– MBN12044-21022,6NZ91415-92097,C2A131-141MBN12044-21022,6NZ91415-92097,C2A131-141– 8SB3066-3067,7XC12188-12259,2MZ562-5838SB3066-3067,7XC12188-12259,2MZ562-583– 4AS665-6894AS665-689

Inspect date codesInspect date codes– Replace affected liners as outlined in the Replace affected liners as outlined in the

service letterservice letter

C15 BXS Turbo C15 BXS Turbo MountingMounting

Use Spiralock nuts onlyUse Spiralock nuts only– Part Number 168-7800Part Number 168-7800– Torque to 55 ± 5 N·m (40.6 ± 3.7 lb ft.)Torque to 55 ± 5 N·m (40.6 ± 3.7 lb ft.)

Use Stainless Steel StudsUse Stainless Steel Studs– Part Number 238-4665Part Number 238-4665

Use turbo mounting gasket  Use turbo mounting gasket  – Part Number 243-6462Part Number 243-6462

Nuts will spin on easilyNuts will spin on easily No stake marks on nutNo stake marks on nut Over tightening can cause the stud to failOver tightening can cause the stud to fail

C15 BXS Turbo C15 BXS Turbo MountingMounting

C15 BXS Turbo C15 BXS Turbo MountingMounting

238-4665 Stud168-7800 Spiralock Nuts

Use turbo gasket 243-6462 

C15 BXS Valve Actuator C15 BXS Valve Actuator WiringWiring

Solenoid connector same as medium Solenoid connector same as medium duty injectorduty injector

Kit can be used for repairKit can be used for repair– Part number 156-7106Part number 156-7106

Repair procedureRepair procedure– REHS1809 Special Instruction REHS1809 Special Instruction

Less downtime for the customerLess downtime for the customer Keep wiring out of discharge stream Keep wiring out of discharge stream

of valve actuatorof valve actuator– Can deflect oil causing oil mist from Can deflect oil causing oil mist from

breatherbreather

What’s NewWhat’s NewEaton Top IIEaton Top II

New Gear Fast Run Slow flash files. (GFRS)New Gear Fast Run Slow flash files. (GFRS)On GFRS flash files the transmission style will show up as Eaton On GFRS flash files the transmission style will show up as Eaton

Top II. The transmission style is not programmable with the Top II. The transmission style is not programmable with the GFRS files.GFRS files.

Only for Eaton Top II Transmissions. Only for Eaton Top II Transmissions. Change in flash file from GFRS to other flash file requires Change in flash file from GFRS to other flash file requires

factory passwords. factory passwords. Changing the transmission from Eaton Top II to different Changing the transmission from Eaton Top II to different

transmission will require a different flash file. Factory transmission will require a different flash file. Factory Passwords are required to make this change. Passwords are required to make this change.

Transmission Neutral SwitchTransmission Neutral SwitchNeutral Switch is located on J1/P1:62 or over the 1939 Data link.Neutral Switch is located on J1/P1:62 or over the 1939 Data link.Neutral Switch is now programmable for all transmission styles. Neutral Switch is now programmable for all transmission styles. This can affect Fast Idle, PTO, Elevated Idle, and Cruise Control. This can affect Fast Idle, PTO, Elevated Idle, and Cruise Control. Important to check neutral switch programming and operation Important to check neutral switch programming and operation

if there is a complaint with Fast Idle, PTO, Elevated Idle, or if there is a complaint with Fast Idle, PTO, Elevated Idle, or Cruise Control. Cruise Control.

Caterpillar ET 2003B is required. Caterpillar ET 2003B is required.

ReminderReminder Outside Temperature Based Idle ShutdownOutside Temperature Based Idle Shutdown

– Installation of sensor kit 185-7733 is required when the idle Installation of sensor kit 185-7733 is required when the idle shutdown is programmed to “Outside Temp Based” If this kit is shutdown is programmed to “Outside Temp Based” If this kit is not installed the idle shutdown system may not function not installed the idle shutdown system may not function properly. properly.

– The sensor kit must be mounted so an accurate measurement of The sensor kit must be mounted so an accurate measurement of the outside ambient air temperature can be taken.the outside ambient air temperature can be taken.

Flashing ECMsFlashing ECMs– Always transfer the flash file to the hard drive of your Always transfer the flash file to the hard drive of your

computer. Computers communicate faster when the file is on computer. Computers communicate faster when the file is on the hard drive. the hard drive.

– Also try the bypass harness. There is a lot of information on the Also try the bypass harness. There is a lot of information on the data link from other devices such as ABS, or transmissions. This data link from other devices such as ABS, or transmissions. This isolates the ECM from this noise. isolates the ECM from this noise.

– By putting the file on the hard drive and using the bypass By putting the file on the hard drive and using the bypass harness this will allow a ECM to be flashed in less time. harness this will allow a ECM to be flashed in less time.

– ACERT flash files are too big for floppy disks. Do not download ACERT flash files are too big for floppy disks. Do not download ACERT flash files to a floppy. The flash will abort. File needs to ACERT flash files to a floppy. The flash will abort. File needs to be on a CD or downloaded directly from SIS web to the computer be on a CD or downloaded directly from SIS web to the computer you are using to flash the ecm. Files downloaded to a CD still you are using to flash the ecm. Files downloaded to a CD still need to be copied to the computers hard drive. need to be copied to the computers hard drive.

Is this “overcooling”?Is this “overcooling”?

Overcooling Overcooling TroubleshootingTroubleshooting

Overcooling Engine Overcooling Engine DiscussionDiscussion

Definition: Overcooling can be defined as the condition Definition: Overcooling can be defined as the condition where the normal temperature at which an engine operates where the normal temperature at which an engine operates cannot be reached.cannot be reached.

– This condition is most commonly reported as:This condition is most commonly reported as:– Engine coolant temperature runs cool only at idle.Engine coolant temperature runs cool only at idle.– Engine coolant temperature runs normal at idle, but overcools Engine coolant temperature runs normal at idle, but overcools

noticeably while driving or operating in cool ambient temperatures.noticeably while driving or operating in cool ambient temperatures. The recommended minimum operating temperature for The recommended minimum operating temperature for

diesel engines that operate on high sulfur fuel is 80C (175F). diesel engines that operate on high sulfur fuel is 80C (175F). This can be achieved by elevating the idle to 1000 RPM. This This can be achieved by elevating the idle to 1000 RPM. This

results in the engine adding more heat into the system. results in the engine adding more heat into the system. – Customers operating engines with temperatures below 80C (175F), may Customers operating engines with temperatures below 80C (175F), may

report several of the following complaints:report several of the following complaints:– Reduced fuel economy <OKReduced fuel economy <OK– White smoke <OKWhite smoke <OK– Reduced power <OKReduced power <OK– Reduced component life <OK Reduced component life <OK

Overcooling Engine Overcooling Engine DiscussionDiscussion

6NZ C-15 “Primary source of 6NZ C-15 “Primary source of heat into the system”heat into the system”

Overcooling Engine Overcooling Engine DiscussionDiscussion

BXS C15 “Primary source of BXS C15 “Primary source of heat into the system”heat into the system”

Precooler

Overcooling Overcooling Troubleshooting Troubleshooting

From the Troubleshooting GuideFrom the Troubleshooting Guide Engine OvercoolingEngine Overcooling Probable CauseProbable Cause Long Idle Periods - When the engine is running with no load, only a Long Idle Periods - When the engine is running with no load, only a

small quantity of fuel is burned. small quantity of fuel is burned. Therefore, the heat from the engine is Therefore, the heat from the engine is removed too fast.removed too fast. The check valve in the vent line may be missing, or The check valve in the vent line may be missing, or the orifice in the vent line may be missing. When the check valve or the orifice in the vent line may be missing. When the check valve or the orifice is missing, too much heat is removed from the engine. the orifice is missing, too much heat is removed from the engine.

Very Light Load - Very light loads, a very slow speed or downhill travel Very Light Load - Very light loads, a very slow speed or downhill travel can cause overcooling. can cause overcooling. This overcooling is caused by the low heat This overcooling is caused by the low heat input of the engineinput of the engine. The installation of . The installation of shuttersshutters helps to correct this helps to correct this condition. <<“condition. <<“Shutters DatedShutters Dated””

Faulty Water Temperature Regulator (thermostat) - A water Faulty Water Temperature Regulator (thermostat) - A water temperature regulator that is stuck open can cause overcooling. temperature regulator that is stuck open can cause overcooling. Overcooling also occurs when the water temperature regulator is Overcooling also occurs when the water temperature regulator is stuck between the following positions: open position and closed stuck between the following positions: open position and closed position. Coolant leaks that are around the water temperature position. Coolant leaks that are around the water temperature regulator can cause overcooling. An example would be a vent line regulator can cause overcooling. An example would be a vent line leak. leak. <<“how do you check”<<“how do you check”

Thermostat leakage rate is 10cc/min per stat. Need a way to Thermostat leakage rate is 10cc/min per stat. Need a way to measure?measure?

Overcooling Overcooling TroubleshootingTroubleshooting

Inspect the vent line for excess leakage.Inspect the vent line for excess leakage.– Quick check is to plug the line and cap #4 fitting.Quick check is to plug the line and cap #4 fitting.– Install check ball.Install check ball.– ACERT engines have two vent lines. This will require an ACERT engines have two vent lines. This will require an

update to the vent line recommendation. Current line update to the vent line recommendation. Current line configuration is above the fitting for the check ball.configuration is above the fitting for the check ball.

Truck Engine NewsTruck Engine News 1999/04/011999/04/01 Media Number -SEBD6710-00 Publication Date Media Number -SEBD6710-00 Publication Date --New Cooling SystemNew Cooling System Vent LineVent Line Check Valve Helps Check Valve Helps PreventPrevent Over CoolingOver Cooling{1370}{1370}

Know Your Cooling System; SEBD0518 (paper)Know Your Cooling System; SEBD0518 (paper) Know Your Track-Type Tractor Cooling System; REHS1063Know Your Track-Type Tractor Cooling System; REHS1063

Overcooling TroubleshootingOvercooling Troubleshooting Investigate thermostat or thermostat seal leakage. Investigate thermostat or thermostat seal leakage.

– Several methods used to test.Several methods used to test.– 1) Historically, thermostats were checked with a hot plate 1) Historically, thermostats were checked with a hot plate

and and thermometer. It has since become economical to replace thermometer. It has since become economical to replace them if them if removed. Note: this test gives thermostat removed. Note: this test gives thermostat performance not leak performance not leak rate. rate.

– 2) Recently the increased use of infared temperature 2) Recently the increased use of infared temperature instruments to estimate leakage of the thermostats. The results instruments to estimate leakage of the thermostats. The results

are qestionable. (40% of thermostats replaced are no are qestionable. (40% of thermostats replaced are no fault fault found.)found.)

– 3) Measure the leakage rate and compare to known 3) Measure the leakage rate and compare to known specifications. More accurate with results that can be specifications. More accurate with results that can be documented. Criteria with this test is pass or fail. Less invasive documented. Criteria with this test is pass or fail. Less invasive

and conclusive. and conclusive. – P/N 7C3095 = 2 x 10cc/min max leakage. Opening Temp 190-P/N 7C3095 = 2 x 10cc/min max leakage. Opening Temp 190-

208degF208degF– P/N 7W0317 = 2 x 50cc/min max leakage. Opening Temp 200-P/N 7W0317 = 2 x 50cc/min max leakage. Opening Temp 200-

219degF 219degF – Fabricate tool to measure volume change. Accurate method and Fabricate tool to measure volume change. Accurate method and

gives good results. Todd and Doug to show an example tool that gives good results. Todd and Doug to show an example tool that was fabricated.was fabricated.

Form Number Booklet Description Serial Number PrefixesRENR2238-04 C-10,C-12 & 3406E 1MM,2KS,2WS,3CS, 6NZ, 7CZ,

CPDRENR1328-02 C-10,C-12 & 3406E 5DS,8YS,9NS,1LWSENR5582-06 3176B,C-10,C-12 & 3406E 5EK,9CK,1YN,2PN,6TSSENR5503-00 3406C (PEEC III) 4CKSENR3479-05 3406B (PEEC II) 2EK,5YG,8TCSENR3913-04 3176 2YGSENR5112-01 3176 7LGRENR1367-04 3126B 7AS, 8YL,8SZ,BKD, 1AJ,CKM,

CRP,9SZSENR6566-03 3100 HEUI 8WL,1WM,4ES,2CW, 8HW, 7LZ

Troubleshooting Guide Troubleshooting Guide ListingListing

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

2YG 31762YG 3176– 1988 to 19901988 to 1990

7LG 31767LG 3176– 1991 to December 19931991 to December 1993

9CK 3176B9CK 3176B– May 1993 to March 1995May 1993 to March 1995

2PN C-102PN C-10– March 1995 to September March 1995 to September

19971997 8YS C-108YS C-10

– September 1997 to September 1997 to November 1998November 1998

1YN C-121YN C-12– March 1995 to September March 1995 to September

19971997

9NS C-129NS C-12– September 1997 to September 1997 to

November 1998November 1998 3CS C-103CS C-10

– November 1998 to November 1998 to September 2002September 2002

2KS C-122KS C-12– November 1998 to November 1998 to

September 2002September 2002 MBJ C-10MBJ C-10

– October 2002 to CurrentOctober 2002 to Current MBL C-12MBL C-12

– October 2002 to CurrentOctober 2002 to Current

Serial Number PrefixesSerial Number Prefixes3406/C-15/C-163406/C-15/C-16

8TC PEEC II and PEEC II.V8TC PEEC II and PEEC II.V– 1987 to 19901987 to 1990

5YG PEEC II - 460Hp Only5YG PEEC II - 460Hp Only– 19901990

2EK PEEC II and PEEC II.V2EK PEEC II and PEEC II.V– 19911991

4CK 3406C Electronic4CK 3406C Electronic– August 1991 to December August 1991 to December

19931993 5EK 3406E5EK 3406E

– May 1993 to December 1996May 1993 to December 1996 6TS 3406E6TS 3406E

– January 1997 to December January 1997 to December 19971997

1LW 3406E 14.6L1LW 3406E 14.6L– December 1997 - November 1998December 1997 - November 1998

5DS 3406E 15.8L5DS 3406E 15.8L– December 1997 - November 1998December 1997 - November 1998

2WS 3406E 14.6L2WS 3406E 14.6L– November 1998 to CurrentNovember 1998 to Current

1MM 3406E 15.8L1MM 3406E 15.8L– November 1998 to CurrentNovember 1998 to Current

6NZ C-156NZ C-15– November 1999 to September November 1999 to September

20022002 7CZ C-167CZ C-16

– November 1999 to September November 1999 to September 20022002

MBN C-15MBN C-15– October 2002 to CurrentOctober 2002 to Current

CATERPILLARCATERPILLARTRUCK ENGINE TRUCK ENGINE

SUPPORT CENTERSUPPORT CENTER 1-800-447-4986 OR 1-309-578-39011-800-447-4986 OR 1-309-578-3901 E-MAIL: E-MAIL: call_cat@cat.comcall_cat@cat.com Available 24 hours per day, 7 days pre Available 24 hours per day, 7 days pre

week, 365 days per year week, 365 days per year (11am Saturday – 7am Monday call rolls to Morton Parts – CSR will direct (11am Saturday – 7am Monday call rolls to Morton Parts – CSR will direct customer to nearest Cat Dealer.)customer to nearest Cat Dealer.)

Benefits: Emergency road service / Cat Benefits: Emergency road service / Cat Service Location Assistance/ Technical helpService Location Assistance/ Technical help

Fleet Hotline: 1-888-353-3821Fleet Hotline: 1-888-353-3821 Jim Tresenwriter M-F, 8-4pmJim Tresenwriter M-F, 8-4pm