TECH TIPS+ 11+08+1999

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August 1999LEVN4715

Page 1

Tech Tips

August 11, 199910:00AM CDT

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August 1999LEVN4715

Page 2

Index

Page PageIron Electronic Engine Software

3100 Service Letter – PI1419 4 3126/3126B Service Letter – PS4701 39C-10/C-12 New Oil Filter Base 5 3126B Mid Year Update 8YL Serial Number 40Improved High Efficiency Fuel Filter 7 3126B Mid Year Update 7AS Serial Number 50

3406E Aluminum Piston Kit 9 3126B Service ECMs 533406E Exhaust Manifold Sleeve (138-6756) 10 Coolant Level Sensor 543406E Valve & Injector Rocker Arm Wear Limit 113406E Valve Cover Seal – Design Change 12 Electronic Service Tools

Quick Tip #1 Caterpillar Electronic Technician Release Information 56Software Help Desk Changes 57

TOPP 16 Remanufactured Engine Serial Numbers 59Service Technician Workbench 60

Quick Tip #2 Pro-Link 9000 Cartridge 65

Engine Service Training Quick Tip #3

Topics Covered 21 Binder Labels 67Broadcast Information 68

Electronic Troubleshooting Keepin’ In Touch 69

ADEM 2000 Test ECM 26 Reference information 71Ambient Air Temp Sensor Kits 27CAT ID 2.0 Software Problems 28

New 3126B Troubleshooting Guide 29ET 2.4 Special Tests for 3126B (8YL) 303126B (7AS) IAPCV – Special Test 32Cam & Crank Sensor Faults 34Jul 99 Parts Service Software 37

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Iron

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3100 Service Letter

4PI1419 - 3100 Mechanical Rack Linkagen Affected Serial numbers

n 9GK45180 - 68297

n 9YN03132 - 04763

n 7HJ01000 - 02900

n 2FR00394 - 04297n 9LN05573 - 08669

n 7HS00316 - 01794

n 7JL00439 - 00906

n 7AG02806 - 05461

n 5RM01263 - 03669

n 3RJ01653 - 02990

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C-10 / C-12 New Oil Filter Base

4 New 166-1329 Oil Filter Base Gp Replaces former 122-0725 Base Gp

4 Removed 9Y-3902 Oil Cooler Bypass Temperature Valve and Replaced with 7C-2891Cover, 9M-0853 plunger and 7C-3953 Spring Assembly

OLD NEW

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C-10 / C-12 New Oil Filter Base

4New Parts identical to those used for Oil Filter Bypass valve

4Bolt Pattern has been changed for new valve parts, will notaccept former 9Y-3902 Oil Cooler Bypass Temperature Valve

4New Oil Filter Base services the Old

4 In Effect July 6, 1999 with Following Serial Numbers:n ‘98 C-10 8YS07368

n ‘99 C-10 3CS05801

n ‘99 C-12 2KS17296

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4Old material used for “Stay Clean Valve” may fatigue andcause valve to dislodge

4Dislodged valve could block fuel flow to engine

4Old Valve molded in BLACK

4New Valve made of moredurable material andis molded in WHITE

4 Introduced in July 1999

4Pre-Filling of Fuel Filtersis NOT recommendedby Caterpillar

Improved High Efficiency Fuel Filters

Stay Clean Valve

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Improved High Efficiency Fuel Filters

New HighEfficiency Filters

Former StandardFilter Part No.

StandardBack-UpFilter Part No.

1R-0749 1R-0712 1R-1712

1R-0755 1R-0715 NONE

1R-0756 1R-0718 NONE

1R-0750 1P-2299

(1R-0740)

1R-1740

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3406E Aluminum Piston Kit

4Optional Repair for 5EK 1-80,000 Low Horsepower Engines410 & less.

n 177-7493 Piston Kit (Repairs one cylinder)

n 1 - 108-2716 - Piston

n 1 - 134-3761 - Ring-Top

n 1 - 2P2817 - Ring-Intermediaten 1 - 7N7078 - Ring-oil

n 1 - 160-9874 - Liner Seal Kit

n 2 - 7E1177 - Retainer-Piston Pin

n

The 108-2716 Piston is Only Available In Piston Kitn Reuse current rod assembly and pin. Cylinder liner may be reused, refurbished or

replaced as required for each individual cylinder.

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3406E Exhaust Manifold Sleeve

138-6756

4ShimGasket Retention For Initial Assembly Only

4Always Replace With 6 New Sleeve Assemblies If ManifoldIs Removed

4Testing Continues On Best Method To Repair With ManifoldThat Have Flanges Not Meeting “As New” Flatness.

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3406E Valve & Injector Rocker ArmBearing Wear Limit

4New Specification 40.065 ±0.015 mm(1.5774 ±0.0006 Inch)n The “Use Again” dimension for wear in the lower portion of the bearing is a

vertical dimension that allows 0.3 mm(0.012 Inch) addition to the abovedimension.

The maximum“Use Again” dimension is then 40.38 mm(1.590 Inch).

This dimension still leaves approximately 1/3 of the bronze bearing material

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3406E Valve Cover Seal - DesignChange

Effective 4Q99 for 1998 & 1999 Model Year Valve Covers withSerial Numbers 1LW, 2WS, 5DS & 1MM

4“Press In Place” seal and fasteners & gromments replaceformer seal and fasteners & gromments

4New fasteners & gromment required to provide appropriateseal “crush” for sealing and noise reduction

4Retainer tabs in seal mounting holes retain fasteners duringservicing.

— Remember “Press In Place” seal and new fastener & gromments must beused in sets.

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3406E Valve Cover Seal - DesignChange

8mm

Grommet Height

Old

10.75mm

New

34.836mm

1.37inch

New

35.21mm

1.39inch

Old

New For Press In Place Seal

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Quick Tip #1

4 - Adjusting Valves on 3406E Engines

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TOPP

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TOPP

4Only Cat labs are approved to analyze oil samples taken fromunits enrolled on TOPP

4PM 1 full service and PM 2 inspection forms requireinspection of the engine mounting system.

4Loose bolts in rear engine mounts have caused need to

replace flywheel housings. Flywheel housings not coveredby TOPP.

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TOPP

4PM 2 service performed approximately every 200,000 miles.

4Besides the inspection, cooling systemflush / refill andthermostat replacement may also be required at this time.

4TOPP allows 2 hours for the inspection portion of the PM 2service.

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TOPP

4Additional time allowed based on TRG if additional work isperformed

4Call TOPP as soon as unit arrives in shop.

4TOPP is staffed around the clock.

4Phone (800) 338-3428.

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August 1999LEVN4715

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Quick Tip #2

4 Installing CamSeal O-Ring On 3406E

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Engine Service Training

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Engine Service TrainingTopics Covered

4Heavy Duty Truck Technician Program

4Training Courses

4New Course Development

4Training Managers Meeting

4New 3116 Coining Tool

4Employee Addition

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4Heavy Duty Truck Technician Programn Caterpillar Certified Technician

4Training Coursesn 3000 Series Fuel Systems

n

Small Engine Fuel Systemsn MediumEngine Fuel Systems

4New Course Developmentn Dyno Installation-Engine PAR

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4Training Managers Meetingn September 1999

4Engine Training /CSTGn Working on 3116 Sleeve coining tool/video

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4Todd Rothn Electronics Training

4Chuck Ellisn Fuel Systems Training

4Adrian Braziln Field Training

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Electronic Troubleshooting

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ADEM 2000 Test ECM

4New Test ECM now available for troubleshooting all Truck Engines with ADEM 2000 Electronic Controls

n 3126B, C-10, C-12, 3406E, C-15 and C-16

4To order a test ECM:n

Send a Fax (created on Dealership letter head) to the Caterpillar Tech Center -Attention Erin Blanch (309) 578-4572

n Specify the type of test ECM(s)

n Quantity of each

n Name and Address the ECM(s) should be shipped to

n Purchase Order Number

n Billing Address

n Dealer Code or TEPs Dealer Code

n Your Phone Number

TM

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Ambient Air Temp Sensor Kits

4Ambient Air Temp Sensor Kits are Not Available for the 1999C-10, C-12 and 3406E engines at this time, but are planned fora late summer release

4

Part Number listed in the handouts for MAY Tech Tips wasused for another purpose and must NOT be used to order theAmbient Air Temp Sensor Kit

4An Electronic Communicator Newsletter will be published

to announce Availability and the correct part number forordering purposes

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Page 28

CAT ID 2.0 Software Problems

4CAT ID 2.0 Personality Module software must be replacedwith CAT ID 2.1 software in order to correct the followingproblems:

n Language selection defaults to English with each key switch cycle

n Incorrect Parameter data after Lifetime Total Miles exceeds 6553. The

following parameters values will be displayed incorrectly:n Driver and Fleet Total Miles

n Average and Instantaneous Fuel Economy

4To correct these problems, upgrade to Version 2.1 software.Do NOT replace the CAT ID Display unit

4Replace the CAT ID 2.0 software with CAT ID 2.1 SoftwarePart Number 168-7931

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New 3126B Troubleshooting Guide

4RENR1367-01 Revision (7AS, 8YL, & 8SZ engines)

4New content:n 7 New Diagnostic Codes (Open, Short and Low Oil Pressure, Theft Deterrent

Active and Active While Cranking, Excessive Boost, and Truck ManufacturerNot Programmed)

n 4 New Test Procedures (Optional Engine Oil Pressure Sensor, Engine RunningOutput, Input Selections, and Powertrain Datalink)

n Several Updated Test Procedures (Wait to Start Lamp, Intake Air HeaterAltitude Compensation, Truck Manufacturer Parameter, Automated CylinderCutout Test, Timing Cal Connector Kit, etc.)

n Fleet Information Software (FIS) and Fleet Trip information

n Customer Programmable Parameter updates

n New Wiring and Component Location diagrams

n Additional Service Tool information

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ET 2.4 Special Tests for 3126B (8YL)

4ET 2.4 Special Tests are not accessible for the 2000 Model Year 3126B (8YL) Truck Engines

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ET 2.4 Special Tests for 3126B (8YL)

4Selecting the “Special Tests” located under the Diagnosticsmenu causes ET programto Lock Up

4ET 3.0 (October 99) will correct this problem

4An ET 2.4 software patch is also available on a limited basis if necessary:

n Call the Truck Engine Call Center at 1 (800) 447-4986 to obtain a copy of thissoftware patch if you must performone of the special test procedures prior tothe release of ET 3.0

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3126B (7AS) IAPCV - Special Test

4One of the Special Tests (Injection Actuation Pressure Driver)does not function properly on 3126B (7AS) engines using thefollowing software:

n JUN98 through APR99 Personality Modules

4The PC-37: Injection Actuation Pressure Control Valve CircuitTest used in the Troubleshooting Guide for 3126B Engines(RENR1367) is affected

n The Results of Step 5 and Step 7 are misleading

n With JUN98 - APR99 Personality Modules, the Special Test cannot turn the

IAPCV Output OFF when the engine is not running

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3126B (7AS) IAPCV - Special Test

4The Special Test is normally used to turn the IAPCV OutputDriver ON and OFF for troubleshooting

n To troubleshoot the IAPCV output of the ECM, a test lamp is connected todetermine if the output is functioning

n When the Special Test is turned ON (Active), the IAPCV Output Driver should

turn ON (test lamp ON)n When the Special Test is turned OFF, IAPCV Output Driver

should turn OFF (test lamp OFF)

n JUN98 - APR99 Personality Modules cannot turn the Output Driver OFF, so thetest lamp will not turn OFF when the test is disabled

4DO NOT replace the ECM if the IAPCV Special Test cannotturn the IAPCV Output (test lamp) OFF

4Update the Personality Module software and retest

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Cam and Crank Sensor Faults

4Some 1999 C-10, C-12 & 3406E engines may log intermittentfault codes due to wiring connections

n 64-12 Loss of Engine CamSensor RPM Signal (34)

n 190-12 Loss of Engine Crank Sensor RPM Signal (34)

4Engine performance may be accompanied by a slight speedburp when the fault occurs

4The following truck engines are affected:n

C-10 (3CS00001 - 05369 )n C-12 (2KS00001 - 15070 )

n 3406E (1MM00390 - 00838, 2WS08900 - 20705 )

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4 If you have an engine exhibiting similar behavior, performthe PC-31: Engine Speed/Timing Sensor Circuit Test foundin the Troubleshooting Guide for C-10, C-12 & 3406Eengines (RENR2238)

4

If the Troubleshooting Procedure does not resolve theproblem, and the engine is within the suspect serialnumber range, check the Camand Crank sensor connectorSocket Terminals

4 If Stamped and Formed Socket Terminals are used in the

Camand Crank sensor wiring harness connector, theymust be replaced with Machined Socket Terminals

M achined

Socket Terminal Stamped and Formed

Socket Terminal

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4Socket Terminal Replacement Proceduren Turn the Ignition Key Switch to the OFF position.

n Remove the Sockets (one at a time) fromthe Deutsch DT connectors thatconnect to the Camand Crank Sensors.

n Remove each socket fromthe wire and replace it with a 8T-8730 Deutsch

Machined Socket Terminal.n Reinsert the socket into the connector while maintaining at least 1 inch twists

in the harness wiring.

n Check the harness clips to ensure they are properly secured. These clips areused to prevent excessive movement and dampen vibration during engineoperation.

n Ensure the ECM Personality Module is MAR99 or newer, or Flash Programif required to update to MAR99 or newer software.

n Use an Electronic Service Tool to clear the logged fault codes.

NOTE: Remove the wires and repair one at a time to ensure the polarity is not accidentally reversed.

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JUL99 Parts Service Software

4Personality Module software update for 1999 C-10 (3CS), C-12(2KS) and 3406E (1MM, & 2WS) engines

n Available mid-August for Production and Parts Service Update

4Addresses Eaton Autoshift Transmission Problemsn

Engine stall possible on engines with Eaton 18 Speed Autoshift Transmissionsor on engines with 10 Speed Autoshift Transmissions with TEL programmed to1900 rpmor higher

n Problemcan only occur when the Auto Retarder in Cruise parameter is enabled(Programmed above 0 MPH default)

n Prior to this software change the Auto Retarder in Cruise parameter must beprogrammed to 0 MPH to avoid this potential problem

4Addressed C-10 Throttle Deceleration Raten During Idle Conditions if the C-10 Throttle is depressed and then quickly

released the engine rpmslowly descends to low idle

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Electronic Engine Software

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3126 / 3126B Service Letter

4PS4701n Expired 06/30/99

n Date in FIND systemin error

n Error found 07/09/99

n FIND systemhas been corrected

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3126B Mid Year Update8YL Serial Number4New Serial Number Prefix - 8YL4 July 12 Production for GM - July 31st Full Production

4ADEM 2000 ECM - 70 Pin Connector

4One ECM for all OEMs

4Software version - JUL99

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3126B Mid Year Update8YL Serial Numberl Truck Manufacturer Parameter

– Allows for common Hardware & Software on all 3126B engines

– Parameter is programmed at CAT Factory

– Selects Factory Default Parameter Set

– 253-14 Diagnostic Code Active if parameter is Not Programmed

– No OEM Changes Required – Reduces the number of FLASH files released

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3126B Mid Year Update8YL Serial Number

l Engine Running Output – Can be used to prevent Starter Engagement with engine running

– No parameter programming required

– Identical functionality to heavy duty

OUTPUT #413G836-WH

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l AT/MT/HT Part Throttle Shift Speed

– Selectable shift points Allison non-electronic transmissions

– Regulates shifting - “closed throttle” or “full throttle” modulation

– Provides 3 programmable shift modulation settings

– AT/MT/HT Part Throttle Shift Speed - Default, Mediumor High – Default setting =(80% ON / 65% OFF)

– Mediumsetting =(70% ON / 55% OFF)

– High setting =(60% ON / 45% OFF)

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l Multi-Speed PTO – Provides 2 additional PTO Set Speeds

– Parameter programming required to enable feature

PTO Configuration - Cab Switches, Remote Switches, or Remote Throttle

Input #7 - PTO Engine RPM Set Speed Input A

Input #19 - PTO Engine RPM Set Speed Input B PTO Engine RPM Set Speed A - Low Idle to PTO TEL rpm

PTO Engine RPM Set Speed B - Low Idle to PTO TEL rpm

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3126B Mid Year Update8YL Serial Number – PTO - Continued

– Requires dedicated Speed Switches and a PTO On/Off Switch

– Provides clean installation / simple configuration

– Set Speed A has priority over Set Speed B

– Set Speeds A & B have priority over all existing rpmcontrol inputs

3126BMidYearUpdate

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4Multi-Speed PTO Wiring

303544462353

56

P1 J1

OUTPUT #1SETRESUMEINPUT #7INPUT #19AP SENSOR / SWITCH SENSOR COMMONI NPUT SENSO R CO M M O N # 2INPUT #1

CRUI SE CO NTRO LSET/RESUME SWITCH

PTO ON/OFF SWITCHPTO

INTERLOCK

PTO ENGINE RPMSET SPEED A SWITCH

E CM

K998-BUC978-BRC979-ORG844-PK

H795-PK993-BR

K999-GN

+12 V- PTO SWITCHO N L AM P

PTO ENGINE RPMSET SPEED B SWITCH

NOTE: INPUT SENSOR COMMON #1 (TERMINAL-18) MAY BE USED IN PLACEOF INPUT SENSOR COMMON #2 (TERMINAL-3)

3126BMidYearUpdate

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l Auto Theft Deterrent

– Automatically enables Theft Deterrent when Key is turned OFF

– Driver is not required to enter Password before power down

– Theft Deterrent Feature requires CAT ID 2.1

– New “Auto-Enable” programmable parameter option

Theft Deterrent - Yes, No, Auto-Enable – Provides eligibility for discounts on insurance premium

CAT ID 2.1

3126BMidYearUpdate

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l Secure Idle

– Integral part of Theft Deterrent feature

– Provides ability to leave vehicle unattended at idle

– Limits engine speed to Low Idle until password is entered

– No Parameter Programming required – To activate Secure Idle:

Bring engine to Idle condition

Enter Theft Deterrent Password on CAT ID

– To deactivate Secure Idle (Theft Deterrent)

Enter Theft Deterrent Password on CAT ID

3126BMidYearUpdate

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l Fleet Information Software – Data Transfer and Information Management Tool

– Analyze Driver, Vehicle and overall Fleet performance

– Similar to current C-10, C-12 and 3406E applications

–

Histograms – Snapshots

– Cumulative Totals

3126BMidYearUpdate

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3126B Mid Year Update7AS Serial Number

4Software Version - JUN99

4To be used with all ADEM III ECMs Part Numbers 149-6989,149-6990 and 157-3708

4Fixesn Loss of Vehicle Speed following downshift in Cruise Control

n Disable Exhaust Brake in PTO Mode

n PTO Top Engine Limit Below 1600 RPM

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4Fixes - Continuedn Flash Codes Flash Twice - Both Active and Logged Faults/Events

n PTO Limits are kicked off when PTO Set Speed is Kicked off.

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4New Featuresn High Altitude Inlet Air Heater Strategy

n Above 5500 Ft.

n Turns on for 30 seconds when Inlet Air Temp plus Coolant Temp <53 Deg C. (25C)

n 7 minute and 13 minute Timer based <63C (35C)

n Truck Manufacturer Parametern Software will automatically set - can not be changed

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3126B Service ECMs

ECM 7AS 8YL

1496989 1496989

1496990 1496990 w/ diode kit1573708

1627584 w/JUN99

software

1573708 1496990 w/ diode kit

1573708

1627584 w/Jun99

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Coolant Level Sensor

4No Reliable 2 - pin sensor available4OEM instructed not to use

4ET 2.4 2 - pin Coolant Sensor no longer available

4Change to 4 - pin sensor or programto nonen If none, coolant level monitoring not available

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Electronic Service Tools

C ill El i T h i i

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Caterpillar Electronic TechnicianRelease Information

4Caterpillar Electronic Technician is scheduled forrelease in October 1999.

n Because of the changes made to the software, making it a 32-bitapplication, Caterpillar ET will be version 3.0.

n Caterpillar ET version 3.0 will only support Microsoft Windows 95and NT operating systems.

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Software Help Desk Changes

4For authorization, transfers, subscription information, andordering Caterpillar ET contact:

n Caterpillar Media and Product Information Logistics:

n Voice: (800) 566-7782or (309) 266-0942

n Fax: (309) 266-4394

n E-mail: [email protected]

medial(Caterpi llar Host E-mail)

n Hours: 7:00amto 5:00pm

(Central Standard Time)

n Remember... write your Caterpillar ET serial number down and keep it in a safeplace.

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Software Help Desk Changes

4For software support of Caterpillar ET and Flash contact:

n SIS Help Desk:

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

n Fax: (309) 675-0725

n E-mail: [email protected]

n Hours: 6:00amto 9:00pm

(Central Standard Time)

R f t dE i

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Remanufactured EngineSerial Numbers

4The remanufactured engines have a letter-letter-letter prefixon the engine serial number. Caterpillar ET will not allowprogramming of this engine serial number format.

4 If you need to programone of these letter-letter-letter serialnumbers into an ECM, call the SIS Help Desk and ask for fileEtfix24.exe.

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Service Technician Workbench

4Ties Caterpillar PC service tools together by giving themcommon:

n support

n training

n installation

n delivery

4Working toward a common look and feel for all service tools.

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4The Service Technician Workbench will initially include:

n DataView

n Caterpillar Electronic Technician (Cat ET)

n Service Information System(SIS)

n Caterpillar Diagnostic Advisorn Engine Performance Estimator

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4Two examples of the advantages associated with using theService Technician Workbench are:

n Simplified Report Process

n New Feedback Mechanism

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4Simplified Report Process

•Service Technician

Workbench records the

path you take through the

diagnostic and repair process making reports

easy to create.

•When finished, print the

information recorded as a

service report.

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4Feedback

Feedback mechanism:

•Records which PC service tool

is in use and then presents a

dialog box for comments andquestions

•Is a communication link to

Caterpillar for desired

improvements for service tools

ProLink9000Cartridge

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Pro-Link 9000 Cartridgefor Truck Engines

Market Truck

Application 3116, 3126, 3176, 3406, C-10, C-12, C-15, and C-16 electronicon-highway truck engines

Description Version 1.09 of the Caterpillar approved cartridge for the Pro-Link9000 hand-held service tool is now available through MPSI (Micro

Processor Systems, Inc.) and its distributors.

Feature/Benefits The cartridge contains all the software needed to adapt thePro-Link 9000 to perform a large number of tests on Caterpillar electronic engines from 1987 to the present.

Availability Target date August 1, 1999

Price 25 cents

Engine Division Product News

Media Number: LEXT9289

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Quick Tip #3

4Rerating Engines To New Horsepower

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1999 Binder Labels

4 Binder Labelsn Power Connection

n SENR5550

n Tech Tips

n SENR5548

n Binder

n SENR2910

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Broadcast Information

4Update Broadcast Videosn LEVN4284 - “Tech Tips” Broadcast - February 11, 1998

n LEVN4384 - “Tech Tips” Broadcast - May 13, 1999

n LEVN4453 - “Tech Tips” Broadcast - August 12, 1998

n LEVN4533 - “Tech Tips” Broadcast - November 11, 1998

n LEVN4590 - “Tech Tips” Broadcast - February 10, 1999

n LEVN4651 - “Tech Tips” Broadcast - May 12, 1999

n LEVN4715 - “Tech Tips” Broadcast - August 11, 1999

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

4Broadcast Schedule for 1999n November 10

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Keepin’ In Touch

4Emailn Caterpillar E-Mail

n TECHTIPS

n Internet E-Mail

n [email protected]

4World Wide Web

n http://www.Cat.comn Engine Spec Sheets

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Electronic Controls Part NumberReference

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Troubleshooting Guide Listing

Latest Truck Engine Electronic Troubleshooting Guides:

Form Number Booklet Description Serial Number Prefixes

RENR2238-00 C-10,C-12 & 3406E 1MM,2KS,2WS,3CS RENR1328-02 C-10,C-12 & 3406E 5DS,8YS,9NS,1LW SENR5582-06 3176B,C-10,C-12 & 3406E 5EK,9CK,1YN,2PN,6TS SENR5503-00 3406C (PEEC III) 4CK SENR3479-05 3406B (PEEC) 2EK,5YG,8TC SENR3913-04 3176 Truck Engine 2YG SENR5112-01 3176 Truck Engine 7LG RENR1367-00 3126B Truck Engine 7AS SENR6566-03 3100 HEUI Truck Engine 8WL,1WM,4ES,2CW

HeavyDutyTruckEngineFLS/FTS

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Heavy Duty Truck Engine FLS/FTSAdjustment Policy

The guidelines for HD Truck FLS/FTS changes for Re-Rates are asfollows:

1. FLS/FTS SHOULD be changed to values listed in JTZ101-02 FLS/FTS LOOKUP FOR RATING CHGS screen for 3406E or GKN401-06 ENGINE TEST SPEC screen for 3176B, C-10, C-12 when: Engine is rerated outside the current rating family. Since rerating outside the current rating family requires a "Reason Code 5" factory password, change FLS/FTS if "Reason Code 5" factory passwords are required. (Example: rerating a 3406E engine froma 475 Hp rating to a 550 Hp rating)

NOTE - When using either of the screens listed above (JTZ101-02 or GKN401-06) it will be necessary to enter the new "Performance Spec" number and the serial number of the engine being rerated. After flashing the new software file, you can find the new performance spec on the ET configuration screen. If you are rerating to a multi-torque rating, be sure to use the FLS/FTS values for the second performance spec listed on the configuration screen.

2. FLS/FTS SHOULD NOT be changed when: Engine is rerated within the current rating family. Since rerating within the current rating family does not require a "Reason Code 5" factory password, do not change FLS/FTS if "Reason Code 5” factory passwords are not required. (Example: rerating a 3406E engine froma 475 Hp, 1650 lb-ft rating to a 475 Hp, 1750 lb-ft rating)

3. FLS/FTS SHOULD be changed to 0/0 when: Engine is rerated to a "field rerate only" rating that is not offered on engines directly fromthe factory. (Example: rerating a 3406E engine froma 375 Hp rating to a 410 field rerate only rating)

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Serial Number Prefixes – 3116/3126

41WM 3126 HEUIn 1995 to Current

48WL 3116 HEUIn 1995 to Current

4

7AS 3126Bn 1998 to Current

SerialNumberPrefixes

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

n 1988 to 1990

4 7LG 3176n 1991 to December 1993

4 9CK 3176Bn May 1993 to March 1995

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

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

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

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

4

3CS C10n November 1998 to Current

4 2KS C12n November 1998 to Current

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Serial Number Prefixes - 3406

4

8TC PEEC II and PEEC II.Vn 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 - November 1998

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

4 2WS 3406E 14.6Ln November 1998 to Current

4 1MM 3406E 15.8Ln November 1998 to Current

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3126B Electronic Control and Sensors

4ECM (7AS Basic) 149-6989

(7AS Full Feature w/Jun 99 or New Software & 8YL) 162-7584

4Coolant temperature Sensor - 130-9811 O-Ring Seal 6V6609

4Inlet Manifold temperature Sensor - 130-9811 O-Ring Seal 8L2786

4Speed/Timing Sensors - 119-4142 O-Ring Seal 117-13854Atmospheric Pressure Sensor - 141-4119 O-Ring Seal 6V5049

4Boost Pressure Sensor - 149-7511 O-Ring Seal 3J7354

4Injection Actuation Pressure Sensor - 141-4122 O-Ring Seal 1J9671

4Pedal Position Sensor - 3E7700

4Injector Wiring Harness - 153-8920

4Wire Router - 126-1774

3116HEUI&3126HEUI— Electronic

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3116 HEUI & 3126 HEUI — ElectronicParts

43116 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 – 119-4142

n Includes 117-1385 O-Ring Seals

n

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

n Coolant Temperature Sensor – 106-0735

n Requires 3K0360 Seal

n Boost Pressure Sensor – 111-2351

n Male/Male Adapter – 9X0262 & 3J7354 – Seal

n Injection Actuation Pressure Sensor – 140-3540

n 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

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Other 3116 HEUI & 3126 HEUI Parts

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

n 123-1199 Seal for Injector and IAPCV Connectors

n 118-8622 Service Replacement Harness

n 40 pin to Injectors

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


n 40 pin to IAPCV


n 40 pin to all other sensors

n 141-7060 Injector Wiring Harness Connector Repair Kit

n 143-8325 Injection Actuation Pressure Sensor Guard

C-10 C-12 3176B&3406EPre-’99

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C-10, C-12, 3176B & 3406E Pre-99Current Parts4 C-10 - 2PN & 8YS, C-12 - 1YN & 9NS, 3176B - 9CK & 3406E - 5EK & 6TS, 1LW, 5DS

n Electronic Control Module (ECM) - 145-7806

n ECM with J1939 Data Link Option - 145-7805

n Speed/Timing Sensor

n 3406E — 129-6628 Sensor

n 126-8481 Shim (0.020”)

n

C-10, C-12 & 3176B — 129-6628 Sensor No Shimn Coolant/Fuel Temperature Sensor - 102-2240

n Air Inlet Temperature Sensor - 107-8618

n Boost Sensor - 111-2351

n Atmospheric Pressure Sensor 111-8125

n Oil Pressure Sensor - 111-2350

n Pedal Mounted Throttle Position Sensor - 3E7700

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3176 —2YG Current Parts

43176 - 2YGn ECM - 9X9529 0R6149

n ECM FORD - 9X9528 / 0R6148

n Transducer module - 9X8226 / 0R6132

n Harness - 7E8421

n

Speed/Timing Sensor - 102-9029n Fuel Pressure Sensor - 107-7142

n Coolant Temperature Sensor - 9X5370

n Vehicle Speed Buffer - 3E0020

n Remote Mounted Throttle position Sensor - 9X9647

n Remote Mounted Throttle Position Sensor - FORD - 9X9648

n Pedal Mounted Throttle Position Sensor - 110-8190

C-10 C-12&3406E‘99ModelYear

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C-10, C-12 & 3406E 99 Model YearCurrent Parts4 C-10 - 3CS, C-12 - 2KS, & 3406E - 2WS (14L) & 1MM (16L)



n C-10, C12 CamSensor - 160-0029

n 3406E CamSensor - 160-0030

n C-10, C-12 & 3406E Crank Sensor - 160-0028

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

n Boost Pressure Sensor - 161-9929



n Pedal Mounted Throttle Position Sensor

n Long Pig Tail - 3E-7700

n Short Pig Tail - 121-0231

C-10,C-12,3176B&3406E

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C10, C12, 3176B & 3406EPre-’99 Current Parts

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


n ECM with J1939 Data Link Option - 145-7805


n

3406E — 129-6628 Sensorn 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 Pedal Mounted Throttle Position Sensor - 3E7700

3176 7LGC tP t

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3176 — 7LG Current Parts

43176 7LGn ECM - 3E5293 / 0R6302

n Transducer Module - 9X8226 / 0R6132

n Altitude Retrofit - 3E8644 / 0R6470

n Speed Timing Sensor - 102-9029

n Oil Pressure Sensor

n “DT” Connector 7LG08721 and Up — 111-2350

n “HD” Connector 7LG07500 to 7LG08720 — 107-7142

n Coolant / Inlet Air Temperature Sensors

n Full Range - 7LG07500 and Up — 102-2240

n Limited Rage - 7LG00001 to 7LG07499 — 9X5370

n

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

n Remote Mounted Throttle Position Sensor - FORD - 9X9648


3406CEl t i C tP t

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3406C Electronic Current Parts

43406C - 4CK n ECM - 9X8085 / 0R6486

n Transducer Module - 132-4363

n Speed Sensor - 100-6619

n Rack Sensor - 9X7793

n

Timing Sensor - 129-4501n BTM - 105-2939

n Coolant Temperature Sensor - 102-2240


n Remote Mounted Oil Pressure Sensor Kit - 118-6256

PEECIIVC tP t

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PEEC II.V Current Parts

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




n


n Throttle Position Sensor

n Remote Mounted “Beer Can” Sensor - 9X9648



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

n 6I2382 - Wiring Harnessn 9X5370 - Temperature

PEECIIC tP t

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PEEC II Current Parts

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




n


n Throttle Position Sensor

n Remote Mounted “Beer Can” Sensor - 9X9647



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

n 6I2382 - Wiring Harnessn 9X5370 - Temperature

Documents

TECH TIPS+ 11+08+1999