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EXPERTOS PRODUCTOS CATERPILLAR
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Page 1
TechTips - CatVideoFeb, 2009
Feb2009 CatVideo – Page 2
Program Index
segment page subject expert [email protected]
You Gotta Know H.Wayne Wilson https://truck.cat.com • Index 2• Q&A…not 3• Keepin’InTouch 4• 2009 Broadcast Schedule 5• WebEx Registration 6
HDEngines 8 Josh Evans [email protected] 21 Kevin Kempher [email protected] 27 John F Smith [email protected] 38 Curt Vogel [email protected] 55 Mark Gasper [email protected]
Feb2009 CatVideo – Page 3
Questions…
No Phone Calls today, please
Segment Questions……Contact Information on pg2
Program Comments:[email protected]
Feb2009 CatVideo – Page 4
Keepin’ in Touchht
tps:
//tru
ck.c
at.c
om
Feb2009 CatVideo – Page 5
Future Broadcasts…
check your calendars…
Feb 18th Cat VideoApr 15th WebEx, 10am, CDTJun 17th Cat VideoAug 19th WebEx, 10am, CDTOct 14th Cat VideoDec 16th WebEx, 10am, CST
Feb2009 CatVideo – Page 6
WebEx Registration (for your records)
Search: tech tips
Feb2009 CatVideo – Page 7
WebEx Launch (for viewing)
cat.webex.com
Search: tech tips
Page 8
HD Engine Update
Josh Evans
Feb2009 CatVideo – Page 9
BXS,MXS,NXS Turbo Supply line leaksCPI193456
Turbo line may leakMore robust swivel type connectionReplace both lines if line one of the lines is leakingFix in Production on NXS29064Truck Engine news release in February
Feb2009 CatVideo – Page 10
Oil filler tube falls out. CPI197526Glue for insert fails and falls outPCA is new oil filler tube is available• The 291-5435 has been replaced
by the 316-6552 tubeYou may need a larger O-ring on some tubes. The part number is 3P-0646.
(thanks to Foley Cat)
Truck Engine News will be out soon
LEE Engines in Motor Coaches
Feb2009 CatVideo – Page 11
Drivers are complaining about low power, and noise.• Turbine end bearing balls are running high on the
shoulder of the inner race Dynamic loads due to unsteady flow loading turbine wheelICA Pre lube turbo when replacing failed turboensure all debris is cleanedICACeramic ball bearingOut late JUNEField testing ongoing
HD Turbo bearing failures CPI181577
Feb2009 CatVideo – Page 12
Pre-lube from bottleDO NOT use OIL CAN
HD Turbo bearing failures CPI181577
Fill oil in supply connection
Feb2009 CatVideo – Page 13
Shunt-line Reroute for Certain trucks
The line was improperly routed from the OEM May cause over coolingThe correct routing is to the water inlet elbowService LetterPS42865, PS42801
Feb2009 CatVideo – Page 14
CRS Hot Spot Service Letter
REBE4304 ICA Service Letter will be broken out into several new PCA Service Letters
• 4 PCA Service Letters for various OEM’s. Should be released by late Feb 2009
REBE4585 PCA Service Letter for certain International Chassis Configurations with C15’s
• Service Letter will be released as soon as Morton has enough stock. Should be released early to mid Feb 2009
REBE4738 PCA Service Letter for certain Sterling & International Chassis Configurations
• Service Letter will be released as soon as Morton has enough stock. Should be released early to mid Feb 2009
REBE4750 PCA Service Letter for KW T2000/Pete 387 Chassis Configurations with C15’s
• Service Letter Released Jan 2009REBE4640 PCA Service Letter for certain Freightliner Chassis Configurations with C15’s
• Service Letter Released Jan 2009
Feb2009 CatVideo – Page 15
C15 T2000/Pete387 Combustion Body
Combustion Body Designs
Feb2009 CatVideo – Page 16
Enhancements for ASH reset function
A new look for ash reset in CatET will be coming outStand by we hope to have a publication out soonWill allow dealers to determine how much time hasbeen accumulated since the last ash cleaning
Feb2009 CatVideo – Page 17
Problem• 2007 On-Highway Engines oil samples have shown elevated
values of potassium and aluminum (C7, C9, C13 and C15)
Root Cause• Source of these elements has been traced to the brazing flux
used to manufacture the aluminum Air to Air Aftercooler (ATAAC) heat exchanger
PCA• Special wear tables for C13 (LEE) and C15 ( SDP & B5R)• C7 & C9 Tables not available at this time
(Levels will be higher than previous engines)
Pubs• SOS Services Knowledge Network – Special Wear Tables
https://kn.cat.com/know.cfm?id=207343
MY07 Oil Sample Guidelines
Feb2009 CatVideo – Page 18
C13 Wear Table @ 30,000 miles
Feb2009 CatVideo – Page 19
C15 Wear Table @ 30,000 miles
Feb2009 CatVideo – Page 20
The minimum machined head height has changed to” 165 +/- 0.5 MM
Specifications, Salvage and Reuse have been updated
C13 Cylinder Head Thickness
Page 21
Publications UpdateKevin Kempher
Feb2009 CatVideo – Page 22
PS42851 & PS42852 Updates
Technicians performing these updates are required to have viewed the “EPA 07 Assessment” video and passed the associated training as noted under the “Action Required” page of the Service Letters and again in Special Instruction REHS 4801.Both of these Service Letters require the following information to be included with the warranty updates• Technician CWS or SSO Logon ID must be included
in the Technician Name field of the Warranty Report. • Attach copies of both the Air Systems Verification
Test and the Regen Data Log
Feb2009 CatVideo – Page 23
PS42851 & PS42852 Updates
We’ve instituted a “Grace Period” through the end of February, 2009 to make sure that each Dealer has time to go back and make sure all Technicians understand what is required. Beginning on March 1st, 2009, claims that do not have the Technician’s Logon Information properly recorded or do not have both a copy of the ASVT and a copy of the Regen Data Log attached will be debited.
Feb2009 CatVideo – Page 24
PS42851 & PS42852 Updates
Step 4 of the Special Instructions REHS4801 states:Utilize Caterpillar Electronic Technician (ET) for any active diagnostic fault codes or logged diagnostic fault codes. Troubleshoot and resolve all active fault codes that are found before proceeding.
This line should read:Utilize Caterpillar Electronic Technician (ET) for any active diagnostic fault codes or logged diagnostic fault codes. If active fault codes are found that are unrelated to the CRS System and are not likely to be resolved by the updates, troubleshoot and resolve those fault codes before proceeding.
Feb2009 CatVideo – Page 25
DPF Hotline
Warranty Update #09xxAll DPF ReplacementsDPF Hotline 877-598-8920
M-F 7:30am-10pm - Peoria TimeSat 7am-5pm - Peoria Time
Call CatTC firstParts Return Request will be issuedClaim will be debited if:
DPF not returnedDPF unfailed and no Authorization NumberClaim has the wrong PN and no Auth Number
Feb2009 CatVideo – Page 26
Cat will provide:Failure analysis and root cause assistanceDocumentation Instructions and Warranty Authorization
Cat Dealer Responsibilities:Provide Dealer Code or TC NameProvide ECM DownloadConduct a successful Regen and ASVT after repairInclude DPF SN in claim storyObtain Authorization – enter # in Warranty Comments
TEPS Dealer Responsibilities:Contact CatTC After 30min wait…contact DPF Hotline and follow “Cat Dealer Responsibilities”
DPF Hotlinecontinued
Page 27
Electronics UpdateJohn F. Smith
Feb2009 CatVideo – Page 28
‘07 C7S Service Letter PS42868
Feb2009 CatVideo – Page 29
A new service test will soon be available for troubleshooting the Intake Valve Actuation (IVA) SystemCat ET Override – “Acceleration Based Intake Valve Actuation Test Override”Override requests the test to run when these enablement conditions are met:
• Engine at Idle RPM• Engine at Normal Operating Temperature• Engine Oil Pressure AdequateEnable the override, the service test runs continuously until disabled.ECM uses the crank speed timing sensor to analyze crankshaft accelerations as IVAs are activated and deactivated. A better technique than using the IVA rail pressure sensor.An IVA actuator –7 diagnostic code or an IVA rail pressure event code indicate there’s a problem with the IVA system. Troubleshoot the code according to published procedure.
EPA ’07 Engines – New IVA Service Test
Feb2009 CatVideo – Page 30
Software Requirements:• Cat ET version 2008C or newer (already available)• Engine software PN 343-XXXX or newer (scheduled release in
early February 2009)Hardware Changes
• No hardware changes are requiredTroubleshooting Guide Changes
• The troubleshooting procedure for IVA Response is being revised to reference this new service test
• Details on the new service test are being added to the troubleshooting guide
Additional Information• A Truck Engine News Article will describe this new service test
EPA ’07 Engines – New IVA Service Test
Feb2009 CatVideo – Page 31
EPA ’07 Engines – New ECM Parameters
Two new configuration parameters are displayed in ET• “CAN Communication Protocol Read Security”• “CAN Communication Protocol Write Security”These parameters are for factory use only
Feb2009 CatVideo – Page 32
EPA ’07 Engines – New ECM ParametersSystem Settings Group of Parameters
Feb2009 CatVideo – Page 33
EPA ’07 Engines – CGI Actuators
When should a CGI Actuator be replaced?A small amount of oil may be present around the weep hole• This is normal• Do not replace the actuator for this conditionExamples of serviceable and non-serviceable actuators are on the following slides
Feb2009 CatVideo – Page 34
EPA ’07 Engines – CGI ActuatorsGood
Feb2009 CatVideo – Page 35
EPA ’07 Engines – CGI ActuatorsGood
Feb2009 CatVideo – Page 36
EPA ’07 Engines – CGI ActuatorsBad
Feb2009 CatVideo – Page 37
EPA ’07 Engines – CGI ActuatorsBad
Page 38
Transmission UpdateCurt Vogel
Feb2009 CatVideo – Page 39
NPI ISSUE #: 186170 (CX35)205129 (CX31)
HOURS: 0-500 transmission hours ISSUE DESCRIPTION: Integral seal splitting in
o- ring portion of the part.
SEAL PART #’s: 272-7264 (CX31)299-1900 (CX35)
ROOT CAUSE: Molding defectsINTERIM CONTAINMENT: 100% Internal
Ultrasonic TestingPERMANENT CORRECTIVE ACTION: Re-
milling & Seal gate change, sandblasting of metal carriers and Control Plan with the supplier. (Sample o-ring molded with each seal and supplier-inspected for defects via ultrasonic testing.)
Integral Seal Issue
Feb2009 CatVideo – Page 40
Integral Seal Location
Integral Seal
Feb2009 CatVideo – Page 41
Integral Seal installed on Case
Integral Seal(s)
Feb2009 CatVideo – Page 42
Oil Pan ECPC Guard
Main ReliefControl Valve
Common Leak Location (Bottom of the transmission)
Feb2009 CatVideo – Page 43
Common Leak Location (Bottom of the transmission)
Feb2009 CatVideo – Page 44
Common Leak Location (Integral seal)
Clutch Pressure Ports
Feb2009 CatVideo – Page 45
Integral Seal Replacement
Torque Converter Housing – Removal / Installation• Disassembly and Assembly Manual (SIS web)
NOTE: CX31/CX35 (excluding CX31R) It is not required to remove the Torque Converter prior to Torque Converter Housing removal. This will ease service replacement of the Integral Seal.
Feb2009 CatVideo – Page 46
CX31(272-7264 Seal) – Step 1
Apply a thin bead of RTV on face of case at T-joint before seal is installed
Feb2009 CatVideo – Page 47
CX31 (272-7264 Seal) – Step 2
Apply a thin bead of RTV on face of seal at T-joint before TC hsg is installed
Feb2009 CatVideo – Page 48
CX31 (272-7264 Seal) – Step 3
Wipe off any excess RTV and carefully cut-off the seal tag flush with the case and TC hsg
Excess RTV squished out of joint after TC hsg-to-case assembly
Feb2009 CatVideo – Page 49
CX31 (272-7264 Seal) – Step 4Apply a fresh bead of RTV across each T-joint and install the oil pan and PIP seal
Feb2009 CatVideo – Page 50
Do not apply RTV to the face of the case or the face of the seal before assembling the seal and TC housing to the case
Unlike the old CX31 seal, the new 339-5397 seal bead wraps around the edge of the retainer (there is no tag to cut off)
CX35 (299-1900)New CX35 Seal (339-5398)New CX31 Seal (339-5397)
Step 1
Feb2009 CatVideo – Page 51
Apply a bead of RTV across each T-joint and install the oil pan and PIP seal
CX35 (299-1900)New CX35 Seal (339-5398)New CX31 Seal (339-5397)
Step 2
Feb2009 CatVideo – Page 52
Integral Seal Repairs
Current Integral Seal Part #’s 272-7264 (CX31)299-1900 (CX35)
New Integral Seal Part #’s339-5397(CX31)339-5398 (CX35)
Feb2009 CatVideo – Page 53
Internal Torque Converter Bolt Sealing Procedure
Internal Torque Converter Bolt
Feb2009 CatVideo – Page 54
Apply small bead of RTV to case spotface and washer (under the head of the bolt) before installing bolt
Internal Torque Converter BoltSealing Procedure
Page 55
Reman UpdateMark Gasper
Feb2009 CatVideo – Page 56
3406E, C15 / Camshaft / Gear Bolts
There have been many issues with spun cam bearings on 3406E and C15 enginesOne of the root causes of these failures is improper bolt torque on the camshaft gear boltsFollow this procedure to torque the camshaft bolts:
1. Lightly lubricate the O-ring seal on the outside of the sealing plate of the camshaft with a 50/50 mixture of 8T-2998 Lubricant and engine oil that is clean.
2. Apply 9S-3263 Thread Lock Compound to the three bolts for the sealing plate of the camshaft.
3. Tighten the three sealing plate bolts on the camshaft to the following torque: 12 ± 3 N·m (9 ± 2 lb ft)
4. Tighten the camshaft bolts to 240 ± 40 N·m (177 ± 30 lb ft) in the following sequence: 1, 4, 2, 5, 3, 6, 1, 4
See TEN #SEBD6799 CPI Project 108835
Feb2009 CatVideo – Page 57
0R1623 / 0R1624 Air Compressor
New Lines Group
Updated Lines Group• We continue to see failures on 0R1623 Compressors due to stripped threads in the head…Analysis shows that most on most of these failures the old lines group is still being utilized.• Make sure if you replace the air compressor you update the lines group.• See TEN #SEBD6799 for further details
Old lines group
CPI Project #123224
Feb2009 CatVideo – Page 58
New Reman Websitecatreman.cat.com
Login
Feb2009 CatVideo – Page 59
Technical Resourcescatreman.cat.com