Tech Tips Febrero 2009

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Page 1 TechTips - CatVideo Feb, 2009

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EXPERTOS PRODUCTOS CATERPILLAR

Transcript of Tech Tips Febrero 2009

Page 1: Tech Tips Febrero 2009

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TechTips - CatVideoFeb, 2009

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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]

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Questions…

No Phone Calls today, please

Segment Questions……Contact Information on pg2

Program Comments:[email protected]

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Keepin’ in Touchht

tps:

//tru

ck.c

at.c

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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

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WebEx Registration (for your records)

Search: tech tips

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WebEx Launch (for viewing)

cat.webex.com

Search: tech tips

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HD Engine Update

Josh Evans

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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

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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

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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

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Pre-lube from bottleDO NOT use OIL CAN

HD Turbo bearing failures CPI181577

Fill oil in supply connection

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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

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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

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C15 T2000/Pete387 Combustion Body

Combustion Body Designs

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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

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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

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C13 Wear Table @ 30,000 miles

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C15 Wear Table @ 30,000 miles

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The minimum machined head height has changed to” 165 +/- 0.5 MM

Specifications, Salvage and Reuse have been updated

C13 Cylinder Head Thickness

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Publications UpdateKevin Kempher

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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

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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.

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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.

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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

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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

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Electronics UpdateJohn F. Smith

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‘07 C7S Service Letter PS42868

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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

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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

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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

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EPA ’07 Engines – New ECM ParametersSystem Settings Group of Parameters

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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

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EPA ’07 Engines – CGI ActuatorsGood

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EPA ’07 Engines – CGI ActuatorsGood

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EPA ’07 Engines – CGI ActuatorsBad

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EPA ’07 Engines – CGI ActuatorsBad

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Transmission UpdateCurt Vogel

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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

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Integral Seal Location

Integral Seal

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Integral Seal installed on Case

Integral Seal(s)

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Oil Pan ECPC Guard

Main ReliefControl Valve

Common Leak Location (Bottom of the transmission)

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Common Leak Location (Bottom of the transmission)

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Common Leak Location (Integral seal)

Clutch Pressure Ports

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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.

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CX31(272-7264 Seal) – Step 1

Apply a thin bead of RTV on face of case at T-joint before seal is installed

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CX31 (272-7264 Seal) – Step 2

Apply a thin bead of RTV on face of seal at T-joint before TC hsg is installed

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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

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CX31 (272-7264 Seal) – Step 4Apply a fresh bead of RTV across each T-joint and install the oil pan and PIP seal

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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

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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

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Integral Seal Repairs

Current Integral Seal Part #’s 272-7264 (CX31)299-1900 (CX35)

New Integral Seal Part #’s339-5397(CX31)339-5398 (CX35)

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Internal Torque Converter Bolt Sealing Procedure

Internal Torque Converter Bolt

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Apply small bead of RTV to case spotface and washer (under the head of the bolt) before installing bolt

Internal Torque Converter BoltSealing Procedure

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Reman UpdateMark Gasper

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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

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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

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New Reman Websitecatreman.cat.com

Login

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Technical Resourcescatreman.cat.com