Robert Falkingham National Accounts Product Support Manager On-Highway Engine Products

10-13L Service Letter Update  PS50041 (C-10/C-12 Head Gasket Repair) –Scheduled to Expire January 31 st 2004 –Extended Until the End of May  PS50338 (C-10 – C-15 Injector Tip) –Expired December 2003 –Will Not be Extended

C11/C13 Push Tube Installation  Valve Push Tube Installation Problems –CPI Issue: –Problem: Intake and Exhaust Push Tubes can be installed incorrectly Ball end outside of lifter pocketBall end outside of lifter pocket

C11/C13 Push Tube Installation –Affected Product: All C11/C13 –Fix: Ensure Push Tubes are installed correctly during assembly by inspection. –Communication: TEN Article Planned 2 nd Quarter 2004

ACERT Air Compressor Air Box  Debris Related Failures on Air Compressor –CPI Issue: –Problem: Carry over debris from Air Box Resulting in Air Compressor Failure –C15 Air Compressor Group Air Box

ACERT Air Compressor Air Box –C13 Air Box –Affected Product: All HD ACERT Engines –Fix: Ensure the air box is free of debris after a repair where the air compressor incurred a core iron failure (ie. Piston failure) –Communication: TEN Article 2 nd Quarter 2004 Air Box

C13 Air Compressor Vibration  BA 921 Single Cylinder Air Compressor –CPI Issue: –Problem: The new BA-921 Single Cylinder Air Compressor can excite engine chassis vibration Vibration Meter Reading 1.14 Order (1.14 x crank speed)Vibration Meter Reading 1.14 Order (1.14 x crank speed) –Affected Product: KCB00508 – KCB01638 –Fix: New Counter Weight Gear to Reduce Air Compressor imbalance. –Communication: TEN Article Planned Late 1 st Quarter 2004

C13 AC Pressure Switch Function  AC Pressure Switch Function –CPI Issue: –Problem: ECM software has a non- functional Air Conditioner Input Switch –Affected Product: KCB00891 – KCB01676 –Fix: February Release Software –Communication: TIB Planned for Mid February

C13 Surge  C13 Surge –CPI Issue: –Problem: Small Number of Chassis Configurations Excite the Driveline with the C13 Engine Typically referred to as “violent” surge during slight accelerationTypically referred to as “violent” surge during slight acceleration –Affected Product: KCB00508 – KCB02033 –Fix: February Release Software –Communication: Scheduled TIB for Early February

C-10/C-12/C-15/C-16 Injector R&I  Slightly modified procedure for R&I injectors –CPI Issue: –Problem: Injector hold down bolt failures after service –Affected Product: All Heavy Duty Engines

C-10/C-12/C-15/C-16 Injector R&I  Slightly modified procedure for R&I injectors –Fix: New Remove and Install Procedure A.Make sure to mark which cylinder unit injector, spacer, clamp, and bride assemblies came from. i.Reinstall these parts on the same cylinder they were removed from. B.Inspect the hold down bolt assembly prior to disassembly. i.If the bolt is NOT loose during disassembly, then proceed directly to step C. ii.If the hold down bolt IS loose during disassembly: a.Inspect the injector bore for debris b.Inspect the bore for wear c.Replace the clamp, and spacer Proceed to step C C.NOTE: In ALL instances, replace the injector hold down bolt with a NEW bolt D.Do NOT reuse seals or hold down bolts. –Communication: TEN Article Planned 1 st Quarter 2004

PS50667 Exhaust Rocker Arms  Affected serial numbers –6NZ83126-Up –7CZ3834-Up –MBN  Engines with Jacobs 340D Brake  Replace all exhaust rocker arms  Replace intake rocker arm on failed cylinder  Replace all compression brake bolts and studs  Set brake slave lash –6NZ83126-Up 0.025” –7CZ3834-Up 0.025” –MBN ”

PS50740 C-15 Truck Cylinder Liner  After Failure  Serial numbers included –MBN ,6NZ ,C2A –8SB ,7XC ,2MZ –4AS  Inspect date codes –Replace affected liners as outlined in the service letter

C15 BXS Turbo Mounting  Use Spiralock nuts only –Part Number –Torque to 55 ± 5 N·m (40.6 ± 3.7 lb ft.)  Use Stainless Steel Studs –Part Number  Use turbo mounting gasket  Use turbo mounting gasket –Part Number  Nuts will spin on easily  No stake marks on nut  Over tightening can cause the stud to fail

C15 BXS Turbo Mounting

Stud Spiralock Nuts Use turbo gasket

C15 BXS Valve Actuator Wiring  Solenoid connector same as medium duty injector  Kit can be used for repair –Part number  Repair procedure –REHS1809 Special Instruction  Less downtime for the customer  Keep wiring out of discharge stream of valve actuator –Can deflect oil causing oil mist from breather

What’s New Eaton Top II Eaton 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 Top II. The transmission style is not programmable with the GFRS files. On GFRS flash files the transmission style will show up as Eaton Top II. The transmission style is not programmable with the 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 factory passwords. Change in flash file from GFRS to other flash file requires factory passwords. Changing the transmission from Eaton Top II to different transmission will require a different flash file. Factory Passwords are required to make this change. Changing the transmission from Eaton Top II to different transmission will require a different flash file. Factory Passwords are required to make this change. Transmission Neutral Switch Transmission Neutral Switch Neutral 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 if there is a complaint with Fast Idle, PTO, Elevated Idle, or Cruise Control. Important to check neutral switch programming and operation if there is a complaint with Fast Idle, PTO, Elevated Idle, or Cruise Control. Caterpillar ET 2003B is required. Caterpillar ET 2003B is required.

Reminder  Outside Temperature Based Idle Shutdown –Installation of sensor kit is required when the idle shutdown is programmed to “Outside Temp Based” If this kit is not installed the idle shutdown system may not function properly. –The sensor kit must be mounted so an accurate measurement of the outside ambient air temperature can be taken.  Flashing ECMs –Always transfer the flash file to the hard drive of your computer. Computers communicate faster when the file is on the hard drive. –Also try the bypass harness. There is a lot of information on the data link from other devices such as ABS, or transmissions. This isolates the ECM from this noise. –By putting the file on the hard drive and using the bypass 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 to a floppy. The flash will abort. File needs to 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 need to be copied to the computers hard drive.

 Is this “overcooling”? Overcooling Troubleshooting

Overcooling Engine Discussion  Definition: Overcooling can be defined as the condition where the normal temperature at which an engine operates cannot be reached. –This condition is most commonly reported as: –Engine coolant temperature runs cool only at idle. –Engine coolant temperature runs normal at idle, but overcools noticeably while driving or operating in cool ambient temperatures.  The recommended minimum operating temperature for diesel engines that operate on high sulfur fuel is 80C (175F).  This can be achieved by elevating the idle to 1000 RPM. This results in the engine adding more heat into the system. –Customers operating engines with temperatures below 80C (175F), may report several of the following complaints: –Reduced fuel economy <OK –White smoke <OK –Reduced power <OK –Reduced component life <OK

Overcooling Engine Discussion  6NZ C-15 “Primary source of heat into the system”

Overcooling Engine Discussion  BXS C15 “Primary source of heat into the system” Precooler

Overcooling Troubleshooting  From the Troubleshooting Guide  Engine Overcooling  Probable Cause  Long Idle Periods - When the engine is running with no load, only a small quantity of fuel is burned. Therefore, the heat from the engine is removed too fast. 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 is missing, too much heat is removed from the engine.  Very Light Load - Very light loads, a very slow speed or downhill travel can cause overcooling. This overcooling is caused by the low heat input of the engine. The installation of shutters helps to correct this condition. <<“Shutters Dated”  Faulty Water Temperature Regulator (thermostat) - A water temperature regulator that is stuck open can cause overcooling. Overcooling also occurs when the water temperature regulator is stuck between the following positions: open position and closed position. Coolant leaks that are around the water temperature regulator can cause overcooling. An example would be a vent line leak. <<“how do you check”  Thermostat leakage rate is 10cc/min per stat. Need a way to measure?

Overcooling Troubleshooting  Inspect the vent line for excess leakage. –Quick check is to plug the line and cap #4 fitting. –Install check ball. –ACERT engines have two vent lines. This will require an update to the vent line recommendation. Current line configuration is above the fitting for the check ball.  Truck Engine News 1999/04/01 Media Number -SEBD Publication Date -New Cooling System Vent Line Check Valve Helps Prevent Over Cooling{1370}  Know Your Cooling System; SEBD0518 (paper)  Know Your Track-Type Tractor Cooling System; REHS1063

Overcooling Troubleshooting  Investigate thermostat or thermostat seal leakage. –Several methods used to test. –1) Historically, thermostats were checked with a hot plate and thermometer. It has since become economical to replace them if removed. Note: this test gives thermostat performance not leak rate. –2) Recently the increased use of infared temperature instruments to estimate leakage of the thermostats. The results are qestionable. (40% of thermostats replaced are no fault found.) –3) Measure the leakage rate and compare to known specifications. More accurate with results that can be documented. Criteria with this test is pass or fail. Less invasive and conclusive. –P/N 7C3095 = 2 x 10cc/min max leakage. Opening Temp degF –P/N 7W0317 = 2 x 50cc/min max leakage. Opening Temp degF –Fabricate tool to measure volume change. Accurate method and gives good results. Todd and Doug to show an example tool that was fabricated.

Form NumberBooklet DescriptionSerial Number Prefixes RENR C-10,C-12 & 3406E1MM,2KS,2WS,3CS, 6NZ, 7CZ, CPD RENR C-10,C-12 & 3406E5DS,8YS,9NS,1LW SENR B,C-10,C-12 & 3406E5EK,9CK,1YN,2PN,6TS SENR C (PEEC III)4CK SENR B (PEEC II)2EK,5YG,8TC SENR YG SENR LG RENR B 7AS, 8YL,8SZ,BKD, 1AJ,CKM, CRP,9SZ SENR HEUI 8WL,1WM,4ES,2CW, 8HW, 7LZ Troubleshooting Guide Listing

Serial Number Prefixes C-10, C-12 & 3176  2YG 3176 –1988 to 1990  7LG 3176 –1991 to December 1993  9CK 3176B –May 1993 to March 1995  2PN C-10 –March 1995 to September 1997  8YS C-10 –September 1997 to November 1998  1YN C-12 –March 1995 to September 1997  9NS C-12 –September 1997 to November 1998  3CS C-10 –November 1998 to September 2002  2KS C-12 –November 1998 to September 2002  MBJ C-10 –October 2002 to Current  MBL C-12 –October 2002 to Current

Serial Number Prefixes 3406/C-15/C-16  8TC PEEC II and PEEC II.V –1987 to 1990  5YG PEEC II - 460Hp Only –1990  2EK PEEC II and PEEC II.V –1991  4CK 3406C Electronic –August 1991 to December 1993  5EK 3406E –May 1993 to December 1996  6TS 3406E –January 1997 to December 1997  1LW 3406E 14.6L –December November 1998  5DS 3406E 15.8L –December November 1998  2WS 3406E 14.6L –November 1998 to Current  1MM 3406E 15.8L –November 1998 to Current  6NZ C-15 –November 1999 to September 2002  7CZ C-16 –November 1999 to September 2002  MBN C-15 –October 2002 to Current

CATERPILLAR TRUCK ENGINE SUPPORT CENTER  OR   Available 24 hours per day, 7 days pre week, 365 days per year (11am Saturday – 7am Monday call rolls to Morton Parts – CSR will direct customer to nearest Cat Dealer.)  Benefits: Emergency road service / Cat Service Location Assistance/ Technical help  Fleet Hotline: Jim Tresenwriter M-F, 8-4pm Jim Tresenwriter M-F, 8-4pm