tech tips 24 mayo 2006

TechTipsMay 24th 2006

10:00 a.m. CDT

May 2006 - LEVD6113 -

Program IndexPage

Rules of the Road – H.Wayne Wilson 3eEvaluations, eLearning, DVD Subscriptions, eMail7-9L Engine Update – Kory Endress 7Injector Cutout Tests, Exhaust Brakes, PI30870 Software, CatET DataLogger, Injector Flash Files, Reman Injectors DSN Update – Don Kirman 18PAR Data, Low VVA Oil Pressure, C13 Oil Consumption11-15L Engine Update - Roger Hudson 25VVA No Response, C15 VVA Stud, Low Pressure FuelElectronics Update - Dave Morrow 30C15 VVA Sensor, Mileage Totals, Flashing Problems, Communication Problems, New Hotline VoiceCatET Update – Robert Bullock 362006A v1.0, ECM Icon, DataLogger, FAQs, Contact InfoMaintenance Products Update – H. 44Truck Batteries, Hardware, Seals, New Tools, Shop SuppliesReman Update – Marty Young 503126 Oil Sensor, 3126E Injector, 15L Valve Bridge Contact, 3100 Injector Sleeves, 3406C Piston Cooling Jet, NPI News SIS Tips – Ron Morse 58ECM Replacement Files, Save & Load CatET Files, File Access2007 Engine Systems – Steve Ashburn 67Clean Gas Induction (CGI), Emissions, Diagram, Sensors, Venturi,Cooler, Controls, Actuator, Field Training, Factory Contact Filter & Fluids Update – H. 99Broadcast Contact – H. 102

May 2006 - LEVD6113 -

eEvaluationshttps://truck.cat.com | Parts&Service | TechTips | eEvaluation Survey

1. SegmentReview

2. Caterpillarexperience:

< 2 year2-10 years>10 years

3. I watched:Live Tape/DVD

4. I have taken2007 WebexTraining…Yes No

5. I will be taking the eLearningquiz: Yes No

7. Job Function:Service TechManagement or Training

8. Viewer Name:

9. Dealer Code: (4 digits)

10. Dealer Name:

11. How many in your dealership willsee this TechTips before August?

12. Comments (please):

Kory Endress

May 2006 - LEVD6113 -

eLearninghttps://truck.cat.com | Parts&Service | TechTips | eLearning test

May2006 TechTips eLearning Quiz…

What is the TIBU number for the Injector Cutout procedure? TIBU7443 / TIBU4743 / TIBU4734 / TIBU4473

PI30870 Service letter covers what Truck Engine platform? C7 / C9 / C13 / C15

What web site do you access to locate the CatET data logger information? Truck.cat.com / Google.cat.com /Loggerdata.cat.com / Engines.cat.com

What is the IRM number for the new C7/C9 Reman injectors? REM08-06 / REM08-60 / REM06-80 / REM06-08

The diagnostic code 385-01 for Low Intake Valve Actuation System Pressure gets logged under what conditions? When there is a leak in the VVA oil system. / When the engine oil pressure and the VVA oil pressure differential is lower than expected. / When the VVA oil pressure is below engine oil pressure. / When the engine oil pressure is higher than VVA oil pressure. / All the above

The VVA oil system pressure is? 80 psi / Not an input to the ECM. / Varies but should be above engine oil pressure./ Will be very close to engine oil pressure. / Regulated by the checkvalve.

For C11/C13/C15 MXS engines with 285 through 290-07 fault codes: Always following the troubleshooting guideCall DSN / Flash in software dated January 2006 or newer before any troubleshooting. / Clear the codes and tell the customer to let you know if they have any other problem

If a VVA stud breaks, replace the stud with?233-3672 torque to 135Nm / 288-4109 torque to 135Nm /233-3672 torque to 109Nm / 288-4109 torque to 109Nm

Hard starting and poor performance can be caused by air entry into the fuel system because?Failed air compressor / Poor quality oil / Fuel line restriction, primary fuel filter, or sticky regulator in filter base / Fuel tank location

What is the new part number for the VVA sensor on the C15: 224-4535 / 248-2168 / 284-2728 / 249-5293

How long after you reprogram the total mileage on ACERT engines would you have to wait to turn off the Key? 5 min / 1 hr / 1 min / 1 sec

What drop down allows you to change icons?VIEW | CUSTOM | TOOLBARSELECT | DIFFERENT | ICONEDIT | OTHER | OPTIONSBUY | CAT | FILTERS

The troubleshooting guide for CatET does NOT open up in a separate window? (T/F)

What Battery CCA’s does Truck Maintenance Council recommend for "starting" the largest highway truck engines at 0degF?1000 (total) CCA / 1800 (total) CCA / 3600 (total) CCA / 5000 (total) CCA

What other battery system design features may be more important to truckers? deep cycle capability for key-off sleeper or other accessory use / deep cycle capability for inverter use / deep cycle capability for reefers or heavy P&D operation / low voltage disconnect set at 12.3V / all of the above

The Service Software search is used to find the ECM Replacement files on the SIS Web Main menu. (T/F)

The ECM replacement file can permit the Cat ET user to restore the As Shipped configuration parameters to a new ECM or reset the current ECM to the AS Shipped settings (T/F).

May 2006 - LEVD6113 -

DVD SubscriptionMay 24th, 2006 Broadcast:

LEVD6113 – DVD only LEVN6113 – VHS only

DVD Subscription - LEVD3947• Menu Driven for fast forward to any segment• Rapid word search of 2yrs of Broadcast Handouts• Script from current show for reference or hearing impaired

VHS Subscription – LEVN3947• All VHS Subscriptions Discontinued Jan 2006• Individual VHS Tapes WILL be available

Subscription Information• Janel Green, CatTV Admin, 1-309-675-4556• Media Logistics, 1-800-566-7782

2006

May 2006 - LEVD6113 -

Q&A…Email Now! Email: [email protected]

C7/C9 Engine UpdateKory Endress

May 2006 - LEVD6113 -

C7 Injector Cutout Test

TIBU4734 Injector Cutout Test (C7 Engines Only)• The software listed below is strictly for diagnostic purposes• The software is divided into specific engine families • The engine will operate in a de-rated mode with these files• NO PASSWORDS ARE NECESSARY• C7 (190-210hp) P/N 286-0201• C7 (230hp-250/660) P/N 286-0202• C7 (250/800 hp-350 hp) P/N 286-0203

Notice: Do NOT use this software on early KAL engines unless updated Injectors have been installed. (KAL1-12898)

May 2006 - LEVD6113 -

C9 Injector Cutout Test

TIBU4734 Injector Cutout Test (C9 Engines Only)• Great News!!! The latest C9 Flash files have the diagnostic

software built in! When running injector diagnostics flash the latest production file. Reference the chart below for the correct flash files.

• Updated C7 Files will be out in June with the same features.

400HP RVP/N 289-1223350HP TruckP/N 286-5300335HP TruckP/N 292-5521400HP ERP/N 290-9008350HP ERP/N 264-1215335HP ERP/N 292-5522

May 2006 - LEVD6113 -

Exhaust BrakesOperation• Designed for continuous use• Lack of use can cause the valve body to stick shut

intermittently• Symptoms of valve body sticking include:

• Reduced performance & fuel economy• Abnormally high exhaust temperatures

Maintenance Tips - Recommended lube points• Cylinder anchor pin - Back of cylinder at bracket• Clevis pin - Passes through actuator arm down to butterfly

valve and into brake housing• Use non-petroleum or synthetic silicon spray lube

only as recommended by the manufacturer

May 2006 - LEVD6113 -

C9 Truck Software - PI30870This Priority service letter is for a flash file update only. The letter needs to be completed ASAP. If you have flashed any 350HP C9 engines with flash file P/N 280-9033 or P/N 286-5300 for diagnostic purposes then also enter a SIMS entry for PI30870.Caterpillar Inc. has to document that we have flashed 100% of these engines. Your help is appreciated. Flash file P/N 286-5300 has the stutter stumble fix and diagnostic software in it.

May 2006 - LEVD6113 -

CatET Data Logger Refresher

We still sometimes run into issues when askingfor a data logger file.

• The same training Geoff & Don provided at the Technical Communicator Conference is available at truck.cat.com

• This material includes setting up the data logger and also creating a new group, which will be necessary if a 2007 test engine arrives in your shop.

May 2006 - LEVD6113 -

ET Data Logger Refresher

May 2006 - LEVD6113 -

Injector Flash Files SEBD6763 is effective on the following engines

-07985 • KAL1-07895 190hp - 210hp• KAL1-11870 230hp - 250 / 660lb-ft• KAL1-12897 250/800 - 350RV

• Make sure and flash the appropriate flash file after replacing the set of injectors. Do not flash the most recent flash file for these engines because the software is for the old injectors. Refer to SEBD6763 for more detailed information.

• Do NOT replace a full set of injectors on any engines KAL12987 and up without DSN authorization.

• If the engine already has updated injectors then do not perform SEBD6763

May 2006 - LEVD6113 -

SEBD6777 is effective on the following engines07986

• KAL07896-Up 190hp - 210hp• KAL11871-Up 230hp - 250/660lb-ft• KAL12898-Up 250/800 - 350RV

• Previous slides discuss injector replacement and test flashfiles• SEBD6777 is an update to SEBD6763 letting you know the

serial numbers above are the new design injector and they do NOT need to be replaced.

• Always check SIS web or TMI to get the latest flashfile before replacing injectors

Injector Flash Files

May 2006 - LEVD6113 -

New and Upcoming software

C9• New software is available that has the injector diagnostic

fix built in. TIBU4734• A file that addresses RV/ER in gear surge and cold mode

black smoke is available. SEBD6789

C7• New software will be available in June 2006 that addresses

black smoke on acceleration when in cold mode.• The same software will also have the injector diagnostic

fix built in.

May 2006 - LEVD6113 -

Reman C7/C9 Injectors

• Now Available! The table below is from the Cat. Reman IRM REM06-08 / PELJ0637

DSN UpdateDon Kirman

May 2006 - LEVD6113 -

PAR Dyno FaxesRecord ALL the data on page two of the report to prevent a dyno re-runFaxing information:

• Don Kirman’s primary fax is (still) 309-578-9826• Back-up fax has changed to 309-578-9336• Please leave a voice message on the primary line if the

back-up line is used

On the cover sheet please have:• Your callback phone number• Current FLS/FTS settings• The CAT ET S/N that will be used to reset the FLS/FTS• Type or write legibly

May 2006 - LEVD6113 -

Low VVA Oil PressureMain causes of the 385-01 code covered on Nov2005 TechTips

• Broken Accumulators… p/n 229-0882• Check Valve… p/n 239-6248• Leaking seals…p/n 247-0708• Warm-up valve…p/n 228-4800

Other causes…• Oil Pan overfilled or dipstick not calibrated (see O&M manual)• Bad engine oil pressure sensor or VVA oil pressure sensor• Oil aeration at oil pick up tube

May 2006 - LEVD6113 -

Faulty engine or VVA oil pressure sensor.• The 385-01 code logs when the pressure differential between

the engine oil pressure and the VVA system oil pressure is less than expected, false readings will trigger this code.

• One can expect VVA oil pressure to be 20-35 psi higher than engine oil pressure at 1800 rpm with the engine fully warmed up.

• CatET does not display VVA oil system pressure. To determine the VVA oil pressure, some dealers have installed a gauge in one of the plugs at the rear of the valve cover base in the VVA oil rail. It is possible to drill and tap one of the plugs to mount a gauge. (picture on next slide)

Low VVA Oil Pressure…cont’d

May 2006 - LEVD6113 -

VVA Oil Rail Plug, drilled and tapped, 1/8 NPT

Low VVA Oil Pressure…cont’d

May 2006 - LEVD6113 -

Oil Aeration at Oil Pick-Up Tube• Symptoms were 385-01

code and lower than normal engine oil pressure

• Oil pickup tube at elbow (210-1743)…2 occurrences

• O-ring seal at block (5P8211)…2 occurrences

• Few occurrences thus far, check ONLY after exhausting normal troubleshooting and if engine oil pressure seems lower than normal

Pinched O-ring seal

Joint leaks or broken weld

May 2006 - LEVD6113 -

C13 Oil ConsumptionCPI 80136Several causes

• Overfilled oil sumps or mis-calibrated dipsticks • Breather media quality• Engine operation at sustained high rpm

DSN request –• Read “Excessive Engine Oil Consumption” in

“Testing and Adjusting” of Service Manual • Include Vehicle Model and Application Information• Include completed oil usage log• Include Warranty and Prognostic Downloads

11-15L Engine UpdateRoger Hudson

May 2006 - LEVD6113 -

One Piece Design Two Piece Design

C11-15 VVA Not Responding FaultsDescription:

Engines may have VVA fault codes that can’t be fixed using normal troubleshooting…285-07, 286-07, 287-07, 288-07, 289-07, or 290-07

Root Cause:VVA built with one piece Low Pressure Actuator (LPA)

C15’s built or repaired since Sept2005 (MXS37579-77957) C11’s built or repaired since Dec2005 (KCA08296-08905) C13’s built or repaired since Dec2005 (KCB42051-58641)

Solution: Flash new softwareUse VVA as part causing failure

C15 – 263-8280C13 – 276-4367

TIBU4813 for C15TIBU4812 for C11/C13

May 2006 - LEVD6113 -

New C15 MXS VVA Stud

Description:Broken VVA studs.

Root Cause:New VVA stud in production on 10April2006288-4109 (grade 9) cancel/replaced the 233-3672 (grade 8)

Solution: 288-4109 available in Morton partsTorque to 135Nm (100 lb-ft)

May 2006 - LEVD6113 -

Low Pressure Fuel SystemDescription:

Some customers complain of hard starting or poor performance.

Root Cause:Air entry into the fuel systemCapability of fuel system

Solution: Check the low pressure fuel system for airC15 Requirements

Primary filter flow capacity (97 GPH minimum)Fuel supply line restriction not to exceed 8.9 IN HG ( 30KPa)

C13 RequirementsPrimary filter flow capacity (88 GPH minimum)Fuel supply line restriction not to exceed 8.9 IN HG ( 30KPa)

May 2006 - LEVD6113 -

Under sized lines from tank or lines that trap air generate aerated fuel, poor performance and hard starts. Excessive pressure drops across primary filter cause pressure to drop below saturation pressure of fuel, thus causing air to

come out of solution.

Heavy Duty Low Pressure Fuel System

Electronics UpdateDave Morrow

May 2006 - LEVD6113 -

New VVA Pressure SensorsA new VVA Pressure sensor ( P/N 284-2728) is now available for the C15 ACERT truck engines.This sensor must be used to service only BXS and MXS enginesPlease look for a truck engine news article and a special instruction in the near future.

May 2006 - LEVD6113 -

Mileage Totals in ECM for ACERTTo change the truck mileage in the current totals in the ECM, please follow these steps:

1. Change the mileage to the corrected value.2. Right after changing the mileage, go into the totals screen

and put the engine hours forward 1 more hour before turning the key off.

Now the mileage is programmed in the ECM permanently.

May 2006 - LEVD6113 -

Have Flashing Problems?

Steps to resolve problems flashing an ECM.1. Have your flash file on the hard drive of your computer.2. If using a Caterpillar Communication Adapter 2, adjust your

baud rate to around 38400.3. Hook up an Cat supplied bypass harness to the ECM.

• ADEM 2 (P/N 129-2018)• ADEM 3 and 4 (P/N 167-9225)• Messenger (P/N 239-9967)

May 2006 - LEVD6113 -

Have Communication Problems?

Steps to perform if having Communications problems with an ECM

1. Have the most up to Date Version of Cat ET.2. Hook up a Cat supplied bypass harness.3. If using a Cat Comm Adapter 2, Have the correct cable

from the Comm adapter to the truck.• ( P/N 207-6845)

May 2006 - LEVD6113 -

New Voice on the ECM Hotline

We have added a new person to the ECM hotline.Dave Abrams has joined the ECM Hotline staff.Dave’s background includes engine software development and ECM failure analysis.

Cat ETTM UpdateRobert Bullock

May 2006 - LEVD6113 -

Caterpillar Electronic Technician

2006A v1.0 Release Information

Released on websites in April

Should arrive at your Dealership sometime in July

May 2006 - LEVD6113 -

Select ECM Icon

Data Logger

Frequently Asked Question

Electronic Technician Topics

May 2006 - LEVD6113 -

Select ECM Icon

May 2006 - LEVD6113 -

Data LoggerCapture engine performance dataAbility to define sample rate and durationStore data in any locationData may be graphed using Cat ET

Note: Data Logger must be enabled prior to launching any other feature

May 2006 - LEVD6113 -

Frequently Asked Question

How do I access the new troubleshooting guide?Select Help menu then Troubleshooting

May 2006 - LEVD6113 -

Contact InformationTruck Engines: https://truck.cat.comNACD Infocast: https://nacd.cat.comDBSi website: https://dbsi.cat.com• Select “DCS Knowledge Database.”• Enter a description of your problem and submit

PC Support - Dealer Channel Systems • M-F 6am-6pm Central• 800-765-0999 or 309-675-4000• [email protected]

Licensing Cat ET- Media Logistics• M-F 7:30am-4:30pm Central• 800-566-7782 or 309-266-0942• [email protected]

Maintenance Products Update

May 2006 - LEVD6113 -

Truck / Batteries

1,800 CCA’s to Start the largest Trucks!

Most want 1000 CCA / battery = 3,000 to 4,000 CCA

Most Need Deep Cycle Capability…due to high key-off loads

Dual Purpose 825 CCA 175-4370 x 3 = 2,475 CCA x 4 = 3,300 CCA

(some accessory usage and light duty cycling)

Deep Cycle 710 CCA 175-4360 x 3 = 2,130 CCA x 4 = 2,840 CCA

(high level of accessory usage…lots of lights…inverter usage.) Also…recommend Low Voltage Disconnect devise set at 12.3V

May 2006 - LEVD6113 -

Truck / Batteries

Check out this Literature on Truck Batteries

Cat Truck Battery Data Sheet – LEDT4492Cat Truck Battery vs. Competitors – LEDT4490Battery Care & Maintenance Guide – PEWJ0116Truck Battery Charging Tips - IRM PELJ0298Battery Inventory Tips – IRM PELJ0336

Display Rack… See IRM PELJ0499

May 2006 - LEVD6113 -

Convenient Resealable Packaging!• 135 Hardware Resealable Packages• 67 O-ring Resealable Packages• See Cat 2004 IRM HRD 04-01

Updated O-ring Assortment Kits• Nitrile, Silicone, FKM O-ring Assortments• Ideal for Field Service• Coming June 2006

- Watch for Cat IRM Announcement

New Hardware & Seal Products

May 2006 - LEVD6113 -

New Shop Supply and Tool Products Available Through Cat Parts Distribution

• Power Module White and Cat Gray 61 High Gloss Paints • High Temperature Engine Yellow High Gloss Paint for

ACERT Engines • Bluing Paste – to check fit between mating parts• Light weight Composite Impact Wrenches (NACD Only)• Shop Wipers with higher performance - replaces rags • Cap & Plug Kits convenient contamination control • Slide Sledge Tool - replaces sledge hammers and

chisels/punches (NACD Only)

New Tools and Shop Supplies

May 2006 - LEVD6113 -

Contact Information

For additional information on these products -Please Visit The Following MPC Web Sites:

NACD Infocast: https://nacd.cat.com/infocast/frames/prodsupp/supplies/APD Net: https://apdnet.cat.com/cda/layout?m=54340&x=7EAME Flashnet: https://eame.cat.com/cda/layout?m=48900&x=7LACD Net: https://lacd.cat.com/cda/layout?m=61903&x=7Cat Power Nethttps://engines.cat.com/infocast/frames/partserv/

Reman UpdateMarty Young

May 2006 - LEVD6113 -

3126 HEUI Oil Sensor Wire

167-1709 Sensor Failing on 3126A Engines• When replacing sensor, make sure to leave slack in the wires.• Reference TIBU4752, RENR6566 – “PC-36”

INCORRECT CORRECT

CPI Project 102625

May 2006 - LEVD6113 -

3126B/E Injectors – Poppet Seat Leak

CPI Project 73196CPI Project 73196

May 2006 - LEVD6113 -

Serial Number Prefixes: 7AS, 8YL, 1WM, CKM, HEP, 9SZ, 7LZ, 6RW, BES, and BEJ

• Some of the Reman HI300 HEUI injectors are failing in the field for Hard Starting, Misfire, and Low Power. When these injectors are returned for analysis, they are found to fail for lower seatleak in the oil poppet valve.

• Excessive runout conditions in the lower valve seat of the injector may cause excessive oil leakage past the valve. Excessive oil leakage in the injectors can degrade the ability of the overall system to maintain rail oil pressure.

• New production fixtures for lower seat grinder are on order. Thenew fixtures will improve the ability of the grinder to hold thelower seat runout tolerance.

CPI Project 73196

3126B/E Injectors – Poppet Seat Leak

May 2006 - LEVD6113 -

15L Valve Bridge ContactWhen installing a replacement head on these engines, check for .020” clearance between the bottom of the valve bridge and the rotocoil.

• If less than 0.020” of clearance is found, replace the valve bridge and notify DSN.

• For more information, refer to the following publications:Engine News - SEBD9390Truck Engine News - SEBD6788Service Magazine - SEBD0827

CPI Project 115028

May 2006 - LEVD6113 -

3100 2-Valve Injector Sleeve Leaks• Exhaust Gas Leaking Past Injector into Fuel• Injectors Must be Pressed with 173-1530 for Proper

Sealing• If Combustion Leak Occurs, Re-Press Injector • Re-torque the injector hold down bolt after the

injector has been seated• Refer to Publications – NEHS0738 and REHS3035

CPI Project 60160

May 2006 - LEVD6113 -

3406C Piston Cooling Jet ContactInterference may occur between the 9Y-4004 Piston and the Piston Cooling Jet. A bent cooling jet or a broken piston cooling jet can cause the piston to seize due to lack of lubrication. The 9Y-4004 Piston is used in 0R-4515 Cylinder Kit and 0R-2694 Cylinder Kit .Resolution:

• Check the clearance between the piston and the cooling jet with a 0.80 mm (0.0315 inch) wire when you install new 9Y-4004 pistons.

• New jets with more clearance have been. • SM, EN, and TEN have been released…

…SEPD0833, SEBD6790 and SEBD9397

CPI Project 104460

May 2006 - LEVD6113 -

Reman Truck Engine NPI NewsRemanufactured Injectors For C7 And C9 Engines

• IRM REM06-08 PELJ0637

Reman Intake Valve Actuators For C15 / BXS• IRM REM06-09 PELJ0638

Remanufactured Variable Valve Actuators and Cat Compression Brake for C15 & C18 Engines

• IRM to be Released This Month

SIS TipsRon Morse

May 2006 - LEVD6113 -

SIS – ECM Replacement Files

Service Software – ECM Replacement FilesWhat are they?What Models are available?How do I get access?

May 2006 - LEVD6113 -

Access ECM Replacement Files

May 2006 - LEVD6113 -

ECM Replacement Files

Select the orange ECM Replacement Files link. The files contain the As shipped configuration. ECM Replacement files are not flash files.

May 2006 - LEVD6113 -

Product ID or Serial Number

Enter the serial number in the white text box and select search. The results will be displayed. Two results are

displayed. Select the orange link / filename to save the file to another location.

May 2006 - LEVD6113 -

Save the ECM File

May 2006 - LEVD6113 -

Save the ECM File

A few 3512B Gen-sets with BRK and C5E prefixes are currently available in ECM Replacement Files.

May 2006 - LEVD6113 -

Open Cat ET and load ECM file

Connect to the ECM – Select File > Open > ECM Replacement File. Program the ECM.

May 2006 - LEVD6113 -

Access to ECM Replacement Files

Contact the SIS service software administrator at your Caterpillar Dealer to obtain access to the ECM Replacement Files. The service software administrator will add the functionality to your SIS user profile.

2007 Engine SystemsSteve Ashburn

May 2006 - LEVD6113 -

Clean Gas Induction (CGI)

What is CGI?• Exhaust Gas from the Clean Side of the DPF• Cooled and Recycled through the Engine• No more the 15%

How does it help Emissions?• Dramatic reduction in NOx

May 2006 - LEVD6113 -

NOx H2O CO2

NOx H2O CO2

Diesel Particulate Filter (DPF)

CGI

PM NOx

CO2 HC

PM PM NOx NOx

COCO22 HCHC

PM NO x CO 2 HC

Chemistry Lesson

NOx H2O CO2

NOx H2O CO2

May 2006 - LEVD6113 -

System View

TC

TC

Variable Valve Actuationwith Thermal Management

Function

HighPressureInjectionSystem

SeriesTurbochargers Throttle

TC

CGIValve

CGICooler

FlowSensor

Diesel Particulate

Filter

TC

ATA

AC

OCV Filter

CGI Air Flow Circuit

May 2006 - LEVD6113 -

Clean Gas Induction

Where’s the CGI Line?

CGI Line

CGILine

May 2006 - LEVD6113 -

CGI System

Sensors are Remote MountedTo CGI Cooler

CGI DifferentialPressure SensorAndCGI AbsolutePressure

Venturi

Air Flow

May 2006 - LEVD6113 -

Venturi

Exit View

Side View

MAF Sensor Ports

AirFlow

May 2006 - LEVD6113 -

Sensors

CGI GasTemperature

Sensor

To DifferentialPressure

Sensor andAbsolutePressure

(Remotely Mounted)

May 2006 - LEVD6113 -

CGI Cooler Flows

Coolant

From DPF

May 2006 - LEVD6113 -

CGI Cooler

Side View

Inlet View

May 2006 - LEVD6113 -

CGI Flow

May 2006 - LEVD6113 -

CGI Housing

May 2006 - LEVD6113 -

CGI Controls

CGI Valve Housing

May 2006 - LEVD6113 -

CGI Controls

LP Turbo Compressor Inlet

LP Compressor Outlet to HP Turbo Compressor Inlet

Flow Control/Mixing Door

Electrically controlled hydraulic actuator

Gas Inlet from CGI Cooler

Filtered Air Inlet

Air Flow

May 2006 - LEVD6113 -

Mixing door completely seals off CGI intake Passage while allowing unobstructed flow of air from the truck air filter

CGI OffAir Flow

Flow from CGI Cooler

May 2006 - LEVD6113 -

CGI Moderate flow


Mixing door begins to open allowing flow of gas from CGI cooler while leaving main intake air flow from filter largely unobstructed

May 2006 - LEVD6113 -

Mixing door opens wider, increasing flow from the CGI cooler and partially obstructing flow from the air filter

CGI High flow


May 2006 - LEVD6113 -

CGI HousingCGI

Mixing Door

Air Inlet Temperature

Sensor

May 2006 - LEVD6113 -

CGI Actuator

CGI Actuator Solenoid

CGI Actuator

CGI Actuator Oil Lines

May 2006 - LEVD6113 -

New Sensors

Differential Pressure• 3 Wire

Plus, Minus, Signal• Measures the difference

between the Two Pressures• Troubleshoots like any 3

wire sensor

Temperature• Thermocouples

2 Types – Dual and SingleSignal Conditioning in

connector housing

Measurement Diaphragm

In #1 In #2

In #1 = 10- In # 2 = 8

Differential = 2

May 2006 - LEVD6113 -

New Diagnostic Codes

J1939 Codes

• 520192-15 CGI Mass Flow Rate : High - Least Severe (1)• 520192-16 CGI Mass Flow Rate : High - Moderate Severity (2)• 520192-18 CGI Mass Flow Rate : Low - Moderate Severity (2)

• 520193-18 CGI Gas Temperature : Low - Moderate Severity (2)

520193-3 CGI Gas Temperature : Voltage Above Normal• 520193-4 CGI Gas Temperature : Voltage Below Normal• 520194-5 CGI Actuator Shaft Position : Current Below Normal• 520194-6 CGI Actuator Shaft Position : Current Above Normal• 520196-3 CGI Differential Pressure : Voltage Above Normal• 520196-4 CGI Differential Pressure : Voltage Below Normal• 520197-3 CGI Absolute Pressure : Voltage Above Normal• 520197-4 CGI Absolute Pressure : Voltage Below Normal

May 2006 - LEVD6113 -

CatET Tests

New CatET Tests• CGI Function• CGI Actuator Sweep Test

May 2006 - LEVD6113 -

From the Factory Floor

Make sure all joints are properly aligned and clamps torqued to the proper torqueLeaks can affect performance

2007 Field Training

May 2006 - LEVD6113 -

WebEx• WebEx 1 – 2007 System Awareness

Feb 17On-Demand

• WebEx 2 – Clean Gas Induction (CGI)June 26th

• WebEx 3 – Cat Regeneration System (CRS)Late August

• WebEx 4 – Cat Common Rail (CCR) Fuel SystemNovember

• Open to both Cat and TEPS Dealers• Can be downloaded and put on a CD with WebEx Viewer• All have an on-line test

The Plan

May 2006 - LEVD6113 -

The Plan

WebEx• Sign-up & Download

Truck.Cat.com>Training>2007

May 2006 - LEVD6113 -

How Are You Doing?

1750+ Participants• Almost Equal Cat Dealers and TEPS Dealers• Some Districts need to “Kick it up a notch”

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Charlotte Colum

bus Dallas Denver Hartford JacksonvilleLos Angeles Nashville Peoria Seattle Toronto

TEPS FailTEPS PassCat FailCat Pass

May 2006 - LEVD6113 -

CWS Passwords

Individual CWS Password PreferredHow do I get one?• Cat – Contact your IT Help desk• TEPS – Contact your Service Manager.

May 2006 - LEVD6113 -

Peoria Based Training

Training Classes• Peoria Based - Starting 4th Qtr 2006 - By Invitation

Currently active North American Cat Training Instructors4½ day CourseOpen to All after 1/1/07

May 2006 - LEVD6113 -

Operation Readiness

1st Qtr ’0712 Sites

• 100 participants/site• Cat & TEPS2 dayHands On

• Truck TransporterTest

• Certificate• Tool Box Plaque

May 2006 - LEVD6113 -

Training DatesSeattle – Jan 8, 2007Calgary – Jan 15San Leandro – Jan 22San Bernardino – Jan 29

Denver – Feb 5Dallas – Feb 11Minn/St.Paul – Feb 19Montreal – Feb 26

Boston – March 5Columbus – March 12Atlanta – March 19Orlando – March 26

May 2006 - LEVD6113 -

How About Today?

1-866-336-5569

Fluids & Filters Update

May 2006 - LEVD6113 -


DEO-ULS• Engine Oil for Ultra Low Sulfur Diesel Fuel• Preproduction DEO-ULS…

used ONLY on 2007 On-Highway Pilot Engines• Limited Release - June 1, 2006 (IRM-PELJ0646)• Full Release - October 15, 2006

(More information released as it is available)

Advanced High Efficiency Oil Filter• HD ACERT Truck• 1R-1808 Upgrades 1R-0716 in Production• Benefits – excellent life, sealing, and strength • Parts Comparison Bulletin (IRM-PEJJ0025)

Baldwin, Donaldson, Fleetguard, Luber-Finer and WIX

May 2006 - LEVD6113 -

Filter and Fluid Technical Support Hotline1-800-542-8665 (USA) (opt4)1-800-523-8665 (Canada) (opt4)E-mail: [email protected]

• Info Release Memo - PELJ0626

Reference Card - PM Products • Reference card that includes part

numbers for filters, engine oil, coolant, PM Kits, and batteries

• Media Number – LEWT4614


May 2006 - LEVD6113 -

Broadcast Contact

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ElectronicPNsMaster IndexHandouts

May 2006 - LEVD6113 -

Next Broadcasts…

2006…

August 16th 10am CDTNovember 15th 10am CST

tech tips 24 mayo 2006

Documents

engine oil pressure

low vva oil pressure

vva oil pressure differential

oil sensor

c13 oil consumption11

engine update kory endress

engine update roger

c15 vva stud