se60 xw v and se60 xw vt asphalt screed

SE60 XW V and SE60 XW VT Asphalt Screed-Feeder Control SensorFeeder Control SensorFeed sensors control the level of material on the outboard end of the augers. Feed sensors control the speed of the auger infinitely from zero to full speed. There are two types of feed sensors.

The feeder control paddles The sonic sensorsNote: The desired material height must be greater than 0%, or the feeder control system will not operate in automatic mode.

Feeder Control Paddle

There are two feeder control paddles. There is one paddle on each side of the machine. The feeder control paddles provide feedback to the electronic control module. The mix height control provides the operational input of the height of material that is desired.The feeder control paddles should be mounted within 1 foot of the auger. The angle of the feeder control paddle determines the speed of the drag conveyor and the auger conveyor. The operating range of the feeder control paddle is zero degrees to 45 degrees. Adjust the length of the paddle in order to gain additional material height. Decrease the length of the paddle in order to increase the material height.The feeder control paddles are connected to the round connectors located on the rear of the paver frame near the screed lift cylinder brackets.

Sonic SensorThe sonic sensor emits sound waves in order to detect the material level in front of the screed. The sound waves bounce off the material and back to the sensor. The sensor measures this time in order to determine the material level. The electronic control module then generates an output signal which controls the proportional valve. The proportional valve adjusts the auger and conveyor speeds in order to maintain the proper level of material.The sonic sensors should be placed between 30.5 cm (12 inch) to 76 cm (30 inch) from the face of the material. The sensor should be positioned perpendicular to the face of the material for the best results.The sonic sensors are mounted to the end gate. The sonic sensors are connected to the four pin connector on the screed extender harness. The extender harness is located near the control panel that is mounted on the extender.

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SE60 XW V and SE60 XW VT Asphalt Screed-Daily InspectionDaily Inspection

For a maximum service life of the machine, complete a thorough walk-around inspection before you mount the machine.Inspect the area around the machine and under the machine. Look for loose bolts, trash buildup, oil, broken parts, or worn parts.Inspect the condition of the equipment and of the hydraulic components.Remove any trash buildup and debris. Make all necessary repairs before you operate the machine.

NOTICEAccumulated grease and oil on a machine is a fire hazard. Remove this debris with steam cleaning or high pressure water, at least every 1000 hours or each time any significant quantity of oil is spilled on a machine.

Make sure that all covers and guards are securely attached. Inspect the covers and guards for damage. Repair any damaged components.Wipe all fittings, all caps, and all plugs before you service the screed.Grease all of the fittings that must be serviced on a daily basis. Grease the fittings when the screed

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is at operating temperature, preferably at the end of the shift.Note: If any leaks are observed on the machine, repair the leak immediately. Check the fluid levels more frequently if there is a suspected leak.Before you start the machine, inspect the wiring for the electric heating system. Crushed wires and damaged cables can cause short circuits. Repair any damaged components before you operate the machine.Check the walkway isolation mounts for any deterioration. Replace any isolation mounts that are damaged.Inspect the hydraulic system for your machine. Look for leaks on the hose fittings and on the vibratory housing. Repair any leaks before you operate the machine.

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SE60 XW V and SE60 XW VT Asphalt Screed-Tamper Blade - Check/Clean/LubricateTamper Blade - Check/Clean/Lubricate

Lift the screed to the highest point and engage the screed service lock pins. Spray the screed with a releasing agent. Refer to Operation and Maintenance Manual, "Screed - Clean" for more information on cleaning the screed.


1. Spray the tamper blade with a releasing agent. Operate the tamper blade for five minutes under no load. When you operate the tamper bar under no load, debris will be removed from the tamper bar.

2. Check the clearance between the tamper bar and the guard. Refer to Operation and Maintenance Manual, "Tamper Blade - Check" for more information on checking the clearance.

3. After the tamper blade is clean, pump grease directly onto the tamper blade.


SE60 XW V and SE60 XW VT Asphalt Screed-Tamper Blade - CheckTamper Blade - Check

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Some parts have been removed in order to show the necessary components.Check the position of the tamper blade (6). Use the screed plate (7) as a reference. The tamper blade should be 0.5 mm (0.02 inch) below the screed plate when the tamper blade is at the lowest point.


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Check the position of the tamper blade (6) relative to the front guard (5). The tamper blade should have a clearance of 0.5 mm (0.02 inch).Perform the following steps in order to adjust the position of the tamper blade.

1. Loosen the bolts (2) that attach the tamper support to the frame of the screed.

2. Rotate adjuster (1) clockwise in order to lower the tamper. Rotate adjuster (1) counter clockwise in order to raise the tamper.

3. Tighten the bolts (2) .

4. Loosen nut (3) in order to allow adjustment of the front deflector. Turn adjustor (4) clockwise in order to increase the gap. Turn adjuster (4) counter clockwise in order to decrease the gap. The gap between the guard and the blade should be no more than 0.5 mm (0.012 inch). The guard may be adjusted closer to the tamper blade as needed.Note: Adjust the position of the tamper bar for all four sections of the screed.


SE60 XW V and SE60 XW VT Asphalt Screed-Fuses - ReplaceFuses - Replace

Fuses - Fuses protect the electrical system from damage that is caused by overloaded circuits. Change a fuse if the element separates. If the element of a new fuse separates, check the circuit and/or repair the circuit.

NOTICEAlways replace fuses with the same type and capacity fuse that was removed. Otherwise, electrical damage could result.

NOTICEIf it is necessary to replace fuses frequently, an electrical problem may exist.Contact your Cat dealer.


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(1) Left Slope Raise - Relay(2) Left Slope Lower - Relay(3) Crown Decrease - Relay(4) Left Extension Warning Light - Relay(5) Right Slope Raise - Relay(6) Right Slope Lower - Relay(7) Crown Increase - Relay(8) Right Extender Motion Warning Light - Relay(9) Power to Slope and Crown Relays - 5 A(10) Grade and Slope - 10 A(11) Turn Signals and Horn - 5 A(12) Material Feed Sensors and Position Sensing Cylinders - 5 A(13) Tail Lights - 5 A(14) Spare - 5 A

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SE60 XW V and SE60 XW VT Asphalt Screed-Eccentric Weight Housing Oil Level - CheckEccentric Weight Housing Oil Level - Check


Install the filler plug (2) .

1. Remove the filler plug (2) from the vibratory housing. Check the oil level. Make sure that the oil reaches the lower edge of the fill port.

2. If necessary, add oil.

4. Clean the breather (1) .


SE60 XW V and SE60 XW VT Asphalt Screed-Eccentric Weight Housing Oil - ChangeEccentric Weight Housing Oil - Change

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Refer to Operation and Maintenance Manual, "General Hazard Information" for information on containing spilled fluids.

1. Remove the drain plug (3) and drain the oil into a suitable container.Note: Dispose of fluids according to the local regulations.

2. Install the drain plug (3) .

3. Remove the filler plug (2) .

4. Add new oil to the vibratory housing until the oil reaches the lower edge of the hole.

5. Install the filler plug (2) .

6. Clean the breather (1) .Note: Change the vibratory housing oil for every section of the screed.


SE60 XW V and SE60 XW VT Asphalt Screed-Maintenance Interval ScheduleMaintenance Interval Schedule

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Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed.The user is responsible for the performance of maintenance. All adjustments, the use of proper lubricants, fluids, filters, and the replacement of components due to normal wear and aging are included. Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and/or accelerated wear of components.Use mileage, fuel consumption, service hours, or calendar time, WHICH EVER OCCURS FIRST, in order to determine the maintenance intervals. Products that operate in severe operating conditions may require more frequent maintenance. Refer to the maintenance procedure for any other exceptions that may change the maintenance intervals.Note: Before each consecutive interval is performed, all maintenance from the previous interval must be performed.

When RequiredFilm (Product Identification) - Clean Fuses - Replace Screed - Check/Adjust

Every 10 Service Hours or DailyScreed - Clean Tamper Blade - Clean

Every 50 Service Hours


Eccentric Weight Housing Oil Level - Check Screed - Lubricate

Every 500 Service Hours or 3 MonthsEccentric Weight Housing Oil - Change Tamper Blade - Check Tamper Blade - Check/Clean/Lubricate


SE60 XW V and SE60 XW VT Asphalt Screed-Welding on Machines and Engines with Electronic ControlsWelding on Machines and Engines with Electronic Controls

Do not weld on any protective structure. If it is necessary to repair a protective structure, contact your Caterpillar dealer.Proper welding procedures are necessary in order to avoid damage to the electronic controls and to the bearings. When possible, remove the component that must be welded from the machine or the engine and then weld the component. If you must weld near an electronic control on the machine or the engine, temporarily remove the electronic control in order to prevent heat related damage. The following steps should be followed in order to weld on a machine or an engine with electronic controls.


1. Turn off the engine. Place the engine start switch in the OFF position.

2. If equipped, turn the battery disconnect switch to the OFF position. If there is no battery disconnect switch, remove the negative battery cable at the battery.

NOTICEDo NOT use electrical components (ECM or ECM sensors) or electronic component grounding points for grounding the welder.

3. Clamp the ground cable from the welder to the component that will be welded. Place the clamp as close as possible to the weld. Make sure that the electrical path from the ground cable to the component does not go through any bearing. Use this procedure in order to reduce the possibility of damage to the following components:

Bearings of the drive train Hydraulic components Electrical components Other components of the machine

4. Protect any wiring harnesses and components from the debris and the spatter which is created from welding.

5. Use standard welding procedures in order to weld the materials together.


SE60 XW V and SE60 XW VT Asphalt Screed-Lubricant ViscositiesLubricant Viscosities

Selecting the ViscosityAmbient temperature is the temperature of the air in the immediate vicinity of the machine. This may differ due to the machine application from the generic ambient temperature for a geographic region. When selecting the proper oil viscosity for use, review both the regional ambient temperature and the potential ambient temperature for a given machine application. Generally, use the higher temperature as the criterion for the selection of the oil viscosity. Generally, use the highest oil viscosity that is allowed for the ambient temperature when you start the machine. Refer to the "Lubricant Viscosities for Ambient Temperatures" tables for guidance. In cold weather applications, the preferred method is to use properly sized machine compartment heaters and a higher viscosity grade oil. Thermostatically controlled heaters that circulate the oil are preferred.The proper oil viscosity grade is determined by the minimum ambient temperature (the air in the immediate vicinity of the machine). This is the temperature when the machine is started and while the machine is operated. In order to determine the proper oil viscosity grade, refer to the "Min" column in the table. This information reflects the coldest ambient temperature condition for starting a cold machine and for operating a cold machine. Refer to the "Max" column in the table in order to select the oil viscosity grade for operating the machine at the highest temperature that is anticipated. Unless specified otherwise in the "Lubricant Viscosities for Ambient Temperatures" tables, use the highest oil viscosity that is allowed for the ambient temperature when you start the machine.Machines that are operated continuously should use oils that have the higher oil viscosity in the final drives and in the differentials. The oils that have the higher oil viscosity will maintain the highest possible oil film thickness. Refer to "General Information for Lubricants" article, "Lubricant


Viscosities" tables, and any associated footnotes. Consult your Caterpillar dealer if additional information is needed.Note: SAE 0W and SAE 5W oils, where allowed for use in non-hydraulic system compartments, are generally not recommended for use in machines that are operated continuously and/or are heavily loaded. Refer to the "Lubricant Viscosities for Ambient Temperatures" tables for guidance. The oils that have the higher oil viscosity will maintain the highest possible oil film thickness. Consult your Caterpillar dealer if additional information is needed.Note: Oil viscosity grade selection is also machine compartment specific. For guidance on selecting oil viscosity, refer to the "Lubricant Viscosities for Ambient Temperatures" tables.Note: Generally, use the highest oil viscosity that is available to meet the requirement for the temperature at start-up.

NOTICEProper oil viscosity AND oil type/specification are required to maximize machine compartment performance and life. Do NOT use only oil viscosity, or only oil type to determine the machine compartment oil selection. Using only the oil viscosity or only the oil type to determine a machine compartment oil selection can lead to reduced performance and compartment failure. Refer to the "Lubricant Viscosities for Ambient Temperatures" tables and to ALL of the associated footnotes.

NOTICENot following the recommendations found in the "Lubricant Viscosities for Ambient Temperatures" tables and associated footnotes can lead to reduced performance and compartment failure.

General Information for LubricantsThe information provided in this "Lubricant Viscosities for Ambient Temperatures" article and Tables should be used in conjunction with the information provided in the "Lubricant Specifications" section.Refer to Caterpillar Machine Fluids Recommendations, SEBU6250 for more details about lubricants and Tier 4 requirements.

NOTICECaterpillar does not warrant the quality or performance of non-Caterpillar fluids and greases.

NOTICEDo NOT use only the oil viscosities when determining the recommended oil for an engine compartment. The oil type (specification) MUST also

be used.

Note: Only use the oil type and the specification that is recommended for the various machine compartments.Note: Some machine compartments allow the use of more than one oil type. For the best results, do not mix oil types.Note: Different brand oils may use different additive packages to meet the various machine compartment performance specification recommendations. For the best results, do not mix oil brands.Note: The availability of the various Caterpillar oils will vary by region.Note: SAE 10W viscosity grade oil used in most Caterpillar machine compartments must have a minimum viscosity of 5.8 cSt at 100 °C (212 °F) ("ASTM D445").Note: The minimum acceptable viscosity for commercial alternative oils in most Caterpillar machine hydraulic and hydrostatic transmission systems is 6.6 cSt at 100 °C (212 °F) ("ASTM D445").Note: Caterpillar oils are the preferred oils. ALL other oil types and specifications that are listed in the applicable section are acceptable oils.When you are operating the machine in temperatures below −20°C (−4°F), refer to Special Publication, SEBU5898, "Cold Weather Recommendations". This is available from your Caterpillar dealer.For cold weather applications where transmission oil SAE 0W-20 is recommended, Cat Cold Weather TDTO is the first choice oil. Second choice for cold weather transmission applications are commercial oils of full synthetic basestock that do not have viscosity index improvers and do meet the performance requirements of the Cat TO-4 specification. Typical lubricant viscosity grades are SAE 0W-20, SAE 0W-30, and SAE 5W-30. Commercial oils that contain a Cat TO-4 additive package and a lubricant viscosity grade of SAE 0W-20, SAE 0W-30, or SAE 5W-30 are a last choice.Caterpillar has determined that Medium Wheel Loaders equipped with the High Ambient Cooling Attachment can operate with Cat HYDO Advanced 10 Hydraulic System Oil in ambient temperatures from −20° C (−4° F) to 50° C (122° F).The footnotes are a key part of the tables. Read ALL footnotes that pertain to the machine compartment in question.

Cat Hydraulic Systems and Hydrostatic TransmissionsRefer to the "General Information for Lubricants" article for important lubricant information.Cat HYDO Advanced 10 SAE 10W, Cat HYDO Advanced 30 SAE 30W, or Cat BIO HYDO Advanced are the preferred oils for use in most Caterpillar machine hydraulic and hydrostatic transmission systems. Cat HYDO Advanced fluids have a 50% increase in the standard oil drain interval for machine hydraulic systems (3000 hours versus 2000 hours) over second and third choice oils - when following the maintenance interval schedule for oil filter changes and for oil sampling that is stated in the Operation and Maintenance Manual for your particular machine. 6000 hour oil drain intervals are possible when using S·O·S Services oil analysis. Contact your Caterpillar dealer for details. In order to gain the most benefit from the improved performance designed into Cat HYDO Advanced fluids, when switching to Cat HYDO Advanced fluids, cross contamination with the previous oil should be kept to less than 10%.Second choice oils are Cat MTO, Cat DEO, Cat DEO-ULS, Cat TDTO, Cat Cold Weather TDTO, Cat TDTO-TMS, Cat DEO-ULS SYN, Cat DEO SYN, Cat Cold Weather DEO-ULS. Third choice oils are commercial oils that meet Cat ECF-1-a, Cat ECF-2, Cat ECF-3, Cat TO-4, or the Cat TO-4M performance requirements, and that have a minimum zinc additive level of 0.09 percent (900 ppm). Commercial biodegradable hydraulic oil must meet the Cat BF-2 specification.The minimum viscosity for commercial alternative oils used in most Cat machine hydraulic and hydrostatic transmission systems is 6.6 cSt at 100 °C (212 °F) ("ASTM D445").

Table 1

Lubricant Viscosities for Ambient Temperatures

Compartment or System

Oil Type and Classification

Oil Viscosities

°C °F

Min Max Min Max

Vibratory Housing

Cat HYDO Advanced 10Cat HYDO Advanced 30

Cat BIO HYDO AdvancedCat MTO

Cat DEO-ULSCat DEO

Cat DEO-ULS SYNCat DEO SYN

Cat TDTOCat TDTO-TMS

Cat Cold Weather DEO-ULS

Cat Cold Weather TDTOCat ECF-1-a, Cat ECF-2, Cat ECF-3, Cat TO-4, Cat

TO-4M, Cat BF-2

SAE 0W-20 −40 40 −40 104

SAE 0W-30 −40 40 −40 104

SAE 0W-40 −40 40 −40 104

SAE 5W-30 −30 40 −22 104

SAE 5W-40 −30 40 −22 104

SAE 10W −20 50 −4 122

SAE 30 10 50 50 122

Bio HYDO Advanced −40 40 −40 104

SAE10W-30 −20 40 −4 104

SAE15W-40 −15 50 5 122

Cat MTO −20 40 −4 104

Cat TDTO-TMS −15 50 5 122

Lubricating Grease

Cat Multipurpose GreaseCat Multipurpose Grease is a National Lubricating Grease Institute (NLGI) grade 2 grease. This grease is made with petroleum base oil and a lithium complex thickener. Cat Multipurpose Grease is formulated for use in applications that have a low severity to a medium severity and moderate temperatures.Cat Multipurpose Grease meets the NLGI certification of "GC-LB". (This certification relates to extended service intervals in automotive chassis points and in wheel bearings with disc brakes in automobiles, vans and light trucks.)Note: If the application calls for a multipurpose grease and Cat Multipurpose Grease is not available, consult the grease data sheets. Use a substitute that meets or exceeds the performance characteristics of Cat Multipurpose Grease.

Cat Advanced 3Moly GreaseCat Advanced 3Moly Grease is an NLGI grade 2 grease. This grease is made with petroleum base oil and a lithium complex thickener. This grease also has 3% Molybdenum diSulfide (MoS2 or "Moly"). Cat Advanced 3Moly Grease is formulated for use in applications with low severity to high severity at moderate temperatures. In addition, the molybdenum in Cat Advanced 3Moly Grease is a special grade that has a median particle size of 3 microns in order to meet the special requirements of some rolling element bearings. Cat Advanced 3Moly Grease is recommended for heavily loaded pin joints, and high impact applications in machines such as track-type tractors, backhoe loaders and skid steer loaders.

Cat Advanced 3Moly Grease meets the NLGI certification of "GC-LB". (This certification relates to extended service intervals in automotive chassis points and in wheel bearings with disc brakes in automobiles, vans, and light trucks.)Note: If the application calls for a multipurpose grease with molybdenum and Cat Advanced 3Moly Grease is not available, consult the data sheets for the greases. Use a substitute that meets or exceeds the performance characteristics of Cat Advanced 3Moly Grease.

Cat Ultra 5Moly GreaseCat Ultra 5Moly Greases are available in NLGI grades 0, 1, and 2. Cat Ultra 5Moly Greases are made with special blends of petroleum base oils and a Calcium Sulfonate Complex thickener. These greases also have 5% Molybdenum diSulfide (MoS2 or "Moly") and added tackifier. Cat Ultra 5Moly Greases are specially formulated in order to protect all of the most heavily loaded joints in any Caterpillar machine against galling, wear, and corrosion. This protection is sustained while work is being done in moderate temperatures and with wet working conditions or dry working conditions.Cat Ultra 5Moly Greases are formulated with special blends of naphthenic petroleum base oils that have low pour points. This allows the Cat Ultra 5Moly Greases to pump at lower temperatures. The ability to pump Cat Ultra 5Moly Greases at lower temperatures means added insurance that all of the grease joints in the machine will be adequately lubricated even if the ambient temperature drops unexpectedly. This is particularly important when the machine's critical lubrication points rely on an automatic lubrication system.A significant challenge exists in order to get grease to pump into the joints at low temperatures. Once the grease gets to the joint, the grease must have extremely high resistance to galling, wear, fretting, water washout, and corrosion in order to adequately protect highly loaded joints.Even under severely loaded conditions, the grease should preferably have a very long working life. In order to make greases that meet these greater demands, a Calcium Sulfonate Complex thickener with a properly blended naphthenic oil and/or a synthetic base oil is required. This is the reason that Caterpillar uses these ingredients in Cat Ultra 5Moly Greases.Cat Ultra 5Moly Greases also have 5% Moly, instead of the 0% to 3% that is found in most other greases. This additional Moly greatly improves the ability of the grease to protect parts from damage in applications with severe impact (slamming). In addition, the Moly in Cat Ultra 5Moly Grease is a special grade that has a median particle size of 3 microns in order to meet the special requirements of some rolling element bearings.Cat Ultra 5Moly Greases are also made to be extra tacky. In some applications, the film of grease must adhere to the vertical surfaces. An example of this application is swing gears for excavators. Many conventional greases do not have enough of the tacky characteristic in order to allow the grease to stay in place. In addition, many of these greases do not have the performance in order to adequately protect the gear teeth in these applications.Cat Ultra 5Moly Grease exceeds the NLGI certification of "GC-LB". (This certification relates to extended service intervals in automotive chassis points and in wheel bearings with disc brakes in automobiles, vans, and light trucks.)Note: If the application calls for Cat Ultra 5Moly Grease and Cat Ultra 5Moly Grease is not available, consult the data sheets for the grease. From these data sheets, use a substitute that meets the performance characteristics of Cat Ultra 5Moly Grease.Cat Ultra 5Moly Grease is formulated not to contain lead, antimony, barium, zinc, phosphorous, or chlorine additives. Thus, when Cat Ultra 5Moly Greases are compared to many other types of grease, the Cat Ultra 5Moly Greases are more environmentally friendly.

Grease Application Chart

Table 2

Application Point

Typical Load and

Load Factor

Ambient Temperature Range

NLGI Grade

Grease Type

° C ° F

Speed Min Max Min Max

All Grease Points

High

457 mm (18)

soil/305 mm (12)

asphalt.

−35 40 −31 104 1

Ultra 5Moly Grease −30 50 −22 122 2

Medium

305 mm (12)

soil/150 mm (6)

asphalt.

−20 40 −4 104 2 Advanced 3Moly Grease

Low

150 mm (6)

soil/100 mm (4)

asphalt.

−30 40 −22 104 2 Multipurpose Grease

Standard Factory Fill Fluids

Table 3

Standard Factory Fill Fluids (1)

Compartment or System Oil Viscosities °C °F

Min Max Min Max

Vibratory Housing Cat HYDO Advanced 10 -20 40 -4 104 ( 1 ) The machine is delivered from the factory with the designated fluids.


Wednesday, September 17, 2014

C13, C15, and C18 Tier 4 Final Engines-Timing - CalibrateTiming - Calibrate

Use this procedure if the diagnostic code in Table 1 is active.

Table 1

Diagnostic Trouble Codes

J1939 Code

CDL Code

Code Description(code descriptions

may vary) Comments

637-11 261-11 Engine Timing Offset fault The wiring to the sensors has the wrong polarity.

637-13 261-13 Engine Timing Calibration :

Calibration Required

A timing calibration is required for a new engine, replacing an Electronic Control Module (ECM) that fails to communicate or following work on

the front gear train, the camshaft, or the crankshaft.

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If a 261-11 or 637-11 diagnostic code is active, verify that the wiring is installed correctly to the engine speed/timing sensors.The ECM can calibrate the mechanical differences between the Top Center (TC) of the flywheel and the TC of the timing gear on the camshaft. A transducer signals the TC of the flywheel to the ECM when a notch on a counterweight passes by the transducer. The engine speed/timing sensor signals the TC of the timing gear to the ECM. Any offset between the TC of the flywheel and the TC of the timing gear is stored into the memory of the ECM.Note: A timing calibration will not increase the available engine power.Table 2 lists the special tools that are required in order to perform this procedure.

Table 2

Required Special Tools

Part Number Description

7X-1171 Transducer Adapter

6V-2197 Transducer

7X-1695 Cable as

170-3519 Harness (1) ( 1 ) This item is not required if the engine harness has a connector for timing calibration.

(A) Timing mark(B) Idler gearTable 3

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Troubleshooting Test Steps Values Results

Step 1 applies to C15 and C18 engines only.

1. Check the Gear Train Timing

The camshaft gear will be off a half tooth if the engine is timed when Cylinder # 6 is at Top Dead Center (TDC). The engine MUST be timed when Cylinder #1 is at TDC. This could be possible anytime you do not time the engine at the crank to idle gear mesh.

Note: Remove the rocker arms before rotating the engine to prevent piston/valve damage from occurring.

A. If the engine is at TDC for cylinder 6, remove cam idler gear (B) and rotate the crankshaft 360 degrees and repin the flywheel.

B. Install idler gear (B) .

C. Check timing mark (A) .

D. Rotate the engine by hand 360° to ensure that the engine rotates freely. If the engine does not rotate freely, the engine is not timed correctly. Remove the front housing and check all timing marks. Refer to Testing and Adjusting, "Gear Group (Front) - Time" for the correct procedure.

E. Connect to Cat ET and clear the DTC.

F. Start the engine.

Diagnostic code

Result: After starting the engine the code is still present.

Proceed to Test Step 2.

Result: After starting the engine the code did not return.

Return the unit to service.

Table 4

Crankshaft Rotation

Engine Model Number of Degrees Direction of Rotation

C9.3 85 Normal Rotation

C13 75 Normal Rotation

C15 60 Opposite Normal Rotation

C18 30 Opposite Normal Rotation

Table 5

Location of the Timing Calibration Port

Engine Model Crankshaft Counterweight Engine Location

C9.3 3 Left Side

C13 8 Left Side

C15 2 Left Side

C18 2 Left Side

Table 6


2. Install the Transducer Adapter

A. Remove the electrical power from the ECM.

B. Use the appropriate engine turning tool to put either the No. 1 piston or the No. 6 piston at the top center. Refer to the Systems Operation/Testing and Adjusting.

C. Refer to Table 4. After the top center position has been located, rotate the crankshaft for the number of degrees that is applicable to your engine model. Be sure to rotate the crankshaft in the direction of rotation that is specified in the Table.

D. Refer to Table 5. Locate the engines timing calibration port.

E. Remove the plug from the timing calibration port.

F. Thread the transducer adapter into the port

Transducer adapter

Result: The transducer adapter was installed.


3. Install the Transducer

If the crankshaft is not in the correct position when the transducer is installed, the transducer will be damaged when the engine is started.

A. Apply clean engine oil to a 2D-6392 O-Ring Seal .

Transducer Result: The transducer was installed.


Install the O-ring seal on the end of the 6V-2197 Transducer .

B. Push the transducer through the transducer adapter until the transducer contacts the crankshaft counterweight.

C. Withdraw the transducer 1.0 mm (0.04 inch) and hand tighten the nut on the adapter sleeve in order to secure the transducer. Move the O-ring seal against the adapter.

Engine Control ModuleTable 7

Terminal Locations for Connection of the 170-3519 Harness

ECM Type ADEM 4

Connector P2 P1

Timing Calibration +(White)

(Terminal 1) Location 26 24

Timing Calibration -(Yellow)

(Terminal 2) Location 36 25

Table 8

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4. Connect the 7X-1695 Cable as

A. If the engine harness is equipped with a connector for timing calibration, connect the 7X-1695 Cable as to the connector for timing calibration and to the transducer.

B. If the engine harness is not equipped with a connector for timing calibration, or the connector is not easily accessible, a connector can be installed. The connector can be installed on either ECM connector.

C. Refer to Illustration 2 to determine the type of engine ECM. Also, determine the ECM connector that is easily accessible.

D. Refer to Table 7 to determine the proper terminal locations for the connector that is easily accessible.

E. Remove the sealing plugs from the appropriate terminals. Do not discard the sealing plugs. The sealing plugs may be reinstalled when the timing calibration is complete.

F. Install the white wire of the 170-3519 Harness into the appropriate location.

G. Install the yellow wire of the 170-3519 Harness into the appropriate location. Disregard the pin-outs on the label of the harness.

H. Ensure that each wire is installed into the correct location. The timing calibration will not be successful if the wires are installed incorrectly.

Wiring

Result: The wiring is installed correctly.


5. Check for Diagnostic Codes

A. Connect Caterpillar Electronic Technician (ET) to the service tool connector. Refer to Troubleshooting, "Electronic Service Tools".

Diagnostic codes

Result: There are active codes other than a 261-13 or 637-13 diagnostic code.

B. Start the engine and run the engine until the engine is at the normal operating temperature.

C. Check for active diagnostic codes. Wait at least 30 seconds in order for the codes to become active.

The engine must not have any active diagnostic codes during the timing calibration except for a 261-13 or 637-13 diagnostic code.

Troubleshoot the active diagnostic other than the 261-13 or 637-13 diagnostic codes.

Result: There are no active codes other than a 261-13 or 637-13 diagnostic code.


Table 9


6. Calibrate the Timing

A. After the engine has warmed up, access the "Timing Calibration" screen on the Cat ET. Access the following display screens in order:

· Service

· Calibrations

· Timing Calibration

B. Set the engine speed to 1100 ± 50 rpm. The engine speed must be steady within this rpm range in order for the calibration to be successful.

C. To calibrate the timing, select "Continue" on Cat ET. Wait until Cat ET indicates that the timing is calibrated.

D. Perform the following procedure if Cat ET indicates that the timing is calibrated:

1. Set the engine speed to low idle.

2. Disconnect the 7X-1695 Cable as before you exit the "Timing Calibration" screen.

Timing calibration

Result: The timing calibration was successful.


Result: The timing calibration was not successful.

The following conditions can cause the timing calibration to fail:

1. The crankshaft and camshaft gears have been reassembled incorrectly.

2. The timing calibration probe is not installed correctly.

3. The engine speed is not correct and the engine speed is unstable. If the engine speed is unstable, refer to Troubleshooting, "Engine Misfires, Runs Rough, or Is Unstable".

4. There is a problem with the transducer or with the cables.

Otherwise, diagnostic codes may be activated.

3. Exit the "Timing Calibration" screen on Cat ET.

4. Remove the electrical power from the ECM.

5. Remove the transducer and remove the transducer adapter.

6. Install the plug into the timing calibration port.

7. If you installed a 170-3519 Harness , you may remove the harness or you may permanently install the harness for future use. If you remove the harness, install the sealing plugs into the unused cavities of the ECM connector. Otherwise, moisture and debris will enter the connector.

8. If you permanently installed the harness, fasten the harness to the existing engine wiring harness with cable ties. Also, install a 3E-3364 Receptacle and two 8T-8737 Seal Plugs on the P400timing calibration probe connector in order to prevent moisture and debris from entering the connector.

Obtain a new transducer and/or a new cable and repeat the timing calibration.

5. There is an active 190-8 code or an active 723-8 code. Troubleshoot the active codes before calibration.

Correct any of the above conditions and repeat the calibration procedure.

Complete the procedure in the order in which the steps are listed.Posted by LUCCIANO at 10:19 PM No comments: Email ThisBlogThis!Share to TwitterShare to FacebookShare to Pinterest

C13, C15, and C18 Tier 4 Final Engines-Cooling Fan - CalibrateCooling Fan - Calibrate

Use this procedure if the diagnostic code in Table 1 is active.

Table 1


J1939 Code CDL Code

Code Description(code descriptions may vary) Comments

4212-13 1551-13 Fan Drive Bypass Command Status : Out of Calibration

The code is logged.

The Electronic Control Module (ECM) supplies current to the engine fan control solenoid. The engine fan control solenoid controls the pressure to the fan pump by allowing oil to bypass the fan pump. The fan pump drives the fan. For accuracy, the ECM must determine the relationship between the current to the engine fan control solenoid and the actual fan speed. Caterpillar Electronic Technician (ET) enables the user to calibrate the current to a known fan speed manually.Note: The ECM will use a nominal current to drive the engine fan control solenoid on the initial calibration. The ECM uses the last calibrated value as the starting point on subsequent calibrations.

1. Select the "Service" tab and select "Calibrations". Start the "Fan Calibration".

2. Meet the required conditions in order to proceed with the calibration. Follow the directions that are provided on Cat ET. Proceed by pressing the "Next" button.


3. Measure actual fan speed with the following service tools and Software License, NETG5044:

348-5430 Multi-Tool Gp 308-7264 Multitach Tool Gp

a. If actual fan speed matches the fan speed on Cat ET, press the "Next" button.

b. Actual fan speed may not match the fan speed on Cat ET. The current must then be decremented or incremented in order to change fan speed.

4. When actual fan speed matches the fan speed on Cat ET, the calibration is complete. Follow the directions that are provided on Cat ET.


C13, C15, and C18 Tier 4 Final Engines-Electrical Connectors - InspectElectrical Connectors - InspectMost electrical faults are caused by poor connections. The following procedure will assist in detecting faults with connectors and with wiring. If a fault is found, correct the condition and verify that the fault is resolved.Intermittent electrical faults are sometimes resolved by disconnecting and reconnecting connectors. Check for diagnostic codes immediately before you disconnect a connector. Also check for diagnostic codes after you reconnect the connector. If the status of a diagnostic code is changed due to disconnecting and reconnecting a connector, there are several possible reasons. The likely reasons are loose terminals, improperly crimped terminals, moisture, corrosion, and inadequate mating of a connection.Follow these guidelines:

Always use a 1U-5804 Crimp Tool to service Deutsch HD and DT connectors. Never solder the terminals onto the wires. Refer to "SEHS9615, Servicing Deutsch HD, and DT Style Connectors". Always use a 147-6456 Wedge Removal Tool in order to remove wedges from DT connectors. Never use a screwdriver to pry a wedge from a connector. Always use a breakout harness for a voltmeter probe or a test light. Never break the insulation of a wire in order to access to a circuit for measurements. If a wire is cut, always install a new terminal for the repair. Determine if the problem is intermittent. If the problem is intermittent, attempt to test the circuit before you disconnect any electrical connectors. The test will help identify the root cause of intermittent problems. The "Wiggle Test" on Caterpillar Electronic Technician (ET) may be able to test the circuit. Refer to the documentation that accompanies Cat ET. Perform the wiggle test on the circuit, when possible. Otherwise, continue with this procedure.

Check Connectors for Moisture and Corrosion

Detail A illustrates the incorrect angle of wire entry into the connector. The wire should enter the connector at a perpendicular angle. (typical example)Inspect all the harnesses. Ensure that the routing of the wiring harness allows the wires to enter the face of each connector at a perpendicular angle. Otherwise, the wire will deform the seal bore. The damaged seal will create a path for the entrance of moisture. Verify that the seals for the wires are sealing correctly.

Diagram for the installation of a connector plug (typical example)(1) Electronic Control Module (ECM) connector(2) Correctly inserted plug(3) Incorrectly inserted plugEnsure that the sealing plugs are in place. If any of the plugs are missing, replace the plug. Ensure that the plugs are inserted correctly into the connector.

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Seal for a three-pin connector (typical example)

Seal for the ECM connector (typical example)Disconnect the suspect connector and inspect the connector seal. Ensure that the seal is in good condition. If necessary, replace the connector.Thoroughly inspect the connectors for evidence of moisture entry.Note: Some minor seal abrasion on connector seals is normal. Minor seal abrasion will not allow the entry of moisture.If moisture or corrosion is evident in the connector, the source of the moisture entry must be found. The source of the moisture entry must be repaired. If the source of the moisture entry is not repaired, the fault will recur. Simply drying the connector will not fix the fault. Check the following items for the possible moisture entry path:

Missing seals Incorrectly installed seals Nicks in exposed insulation Improperly mated connectorsMoisture can also travel to a connector through the inside of a wire. If moisture is found in a connector, thoroughly check the connector harness for damage. Also check other connectors that share the harness for moisture.

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Check the Wires for Damage to the InsulationCarefully inspect each wire for signs of abrasion, nicks, and cuts.Inspect the wires for the following conditions:

Exposed insulation Rubbing of a wire against the engine Rubbing of a wire against a sharp pointCheck all of the fasteners for the harness and the ECM in order to verify that the harness is correctly secured. Also check all of the fasteners in order to verify that the harness is not compressed. Pull back the harness sleeves in order to check for a flattened portion of wire. A fastener that has been overtightened flattens the harness. This damages the wires that are inside the harness.

Inspect the Connector TerminalsVisually inspect each terminal in the connector. Verify that the terminals are not damaged. Verify that the terminals are correctly aligned in the connector and verify that the terminals are correctly located in the connector.

Perform a Pull Test on Each Wire Terminal Connection

Receptacle lock wedge (typical example)Ensure that the locking wedge for the connector is installed correctly. Terminals cannot be retained inside the connector if the locking wedge is not installed correctly.Perform the 45 N (10 lb) pull test on each wire. Each terminal and each connector should easily withstand 45 N (10 lb) of tension and each wire should remain in the connector body. This test checks whether the wire was correctly crimped in the terminal and whether the terminal was correctly inserted into the connector.

Check Individual Pin Retention into the Socket

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Diagram for testing pin retention (typical example)Verify that the sockets provide good retention for the pins. Insert a new pin into each socket one at a time in order to check for a good grip on the pin by the socket.

Check the Locking Mechanism of the ConnectorsEnsure that the connectors lock correctly. After you lock the connectors, ensure that the two halves cannot be pulled apart.Verify that the latch tab of the connector is correctly latched. Also verify that the latch tab of the connector returns to the locked position.

Check the Allen Head Screws on the ConnectorsVisually inspect the allen head screws for the ECM connectors. Ensure that the threads on each allen head screw are not damaged.

Allen head screw for the 120 pin ECM connector (typical example)Torque the allen head bolt for the 120 pin ECM connector to 7.0 ± 0.5 N·m (60 ± 4 lb in).

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Allen head screw for the 70 pin ECM connector (typical example)Torque the allen head screw for the 70 pin ECM connector to 6.0 + 1.5 - 1.0 N·m (55 + 13 - 9 lb in).

Allen head screw for the 40 pin customer connector and the 70 pin customer connector (typical example)Torque the allen head screw for the 40 pin customer connector and the 70 pin customer connector to 2.25 ± 0.25 N·m (20 ± 2 lb in).

Perform the Wiggle Test on the Caterpillar Electronic Technician (ET)Select the "Wiggle Test" from the diagnostic tests on Cat ET.Choose the appropriate group of parameters to monitor.Press the "Start" button. Wiggle the wiring harness in order to reproduce intermittent faults.If an intermittent fault exists, the status will be highlighted and an audible beep will be heard.


C13, C15, and C18 Tier 4 Final Engines-ARD Combustion Air Valve - ReplaceARD Combustion Air Valve - Replace

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This code will trip if the automated ARD air valve calibration sweep exceeds the calibration limits and a failed regeneration occurs. The ARD air valve calibration is automatically controlled by the A5:E2 aftertreatment ECM. The calibration occurs after the A5:E2 aftertreatment ECM powers up and again before a regeneration starts. Any combustion air valve faults will prevent the calibration cycle from occurring.

Table 1


J1939 Code

CDL Code Code Description Comments

3487-13 2489-13

Aftertreatment #1 Air Pressure Control : Out of

Calibration

The automated ARD Air Valve Calibration sweep has exceeded the

calibration limits AND a failed regeneration has occurred.

The code is logged.

Follow the troubleshooting procedure in order to identify the root cause of the problem.

Table 2



1. Check for Active or Logged Codes

A. Establish communication between Caterpillar Electronic Technician (ET) and the aftertreatment ECM (A5).

B. Look for active or logged codes.


Result: There are no active or logged codes.


Result: A 3487-13 or 2489-13 code is still active or logged.


2. Replace the ARD Air Valve

A. Replace the ARD air valve.

B. Clear all codes using Cat ET.

C. Perform an ARD Ignition Test using Cat ET.

The ARD Ignition Test cannot be performed if the DPF soot loading is above 80%. When the DPF soot loading is above 80%, the Manual DPF Regeneration must be performed using Cat ET.

Test Passed

Result: The ARD Ignition Test passed.


Result: The ARD Ignition Test failed.

Troubleshoot the active codes.

Complete the procedure in the order in which the steps are listed.