PSP FOR PREDELIVERY INSPECTION OF 3176 ENGINES - PS9128 - MAILED US AND CANADAC TRUCK TEPS Caterpillar

U-180
TT-12
7588   PS9128
NOTE: This Program can be administered either before or after a
failure. In either case the decision whether to apply the
Program is made by the dealer. When reporting the repair, use
"PS9128" as Part Number, "7755" as Group Number, and "96" as
Description Code.

March 31, 1990

Caterpillar is requesting that dealers complete a predelivery inspection on
initial production of the 3176 Truck Engine. The purpose of the inspection
is to ensure that the 3176 Engine and OEM wiring, interface and function
properly. The inspection consists of a visual inspection of wiring and
attachments, and an operational test of switches and parameters.

Model Identification Number
3176 2YG2001 - 2YG4000

Not Applicable

Complete predelivery inspection checklist is attached. The checklist
consists of two parts; visual inspection and operational check. Complete
each section and record results on the checklist. Use separate sheets for
each serial number completed.
Make sure the checklist is completely filled out, including customer name,
address and phone number, as this is required for credit under the program.
Return the completed predelivery inspection checklist only to:
Caterpillar Engine Division
3176 Service Consultant
Mossville Bldg. A
P.O. Box 610
Mossville, IL 61552-0610

Product Caterpillar Dealer Suggested Customer Suggested
Miles Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
(D/N) (Sell)  (C/L) (Sell)
0-5000 - 1 0 0 0 0
NOTE: This is a 1-hour job. File an on-line warranty claim using the
guidelines for Product Improvement Programs. For the predelivery
inspection, Caterpillar will reimburse the dealer for one hour
labor at the dealer's selling rate. If corrective action is
required, please identify the responsible party, Caterpillar or
OEM, and submit a separate warranty claim to the responsible
party. Do not include labor or parts for repairs under this
program.

Not Applicable
Attach. (1-Explanation And Reference For 3176 Engine
Predelivery Inspection)
(2-3176 Engine Predelivery Inspection)
(3-3176 Engine Parameter List)
(4- Servicing and Programming 3176 Truck Engines
Equipped with Kysor Shutdown Systems)
Explanation And Reference
For 3176 Engine Predelivery Inspection
The purpose of the 3176 Engine predelivery inspection is to visually and
functionally test the 3176 Engine related truck wiring and systems. If at
any time during the inspection process a problem is found, please refer to
the OEM wiring diagram or 3176 Engine Service Manual for additional
troubleshooting assistance.
Explanation and more detail on the quality checks:
1. Connectors -- Wires not pulled tight so seals are stressed and cause
water to leak on pins. At least 1-1/2 in. extra wire at each Deutsch
connector. Wire ties more than 2 in. from Deutsch connector.
IMPORTANT: Lock rings must be locked and connectors in their
retaining clips.
2. Proper electrical grounding of the 3176 Engine is important since stray
electrical currents through the aluminum engine components can result in
erosion.
Therefore the following grounding practices are necessary:
a. Alternator must be grounded to the grounding stud on the the cylinder
head (stud that ECM is grounded to). This wire MUST connect to the
alternator ground terminal, not to the to the alternator mounting
bracket or bolts.
b. The cylinder head must have a direct grounding path to the battery
negative terminal in one of two ways.
Option 1: Wire from cylinder head ground stud to starter negative
terminal then a wire to the battery negative terminal (AWG #0 or larger
wire).
Option 2: Wire from cylinder head grounding stud to common frame ground
stud and then a wire to the negative battery terminal (AWG #0 or larger
wire).
c: The starter must be directly grounded to the battery negative with a
dedicated ground cable.
3. Atmospheric line installed (from clean side of air cleaner to transducer
module).
-2 of 3-
4. If unit has a fuel heater, is it thermostatically controlled or self-
regulating? Self-regulating is defined as a fuel heater too small to
heat the fuel above 150 degrees Fahrenheit or coolant heater plumbed in
series with a coolant controlled cab heater valve. Since fuel is used
to cool the ECM, excessive fuel temperature (above 150 deg F) can
shorten the ECM's service life.
5. Self explanatory.
6. Self explanatory.
7. If engine is not equipped with cooling system conditioner spin-on
element, check the cooling conditioner concentration with the 8T5296
Supplemental Coolant Additive Test Kit for the correct 3 - 6%
concentration.
8. Self explanatory.
Note: Steps 9 - 11 require hooking up the ECAP or DDT tool. OEM
warning and shutdown systems buzz and/or interrupt power to the
3176 Engine if no oil pressure is detected. Manual types usually
have an override system. If necessary, power can be supplied
directly to the 3176 Engine (refer to attachment 2).
9. Hook up ECAP or DDT. With foot off of accelerator, throttle position
should read 1 - 3%. With accelerator pedal completely to the floor,
throttle position should be between 95% - 100%.
Note: Every truck should be tested for excessive dead pedal motion at
low idle. More than 1/2 in. is probably unacceptable to most
drivers. Also, there must be no contact of throttle position
sensor internal stop pins at low idle or high idle. Both
mechanical stops must be in the truck pedal linkages.
The retarder enable circuit which turns on the Jacobs Brake or
other types of exhaust brakes activates when the foot pedal
returns to less than 7% throttle. If the minimum throttle
position is 7% or higher, the retarder enable circuit will not
function.
10. Verify that the customer specified parameters are correct. This will
require obtaining the customer parameters input sheet from either the
customer or the sales department (a 3176 Engine parameter checklist is
attached). Use the ECAP or DDT to compare the parameters.
-3 of 3-
11. Check cruise/pto switches.
a. Go to the "Display/Status" function of the ECAP to observe the
cruise/pto switch status. Push cruise/pto on/off switch to on. Observe
cruise mode on ECAP or DDT.
b. Push set/resume switch to set and check its status on the ECAP.
c. Momentarily and slowly push down on the clutch and observe the
change in status on the ECAP. This switch should activate before the
end of the clutch pedal free play (approximately 1/2 in. to 1 in. of
pedal motion). A switch which is too sensitive may activate from normal
lever movement during road operation. This would cause undesirable
dropout of the cruise control function.
d. Momentarily and slowly push down on the brake. Check the brake
switch status change on the ECAP.
e. On the 3176 Engine, the parking brake switch is used to activate the
idle shutdown timer. Using the ECAP or DDT with the engine running,
apply the parking brake and observe the idle shutdown mode and the
parking brake switch status. The idle shutdown timer should begin
counting when these conditions are met:
1) Throttle position is 0.
2) Vehicle speed is 0.
3) The parking brake switch on "ON".
Note: Obtaining the expected results verifies the five switches (cruise
PTO on/of switch, set/resume switch, clutch switch, brake switch
and parking brake switch) plus the wiring to and from these
switches are correct. However, if these manual tests do not
yield the expected results, the problem usually exists in either
the switch circuits or the customer-specified parameters (in rare
cases, the problem could be the ECM).
12. Turn the cruise control switch "OFF" and turn the Jake Brake "ON".
Using the accelerator pedal bring the engine to hi idle and release the
accelerator pedal. The Jake Brake should operate for a short period of
time during deceleration.
3176 Engine Predelivery Inspection
Engine Serial No. ...................Customer Name ...............
Chassis Serial No. ..................Address......................
Mfg/Model ...........................City ..............State.....
Date .../.../... Unit # ..........Zip.........Phone(...)...-.....
Mal- Not
OK function Equipped Visual/Mechanical Inspection
-- -------- --------
( ) ( ) 1. Connectors (seal intact and lock rings
locked).
( ) ( ) 2. Proper engine ground to chassis
electrical grounds (see attachment 1)
( ) ( ) 3. Atmospheric line installed.
( ) ( ) ( ) 4. Thermostatically controlled or self
regulating fuel heater.
( )  ( ) 5. Engine equipped with water separator.
( )  ( ) 6. Engine equipped with spin-on cooling
system conditioner element?
Mfg: Model:
( ) ( ) ( ) 7. If 6 is no -- 3-6% coolant conditioner
OK?
OPERATIONAL CHECKS
( ) ( ) 8. Check engine light comes on when
ignition is turned on and goes out
within 10 seconds after engine is
started.
9. Throttle linkage adjusted properly.
( ) ( ) a. Minimum throttle position (1%-3%).
( ) ( ) b. Maximum throttle position (95%-100%)
( ) ( ) 10. Verify customer specified parameter are
correct. (see attached)
11. Check cruise/pto switches:
( ) ( ) ( ) a. Cruise/pto on/off switch
( ) ( ) ( ) b. Set/resume
( ) ( ) ( ) c. Clutch
( ) ( ) ( ) d. Brake
( ) ( ) ( ) e. Parking brake
( ) ( ) 12. Jake Brake operates properly.
Note: If a problem is found, make repairs and file a separate
warranty claim with the responsibility party (CAT or OEM).
3176 Engine Parameter List
Rating Selection .......................BHP @ ...............RPM
Vehicle Speed Parameters:
Vehicle Speed Calibration.....................pulses per mile.
Vehicle Speed Limit .......................................MPH
Engine RPM at Vehicle Speed Limit .........................RPM
(for no vehicle speed input condition)
Cruise Control Parameters:
Low Cruise Control Speed Set Limit ........................MPH
High Cruise Control Speed Set Limit .......................MPH
Engine Retarder (coast or latch) ..........................
PTO Governor Parameters:
PTO Mode Vehicle Speed Limit ..............................MPH
PTO Mode Engine RPM Limit .................................RPM
Engine/Gear Speed Limit Parameters:
Low Gears #1 Engine RPM Limit .............................RPM
Low Gears #1 Turn Off Speed ...............................MPH
Low Gears #2 Engine RPM Limit .............................RPM
Low Gears #2 Turn Off Speed ...............................MPH
High Gears Engine RPM Limit ...............................RPM
High Gears Turn On Speed ..................................MPH
Idle Shutdown Timer ...........................minutes.
Top Engine Limit ..............................RPM
Low Engine Idle RPM ...........................RPM
Customer Passwords
Password #1 ..................................
Password #2 ..................................
Note: If a problem is found, make repairs and file a separate
warranty claim with the responsibility party (CAT or OEM).
Servicing and Programming 3176 Truck Engines
Equipped with Kysor Shutdown Systems
3176 Truck Engines Equipped With Kysor Shutdown System
------------------------------------------------------
Reports indicate a problem servicing and programming a 3176 Truck
Engine equipped with a Kysor Engine Shutdown System. The Kysor
Engine Shutdown disconnects the 3176 Engine voltage supply when
the engine is without oil pressure for a specified amount of time
(approximately 30 seconds). This results in an inability and
program and service the 3176 Engine electrical system.
Servicing and programming the 3176 Engine can be accomplished by
supplying power directly to the 3176 Engine. This can be done as
follows:
1. Remove the "A" wire from the P8 connector with a Deutsch pin
remover (part to the 1U5803 Deutsch Connector Repair Kit).
2. Attach a 8T8729 Pin to a 12 AWG jumper wire and insert the pin
"A" position of the P8 connector.
3. Connect the other end of the jumper wire to a battery position
(+) source.
4. Connect power to the Throttle Position Sensor and the Vehicle
Speed Buffer. In most cases (dependant on OEM wiring) this
can be done by connecting a jumper wire from a battery
positive (+) source to "A" wire removed in Step 1. An 8T8730
Socket can be used to connect the jumper wire to the 8T8729
Pin on the end of wire "A".
NOTE: Be sure to keep all contacts isolated from any
grounded surface.
When power is supplied to all units of the 3176 Engine system,
normal servicing and programming capabilities are restored. When
servicing and programming are complete, remove the jumpers and
install wire "A" in position "A" in the P8 connector. Be sure the
8T8729 Pin is fully installed in the connector. Tug slightly on
wire "A". If fully inserted into J8, wire "A" will not be
removed.