Installation of 185-7733 Sensor Kit {1928} Caterpillar

Engine:

3406E (S/N: 1MM1-UP; 2WS1-UP)

C-10 (S/N: 3CS1-UP)

C-12 (S/N: 8YF1-UP; 2KS1-UP)

C-15 (S/N: 6NZ1-UP)

C-16 (S/N: 7CZ1-UP)

Introduction

The 185-7733 Sensor Kit is installed on truck engines in order to override the idle shutdown feature.

Truck engines that are equipped with an optional Idle Shutdown Timer will shut down the engine, if the engine is operating at a reduced load and the vehicle is stopped for a specified period of time. This feature does not shut down the electrical power to the vehicle.

The check engine lamp will flash for 90 seconds before the engine shuts down. The operator can override the idle shutdown timer during the final 90 seconds, if the "Allow Idle Shutdown Override" parameter is programmed to yes. The operator must press the brake pedal or the clutch pedal in order to override the timer.

If the "Allow Idle Shutdown Override" parameter is programmed to the "Outside Temp Based", the brake pedal or the clutch pedal can override the engine shutdown timer, when the outside air temperature is above a programmed range or below a programmed range. The Maximum Idle Shutdown Outside Temperature and the "Minimum Idle Shutdown Outside Temperature" parameters determine the range. The 71-00 Idle Shutdown Override event code is logged when the timer is overridden. If the timer is not reset, the engine will shut down when the programmed Idle Shutdown Time expires. When the engine is shutdown, the 71-01 Idle Shutdown Occurrence event code is logged.

The outside Temp Based option requires an additional temperature sensor. The 185-7733 Sensor Kit is mounted in a location that provides an accurate measurement of the ambient outside air temperature. A minimum and maximum temperature is programmed into the Idle Shutdown Timer. If the 130-9811 Temperature Sensor detects an outside temperature that is above the maximum temperature or below the minimum temperature the timer can be overridden by depressing the clutch or the service brake when the "CHECK ENGINE" lamp begins to flash.

The minimum and maximum values for the timer and the temperature range are given in illustration 1 and table 1.

Illustration 1	g00690873
Outside Air Temperature °F (°C).

Temperature Range

Reference Materials

Troubleshooting Manual, RENR2238, "C-10, C-12, 3406E, C-15 and C-16 Truck Engines".

Electronic Manual, LEBT9010, "Electrical and Electronic Application and Installation Guide for 2000 C-10, C-12, C-15, and C-16 Truck Engines".

Tooling and Equipment

The tools and the parts that are required to complete the installation of the 185-7733 Sensor Kit are given in the following table.

Installation Procedure

1. Determine a location for the sensor. The location should be away from the engine in order to ensure that an inaccurate reading is not obtained. Caterpillar recommended mounting the sensor on the frame of the truck near the front bumper or inside of the battery box.

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NOTICE
Because the strength of the frame may decrease, some manufacturers do not recommend welding onto a chassis frame or rail. Consult the OEM of the equipment or your Caterpillar dealer regarding welding on a chassis frame or rail.

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Illustration 2	g00591137
(1) Radiator (2) Engine compartment (3) Mount for front bumper (4) Weld connection (5) Ambient Air Temperature Sensor (6) Block Fitting or hose clip (7) 18 AWG extension harness

Note: A hose clip can be used in place of the block fitting to mount the sensor.

2. Once the location for the sensor has been determined, prepare the area for mounting the sensor on the 135-2544 Block or use a hose clip to mount the sensor. Before welding on a vehicle that is equipped with an electronic engine, the following precautions should be observed:
   • Disconnect all cables that are connected to the batteries of the vehicle.

   • Do not use the ECM or the Engine Ground Stud in order to ground the welder.

   • Locate a ground for welding as close as possible to the welding area.

3. Install 130-9811 Temperature Sensor into 135-2544 Block . Tighten the sensor to a torque of 20 ± 3 N·m (15 ± 2 lb ft).

   Note: The sensor may be damaged if the torque specification is exceeded.

   Note: If a hose clip is used instead of the block fitting, ensure that the hose clip is adequately secured.

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Illustration 3	g00591350
(8) Engine Control Module (9) Engine harness connector (10) Vehicle harness connector

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Illustration 4	g00681847
(10) Vehicle harness connector (11) Terminal 18 of the P1 ECM vehicle harness connector (12) Terminal 26 of the P1 ECM vehicle harness connector

4. Remove the sealing plug from terminal 18 (11) and terminal 26 (12) of the P1 vehicle harness connector (10). It may be necessary to disconnect vehicle harness connector (10) in order to remove the sealing plugs.

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Illustration 5	g00592736
Input Sensor Signal 2 may be used in place of Input Sensor Signal 1.

5. Insert the socket for the 185-7734 Harness Assembly that is connected to wire C453-YL into terminal 26 (12) of the P1 ECM vehicle harness connector (10). Insert the socket for the 185-7734 Harness Assembly that is connected to wire L901-GY into terminal 18 (11) of P1 ECM vehicle harness connector (10) .

6. Connect the 185-7734 Harness Assembly to the 130-9811 Temperature Sensor . See Illustration 5. The length of the wiring harness is determined by the location of the sensor and the routing of the wiring harness. Fabricate an extension for the wiring harness if the wiring harness is not long enough. Use the following steps to fabricate the extension.

   1. Measure the required length for the wiring harness.
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   Illustration 6	g00593104
   (5) Ambient Air Temperature (7) Extension harness (9) Engine harness connector (13) Harness (15) 8T-8729 Connector Pin (1) and (2)

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   Illustration 7	g00670012
   (7) Extension harness (14) 102-8807 Connecting Plug Kit (15) 8T-8729 Connector Pin (1) and (2) (16) 8T-8730 Connector Socket (17) 102-8802 Receptacle Kit

   2. Assemble the extended wiring harness with a 102-8802 Receptacle Kit (17). The 102-8802 Receptacle Kit consists of the following components: two 8T-8729 Connector Pins (15), 102-8807 Connecting Plug Kit (14), two 8T-8730 Connector Sockets (16) and two 18 AWG wires (7) .

   3. Connect extension (7) to wiring harness (13) and connect the extension (7) to sensor (5). Secure the wires with 3S-2093 Cable Strap .

7. Connect an Electronic Service Tool to the Cab Data Link Connector in order to verify that there are no active diagnostic codes.

8. Start the engine and allow the engine to run at low idle rpm for at least three minutes. This will allow the temperature reading to stabilize.

9. Verify that the 130-9811 Temperature Sensor is operating correctly.

   Note: If the status of the outside temperature sensor that is indicated on the Electronic Service Tool is not within ± 3 °C (± 5 °F) of the actual outside temperature, verify that the sensor is installed correctly. If the sensor appears to be installed correctly, refer to the Functional Test for the Outside Air Temperature Sensor.

10. Contact the owner in order to acquire the desired values for programming the minimum idle shutdown outside temperature and the maximum idle shutdown outside temperature.

11. The following steps are an example of an ECM setting.

    1. "Set the Allow Idle Shutdown Override to Outside Temp Based."

    2. Set the "Minimum Idle Shutdown Outside Temperature" to 4 °C (39 °F).

    3. Set the "Maximum Idle Shutdown Outside Temperature" to 27 °C (80 °F).

The example of the operation of an ECM is described below.

• The Driver Alert Function is activated during the final 90 seconds of the Idle Shutdown Time. Momentarily engage the service brake pedal or the clutch pedal in order to override the engine shutdown timer.

• When the ECM is programmed to the settings from the previous steps, and the outside temperature is between 4 °C (40 °F) and 27 °C (80°F), the "Allow Idle Shutdown Override" is not permitted. The engine will be shutdown. If the outside temperature is less than 4 °C (40 °F) or greater than 27 °C (80 °F), idle shutdown override will be permitted and the engine will continue to run.

Functional Test For The Ambient Air Temperature Sensor

1. Inspect the electrical connectors and the wiring.

2. Thoroughly inspect the ECM vehicle harness connector J1/P1. Also inspect all of the connectors and the terminals in the 185-7534 Harness Assembly and the extension harness, if equipped.

   Note: Refer to the C-10, C-12, 3406E, C-15, and C-16 Truck Engine Module, RENR2238, "Inspecting Electrical Connectors" for the correct procedure.

   1. Perform the 45 N (10 lb) pull test on each of the wires for the sensor that is in the ECM vehicle harness connector.

   2. Check the vehicle harness connector for the proper torque. The allen head screw should be torqued to 6.0 N·m (53 lb in).

   3. Check the harness and the wiring for abrasion. Check for crimps in the wire from the sensor to the ECM.

   4. Connect all sockets, connectors and the pins completely.

   5. If all of the connectors and the wires are in good condition, proceed to Step 3. If the connectors and the wires are not in working condition, replace the faulty equipment and test the system again.

3. Make sure that the override for the Idle Shutdown is working properly.

   1. Access the "Customer Parameters" on the Electronic Service Tool. Verify that the "Allow Idle Shutdown Override" is programmed to the "Outside Temperature Based". The "Allow Idle Shutdown Time" must be programmed to a value that is more than zero minutes.

      Note: It may be helpful to temporarily program the Idle Shutdown Time to 3 minutes for testing purposes.

   2. Record the programmed "Minimum Idle Shutdown Outside Temp" and the "Maximum Idle Shutdown Outside Temp". View the status of the ambient temperature sensor on the Electronic Service Tool. If the air temperature is below the programmed "Minimum Idle Shutdown Outside Temp." or above the programmed "Maximum Idle Shutdown Outside Temp.", the timer can be overridden. The service brake pedal or the clutch pedal can be used to override the "idle shutdown timer" during the last 90 seconds of operation. After the "CHECK ENGINE" lamp starts flashing, the idle shutdown timer can also be overridden by depressing the service brake pedal or the clutch pedal. If the air temperature is between the two values that are programmed, the timer can not be overridden.

      Note: The "Idle Shutdown Override" feature will become inoperable and this feature can not be overridden, if the "Minimum Idle Shutdown Outside Temperature " is greater than the "Maximum Idle Shutdown Outside Temperature "or equal to the "Maximum Idle Shutdown Outside Temperature ".

4. After depressing the service brake pedal or the clutch pedal, ensure that the "Allow Idle Shutdown Override" is functioning properly.
   • If the Idle Shutdown Timer is operating properly, clear all of the diagnostic codes and restore the original Idle Shutdown time.

   • If the ECM does not detect a change in the status of the clutch pedal or the service brake, refer to C-10, C-12, 3406E, C-15, and C-16 Truck Engine Module, RENR2238, "Cruise Control, Service Brake Pedal Position Switch # 1, and Clutch Pedal Position Switch Test".

   • If the "Allow Idle Shutdown Override" parameter is programmed to the "Outside Temperature Based", check the "Active Diagnostic Codes". Ensure that there is not an active open circuit for the Ambient Air Temperature Sensor 171- 04. If one of these codes or both of these codes are active, refer to Troubleshooting, RENR2238, "C-10, C-12, 3406E, C-15, and C-16 Truck Engine", " Engine Temperature Sensor Open or Short Circuit Test".

   • If the temperature that is indicated on the status screen is not within ±3 °C (± 5 °F) of the actual outside temperature, go to Step 5.

5. Compare the temperature sensor to the temperature from another gauge.

   1. Remove the temperature sensor from the vehicle.

   2. Connect the sensor to the ECM vehicle harness connector and hold the sensor in the air with a thermocouple probe from the 6V-9130 Temperature Adapter . Wait for three minutes in order for the probe to respond.

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   NOTICE
   To avoid damage to the sensor, DO NOT EXPOSE THE SENSOR to a flame or a fluid.

   3. Hold the sensor and the thermocouple probe and check the temperature again. The temperatures should be within ±3 °C (± 5 °F) of each other.

      Note: Do not expect the sensor and the thermocouple probe to respond to the temperature change at the same rate.

      • The location of the sensor may cause erratic air temperature readings. In order to test the sensor, remove the sensor from the vehicle. If the sensor functions properly, the location is the problem. The problem is due to heat soak from the engine or the cooling system. Reposition the sensor to a location that provides an accurate reading of the outside temperature.

      • If the two measurements do not agree, temporarily install a new sensor. Repeat Step 5. If the problem is resolved replace the sensor.