Installing 133-0659 Temperature Sensor Kit{1900, 1921} Caterpillar

Introduction

This Special Instruction describes the procedures for installation of 133-0659 Temperature Sensor Kit on vehicles equipped with 3176B, C-10, C-12, or 3406E Truck Engines. The purpose of the temperature sensor kit is to measure ambient air temperature.

The 133-0659 Temperature Sensor Kit contains all necessary parts for the installation.

Reference: 3176B, C-10, C-12, and 3406E Truck Engine Electronic Troubleshooting Manual, SENR5582.

Requirements

1. Personality Module Release Date must be November 1995 or later.

2. Customer Specified Parameter Allow Idle Shutdown Override must be programmed to Outside Temperature. The default for this parameter is Yes.

3. Customer Specified Parameters Minimum Idle Shutdown Outside Temperature and Maximum Idle Shutdown Outside Temperature must be programmed to establish a temperature range. The default for these parameters is 49 C° (120 F°).

Necessary Parts

Installation

NOTE: Ensure that the engine key is OFF and the engine is OFF.

Inspect the inlet air system in the vehicle's engine compartment and inspect the frame rails near the front bumper.

Inspect these areas and read the entire Special Instruction to determine the best location for installation of 106-0735 Electronic Sensor (Temperature) BEFORE attempting to install the kit.

The inlet air system is normally made up of an air filter element and element housing; aluminum, steel, or plastic pipes; and rubber/plastic fittings. This kit is designed to be installed in one of the pipes, in the air filter element housing, or on one of the frame rails near the front bumper.

Considerations in determining the best location for sensor installation

* The frame rail outside of the engine compartment near the front bumper is the preferred location for sensor mounting. This location is preferred because it will provide the most accurate measurement of outside air temperature. This location may require a harness addition depending on harness routing.

* If a metal pipe in the inlet air system is selected the sensor should be positioned as close as possible to the air filter element housing and furthest away from the exhaust manifold.

* If the air filter housing is selected, ensure there are no obstructions present within the housing interior. The sensor should not impede the air filter replacement.

* The location should allow for secure routing of 133-0660 Harness Assembly.

Illustration 1. 3176B, C-10, and C-12 Location Detail (Left Side View): (1) Fuel Temperature Sensor Connector J23/P23. (2) Fuel Temperature Sensor. (3) ECM Connector J2/P2. (4) ECM Connector J1/P1. (5) Electronic Control Module (ECM)

Illustration 2. 3406E Location Detail (Left Side View): (1) Fuel Temperature Sensor. (2) Fuel Temperature Sensor Connector J23/P23. (3) ECM Connector J2/P2. (4) ECM Connector J1/P1. (5) Electronic Control Module (ECM).

Installation Procedure-Frame Rail Near Front Bumper

1. Once the location has been determined, prepare the area for welding 135-2544 Block-Fitting (Rectangular) to the frame rail. Before welding on a vehicle equipped with an electronic engine, the following precautions should be observed.

* Disconnect all cables connected to the vehicle batteries.

* Disconnect both ECM Connectors (J1/P1 and J2/P2).

* Do not use the ECM or Engine Ground Stud for grounding of the welder.

* Locate the welding ground as close as possible to the welding area.

NOTE: Refer to Illustration 3: Frame Rail Mounting Detail. Sensor probe points toward the front bumper, away from the engine compartment, and the block is mounted in front of the radiator.

2. Install 106-0735 Electronic Sensor (Temperature) into 135-2544 Block-Fitting (Rectangular) threaded hole. Tighten the sensor to a torque of 20 ± 3 N·m (15 ± 2 lb ft).

Illustration 3: Frame Rail Mounting Detail.

3. Locate and disconnect the Fuel Temperature Sensor Connector J23/P23. Refer to Illustration 1: 3176B, C-10, and C-12 Location Detail or Illustration 2: 3406E Location Detail.

4. Use the connectors on the "Y" end of 133-0660 Harness Assembly to connect the connector plug to Connector J23 and the connector receptacle to Connector P23. Refer to Illustration 4: Outside Air Temperature Sensor Harness Diagram With Extension.

Route the harness and connect the connector plug on the opposite end of the harness to the Outside Air Temperature Sensor Connector. Secure the harness and connectors with 3S-2093 Straps.

5. Harness length requirements will vary based on sensor location selection and harness routing.

If the kit harness is too long, the harness may be looped or coiled to remove any slack. It can then be secured with 3S-2093 Straps.

If the harness is not long enough, then a harness extension must be fabricated.

* Measure to determine the required harness extension length.

* The harness extension requires 3E-3370 Receptacle Assembly-Connector with three 8T-8729 Pins and one 3E-3371 Wedge-Receptacle Lock; one 3E-3367 Plug Assembly-Connector with three 8T-8730 Sockets and one 3E-3368 Wedge-Plug Lock; and three 16 AWG wires. If possible, select wire colors that correspond to the wire colors used in 133-0660 Harness Assembly.

Illustration 4: Outside Air Temperature Sensor Harness Diagram With Extension.

* Install each pin and socket in connectors to corresponding locations. Complete the assembly of the connectors by inserting the appropriate wedge.

* Connect the harness extension connector receptacle J97 to harness connector P98. Connect the harness extension connector plug P97 to sensor connector J98.

* Secure harness extension wires with 3S-2093 Straps.

6. The signal wire exiting the harness on the "Y" end must be routed to Engine Harness Connector P2. Remove the sealing plug from Connector P2 and insert the socket into the pin-9 location in Engine Harness Connector P2. (It may be necessary to disconnect Engine Harness Connector P2 from ECM Connector J2 in order to install the socket.) Refer to Illustration 5: Wiring Schematic With Harness Extension For Electronic Sensor (Temperature) Installation.

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

* Start the engine. Allow the engine to run at low idle rpm for at least three minutes permitting the sensor temperature reading to stabilize.

Verify 106-0735 Electronic Sensor (Temperature) is operating correctly.

NOTE: The sensor signal output can not be correctly measured when the signal line is disconnected from the ECM. If the Outside Temperature indicated on the status screen is not within ±3 C° (±5 F°) of the actual outside temperature, verify the sensor is installed correctly in order to read an accurate temperature. Refer to Illustration 5: Wiring Schematic With Harness Extension For Electronic Sensor (Temperature) Installation.

If the sensor appears to be installed correctly refer to Outside Air Temperature Sensor Functional Test.

8. Contact the owner to acquire the desired values for programming the associated parameters.

* Allow Idle Shutdown Override set to Outside Temperature.

* Minimum Idle Shutdown Outside Temperature set to 4 C° (40 F°).

* Maximum Idle Shutdown Outside Temperature set to 27 C° (80 F°).

The operation of the system is as follows:

* During the final 90 seconds of Idle Shutdown Time (Driver Alert Mode) the service brake pedal is depressed momentarily.

* Based upon these parameter settings if the outside temperature is between 4 C° (40 F°) and 27 C° (80 F°), idle shutdown override will not be permitted and the engine will shutdown. Alternatively, 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.

TROUBLESHOOTING: Refer to Outside Air Temperature Sensor Functional Test.

Illustration 5. Wiring Schematic With Harness Extension For Electronic Sensor (Temperature) Installation.

Installation Procedure-Inlet Air System Location

1. Once the location has been determined, remove the section of duct or housing from the inlet air system. Drill a 25.4 mm (1.00 in) diameter hole to allow mounting of 133-0662 Boss-Fitting (Steel). The pipe or housing material should match the Boss Fitting. If the pipe or housing is composed of steel then use 133-0661 Boss-Fitting (Steel). If the pipe or housing is composed of aluminum, use 133-0662 Boss-Fitting (Aluminum).

Illustration 6. Boss Fitting Detail: (1) 106-0735 Sensor. (2) 3/4-16 Thread. (3) Inlet Air Pipe. (4) 8L-2786 Seal (O-ring). (5) Boss-Fitting. (6) 25 ± 0.5 mm (0.98 ± 0.02 in).

2. Install 133-0662 Boss-Fitting (Aluminum) or 133-0661 Boss-Fitting (Steel) in the hole so that the larger 30.0 mm (1.18 in) diameter is on the exterior of the pipe or housing. The Boss Fitting should be welded or brazed. The method used is determined by the pipe or housing material. Refer to Illustration 6: Boss Fitting Detail.

3. Slide 8L-2786 Seal (O-ring) over the sensor probe and install 106-0735 Electronic Sensor (Temperature) into 133-0662 Boss-Fitting (Aluminum) or 133-0661 Boss-Fitting (Steel) threaded hole. Tighten the sensor to a torque of 20 ± 3 N·m (15 ± 2 lb ft).

4. Locate and disconnect the Fuel Temperature Sensor Connector J23/P23. Refer to Illustration 1: 3176B, C-10, and C-12 Location Detail or Illustration 2: 3406E Location Detail.

Use the connectors on the "Y" end of 133-0660 Harness Assembly to connect the connector plug to Connector J23 and the connector receptacle to Connector P23. Refer to Illustration 7: Outside Air Temperature Sensor Harness Diagram.

Route the harness and connect the connector plug on the opposite end of the harness to the Outside Air Temperature Sensor Connector. Secure the harness and connectors with 3S-2093 Straps.

NOTE: The harness may be looped or coiled to remove any slack. It can then be secured with 3S-2093 Straps.

6. The signal wire exiting the harness on the "Y" end must be routed to Engine Harness Connector P2. Remove the sealing plug from Connector P2 pin-9 location and insert the socket into pin-9 location in Engine Harness Connector P2. (It may be necessary to disconnect Engine Harness Connector P2 from ECM Connector J2 in order to install the socket.) Refer to Illustration 8: Wiring Schematic For Electronic Sensor (Temperature) Installation.

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

* Start the engine. Allow the engine to run at low idle rpm for at least three minutes permitting the sensor temperature reading to stabilize.

* Verify 106-0735 Electronic Sensor (Temperature) is operating correctly.

NOTE: The sensor signal output can not be correctly measured when the signal line is disconnected from the ECM. If the Outside Temperature indicated on the status screen is not within ±3 C° (±5 F°) of the actual outside temperature, verify the sensor is installed correctly in order to read an accurate temperature. Refer to Illustration 8: Wiring Schematic For Electronic Sensor (Temperature) Installation.

If the sensor appears to be installed correctly, refer to Outside Air Temperature Sensor Functional Text.

Illustration 7: Outside Air Temperature Sensor Harness Diagram.

8. Contact the owner in order to acquire the desired values for programming the associated parameters.

* Allow Idle Shutdown Override must be set to Outside Temperature.

* Minimum Idle Shutdown Outside Temperature is set to 4 C° (40 F°).

* Maximum Idle Shutdown Outside Temperature is set to 27 C° (80 F°)

Operation of the system is as follows:

* During the final 90 seconds of Idle Shutdown Time (Driver Alert Mode) the service brake or clutch pedal is depressed momentarily.

* Based upon these parameter settings if the outside temperature is between 4 C° (40 F°) and 27 C° (80 F°), idle shutdown override will not be permitted and the engine will shutdown. Alternately, 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.

TROUBLESHOOTING: Refer to Outside Air Temperature Sensor Functional Test.

Illustration 8: Wiring Schematic For Electronic Sensor (Temperature) Installation.

Outside Air Temperature Sensor Functional Test

1. Check the electrical connectors and wiring.

A. Thoroughly inspect ECM Engine Harness Connector J2/P2; Harness Connectors J23/P99, J99/P23, and J98/P98 (Use connectors J98/P97 and J97/P98 if the harness extension is used.); and the Sensor pins in the Connectors. (Refer to procedure PB-10: Inspecting Electrical Connectors in the 3176B, C-10, C-12, and 3406E Truck Engine Electronic Troubleshooting Manual, SENR5582, for details on inspecting the connectors.)

B. Perform 44.5 N (10 lb) pull test on each of the wires in the ECM Connector associated with the Outside Air Temperature Sensor.

C. Check ECM Connector (allen screw) for proper torque.

D. Check the harness and wiring for abrasion and pinch points from the sensor back to the ECM.

E. All connectors/pins/sockets should be completely mated/inserted and the harness/wiring should be free of corrosion, abrasion, or pinch points.

* If ok, proceed to Step 2.

* If not ok, repair or replace wiring or connectors as necessary. Verify all seals are properly in place and connectors completely mated. Verify that the repair eliminates the problem.

2. Verify the Idle Shutdown Override Function.

A. Access the Read Customer Parameters. Verify that the customer parameter Allow Idle Shutdown Override is programmed to Outside Temperature Based.

B. Record the programmed Minimum Idle Shutdown Outside Temperature and Maximum Idle Shutdown Outside Temperature. View the actual air temperature on the Electronic Service Tool status screen. If the air temperature on the status screen is below the programmed Minimum Idle shutdown Outside Temperature or above the programmed Maximum Idle Shutdown Outside Temperature, the Timer will override. If the air temperature on the status screen is in between these two programmed values, the Timer will NOT override. During the last 90 seconds, after the Check Engine lamp is flashing, press either the service brake or the clutch pedal to override the shutdown.

NOTE: If the Minimum Idle Shutdown Outside Temperature is greater than or equal to the Maximum Idle Shutdown Outside Temperature, the temperature based Idle Shutdown Override feature is disabled. The Idle Shutdown will not allow override.

C. After pressing the service brake or clutch pedal, check that Allow Idle Shutdown Override is properly operating.

* If the idle shutdown timer is operating properly, clear all diagnostic codes and restore the original Idle Shutdown Time.

* If the ECM does not sense a change in clutch or brake status, refer to PB-15: Cruise Control And Kickout Switches Circuit Test in the 3176B, C-10, C-12, and 3406E Truck Engine Electronic Troubleshooting Manual, SENR5582.

* If Allow Idle Shutdown Override parameter is programmed to Outside Temperature Based, check the Active Diagnostic Codes. Verify there is not an Active 171-03 Outside Temperature Sensor Open Circuit, or 171-04 Outside Temperature Sensor Short Circuit code. If either of these codes is Active, refer to PC-35: Engine Sensor Open Or Short Circuit Test in the 3176B, C-10, C-12, and 3406E Truck Engine Electronic Troubleshooting Manual, SENR5582.

* If the Outside Temperature indicated on the status screen is not within ±3 C° (±5 F°) of the actual outside temperature, proceed with Step 3.

3. Check The Temperature Sensors To Temperature From Another Gauge

NOTE: Outside Air Temperature requires November 1995 or later Personality Module Release Date.

A. Remove the temperature sensor from the vehicle.

B. Connect the sensor to the engine harness and hold it in the air with the thermocouple probe from 6V-9130 Temperature Adapter Group. Wait three minutes to give the sensor and probe time to respond.

C. Compare the sensor temperature shown on the Electronic Service Tool status display to the temperature as measured by 6V-9130 Temperature Adapter Group.

D. Hold the sensor and thermocouple probe in your hand and check the temperature again.

The two measurements should agree within ±3 C° (±5 F°)

NOTE: Do not expect the sensor and thermocouple probe from 6V-9130 Temperature Adapter Group to respond to the temperature change at the same rate.

* If the two measurements agree but a problem is still suspected with the sensor functioning correctly, it is most likely a mechanical, not an electronic, problem.

* If the two measurements disagree, temporarily install another sensor. Repeat Step 3. If the problem is resolved with the new sensor, replace the sensor.