Installing Optional Migration Kits on C9.3 through C15 ACERT Tier 4 Interim Machine Engines {1000, 1261, 1380, 775E} Caterpillar

Articulated Truck

735B (S/N: T4P1-UP)

740B (S/N: T4R1-UP)

740B EJECTOR (S/N: T4S1-UP)

Excavator

336E (S/N: JEA1-UP; RZA1-UP; KED1-UP; YCE1-UP; TEG1-UP; BMH1-UP; FJH1-UP; GTJ1-UP; JRJ1-UP; SSL1-UP; YEP1-UP; CMR1-UP; HDW1-UP; DPX1-UP; BZY1-UP; GNY1-UP; TMZ1-UP)

336F (S/N: ZBJ1-UP)

349E (S/N: FJB1-UP; ETC1-UP; DGE1-UP; SPG1-UP; TFG1-UP; RGH1-UP; KCN1-UP; MZW1-UP; KFX1-UP; MPZ1-UP; WHZ1-UP)

Mobile Hydraulic Power Unit

336E MHPU (S/N: PCE1-UP; RBS1-UP; T3Z1-UP)

Motor Grader

12M Series 2 (S/N: F9B1-UP; F9M1-UP; R9P1-UP; R9S1-UP)

140M Series 2 (S/N: M9D1-UP; R9G1-UP; M9J1-UP; R9M1-UP)

160M Series 2 (S/N: M9E1-UP; M9K1-UP; R9L1-UP; R9T1-UP)

Track-Type Tractor

D6R (S/N: T3J1-UP)

D6T (S/N: KSB1-UP; ZJB1-UP; JZC1-UP; DTD1-UP; EJJ1-UP; SLJ1-UP; GMK1-UP; RRK1-UP; TSM1-UP; WLM1-UP; PLR1-UP; JRW1-UP; RCW1-UP)

D7E (S/N: TJA1-UP; TAN1-UP)

D8T (S/N: MLN1-UP; FCT1-UP)

Wheel Loader

966K (S/N: PBG1-UP; TFS1-UP)

966K Series XE (S/N: NGX1-UP)

972K (S/N: PEM1-UP; Z4W1-UP)

980K (S/N: W7K1-UP; NEP1-UP; GTZ1-UP)

Introduction

Note: Order the emissions labels first. The ordering process can take some time.

This Special Instruction is used for the installation of the optional migration kits on C9.3 through C15 ACERT Tier 4 Interim Machine Engines.

Read the entire Special Instruction and understand the information before you perform any procedures.

Migration Kit Part Numbers

Note: All required parts listed in the Special Instruction are included in Table 1 kits.

Instructions for Ordering Migration/ Decertification Emissions Labels

1. Log on to the "Emissions Regulation and Conformance" website at the following web address:
   https://ercrequestspilotprogram.atlassian.net/servicedesk/customer/portal/2
   
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   Illustration 1	g06174531

2. Click Option 3. Tier 4 Migration/Decertification.
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   Illustration 2	g06174530

3. Click Migration / Decertification Request – C9.3 - C15.

4. The Migration / Decertification Request form will appear. All fields marked with an "*" must be completed. Refer to Table 1 for the Migration Kit Part Number.

   Note: Requests that do not have the decertification serial number included in "Section 5" and do not have the box checked which confirms that applicable local and national regulations permit the engine to be decertified will be rejected.

5. Proceed to TMI to determine the current "Engine Arrangement Number".
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   Illustration 3	g03890905
   (1) "Reference Number" field (2) Drop down box (3) "Retrieve Data" (4) Current "Engine Arrangement Number"

   1. Enter the machine serial number in the "Reference Number" field.

   2. Select "Serial Number" in the drop-down box.

   3. Click "Retrieve Data".

Fuel System Conversion

Required Parts

Conversion Procedure

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Illustration 4	g03887760
(1) Fuel diverter valve (2) Fuel outlet port fitting

1. Remove fuel diverter valve (1) from the ARD fuel pump.

2. Plug the diverter valve port with a 360-3693 Plug and 033-6028 O-Ring Seal.

3. Disconnect the existing fuel line from fitting (2) and cap the fitting with the cap assembly specified in Table 4.

   Note: The fuel pump will remain operational to prime the engine fuel system.

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   Illustration 5	g03888062
   (3) ARD fuel manifold inlet fitting (4) 6V-9829 Cap As

4. Disconnect the fuel line attached to fitting (3) and discard the hose.

5. Cap fitting (3) using cap assembly (4).

Exhaust System Conversion

Required Parts

Conversion Procedure

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Illustration 6	g03890235
(1) Diesel Particulate Filter (DPF) straps (2) DPF center section

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Illustration 7	g06074938
Incorrect alignment

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Illustration 8	g06074942
Correct alignment

1. Put identification marks on both sides of clamp assemblies (1) for installation purposes

2. Disconnect exhaust stack with outlet assembly.

3. Disconnect straps (1) to remove the diesel particulate filter group.

4. Attach a suitable lifting device to the DPF.

5. Remove the DPF center section.

6. Install new muffler kit specified in Table 3 in place of the DPF center section. Be sure to fully engage the pin and slot on both sides of the muffler.

7. Position the muffler assembly and tighten the new strap groups (1) to a torque of 15 +3/-0 N·m (11 +2/-0 lb ft) after aligning the new straps with the identification marks on the inlet and outlet sections.

Rework Procedure for 349E

Machines have a possibility of exhaust leaking from the hole.

1. Plug the hole at the bottom of the exhaust pipe.

2. Use high temperature paste with a tolerance (above 600° C (1112° F)).
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   Illustration 9	g06120718

3. Plug and spread the paste around the hole approximately 2 cm in diameter. As shown in Illustration 9.

Cooling System Conversion

Required Parts

Conversion Procedure

12M2, 140M2, and 160M2 Motor Graders

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Illustration 10	g03888492
(1) 398-5598 Plug As (2) 396-0404 Plug As

1. Disconnect the coolant lines and remove the fittings from the locations shown in Illustration 10. Replace the existing fittings with plugs (1) and (2).

2. Remove and discard coolant lines from the machine.

D6T Track-Type Tractors

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Illustration 11	g03888675
(3) 307-2671 Plug As (4) 398-5612 Plug As

1. Disconnect the coolant lines and remove the fittings from the locations shown in Illustration 11. Replace the existing fittings with plugs (3) and (4).

2. Remove and discard coolant lines from the machine.

D7E Track-Type Tractors

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Illustration 12	g03888697
(5) 307-2671 Plug As (6) 307-2673 Plug As

1. Disconnect the coolant lines and remove the fittings from the locations shown in Illustration 12. Replace the existing fittings with plugs (5) and (6).

2. Remove and discard coolant lines from the machine.

D8T Track-Type Tractors

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Illustration 13	g03888710
(7) 353-5126 Plug As (8) 353-5124 Plug As

1. Disconnect the coolant lines and remove the fittings from the locations shown in Illustration 13. Replace the existing fittings with plugs (7) and (8).

2. Remove and discard coolant lines from the machine.

336E and 349E Excavators

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Illustration 14	g03888727
(9) 6V-9828 Cap As

1. Disconnect the coolant lines and cap the lines shown in Illustration 14 with cap assemblies (9).

2. Remove and discard coolant lines from the machine.

735B and 740B Articulated Trucks

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Illustration 15	g03888743
(10) 398-5612 Plug As (11) 353-5124 Plug As

1. Disconnect the coolant lines and remove the fittings from the locations shown in Illustration 15. Replace the existing fittings with plugs (10) and (11).

2. Remove and discard coolant lines from the machine.

966K and 972K Wheel Loaders

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Illustration 16	g03888760
(12) 396-0405 Plug As (13) 396-0404 Plug As

1. Disconnect the coolant lines and remove the fittings from the locations shown in Illustration 16. Replace the existing fittings with plugs (12) and (13).

2. Remove and discard coolant lines from the machine.

980K Wheel Loaders

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Illustration 17	g03888770
(14) 6V-9828 Cap As (15) 353-5140 Plug As

1. Disconnect the coolant lines and remove the fittings from the locations shown in Illustration 17. Replace the existing fittings with cap (14) and plug (15).

2. Remove and discard coolant lines from the machine.

All Applications

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Illustration 18	g03891808
Typical example (16) ARD coolant manifold (17) Coolant lines

1. Disconnect coolant lines (17) from manifold (16). Remove and discard coolant lines (17) from the machine.

2. Replace the coolant fittings on manifold (16) with two 9S-8002 Plugs and two 6V-9027 O-Ring Seals.

Engine Software

Note: When migration kit rework has been completed, the technician must confirm that the latest machine software and monitor software is installed. If not, the latest machine software and monitor software must be installed at the same time as the new engine software.

Note: Factory passwords are required to install the decertification flash file.

1. Download the decertification flash file from Service Information System (SIS). Refer to Table 5.

2. Factory passwords will be issued utilizing the Dealer Solution Network (DSN).
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   Illustration 19	g03672156

3. When the decertification flash file is downloaded, this screen will appear in the electronic service tool. Refer to Illustration 19.

4. Click "Save to File". This action will create an HTML file.

5. Attach the HTML file to the DSN factory password request. Do not change the file to a PDF format.

6. The following text must be included in the DSN factory password request:

   This password request is for the decertification procedure outlined in Special Instruction, REHS9720. I acknowledge that the applicable local and national regulations permit engine serial number <enter engine serial number> to be decertified, and I will ensure export from the country if the decertified machine no longer complies with local or national regulations governing the sale and/or use of the machine. The labels to confirm that this decertification has been ordered and will be applied as per Special Instruction, REHS9720.

   Note: Any service requests for passwords that do not contain the above verbiage will be rejected

7. Once the factory passwords have been entered, install the flash file. Refer to Troubleshooting, "ECM Software - Install"

Machine Labels

The certified emissions labels are located in the machine cab and on the engine block. These labels must be removed. The new decertified emissions labels must then be installed in the machine cab and on the engine block. Refer to the information below for label removal and installation instructions.

Removing Adhesive Labels

1. Remove films and discard the pieces.

2. Clean the surface with a 1:1 mixture of isopropyl alcohol (IPA) and water. Use a clean, lint-free paper towel to remove all dirt and adhesive from the surface. Allow the surface to dry before installing the replacement films.

   Note: Never use acetone (propanone) to clean the engine or label surface.

Applying Adhesive Labels

1. Carefully remove the new film from the backing. Immediately apply the label in place of removed film.

   Note: Avoid trapping air bubbles under the label material.

2. Apply pressure to entire label to ensure adhesion.

3. Wait at least 60 minutes before disturbing the labels.

CE Plate Removal

1. Since a migrated machine will no longer be CE-compliant, the CE plate must be removed.

Removing Spark Plug Maintenance Interval Information on 336E and 349E Excavators

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Illustration 20	g03894160

1. Use the following steps to set the "Spark Plug" interval to "0".

   1. Press "Service" in the main menu.

   2. Press "Configuration".

   3. Press "Recommended Interval".

   4. Press "Spark Plug"

   5. Set the interval to "0".

1. Use the following steps to set the "Fuel Priming Pump" interval to "Off".

   1. Press "Service" in the main menu.

   2. Press "Configuration".

   3. Press "Recommended Interval".

   4. Press "Fuel Priming Pump"

   5. Set the interval to "Off".

Note: Once the "Recommended Interval" is set as "0", the spark plug information is no longer shown on the "Maintenance Intervals" menu.

Illustration 21	g03894045

Disabling the Product Link Lockout on 336E and 349E Excavators

If Product Link Japan is installed on migrated machine, the machine lockout system must be disabled. This disable configuration setting is needed to prevent the engine start limitation.

1. Access to machine ECM configuration in Caterpillar Electronic Technician (Cat ^® ET).

2. Change the "Machine Lockout System Installation Status" to the setting of "Not Installed".