Procedure to Install an Aftertreatment (Mechanical) Kit on All Caterpillar® Diesel Engines {108D, 108U, 1408, 1907, 1921, 1923, 7553} Caterpillar

Engine Commercial

All Diesel

Introduction

This Special Instruction contains information for installing the Aftertreatment (Mechanical) Kit on all Caterpillar^® engines. The Aftertreatment (Mechanical) Kit is used with the aftertreatment system to gather information regarding engine performance. The system gathers information from various sensors and is transmitted on the main J1939 data link and the main CDL data link to be received by the aftertreatment system.

Safety Section

Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. The installer must be alert to potential hazards and have the necessary training, skills, and tools needed to perform these functions properly. Wear safety equipment, such as eye protection and foot protection, and other protection as is appropriate to the work site.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe. Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Personal injury or death can result from improper assembly procedures. Do not attempt any assembly until you have read and understand the assembly instructions.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

Prepare the Machine

1. If the machine is portable, then move the machine to a smooth, level surface that will support the weight of the machine.

2. Turn off the machine with the engine switch to the OFF position.

3. Use proper Lock out and Tag out procedures. Attach a "Do Not Operate" warning tag to the machine start switch or the controls before you perform any service to the machine. These warning tags Special Instruction, SEHS7332 are available from your Caterpillar dealer.

Overview

Applicability

The Aftertreatment (Mechanical) Kit is offered as an aftermarket attachment for use on all diesel fueled, off-highway engines, both Caterpillar and competitive brands, providing a fleet solution for equipment owners.

Electrical Requirements

This control is designed to operate on 12 or 24 volts DC, negative ground. Current draw of the control package is less than 2.0 amps. External solenoids or other loads driven by the control and connection of a Caterpillar Electronic Technician (ET) communications adapter will add to the current draw.

Remote Monitoring Requirements

Remote monitoring requires that a telematics system, such as Product Link, be installed on the machine or equipment to transmit the data off board. The Aftertreatment (Mechanical) Kit does not include any required hardware to install a data monitoring and recording device.

Features

A new kit will come with these configuration parameters already programmed into the ECM.

The Aftertreatment (Mechanical) Kit supports both J1939 and Cat Data Link protocols for communication with a monitoring and recording device.

When connected, Cat ET will display Fuel Consumption, Engine Speed, Coolant Temperature, Ambient, and Boost Pressures.

Installation of Product Link or VIMS

Inorder to collect performance data using the installed Aftertreatment (Mechanical) Kit, there must be a data monitoring and recording device, such as Product Link, installed on the machine or equipment. The Aftertreatment (Mechanical) Kit does not include any required installation instructions or hardware to mount a data monitoring and recording device.

Required Parts

Aftertreatment (Mechanical) Kit Supplied Parts for Installation

Note: Listed below are the contents of the bill of materials for 519-7504 Instl GP-Field at the time of publication of this document.

Additional Parts Needed for Installation

Flow Transducers Mounting Bracket

A mounting bracket must be fabricated to support each of the two flow transducers. Since the kit can be used on a large range of engines in both stationary and machine applications, no universal mounting bracket design is possible. A bracket must be field fabricated to allow mounting of the transducer(s) to either the engine or a structural component of the machine. Leave room above the transducer for electrical connections and room at each end for fuel line connections.

Transducers can be mounted one over the other with room left for electrical connections on the bottom transducer. They can also be stacked together by using longer bolts than are provided in the kit. Transducers can be located apart from each other if installation would be easier as each transducer has its own harness to connect it to the ECM.

Fittings and Adapters

Due to the large range of engines that this system may be used on, a list of all fuel line fittings, sizes, styles and adapters is not possible. As a starting point, the inlet and outlet of each flow transducer is a #12 STOR, female thread. This must be adapted to the correct size fuel line tubing required for each engine. It is likely that the supply and return fuel lines will be of different sizes. It is recommended that the fuel line tubing be new and in good condition. The tubing MUST be clean inside. Any small particles that are carried from the inlet hose through the transducer will clog the transducer. In that event, it will become necessary to remove the transducer from the system and dislodge the particles. If hoses are equipped with O-ring fittings, the O-rings must be new.

Electronic Control Module Mounting Bracket

Given the wide range of machines to which the Fuel Consumption Monitoring system can be applied, a standardized mounting method is not possible. Some of the considerations to be made when selecting an ECM mounting location include:

• Installation within 121 cm (48 inch) of the transducers will require only the base transducer harnesses. Additional extension harnesses are available to allow installation distances up to 9 m (30 ft).

• Access to a fused source of +24V power.

• Access to "Keyswitch" as supplied by the ignition system.

• Access to battery ground.

• Access to the main data link(s) on the machine.

Ambient Pressure Sensor Bracket

Given the wide range of machines to which the Aftertreatment (Mechanical) Kit can be applied, a standardized mounting method is not possible. It is recommended that the sensor be mounted off the engine with easy access to the connector.

Wiring Diagram

Note: During installation, it is important to protect wiring in key locations. Key locations are any area where the wiring could be nicked or cut and come in contact with the chassis. Avoid Installation practices where there could be excessive flexing, chafing, or cutting of the wiring.

Illustration 1	g06136071

Installation

Machine Preparation

1. Move the machine to a smooth, level location, and away from other working machines and personnel.

2. Lower the implements to the ground.

3. Stop the engine.

4. Engage the parking brake for the machine.

5. Place the disconnect switch in the OFF position.

Installation of the Fuel Flow Transducers

The transducers will be located on a field fabricated bracket in a location of the installers choice. When selecting a mounting location, consider accessibility of fuel lines as well as the ECM. Electrical connections should avoid sharp bends at connectors, sharp edges, and chafing surfaces. Harnesses should be supported at no less than 30.48 cm (12 inch) intervals.

The following parts are included in the kit for fastening the transducer to the mounting plate.

Installation of the Electronic Control Module

The ECM will need to be secured to a field fabricated bracket. Use the following ECM requirements to fabricate a bracket for the ECM in a location that meets the requirements.

• Installation within 121.92 cm (48 inch) of the transducers will require only the base transducer harnesses. Additional extension harnesses are available to allow installation distances up to 9.144 m (30 ft).

• Access to a fused source of 24V power.

• Access to key switched power as supplied by the ignition system.

• Access to battery ground.

• Access to the main data link or links on the machine.

The following hardware is provided in the kit for mounting the ECM:

1. There are four mounting points on the ECM, one at each corner. Drill a hole to accommodate a size M8 bolt that corresponds to each mounting point.

2. Use one 6V-5221 Bolt, two 9N-0869 Hard Washers, one 8T-9658 Spacer, two 8T-9655 Isolation Mounts, and one 3T-0852 Locknut at each mounting location of the ECM.

3. Ground the ECM. One corner of the ECM includes a ground strap. If the ECM must be mounted to a non-conductive portion of the machine, use a ring lug and wire to connect the ground strap to the nearest ground point on the machine chassis. The conductive flat surface of the lug must be directly connected to a conductive surface that is bonded to the machine chassis.

Installation of the Electrical Harnesses

Note: During installation, it is important to protect wiring in key locations. Key locations are any area where the wiring could be nicked or cut and come in contact with the chassis. Avoid installation practices where there could be excessive flexing, chafing, or cutting of the wiring.

1. Install the 519-7506 Wiring Harness on the ECM.

2. Connect the three connectors of the 448-8685 Wiring Harness to the Supply Transducer. Refer to for connector locations.

3. Connect the three connectors of the 448-8686 Wiring Harness to the Return Transducer. Refer to for connector locations.

4. Connect the 448-8685 Wiring Harness and the 448-8686 Wiring Harness to the 519-7506 Wiring Harness. If the 448-8685 Wiring Harness and or the 448-8686 Wiring Harness are too short, then extension harnesses are available.

   Note: The 3 m (10 ft) extension harness is part number 448-8687 Wiring Harness. The 6 m (20 ft) extension harness is part number 448-8688 Wiring Harness.

5. Provide positive battery voltage, ground, and key switch to connector J-C16 of the 519-7505 Wiring Harness. Positive battery voltage should be connected to a fuse protected source. The key switch input is the positive battery voltage signal provided when the ignition is turned on.

For systems that do not have a key switch signal, this input should be tied to positive battery voltage.

Installation of the 489-3080 Engine Speed Sensor Gp

Locate an accessible speed sensor port on the flywheel housing. Remove the plug and rotate the flywheel until a tooth is visible in the center of the port. Install the sensor into the port until the sensor just touched the flywheel. Mark the housing and speed sensor, then back the sensor out 1/2 turn until the marks are opposite or 180 degrees from each other. Holding the sensor, tighten down the jam nut to a torque of 45 ± 7 N·m (33 ± 5 lb ft) to prevent the sensor from backing out.

To install the engine speed sensor harness, cut 7.6 m (25 ft) of cable from 481-2115 Cable As. On one end, remove 38.1 mm (1.5 inch) of the cable jacket and crimp 9X-3402 Connector Socket onto the red, black, and white wires and insert them into the 8T-8731 Connector Plug per Illustration 2 and install 3E-3377 Receptacle Lock Wedge.

Illustration 2	g06135213
Engine Speed Sensor

Installation of the 498-5588 Intake Manifold Temperature Sensor

Locate an accessible port on the intake manifold housing. Install 3J-1907 O-Ring Seal onto 288-8390 Temperature Sensor Gp. Remove the plug and install the sensor into the port. Tighten sensor to 20 ± 5 N·m (15 ± 4 lb ft).

To install the intake manifold sensor harness, cut 7.62 m (25 ft) of cable from 481-2115 Cable As. On one end, remove 38.1 mm (1.5 inch) of the cable jacket and crimp 9X-3402 Connector Socket onto the red, black, and white wires and insert them into the 230-5008 Connector Plug As per Illustration 3. Insert 8T-8737 Seal Plug into empty socket in connector. On the other end, remove 38.1 mm (1.5 inch) of the cable jacket and crimp a 9X-3402 Connector Socket onto the red, black, and white wires. Crimp 133-0967 Connector Pin onto shield wire and insert into 3E-3376 Connector Receptacle As per Illustration 3 and install 3E-3377 Receptacle Lock Wedge.

Illustration 3	g06135228
Intake Manifold Temperature Sensor

Installation of the 519-7509 Ambient Pressure Sensor

Locate and install the field bracket described in Section "Ambient Pressure Sensor Bracket" and fasten the ambient pressure sensor to the bracket. Be sure that the sensor is installed with the open port in the down position.

To install the ambient pressure sensor harness, cut 7.62 m (25 ft) of cable from 481-2115 Cable As. On one end, remove 38.1 mm (1.5 inch) of the cable jacket and crimp 9X-3402 Connector Socket onto the red, black, and white wires and insert them into the 281-8803 Connector Plug As per Illustration 4. On the other end, remove 38.1 mm (1.5 inch) of the cable jacket and crimp a 9X-3402 Connector Socket onto the red, black, and white wires. Crimp 133-0967 Connector Pin onto shield wire and insert into 3E-3376 Connector Receptacle As per Illustration 4 and install 3E-3377 Receptacle Lock Wedge.

Illustration 4	g06135514
Ambient Pressure Sensor

Installation of the 519-7510 Boost Pressure Sensor

Locate a port on the outlet side of the Compressor Post After-Cooler. Install 6V-6560 O-Ring Seal onto 320-3061 Pressure Sensor Gp. Remove the plug from the port and install the sensor. Tighten to 10 ± 2 N·m (7 ± 1 lb ft).

To install the boost pressure sensor harness, cut 7.62 m (25 ft) of cable from 481-2115 Cable As. On one end, remove 38.1 mm (1.5 inch) of the cable jacket and crimp 9X-3402 Connector Socket onto the red, black, and white wires and insert them into the 281-8803 Connector Plug As per Illustration 5. On the other end, remove 38.1 mm (1.5 inch) of the cable jacket and crimp 9X-3402 Connector Socket onto the red, black, and white wires. Crimp 133-0967 Connector Pin onto shield wire and insert into 3E-3376 Connector Receptacle As per Illustration 5 and install 3E-3377 Receptacle Lock Wedge.

Illustration 5	g06135536
Boost Pressure Sensor

Wiring Connectors to Aftertreatment Systems

The 519-7506 Harness needs to be wired using connector J-C16 and J-C15. See Illustration 1 for connector locations. Following the wiring connections described in the table below:

Configuration of the Installed System

Each Aftertreatment (Mechanical) Kit will come from the manufacturer with the software flashed into the ECM and the system configuration already loaded into the ECM. This information is provided here in the event that a transducer fails and must be replaced. Configuration of the system requires Cat ET.

Fuel Flow Transducer Configuration

Should you need to replace a fuel flow transducer, the system will need to be reconfigured. You will need the following information supplied with the new transducer.

1. The flow transducer serial number.

2. The temperature at which the calibration values were calculated.

3. Seven (7) frequencies and seven (7) corresponding K-Factors for each transducer that were calculated during calibration at the manufacturer. These numbers must be entered in the order that they are listed, as there is one to one correspondence between them.

At the main Cat ET screen, you will select Service in the menu bar. A drop-down menu will appear and you will select Calibrations. See Illustration 6.

Illustration 6	g06135582

After selecting Calibrations, the calibration screen will appear. You will select Fuel Flow Transducer Calibration and then select Start at the bottom of the screen. See Illustration 7.

Illustration 7	g06135587

The screen for entering all the new information for the replacement transducer will appear. See Illustration 8.

Illustration 8	g06135591

Enter the information for the appropriate transducer you are replacing. Once the data is entered, select Program ECM at the bottom of the screen.

Electrical Validation of the Installed System

Conditions to Perform the Validation Procedure

Note: Before beginning the validation procedure, make sure that all the following conditions are as listed.

Remove the J-C1 connector from the ECM. Validate that:

1. J-C5 is connected to A-C1.

2. A-C2 is connected to supply speed sensor 1.

3. A-C3 is connected to supply speed sensor 2.

4. A-C4 is connected to supply temperature sensor.

5. J-C9 is connected to J-C13.

6. J-C6 is connected to C-C1.

7. C-C2 is connected to return speed sensor 1.

8. C-C3 is connected to return speed sensor 2.

9. C-C4 is connected to return temperature sensor.

10. J-C16 is disconnected.

11. J-C15 is disconnected.

12. CAN A RES1 is connected to J-C3.

13. CAN A RES2 is connected to J-C11.

Power Off Test

Speed Sensor Connections Test

Conditions:

Ignition switch in Off position.

Fluke 177 Digital Volt Meter (+) lead connected to J-C1-68.

Connect the negative lead to the following pins:

• J-C1–6

• J-C1–52

• J-C1–61

• J-C1–63

Each measurement should have a resistance reading between 827K ohms and 863K ohms.

Temperature Sensors Connections Test

Verify that the ignition is in the OFF position.

Connect a digital volt meter positive lead to J-C1-56.

Connect the negative lead to the following pins:

• J-C1-36

• J-C1-37

The target resistance depends upon ambient temperature. Use Appendix A to determine the target resistance.

Power on Test

Power, Ground, Keyswitch Connections Test

1. Connect J-C16 to machine power, ground, and keyswitch.

2. Connect a digital volt meter negative lead to the machine chassis.

3. With the power OFF connect a digital volt meter positive lead to J-C1-2. The resistance should be less than three (3) ohms and no voltage present.

4. With the power On connect a digital volt meter positive lead to J-C1-1. The expected result is battery voltage.

5. With the power ON and the key switch OFF, connect a digital volt meter positive lead to J-C1-3. The expected result is close to zero (0) volts.

Communications Link Connections Test

1. Turn keyswitch to the OFF position.

2. Connect J-C1 to ECM.

3. Turn keyswitch to the On position.

4. Connect Caterpillar Communications Adapter to J-C175. Set protocol option to J1939.

5. Using CAT ET, verify that one ECM is detected.

6. Start the engine and check each of the fuel line connections for leaks.

7. Read Cat ET status screen to check that fuel flow is being reported for the supply transducer "Engine Fuel Flow Rate 1" and the return transducer "Engine Fuel Flow Rate 2". For small engines running at idle, it may take up to 10 seconds for the value to be updated.

8. Check to make sure that there are no errors being reported.

9. Move the throttle to run and observe that fuel consumption values update more frequently. Allow the engine to warmup before going to the idle flow rate settings.

10. Verify that the total fuel consumed is updating on the Totals screen. R11. Refer to Illustration 1.

Maintenance

Best operation and maintenance practices for the fuel consumption monitoring system are as follows:

• Operator visually inspects fuel line/transducer connections daily to ensure that there is no leakage.

• Technician manually inspects fuel line/transducer connections weekly to ensure that there is no leakage.

• Technician manually inspects harness and connections monthly.