Installation of the Heated Nozzle for the Caterpillar Regeneration System (CRS){107P, 108B, 1408, 1743, 1803, 1901, 7620} Caterpillar

Engine:

C13 (S/N: LEE815-9700)

C15 (S/N: SDP719-11500)

Introduction

Do not perform any procedure in this Special Instruction until you have read this information and you understand this information.

Remove the Fuse for the ARD Purge Air Pump

Note: The fuse must be removed before performing this procedure. If the fuse has not been removed, the fuse can be blown when the jumper harness is installed.

1. Remove the fuse for the ARD purge air pump. Consult the manufacturer of the chassis for the location of the fuse.

Installing the Software

Note: The software must be updated before the iron is updated.

1. Update Cat ET to the ET2008A or a later version.

2. Download the current data for the truck.

Show/hide table

NOTICE
The new software must be flashed before the engine is updated with the hardware. Damage will occur if the hardware is updated first.

3. Flash new software into the engine ECM. The software must be updated to 320-XXXX or later.

Show/hide table



Illustration 1	g01443782

4. Set the configuration in Cat ET. Refer to Illustration 1.

   1. Select "Emissions Parameters".

   2. Select "ARD Fuel Nozzle Cleaner Configuration A".

   3. Select "Nozzle Heater".

Jumper Harness

Use the following procedure in order to complete the jumper harness.

1. Disconnect the electrical connector for the ARD purge air pump from the engine harness.

2. Check the engine harness connector for the ARD purge air pump. There are two possible configurations for the engine wiring:

   1. If four wires are inserted into the engine harness connector for the ARD purge air pump, the engine wiring is already configured for the heated nozzle. Proceed to the ""Installing the Hardware" " section of this procedure.

      Note: This is effective with (S/N: SDP8270-UP) and (S/N: LEE6575-UP).

   2. If three wires are inserted into the engine harness connector for the ARD purge air pump, the engine wiring is not configured for the heated nozzle. Continue with this procedure in order to configure the engine wiring for the heated nozzle.

3. Cut the three wires that are inserted into the engine harness connector for the ARD purge air pump. Be sure to cut the wires near the engine harness connector. Discard the electrical connector.

4. Crimp a new terminal onto the end of each wire.

Show/hide table



Illustration 2	g01454961

5. Refer to Illustration 2 before you insert the wires into the 230-5008 Connector Plug As . Insert the pink wire into location 1. Insert the red wire into location 3. Insert the black wire into location 4. Insert the orange wire from the 317-0642 Wiring Kit into terminal 2.

   Note: The pink wire, the red wire, and the black wire are the wires from the engine harness. The orange wire is from the 317-0642 Wiring Kit .

6. Pull on each wire in order to verify that wire is fully inserted into the electrical connector.

Illustration 3	g01469937
Electrical schematic for the ARD purge air system

Illustration 4	g01469897
Electrical schematic for the heated nozzle

Installing the Hardware

Show/hide table



Illustration 5	g01443304
(1) ARD purge air pump

1. Remove pump (1) and remove the associated components. Remove the lines for the purge air as well as the tee for the purge air. Install 9S-5518 Plug . Discard the pump and the components. Remove the cleaning port and the lines for the cleaning port.

Note: Maintain cleanliness in order to prevent contamination.

2. There are two options for configuring the elbow for the air compressor.

   Note: Use the following three procedures for one of the options.

   1. The open port of tee (2) must be sealed. Use one of the following procedures in order to seal the port:
   Show/hide table
   
   

   Illustration 6	g01447312
   (2) Tee (3) Hex fitting

   Note: Use the following procedure for the listed serial numbers C15 S/N:SDP00719-06890.

   2. Remove the intake hose from tee (2). Replace tee (2) with a new 247-4602 Elbow . Assemble intake hose onto the elbow. Position 8T-1117 Hose Clamp . Tighten the hose clamp.

   Note: Use the following procedure for the listed serial numbers C13 S/N:LEE05515-09000 and C15 S/N:SDP06891-11000.

   3. Perform this step if tee (2) has hex fitting (3). Remove hex fitting (3) from tee (2). Install 9S-8004 O-Ring Plug and 153-4906 O-Ring Seal into the open port of tee (2). Refer to Illustration 6.
   Show/hide table
   
   

   Illustration 7	g01447311
   (2) Tee (4) Tee without hex fitting (5) Hose Clamp (6) Hose (7) Plug

   Note: Use the following procedure for the listed serial numbers C13 S/N:LEE00815-05514.

   4. Perform this step for tee (2) without hex fitting (4). Cut a section of the used 5P-1442 Hose 70 mm (2.75 inch) in length. Ensure that the cut is square and clean. On one end of the 70 mm (2.75 inch) hose install the 9S-5518 Plug (7). Secure the plug in the hose with a 109-1145 Hose Clamp (5). Slide the other end of the 70 mm (2.75 inch) hose over the end of tee (2) without hex fitting (4). Secure the hose (6) with a 109-1145 Hose Clamp (5) .
   Show/hide table
   
   

   Illustration 8	g01588054
   (2) Tee (8) Hose (9) Air compressor

   Note: The following procedures are the second option.

   5. If Service Letter, REBE2795 has been performed, replace hose (8) .

3. Disconnect the sensors, the lines, and the spark plug from the combustion head on the aftertreatment regeneration device.

Show/hide table



Illustration 9	g01443515
New combustion head (10) Electrical connector for heated nozzle

4. Remove the combustion head on the aftertreatment regeneration device. Refer to Disassembly and Assembly, "Combustion Head Group (ARD) - Remove and Install".

5. Remove the line for the purge air to the combustion head. Install 9S-8004 O-Ring Plug and 214-7568 O-Ring Seal for C15 onto the manifold. Install 9S-8003 O-Ring Plug and 1J-9671 O-Ring Seal onto the manifold.

6. Install the 331-5726 Combustion Head Gp . Install a new spark plug on the 331-5726 Combustion Head Gp .

7. Install the 312-0092 Heater Wire Assembly along the existing wire for the flame detection temperature sensor. Ensure that the wire for the heater is tied to the sensor wires within 152.4 mm (6 inch) of the combustion head.

Show/hide table



Illustration 10	g01446671
(11) 315-0225 Wire Clamp

8. Install 315-0225 Wire Clamp in order to secure the heater wire. Ensure that the "ears" of the clamp are facing upward. Tighten the bolt for the clamp to 3.0 ± 0.5 N·m (26.55 ± 4.43 lb in).

Installing the Relay and the Bracket for C13

Show/hide table



Illustration 11	g01455014
(12) 314-7659 Bracket (13) 090-8747 Spacer (14) 6V-5839 Washer (15) 6V-5230 Bolt (16) 156-6175 Clip (17) 9X-8267 Washer (18) 8T-0639 Bolt (19) 289-0704 Fuel Line (20) 7M-6425 Clip (21) 230-2599 Bolt (22) 312-1079 Relay As (23) 6V-3822 Bolt (24) 6V-5839 Washer

1. The bracket for the relay will be installed in the same location as the ARD purge air pump. Refer to Illustration 11.

2. Install two bolts (23) and two washers (24) .

3. Install new fuel line (19). Install clip (20), spacer (13), washer (14) and bolt (15).

4. Install clips (16), washers (17) and bolts (18) .

5. Install bolt (23) and washer (24) in two locations.

6. Mount the relay to the bracket with two bolts (21). Ensure that the head of bolt (21) is facing outward from the cover of the relay.

7. Install the fuse for the ARD purge air pump.

Installing the Relay and the Bracket for C15

Show/hide table



Illustration 12	g01455015
(25) Bolt (26) 156-6175 Clip (27) 5P-0537 Hard Washer (28) 0S-1614 Bolt (29) 5M-2894 Hard Washer (30) 9S-8752 Full Nut (31) 312-1079 Relay As (32) 9F-7022 Bolt (33) 314-7660 Bracket

1. Use existing bolts (25), washers (29) and nuts (30) in order to install bracket (33) .

2. Install clips (26), washers (27) and bolts (28) .

3. Mount the relay to the bracket with bolts (32). Ensure that the head of bolt (32) is facing outward from the cover of the relay.

4. Install the fuse for the ARD purge air pump.

Installing the Wire Harness

Show/hide table



Illustration 13	g01588093
(34) 317-0642 Wiring Kit (35) 3S-2093 Cable Strap (36) 6K-0806 Cable Strap (37) 206-1345 Cable Strap (38) 204-1611 Cable Strap (39) 287-0569 Clip

1. Route wiring kit (34) along the existing wiring harness. Install cable straps in order to secure wiring kit (34) to the existing wiring harness.

   Note: When you replace the cable straps, use the existing clips in order to secure wiring kit (34) to the main wiring harness. When you add the cable straps, secure wiring kit (34) to the main wiring harness.

Show/hide table



Illustration 14	g01455020
(40) 230-5008 Connector Plug As (41) Connector from the relay

2. Insert connector (40) into connector (41) .

3. Insert the opposite end of 317-0642 Wiring Kit into the connector from the heated wire.

Verifying Proper Operation

1. Verify that the engine is off.

Show/hide table



Illustration 15	g01607074
Measuring the current flow (42) Clamp-on ammeter (43) Wire (44) Metal part of the electrical connector

2. Connect the clamp-on ammeter (42) around wire (43). Make sure that the jaws of the ammeter are away from the metal part of the electrical connector (44) .

Show/hide table



Illustration 16	g01455035

3. Start the engine. Use the following steps in order to activate the "ARD Fuel Nozzle Heater Electric Circuit" within Cat ET. Refer to Illustration 16.

   1. Select "Diagnostic".

   2. Select "Diagnostic Test".

   3. Select "System Troubleshooting".

   4. Select "ARD Fuel Nozzle Heater Electric Circuit".

4. Observe the current reading on the ammeter. The current flow must be above 6.0 amperes.

5. Disable the override. Stop the engine.

   Note: After the override has been disabled and the engine has been shut down, check the amperage again. Make sure that the ignition key is in the OFF position before checking for any amperage. A small amperage might be present, but the amperage should be less than 0.5 amperes. If the amperage is more than 0.5 amperes then there is a problem with the wiring. Refer to Illustration 4 for the proper wiring.

6. Remove the clamp-on ammeter.

Perform a Stationary Regeneration

1. Click the "Disconnect" icon on Cat ET in order to disconnect Cat ET from the engine.

2. Turn the keyswitch to the OFF position. Wait for five seconds.

3. Turn the keyswitch to the ON position.

4. Click the "Connect" icon on Cat ET in order to connect Cat ET to the engine.

5. Start the engine. Allow the engine to idle for three minutes.

6. Start a stationary regeneration by selecting the following menus on Cat ET:
   • "Service"

   • "Service Procedures"

   • "Manual Diesel Particulate Filter Regeneration"

   Cat ET will display a "Waiting On Requirements" window. The ECM will automatically elevate the engine speed to 1400 rpm. If the "Waiting On Requirements" window remains displayed for more than five minutes, abort the regeneration. Then, select the menu options again in order to start the stationary regeneration.

   The duration of the stationary regeneration depends on the soot load in the DPF. The ECM will automatically return the engine speed to low idle after the stationary regeneration is complete.

   Note: The ECM tests the nozzles for plugging after the stationary regeneration is complete. Approximately ten minutes are required in order for the test to provide a result. A code will become active if the nozzles are plugged.