Installing the 6I3553 Intake Manifold Heater{1450} Caterpillar

Introduction

Extremely low temperatures below 0°C (32°F) give rise to additional starting problems. This results in excessive white smoke.

The 6I3553 Intake Manifold Heater is used to increase the air temperature, in the intake manifold, to prevent the development of excessive white smoke during and immediately after engine starting.

This preheating considerably improves the engine's cold starting ability at very low temperatures and ensures smooth engine operation within the shortest possible time.

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This engine is equipped with a Flammstart fuel ignited inlet manifold heater for cold weather starting. Do not use other types of starting aids such as ether. Such use could result in an explosion and/or personal injury.

The heater plug is installed in the engine's intake manifold and is activated electrically to start the preheat cycle.

Once the required temperature, at the heater plug element, is reached the dash mounted indicator light will go out and the engine can be cranked to start.

During the cranking mode, a fuel solenoid valve directs diesel fuel to the heater plug nozzle. The nozzle meters diesel fuel onto the heater plug where it mixes with air and ignites. The air is now heated before entering the intake manifold.

By maintaining the flame for a predetermined duration after engine start, the engine can warm up much more quickly and the white smoke that normally occurs during and immediately after engine starting is reduced to a minimum.

The entire temperature dependent engine starting process is preprogrammed and is controlled automatically by the microprocessor.

The system provides monitoring functions which switch off the system if the engine starts before the required heater plug temperature is reached, or if the engine fails to start within a 30 ± 8 second period of engine cranking.

Reference: Service Manual, SEBR0544-03 ... 3406B Diesel Truck Engine

Parts Manual

6I3553 Heater Group Contents

The 6I3553 Heater Group contains all the parts required for the installation except for fabricated and/or modified parts.

Installing the 6I3553 Heater Group

Installing the 6I3049 Heater Plug

NOTE: The 6I3049 Heater plug MUST be installed in the air intake elbow UPSTREAM of the inlet manifold.

NOTE: The intake elbow MUST be removed before installation of the heater plug. Before removing the intake elbow inspect the area of installation for sufficient clearance between the cab/hood and the heater plug when it is installed.

1. Remove the air intake elbow.

2. If the air intake elbow is not provided with a suitably positioned casting boss, an adapter plate for mounting the heater plug must be fabricated and welded in place:

* Fabricate an adapter plate 31.75 mm (1.250 in) diameter x 6.35 mm (.250 in) thick.

NOTE: The fabricated adapter plate must be of the same material composition as the air intake elbow.

Example of the adapter plate location (close to vertical) upstream from the air intake manifold.

* Position adapter plate as close to vertical as possible with the center line of the air intake elbow and tack weld to secure in position for finish welding.

* Finish weld adapter plate to the air intake elbow.

* Scribe center line(s) on adapter plate.

* Use a 1U8184 Drill Bit to drill a through hole of 18 mm diameter ... or

* Use a 1U5688 Drill Bit to drill a through hole of 23/32inch diameter.

* Use a 9U5794 Tap to tap M20 mm x 1.5 mm thread.

NOTE: The welded area should be inspected to ensure complete weldment/sealing and that the interior of air intake elbow is free of any drill/tap cuttings.

3. Install 6I3049 Heater Plug (1) into air inlet elbow (2).

NOTE: Do not install fuel line and electrical wiring at this time.

Refer to Installing the 6I3051 Fuel Supply Lines, General Installation Instructions/Recommendations and Electrical Wiring in this instruction.

Installing the 6I3047 Fuel Solenoid Valve

4. Install 6I3784 Bracket at the rear of the intake manifold. Use the rear four bolt intake cover as shown.

Direction of fuel flow after installation of fuel solenoid valve, braided fuel line and heater plug: 1. Fuel Tank. 2. Fuel Transfer Pump. 3. Secondary Fuel Filter. 4. Injection Pump. 5. Injection Nozzle. 6. Braided Fuel Line. 7. Fuel Solenoid Valve. 8. Heater Plug.

5. Use the above illustration as a guide to install the #4 Aeroquip fuel lines, #4 Aeroquip fuel line adapters and the fuel solenoid valve:

* Install metric #4 Aeroquip adapters into the fuel solenoid valve.

NOTE: Use 5P3413 Pipe Sealant, or equivalent, on the adaptor threads.

* Install fuel solenoid valve into mounting bracket using two 5P0537 Washers (3) and two 6V8837 Bolts (4).

NOTE: Check the bottom side of the fuel solenoid valve for the fuel direction arrow before installation.

* Fabricate, to length, and install a #4 Aeroquip fuel line from the injection pump return elbow to the fuel solenoid valve.

NOTE: Do NOT remove the fuel solenoid valve fitting as received and do NOT remove the fuel pump return elbow as it is internally orificed.

Installing the 6I3051 Fuel Supply Lines

NOTE: Use the illustration in Installing the 6I3047 Fuel Solenoid Valve as a guide for the fuel supply lines location.

6. Install the braided fuel between the fuel solenoid valve and the heater plug:

* Install nut into braided fuel line.

* Insert the reinforcing ferrule with the larger diameter of the ferrule towards the nut onto the end of the braided fuel line ... and

* Install the line into the inlet of the fuel solenoid valve and tighten the nut.

Installing the 3T4418 Oil Pressure Switch

7. Remove the 3/8 inch NPT plug in the main oil galley below the turbocharger and replace with a 3/8 inch NPT x 1/8 inch adapter (not shown).

Install oil pressure switch (5) into adapter.

NOTE: Other pugs may be present on some engines. The preferred location is close to the center of the engine.

Installing the 6I3046 Electronic Control Unit (ECU)

Example of ECM installation.

8. The ECU (6) should be installed and securely mounted in a dry location in the cab. The preferred location, for ease of wiring, is under the dash near the steering column.

The ECU electrical connections (7) are color coded. Refer to Connecting the 6I3051 Wiring Harness Individual Leads to Vehicle Power, in this instruction.

NOTE: Due to chassis variables the mounting location may vary.

Installing the 6I3052 Indicator Light

NOTE: The indicator light MUST be installed in:

* An area that provides sufficient clearance for installation ... and

* In a visible position, as close as possible to the starting switch.

9. The indicator light requires a 19.05 mm (.750 in) diameter hole for mounting.

A 3/4 inch GREENLEE® knockout punch, or equivalent tool, is recommended.

This type of tool creates a clean/neat hole for the installation.

NOTE: If the hole is drilled rather than punched, the area behind and below MUST be inspected for any drill cuttings.

10. Install and wire the indicator light.

Installing the 6I3050 Temperature Sensor

NOTE: A modified plug must be fabricated, from a 1/2inch hex head NPT plug, before the installation of the temperature sensor.

11. Remove existing plug in regulator housing.

12. Scribe center lines on the hex head of the 1/2 inch hex head NPT plug (not shown):

* Drill a through hole of 12.7 mm (.500 in) diameter.

* Tap the hole to M14 mm x 1.5 mm thread.

NOTE: The drilled/tapped hole should be inspected to ensure it is free of any drill/tap cuttings.

13. Install the modified plug into regulator housing.

NOTE: Use 5P3413 Pipe Sealant, or equivalent, on the adaptor and temperature sensor threads.

14. Install temperature sensor into plug.

General Installation Instructions/Recommendations

6I3051 Wiring Harness

The wiring harness is, for the most part, ready assembled.

A corrugated conduit is supplied with each wiring harness to provide optimum protection for the wiring in the engine compartment.

NOTE: Additional conduit may need to be ordered for your application.

Connecting Electrical Wires From Installed Componets to 6I3051 Wiring Harness

Example of wiring pulled through conduit wall and taped for protection and appearance.

A slit cut CAREFULLY through the conduit wall, at the appropriate location, will allow the wire(s) to be pulled out for connection to the related component(s).

Connect the preattached plug ends to the ECU. The plug ends and matching ECU connectors can only be assembled one way.

Installing Conduit Through Firewall

After connection to the ECM, feed the wiring harness through the firewall.

Use a silicone sealant to completely seal and weather proof the installation.

After installation of the wiring harness it can be routed with the existing chassis/engine wiring.

Cable ties should be used for a neat installation.

Fuse Block (50 Amp)

The fuse block should be installed in a protected/accessible area on the engine side of the fire wall.

Proper Connection and Grounding of Electrical Wiring

The heater plug connection and fuel solenoid valve ground wire have screwed cable design connections. Use serrated washers to ensure a good ground.

Inspect all ground wiring/connections for proper grounding at the:

* Ground wire between fuel solenoid valve and mounting bracket.* Ground wire from fuel solenoid valve mounting bracket to frame.* Ground wire from fuel solenoid valve mounting bracket to air inlet elbow to ensure that the heater plug is properly grounded.

Electrical Wiring

Connecting the 6I3051 Wiring Harness Individual Leads to Vehicle Power

Use the above as a guide for connecting the wiring harness individual leads to vehicle power, 10 A and 50 A fuses, heater plug, fuel solenoid valve and temperature transmitter: 1. Battery. 2. Starter. 3. Alternator. 4. Oil Pressure Switch. 5. Ignition Switch. 6. Electronic Control Unit (ECU). 7. Dash Light (for intake manifold heating system). 8. Fuel Solenoid Valve. 9. Heater Plug. 10. Air Inlet elbow. 11. Coolant Temperature Sensor.

WHITE: Use to connect to the cranking side of the switch (terminal 50)

Voltage during cranking operation ONLY.

BLUE: Use to connect to the alternator and terminal D+ thru the oil pressure switch.

Voltage + (POS) ONLY for as long as the engine is running.

GREY: Use to connect to key switch (terminal 15) RUN position

Voltage + (POS) via 10A fuse as soon as, and for as long as, the main switch is switched ON.

NOTE: The current must NOT be interrupted during the starting operation.

Ascertain correct terminal on main switch.

2 x YELLOW (1.0 mm): Use to connect to the pilot lamp for heater system.

GREEN: Use to connect to ground terminal 31.

BLUE (6 mm dia): Use to connect to the main feeder via 50A to + (POS) battery terminal.

RED (6 mm dia): Use to connect to the heater plug.

BROWN: Use to connect to the fuel solenoid valve.

BLACK: Use to connect to the temperature sensor.

Installing the Warning Decal(s)

Two 8T2930 WARNING decals are included in the group:

Example of the 8T2930 WARNING decal installed close to the engine's 9L6531 Engine Information Plate.

* Install one in a VISIBLE location in vehicle cab .. and

* Install one in a VISIBLE location in engine compartment or on engine.

Operating the Intake Manifold Heater

This portion of the instruction will explain the operation of the intake manifold heater and a basic explanation of how it works.

A few moments spent learning the sequential steps required to engage the system, and a reasonable knowledge of the components functions during cranking, will allow the operator to start the engine in a minimum amount of time.

Procedures to Start the Engine

Switch on (RUN position) the main key operated switch:

* The indicator light MUST light up and stay on for the duration of heating process.

* This will start the (40 - 60 seconds) heater plug preheat mode.

NOTE: The heater plug will start to heat as soon as the switch is activated (RUN position). The heater plug will soon be too HOT to touch.

The preheating process is voltage dependent, refer to the Corrective Action column in the Troubleshooting chart.

* The preheating process will last 40 - 60 seconds (depending on the voltage).

* Upon completion of the preheating process the pilot lamp will go out.

* The engine can now be started.

Start the Engine

NOTE: The engine must be started:

As soon as the engine starts:

* The indicator light will light up again for the entire duration of the inlet manifold heating process.

* Not later than 30 ± 8 seconds AFTER the indicator light goes out .. and

* The alternator MUST reach charging speed.

If these two requirements are NOT met:

* The intake manifold heating system will be switched OFF automatically.

This happens when the alternator does not provide a signal to the D+ terminal of the ECM.

If this occurs:

To restart the engine the main key operated switch must now be:

* Switched OFF for several seconds before attempting to start the engine.

When the main switch is switched on (RUN position) again:

* The pilot lamp will light up to indicate the start of the preheating process.

The engine can be started as:

* The pilot light goes out.

After Engine Start

After the engine is started:

* The engine speed must NOT be allowed to exceed low idle rpm for the duration of the intake manifold heating process.

The heating cycle is completed as soon as:

* The indicator light goes out.

The duration of the intake manifold heating process is up to 10 minutes and is controlled automatically by the Electronic Control Unit (ECU).

Intake Manifold Heater System Functional Check

Fuel Lines

Inspect all fuel supply/return lines, connections, and screw type fittings for fuel leakage.

Replace/repair/tighten if required.

Checking the System At Ambient Temperature

The system can be checked for correct operation at any temperature by:

* Disconnecting the temperature sensor .. and

* Performing the normal (cold start) engine starting procedures.

The system can now be checked for correct operation even when the engine is at normal operating temperature.

Refer to Operating the Intake Manifold Heater in this instruction.

Intake Manifold Heating Phase

During the intake manifold heating phase (indicator light ON) the fuel solenoid valve is energized and allows fuel flow to the heater plug.

Use a test light or voltmeter to check current.

NOTE: The intake manifold elbow will become hot in the area around the heater plug. This is a reliable indication that the system is functioning properly.

Monitoring Function

Fuel Solenoid Valve and Heater Plug

The pilot light will flash (similar to a vehicle turn indicator), when the system is in the preheat mode, to indicate an electrical defect in the fuel solenoid valve or heater plug.

If the glow plug heats up during the preheat mode:

* Check for voltage at the fuel solenoid valve.

If voltage is present:

* The problem is in the fuel solenoid valve.

Inspect the fuel solenoid valve for proper ground.

Indicator Light Flashes

If the indicator light FLASHES:

* For 60 seconds AFTER an engine start, WITHOUT the use of the intake manifold heater .. or

* For 60 seconds AFTER an engine start WITH the use of the intake manifold heater .. the

* Temperature sensor is either disconnected or defective.

Starting the Engine Without Using the Intake Manifold Heater

The engine may be started normally by going immediately to the cranking cycle without preheating the plug.

Important Notes

Premature Start Up

NOTE: If the engine starts during the preheating phase (BEFORE the indicator light goes out):

* The system will automatically switch OFF.

Preheating Without Engine Start

NOTE: If the engine is not started AFTER the preheating phase:

* The system will automatically switch OFF.

Alternator Fails to Charge After Engine Start

NOTE: If the engine fails to start within 30 ± 8 seconds and a signal is not sent to the controller:

* The system will automatically switch OFF.

If the engine starts and then cuts out almost immediately OR the engine continues to run normally but the alternator does not supply any current (no voltage at terminal D + of the ECU):

* The system will automatically switch OFF after 3 seconds.

Restarting Procedure When Additional Heating Time Is Desired

NOTE: Before restarting the engine:

* Switch the main key operated switch to the OFF position.

* Wait at LEAST 4 seconds.

* Return the Switch the main key operated switch to the ON position.

After completion of the preheat phase:

* The pilot lamp will go out, indicating the engine can be started.

NOTE: The system should NOT be run through more than two back to back cycles to prolong component life.

Troubleshooting

The first column is the symptom, the second column is a description or possible cause of the problem (if not explained in the error message) and the third column is the action which you should take to correct the symptom.

Maintenance

The intake manifold heating system requires neither maintenance nor regular care.

However, like any other system designed for a particular seasonal use, it should be checked for proper use before needed.