Installing The 104-7618 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 104-3180, 106-1572, and 101-9885 Intake Manifold Heaters are 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, SEBR0552 .. 3306C Diesel Truck Engine (7RJ1-Up)

Service Manual, SENR6495 .. 3306C Diesel Truck Engine (9TL1-Up)

Parts Manual, SEBP1990 .. 3306C Diesel Truck Engine (7RJ1-Up)

Parts Manual, SEBP2269 .. 3306C Diesel Truck Engine (9TL1-Up)

104-3180, 106-1572, and 101-9885 Heater Group Contents

The 104-3180, 106-1572, and 101-9885 Heater Groups have the following parts mounted on the engine: water temperature sensor, fuel solenoid, oil pressure switch, fuel supply line, wiring harness, and a seven-pin connector. To install these heater groups, the parts shown in chart below must be installed. See Air Inlet Manifold Heater System and Wiring Diagram for 104-7618 Installation Group illustrations for additional reference.

Installing the 104-7618 Heater Group

Installing the 101-0612 Heater Plug

NOTE: The 101-0612 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.

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

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

For aluminum air intake elbows:

* Weld a 101-9883 Boss to the air intake elbow, or fabricate an aluminum adapter plate 31.75 mm (1.250 in) diameter x 6.35 mm (.250 in) thick.

For steel air intake elbows:

* Weld a 101-9882 Boss to the air intake elbow, or fabricate a steel adapter plate 31.75 mm (1.250 in) diameter x 6.35 mm (.250 in) thick.

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

Installing a 101-9883 Boss or 101-9882 Boss

* Position the 101-9883 Boss or 101-9882 Boss as close to vertical as possible with the center line of the air intake elbow and mark the location of the drilled hole on the air intake elbow.

* Remove the boss and drill an 18 mm diameter hole through the air intake elbow.

* Align the threaded hole of the 101-9883 Boss or 101-9882 Boss with the drilled hole in the air intake manifold and tack weld the boss to the air intake manifold.

* Finish weld the boss to the air intake elbow.

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.

Installing A Fabricated Adapter Plate

* 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.

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

* Finish weld the adapter plate to the air intake elbow.

* Scribe center line(s) on the adapter plate.

* Use a 1U8184 Drill Bit to drill an 18 mm diameter hole through the adapter plate and the air intake elbow.

* Use a 9U5794 Tap to tap M20 mm x 1.5 mm thread in the adapter plate.

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.

2. Install the air intake elbow.

3. Install 101-0612 Heater Plug (1) into the air inlet elbow.

Direction of fuel flow after installation of fuel solenoid valve, flexible fuel line and heater plug: (1) Heater plug. (2) Injection pump. (3) Fuel line. (4) Fuel solenoid valve. (5) Fuel line. (6) Secondary fuel filter. (7) Transfer pump. (8) Flexible fuel line. (9) Fuel tank.

* Install return to tank fuel line (5).

* Fabricate, to length, a #4 Aeroquip fuel line (3) from the OEM return to tank line to the solenoid valve (4).

4. Install 3J7352 Connector to the fuel solenoid.

* Install 001-6285 Straight Swivel to the fuel line.

* Install 3J7355 Union to the swivel and connect to OEM return to tank line.

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 101-9644 Flexible Fuel Lines

5. Install flexible fuel line (8) between fuel solenoid valve (4) and heater plug (1):

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

* Install the remaining end of the line into the heater plug and tighten nut.

Installing the 101-9643 Electronic Control Unit (ECU)

Example of the preferred location of the ECU installation.

NOTE: The ECU can be mounted under the hood. The ECU MUST be mounted with the wire connections in the down position.

6. The ECU (10) 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 (11) are coded.

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.

7. 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.

8. Install the indicator light.

Installing Warning Decals

Install 8T2930, 4P6422, and 101-9767 Warning Decals which are included in the group:

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

9. Install 8T2930 Warning Decal on the dash and in engine compartment or on engine.

10. Install 4P6422 No Ether Decal on air cleaner near the inlet.

11. Install 101-9767 Starting Instruction Decal on dash or visor.

General Installation Instructions/Recommendations

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

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

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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 from heater plug boss to cylinder block.

Fabricated Electrical Wires from Installed Components to Engine Connection

NOTE: Wire lengths will vary by OEM.

1. Use a piece of wire to determine the distance between the ECU and the seven-pin connector on the intake manifold. Cut the following wires to that measured distance.

1 10 AWG

1 16 AWG

3 14 AWG

2. Install these five wires to 8N1535 Endbell and 8N1533 Plug Assembly with connectors. Install opposite end of wires into 104-7624 Receptacle Housing and 104-7622 Receptacle Housing. See illustration Wiring Diagram for 104-7618 Installation Group for reference.

3. Cut four 16 AWG wires and route into cab. Two wires go to ignition switch and two wires to indicator lamp.

4. Connect one end of wire to ignition switch and indicator lamp (see illustration). Connect opposite end of wire to 104-7624 Receptacle Housing and 104-7622 Receptacle Housing with connectors as shown.

NOTE: ECU terminal 50 wire (voltage during cranking mode only). ECU terminal wire 5 (voltage as long as switch is ON and must be fused as shown).

5. Cut two 10 AWG to length. Install one wire from ECU to 50 amp fuse block. Install the other wire from fuse block to starter. See illustration.

Electrical Wiring

Air Inlet Manifold Heater System

Use the above as a guide for connecting the wiring harness individual leads to vehicle power.

Wiring Diagram for 104-7618 Installation Group

Use the above as a guide for connecting the wiring harness individual leads to vehicle power.

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 .. or

* The oil pressure switch MUST close.

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 ECU.

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 after:

* 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 six 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.

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 three 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 four 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.

Troubleshooting the Heater Plug

Troubleshooting the Fuel Solenoid and Heater Plug

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.