Replacement of the Aftertreatment Regeneration Device (ARD) Combustion Head on Caterpillar Products with Clean Emissions Modules {108B, 108M} Caterpillar

Articulated Truck

725C (S/N: TFB1-UP)

730C (S/N: TFF1-UP)

730C EJECTOR (S/N: TFH1-UP)

735C (S/N: TFJ1-UP)

740C EJECTOR (S/N: TFN1-UP)

745C (S/N: TFK1-UP)

Engine

C13 (S/N: N3F1-UP; T4F1-UP; KWJ1-UP)

C15 (S/N: N5F1-UP; ENG1-UP; TXL1-UP; LDN1-UP; TXY1-UP)

C18 (S/N: N8F1-UP; BDN1-UP; RDP1-UP)

Excavator

349E (S/N: TFG1-UP; KCN1-UP; KFX1-UP; WHZ1-UP)

Industrial Engine

C13 INDUSTRIAL (S/N: RRA1-UP)

C7.1 (S/N: 7701-UP)

C9.3 (S/N: CS91-UP; MME1-UP; SSE1-UP; SYE1-UP; C9N1-UP)

Landfill Compactor

836K (S/N: B4K1-UP; TWZ1-UP)

Motor Grader

12M Series 3 (S/N: N9P1-UP; N9R1-UP)

140M Series 2 (S/N: M9D1-UP)

140M Series 3 (S/N: N9G1-UP; N9M1-UP)

14N (S/N: N9X1-UP)

160M Series 2 (S/N: M9K1-UP)

160M Series 3 (S/N: N9L1-UP; N9T1-UP)

16M Series 3 (S/N: N9Y1-UP)

Off-Highway Truck/Tractor

770G (S/N: RMA1-UP; KDH1-UP)

772G (S/N: RME1-UP; KEX1-UP)

Road Reclaimer/Soil Stabilizer

RM-500 (S/N: ASW1-UP)

Track-Type Tractor

D6T (S/N: KSB1-UP; ZJB1-UP; SLJ1-UP; GMK1-UP; KMR1-UP; WES1-UP; RCW1-UP; TMY1-UP; HTZ1-UP)

D7E (S/N: HKA1-UP; TJA1-UP; SSH1-UP; TAN1-UP)

D8T (S/N: AW41-UP; FMC1-UP)

D9T (S/N: REX1-UP)

Wheel Dozer

834K (S/N: B8M1-UP; TWY1-UP)

Wheel Loader

966M (S/N: KJP1-UP)

972M (S/N: A8P1-UP)

980M (S/N: KRS1-UP)

982M (S/N: K1Y1-UP)

988K (S/N: B4X1-UP; TWX1-UP)

Wheel Tractor-Scraper

621K (S/N: WTA1-UP)

627K (S/N: WTC1-UP)

631K (S/N: WTR1-UP)

637K (S/N: WTS1-UP; WTT1-UP; WTX1-UP)

Introduction

Do not perform any procedure in this special instruction until you have read this information and you understand this information.

Required Parts

Using Table 1 and Table 2 determine which ARD combustion head is needed for your application.

Procedure

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Illustration 1	g01994753
ARD combustion head (1) Spark plug (2) Wire for the heated nozzle (3) Flame detection temperature sensor

1. Remove spark plug (1) from the old ARD combustion head.

2. Remove flame detection temperature sensor (3).

3. Remove wire for the heated nozzle (2) from the old head.

4. Remove the ARD combustion head. Refer to the Disassembly and Assembly Manual, "Combustion Head Group (ARD) – Remove and Install (Clean Emissions Module)".
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   Illustration 2	g01994773
   (4) Gaskets (5) Studs

5. Remove gaskets (4).

6. Install new gaskets (4).

7. Apply 4C-5597 Anti-Seize Compound to the threads of studs (5).

8. Install the ARD combustion head. Refer to the Disassembly and Assembly Manual, "Combustion Head Group (ARD) – Remove and Install (Clean Emissions Module)".

9. Apply 4C-5597 Anti-Seize Compound to nuts (6). Tighten the nuts in a crisscross pattern to a torque of 23 ± 3 N·m (17 ± 2 lb ft). Tighten nuts (6) again in a crisscross pattern to a torque of 28 ± 3 N·m (21 ± 2 lb ft). Tighten nuts (6) again in a crisscross pattern to a torque of 28 ± 3 N·m (21 ± 2 lb ft).
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   Illustration 3	g01994838
   (7) Gasket for the ARD combustion air

10. Install a new gasket for the ARD combustion air (7).

11. Install the spark plug (1) from the old combustion head into the new combustion head. Torque the spark plug to 47 ± 4 N·m (35 ± 3 lb ft).

12. Install flame detection temperature sensor (3) into the new combustion head.

13. Install wire for the heated nozzle (2) into the new combustion head using new o-rings and lubricate the o-ring with isopropyl alcohol.

    Note: This connection is an electrical connection and cannot be lubricated with a petroleum-based lubricant. Isopropyl alcohol is the only approved lubrication for this connection.

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    Illustration 4	g01994855
    Typical example (8) Pilot fuel fitting (9) Main fuel fitting (10) Fittings for the coolant

14. Install the ARD coolant lines on fittings for the coolant (10). Tighten the lines to a torque of 25 ± 4 N·m (18 ± 3 lb ft).

15. Install the ARD pilot fuel line onto pilot fuel fitting (8). Tighten the line to a torque of 11 ± 2 N·m (8 ± 1.5 lb ft).

16. Install the ARD main fuel line onto main fuel fitting (9). Tighten the line to a torque of 11 ± 2 N·m (8 ± 1.5 lb ft).
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    If a visual inspection of the fuel line connections and the coolant line connections is not performed during the ARD ignition test, fuel leaks or coolant leaks may result in a fire hazard which could result in personal injury or death. Visual inspection of the fuel line connections and the coolant line connections is the only method to detect a fuel leak or a coolant leak on the ARD system. Visually inspect the fuel line connections and the coolant line connections at the ARD head and the ARD manifold when the ARD ignition test is active.

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    Illustration 5	g02016674

17. Perform a test for ARD ignition. Refer to Troubleshooting, "ARD Ignition - Test". Refer to Illustration 5.

    Note: The "ARD Ignition - Test" can be successful even if a fuel leak is present. The ARD ignition test pressurizes the main fuel line and pilot fuel line with pressure to help assist with detecting a leak. Visually inspect all fuel line connections for a leak during the test for the ARD ignition. Visual inspection is the only method in order to detect a fuel leak on the ARD system.

    Note: Also, check the fuel connections at the ARD fuel manifold and the connections for the coolant at the ARD combustion head for any possible leaks.

    Note: The soot load must be below 80 percent in order to perform an ARD Ignition Test.