Installing the Air Inlet Heater System{1090} Caterpillar


Installing the Air Inlet Heater System{1090}

Usage:

3406C(8PN1-UP)

NOTE: Do not perform any procedure outlined in this Special Instruction until you have read and understood all of the information.

Introduction

Low ambient temperatures below 0°C (32°F) may cause starting problems. Once the engine is started, excessive white smoke may also be a problem.

The Air Inlet Heater System is used to increase the inlet air temperature to prevent the development of excessive white smoke during and immediately after engine starting. The preheating of the inlet air improves the engine's cold starting ability at very low ambient temperatures and ensures smooth engine operation within the shortest possible time.

The 138-2150 Flame Start Plug is installed in the engine's air inlet elbow. It is activated electronically to start the preheat cycle. Once the flame start plug is at the required preheat temperature, a dash mounted indicator light will go out and the engine can be cranked over to start.

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

The flame is maintained after the engine is running. The system will run a minimum of four minutes and a maximum of six minutes. By doing so, the white smoke that normally occurs during and immediately after engine starting is reduced to a minimum.

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

Reference: Service Manual, SENR6550 3406C Diesel Truck Engine (8PN1-UP)

Parts Manual, SEBP2677 ... 3406C Diesel Truck Engine (8PN1-UP)

Installing the Air Inlet Heater System

Installing the 138-2150 Flame Start Plug

NOTE: The 138-2150 Flame Start Plug MUST be installed in the air inlet elbow upstream of the air inlet manifold.

NOTE: The air inlet elbow must be removed before installation of the flame start plug. Before removing the air inlet elbow, inspect the area of installation for sufficient clearance between the cab/hood and the flame start plug.

1. Remove the air inlet elbow.

2. If the air inlet elbow is not provided with a suitably positioned casting boss, an adapter plate or boss for mounting the flame start plug must be fabricated and welded in place. The procedure is as follows:

NOTE: The flame start plug should have a minimum of 25.4 mm (1.00 inch) of the flame tip exposed beyond the welded boss. This will ensure that carbon does not build up in the flame start plug. Carbon buildup will shorten the life of the flame start plug.

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

For aluminum air inlet elbows:

* Weld a 141-8950 Boss to the air inlet elbow, or fabricate an aluminum adapter plate 50.8 mm (2.00 inch) diameter x 12.0 mm (.50 inch) thick.

For steel air inlet elbows:

* Weld a 141-8949 Boss to the air inlet elbow, or fabricate a steel adapter plate 50.8 mm (2.00 inch) diameter x 12.0 mm (.50 inch) thick.


Example of the adapter plate/boss location (as close to vertical as possible) upstream from the air inlet manifold.

Installing a 141-8950 Boss or 141-8949 Boss

3. Position the 141-8950 Boss or the 141-8949 Boss as close to vertical as possible to the centerline of the air inlet elbow. Mark the location of the threaded hole, that is on the boss, onto the air inlet elbow.

4. Remove the boss and drill a 46 mm (1.81 inch) hole through the air inlet elbow.

5. Locate the 44 mm (1.73 inch) positioning step of the 141-8950 Boss or the 141-8949 Boss within the drilled hole that is now in the air inlet elbow. Tack weld the boss to the air inlet elbow to secure its position. Inspect the threaded hole in the boss for alignment to the drilled hole in the air inlet elbow.

6. Finish weld the boss to the air inlet elbow.

NOTE: The welded area should be inspected to ensure a complete weld/seal around the boss. Make sure that the interior of the air inlet elbow is free of any drill/tap cuttings.

Installing A Fabricated Adapter Plate

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

7. Position an adapter plate that is 50.8 mm (2.00 inch) diameter x 12.7 mm (.50 inch) thick as close to vertical as possible with the centerline of the air inlet elbow. Tack weld the adapter plate to the air inlet elbow to secure its position.

8. Finish weld the adapter plate to the air inlet elbow.

9. Locate and scribe the center of the adapter plate.

10. Drill a 46 mm (1.81 inch) diameter hole through the adapter plate and the air inlet elbow.

11. Tap an M32 mm x 1.5 mm thread into the adapter plate.

NOTE: The welded area should be inspected to ensure a complete weld/seal around the boss. Make sure that the interior of the air inlet elbow is free of any drill/tap cuttings.

12. Install the air inlet elbow.


Typical example of the installation

13. Install the 138-2150 Flame Start Plug into the air inlet elbow.

14. Install the 117-7001 Cover Group.


(1) 117-7001 Cover Group. (2) Ground stud.

NOTE: Most 3406C engines already have the 117-7001 Cover Group (1) installed. The cover group is located on the left side (as viewed from the flywheel end) top rear of the cylinder block. The cover group provides a ground stud (2) connection. If the engine is equipped with a plain, two bolt cover, it will need to be replaced by using the directions that follow.

15. Remove the two bolt cover, if equipped, and install a 4P-6789 Plate assembly and a 1S-9799 Seal.

16. Attach the plate assembly with two (2) 4L-6454 Bolts and two (2) 8T-4896 Washers.

Installing Fuel Supply Tee, Various Brackets, and Switches

17. Disconnect the fuel line from the clean side of the filter base. The fuel line runs from the fuel filter base to the fuel injection pump.

18. Remove the 90 degree elbow and seal that is at the fuel filter base.


(1) 030-7955 Fuel Supply Tee. (2) Bottom connection of the fuel supply tee.

19. Install the 030-7955 Fuel Supply Tee (1) and a 6V-5049 Seal.

20. Reconnect the fuel line from the fuel injection pump to the bottom tee connection (2). The other tee location is used to supply fuel to the solenoid valve.

Installing the Temperature Sensor Bracket and Temperature Sensor

21. Remove the two bolts from the front housing.


101-9646 Temperature Sensor.

22. Thread the 101-9646 Temperature Sensor into the 150-5028 Bracket assembly and tighten. Orient the sensor so that the harness connection faces the rear (flywheel) end of the engine and that the sensor end faces the front of the engine.


(1) Bolt, spacer, and washer in front housing. (2) Bolt and washer that hold the temperature sensor bracket assembly. (3) 150-5028 Temperature Sensor Bracket assembly.

23. Install a 1A-5964 Bolt, 152-1332 Spacer, and 5M-2894 Washer into the front housing. The bolt goes through the front housing and into the cylinder block. The bolt and spacer will ensure that the 150-5028 Temperature Sensor Bracket assembly is oriented correctly when tightened.

24. If the engine is equipped with a belt tightener, install a 1A-5964 Bolt and a 5M-2894 Washer through the 150-5028 Temperature Sensor Bracket assembly (with the sensor attached) and into the engine.

25. If the engine is not equipped with a belt tightener, install a 1A-5183 Bolt and a 5M-2894 Washer through the 150-5028 Temperature Sensor Bracket assembly (with the sensor attached) and into the engine.

Installing the Oil Pressure Switch

26. Remove the main oil gallery plug that is located on the right side of the engine block. Install a 3B-7722 Bushing into the cylinder block and a 101-5459 Oil Pressure Switch into the bushing.

Installing the Fuel Solenoid Mounting Bracket and Solenoid Valve

27. Install the fuel solenoid mounting bracket.


Typical fuel solenoid mounting bracket arrangement.

NOTE: Two fuel solenoid mounting brackets are provided. Depending upon the engine arrangement, there are three different fuel solenoid mounting bracket arrangements that can be used. All three fuel solenoid mounting bracket arrangements are supplied with the kit. Choose one of the three arrangements that is best suited to your engine arrangement.

* 143-4658 Bracket, 0S-0509 Bolt, and 5M-2894 Washer.
* 6I-3784 Bracket, (2) 0S-1588 Bolts, and (2) 5M-2894 Washers.
* 6I-3784 Bracket, (2) 0S-0509 Bolts, and (2) 5M-2894 Washers.

28. Install the 138-3316 Solenoid Valve. Use (2) 6V-8836 Bolts and (2) 9X-8267 Washers to mount the solenoid valve to the solenoid mounting bracket.

Installing the Engine Wiring Harness

29. Install the 138-2153 Engine Wiring Harness. Below is the 138-2153 Engine Wiring Harness schematic. Use the schematic as a general reference as to the layout of the wiring harness. Use the four routing drawings that follow as a reference for actual clip and wiring harness locations. The routing reference drawings show four different installations. One of the reference drawings should be applicable to your engine arrangement and installation.


Wiring harness schematic.


Wiring harness routing reference 1.


Wiring harness routing reference 2.


Wiring harness routing reference 3.


Wiring harness routing reference 4.

30. Attach a 4P-7581 Clip onto the block, just above the oil pressure switch, using 2H-3755 Bolt and 3E-4352 Washer. Attach the wiring harness to the clip with 3S-2093 Strap. Attach the 2-pin connector to the oil pressure switch.


Typical location for 4P-8134 Clip on the 116-8773 Fastener Group.

31. Attach a 4P-8134 Clip at the front of the engine above the temperature sensor on the 116-8773 Fastener Group and near the engine lifting bracket using a 1A-2029 Bolt and 5M-2894 Washer. Attach the wiring harness to the clip with 3S-2093 Strap. Attach the 2-pin connector to the temperature sensor by screwing the connector onto the sensor.

32. Attach two 4P-7581 Clips onto the engine block, above the fuel injection pump, using two 0S-0509 Bolts and two 5M-2894 Washers. Attach the wiring harness to the clips using two 3S-2093 Straps.

33. Remove the top bolt from the 117-7001 Cover Group and attach a 4P-8134 Clip to the cover. Attach the power supply and the P2 connector (6-pin) to the clip using a 3S-2093 Strap.


(1) Wire harness ground wire. (2) OEM negative battery cable.

34. Remove the OEM negative battery cable, if it is attached to the ground stud. Attach the wiring harness ground wire to the 117-7001 Cover Group ground stud using an 8T-4896 Washer and 6V-8801 Nut. Attach the OEM negative battery cable to the same ground stud, between two 8T-4896 Washers. Secure with a 6V-8801 Nut.

35. Route the wiring harness up to the fuel solenoid valve and the flame start plug. Attach the wiring harness to the solenoid valve by screwing the 2-pin connector onto the fuel solenoid valve.

36. Attach the large terminal black wire (wire ident no A275) to the ground location that is on the flame start plug. Use a 0L-1351 Bolt, (2) 5M-2894 Washers, and 9S-8752 Nut.

37. Attach the small terminal purple wire (wire ident no. A571) to one of the studs that is on top of the flame start plug. Use the nut and washer that is provided on flame start plug terminal.

NOTE: It does not matter which stud is used on the flame start plug to attach the purple wire.

Installing Fuel Lines

38. Install (1) 152-6838 Elbow onto the 7/16-20 45 degree flare end of the fuel solenoid valve. The other end of the fuel solenoid valve is a 9/16-18 37 degree flare end.

39. Install (1) 152-6838 Elbow on the 7/16-20 45 degree flare end connection that is on the flame start plug.

40. Fabricate (2) fuel lines. One fuel line must be connected between the fuel filter base at the tee, and the fuel solenoid valve. The second fuel line must be connected to the fuel solenoid valve and the flame start plug.

NOTE: Due to the many different fuel filter locations and the many different air inlet elbows and locations, several parts are being provided so that the fuel lines can be fabricated to the correct length. Refer to the chart below for the provided parts.

41. Tighten the fuel line nuts on both ends of the fuel lines. Refer to the Torque Specifications Manual for more information.

Installing the 149-7479 Electronic Control Unit (ECU)


Typical example of the ECU mounted to the firewall.

42. Securely mount and install the ECU in a dry location. The preferred location is under the dash near the steering column. This will ease in wiring the ECU and should prevent water from coming in contact with the ECU.

NOTE: Due to chassis variables, the actual mounting location may vary. The ECU can be mounted under the hood. If the ECU is mounted under the hood, the wire connections MUST face the down position.

Installing the 6I-3052 Indicator Light


Typical example of the indicator light installation.

NOTE: The indicator light must be installed in a visible position, as close as possible to the starting switch. It must also be in an area that provides sufficient clearance for the installation.

43. The indicator light requires a 19.05 mm (.75 inch) 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 of the indicator light.

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

44. Install the indicator light.

Installing Warning Labels

45. Install one 8T-2930 Warning Label on the dash, near the indicator light for the air inlet heater. Install one 8T-2930 Warning Label in the engine compartment or on the valve cover of the engine.

46. Install one 4P-6422 No Ether Warning Label on the air cleaner, near the air inlet.

47. Install one 101-9767 Starting Instruction Decal on the dash or on the visor.

General Installation Instructions/Recommendations

NOTE: Additional conduit may be needed for your specific application.

Connecting Electrical Wires from Installed Components to Wiring Harness


NOTICE

A grommet/bulkhead connector MUST be used when routing the wiring harness through the fire wall. Failure to install a grommet/bulkhead can cause damage to the harness wiring due to possible abrasion between the conduit and 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 the ground wire from the heater plug boss to the cylinder block for proper connection. Inspect all wiring/connections for proper grounding.

Fabricated Electrical Wires from Installed Components to Engine Connection

NOTE: Required wire lengths will vary by OEM.

Install the 145-6758 Harness assembly. The 145-6758 Harness assembly is routed from the engine to the chassis. Please note that the lengths of the wires may not be correct for all applications. Additional wire length may be added by splicing the wire and adding more. The wire that is spliced into the harness must be the same gauge as the wire being spliced.

Operating the Air Inlet Heater

This section will explain how to operate the air inlet heater. A brief explanation of how the air inlet heater functions is also included.

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

Preheat Mode

By switching the main key operated switch to the RUN position, the preheat mode begins. The list that follows includes information about the preheat mode:

* The preheat mode will last 40 to 60 seconds to warm the flame start plug.
* The indicator light on the dash must stay on for the duration of the preheat process.

------ WARNING! ------

The flame start plug will begin to heat as soon as the switch is activated to the ON (RUN) position. The flame start plug and the air inlet elbow will be too HOT to touch. Personal injury may occur if the flame start plug or the air inlet elbow is touched after the unit is activated. Avoid touching the flame start plug and the air inlet elbow.

-------WARNING!-------
* The preheat mode process is voltage dependent.
* Upon completion of the preheat mode, the indicator light on the dash will go out.
* The engine can now be started.

Starting the Engine

NOTE: Refer to the Operation and Maintenance Manual for your engine for the complete starting procedure. The information that follows refers to starting the engine when using an air inlet heater.

* The engine must be started no later than 30 ± 8 seconds after the indicator light goes out. The preheat mode is over when the indicator light goes out.
* The alternator must reach charging speed. When the alternator reaches charging speed, a signal is sent to the D+ terminal of the ECU.
* The oil pressure sensor must close. Oil pressure must be registered for the air inlet heater to operate.

If the alternator and oil pressure requirements are not met, the air inlet heater system will be switched off automatically. Locate the source of the problem. Refer to the service manual for your engine for more information. Once the problem is solved, perform the following steps in order to restart the engine.

1. The main key operated switch must be turned to the OFF position for several seconds before attempting to restart the engine.

2. Turn the main key operated switch to the ON position. The indicator light will illuminate, indicating the start of the preheating process.

3. The engine can be started after the indicator light goes out. Refer to the Operation and Maintenance Manual for your engine for the complete starting procedure.

After Starting the Engine

NOTE: Refer to the Operation and Maintenance Manual for your engine for the complete procedure after starting the engine. The information that follows is in addition to the information found in the After Starting The Engine section in the Operation and Maintenance Manual

* The engine speed must not be allowed to exceed low idle rpm for the duration of the air inlet heater process.
* The heating cycle is completed as soon as the indicator light goes out.
* The air inlet heater process is controlled automatically by the Electronic Control Unit (ECU). The inlet air heater system will operate for a minimum of four minutes and a maximum of six minutes.

Air Inlet Heater System Functional Checks

Fuel Lines

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

Replace/repair/tighten when required.

Checking the System At Ambient Temperature

The system can be checked for correct operation at any ambient temperature by performing the steps that follow.

* 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 Air Inlet Heater in this special instruction for further information.

Air Inlet Heater Phase

During the air inlet heater phase (indicator light ON), the fuel solenoid valve is energized. This allows fuel to flow to the flame start plug.

Use a test light or voltmeter to check current.

NOTE: The air inlet elbow, where the flame start plug is installed, will become hot in the area around the flame start plug, which indicates that the system is functioning properly. Do not touch the flame start plug or the air inlet elbow.

------ WARNING! ------

The flame start plug will begin to heat as soon as the switch is activated to the RUN position. The flame start plug and the air inlet elbow will be too HOT to touch. Personal injury may occur if the flame start plug or the air inlet elbow is touched after the unit is activated. Avoid touching the flame start plug and the air inlet elbow.

-------WARNING!-------

Monitoring Function

Fuel Solenoid Valve and Flame Start Plug

If the indicator light flashes (similar to a vehicle turn indicator) when the system is in the preheat mode, this will indicate an electrical defect in the fuel solenoid valve or the flame start plug. Perform the checks that follow if the indicator light flashes.

* If the glow plug heats up during the preheat mode, then check for voltage at the fuel solenoid valve.
* If voltage is present at the fuel solenoid valve, the fuel solenoid valve may not be operating. Check the fuel solenoid valve for a proper ground.

Important Notes

Premature Starting

NOTE: If the engine is started 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 main key operated switch to the ON position.

After completion of the preheat phase, the indicator light will go out, indicating the engine can be started.

NOTE: To prolong component life, the system should not be run through more than two back to back cycles.

Troubleshooting

Refer to the service manual for your engine for information on troubleshooting.

Maintenance

The air inlet heater does require regular maintenance. However, like any other system designed for a particular seasonal use, it should be checked for proper operation BEFORE it is needed.

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