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• Felix Wilber Florez Velazco

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Installing Optional Migration Kits on C9.3 through C15 ACERT Tier 4 Interim Machine Engines {1000, 1261, 1380, 775E} -REHS9720-09

-24/09/2015

-19/09/2017

i07181315

Installing Optional Migration Kits on C9.3 through C15 ACERT Tier 4 Interim Machine Engines {1000, 1261, 1380, 775E} SMCS - 1000; 1261; 1380; 775E Articulated Truck 735B (S/N: T4P1-UP) 740B (S/N: T4R1-UP) 740B EJECTOR (S/N: T4S1-UP) Excavator 336E (S/N: JEA1-UP; RZA1-UP; KED1-UP; YCE1-UP; TEG1-UP; BMH1-UP; FJH1-UP; GTJ1UP; JRJ1-UP; SSL1-UP; YEP1-UP; CMR1-UP; HDW1-UP; DPX1-UP; BZY1-UP; GNY1-UP; TMZ1-UP) 349E (S/N: FJB1-UP; ETC1-UP; DGE1-UP; SPG1-UP; TFG1-UP; RGH1-UP; FEJ1-UP; KCN1-UP; MZW1-UP; KFX1-UP; MPZ1-UP; WHZ1-UP) Mobile Hydraulic Power Unit 336E MHPU (S/N: PCE1-UP; RBS1-UP; T3Z1-UP) Motor Grader 12M Series 2 (S/N: F9B1-UP; F9M1-UP; R9P1-UP; R9S1-UP) 140M Series 2 (S/N: M9D1-UP; R9G1-UP; M9J1-UP; R9M1-UP) 160M Series 2 (S/N: M9E1-UP; M9K1-UP; R9L1-UP; R9T1-UP) Track-Type Tractor D6R (S/N: T3J1-UP) D6T (S/N: KSB1-UP; ZJB1-UP; JZC1-UP; DTD1-UP; EJJ1-UP; SLJ1-UP; GMK1-UP; RRK1-UP; TSM1-UP; WLM1-UP; PLR1-UP; JRW1-UP; RCW1-UP) D7E (S/N: TJA1-UP; TAN1-UP) D8T (S/N: MLN1-UP; FCT1-UP) Wheel Loader 966K (S/N: PBG1-UP; TFS1-UP) 966K Series XE (S/N: NGX1-UP) 972K (S/N: PEM1-UP; Z4W1-UP) 980K (S/N: W7K1-UP; NEP1-UP; GTZ1-UP)

Introduction Note: Order the emissions labels first. The ordering process can take some time. This Special Instruction is used for the installation of the optional migration kits on C9.3 through C15 ACERT Tier 4 Interim Machine Engines. Read the entire Special Instruction and understand the information before you perform any procedures.

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Migration Kit Part Numbers Table 1 Sales Model

Migration Kit Part Number

12M2

481-6747(1)

140M2 481-6748(1) 160M2 D6T

481-6751(1)

D7E

481-6752(1)

D8T

481-6753(1)

336E 481-8175(1) 336E H 349E

509-9290(1)

735

481-8176(1)

740

481-8177(1)

966K 966K XE

481-8178(1)

972K 980K (1)

481-8181(1)

Order the emissions labels first. The ordering process can take some time.

Note: All required parts listed in the Special Instruction are included in Table 1 kits.

Instructions for Ordering Migration/ Decertification Emissions Labels 1. Log on to the "Emissions Regulation and Conformance" website at the following web address: https://ercrequestspilotprogram.atlassian.net/servicedesk/customer/portal/2

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Illustration 1

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2. Click Option 3. Tier 4 Migration/Decertification.

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Illustration 2

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3. Click Migration / Decertification Request – C9.3 - C15. 4. The Migration / Decertification Request form will appear. All fields marked with an "*" must be completed. Refer to Table 1 for the Migration Kit Part Number. Note: Requests that do not have the decertification serial number included in "Section 5" and do not have the box checked which confirms that applicable local and national regulations permit the engine to be decertified will be rejected. 5. Proceed to TMI to determine the current "Engine Arrangement Number".

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Illustration 3

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(1) "Reference Number" field (2) Drop down box (3) "Retrieve Data" (4) Current "Engine Arrangement Number"

a. Enter the machine serial number in the "Reference Number" field. b. Select "Serial Number" in the drop-down box. c. Click "Retrieve Data".

Fuel System Conversion Required Parts Table 2 Sales Model

Cap for ARD Fuel Pump

Plug and O-ring for Diverter Valve

Cap for ARD Fuel Manifold

12M2 140M2 160M2

6V-9828

360-3693 Plug 033-6028 O-Ring Seal

6V-9829

D6T D7E D8T 336E

6V-9829

360-3693 Plug 033-6028 O-Ring Seal

6V-9829

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336E H 349E 735 740 966K 966K XE 972K 980K

Conversion Procedure

Illustration 4

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(1) Fuel diverter valve (2) Fuel outlet port fitting

1. Remove fuel diverter valve (1) from the ARD fuel pump. 2. Plug the diverter valve port with a 360-3693 Plug and 033-6028 O-Ring Seal. 3. Disconnect the existing fuel line from fitting (2) and cap the fitting with the cap assembly specified in Table 4. Note: The fuel pump will remain operational to prime the engine fuel system.

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Illustration 5

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(3) ARD fuel manifold inlet fitting (4) 6V-9829 Cap As

4. Disconnect the fuel line attached to fitting (3) and discard the hose. 5. Cap fitting (3) using cap assembly (4).

Exhaust System Conversion Required Parts Table 3 Sales Model

Muffler Kit Part Number

12M2

469-7576

140M2 469-7582 160M2 D6T

469-7582

D7E

469-7576

D8T

469-7583

336E 469-7582 336E H 349E

469-7584

735 469-7584 740

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966K 966K XE

474-4453

972K 980K

469-7584

Conversion Procedure

Illustration 6

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(1) Diesel Particulate Filter (DPF) straps (2) DPF center section

Illustration 7

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Incorrect alignment

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Illustration 8

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Correct alignment

1. Put identification marks on both sides of clamp assemblies (1) for installation purposes 2. Disconnect exhaust stack with outlet assembly. 3. Disconnect straps (1) to remove the diesel particulate filter group. 4. Attach a suitable lifting device to the DPF. 5. Remove the DPF center section. 6. Install new muffler kit specified in Table 3 in place of the DPF center section. Be sure to fully engage the pin and slot on both sides of the muffler. 7. Position the muffler assembly and tighten the new strap groups (1) to a torque of 15 +3/-0 N·m (11 +2/-0 lb ft) after aligning the new straps with the identification marks on the inlet and outlet sections.

Rework Procedure for 349E Machines have a possibility of exhaust leaking from the hole. 1. Plug the hole at the bottom of the exhaust pipe. 2. Use high temperature paste with a tolerance (above 600° C (1112° F)).

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Illustration 9

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3. Plug and spread the paste around the hole approximately 2 cm in diameter. As shown in Illustration 9.

Cooling System Conversion Required Parts Table 4 Sales Model

Plug Assemblies or Cap Assemblies for Coolant Fittings (Engine Side)

12M2 140M2 160M2

398-5598 Plug As 396-0404 Plug As

D6T

307-2671 Plug As 398-5612 Plug As

D7E

307-2671 Plug As 307-2673 Plug As

D8T (Std) D8T (EU)

353-5126 Plug As 353-5124 Plug As

336E 336E H

Plugs and O-rings for Coolant Fittings (CEM Side)

Two 6V-9828 Cap As

Two 9S-8002 Plugs Two 6V-9027 O-Ring Seals

349E 735B 740B

398-5612 Plug As 353-5124 Plug As

966K 966K XE

396-0405 Plug As 396-0404 Plug As

972K 980K

353-5140 Plug As 6V-9828 Cap As

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Conversion Procedure 12M2, 140M2, and 160M2 Motor Graders

Illustration 10

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(1) 398-5598 Plug As (2) 396-0404 Plug As

1. Disconnect the coolant lines and remove the fittings from the locations shown in Illustration 10. Replace the existing fittings with plugs (1) and (2). 2. Remove and discard coolant lines from the machine. D6T Track-Type Tractors

Illustration 11

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(3) 307-2671 Plug As (4) 398-5612 Plug As

1. Disconnect the coolant lines and remove the fittings from the locations shown in Illustration 11. Replace the existing fittings with plugs (3) and (4). 2. Remove and discard coolant lines from the machine. D7E Track-Type Tractors

Illustration 12

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(5) 307-2671 Plug As (6) 307-2673 Plug As

1. Disconnect the coolant lines and remove the fittings from the locations shown in Illustration 12. Replace the existing fittings with plugs (5) and (6). 2. Remove and discard coolant lines from the machine. D8T Track-Type Tractors

Illustration 13

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(7) 353-5126 Plug As (8) 353-5124 Plug As

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1. Disconnect the coolant lines and remove the fittings from the locations shown in Illustration 13. Replace the existing fittings with plugs (7) and (8). 2. Remove and discard coolant lines from the machine. 336E and 349E Excavators

Illustration 14

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(9) 6V-9828 Cap As

1. Disconnect the coolant lines and cap the lines shown in Illustration 14 with cap assemblies (9). 2. Remove and discard coolant lines from the machine. 735B and 740B Articulated Trucks

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Illustration 15

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(10) 398-5612 Plug As (11) 353-5124 Plug As

1. Disconnect the coolant lines and remove the fittings from the locations shown in Illustration 15. Replace the existing fittings with plugs (10) and (11). 2. Remove and discard coolant lines from the machine. 966K and 972K Wheel Loaders

Illustration 16

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(12) 396-0405 Plug As (13) 396-0404 Plug As

1. Disconnect the coolant lines and remove the fittings from the locations shown in Illustration 16. Replace the existing fittings with plugs (12) and (13). 2. Remove and discard coolant lines from the machine. 980K Wheel Loaders

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Illustration 17

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(14) 6V-9828 Cap As (15) 353-5140 Plug As

1. Disconnect the coolant lines and remove the fittings from the locations shown in Illustration 17. Replace the existing fittings with cap (14) and plug (15). 2. Remove and discard coolant lines from the machine. All Applications

Illustration 18

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Typical example (16) ARD coolant manifold (17) Coolant lines

1. Disconnect coolant lines (17) from manifold (16). Remove and discard coolant lines (17) from the machine. 2. Replace the coolant fittings on manifold (16) with two 9S-8002 Plugs and two 6V-9027 O-Ring Seals.

Engine Software Note: When migration kit rework has been completed, the technician must confirm that the latest machine software and monitor software is installed. If not, the latest machine software and monitor software must be installed at the same time as the new engine software. Table 5 Sales Model

Software Part Number

12M2

483-3705

140M2

483-3704

160M2

483-3703

D6T

486-2751

D7E

487-6050

D8T

482-9922

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336E

481-8234

336E H

481-8235

349E

507-8936

735

483-3650

740

483-4183

966K

483-7468

966K XE

483-7470

972K

483-7467

980K

483-7465

Note: Factory passwords are required to install the decertification flash file. 1. Download the decertification flash file from Service Information System (SIS). Refer to Table 5. 2. Factory passwords will be issued utilizing the Dealer Solution Network (DSN).

Illustration 19

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3. When the decertification flash file is downloaded, this screen will appear in the electronic service tool. Refer to Illustration 19. 4. Click "Save to File". This action will create an HTML file. 5. Attach the HTML file to the DSN factory password request. Do not change the file to a PDF format. 6. The following text must be included in the DSN factory password request: This password request is for the decertification procedure outlined in Special Instruction, REHS9720. I acknowledge that the applicable local and national regulations permit engine serial number to be decertified, and I will ensure export from the country if the decertified machine no longer complies with local or national regulations governing the sale and/or use of the machine. The labels to confirm that this decertification has been ordered and will be applied as per Special Instruction, REHS9720. Note: Any service requests for passwords that do not contain the above verbiage will be rejected

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7. Once the factory passwords have been entered, install the flash file. Refer to Troubleshooting, "ECM Software - Install"

Machine Labels The certified emissions labels are located in the machine cab and on the engine block. These labels must be removed. The new decertified emissions labels must then be installed in the machine cab and on the engine block. Refer to the information below for label removal and installation instructions.

Removing Adhesive Labels

NOTICE Do not install the new film over the old film. Layered labels compromise label adhesion and durability. Adhesive films must be applied to a clean, dry, smooth painted surface. Surface temperature should be between 15° C (59° F) and 27° C (80.6° F).

1. Remove films and discard the pieces. 2. Clean the surface with a 1:1 mixture of isopropyl alcohol (IPA) and water. Use a clean, lint-free paper towel to remove all dirt and adhesive from the surface. Allow the surface to dry before installing the replacement films. Note: Never use acetone (propanone) to clean the engine or label surface.

Applying Adhesive Labels 1. Carefully remove the new film from the backing. Immediately apply the label in place of removed film. Note: Avoid trapping air bubbles under the label material. 2. Apply pressure to entire label to ensure adhesion. 3. Wait at least 60 minutes before disturbing the labels.

Removing Spark Plug Maintenance Interval Information on 336E and 349E Excavators

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Illustration 20

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1. Use the following steps to set the "Spark Plug" interval to "0". a. Press "Service" in the main menu. b. Press "Configuration". c. Press "Recommended Interval". d. Press "Spark Plug" e. Set the interval to "0". 1. Use the following steps to set the "Fuel Priming Pump" interval to "Off". a. Press "Service" in the main menu. b. Press "Configuration". c. Press "Recommended Interval". d. Press "Fuel Priming Pump" e. Set the interval to "Off". Note: Once the "Recommended Interval" is set as "0", the spark plug information is no longer shown on the "Maintenance Intervals" menu.

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Illustration 21

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Disabling the Product Link Lockout on 336E and 349E Excavators If Product Link Japan is installed on migrated machine, the machine lockout system must be disabled. This disable configuration setting is needed to prevent the engine start limitation. 1. Access to machine ECM configuration in Caterpillar Electronic Technician (Cat ® ET). 2. Change the "Machine Lockout System Installation Status" to the setting of "Not Installed". 1993 — 2018

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