730C-725C T4F SVC ITTP M03 T4 FEng SupSys EN INS
730C-725C T4F SVC ITTP M03 T4 FEng SupSys EN INS
SERV1977
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SERV1977 - 09/13 -2- Module 3 - Tier 4 Final Engine and Support Systems
TABLE OF CONTENTS
MODULE DESCRIPTION........................................................................................................... 3
MODULE PRE-WORK............................................................................................................... 4
RECOMMENDED DELIVERY.................................................................................................... 5
PREPARATION CHECKLIST..................................................................................................... 6
LESSON PLAN........................................................................................................................... 8
LEARNING OUTCOMES........................................................................................................... 9
LABORATORY EXERCISES..................................................................................................... 10
POST-ASSESSMENT............................................................................................................... 16
MODULE DESCRIPTION
MODULE OBJECTIVE This module is designed to introduce the C9.3 and C13 ACERT technology Tier 4
Final engine and support systems. Major component locations of the engine,
cooling system, intake air and exhaust system, and fuel system are discussed and
basic operational strategies are explained. Lab exercises and a written
Post-Assessment will be used for skills development and a knowledge check.
Participants will be expected to demonstrate knowledge and proficiency in each
major area of instruction.
This module includes approximately 50% theory (classroom) and 50% practical (lab
exercises).
MODULE PRE-WORK
PREREQUISITE COURSES Successful completion of the following web-based training courses are
recommended before receiving the engine and emissions training contained in this
engine module.
-- Tier 4 Interim Regeneration Strategy - DPC Course # 33983
-- Tier 4 Interim Air Systems - DPC Course # 33980
-- Tier 4 Interim Aftertreatment - DPC Course # 33979
-- Tier 4 Interim Systems Overview - DPC Course # 33963
-- Tier 4 Interim Regeneration Operator Interface - DPC Course # 33984
-- Tier 4 Interim Knowledge Assessment - DPC Course # 41913
-- Tier 4 Final C7.1 to C18 Engine Systems Overview -
DPC Course # 40223
-- Tier 4 Final Operator Interface Warnings and Inducements -
DPC Course # 40917
Successful completion of the following instructor led training courses are also
recommended before receiving the engine and emissions training contained in this
engine module.
-- Electronics Troubleshooting ILT - # 26679 ILT
RECOMMENDED DELIVERY
TIME Estimated Delivery Time
3 hrs
ENVIRONMENT Classroom
______ Projector
______ Whiteboard
Lab
Parts Book
725C Articulated Trucks Parts Manual (HRC) SEBP6404
730C Articulated Trucks Parts Manual (HRC) SEBP5991
730C Ejector Articulated Trucks Parts Manual (HRC) SEBP6816
725C Articulated Trucks Parts Manual (LRC) SEBP6403
730C Articulated Trucks Parts Manual (LRC) SEBP6817
730C Ejector Articulated Trucks Parts Manual (LRC) SEBP5994
PREPARATION CHECKLIST
MODULE Prior to conducting the module, gather the following materials:
A printed copy of the following for the classroom training session and lab exercises
and access to SIS Web or SIS DVD:
CLASSROOM Prior to delivering the classroom module, perform the following steps:
______ Check for applicable Service Magazine articles, Service Letters, and
Technical Information Bulletins related to the topic.
LABS Prior to conducting the lab exercise(s), perform the following steps:
______ Review the lab exercise(s) to ensure participants can demonstrate their
ability to accomplish the objectives.
______ Basic hand tools to remove guards and/or panels to access all engine
components for the location and identification lab exercise.
LESSON PLAN
• Provide each participant with a Participant Introduction, Module Objective, and Learning Outcomes
copy of the module objectives
and learning outcomes. Instructor and participant introductions, if not already done
Safety briefing, objectives, class agenda, and hand out participant materials,
if not already done
• Distribute Lab 1 Worksheets Classroom visual presentation of machine Introduction (as required) and
Tier 4 Final Engine and Support Systems; participants take notes on
component location and functionality using the Lab 1 Worksheets.
• Conduct Lab 1 Lab 1: 725C/730C/730C EJ Articulated Trucks Tier 4 Final Engine and Support
Systems Component Identification and Function
LEARNING OUTCOMES
You will meet the following learning outcomes during the presentations, laboratory
exercises, and post-assessment in this Tier 4 Final Engine and Support Systems
module of the 725C, 730C, and 730C EJ Articulated Truck course:
• Visual Presentation 1. Given the classroom presentation and the Lab 1 Worksheet(s), participants will
take notes on the identification, location, and the basic function of major
components and service points of the C9.3 and/or the C13 ACERT™ technology
engine and support systems.
• Lab 1 1. Given the Lab 1 Worksheet(s) and a 725C, 730C, and/or a 730C EJ Articulated
Truck, participants will locate, identify, and confirm the basic functionality of the
major components of the C9.3 and/or the C13 ACERT technology engine and
support systems.
• Post-Assessment 1. Given the classroom presentation, all reference materials and class notes,
participants will answer questions regarding the flow of fuel through the engine
and aftertreatment fuel delivery systems during a Post-Assessment with at least
80% accuracy.
2. Given the classroom presentation, all reference materials and class notes,
participants will answer questions regarding the flow of air through the engine air
intake, exhaust, and NOX reduction systems during a Post-Assessment with at
least 80% accuracy.
3. Given the classroom presentation, all reference materials and class notes,
participants will answer questions regarding the flow of coolant through the
engine cooling system during a Post-Assessment with at least 80% accuracy
LABORATORY EXERCISES
INSTRUCTOR NOTE The following section provides directions to set up, facilitate, and assist during the
lab exercise(s).
Some lab exercises are the written type with worksheets, while other labs are the
traditional “on the iron” labs. Answers are provided in this document for the worksheet
exercise(s).
The participant lab sheet(s), along with accompanying materials, are located in the
Student Material PDF (included in the module PDF).
NOTE: Discuss safety procedures with the participants for each shop lab (i.e.
safety glasses, clothing). Safely Home. Everyone. Every Day.™
EXERCISE Participants will form teams of two persons and will identify the location and explain
the basic functionality of the major components, service points, and troubleshooting
points of the Tier 4 Final engine and support systems components using the
Lab 1 Worksheets.
Procedure: Explain the lab exercise. Inform participants they may refer to their
printed materials and notes while completing the exercise. Participants will use the
Lab 1 Worksheets to document completion of the task.
At the end of the lab exercise, the instructor should gather the participants to
discuss the results of the exercise and answer any questions from the participants.
MATERIALS NEEDED ______ 725C, 730C, and/or a 730C EJ Articulated Truck with Tier 4 Final engine.
LAB 1: 7 25C/730C/730C EJ Articulated Trucks TIER 4 FINAL ENGINE AND SUPPORT SYSTEMS Component
Identification and Function
Directions: Use this checklist to take notes during the classroom presentation regarding component function and location.
During the lab exercise, use these sheets as a checklist when locating and identifying components.
Function: [Filters engine oil to remove contaminants - the S•O•S port allows engine oil samples to be taken]
Function: [10-micron filter that removes large contaminants from the fuel - sediment bowl removes and
provides a container to hold water that may be present in the fuel]
Function: [Provides low pressure fuel flow to prime the fuel system when the switch is moved to ON or the
key-start switch is moved to the START position]
Location: [Priming pump is installed in the primary fuel filter base - front left of the engine compartment,
beneath the hood : switch is located on the fuel filter bracket, above the primary fuel filter base.]
Function: [Two 4-micron filters that remove fine contaminants from the fuel]
Function: [ENERGIZED by the Engine ECM at key ON to prime the fuel system - DE-ENERGIZED all other
times]
Location: [Installed in the primary fuel filter base - front left of the engine compartment, beneath the hood ]
Function: [Mechanical metal level gauge that allows visual confirmation of the engine oil level in the oil pan]
Function: [Small filter that removes most oil and other contaminants from the vapors emitted through the
engine crankcase breather tube]
LAB 1: 7 25C/730C/730C EJ Articulated Trucks TIER 4 FINAL ENGINE AND SUPPORT SYSTEMS Component
Identification and Function (CONT’D.)
Function: [Allows access to the engine air filter for service or replacement]
Function: [Allows engine oil to be added or replaced to the engine oil system]
Location: [On top of the engine valve cover, accessible from either side of the engine compartment]
Location: [Installed on top of the coolant tube from the thermostat housing - accessible from the right side of
the engine compartment]
Function: [Contains the thermostat(s) that regulate the flow of coolant to the radiator when the engine is hot]
Location: [Top, right corner of the engine(s), accessible from the right side of the engine compartment]
Function: [Allows the timing calibration probe to be threaded into the block to perform a timing calibration]
Location: [Bottom, rear of the oil pan, on the right side of the engine - accessible through a panel beneath the
engine compartment right side]
Function: [Monitors and controls all electronic components mounted to the engine]
_______ Alternator
Function: [Provides electrical energy to power all machine electronics and maintain machine battery charge]
LAB 1: 7 25C/730C/730C EJ Articulated Trucks TIER 4 FINAL ENGINE AND SUPPORT SYSTEMS Component
Identification and Function (CONT’D.)
Function: [Draws fuel from the fuel tank and provides fuel flow through the engine fuel system]
Location: [Installed to the rear of the timing gear housing, on the left side of the engine (both engines)]
Function: [Maintains fuel pressure to the MEUI injector on the C13 engine - maintains the fuel cooling loop
pressure in the cylinder head on the C9.3 engine]
Location: [Installed in the small manifold at the left rear corner of the engine, above the Engine ECM]
_______ Starter
Function: [Engages with and turns the engine flywheel to start the engine when the key switch is turned to the
START position]
Location: [Installed to the front of the flywheel housing at the left rear of the engine(s)]
_______ Radiator
Function: [Provides for cooling the engine coolant when the engine is warm and the thermostats open]
Location: [Installed at the rear of the tractor, inside the cooling compartment, forward of the hydraulic fan]
Function: [Connects the TDC service probe to the engine electrical system when using Cat ET to perform the
engine timing calibration routine]
Location: [Tied to the upper wiring harness above the Engine ECM ]
_______ ATAAC
Function: [Cooler core that cools the intake air being forced through it by the turbocharger compressor]
Location: [Large cooler core at the front, center of the engine compartment]
Function: [Cools the fuel returning from the fuel pressure regulator prior to flowing to the fuel tank]
Location: [Small bottom cooler core forward of the ATAAC at the front center of the engine compartment]
Function: [Allows checking of the coolant level and addition of engine coolant into the cooling system]
Location: [On top of the cooling compartment, at the left rear of the tractor]
LAB 1: 7 25C/730C/730C EJ Articulated Trucks TIER 4 FINAL ENGINE AND SUPPORT SYSTEMS Component
Identification and Function (CONT’D.)
Function: [Allows all coolant to be drained from the engine cooling system]
Location: [Located beneath and inside the left tractor frame rail, forward of the front axle]
POST-ASSESSMENT
INSTRUCTOR NOTE The following Post-Assessment is a paper test designed to measure the
participant’s ability to identify the major components of and determine the general
knowledge of the Tier 4 Final engine fuel systems, air systems, and cooling
systems in the 725C, 730C, and 730C EJ Articulated Trucks. The answers are
provided on the following pages. The actual participant Post-Assessments are
provided in the Participant Materials section.
Participants may refer to their course materials and class notes when taking the
Post-Assessment.
MATERIALS NEEDED ______ 725C/730C/730C EJ Articulated Trucks Tier 4 Final Engine and Support
Systems Post-Assessment
(17)
(11) (10)
(8) (12)
(18)
(5)
(14) (7) (3)
(13)
(15) P (2)
(1)
(16)
(6)
(4)
(9)
18_1
725C/730C/730C EJ Articulated Trucks Tier 4 Final Engine and Support Systems Post-Assessment
Trace the flow of fuel through C9.3 ACERT technology engine fuel delivery system.
Directions - Part 1: Write the numbers in the blanks below to show the sequential order of fuel flow through the Emissions
Fuel Circuit beginning with the fuel tank.
1. [12] 2. [3] 3. [10] 4. [11]
Directions - Part 2: Write the numbers in the blanks below to show the sequential order of fuel flow through the Engine Fuel
Circuit, beginning with the fuel tank and ending at the high pressure fuel pump.
1. [12] 2. [10] 3. [3] 4. [16] 5. [7] 6. [14] 7. [6]
Directions - Part 3: Write the numbers in the blanks below to show the sequential order of fuel flow through the High Pressure
Fuel Circuit, beginning with the high pressure fuel pump and ending with the fuel tank. [NOTE: Answers for questions #3 and
#4 can be exchanged, as they occur at the same time]
1. [6] 2. [2] 3. [8] 4. [5] 5. [4] 6. [1] 7. [12]
Directions - Part 4: Write the numbers in the blanks below to show the sequential order of fuel flow through the Low
Pressure Fuel Circuit, beginning with the high pressure fuel pump and ending with the fuel tank.
1. [6] 2. [8] 3. [13] 4. [4] 5. [1] 6. [12]
(2) (6)
(1)
(10) (3)
(4)
(13)
(4)
(7)
(12)
19_1
7725C/730C/730C EJ Articulated Trucks Tier 4 Final Engine and Support Systems Post-Assessment (Cont’d)
Trace the flow of fuel through C13 ACERT technology engine fuel delivery system.
Directions - Part 1: Write the numbers in the blanks below to show the sequential order of fuel flow through the Emissions
Fuel Circuit beginning with the fuel tank.
1. [3] 2. [5] 3. [6] 4. [1]
Directions - Part 2: Write the numbers in the blanks below to show the sequential order of fuel flow through the Engine Fuel
Circuit, beginning with the fuel tank and ending at the fuel tank. Include the fuel tank number at the beginning and at the end.
1. [3] 2. [6] 3. [5] 4. [7] 5. [9] 6. [11] 7. [10]
(4)
(2)
(12)
(7)
(6)
(8)
(3)
(15) (16)
(1)
(10) (13)
(9)
(5)
(11)
20_1
725C/730C/730C EJ Articulated Trucks Tier 4 Final Engine and Support Systems Post-Assessment (Cont’d)
Identify the components in the 725C, 730C, and 730C EJ Articulated Trucks engine air, exhaust, and NOx reduction systems.
Assessment Directions: Fill in the blanks next to the numbers with the correct term.
10. [Engine] 11. [Balance valve solenoid] 12. [NRS cooler outlet]
13. [NRS venturi] 14. [Clean Emissions Module (CEM)] 15. [Exhaust from cylinders 1, 2, 3]
Cooling Compartment
SCR
CEM
Overflow
Tube DPF
Shunt ARD
Tank DEF
Injector
Cab
Heater S•O•S
≥ 92°C Hottest
Water
Temperature
Vent Regulator
Lines PETU
Increasing
87°C Coolant NRS Cooler
Temperature Internal
Air Bypass
Demand Passage
Fan Flow
C9.3 Engine
≤ 81°C Coldest
Coolant
Manifold Transmission
Oil Cooler
21_1
725C/730C/730C EJ Articulated Trucks Tier 4 Final Engine and Support Systems Post-Assessment (Cont’d)
Trace the flow of coolant through 725C Articulated Truck cooling system.
Directions - Part 1: W
rite the component names in the blanks below to show the sequential order of coolant flow through the
CEM Cooling Circuit, beginning and ending with the jacket water pump.
Directions - Part 2: W
rite the component names in the blanks below to show the sequential order of coolant flow through the
C9.3 Engine Cooling Circuit, beginning and ending with the jacket water pump, with a cold engine.
Directions - Part 3: W
rite the component names in the blanks below to show the sequential order of coolant flow through the
C9.3 Engine Cooling Circuit, beginning and ending with the jacket water pump, and a warm engine.
≥ 92°C Hottest
Water
Temperature
Regulators
PETU
Increasing
87°C Coolant NRS Cooler External
Temperature Bypass
Demand Air Tube
Fan Flow
C13 Engine
≤ 81°C Coldest
Engine
Oil Cooler
Transmission
Oil Cooler
Radiator Drain Jacket
Valve Water Pump
22_1
725C/730C/730C EJ Articulated Trucks Tier 4 Final Engine and Support Systems Post-Assessment (Cont’d)
Trace the flow of coolant through 730C/730C EJ Articulated Truck cooling system.
Directions - Part 1: W
rite the component names in the blanks below to show the sequential order of coolant flow through the
CEM Cooling Circuit, beginning and ending with the jacket water pump.
Directions - Part 2: W
rite the component names in the blanks below to show the sequential order of coolant flow through the
C13 Engine Cooling Circuit, beginning and ending with the jacket water pump, with a cold engine.
7. [Jacket water pump] [NOTE: #3 and #4 can be interchanged, here and below, as they occur at the same time.]
Directions - Part 3: W
rite the component names in the blanks below to show the sequential order of coolant flow through the
C13 Engine Cooling Circuit, beginning and ending with the jacket water pump, and a warm engine.