Global service training

725C / 730C / 730C EJ articulated trucks 

Emissions System
Module 4 - INSTRUCTOR MATERIALS (COMPETENCY STANDARD)

SERV1977

CAT, CATERPILLAR, their respective logos, ACERT, “Caterpillar Yellow” and the POWER EDGE
trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar
and may not be used without permission. © 2013 Caterpillar Inc. All Rights Reserved.
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TABLE OF CONTENTS
MODULE DESCRIPTION........................................................................................................... 3
MODULE PRE-WORK............................................................................................................... 4
RECOMMENDED DELIVERY.................................................................................................... 5
PREPARATION CHECKLIST..................................................................................................... 6
LESSON PLAN........................................................................................................................... 8
LEARNING OUTCOMES.......................................................................................................... 10
LABORATORY EXERCISES......................................................................................................11

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MODULE DESCRIPTION
MODULE OBJECTIVE This module is designed to introduce the 725C, 730C, and 730C EJ Articulated
Trucks Tier 4 Final emissions systems. Major component locations of the CEM,
ARD, PETU, DEF tank, NOX sensors, and DEF injector are discussed and basic
operational strategies for these machines are explained. Lab exercises 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).

AUDIENCE Level II--Field service personnel, resident mechanics, Technical Communicators,

and shop technicians. All participants should have a working knowledge of basic
electrical, electronic, and hydraulic control systems on Cat machines.

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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 Tier 4 Final emissions 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

PREREQUISITE TESTS There are no prerequisite tests for this module.

SUGGESTED READING There is no suggested reading for this module.

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RECOMMENDED DELIVERY
TIME Estimated Delivery Time

3 hrs, 15 MIN

ENVIRONMENT Classroom

Minimum 4 participants; maximum 8 participants

______ 2-4 Tables; 2 participants/table

______ Projector

______ Whiteboard

______ Participant materials

Lab

Participant/Instructor ratio = 8:1 (suggested maximum)

______ 725C, 730C, and/or 730C EJ Articulated Truck

REFERENCES Service Manual Modules Form No.

Safety SENR7733
725C Operation and Maintenance Manual (HRC and LRC) SEBU8786
730C Operation and Maintenance Manual (HRC and LRC) SEBU8785
730C Ejector Operation and Maintenance Manual (HRC and LRC) SEBU9051
AT Monitoring System - Systems Operation UENR2353
725C Articulated Truck Specifications UENR2380
730C & 730C Ejector Articulated Truck Specifications UENR2345
C9.3 Engines for Caterpillar Built Machines - Sys-Op/T&A UENR3432
C9.3 Engines for Caterpillar Built Machines - Engine Specifications UENR3431
C9.3 Engines for Caterpillar Built Machines - Troubleshooting UENR3433
C13 Engines for Caterpillar Built Machines - Sys-Op/T&A UENR3351
C13 Engines for Caterpillar Built Machines - Engine Specifications KENR9330
C13 Engines for Caterpillar Built Machines - Troubleshooting UENR0955

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

Integrated Technical Training Package (ITTP) Modules

725C/730C/730C EJ Articulated Trucks - Introduction SERV1977
725C/730C/730C EJ Articulated Trucks - Emissions System SERV1977

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PREPARATION CHECKLIST
MODULE Prior to conducting the module, gather the following materials:

______ PDF: ITTP module “725C/730C/730C EJ Articulated Trucks Introduction”

______ PDF: ITTP module “725C/730C/730C EJ Articulated Trucks - Emissions

System”

A printed copy of the following for the classroom training session and lab exercises
and access to SIS Web or SIS DVD:

______ Service Manual Module “Safety” (SENR7733)

______ Service Manual Module “Operation and Maintenance Manual” (SEBU8755)

CLASSROOM Prior to delivering the classroom module, perform the following steps:

______ Prepare a safety briefing containing the following information:

• emergency phone numbers

• first aid responders
• location of exits and fire extinguisher
• room alerts or hazards
• designated location for evacuation
• storm shelter
• hazardous material

______ Review the 725C/730C/730C EJ Articulated Trucks Introduction Text

Reference and the appropriate Operation and Maintenance Manual(s) (see
service manual references).

______ Review the 725C/730C/730C EJ Articulated Trucks Emissions System Text

Reference to become familiar with the topic.

______ Duplicate enough 725C/730C/730C EJ Articulated Trucks Emissions

System Text Reference for each participant in the training session or
provide an electronic copy.

______ Duplicate enough 725C/730C/730C EJ Articulated Emissions System

Participant Materials for each participant in the training session.

______ Check for applicable Service Magazine articles, Service Letters, and
Technical Information Bulletins related to the topic.

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LABS Prior to conducting the lab exercise(s), perform the following steps:

______ Prepare a safety briefing of the lab(s) to be conducted.

______ Select the articulated truck to be used in the lab exercise(s).

______ Make resource/instructional tags for lab exercise(s) as needed.

______ Review the lab exercise(s) to ensure participants can demonstrate their
ability to accomplish the objectives.

Gather the following tools and materials:

______ Basic hand tools to remove guards and/or panels to access all engine
components for the location and identification lab exercise.

______ Laptop computer with the latest version of Cat ET and COM Adapter III

______ 431-7087 Tool Group (Refractometer)

______ 441-0451 Test Kit (DEF Dosing Test Kit)

______ 207-1601 Rubber Lubricant

______ LOCTITE C-5A Copper Anti-Seize

______ DEF Injector seal and gasket kit (One-time use parts - check SIS for
newest part numbers)

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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

Time Estimate: 15 min

• Visual Presentation Visual Presentation:

• Distribute Lab 1 Worksheets Classroom visual presentation of machine Introduction (as required) and
Emissions System; participants take notes on component location and
functionality using the Lab 1 Worksheets.

Time Estimate: 1 hour

• Conduct Lab 1 Lab 1: 725C/730C/730C EJ Articulated Trucks Emissions System Component

Identification and Function

Give safety briefing and describe objective of lab.

Use Lab 1 Worksheets: 725C/730C/730C EJ Articulated Trucks Emissions

System Component Identification and Function

 articipants locate and explain functionality of emissions system

P
components on class machine.

Review completed Lab 1 Worksheets with the class and answer any
questions by participants.

Time Estimate: 45 min

• Conduct Lab 2 Lab 2: 725C/730C/730C EJ Articulated Trucks Emissions System : DEF

Quality Test and Aftertreatment SCR System Dosing Test

Give safety briefing and describe objectives of lab.

No lab worksheets are needed for this exercise.

 articipants follow the testing procedures found in the engine testing and
P
adjusting manuals to properly test the Diesel Exhaust Fluid (DEF) quality
and properly test the SCR system for proper DEF dosing on the class
machine.

Discuss the Lab 2 testing outcomes and answer any questions by

participants.

Time Estimate: 45 min

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• Conduct Lab 3 Lab 3: 725C/730C/730C EJ Articulated Trucks Emissions System : Data Link
Test

Give safety briefing and describe objectives of lab.

No lab worksheets are needed for this exercise.

 articipants follow the troubleshooting procedure found in the engine

P
troubleshooting manuals to test the machine data links for proper
connectivity and communications using the class machine.

Discuss the Lab 3 test outcomes and answer any questions by

participants.

Time Estimate: 30 min

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LEARNING OUTCOMES
You will meet the following learning outcomes during the presentations, laboratory
exercises, and post-assessment in this Emissions System module of the 725C,
730C, and 730C EJ Articulated Truck course:

• Visual Presentation 1. Given the classroom presentation of the Emissions System, participants will take
notes on the identification, location, and the basic functionality of the major
components and service points of the engine emissions system.

• 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 engine emissions system.

• Lab 2 1. Given a 725C, 730C, and/or a 730C EJ Articulated Truck, participants will use
the tools listed in the Preparation Checklist and follow the testing procedures
found in the engine testing and adjusting manuals to properly test the DEF
quality and properly test the SCR system for proper DEF dosing.

• Lab 3 1. Given a 725C, 730C, and/or a 730C EJ Articulated Truck, participants will use
the tools listed in the Preparation Checklist and follow the testing procedures
found in the engine troubleshooting guide to properly test the machine data link
system for proper communications.

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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).

At the beginning of each lab, review the lab description.

NOTE: Discuss safety procedures with the participants for each shop lab (i.e.
safety glasses, clothing). Safely Home. Everyone. Every Day.™

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LAB 1: 7 25C, 730C, and/or a 730C EJ Articulated

Truck EMISSIONS SYSTEM COMPONENT
IDENTIFICATION AND FUNCTION
INSTRUCTOR NOTE Lab Exercise

This is a shop exercise. Ensure participants understand the recognized safety

zones in, on, and around the machine.

SAFETY Participants will adhere to all applicable safety regulations.

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.

NOTE: Do not start the engine during this lab exercise.

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 Worksheets: 725C, 730C, and/or a 730C EJ Articulated Truck

Emissions System Component Identification and
Function

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LAB 1: 7 25C/730C/730C EJ Articulated Trucks EMISSIONS SYSTEM 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.

_______ CEM Electronics Panel

Function: [Contains most of the electronic components that monitor and control the exhaust aftetreatment
system]

Location: [Right side of engine compartment, mounted horizontally above the aftertreatment package]

_______ Diesel Particulate Filter (DPF) Assembly

Function: [A particulate trap that is used to reduce particulate and soot emissions from the exhaust gases.
Trapped materials can then be burned, producing carbon dioxide and water vapor during
regeneration.]

Location: [Right side of engine compartment, upper round canister in the aftertreatment package]

_____ Diesel Oxidation Catalyst (DOC)

Function: [The flow-through device through which hot exhaust gases pass. A chemical reaction occurs, which
reignites the hydrocarbons in the exhaust gas allowing the remaining carbon atoms to be burned.]

Location: [Contained inside the DPF assembly, toward the inlet of the DPF assembly.]

_______ Selective Catalytic Reduction (SCR) Assembly

Function: [Converts NOX (Nitric Oxide and Nitrogen Dioxide) to N2 and H2O (Nitrogen and water)]

Location: [Right side of engine compartment, lower round canister in the aftertreatment package]

_____  Aftertreatment Regeneration Device (ARD) Head

Function: [The ARD head assembly contains a spark plug used to ignite a flame that elevates the exhaust gas
temperature entering the DPF assembly]

Location: [Located on the lower, front of the CEM module]

_____ ARD Fuel Nozzle Heater

Function: [An electronic heater used to prevent the formation of deposits on the injector tip when the ARD is
not performing a regeneration cycle]

Location: [Located near the center of the ARD head, below the spark plug]

_____ ARD Flame Detection Sensor

Function: [The flame detection sensor monitors the temperature inside the ARD head. The output of the flame
detection sensor is monitored by the Aftertreatment ECM]

Location: [Located near the bottom center of the ARD head, below the spark plug (identified by a shielded wire
harness)]

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LAB 1: 7 25C/730C/730C EJ Articulated Trucks EMISSIONS SYSTEM Component Identification and

Function (CONT’D.)

_____ ARD Spark Ignition Coil Assembly

Function: [The coil is used to provide the high voltage needed to create a spark in the ARD head and ignite
the fuel and air mixture - controlled by the Aftertreatment ECM]

Location: [Located on the right side, at the front of the CEM module, behind the DPF assembly]

_____ Pilot and Main Fuel Solenoids

Function: [The pilot and main fuel pressure solenoids are controlled independently by the Engine ECM, which
varies the strength of the current to increase or decrease fuel flow, depending on the amount of
exhaust gases flowing through the ARD]

Location: [Located near the center of the CEM module, to the right of the DPF assembly - installed in the ARD
fuel manifold]

_____ Pilot And Main Fuel Pressure Sensors

Function: [The pilot fuel and main fuel pressure sensors monitor the pressure of the pilot and main fuel after
the fuel solenoids]

Location: [Located near the center of the CEM module, behind the DPF assembly - installed in the ARD fuel
manifold, to the rear of the fuel solenoids]

_____ Combustion Air Valve

Function: [Precisely controls the air flow into the ARD by adjusting the position of the disc valve within the
valve body. An electric motor in the valve actuator body is used to control the disc valve position]

Location: [Located to the left rear of the CEM module, to the left of the DPF assembly]

_____ Combustion Air valve Pressure Sensor

Function: [Measures the pressure of the air flow through the combustion air valve actuator so the Engine
ECM can determine the correct position for the air valve disc]

Location: [Located above and forward of the combustion air valve assembly, on the left side of the DPF]

_____ DPF Pressure Sensors

Function: [Measure the difference in exhaust gas pressure between the DPF assembly inlet and the outlet]

Location: [Installed at the inlet and the outlet of the DPF assembly, below the CEM electronics panel]

_____ Pump Electronics Tank Unit (PETU)

Function: [Contains the DEF tank and most of the components associated with the injection and safe storage
of the Diesel Exhaust Fluid]

Location: [Located on the right side, at the front of the truck, accessible through the compartment door]

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LAB 1: 7 25C/730C/730C EJ Articulated Trucks EMISSIONS SYSTEM Component Identification and

Function (CONT’D.)

_____ DEF Tank

Function: [Container used for storing the diesel exhaust fluid on the truck] 

Location: [Large plastic container that comprises the majority of the PETU - right front of the truck]

_____ Coolant Diverter Valve

Function: [Solenoid controlled valve that controls coolant flow to the DEF tank and DEF pump]

Location: [Located on top of the PETU]

_____ DEF Tank Heater

Function: [Activated by the Aftertreatment ECM when the DEF tank temperature is less than 15°C (59°F) to
prevent DEF from freezing during engine operation] 

Location: [Coil shaped heating element inside the DEF tank]

_____ DEF Dosing Control Unit (DCU)

Function: [An ECM that controls all the electrical components on the PETU and the DEF injectors]

Location: [Located on the left side of the PETU]

_____ DEF Pump Assembly

Function: [Supplies filtered DEF fluid to the DEF injector] 

Location: [Located on the front of the PETU]

_____ DEF Level Sensor

Function: [Measures the amount of DEF in the tank]

Location: [Located inside the DEF tank and inside the heater coil]

_____ DEF Temperature Sensor

Function: [Measures the temperature of the DEF in the tank to determine if the heater is required] 

Location: [Integrated with the level sensor - located at the bottom of the tank]

_____ DEF Injector

Function: [Electronically controlled valve that sprays DEF into the exhaust stream during engine operation]

Location: [Installed in the front of the exhaust tube between the DPF and the SCR]

_____ NOX Sensors

Function: [Two sensors that measure the amount of NOX in the exhaust before and after the CEM]

Location: [Located on the right side, at the front of the truck, accessible through the compartment door]

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LAB 1: 7 25C/730C/730C EJ Articulated Trucks EMISSIONS SYSTEM Component Identification and

Function (CONT’D.)

_____ DPF Regeneration Switch

Function: [Container used for storing the diesel exhaust fluid on the truck] 

Location: [3-position momentary-type rocker switch used to manually activates a DPF regeneration cycle, to
stop an active regeneration cycle, or to inhibit an automatic regeneration cycle]

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LAB 2: 7 25C, 730C, and/or a 730C EJ Articulated

Truck TIER 4 FINAL ENGINE AND SUPPORT
SYSTEMS DEF QUALITY AND AFTERTREATMENT
SCR DOSING TESTS
INSTRUCTOR NOTE Lab Exercise

This is a shop exercise. Ensure participants understand the recognized safety

zones in, on, and around the machine.

SAFETY Participants will adhere to all applicable safety regulations.

EXERCISE Participants will work as a class to perform the following two test procedures:
-- DEF Quality Test
-- Aftertreatment SCR System Dosing Test
Participants are to follow the detailed step-by-step instructions for these two tests
outlined in the testing and adjusting service manual modules for the C9.3 engine
(UENR3432) and/or the C13 engine (UENR3351). Afterward, the participants and
the instructor will discuss the outcomes to ensure all participants understand how
the test procedure produced the observed results and what actions should be taken
as a result of the outcomes.

Procedure: Explain the lab exercises. Inform participants they may refer to their
printed materials and notes while completing the exercise. Participants will use a
laptop computer to access the testing procedures found in the Service Information
System (SIS) or use the printed versions of these manuals, if provided.

MATERIALS NEEDED ______ 725C, 730C, and/or a 730C EJ Articulated Truck with Tier 4 Final engine

______ Operation and Maintenance Manual: (SEBU8786, SEBU8785, SEBU9051)

______ PDF: ITTP module “725C/730C/730C EJ Articulated Trucks - Emissions

System”

______ C9.3 Engines for Caterpillar Built Machines - Sys-Op/T&A (UENR3432)

______ C13 Engines for Caterpillar Built Machines - Sys-Op/T&A (UENR3351)

______ 431-7087 Tool Group (Refractometer)

______ 441-0451 Test Kit (DEF Dosing Test Kit)

______ 207-1601 Rubber Lubricant

______ LOCTITE C-5A Copper Anti-Seize

______ DEF Injector seal and gasket kit (One-time use parts - check for newest
part numbers)

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LAB 3: 7 25C, 730C, and/or a 730C EJ Articulated

Truck TIER 4 FINAL ENGINE AND SUPPORT
SYSTEMS DATA LINK TEST
INSTRUCTOR NOTE Lab Exercise

This is a shop exercise. Ensure participants understand the recognized safety

zones in, on, and around the machine.

SAFETY Participants will adhere to all applicable safety regulations.

EXERCISE Participants will work as a class to perform the machine Data Link Test procedure.
Participants are to follow the detailed step-by-step instructions outlined in the
engine troubleshooting service manual module for the C9.3 engine (UENR3433)
and/or the C13 engine (UENR0955). Afterward, the participants and the instructor
will discuss the outcomes to ensure all participants understand how the test
procedure produced the observed results and what actions should be taken as a
result of the outcomes.

Procedure: Explain the lab exercises. Inform participants they may refer to their
printed materials and notes while completing the exercise. Participants will use a
laptop computer to access the testing procedures found in the Service Information
System (SIS) or use the printed versions of these manuals, if provided.

MATERIALS NEEDED ______ 725C, 730C, and/or a 730C EJ Articulated Truck with Tier 4 Final engine

______ Operation and Maintenance Manual: (SEBU8786, SEBU8785, SEBU9051)

______ PDF: ITTP module “725C/730C/730C EJ Articulated Trucks - Emissions

System”

______ C9.3 Engines for Caterpillar Built Machines - Troubleshooting (UENR3433)

______ C13 Engines for Caterpillar Built Machines - Troubleshooting (UENR0955)

______ Laptop computer with the latest version of Cat ET and COM Adapter III

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