| Machine | Powerscreen Warrior 1800 (mobile screener) |
|---|---|
| Engine | CAT, 111 hp stock |
| ECU | Caterpillar ADEM IV |
| Solution | Stage 1 + AdBlue/SCR off* + DPF off* + EGR off* |
The situation
A mobile screener runs for hours at a constant load, often on a quarry floor or a recycling yard far from the nearest workshop. The Warrior 1800 with its 111 hp CAT engine under the ADEM IV is built for exactly that. What interrupted it was the after-treatment: AdBlue sensors that failed and were expensive to replace, a DPF whose regenerations ended in blockages and limp mode, and an EGR system that fouled the intake and cost output over time. Each fault meant a stop, a workshop visit and a plant standing idle.
The contractor wanted the screener to run without after-treatment interruptions and with the full output of the engine available.
What we did
The ADEM IV was read and the file developed for this software version. All three after-treatment systems were handled together with a power file.
- Stage 1: injection quantity and torque limits adjusted within the limits of the stock hardware – more power with a stable delivery at the constant rpm a screener runs at. Engine protection is kept intact.
- AdBlue/SCR: dosing and level monitoring deactivated in software, related DTCs and the derate strategy handled. No DEF top-ups, no sensor faults, no derate.
- DPF: regeneration logic disabled, back-pressure model and sensors neutralised – no blockages, no limp mode, the engine breathes freely.
- EGR: valve closed in software – clean intake, no recirculated soot, stable combustion temperatures.
Checksum corrected and the file written to the ECU.
The result
The contractor reports noticeably fewer breakdowns and a clear gain in performance. No fault messages from DEF, DPF or EGR, fewer workshop visits because the systems that used to fail are no longer in the loop, and longer uninterrupted running time per day. Files for the ADEM IV are developed from the original read of each machine, not from a generic base – the software version decides what the file looks like.
Need a file for this machine?
Byte Performance develops files individually for engine, ECU and software version. Dealers get access to the full database, dealer pricing and direct engineer support. Become a dealer or ask about a machine.
* Emission-related solutions (DPF, EGR, AdBlue/SCR) are intended for off-road, agricultural, export and motorsport use only, where permitted by local law. The operator is responsible for legal use in their market.
