Updating the NOx Reduction System Delta Pressure Sensor on Certain C9.3 Through C32 Engines {1408, 191N} Caterpillar

Articulated Truck

735B (S/N: T4P1-UP)

740B (S/N: T4R1-UP)

Ejector Truck

740B EJECTOR (S/N: T4S1-UP)

Excavator

336E (S/N: JEA1-UP; RZA1-UP; KED1-UP; YCE1-UP; TEG1-UP; FJH1-UP; GTJ1-UP; JRJ1-UP; SSL1-UP; YEP1-UP; CMR1-UP; HDW1-UP; BZY1-UP; GNY1-UP; TMZ1-UP)

336E MHPU (S/N: PCE1-UP)

349E (S/N: FJB1-UP; DGE1-UP; TFG1-UP; RGH1-UP; KCN1-UP; MZW1-UP; KFX1-UP; MPZ1-UP; WHZ1-UP)

Forest Machine

568 (S/N: BRB1-UP; YJX1-UP)

Generator Set

C27 GEN SET (S/N: N1B1-UP; T4Z1-UP)

C27 PET GEN SET (S/N: EGG1-UP)

Industrial Engine

C13 (S/N: KWJ1-UP)

C15 (S/N: LDN1-UP)

C18 (S/N: BDN1-UP; ZPS1-UP)

C27 INDUSTRIAL (S/N: RAM1-UP)

C32 INDUSTRIAL (S/N: NST1-UP)

C9.3 (S/N: C9N1-UP; D9N1-UP)

Locomotive Engine

C27 LOCO (S/N: WJC1-UP)

Mobile Hydraulic Power Unit

336E MHPU (S/N: RBS1-UP; DSZ1-UP; T3Z1-UP)

349E MHPU (S/N: JAE1-UP; S3P1-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)

Off Highway Truck

773G (S/N: JWS1-UP)

775G (S/N: MJS1-UP)

777G (S/N: T5A1-UP; RDR1-UP)

Petroleum Engine

C27 PETROLEUM (S/N: NAR1-UP)

C32 PETROLEUM (S/N: SDK1-UP)

Track-Type Tractor

D10T2 (S/N: JJW1-UP)

D11T (S/N: MDG1-UP; JEL1-UP; JNS1-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 Dozer

854K (S/N: H8M1-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; GTZ1-UP)

992K (S/N: 8801-UP)

993K (S/N: Z4D1-UP)

Wheel Tractor Scraper

621H (S/N: DBK1-UP)

623H (S/N: DBF1-UP)

627H (S/N: DBW1-UP)

Introduction

Do not perform any part of this special instruction until you have read and understand the material that follows.

This special instruction covers the replacement of the 365-9858 Pressure Sensor Gp and 382-4384 Pressure Sensor Gp with the new 385-1173 Pressure Sensor Gp.

Replacing the NOx Reduction System Delta Sensor On C9.3 Engines

In order to update the sensor on C9.3 engines using Tier 4 Interim technology, the venturi must be updated at the same time. This change is due to the new 385-1173 Pressure Sensor Gp interfering with the intake pressure sensor or chassis on the previous venturi.

The following process covers the required parts and installation procedure for the new NOx Reduction System (NRS) delta pressure sensor.

Procedure to Update the NRS Delta Pressure Sensor Mounted to the 353-7158 Venturi Tube

Required Parts

Table 1 contains the parts needed for replacement of the 353-7158 Venturi Tube in the installation procedure below.

Note: Retain all removed hardware until the installation procedure is completed. Some hardware might be reused.

Removal Procedure

Note: This step is for the 966K and 972K models only. For any other model that uses a C9.3 engine continue to Step 1.

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Illustration 1	g03582574
(1) 346-8477 Tube As

1. Remove tube assembly (1) as shown in Illustration 1
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   Illustration 2	g03582575
   (2) NRS delta pressure sensor (3) Wiring harness bracket (21) NRS intake pressure sensor

2. Remove the previous NRS delta pressure sensor (2) and NRS intake pressure sensor (21). Remove wiring harness bracket (3).
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   Illustration 3	g03582576
   (4) Band clamp (5) Clamp

3. Remove band clamp (4) connection at the NRS valve. Loosen clamps (5) connecting the hose to the NRS cooler.
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   Illustration 4	g03582579
   (6) Exhaust elbow (7) Bolt (8) NRS venturi

4. Remove the two bolts (7) that fasten the NRS venturi (8) to the support bracket. Remove the NRS venturi (8) and exhaust elbow (6).
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   Illustration 5	g03582583
   (9) Bolt (10) Lifting eye bracket

5. Remove bolts (9) that fasten the support bracket to the engine and then remove the lifting eye bracket (10).

Installation Procedure

Note: Use the parts listed in Table 1 for the installation procedure that follows below.

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Illustration 6	g03441429

1. Install lifting plate (12) using the four bolts and washers removed previously. Install hose (7) to the inlet side of the venturi using two clamps (8).
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   Illustration 7	g03441577

2. Mount venturi tube (1) using the bolts and washers removed in Step 3.
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   Illustration 8	g03442956

3. Install hose (7) to the outlet of the venturi and secure using clamp (8). Install air tube (5) into the other end of the hose and secure using clamp (8). Connect air tube (5) to the NRS valve using clamp (11) with new o-ring seal (6). Torque clamp (11) to 8.5 N·m (75 lb in), lightly tap the circumference of the clamp with a hammer and torque back to 8.5 N·m (75 lb in).
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   Illustration 9	g03582625

4. Install the NRS intake pressure sensor (21) that was removed in Step 1 using new o-ring seal (18).

5. Install NRS delta pressure sensor (2) installing two o-ring seals (9) underneath.

6. Then install bracket (3) using two bolts (10), torque the bolts to 20 N·m (15 lb ft). Connect sensor harness assembly (4) between sensor (2) and the main engine harness.
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   Illustration 10	g03443265

7. Install clip (13) to air tube (5) using bolt (14) and washer (15). Use cable strap (17) to attach the sensor connection (2) and the wire lead from sensor (D) to the clip.
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   Illustration 11	g03443396

8. Secure and attach the excessive wire to bracket (3) using cable straps (17) and (19) as shown in Illustration 11.

   Note: This step is for the 966K and 972K models only.

9. Install tube assembly (20).

Procedure to Update the NRS Delta Pressure Sensor Mounted to the 380-8541 Venturi Tube

Required Parts

Table 2 contains the part numbers needed for replacement of the 380-8541 Venturi Tube in the installation procedure below.

Removal Procedure

Note: Retain all removed hardware until the installation procedure is completed. Some hardware might be reused.

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Illustration 12	g03792634
(1) Bracket (2) NRS delta pressure sensor (14) NRS intake pressure sensor

1. Remove the previous NRS delta pressure sensor (2) and NRS intake pressure sensor (14). Remove wiring harness bracket (1).
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   Illustration 13	g03582823
   (3) Band clamp (4) Clamp

2. Remove band clamp (3) connection at the NRS valve. Loosen clamps (4) connecting the hose to the NRS cooler.
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   Illustration 14	g03582828

3. Remove the two bolts (6) that fasten the NRS venturi to the support bracket. Remove the NRS venturi and air tube (12).

4. Remove venturi (5) from the mounting bracket.

Installation Procedure

Note: Use the parts listed in Table 2 for the installation procedure that follows below.

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Illustration 15	g03504181

1. Install hose (5) to the inlet side of the venturi using two clamps (6).

2. Mount the venturi tube (1) using two bolts and washer removed in Step 3.
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   Illustration 16	g03792629

3. Install hose (5) to the outlet of the venturi and secure using band clamp (6). Install o-ring seal (13) on the end of air tube (12) that was removed in Step 3. Install the air tube to the other end of the tube using band clamp (6). Connect air tube to the NRS valve and torque to 8.5 N·m (75 lb in). Lightly tap the circumference of the clamp with a hammer and torque back to 8.5 N·m (75 lb in)
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   Illustration 17	g03792638

4. Install the NRS intake pressure sensor (14) that was removed in Step 1 using new o-ring seal (10).

5. Install NRS delta pressure sensor (2) installing two o-ring seals (7) underneath.

6. Then install bracket (3) using two bolts (8), torque the bolts to 20 N·m (15 lb ft). Connect sensor harness assembly (4) between sensor (2) and the main engine harness.
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   Illustration 18	g03504482

7. Secure and attach the excessive wire to bracket (3) using cable straps (9) and (11) as shown in Illustration 18.

Replacing the NOx Reduction System Delta Sensor On C13 Through C32 Engines

Required Parts

Installation of the 385-1173 Pressure Sensor Gp

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Illustration 19	g03444961
C13 engine

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Illustration 20	g03444963
C15 engine

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Illustration 21	g03444965
C27/C32 engine

1. Install pressure sensor group (1) using two o-ring seals (4).

2. Install bracket (2) using two bolts (4). Torques the bolts to 20 N·m (15 lb ft).

3. Connect the sensor to the existing wiring harness using sensor harness assembly (3). Loop the excessive wire and secure to bracket (2) using cable straps (7) .

4. If the NRS intake pressure sensor was removed, use a new o-ring seal (6) for installation.

Replacing the Main Wiring Harness on C13 Through C32 Engines

If replacing the main wiring harness, the NRS Delta Pressure Sensor will also need replaced to the 385-1173 Pressure Sensor Gp. Table 1 contains the part numbers for replacing the main wiring harness.