Installing the New Delta Pressure Lines on Certain Tier 4 Interim C9 To C18 Engines {108D} Caterpillar

Engine

C13 (S/N: KWJ1-UP)

C15 (S/N: LDN1-UP)

C18 (S/N: BDN1-UP)

Industrial Engine

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

Introduction

Before performing any of the following procedure be sure to read and understand all of the information first. The following procedure describes the installation procedure to update the Delta Pressure (Delta P) lines for the Tier 4 Interim engines listed above.

Required Parts

Table 1 lists the references for choosing the correct group for installation. Table 2 through Table 9 lists the parts that are in each group.

Table 2 lists the parts for Group 1.

Table 3 lists the parts for Group 2.

Reference: Refer to Special Instruction, REHS7909, "Replacing the DPF Delta Pressure Sensor Lines and ARD Air Pressure Sensor Lines on D6T and D7E Track-Type Tractors" for installation instructions.

Table 4 lists the parts for Group 3.

Table 5 lists the parts for Group 4.

Table 6 lists the parts for Group 5.

Table 7 lists the parts for Group 6.

Table 8 lists the parts for Group 7.

Table 9 lists the parts for Group 8.

Removal Procedure

Several components need removed before the installation procedure is started. Follow the procedure below.

1. Remove the previous Delta P lines.

   1. Remove the fittings, sensors, manifold, and mounting bracket on the Diesel Particulate Filter (DPF).

2. Leave the electrical harness installed, but disconnect the harness from the removed sensors.

3. Retain the Delta P sensor and the DPF Inlet Pressure sensor for use later in the installation procedure.

Installation Procedure

Installation Procedure For Group 1, Group 3, Group 5, Group 6, And Group 7

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Illustration 1	g03773353
(13) 6V-4365 O-Ring Seal (15) 296-4285 Screw (17) 415-8045 Manifold (18) 424-1200 Bracket (21) Delta P sensor

1. Install Delta P sensor (21).

   1. Install two o-ring seals (13) onto manifold (17).

   2. Install the previous Delta P sensor onto the manifold.

   3. Install bracket (18) over the top of the Delta P sensor and onto the manifold.

   4. Secure the bracket installing six screws (15) through the bracket into the manifold.
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   Illustration 2	g03773366
   (3) 198-4775 Hard Washer (5) 9X-8256 Washer (6) 5C-9553 Bolt (7) 8T-0640 Bolt (8) 5P-1046 Connector (9) 214-7568 O-Ring Seal (19) 415-8047 Bracket

2. Install bracket (19) to the mounting plate using four bolts (7) with four hard washers (5) on the bolts. Place four washers (5) behind bracket (19) before attaching to the mounting plate.

3. Install the manifold and sensor assembly to the bracket using two bolts (6) and two washers (5) as shown in Illustration 2.

4. Install connectors (8) with o-ring seals (9) into the side of the manifold.
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   Illustration 3	g03773457
   (1) 7W-3556 Washer (2) 124-6275 Hose Clamp (4) 216-7951 Elbow Adapter (10) 415-2415 Air Hose (11) 415-8027 Tube As (12) 415-8028 Tube As (20) 330-6710 O-Ring Seal (22) DPF Inlet Sensor

5. Install DPF Inlet sensor (22) with new o-ring seal (20) into the assembled manifold.

6. Install elbow adapters (4) with washers (1) into the DPF and angle the adapters up to the Delta P manifold fittings.

7. Install tube assembly (12) on the DPF outlet elbow and tube assembly (11) onto the DPF inlet elbow.

8. Connect the tube assemblies to the manifold using air hoses (10) and hose clamps (2).

   Note: The 415-2415 Air Hose and the 418-2060 Hose need cut to length during the installation process. Make sure to leave enough hose so that it can be properly installed on the tube assemblies using the hose clamps.

9. Reconnect the electrical harness to the Delta P sensor and the DPF Intake Air Pressure sensor.

Installation Procedure For Group 4

Reference: Refer to Table 5 for the parts needed for the instructions below.

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Illustration 4	g03779296
(1) Wiring harness

1. Remove wiring harness (1) from the ladder clip in the location shown in Illustration 4.

   Note: The wiring harness will be attached to the new sensor group.

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   Illustration 5	g03779297
   (2) Ladder clip

2. Remove ladder clip (2) from the wiring harness and mounting bracket to avoid interference with the installation of the new manifold.
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   Illustration 6	g03779495
   (10) 6V-4365 O-Ring Seals (12) 296-4285 Screws (13) 415-2417 Manifold (14) 424-1200 Bracket (23) Delta P sensor

3. Install Delta P sensor (23).

   1. Install two o-ring seals (10) onto manifold (13).

   2. Install the previously removed Delta P sensor onto the manifold.

   3. Install bracket (14) over the top of the Delta P sensor and onto the manifold.

   4. Secure the bracket to the manifold using six screws (12).
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   Illustration 7	g03779298
   (2) 385-5773 Connector As (5) 344-1206 Bolts (7) 398-3752 Bracket (20) 198-4775 Hard Washers (21) 344-1200 Hard Washers

4. Install bracket (7) using bolts (5) with hard washers (21) and (20). Hard washers (20) are installed between bracket (7) and the mounting bracket.

5. Install manifold (13) in the same place as the previous manifold.

6. Install connector assembly (2) into the manifold in the location shown in Illustration 7.
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   Illustration 8	g03779526
   (1) 313-9614 Adapter As (9) 418-2060 Hose (17) 428-8782 Tube As

7. Install adapter assembly (1) into the inlet port of the DPF assembly.

8. Install hose (9) onto the previously installed adapter in the manifold.

9. Install tube assembly (17) onto adapter (1).

   Note: The tube assembly will have to be cut to the proper length to fit with the hose. Be sure to leave enough length for proper installation using the hose clamps.

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   Illustration 9	g03779539
   (3) 216-7951 Elbow Adapter (9) 418-2060 Hose (18) 428-8783 Tube As

10. Install elbow adapter (3) into the DPF outlet port as shown in Illustration 9.

11. Attach tube assembly (18) to the elbow adapter.

12. Install hose (9) onto the tube assembly.
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    Illustration 10	g03779546
    (9) 418-2060 Hose (22) 415-2406 Tube As

13. Install tube assembly (22) into the previously installed hose (9).

    Note: The tube assembly will have to cut to the proper length. Be sure to leave enough length for proper installation using the hose clamps.

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    Illustration 11	g03779552
    (8) 124-6275 Hose Clamp

14. When all of the tube assemblies and hoses have been cut and fitted to the proper lengths. Install hose clamps (8) in the four locations that are shown in Illustration 11.

Installation Procedure For Group 8

Reference: Refer to Table 9 for the parts needed for the instructions below.

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Illustration 12	g03779606
(14) 6V-4365 O-Ring Seals (16) 296-4285 Screws (19) 424-1200 Bracket (20) 398-3754 Manifold (21) Delta P sensor

1. Install Delta P sensor (21).

   1. Install two o-ring seals (14) onto manifold (20).

   2. Install the previously removed Delta P sensor onto the manifold.

   3. Install bracket (19) over the top of the Delta P sensor and onto the manifold.

   4. Secure the bracket to the manifold using six screws (16).
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   Illustration 13	g03779634
   (3) 198-4775 Hard Washers (5) 9X-8256 Washers (6) 5C-9553 Bolts (7) 8T-4971 Bolts (8) 5P-1046 Connectors (9) 214-7568 O-Ring Seals (13) 415-8043 Bracket

2. Install bracket (13) to the mounting plate using three bolts (7) with three hard washers (5) on the bolts. Place three washers (5) behind bracket (13) before attaching to the mounting plate.

3. Install the manifold and sensor assembly to the bracket using two bolts (6) and two washers (5) as shown in Illustration 13.

4. Install connectors (8) with o-ring seals (9) into the side of the manifold.
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   Illustration 14	g03779668
   (2) 124-6275 Hose Clamp (4) 216-7951 Elbow Adapter (10) 418-2060 Hose (11) 428-8783 Tube As (12) 415-8031 Tube As

5. Install elbow adapters (4) into the DPF and angle the adapters up to the Delta P manifold fittings.

6. Install tube assembly (11) on the DPF outlet elbow and tube assembly (12) onto the DPF inlet elbow.

7. Connect the tube assemblies to the manifold using air hoses (10) and hose clamps (2).

   Note: The 415-2415 Air Hose and the 418-2060 Hose need cut to length during the installation process. Make sure to leave enough hose so that it can be properly installed on the tube assemblies using the hose clamps.

8. Reconnect the electrical harness to the Delta P sensor and the DPF Intake Air Pressure sensor.