System Check after an NOx Reduction System (NRS) Cooler Failure for C9.3 through C18 Tier 4 Engines {1000, 1075, 108C, 108F} Caterpillar

Articulated Truck

725C (S/N: TFB1-UP)

730C (S/N: TFF1-UP)

730C EJECTOR (S/N: TFH1-UP)

735B (S/N: T4P1-UP; E4R1-UP)

735C (S/N: TFJ1-UP)

740B (S/N: T4R1-UP; E4S1-UP)

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

740C EJECTOR (S/N: TFN1-UP)

745C (S/N: JE81-UP; TFK1-UP)

Cold Planer

PM620 (S/N: JB91-UP)

PM622 (S/N: JFC1-UP)

Electric Power Generation

C13GENSET (S/N: X3M1-UP)

C15 PET GEN SET (S/N: LWR1-UP)

XQ375 (S/N: X3F1-UP)

Engine

C13 (S/N: N3F1-UP; KWJ1-UP)

C15 (S/N: MG21-UP; JJF1-UP; N5F1-UP; LDN1-UP)

C18 (S/N: BE21-UP; N8F1-UP; BDN1-UP; ZPS1-UP)

Excavator

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

336F (S/N: TZA1-UP; RKB1-UP; YFD1-UP; KGH1-UP; LCL1-UP; NBL1-UP; LTP1-UP; KFT1-UP; DSW1-UP; WTZ1-UP)

349E (S/N: FJB1-UP; ETC1-UP; DGE1-UP; SPG1-UP; TFG1-UP; RGH1-UP; FEJ1-UP; KCN1-UP; MZW1-UP; KFX1-UP; MPZ1-UP; WHZ1-UP)

349F (S/N: BZ21-UP; KEA1-UP; HLB1-UP; HPD1-UP; TEW1-UP)

352F (S/N: WNA1-UP; YEG1-UP; A9J1-UP; KBP1-UP)

374F (S/N: DNM1-UP)

390F (S/N: TYE1-UP; MGF1-UP; HSM1-UP)

Forest Machine

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

Generator Set

C15 GEN SET (S/N: T4A1-UP; X5M1-UP)

C18 GEN SET (S/N: X5F1-UP; T4X1-UP)

Industrial Engine

C13 INDUSTRIAL (S/N: RRA1-UP)

C9.3 (S/N: CS91-UP; C9N1-UP; D9N1-UP)

Landfill Compactor

826K (S/N: 2321-UP)

836K (S/N: TWZ1-UP)

Mobile Hydraulic Power Unit

336E MHPU (S/N: PCE1-UP; RBS1-UP; T3Z1-UP)

349E MHPU (S/N: JAE1-UP; S3P1-UP; MTS1-UP)

374F MHPU (S/N: DP41-UP)

390F MHPU (S/N: B371-UP)

Motor Grader

12M Series 2 (S/N: F9B1-UP; F9M1-UP)

12M Series 3 (S/N: N9B1-UP; N9F1-UP; N9P1-UP; N9R1-UP)

140M Series 2 (S/N: M9D1-UP; R9G1-UP; M9J1-UP; R9M1-UP)

140M Series 3 (S/N: N9D1-UP; N9G1-UP; N9J1-UP; N9M1-UP)

160M Series 2 (S/N: M9E1-UP; M9K1-UP; R9L1-UP; R9T1-UP)

160M Series 3 (S/N: N9E1-UP; N9K1-UP; N9L1-UP; N9T1-UP)

16M Series 3 (S/N: N9Y1-UP)

18M Series 3 (S/N: N9A1-UP)

OEM Excavator Based Specialty Solution

390F OEM (S/N: PT71-UP)

Off-Highway Truck/Tractor

770G (S/N: RMA1-UP; KDH1-UP)

772G (S/N: RME1-UP; KEX1-UP)

Petroleum Power Train Package

CX31-P600-C18I (S/N: PDC1-UP)

CX35-P800-C18I (S/N: PCF1-UP)

Pipelayer

PL72 (S/N: P721-UP)

PL83 (S/N: CB21-UP)

PL87 (S/N: TEC1-UP)

Reclaimer Mixer

RM500B (S/N: MB91-UP)

Road Reclaimer/Soil Stabilizer

RM-500 (S/N: ASW1-UP)

Site Prep Tractor

2864C (S/N: SP41-UP)

586C (S/N: SP51-UP)

Soil Compactor

825K (S/N: 2331-UP)

Track-Type Tractor

D6T (S/N: CR31-UP; CG81-UP; SGA1-UP; KSB1-UP; ZJB1-UP; JZC1-UP; DTD1-UP; RAD1-UP; STE1-UP; EJJ1-UP; SLJ1-UP; GMK1-UP; RRK1-UP; MEL1-UP; TSM1-UP; WLM1-UP; WRN1-UP; KMR1-UP; PLR1-UP; WES1-UP; SGT1-UP; JRW1-UP; RCW1-UP; TMY1-UP; HTZ1-UP)

D7E (S/N: HKA1-UP; TJA1-UP; SSH1-UP; TAN1-UP)

D8T (S/N: AW41-UP; FMC1-UP; MLN1-UP; FCT1-UP)

D9T (S/N: REX1-UP)

Wheel Dozer

824K (S/N: 2341-UP)

834K (S/N: TWY1-UP)

Wheel Loader

966K (S/N: PBG1-UP; TFS1-UP)

966K Series XE (S/N: NGX1-UP)

966M (S/N: EJA1-UP; DYC1-UP; KJP1-UP)

966M Series XE (S/N: P6C1-UP)

972K (S/N: PEM1-UP)

972M (S/N: LSJ1-UP; A8P1-UP; JPR1-UP)

972M Series XE (S/N: EDW1-UP)

980K (S/N: W7K1-UP; NEP1-UP; GTZ1-UP)

980M (S/N: KRS1-UP; N8T1-UP)

982M (S/N: F9A1-UP; K1Y1-UP)

986H (S/N: L8S1-UP)

988K (S/N: TWX1-UP)

Wheel Tractor-Scraper

621H (S/N: DBK1-UP; HKK1-UP)

621K (S/N: WTA1-UP; WTE1-UP)

623H (S/N: DBF1-UP)

623K (S/N: WTB1-UP)

627H (S/N: DBW1-UP)

627K (S/N: WTC1-UP)

637K (S/N: WTS1-UP; WTT1-UP; WTX1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

Show/hide table

Disconnect batteries before performance of any service work.

System Check Procedure

The NRS cooler and related components must be inspect to ensure that there is not further damage done to the engine. Follow the procedure below.

1. Inspect the components below for signs of coolant. If coolant is discovered, remove the coolant from the components and open drain on the Air to Air Aftercooler (ATAAC) to make sure there is not coolant present.

   • Intake piping

   • Exhaust piping

   • ATAAC

   Note: DO NOT TURN THE ENGINE OVER WITH KEY SWITCH.

2. Turn the engine over by hand with a turning tool to check if the engine is hydro-locked. If the engine abruptly stops during rotation, coolant is possibly present in a cylinder.

   1. The piston height needs checked if the machine was started and the engine was hydro-locked. The connecting rod could have been bent and caused a secondary failure. Refer to M0069780, Piston Height Check for more information.

   Note: Do not use compressed air to clean the NRS Venturi sensor and Absolute Pressure sensor.

3. Inspect the NRS Venturi sensor and Absolute Pressure sensors to ensure that all passages are not plugged. If the passages are found to be plugged, remove the NRS Venturi.

   1. Clean the passages using hot soapy water and a bore brush. Refer to Disassembly and Assembly, Venturi Tube – Remove and Install for installation instructions.

4. Inspect the DPF and DOC for face plugging.

   1. If the DPF is face plugged, the DPF will need replaced.

   2. The DOC needs blown out with compressed air, blowing the air the opposite direction of normal air flow.

   3. Inspect the DOC after cleaning by using a mirror on the inlet side of the DOC. Shine a light though the outlet side to the inlet side, making sure that the light can be seen in the mirror on all sides of the DPF inlet. Refer to Disassembly and Assembly, Inlet Module (Catalyst) – Remove and Install and Diesel Particulate Filter – Remove and Install.

   Note: Do not use compressed air to clean the Delta P sensor.

5. Inspect the Delta P Sensor, DPF Intake Pressure sensor, CCEM Delta Pressure manifold, DPF fittings, and all CCEM pressure lines are free of condensation or soot build-up.

   1. Clean as necessary to remove all soot and condensation. Refer to Disassembly and Assembly, Pressure Sensor (DPF Inlet).

6. Inspect the DPF Inlet and Flame Detect Temperature probes to make sure that burnt coolant has not collected on the probes. Burnt coolant could act as an insulator and cause false temperature measurements leading to regeneration issues.

   1. If necessary, use a nonmetallic cleaning pad to clean the sensors. Refer to Disassembly and Assembly, Temperature Sensor (DPF Inlet, Flame Detect) – Remove and Install.