NOx Sensors Handling and Installation Procedures {191N} Caterpillar

Articulated Truck

725C (S/N: TFB1-UP)

725C2 (S/N: 2T31-UP)

730C (S/N: TFF1-UP)

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

730C2 (S/N: 2T41-UP)

730C2 EJ (S/N: 2T51-UP)

735C (S/N: TFJ1-UP)

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

745 (S/N: 3T61-UP)

745C (S/N: TFK1-UP)

Cold Planer

PM620 (S/N: JB91-UP)

PM622 (S/N: JFC1-UP)

Engine

3516C (S/N: TKG1-UP; TKJ1-UP; TKK1-UP)

C13 (S/N: NF31-UP; N3F1-UP)

C15 (S/N: N5F1-UP; ENG1-UP)

C18 (S/N: N8F1-UP)

Excavator

336F (S/N: B391-UP; TZA1-UP; RKB1-UP; RBC1-UP; YFD1-UP; DKF1-UP; YBH1-UP; NAJ1-UP; ZBJ1-UP; LCL1-UP; NBL1-UP; PFL1-UP; SSN1-UP; LTP1-UP; KCS1-UP; NBS1-UP; KFT1-UP; DSW1-UP; MTW1-UP; DFY1-UP; LJY1-UP; WTZ1-UP)

340F (S/N: RBD1-UP; YBF1-UP; EAR1-UP; WBX1-UP)

349F (S/N: BZ21-UP; KEA1-UP; HLB1-UP; HPD1-UP; SFG1-UP; RAX1-UP)

352F (S/N: SD21-UP; NDC1-UP; YEG1-UP; A9J1-UP; XAL1-UP; KBP1-UP; MDR1-UP)

374F (S/N: AT21-UP; EBF1-UP; DNM1-UP)

390F (S/N: MGF1-UP; FEH1-UP)

Industrial Engine

C13 IND (S/N: JR91-UP)

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

Landfill Compactor

826K (S/N: 2321-UP)

836K (S/N: TWZ1-UP)

Material Handler

MH3295 (S/N: PA91-UP)

Mobile Hydraulic Power Unit

336FMHPU (S/N: B341-UP; B351-UP)

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

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

Motor Grader

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

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

14M Series 3 (S/N: N9S1-UP)

14N (S/N: N9X1-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)

793F (S/N: D3T1-UP)

Pipelayer

PL72 (S/N: P721-UP)

PL83 (S/N: CB21-UP)

PL87 (S/N: TEC1-UP)

Reclaimer Mixer

RM500B (S/N: MB91-UP)

Retrofit Aftertreatment

SCR (S/N: ES71-UP)

Soil Compactor

825K (S/N: 2331-UP)

Track-Type Loader

973K (S/N: MKL1-UP)

Track-Type Tractor

D6T (S/N: CR31-UP; 2B31-UP; MH71-UP; CG81-UP; SGA1-UP; RAD1-UP; STE1-UP; JML1-UP; MEL1-UP; JNM1-UP; WRN1-UP; K1R1-UP; KMR1-UP; WES1-UP; HYT1-UP; SGT1-UP; TMY1-UP; HTZ1-UP)

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

D8T (S/N: AW41-UP; FMC1-UP; JET1-UP)

D9T (S/N: REX1-UP)

Wheel Dozer

824K (S/N: 2341-UP)

834K (S/N: TWY1-UP)

Wheel Loader

966M (S/N: EJA1-UP; DYC1-UP; LMM1-UP; KJP1-UP)

966M Series XE (S/N: P6C1-UP; B8P1-UP)

972M (S/N: LSJ1-UP; GGN1-UP; A8P1-UP; JPR1-UP)

972M Series XE (S/N: M5S1-UP; EDW1-UP)

980M (S/N: MK21-UP; KRS1-UP; N8T1-UP)

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

986K (S/N: MH81-UP)

988K (S/N: TWX1-UP)

Wheel Tractor-Scraper

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

623K (S/N: WTB1-UP)

627K (S/N: WTC1-UP; WTN1-UP)

631K (S/N: WTR1-UP)

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

Introduction

This Special Instruction outlines the steps needed to handle and install NOx sensors. NOx sensors are used in many different applications. Examples of applications include Clean Emissions Modules (CEM) for off-road applications, and different Selective Catalyst Reduction (SCR) systems used in stationary engine applications.

Do not perform any procedure contained in this publication or order any parts until you have read and understand the procedure.

Required Parts

Required Tooling

The table below contains the tooling required to complete this Special Instruction. The following items can be ordered at the address below:

General Handling Procedures

Illustration 1	g03695890
(1) Engine (2) "Engine out" sensing unit (3) Emissions Module (4) "Emissions module out" sensing unit

• Do not unplug the NOx sensor cable when the sensor is powered on. Damage to the engine ECM may occur.

• Avoid impacting the NOx sensor, dropping the sensor could cause permanent damage. If the sensor is impacted, discard the sensor.

• Handle and store the NOx sensor in a clean, dry area that is free of contamination, and inclement weather.

• Do not remove the sensing unit protective cap until the sensor is ready for installation.

• Do not paint any part of the sensing unit.

• Allow the exhaust system to cool before removing the sensor.

• Do not clean any part of the sensor with chemical cleaners.

• Shipping boxes should be transported and stored in a closed condition. Store sensors in the original closed shipping box until the sensor is ready for installation. The maximum storage time for new sensors in production packaging boxes is 18 months after production. The maximum storage time for sensors in spare part packaging is 2 years after production.

• Sensors should be stored in a temperature range of −40° C (−40° F) to 105° C (221° F).

• Avoid temperature shock when opening a shipping box. Avoid a temperature difference of more than ± 5° C (41° F)5° C between the sensors and the environment. Allow at least 4 hours for the sensors to reach ambient temperature before opening the box to avoid condensation on the parts.

• Do not open the shipping box with a knife that can deeply penetrate the box. Knives can damage the sensors or sensor cables.

Sensor Installation Procedures

Illustration 2	g03695896
(1) Electrical connector (2) Cable (with varnish tube sleeve) (3) Grommet (4) Hex nut (5) Threads (6) Protective cover (7) Mounting tabs

Note: Non Metallic anti-seize is the only approved thread lubricant to be used when reinstalling a sensor. See Table 2 for the appropriate anti-seize.

Note: The Electronic Control Unit (ECU) consists of electrical connector (1) and mounting tabs (7). The sensing unit consists of grommet (3), hex nut (4), threads (5), and protective cover (6).

1. Mount the ECU.

2. Verify that the NOx sensor part number is correct for the application.

3. Identify the correct mounting boss on the exhaust system ("engine out" or "Emissions module out").

   Note: For CEM applications: The "engine out" NOx sensor has a black cable and the "Emissions module out" NOx sensor has a gray cable. If the sensing unit is installed in the wrong location, a diagnostic code from the Aftertreatment ECM will become active.

   Show/hide table

   Illustration 3	g03695903
   (8) Last cable attachment point (9) 180 degree loop (10) NOx sensing unit (11) Exhaust

4. The NOx sensor cable should be installed with a security loop for strain relief.

   Note: Do not bend the cable sharply.

   1. The first cable attachment point should be 100 mm (4 inch) from the sensor ECU.

      Note: A security loop must be maintained to guarantee that movement of the exhaust pipe will not tighten and damage the cable/varnish tube. Route the sensor cable and secure the cable as the original cable was installed.

      Note: The wiring entering the rubber grommet on the sensor must not exceed more than 15 degrees of axial alignment. Alignment surpassing 15 degrees can damage the wiring and grommet.

5. Remove the protective cap from the sensing unit. Do Not lubricate the threads of a new sensor, the threads come pre-lubricated from the factory.

   Note: Non Metallic anti seize is the only approved thread lubricant to be used when reinstalling a sensor. See Table 2 for the appropriate anti-seize.

6. Place the sensing unit into the correct mounting boss on the exhaust system and turn the hex nut by hand until tight.

   Note: Hold the base of the sensing unit near the grommet so the cable does not twist while turning the hex nut.

7. Tighten the hex nut to 50 ± 10 N·m (37 ± 7 lb ft).

   Note: Maximum allowable cable rotation after tightening is 180 degrees.

8. Connect the sensor wiring harness to the ECU.