Exhaust Gas Valve (NRS) for C7.1, and C6.6 Engines {5137} Caterpillar

Asphalt Paver

AP1000E (S/N: T1F1-1,102-278)

AP1055E (S/N: TJF1-446)

AP1055F (S/N: TJ51-330)

BG1000E (S/N: RTT1-102)

Engine (Captive)

C7.1 (S/N: 7701-270,272-282,284-294,299-313,315-331,333-382,384-393,395-415,417-876,887-942,948-1173,1176-1205,1207-1326,1328-1365,1367-1796,1799-1807,1810-1875,1879-1969,1971-2022,2024-2030,2032-2041,2045-2078,2082-2083,2097-2097)

Excavator

320E (S/N: SXE1-1,193-2382,2384-2398; AWS1-289; SHX1-163)

320E L (S/N: REE1-516; TNJ1-455; LAK1-312; WBK1-3919; KLT1-187; NAZ1-2300)

320E L RR (S/N: PNL1-654; TFX1-1519)

320E LN (S/N: DFG1-233)

320E RR (S/N: LHN1-747)

320E RR L (S/N: MEW1-208)

323E L (S/N: RAP1-145,147-1040,1042-1044)

323E LN (S/N: TDW1-450)

323E SA (S/N: YRP1-241)

324E (S/N: JCZ1-154)

324E L (S/N: KTE1-203; TLF1-523; PNW1-1,176-1616)

324E LN (S/N: LDG1-682)

326F L (S/N: WGL1-747)

329E (S/N: PTY1-120)

329E L (S/N: ZCD1-820; WJK1-157; TST1-873; PLW1-1717; RDX1-196)

329E LN (S/N: RLD1-789)

329F L (S/N: ERL1-865; GCX1-1)

335F L CR (S/N: KNE1-420)

Generator Set

C7.1 GEN SET (S/N: MRP1-127,129-686,703-731,736-745,747-748,750-751,772-776,782-783)

Industrial Engine

C6.6 (S/N: 6671-253)

C7.1 (S/N: 8811-253,255-255,257-269,271-272,274-274,276-310,313-373,375-382,386-523,525-539,542-591,593-609,611-718,720-909,911-921,924-947,949-950,952-952,954-961,963-1046,1048-1048,1051-1077,1082-1110,1115-1119,1124-1126,1131-1132,1147-1209,1215-1231,1239-1247,1252-1254,1256-1259,1263-1273,1275-1288,1295-1309,1313-1313,1316-1324,1334-1336)

Knuckleboom Loader

2384C (S/N: KAW1-318)

2484C (S/N: KAZ1-264)

559C (S/N: KAS1-1,250-396,398-549)

579C (S/N: KAX1-295)

Mobile Hydraulic Power Unit

320E MHPU (S/N: EGX1-102,136-154,156-181,183-191)

329E MHPU (S/N: K2L1-167; KNR1-155)

Motor Grader

120M Series 2 (S/N: M921-107; M9C1-567; M9H1-376,396-396; R9N1-203; R9W1-104,106-186)

12M Series II (S/N: R9R1-105)

Track-Type Tractor

D6K2 LGP (S/N: RST1-314,317-933,935-1853,1855-2003)

D6K2 XL (S/N: WMR1-1108,1110-1112)

D6N LGP (S/N: SC61-124,126-137; PBA1-439,441-614,616-851,853-1082,1084-1238,1539-3212)

D6N XL (S/N: PER1-1,200-220,222-306,308-545,548-1143)

Wheel Feller Buncher

2570C (S/N: W571-118; F1B1-202,204-204,206-216)

2670C (S/N: W671-132; B3E1-171,1470-UP)

563C (S/N: W631-248; JCB1-324)

573C (S/N: W731-194; RJT1-1,252-296)

Wheel Loader

924K (S/N: PWR1-158,350-4829)

930K (S/N: RHN1-165,167-168,450-4482)

938K (S/N: SWL1-1,160-171,250-4349,10605-10605)

950K (S/N: R4A1-1535,2000-2859; J5M1-558,1000-1267; FER1-1,150-1094,3756-3756)

950M (S/N: FTR1-177,301-557)

962K (S/N: T6A1-453,1000-1096; FLL1-462; X4T1-482)

962M (S/N: F2T1-129,201-315)

Introduction

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

There have been some isolated instances of the exhaust gas valve (NRS) not responding, accompanied by a diagnostic trouble code 112-2 EGR Valve Not Responding. Diagnosis indicates that the valve has a build-up of excessive soot. The exhaust gas valve (NRS) seizes due to erosion of the clearance between the poppet valve stem and guide bush.

An improved design of exhaust gas valve (NRS) has been introduced.

Safety Section

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Sulfuric Acid Burn Hazard may cause serious personal injury or death. The exhaust gas cooler may contain a small amount of sulfuric acid. The use of fuel with sulfur levels greater than 15 ppm may increase the amount of sulfuric acid formed. The sulfuric acid may spill from the cooler during service of the engine. The sulfuric acid will burn the eyes, skin and clothing on contact. Always wear the appropriate personal protective equipment (PPE) that is noted on a material safety data sheet (MSDS) for sulfuric acid. Always follow the directions for first aid that are noted on a material safety data sheet (MSDS) for sulfuric acid.

Required Parts

Removal Procedure

1. Turn the battery disconnect switch to the OFF position.

2. For some applications, an Engine Mounted Aftertreatment (EMAT) may be installed, removal of the EMAT may be required to carry out an effective repair. If necessary, refer to Disassembly and Assembly, Clean Emissions Module - Remove and Install for the correct procedure.

Temperature Sensor (Cooled Exhaust Gas)

Illustration 1	g06015553
Typical example

1. Cut cable straps (1).

2. Slide the locking tab into the unlocked position. Disconnect engine wiring harness assembly (2) from wiring harness assembly (3). Slide connection for wiring harness assembly (3) from bracket (4).

Throttle Valve (Intake Air) for Certain C7.1 Engines (If Equipped)

1. Remove the throttle valve. Refer to Disassembly and Assembly, Throttle Valve (Intake Air) - Remove for the correct procedure.

Inlet Air Control (NRS Inlet Air Mixer)

Illustration 2	g06015679
Typical example

1. If necessary, loosen the hose clamps and disconnect the hose assembly from connection (9) for inlet air control (8).

2. Disconnect engine wiring harness assembly (1) from wiring harness assembly (5) for NRS valve (7). Slide the connection for wiring harness assembly (5) from bracket (3).

3. Disconnect engine wiring harness assembly (2) from wiring harness assembly (4) for wastegate solenoid (6). Slide connection for wiring harness assembly (4) from bracket (3).

4. Loosen hose clamps (10) on the hose assembly that connects inlet air control assembly (8) to inlet elbow (11).
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   Illustration 3	g06015691
   Typical example

5. Slide clip (12) along hose assembly (13). Disconnect the hose assembly from the wastegate actuator.

6. Remove bolt (15) for the tube assembly for the wastegate actuator.

7. Remove bolts (14).
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   Illustration 4	g06015699
   Typical example

8. Release hose clamp (17) for hose assembly (18). Remove the hose assembly from inlet air control assembly (8).

9. Release hose clamp (19) for hose assembly (20). Remove the hose assembly from inlet air control assembly (8).

10. Remove banjo bolt (22) and remove sealing washers (21) (not shown).

11. Remove bolt (23) from tube assembly (24). Remove the tube assembly from inlet air control assembly (8).
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    Illustration 5	g06018304
    Typical example

12. Remove bolts (31) and nut (27) from connection (9).

13. Remove connection (9) and gasket (28) (not shown).

    Note: On certain applications, a spacer and an extra gasket may be installed.

14. If necessary, remove spacer (29) and gasket (30) (not shown).

15. Remove stud (26).

16. Remove bolts (25) from inlet air control assembly (8).

17. Remove inlet air control assembly (8).

18. Remove gasket (16) (not shown).

19. Position inlet air control assembly (8) into a suitable vice that has soft jaws.
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    Illustration 6	g06015720
    Typical example

20. Remove the Allen head bolts (32) from inlet air control assembly (8).
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    Illustration 7	g06015767
    Typical example

21. Follow Step 22 through Step 24 to install Allen head bolts (32) to inlet air control assembly (8) and to remove exhaust gas valve (7) from inlet air control assembly (8).

22. Install the Allen head bolts (32) and leave a Gap (W) of 6 mm (0.236 inch) between exhaust gas valve (7) and the Allen head bolts. Leaving a gap between the Allen head bolts will support the exhaust gas valve as the exhaust gas valve is driven out of inlet air control assembly (8).

23. Position a suitable drift in Position (X) and Position (Y) strike the drift, alternate between Position (X) and Position (Y) to remove exhaust gas valve (7) from inlet air control assembly (8).Ensure that the exhaust gas valve is not subjected to rotational force, as a rotational force could cause the exhaust gas valve to bind in the NRS Induction Mixer.

24. Remove Allen head bolts (32) and remove exhaust gas valve (7) from inlet air control assembly (8).

Installation Procedure

Inlet Air Control (NRS Inlet Air Mixer)

Illustration 8	g06015794
Typical example

1. Clean and remove with a light grade scot pad any soot deposits or burrs left in the bore of the exhaust gas valve in area (34) of inlet air control assembly (8).

2. Ensure that area (34) is not scuffed or damaged when the cleaning procedure is carried out. Use suitable cleaning products to wash out and dirt and residue.
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   Illustration 9	g06015815
   Typical example

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   Illustration 10	g06015807
   Typical example

3. Select the correct exhaust gas valve (7) from Table 1.

4. Ensure that O-ring seal (33) (not shown) is correctly orientated on the exhaust gas valve (7).

5. Lubricate exhaust gas valve (7) with clean engine oil in Positions (Z).

6. Install exhaust gas valve (7) into inlet air control assembly (8). Ensure that the exhaust gas valve slides into the inlet air control assembly without binding. If binding is felt on installation of the exhaust gas valve, remove the valve and carried out cleaning process as Step 1 through Step 2 to repeat the cleaning procedure.

7. Install Allen head bolts (32) and tighten the Allen head bolts to a torque of 10 N·m (89 lb in).
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   Illustration 11	g06015830
   Typical example

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   Illustration 12	g06015831
   Typical example

8. Position a new gasket (16) onto inlet air control assembly (8). Ensure gasket (16) is correctly installed into locating Pins (C).

9. Loosen bolts (36) for bracket (35).
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   Illustration 13	g06015691
   Typical example

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   Illustration 14	g06015699
   Typical example

10. Position inlet air control assembly (8) onto the bracket.

    Note: Ensure that the inlet air control assembly is correctly installed onto the hose assembly for the inlet elbow.

11. Install bolts (25) to inlet air control assembly (8) hand tight.

12. Install bolts (14) hand tight. Ensure that gasket (16) remains correctly positioned onto inlet air control assembly (8).

13. Tighten bolts (25) to a torque of 18 N·m (159 lb in).

14. Tighten bolts (14) to a torque of 22 N·m (195 lb in).
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    Illustration 15	g06015831
    Typical example

15. Tighten bolts (36) for bracket (35) to a torque of 44 N·m (32 lb ft).
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    Illustration 16	g06018304
    Typical example

16. Install stud (26). Tighten the stud to a torque of 11 N·m (97 lb in).

    Note: On certain applications, a spacer an extra gasket may be installed.

17. If necessary, position a new gasket (30) (not shown) over stud (26).

18. If necessary, install spacer (29) to stud (26).

19. Position a new gasket (28) (not shown) over stud (26).

20. Install connection (9).

21. Install bolts (31) and nut (27) to connection (9). Tighten bolts and nut to a torque of 18 N·m (159 lb in)

22. Position tube assembly (24) onto inlet air control assembly (8). Loosely install bolt (23) and bolt (15) to the tube assembly.

23. Install sealing washer (21) (not shown) to banjo bolt (22). Install the banjo bolt to tube assembly (24) and install remaining sealing washer (21) (not shown) to the banjo bolt.

24. Tighten banjo bolt (22) to a torque of 15 N·m (133 lb in).

25. Tighten bolt (23) and bolt (15) to a torque of 22 N·m (195 lb in).

26. Position a new hose clamp (17) onto hose assembly (18). Install hose assembly to inlet air control assembly (8). Tighten hose clamp (17).

27. Position a new hose clamp (19) onto hose assembly (20). Install hose assembly to inlet air control assembly (8). Tighten hose clamp (19).

28. Connect hose assembly (13) to the wastegate actuator. Slide clip (12) along hose assembly (13). Ensure that the clip is correctly positioned onto the hose.
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    Illustration 17	g06015679
    Typical example

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    Illustration 18	g02518536
    Hose clamp Type (A) Hose clamp Type (B)

29. Tighten hose clamps (10) on the hose assembly that connects inlet air control assembly (8) to inlet elbow (11). Refer to Illustration 18 to determine the correct type of hose clamp.

    Tighten hose clamps Type (A) to a torque of 11 N·m (97 lb in).

    Tighten hose clamps Type (B) to a torque of 7 N·m (62 lb in).

30. Slide connection for wiring harness assembly (4) onto bracket (3). Connect engine wiring harness assembly (2) to wiring harness assembly (4) for wastegate solenoid (6).

31. Slide the connection for wiring harness assembly (5) onto bracket (3). Connect engine wiring harness assembly (1) to wiring harness assembly (5) for NRS valve (7).

32. If necessary, connect the hose assembly to connection (9) for inlet air control (8). Tighten the hose clamps to a torque of 6 N·m (53 lb in).

Throttle Valve (Intake Air) for Certain C7.1 Engines (If Equipped)

1. Install the throttle valve. Refer to Disassembly and Assembly, Throttle Valve (Intake Air) - Remove for the correct procedure.

Temperature Sensor (Cooled Exhaust Gas)

Illustration 19	g06015553
Typical example

1. Slide connection for wiring harness assembly (3) onto bracket (4). Connect engine wiring harness assembly (2) to wiring harness assembly (3). Slide the locking tab into the locked position.

2. Install new cable straps (1) to harness assembly (3).

   Note: Ensure that cable straps meet the Original Equipment Manufactures (OEM) specification.