Installing the New NOx Reduction System Pressure Sensor Kit on Certain C7.1 Engines {1718, 1917, 1923, 1924, 7400} Caterpillar


Installing the New NOx Reduction System Pressure Sensor Kit on Certain C7.1 Engines {1718, 1917, 1923, 1924, 7400}

Usage:

C7.1 881
Asphalt Paver
AP1000F (S/N: AC41-361)
AP1055F (S/N: TJ51-709,711-715,719-720)
Excavator
323 (S/N: RAZ1-1,123-153,155-170,172-281,283-300,302-310,312-314)
330F (S/N: JFR1-231,10001-10082,20001-20046)
Forest Machine
538 (S/N: KBJ1-1; HBS1-189; GMY1-103; JEY1-204)
558 (S/N: LRT1-275)
Industrial Engine
C7.1 (S/N: 8811-253,255-255,257-269,271-272,274-274,276-310,313-373,375-382,386-523,525-539,542-609,611-718,720-1288,1291-1519,1521-1656,1658-1700,1703-1745,1747-1932,1934-1934,1936-2461,2464-2601,2606-3252,3269-3309,3312-3396,3399-3434,3437-3439,3441-3448,3450-3485,3487-3492,3494-3500,3502-3506,3508-3536,3539-3539,9999-9999)
Material Handler
MH3022 (S/N: FB31-356,2256-2259)
MH3024 (S/N: FB51-187,190-233,235-236)
MH3037 (S/N: JLH1-1,303-307,309-309,311-311,314-314)
Soil Compactor
815K (S/N: MBB1-203,301-329)
Track-Type Loader
953K (S/N: LJT1-205,207-216)
963K (S/N: LBL1-682)
Track-Type Tractor
D6N (S/N: MG51-197,199-1577,1579-1579,1583-1585,1587-1592,1594-1598,1600-1601,1608-1610,1613-1614; GB61-1,200-630; SGG1-280; NJN1-189)
Wheel Feller Buncher
563D (S/N: D631-143)
573D (S/N: D731-225)
Wheel Loader
950M (S/N: EMB1-1395,2101-2697,3501-4115,39959-39959; XCJ1-137,139-161,10101-10128,10131-10132,10134-10134,10136-10202,10204-10215; FTR1-177,301-724,901-1221; J1S1-1,250-707)
950M Z (S/N: HE81-315,10250-10357)
962M (S/N: EJB1-333,501-562,901-978; JYD1-1,103-129,10101-10116,10120-10281; F2T1-129,201-420,501-622)
962M Z (S/N: SA81-261,10250-10270)
Wheel Skidder
525D (S/N: GKP1-520)
535D (S/N: MTP1-447)
545D (S/N: KGP1-282)
555D (S/N: PGY1-158)
Wheeled Excavator
M318F (S/N: FB81-571)
M320F (S/N: FB21-387,389-431)
M322F (S/N: FBW1-212)

Introduction

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

Safety Section

------ WARNING! ------

Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.


------ WARNING! ------

Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.


------ WARNING! ------

When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.


------ WARNING! ------

Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below.


------ WARNING! ------

Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.


------ WARNING! ------

Do not operate the machine if any guards or covers are missing or inadequately secured. Personnel could be seriously injured or machine damage may occur.


------ WARNING! ------

Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.


Required Parts

Table 1
462-9022 Pressure Sensor Gp 
Qty  Part Number  Description 
385-1174  Pressure Sensor Gp 
422-3830  Sensor Harness As 
531-0262  Bracket 
206-1345  Cable Strap 
8T-7547  Bolt 
217-9039  Cable Strap 

Note: Check that the components of the sensor kit are all present and in good condition. The list of components are listed in Table 1.

Removal Procedure

Perform the following steps to remove the existing NRS differential pressure sensor (1) ( 397-2874 Pressure Sensor Gp).



    Illustration 1g06007308
    (1) NRS differential sensor
    (2) Sensor connection for engine harness
    (3) Head bolts (M8 x 20mm long flanged)

  1. Unplug the engine electrical harness (2) from the sensor.

  2. Remove the two M8 x 20mm long flanged head bolts (3) and discard.

  3. Remove the sensor, complete with 2 seals and discard.

  4. Clean and inspect the mating face of the NRS manifold onto which the sensor sits.

Installation Procedure

Perform the following steps to assemble the 462-9022 Pressure Sensor Gp.

  1. Ensure that both seals are correctly seated in the grooves of the sensor and are still located when fitting the sensor to the engine.


    Illustration 2g06274377
    (4) 385-1174 Pressure Sensor Gp
    (5) 531-0262 Bracket
    (6) - Port
    (7) + Port
    (8) 8T-7547 Bolts

  2. Position the sensor (4) onto the NRS manifold, ensuring that the sensor electrical connector is positioned as shown in Illustration 2. The sensor body is marked with a "+" and "-". Ensure that the sensor is orientated correctly.

  3. Place the support bracket (5) onto the sensor as shown in Illustration 2.

  4. Assemble the sensor and support bracket onto the NRS manifold. Tighten the two bolts (8) to a torque of 18 ± 2 N·m (13.3 ± 1.5 lb ft) using a 13mm AF socket as shown in Illustration 2.


    Illustration 3g06007310
    (9) 422-3830 Sensor Harness As
    (10) Red Latch


    Illustration 4g06274386
    (11) 217-9039 Cable Straps

  5. Plug one end of the sensor harness (9) into the sensor. Engage the red latch (10) to lock the sensor harness to the sensor as shown in Illustrations 3 and 4.

  6. Route the sensor harness as shown in Illustration 4.

    Retain the sensor harness to the support bracket using three cable straps (11). Remove excessive length from the cable straps.



    Illustration 5g06007314
    (12) Engine Harness

  7. Plug the other end of the sensor harness into the engine harness (12). Engage the red latch on the engine harness to lock the sensor harness as shown in Illustration 5.

Caterpillar Information System:

New NOx Reduction System (NRS) Differential Pressure Sensor Kit on Certain C7.1 Engines {1718, 1917, 1923, 1924, 7400} New NOx Reduction System (NRS) Differential Pressure Sensor Kit on Certain C7.1 Engines {1718, 1917, 1923, 1924, 7400}
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