Relocation Procedure of the Engine Outlet NOx Sensor On Certain 834K, 836K, and 988K Machines{7490} Caterpillar


`
Relocation Procedure of the Engine Outlet NOx Sensor On Certain 834K, 836K, and 988K Machines{7490} [REHS9571]
OPERATOR STATION
MONITOR GP
1.1. Introduction
2.1. Parts Required
3.1. Inspection and Rework of 464-1103 Harness As
4.1. Installation Procedure
Landfill Compactor:
836K (S/N: TWZ1-432)
Wheel Dozer:
834K (S/N: TWY1-302)
Wheel Loader:
988K (S/N: TWX1-361)

Introduction

The following Special Instruction covers the procedure for relocating the engine outlet NOx sensor. The NOx sensor location is being moved from the pre-bellow location to a post bellows location to reduce vibration.

Do not perform any procedure or order parts until you have read and understand the following procedure.

Parts Required

There are four different groups that take only certain parts that are listed in Table 1. Ensure that the correct parts are ordered for the appropriate groups. The effectivity for each group is listed below.

  • Group 1 - TWX00150-00260, ; TWY00200-00301

  • Group 2 - TWZ00250-00411

  • Group 3 - TWX00261-00361, ; TWY00302

  • Group 4 - TWZ00412-00432

Table 1
Item     Qty     Part Number     Part Description    
1     2     118-7313     Bolt    
2     1     124-3019     Bracket As    
3     2     125-8534     Plate As    
4     2     132-5789     Clip    
5     1     173-1583     Bracket As    
6     2     198-4780     Hard Washer    
7     1     1W-5455     Clamp    
8     2     204-2281     Cable Strap    
9     2     204-8000     Cable Tie Mounting    
10     1     217-4590     Bracket As    
11     4     342-2135     Clip    
12     1     343-9010     Bellows As    
13     3     344-5675     Nut    
14     1     346-0334     Band Clamp    
15     1     346-0335     Band Clamp    
16     1     359-9171     Nitrogen Oxide Sensor As    
17     1     394-1204     Bracket    
18     1     442-8716 (3)     Heat Shield As    
19     1     442-8718 (3)     Heat Shield As    
20     1     442-8720     Exhaust Tube As    
21     1     444-5130     Diffuser    
22     1     449-2534 (3)     Heat Shield As    
23     1     449-2535 (3)     Heat Shield As    
24     1     464-1103     Harness As    
25     1     464-4331 (1)     Plate    
26     1     464-4332 (1)     Plate    
27     1     4P-7581     Clip    
28     4     4P-8134     Clip    
29     2     5C-9553     Bolt    
30     10     7K-1181     Cable Strap    
31     22     8T-4121     Hard Washer    
32     3     8T-4136     Bolt    
33     6     8T-4137     Bolt    
34     3     8T-4191     Bolt    
35     5     8T-4195     Bolt    
36     2     8T-4196     Bolt    
37     2     9X-8256     Washer    
38     1     445-7910     Exhaust Lines Gp    
39     1     380-6885 (2)     Heat Shield As    
40     1     380-6886 (2)     Heat Shield As    
41     1     380-6887 (2)     Heat Shield As    
( 3 ) For the 836K only
( 1 ) Groups 1 and 2 only
( 2 ) Groups 2 and 4 only

Inspection and Rework of 464-1103 Harness As

The 464-1103 Harness As , in the above parts list, may have incorrect connector wire locations. Inspect the connector wire locations per the chart below. Rework the harness if required. If the harness wire locations are incorrect, numerous fault codes will be generated. Parts inventory rework is in process.

Table 2
Connection to Engine Harness (AY)    
Ampseal Connector Table NX-C1    
CLR-GA     Wire Name     Position     Term/Plug    
PK-14     128-NX1     1     126-1767    
        2     8T-8737    
        3     8T-8737    
BK-14     229-NX2     4     126-1767    
GN-18     K990-NX3     5     9X-3401    
YL-18     K900-NX4     6     9X-3401    
Accessories    
Qty     Part Name     Part Number    
1     Receptacle As.     230-5011    
1     Wedge     155-2262    



Illustration 1g03799445

Use DT tool to remove wedge and move three incorrect wires. Fill position (2) and (3) with 8T-8737 Seal Plugs .

Installation Procedure




    Illustration 2g03718625

  1. Use the existing bosses, add the hardware and jumper harness.



      Illustration 3g03826963

    1. Install clips (28) using bolts (35) with hard washers (31) to secure the clip. Install clip (4) using bolt (33) with hard washers (31) to secure the clips.

    1. Secure the harness to the clips using cable straps (30) as shown in Illustration 3.

    1. Connect jumper harness assembly (24) to the connector.



    Illustration 4g03827063

  1. Install clip (4) onto the existing boss shown in Illustration 4. Route the jumper harness as shown in Illustration 4 using cable straps (30) to secure jumper harness (24) to the clips.

    Note: Steps 3, 4, and plate (25) only applies to Groups 1 and 2. For groups 3 and 4 the hardware can be directly mounted to the machine.




    Illustration 5g03827068

  1. Install the clips to the plate (25) .

    1. Install clip (4) to the plate using bolt (35) with hard washers (31) and nut (13) .

    1. Install clip (28) to the plate using bolt (35) with hard washers (31) and nut (13) .

    1. Install clip (27) to the plate using bolt (35) with hard washers (31) and nut (13) .



    Illustration 6g03827077

  1. Install plate (25) to the existing hardware using bolts (36) with hard washers (31). Route jumper harness (24) as shown in Illustration 6 using cable straps (30) to secure the harness to the clips.



    Illustration 7g03827082

  1. Install brackets (3) and (5) to the existing boss using bolt (32) with hard washer (31) .

  1. Install cable tie mounts (9) to the brackets using bolts (32) with hard washers (31) .

  1. Secure jumper harness (24) to cable mounts (9) using cable straps (8) .

    Note: Step 8 applies only to Groups 1 and 2.




    Illustration 8g03720815

  1. Modify the area of the scab plate shown in Illustration 8 so the bolts do not push into the shield.



      Illustration 9g03735831

      (A) 117 mm (4.61 inch)

      (B) 50 mm (1.97 inch)

      (C) 32.4 mm (1.28 inch)

      (D) 38.1 mm (1.50 inch)

    1. Drill two holes 38.1 mm (1.5 inch) in diameter.

    1. Use the following measurements and Illustration 9 to drill the holes in the correct locations.

      • 117 mm (4.61 inch) from the top surface

      • 50 mm (2 inch) apart from one another

      • 32.4 mm (1.25 inch) from the side

    Note: Step 9 applies only to Groups 1 and 2.




    Illustration 10g03827085

  1. Install plate (26) using bolts (1) with hard washers (6) .

  1. Install nitrogen oxide sensor assembly (16) with two bolts (29) and two hard washers (37) .

  1. Install bracket assembly (10) using bolt (34) with hard washer (31) .

  1. Route jumper harness (24) through clip (11). Install the clip to bracket assembly (10) using bolt (33) with hard washer (31) .

  1. Route jumper harness (24) through clip (11). Install the clip to plate (26) using bolt (34) with hard washer (31) .

  1. Install bracket (17) to plate (26) using bolt (34) with hard washer (31) .

  1. Route jumper harness (24) as shown in Illustration 10. Use cable strap (30) to secure the harness to the clip (17) .

  1. Connect to the new NOx sensor location.



      Illustration 11g03827086

    1. Install plate assembly (3) using bolt (33) with hard washer (31) on one end. On the other end, route jumper harness (25) through clip (11) and secure to the plate assembly using bolt (33) with hard washer (31) .

    1. Install bracket assembly (2) to the existing boss using bolt (33) with hard washer (31) .

    1. Route jumper harness (25) through clip (11) and use bolt (33) with hard washer (31) to secure the clip to the bracket assembly.



    Illustration 12g03827106

    (39) 380-6885 Heat Shield As

    (40) 380-6886 Heat Shield As

    (41) 380-6887 Heat Shield As

  1. Remove heat shield assemblies (39), (40), and (41) .



    Illustration 13g03827122

    (42) 349-9673 Exhaust Diffuser Adapter Gp

    (43) 034-3412 Cable Strap

    (44) 7N-4080 Boot

  1. Remove boot (44) by removing cable strap (43). Remove exhaust diffuser adapter group (42) from the turbocharger.



    Illustration 14g03827123

    (7) 1W-5455 Clamp

    (21) 444-5130 Diffuser

    (38) 445-7910 Exhaust Lines Gp

  1. Install exhaust lines group (38) that consists of clamp (7) and diffuser (21).

    1. Position the diffuser with the outlet 0° to 5° from the engine vertical (straight down).

    1. Position the clamp fastener pointing out or down.



    Illustration 15g03827126

    (39) 380-6885 Heat Shield As

    (40) 380-6886 Heat Shield As

    (41) 380-6887 Heat Shield As

  1. Install heat shield assemblies (39), (40), and (41) .



    Illustration 16g03827127

    (12) 343-9010 Bellows As

    (14) 346-0334 Band Clamp

    (15) 346-0335 Band Clamp

    (20) 442-8720 Exhaust Tube As

  1. Install flexible exhaust pipe group between the turbocharger and the aftertreatment package.

    1. Ensure that the bellows alignment and protective package is on the bellows assemblies. Pre-assemble the slip joint loosely.

    1. Assemble the joint at the turbocharger outlet and loosely tighten band clamp (14) .

    1. Align and assemble exhaust tube assembly (20) at the aftertreatment inlet ball joint and loosely tighten band clamp (15) .

      Note: The slip joint should slide smoothly with a minimum engagement of 40 mm (1.6 inch). Engagement will be verified when ink line on the slip joint inner tube is no longer visible.

    1. Tighten band clamp (15) to 35 ± 2 N·m (26 ± 2 lb ft).

    1. Tighten band clamp (12) to 35 ± 2 N·m (26 ± 2 lb ft).

    1. Verify the ink mark on the slip joint inner tube is still not visible.

    1. Remove the bellows alignment and protective packaging by cutting the straps on these components.

    1. Tighten the clamp at the slip joint to 55 ± 8 N·m (41 ± 6 lb ft)

    Note: The step below is for the installation of the exhaust heat shield assemblies, which only applies to the 836K.




    Illustration 17g03737096

  1. Install the exhaust heat shield assemblies.



      Illustration 18g03827132

      (12) 343-9010 Bellows As

      (14) 346-0334 Band Clamp

      (15) 346-0335 Band Clamp

      (18) 442-8716 Heat Shield As

      (19) 442-8718 Heat Shield As

      (20) 442-8720 Exhaust Tube As

      (22) 449-2534 Heat Shield As

      (23) 449-2535 Heat Shield As

    1. Ensure that the bellows alignment and protective package is on the bellows assemblies. Pre-assemble the slip joint loosely.

    1. Assemble the joint at the turbocharger outlet and loosely tighten band clamp (14) .

    1. Align and assemble exhaust tube assembly (20) at the aftertreatment inlet ball joint and loosely tighten band clamp (15) .

      Note: The slip joint should slide smoothly with a minimum engagement of 40 mm (1.6 inch). Engagement will be verified when ink line on the slip joint inner tube is no longer visible.

    1. Tighten band clamp (15) to 35 ± 2 N·m (26 ± 2 lb ft).

    1. Tighten band clamp (20) to 35 ± 2 N·m (26 ± 2 lb ft).

    1. Verify the ink mark on the slip joint inner tube is still not visible.

    1. Remove the bellows alignment and protective packaging by cutting the straps on these components.

    1. Tighten the clamp at the slip joint to 55 ± 8 N·m (41 ± 6 lb ft)

    1. Install heat shield assembly (23) on the rear of the flex pipe.

    1. Install heat shield assembly (22) on the front of the flex pipe. Secure the springs between heat shield assembly (22) and (23). Secure the springs to the turbocharger wraps also.

    1. Install heat shield assembly (18) on the rear of the flex pipe towards the Clean Emissions Module (CEM). Make sure to insert the heat shield assembly into the CEM wrap.

    1. Install heat shield assembly (19) on the front of the flex pipe towards the CEM.

    1. Secure the springs between heat shield assembly (18) and (19) .

Information System:

3512E Petroleum Engines Engine Governing - Adjust
950 GC Wheel Loader Power Train Trunnion Support (Oscillating Axle, Front) - Remove and Install
980L Medium Wheel Loader Power Train, Steering, Braking, Hydraulic, and Machine Systems Transmission Speed for Reverse Directional Shift - Program
980L Medium Wheel Loader Power Train, Steering, Braking, Hydraulic, and Machine Systems Transmission Speed for Forward Directional Shift - Program
C175-16 Locomotive Engine Configuration Parameters
D4, D6K2 and D6K Track-Type Tractor Systems Electronic Control (Hydraulic System)
2014/10/16 New Ejector Cylinder Group is Now Used on Certain 631G and 637G Wheel Tractor-Scrapers {5305}
D7E Track-Type Tractor Systems Electronic Control (Power Train System)
Fast Fill Hose Inspection On Certain D8TTrack-Type Tractors Equipped With a Fast Fuel Attachment{1273, 1710}
C280 Marine Engines Secondary ECM Assumes Control
3500E EPA Tier 4 Final and IMO-II/III Switchable Marine Engines Engine Control Switch - Test
3516B Generator Set Engines with Dynamic Gas Blending Intake Manifold Air Temperature Is High
2014/10/23 Improved Woodchip Screens are now used on D8T Track-Type Tractors Equipped with Quick Release Radiator Grills {7170}
986H Wheel Loader Differential and Bevel Gear - Disassemble
Instrument Display Turn Signal Indicators Do Not Blink When the Signal Switch is Activated{1430}
Procedure to Install LED Lights on AD30 Underground Articulated Trucks{1429, 1434}
2014/09/05 Water In Fuel Sensor Wiring on Certain C3.4B Engines {1408, 7422}
525D, 535D, 545D and 555D Wheel Skidders C7.1 Engine Supplement System Pressure - Release
2014/09/05 Cat Reman Has Added Valve Actuators, Valve Lifters, Rocker Arms, and Camshafts for Certain Machine Engines {1121, 1130, 1209, 1210}
2014/09/05 Cat Reman Announces New Fuel Pump, Fuel Ratio Control, and Fuel Injector Options for Certain Engines {1251, 1278}
2014/09/04 Cat Reman Announces New Fuel Pump, Fuel Ratio Control, and Fuel Injector Options for Certain Machine Engines {1251, 1278}
Installation Procedure of <NOBR>469-0108</NOBR> Kit Utility Mounting Brackets Inside the Cab of Certain Medium Wheel Loaders {7301}
525D, 535D, 545D, 555D Wheel Skidder Engine Starting with Jump Start Cables
950M Z and 962M Z Wheel Loaders Engine Oil and Filter - Change