Exhaust Gas Valve (NRS) for C4.4 Engines {5137} Caterpillar

Exhaust Gas Valve (NRS) for C4.4 Engines {5137} [M0066148]

AIR INLET AND EXHAUST SYSTEM

VALVE GP-CONTROL

Exhaust Gas Valve (NRS) for C4.4 Engines {5137}

1.1. Introduction

2.1. Safety Section

3.1. Required Parts

4.1. Removal Procedure

5.2. Installation Procedure

Asphalt Compactor
CB54B (S/N: LXD1-308; RJN1-164,166-224)
Backhoe Loader
416F (S/N: KSF1-2254)
420F (S/N: HTG1-1; JWJ1-3288; SKR1-5380,6996-6996,45157-45157; HST1-201)
428F (S/N: RAK1-610)
430F (S/N: RDF1-332,334-870; HBN1-201; HMS1-1; RGS1-376,378-762)
432F (S/N: HRH1-201; PXR1-893)
434F (S/N: MTR1-241)
444F (S/N: JXR1-346)
450F (S/N: HJR1-202,204-490)
Excavator
312E (S/N: GAC1-1785; PZL1-923)
312E L (S/N: MJD1-1523; WEY1-736)
312E MHPU L (S/N: EGR1-127,129-138)
314E CR (S/N: ECN1-916,918-1005)
314E LCR (S/N: DKD1-706; ZJT1-1552; YCW1-481)
316E L (S/N: DZW1-133,135-2261; WZY1-153; YZZ1-459,461-465)
316F L (S/N: YDL1-1,134-134)
318E L (S/N: DZF1-340; WZS1-333)
Industrial Engine
C4.4 (S/N: 4481-294,298-333,335-358,360-415,417-539,541-1010,1012-1142,1144-1226,1236-1246,1249-1441,1453-1997,1999-2103,2105-2593,2595-2835,2837-3169,3171-3492,3494-4209,4211-4231,4233-4303,4305-4966,4968-6241,6243-6958,6960-7179,7181-7570,7572-7603,7605-7701,7703-7717,7719-8059,8061-8144,8146-8198,8234-8535,8537-8728,8730-8730,8732-8734,8736-8826,8829-8923,8963-8971,8981-9028,9032-9043,9059-9080,9088-9088,9092-9094,9098-9165,9171-9189,9192-9211,9213-9213,9218-9236,9238-9250)
Pneumatic Compactor
CW34 (S/N: CT31-232; TLJ1-175,412-412)
Soil Compactor
CP54B (S/N: CPX1-200)
CP56B (S/N: LHC1-749)
CP68B (S/N: LCF1-130)
CP74B (S/N: L7B1-142)
CS54B (S/N: MJ51-140; L4H1-645)
CS56B (S/N: L8H1-103,105-1245,1247-1261)
CS64B (S/N: C641-191)
CS66B (S/N: CS61-288,290-290)
CS68B (S/N: MMS1-181)
CS74B (S/N: LCB1-157)
CS76B (S/N: L9H1-156)
CS78B (S/N: L8C1-102,104-207)
Telehandler
TH336C (S/N: MJR152-152,154-157,159-164,166-171,174-178,180-197,199-229,232-232,235-240,242-243,245-246,248-250,252-258,266-267,269-272,284-285,289-292)
TH337C (S/N: DJB151-151,153-161,163-167,169-232,236-238,244-244,246-246,248-249,251-254,256-262,266-266,268-283,285-285,287-287,289-299,301-303,305-306,308-310,323-324,329-329,332-332,334-335,337-337,339-339,343-348,350-357,360-361,363-368,373-374,386-386,394-395,399-399,406-407,409-410,415-415,424-424,437-438,442-442,444-444,455-466,470-470,473-477,479-481,483-483,485-486,493-493,495-495,498-500,503-503,505-506,509-530,532-532,534-535,540-566,568-583,589-589,592-593,599-602,604-604)
TH406C (S/N: GAT152-165,167-198,200-206,208-216,218-221,225-228,230-230,232-244,246-246,248-250,252-253,258-259,262-262,267-276,280-286,288-291,293-293,295-295,297-300,302-302,304-305,307-308,310-310,312-313,315-321,323-334)
TH407C (S/N: MLH152-153,159-177,179-185,187-189,191-192,194-197,199-226,228-230,232-232,234-234,238-240,242-282,284-373,375-385,387-396,398-408,410-410,412-415,417-418,421-440,443-445,447-450,452-454,458-478,480-485,487-490,492-494,496-505,507-509,511-515,517-518,520-520,522-532,535-536,538-543,545-546,548-549,551-553,555-568,570-570,572-585,587-597,599-599,601-617,619-623,625-625,627-641,643-654,656-663,665-667,669-671,673-674,676-676,678-693,697-728,730-749,754-755,757-764,766-773,775-776,778-779,782-783,785-785,787-788,792-793,796-797,799-802,804-806,808-827,830-831,834-840,842-858,872-881,883-889,892-892,894-899,901-903,905-907,909-915,917-917,921-926,928-951,953-964,967-968,970-980,983-986,992-993,997-998,1000-1000,1005-1005,1007-1007,1009-1009,1011-1013,1015-1015,1017-1018,1020-1027,1029-1029,1031-1042,1044-1052,1054-1066,1068-1068,1070-1070,1072-1080,1083-1083,1086-1101,1104-1113,1115-1116,1120-1120,1122-1124,1127-1134,1136-1140,1142-1144,1146-1150,1154-1154,1156-1175,1177-1177,1179-1185,1188-1194)
TL1055C (S/N: KDE1-154,156-211,213-229,231-238,240-271,273-282,284-358,360-405,407-454,456-463,465-468,470-475,477-554,556-562,564-565,567-567,569-569,571-574,577-587,589-625,627-633,635-660,663-776,778-778,781-781,783-789,791-896,898-906,910-914,916-917,919-922,924-924,928-1032,1034-1062,1064-1072,1075-1077,1079-1225,1227-1262,1264-1293,1295-1415,1417-1495,1497-1604,1606-1622,1624-1648,1650-1652,1654-1654,1656-1656,1658-1658,1660-1664,1666-1666,1669-1715,1717-1721,1726-1743,1745-1745,1747-1763,1765-1771,1773-1777,1779-1783,1785-1792,1794-1805,1807-1823,1826-1828,1830-1832)
TL1255C (S/N: DHW1-207,209-214,216-221,223-374,376-429,431-471,473-583,585-614,616-679,681-743,745-793,795-956,958-995,997-1006,1008-1112,1114-1137,1139-1377,1380-1479,1481-1481,1483-1527,1529-1536,1538-1551,1553-1562,1564-1564,1566-1566,1569-1570)
Track-Type Tractor
D3K2 LGP (S/N: GAE1-187; KLL1-1069)
D3K2 XL (S/N: KFF1-531)
D4K2 LGP (S/N: KRR1-687)
D4K2 XL (S/N: KMM1-707)
D5K2 LGP (S/N: TRF1-335; KYY1-1833)
D5K2 XL (S/N: KWW1-1303)

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 valves 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 seizes due to erosion of the clearance between the poppet valve stem and guide bush.

An improved design of exhaust gas valves is being 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.

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NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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NOTICE

Ensure that the wiring harness assembly is correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness convoluting.

Required Parts

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Table 1
Required Parts
New Part Number	Parts Description	Qty
217-9039	Cable Strap	4
345-0835	Gasket	1
466-7876	Valve	1
466-7877	Valve	1

Removal Procedure

Turn the battery disconnect switch to the OFF position.
For some application 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.
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Illustration 1 g06014160
Disconnect harness assembly (1) for the exhaust gas valve (4) from the engine harness assembly.
Cut cable strap (2) and cable straps (6). Disconnect harness assembly (3) for temperature sensor (7) from the engine harness assembly.
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Illustration 2 g06014173
Remove the Allen head bolts (8) and remove the bracket (5) from NRS Induction Mixer (9).
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Illustration 3 g06014402
Follow Step 6.athrough Step 6.d to install Allen head bolts (8) to NRS Induction Mixer (9) and to remove exhaust gas valve (4) from NRS Induction Mixer (9).
1. Install the Allen head bolts (8) and leave a Gap (W) of 6 mm (0.236 inch) between exhaust gas valve (4) 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 NRS Induction Mixer (9).
2. 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 (4) from NRS Induction Mixer (9).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.
3. Remove Allen head bolts (8) and remove exhaust gas valve (4) from NRS Induction Mixer (9).
4. Remove gasket (10) (not shown).
If the above procedure does not remove the exhaust gas valve (4) from NRS Induction Mixer (9) and the Disassembly and Assembly, Inlet Air Control (NRS Induction Mixer) - Remove and Install for the correct procedure.

Installation Procedure

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Illustration 4	g06014408

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 (11) of NRS Induction Mixer (9).
Ensure that area (11) 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 5 g06014438

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Illustration 6 g06014435

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Illustration 7 g06014160
Select the correct exhaust gas valve (4) and a new gasket (10) (not shown) from the Table 1.
Position gasket (10) (not shown) onto exhaust gas valve (4). Ensure that the gasket is correctly orientated on the exhaust gas valve.
Lubricate exhaust gas valve (4) with clean engine oil in Positions (Z).
Install exhaust gas valve (4) into NRS Induction Mixer (9). Ensure that the exhaust gas valve slides into the NRS Induction Mixer 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.
Position bracket (5) onto exhaust gas valve (4). Ensure that the bracket is correctly orientated. Install. Install Allen head bolts (8) and tighten the Allen head bolts to a torque of 10 N·m (89 lb in).
Connect harness assembly (1) for the exhaust gas valve (4) to the engine harness assembly.
Connect harness assembly (3) for temperature sensor (7) to the engine harness assembly.
Select new cable strap (2) and new cable straps (6) from Table 1. Install to the cable straps to the harness assemblies.
Note: Ensure that the cable straps meet Original Equipment Manufacturers (OEM) specifications.