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

Exhaust Gas Valve (NRS) for C7.1, and C6.6 Engines {5137} [M0066370]

AIR INLET AND EXHAUST SYSTEM

VALVE GP-CONTROL

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

1.1. Introduction

2.1. Safety Section

3.1. Required Parts

4.1. Removal Procedure

5.2. Temperature Sensor (Cooled Exhaust Gas)

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

7.2. Inlet Air Control (NRS Inlet Air Mixer)

8.1. Installation Procedure

9.2. Inlet Air Control (NRS Inlet Air Mixer)

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

11.2. Temperature Sensor (Cooled Exhaust Gas)

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

Show/hide table

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.

Show/hide table

NOTICE

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

Show/hide table

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

Show/hide table

Table 1
Required Parts
Part Number	Part Description	Qty
217-9039	Cable Strap	2
332-7865	Cable Strap	2
225-8526	Cooper Washers	2
346-9501	Gasket	1
346-9507	Gaskets	2
385-0697	Clamps	2
467-0529	Valve	1
467-0543	Valve	1

Removal Procedure

Turn the battery disconnect switch to the OFF position.
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)

Show/hide table




Illustration 1	g06015553
Typical example

Cut cable straps (1).
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)

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)

Show/hide table




Illustration 2	g06015679
Typical example

If necessary, loosen the hose clamps and disconnect the hose assembly from connection (9) for inlet air control (8).
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).
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).
Loosen hose clamps (10) on the hose assembly that connects inlet air control assembly (8) to inlet elbow (11).
Show/hide table

Illustration 3 g06015691

Typical example
Slide clip (12) along hose assembly (13). Disconnect the hose assembly from the wastegate actuator.
Remove bolt (15) for the tube assembly for the wastegate actuator.
Remove bolts (14).
Show/hide table

Illustration 4 g06015699

Typical example
Release hose clamp (17) for hose assembly (18). Remove the hose assembly from inlet air control assembly (8).
Release hose clamp (19) for hose assembly (20). Remove the hose assembly from inlet air control assembly (8).
Remove banjo bolt (22) and remove sealing washers (21) (not shown).
Remove bolt (23) from tube assembly (24). Remove the tube assembly from inlet air control assembly (8).
Show/hide table

Illustration 5 g06018304

Typical example
Remove bolts (31) and nut (27) from connection (9).
Remove connection (9) and gasket (28) (not shown).
Note: On certain applications, a spacer and an extra gasket may be installed.
If necessary, remove spacer (29) and gasket (30) (not shown).
Remove stud (26).
Remove bolts (25) from inlet air control assembly (8).
Remove inlet air control assembly (8).
Remove gasket (16) (not shown).
Position inlet air control assembly (8) into a suitable vice that has soft jaws.
Show/hide table

Illustration 6 g06015720

Typical example
Remove the Allen head bolts (32) from inlet air control assembly (8).
Show/hide table

Illustration 7 g06015767

Typical example
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).
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).
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.
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)

Show/hide table




Illustration 8	g06015794
Typical example

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).
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.
Show/hide table

Illustration 9 g06015815

Typical example

Show/hide table

Illustration 10 g06015807

Typical example
Select the correct exhaust gas valve (7) from Table 1.
Ensure that O-ring seal (33) (not shown) is correctly orientated on the exhaust gas valve (7).
Lubricate exhaust gas valve (7) with clean engine oil in Positions (Z).
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.
Install Allen head bolts (32) and tighten the Allen head bolts to a torque of 10 N·m (89 lb in).
Show/hide table

Illustration 11 g06015830

Typical example

Show/hide table

Illustration 12 g06015831

Typical example
Position a new gasket (16) onto inlet air control assembly (8). Ensure gasket (16) is correctly installed into locating Pins (C).
Loosen bolts (36) for bracket (35).
Show/hide table

Illustration 13 g06015691

Typical example

Show/hide table

Illustration 14 g06015699

Typical example
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.
Install bolts (25) to inlet air control assembly (8) hand tight.
Install bolts (14) hand tight. Ensure that gasket (16) remains correctly positioned onto inlet air control assembly (8).
Tighten bolts (25) to a torque of 18 N·m (159 lb in).
Tighten bolts (14) to a torque of 22 N·m (195 lb in).
Show/hide table

Illustration 15 g06015831

Typical example
Tighten bolts (36) for bracket (35) to a torque of 44 N·m (32 lb ft).
Show/hide table

Illustration 16 g06018304

Typical example
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.
If necessary, position a new gasket (30) (not shown) over stud (26).
If necessary, install spacer (29) to stud (26).
Position a new gasket (28) (not shown) over stud (26).
Install connection (9).
Install bolts (31) and nut (27) to connection (9). Tighten bolts and nut to a torque of 18 N·m (159 lb in)
Position tube assembly (24) onto inlet air control assembly (8). Loosely install bolt (23) and bolt (15) to the tube assembly.
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.
Tighten banjo bolt (22) to a torque of 15 N·m (133 lb in).
Tighten bolt (23) and bolt (15) to a torque of 22 N·m (195 lb in).
Position a new hose clamp (17) onto hose assembly (18). Install hose assembly to inlet air control assembly (8). Tighten hose clamp (17).
Position a new hose clamp (19) onto hose assembly (20). Install hose assembly to inlet air control assembly (8). Tighten hose clamp (19).
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.
Show/hide table

Illustration 17 g06015679

Typical example

Show/hide table

Illustration 18 g02518536

Hose clamp Type (A)
Hose clamp Type (B)
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).
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).
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).
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)

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

Temperature Sensor (Cooled Exhaust Gas)

Show/hide table




Illustration 19	g06015553
Typical example

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.
Install new cable straps (1) to harness assembly (3).
Note: Ensure that cable straps meet the Original Equipment Manufactures (OEM) specification.