TOPIC: Exhaust System

IDENT NO: 8-4061

275GL+
DATE: February 2016
* SUPERSEDES: NEW

SUBJECT: NOx Sensor Modification

MODELS AFFECTED: 16-Cylinder 275GL+

The purpose of this bulletin is to inform the field

of a modified NOx sensor mounting
configuration on current engines and a new
1
service kit developed to address any issues that
might be experienced under certain operating
conditions on early production engines. 2
Some early production 275GL+ engines had NOx
sensors that sloped downward from the
turbocharger exhaust elbow. Under certain
operating conditions, this allowed condensation
or moisture to contaminate the NOx sensor,
resulting in sensor failure. Later production
engines had a modified sensor mounting to
keep the NOx sensor level (at 90 degrees) or at
Figure 1: NOx Sensor Orientation
an upward slope (<90 degrees) to prevent this
condition (see Figure 1). Inspect the orientation
of the NOx sensor on 275GL+ engines at the next 1 - Desired Angle 2 - Not Acceptable
service interval. Replace downward sloping NOx
sensors with the service kit listed in Table 1. Table 1: NOx Sensor Mounting Kit (P/N 495795)
PART NUMBER DESCRIPTION QUANTITY
! WARNING 211476H Nipple, Special 1
Always allow the engine to cool Washer, Copper,
291823 1
to room temperature before 35 x 27 x 2
servicing the engine. Fitting, Turbo
296195A 1
Exhaust
Connector, Male,
194769A 1
0.38 OD x 0.38 NPT
Never handle heated parts with 296751A Tube, NOx 1
bare hands. Always wear
Elbow, Male,
protective insulated gloves. 199111B 1
0.38 OD x 0.25 NPT
Connector, Male,
209999E Stainless Steel, 1
0.25 OD x 0.25 NPT
211477F Block, NOx Sensor 1

* Trademark of INNIO Waukesha Gas Engines, Inc.

All other trademarks are the property of their respective owners.

02/05/2016
Copyright © 2016, INNIO Waukesha Gas Engines, Inc. Page 1 of 3
Service Bulletin No. 8-4061

SENSOR REMOVAL SERVICE KIT INSTALLATION

1. Remove the plug from the turbocharger
exhaust elbow (see Figure 2).
2. Carefully remove the NOx sensor from the
NOx sensor block.
3. Remove the lower NOx tube and fitting from
the NOx sensor block.
4. Remove the NOx sensor block, nipple and
copper washer from the exhaust elbow.
NOTE: The nipple may be galled and difficult to
remove from the turbocharger exhaust elbow.
Use a 1.00"-20 UNEF-2A tap to clean up minor
thread damage.
5. Discard all removed parts except the NOx
sensor and lower NOx tube, which will both
be reused.
2 contaminate the NOx sensor.
3 5. Install the adapter fitting to the turbocharger
4 exhaust elbow.
5 fitting.
1
7
1. Install the elbow to the top of the NOx sensor
block.
2. Apply Loctite LB 771 high-temperature nickel
anti-seize or equivalent to the threads of the
nipple. Install the nipple to the NOx sensor
block.
NOTE: Use caution to ensure anti-seize does not
contaminate the NOx sensor.
3. Install the fitting to the bottom port on the
NOx sensor block.
4. Apply Loctite LB 771 high-temperature nickel
anti-seize or equivalent to the threads of the
nipple. Install the nipple/NOx sensor block
assembly with the copper washer to the
turbocharger exhaust elbow. Tighten the
nipple to 162 ft-lb (220 N·m). Check that the
orientation of the elbow is as shown in
Figure 3.
NOTE: Use caution to ensure anti-seize does not
6. Install the male connector to the adapter
7. Install the upper NOx tube to the elbow and
male connector:
a. Insert the tube into the fitting until it
bottoms in the fitting body. (NOTE: If the
fitting was disassembled, insert the ferrule
into the fitting body with the small,
tapered end first.)
b. Tighten the nut finger-tight.

6 c. Tighten the nut with a wrench an

additional 1-1/4 turns while holding the
fitting body with a second wrench. (NOTE:
It is helpful to mark the nut with a scribe or
ink to count the number of turns.)
8. Install the lower NOx tube to the fitting on the
bottom of the NOx sensor block (follow a – c
Figure 2: Turbocharger Exhaust Elbow with Old Parts in Step 7).
9. Install the NOx sensor to the NOx sensor
1 - Plug 5 - NOx Sensor block.
2 - Copper Washer 6 - Fitting
3 - Nipple 7 - Lower NOx Tube
4 - NOx Sensor Block

02/05/2016
Copyright © 2016, INNIO Waukesha Gas Engines, Inc. Page 2 of 3
 Service Bulletin No. 8-4061

1 2

3
4
5

7
6

Figure 3: Turbocharger Exhaust Elbow with New

Parts

1 - Copper Washer 6 - NOx Tube

(P/N 291823) (P/N 296751A)
2 - Special Nipple 7 - Male Connector
(P/N 211476H) (P/N 194769A)
3 - Male Elbow 8 - Turbo Exhaust
(P/N 199111B) Fitting (P/N
4 - NOx Sensor Block 296195A)
(P/N 211477F) 9 - Lower NOx Tube
5 - Male Connector, (Reused)
Stainless Steel
(P/N 209999E)

02/05/2016
Copyright © 2016, INNIO Waukesha Gas Engines, Inc. Page 3 of 3