Procedure for Removing and Installing the Exhaust Cooler (NRS) on All Tier 4 C15 and C18 Engines {108C, 108G} Caterpillar

Procedure for Removing and Installing the Exhaust Cooler (NRS) on All Tier 4 C15 and C18 Engines {108C, 108G} [REHS7798]

AIR INLET AND EXHAUST SYSTEM

EXHAUST GP

Procedure for Removing and Installing the Exhaust Cooler (NRS) on All Tier 4 C15 and C18 Engines {108C, 108G}

1.1. Introduction

2.1. Removal Procedure

3.1. Installation Procedure

Articulated Truck
735B (S/N: T4P1-UP)
740B (S/N: T4R1-UP)
740B EJECTOR (S/N: T4S1-UP)
Engine
C15 (S/N: N5F1-UP; LDN1-UP)
C18 (S/N: N8F1-UP; BDN1-UP)
Excavator
374F (S/N: DNM1-UP)
390F (S/N: MGF1-UP)
Landfill Compactor
826K (S/N: 2321-UP)
836K (S/N: TWZ1-UP)
Off-Highway Truck/Tractor
770G (S/N: RMA1-UP; KDH1-UP)
772G (S/N: RME1-UP; KEX1-UP)
Reclaimer Mixer
RM500B (S/N: MB91-UP; CXN1-UP)
Road Reclaimer/Soil Stabilizer
RM-500 (S/N: CXN1-UP)
Soil Compactor
825K (S/N: 2331-UP)
Track-Type Tractor
D8T (S/N: AW41-UP; FMC1-UP; MLN1-UP; FCT1-UP)
D9T (S/N: REX1-UP)
Wheel Dozer
824K (S/N: 2341-UP)
834K (S/N: TWY1-UP)
Wheel Loader
988K (S/N: TWX1-UP)

Introduction

Note: Do not reuse NRS cooler clamps.

Note: If ordering the cooler separately, 4 344-2636 Clamp As are required. Failure to install new clamps will lead to a repeat failure of the NRS cooler.

This Special Instruction provides the correct procedure for removing and installing the exhaust cooler (NRS). Do not perform any steps in this publication until you read and understand the steps below.

Removal Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	5P-3931	Anti-Seize Compound	-
B	207-1600⁽¹⁾	Rubber Lubricant	-
B	207-1601	Rubber Lubricant	-

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⁽¹⁾	For Use in EAME

Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".
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Illustration 1 g01842813
Remove clamp assembly (3).
Remove bolts (2) and (6). Remove tube assemblies (4).
If equipped, remove tube assembly (5).
Remove clamp assemblies (1) from both sides of the exhaust cooler.
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Illustration 2 g02485398

Note: NRS cooler clamp assemblies (9) are a one time use only. Discard used clamp assemblies (9).
Remove elbow (10).
Remove bolts (8). Remove and discard clamp assemblies (9). Use two people in order to remove exhaust cooler (7). The weight of exhaust cooler (7) is approximately 18 kg (40 lb).

Installation Procedure

Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the components, if necessary.

Install the exhaust cooler (7) in the reverse order.
1. Apply Tooling (B) to the bore for elbow (10).
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  Illustration 3 g02485236
  
  Note: NRS cooler clamp assemblies (9) are a one time use only. Discard used clamp assemblies (9).
2. When installing new clamp assemblies (9), ensure the rounded edges of clamp spacers (9a) are oriented as shown.
3. Tighten bolts (8) to a torque of 40 ± 5 N·m (30 ± 4 lb ft).
4. Apply Tooling (A) to the threads of clamp assemblies (1) and (5). Tighten clamp assemblies (1) and (5) to a torque of 7.5 ± 1 N·m (66 ± 9 lb in).
5. Lubricate the O-ring seals that are found on tube assembly (4) with the lubricant that is being sealed.