C15 and C18 Engines for Caterpillar Built Machines Exhaust Cooler (NRS) - Remove and Install - For Series Turbocharger Applications Caterpillar

Removal Procedure

1. 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	g02345276

2. Place Mark (X) at all four locations as shown. This action will aid in the installation of the lines group.

3. Loosen clamp assemblies (1) and (3) . Remove lines group (2) .

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Illustration 2	g02125717

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NOTICE
Failure to follow established procedures can lead to damage of the parts. To avoid damage to the parts, always identify and mark the parts so that the parts can be installed in the same location.

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The ends of the bellows are very sharp. Injury could occur if the bellows are not handled properly. Handle the bellows by the convolutions.

Note: Refer to Special Instruction, REHS1728, "Application Guideline for the Bellows" for additional information on handling the bellows if the machine is equipped.

4. Remove both clamp assemblies (5) . Remove bellows (6) and position exhaust tube assemblies (4) and (7) aside. Discard clamp assemblies (5) and bellows (6) .

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Illustration 3	g02345486

5. Place Mark (Y) at all four locations as shown. This action will aid in the installation of the lines group.

6. Loosen clamp assemblies (8) and (10) and discard the clamp assemblies. Remove lines group (9) .

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Illustration 4	g02345541

Note: Refer to Special Instruction, REHS1728, "Application Guideline for the Bellows" for additional information on handling the bellows if the machine is equipped.

7. Remove both clamp assemblies (12) . Remove bellows (13) and position elbow assemblies (11) and (14) aside. Discard clamp assemblies (12) and bellows (13) .

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Illustration 5	g02126160

8. Loosen clamp assembly (15) . Remove two nuts (16) and remove elbow assembly (17) .

9. Loosen clamp assembly (23) and remove bolts (20) and (18) . Remove tube assembly (19) .

10. Remove bolts (22) and remove elbow assembly (21) .

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Illustration 6	g02346038

11. Remove clamp assemblies (15) and separate elbow (17) from bellows (22) . Discard clamp assemblies (15) and bellows (24) after removal.

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Illustration 7	g02345993

12. Remove clamp assembly (25) and disconnect hose assembly (29) .

13. Remove tube assembly (28) .

14. Disconnect tube assemblies (26) and (27) .

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Illustration 8	g02129989
View from the rear of the engine

15. Disconnect fitting (30) . Remove bolts (31) and remove tube assembly (32) .

16. Loosen clamp assemblies (33) and (35) . Remove tube assembly (34) .

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Illustration 9	g02130322

Note: NRS cooler clamp assemblies (9) are a one time use only. Discard used clamp assemblies (9) .

17. Remove and discard clamp assemblies (36) . Use two people in order to remove exhaust cooler (37) . The weight of exhaust cooler (37) 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.

1. Install the exhaust cooler (37) in the reverse order.
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   Illustration 10	g03339899

   Note: NRS cooler clamp assemblies (9) are a one time use only. Discard used clamp assemblies (9) .

   1. When installing new clamp assemblies (36) , ensure the rounded edges of clamp spacers (36a) are oriented as shown.

   2. Tighten new clamp assemblies (36) to a torque of 40 ± 5 N·m (30 ± 4 lb ft).

   3. Tighten clamp assembly (33) to a torque of 8.5 ± 2 N·m (75 ± 18 lb in).
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   Illustration 11	g02346038

   4. Position the new bellows (24) , new clamp assemblies (15) , and elbow (17) into position. Apply Tooling (A) to the threads of clamp assemblies (15) . Ensure that the flow indicator on the bellows is in the position that is shown in the above illustration. Tighten clamp assemblies (15) to a torque of 7.5 ± 2 N·m (66 ± 18 lb in).

   5. Apply Tooling (A) on the threads of the studs and the threads on new nuts (16) . Tighten the new nuts (16) to a torque of 70 ± 5 N·m (52 ± 4 lb ft).

   6. Tighten clamp assemblies (23) to a torque of 20 ± 2 N·m (177 ± 18 lb in).
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   Illustration 12	g02345541

   7. Position new clamp assemblies (12) onto bellows (13) . Position elbow assemblies (11) and (14) .

   8. Tighten clamp assemblies (12) to a torque of 8.5 ± 2 N·m (75 ± 18 lb in).
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   Illustration 13	g02125717

   9. Position new bellows (6) , new clamp assemblies (5) , and exhaust tube assemblies (4) and (7) into position. Ensure that the flow indicator on the bellows is in the position that is shown in the above illustration. Tighten clamp assemblies (5) to a torque of 8.5 ± 1 N·m (75 ± 9 lb in). Torque the clamp assemblies again after the engine has been run.

   10. Position new clamp assemblies (1) and (3) . Tighten clamp assemblies (1) and (3) to a torque of 20 ± 2 N·m (177 ± 18 lb in).

   11. Position new clamp assemblies (8) and (10) . Tighten clamp assemblies (8) and (10) to a torque of 20 ± 2 N·m (177 ± 18 lb in).