Introduces How to Remove and Install Perkins 2806F Engine v>Exhaust Cooler (NRS) l

       This paper mainly introduces how to Remove  and  Install Perkins 2806F Engine v>Exhaust Cooler (NRS) l

 

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Removal Procedure
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.
1. Drain the coolant from the cooling system into a
suitable container for storage or for disposal. Refer
to Operation and Maintenance Manual, “Cooling
System Coolant - Change” for the correct
procedure.

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2. x
M0070446 23
Disassembly and Assembly Section
Remove bolt (1) from clamp (2). Remove the
clamp and bolts from tube assembly (10).
3. Remove bolt (7) from clip (6). Remove the clip
from tube assembly (10).
4. Remove bolt (14) from clip (15). Remove the clip
from tube assembly (10).
5. Remove bolt (11) from elbow (12). Remove tube
assembly (10) and the elbow from NOx Reduction
System (NRS) exhaust cooler (16) and the water
temperature regulator housing. Remove O-ring
seal (3) (not shown) from the tube assembly.
6. Remove O-ring seal (13) (not shown) from elbow
(12).
7. Loosen hose clamp (5) for hose assembly (4).
8. Sufficiently loosen V-band clamp (9) and remove
tube assembly (8).
9. Remove bolts (23) and bolts (26). Remove elbow
(24), tube assembly (25), and elbow (26) from the
engine oil cooler and NRS exhaust cooler (16).
10. Remove elbow (24) from tube assembly (25).
Remove the tube assembly from elbow (26).
11. Remove O-ring seal (22) (not shown) and O-ring
seal (28) (not shown).
12. Attach a suitable lifting equipment onto NRS
exhaust cooler (16) and support the weight. The
weight of NRS exhaust cooler (16) is
approximately 18 kg (40 lb).
13. Sufficiently loosen V-band clamp (17) and V-band
clamp (19) to allow exhaust bellows (18) to be
removed.
14. Remove bolts (20), clamps (21), and bracket
(16a) from NRS exhaust cooler (16).
15. Use the lifting device to remove NRS exhaust
cooler (16) from the bracket.
16. Remove V-band clamp (17), V-band clamp (19),
and allow exhaust bellows (18)

1. Ensure all components of the NRS exhaust cooler,
tube assemblies are free from wear, damage, and
restriction. Replace any component that is worn,
damaged, or not free from restriction

2. Ensure that clamps (21) are correctly assembled
   with the rounded edges of clamp spacers are
   oriented. Refer to Illustration 36 for the orientation.
3. Attach a suitable lifting equipment onto NRS
  exhaust cooler (16). The weight of NRS exhaust
  cooler (16) is approximately 18 kg (40 lb).
4. Apply Tooling (A) threads of new V-band clamp
  (17) and new V-band clamp (19).
5. Install V-band clamp (17) and a new exhaust
  bellows (18). Ensure that the V-band clamp is
  correctly orientated and the bellows and V-band
  clamp is correctly seated onto the exhaust
  manifold.
6. Loosely install V-band clamp (19) onto exhaust
  bellows (18).
7. Use the lifting device to install NRS exhaust cooler
  (16) onto the bracket. Ensure that V-band clamp
  (19) and exhaust bellows (18) are correctly seated
   onto the NRS exhaust cooler.
8. Install bracket (16a) and loosely install new clamps
   (21) and bolts (20) to NRS exhaust cooler (16).
9. Apply Tooling (B) to both ends of tube assembly
   (25). Install the tube assembly to elbow (24) and
   elbow (26). Ensure that the elbows are correctly
   orientated.
10. Install a new O-ring seal (22) (not shown) and a
   new O-ring seal (28) (not shown) to the engine oil
   cooler and NRS exhaust cooler (16). Ensure that
   the O-ring seals are correctly seated into the
   recesses of the engine oil cooler and the NRS
   exhaust cooler
11. Position the assembly of elbow (24), tube
   assembly (25), and elbow (26) onto engine oil
   cooler and NRS exhaust cooler (16).
12. Install bolts (23) and bolts (26) to the assembly of
   elbow (24), tube assembly (25), and elbow (26).
   Hand tighten the bolts.
13. Install tube assembly (8) and V-band clamp (9).
   Hand tighten the V-band clamp. Tighten hose
   clamp (5) for hose assembly (4).
14. Install a new O-ring seal (13) (not shown) to
   elbow (12). Install a new O-ring seal (3) (not
   shown) to tube assembly (10).
15. Install tube assembly (10) and the elbow to NRS
   exhaust cooler (16) and the water temperature
   regulator housing. Install bolt (11) to the elbow.
   Install clamp (2) and bolt (1).
16. Install clip (6) and bolt (7) to tube assembly (10).
   Hand tighten the bolt.
17. Install clip (15) and bolt (14) to tube assembly
   (10). Hand tighten the bolt.

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Illustration 37 g06071264
Bolt (1)
Hose clamp (5)
Bolt (7)
V-band clamp (9)
Bolts (11)
Bolt (14)
V-band clamp (17) and V-band clamp (19)
Bolts (20) for the NRS cooler clamps
Bolts (11)
18. Ensure that NRS exhaust cooler (16) is
correctly aligned with the exhaust bellows (18)
before tightening bolts (20) for clamps (21).
19. Follow Step 19.a through Step 19.h to tighten the
bolts and the V-band clamps as listed in Illustration
37 .
a. Tighten bolts (20) to a torque of 40 N·m
 (30 lb ft).
b. Tighten V-band clamp (9) to a torque of 7.5 N·m
 (66 lb in).
c. Tighten hose clamp () to a torque of 7.5 N·m
 (66 lb in).
d. Tighten bolts (11) to a torque of 12 N·m
 (106 lb in)
e. Tighten bolt (1) to a torque of 47 N·m (35 lb ft).
f. Tighten bolts (14) to a torque of 25 N·m
 (221 lb in).
g. Tighten bolt (7) to a torque of 47 N·m (35 lb ft).
h. Tighten V-band clamp (17) and V-band clamp
 (19) to a torque of 7.5 N·m (66 lb in).
20. Fill the cooling system. Refer to Operation and
 Maintenance Manual, “Cooling System Coolant -
 Change” for the correct procedure.