A New NOx Reduction System Cooler Group and Water Lines Group Are Now Used on Certain C15 / C18 Tier 4 Final Machine Engines {1061, 1087, 108C, 1380} Caterpillar

Landfill Compactor

826K (S/N: 2321-6294)

836K (S/N: TWZ1-621)

Soil Compactor

825K (S/N: 2331-5024)

Wheel Dozer

824K (S/N: 2341-4010)

Description Of Change: The NOx Reduction System (NRS) cooler group has a more robust design and the water lines group is more flexible.

Adaptable To: The following changes are adaptable to the products within the listed serial numbers, and are effective with all products after the listed serial numbers.

Required Parts

Installation Procedure

Illustration 1	g06207090
Current EGR cooler set-up.

1. Drain the coolant into a suitable container for reuse or disposal.
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   Illustration 2	g06207113
   (1) Coolant Outlet (2) Coolant Inlet

2. Remove and retain the clips and retainers as shown in Illustration 2 for reuse.

3. Remove water lines (1) and (2) (outlet and inlet from cooler).
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   Illustration 3	g06207093
   (1) 9N-5085 Clamp

4. Remove and discard the two band clamps.
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   Illustration 4	g06207326
   (4) 344-2636 Clamp As

5. Remove the (4) clamps on EGR cooler.
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   Illustration 5	g06207336
   (5) 362-6634 Bracket As

6. Remove the edge plate (5) from the EGR cooler.
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   Illustration 6	g06207351
   (6) 436-9146 Exhaust Cooler and Mounting Gp (NRS)

7. Remove the EGR cooler (6).
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   Illustration 7	g06207356
   (7) 0S-1608 Bolt (8) 5M-2894 Hard Washer (9) 0L-2070 Bolt (10) 355-8321 Mounting Bracket

8. Remove the bolts (7) and (9) along with the washers (8).

9. Remove the bracket (10).
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   Illustration 8	g06207641
   Updated with new EGR cooler

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   Illustration 9	g06207665
   (8) 5M-2894 Hard Washer (9) 0L-2070 Bolt (11) 0L-1352 Bolt (12) 509-7456 Mounting Bracket

10. Install the EGR Bracket (12) with bolts (11), washers (8). Install bolt (9) and washer 8.

    Tighten bolts to ... 47 ± 9 N·m (34.6 ± 6.6 lb ft)

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    Illustration 10	g06207713
    (13) 449-3065 Cooler As

11. Install the new EGR cooler (13).
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    Illustration 11	g06207729
    Edge bracket assembly (14) 493-1489 Bracket As

12. Install the bracket assembly (14).
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    Illustration 12	g06208498
    (15) 510-3002 Clamp As

13. Install the EGR clamp and secure the cooler to the bracket.

    Tightening Procedure

    Tighten bolts of each clamp assembly in sequence 3, 2, 1, 4 with below steps.

    1. Tighten bolts indicated (Z) to 20 ± 5 N·m (14.7 ± 3.7 lb ft)

    2. Tighten bolts indicated (X) to 20 ± 5 N·m (14.7 ± 3.7 lb ft)

    3. Retighten bolts indicated (Z) to 40 ± 5 N·m (29.5 ± 3.7 lb ft)

    4. Retighten bolts indicated (X) to 40 ± 5 N·m (29.5 ± 3.7 lb ft)

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    Illustration 13	g06208709
    (16) 493-0357 Tube As (17) 8S-0023 Clip (18) 8S-0024 Clip (19) 0S-1594 Bolt (20) 9X-6458 Hard Washer (21) 0S-0509 Bolt (22) 5M-2894 Hard Washer (23) 338-1556 Retainer (24) 7L-6580 O-Ring Seal (25) 493-0358 Tube As (26) Tube As (27) 8T-9588 O-Ring Seal (28) 4F-7957 Bolt (29) 5P-0537 Hard Washer (30) 445-6881 Hose (31) 523-4273 Band Clamp

14. Lubricate the bore lightly while installing the O-Ring (24) to tube and attach the tube (16) to the EGR.

15. Secure the tube with one bolts (21), one washer (22), and one retainer (23).

    Tighten the bolt to ... 47 ± 9 N·m (35 ± 6.6 lb ft)

    Note: The retainer flange needs to be facing out on the cooler outlet.

16. Attach the water lines with clamps (17) and (18) with two bolts (19) and two washers (20).

    Note: The clips are placed in two different places.

    Tighten both bolts ... 47 ± 9 N·m (35 ± 6.6 lb ft)

17. Attach tube (16) with a hose (29) and secure the hose clamps (30).

    Tighten both hose clamps to ... 7 ± 1 N·m (5 ± 0.7 lb ft)

18. Attach tube (25) with a hose (30) and secure the hose clamps (31).

19. Lubricate the bore lightly while installing the O-Ring (24) to tube (25) and attach the tube (25) to the engine.

20. Secure the tube with one bolts (21), one washer (22), and one retainer (23).

    Tighten the bolt to ... 47 ± 9 N·m (35 ± 6.6 lb ft)

21. Lubricate the bore lightly while installing the O-Ring (27) to tube (26) and attach the tube to the EGR.

22. Secure the tube with two bolts (28), two washers (29).

    Tighten both bolts ... 12 ± 3 N·m (8.8 ± 2.2 lb ft)

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    Illustration 14	g06209165
    Lines group turbo oil

23. Refer to Illustration 14 for the placement of the new 509-7456 Mounting Bracket and p-clip.

24. Refill the radiator and engine with coolant. Refer to Special Instruction , M0070968, "Coolant Drain and Vacuum Fill Procedure For Certain C9.3 Through C18 Tier 4 Engines" for proper coolant fill procedure.

Heat Shield Rework

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Illustration 15	g06210649
New EGR cooler with old heat shield (1) Front heat shield wrap 388-9195 Heat Shield As (2) Side heat shield wrap 388-9194 Heat Shield As

1. Remove front heat shield (1).

2. Remove side heat shield (2).
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   Illustration 16	g06210994
   (A) 50 mm (2 inch) (B) 45 mm (1.8 inch)

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   Illustration 17	g06211001
   (C) 20 mm (0.8 inch)

3. Create cutout as show in Illustration 16 and 17.
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   Illustration 18	g06211009

4. Crimp cut out area with pliers, make sure that fiber glass is not exposed as shown in Illustration 18 (D).
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   Illustration 19	g06211028

5. Assemble the modified front wrap 388-9195 Heat Shield Asand side wrap 388-9194 Heat Shield As. On the side spring shifts the clipping location to front as shown in Illustration 19.