Facts About Generators
GeneratorsDirectoryCompareRepairEnginesControllersPartsManufacturersGuides
Search models or part #
Home›Repair guides›Exhaust Cooler Assembly - Remove and Install

Perkins — Exhaust Cooler Assembly - Remove and Install

A Perkins service procedure — check it applies to your exact model before use.

Browse Perkins generators & specs →

Before you start

  • 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).
  • Plug or cap all open ports with new plugs or caps.
  • Remove plugs and caps that were previously installed prior to assembly.
  • The NRS exhaust cooler should not be internally cleaned.
  • Ensure that the exhaust cooler assembly (2) can still move freely.

Procedure

  1. Removal:
  2. 1. Position hose clamp (3) away from the coolant inlet in Position (A). Disconnect hose (4) from exhaust cooler assembly (2).
  3. 2. Reposition hose clamp (7) and hose clamp (10) in order to allow removal of hose (8). Disconnect hose (8) from exhaust cooler assembly (2).
  4. 3. Loosen V-band clamp (9) and position the clamp away from the EGR valve assembly (1).
  5. 4. Remove bolts (5) from exhaust cooler assembly (2).
  6. 5. Remove exhaust cooler assembly (2) from the induction manifold.
  7. 6. Remove gasket (6).
  8. 7. Remove clamp (9) from the exhaust cooler assembly.
  9. Installation:
  10. 1. Check all components for wear and damage. If necessary, replace any components that are worn or damaged.
  11. 2. Ensure that the NRS exhaust cooler is free from restriction and external damage.
  12. 3. Clean the sealing face on the EGR valve assembly (1) is clean and free from damage.
  13. 4. Install a new clamp (9) to NRS mixer chamber (1).
  14. 5. Position a new gasket (6) onto the inlet manifold.
  15. 6. Position exhaust cooler assembly (2) onto the induction manifold. Install bolts (5) finger tight.
  16. 7. Tighten clamp (9) to a torque of 10 N·m (89 lb in).
  17. 8. Tighten bolts (5) to a torque of 25 N·m (221 lb in).
  18. 9. Connect hose (4) to exhaust cooler assembly (2) in Position (A). Position hose clamp (3) onto the coolant inlet.
  19. 10. Install hose assembly (8) to exhaust cooler assembly (2). Position hose clamp (7) and position hose clamp (10) and tighten securely.

Tools required

  • Technologic 15

Specs & torque values

  • V-band clamp torque: 10 N·m (89 lb in)
  • Bolts torque: 25 N·m (221 lb in)

Source: manual:854E-854F Disassebly and Assebly Section UENR0624-02.pdf. Figures and steps are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.