FILTER 3I1249 - Caterpillar

Introduction
Use this procedure for testing the exhaust cooler (NRS) on 3500E diesel engines.Required Tools
Table 1
Required Tools Qty
503-2130 Plug (Expandable rubber plug) 1
367-7437 Plug (Vented turn-tite plug) 1
9S-8140(1) Pressurizing Pump 1
1U-5470(2) Engine Pressure Gp 1
(1) Use for the On engine test.
(2) Use for the Off engine testTest Procedure
Illustration 1 g02297813
(1) NRS cooler
(2) Vent plug
(3) Air inlet
(4) Air 0utlet
(5) Coolant outlet
(6) Coolant inletOn Engine
An external leak of the exhaust cooler can often be found by making a visual inspection. To check for internal leaks in the air side, use the following procedure.
Personal injury can result from hot coolant, steam and alkali.At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand.Cooling System Conditioner contains alkali. Avoid contact with skin and eyes.
Remove the components attached to ports (3), (4) on the air side of the cooler. Typical components are bellows, air lines, or hoses.
Pressurize coolant system with the 9S-8140 Pressurizing Pump. Refer to Testing and Adjusting Section, "Testing the Radiator and Cooling System for Leaks".
While the cooling system is pressurized, observe the cooler for leaks. If no coolant leaks from the air side of the cooler after 15 minutes, the NRS cooler is reusable.
If the NRS cooler does not leak, the problem may be elsewhere in the cooling system or the engine. Refer to the appropriate service manual to check for leakage.Off Engine
Use the 1U-5470 Engine Pressure Gp to perform this test. Refer to Special Instruction, SEHS8907, "Using The 1U-5470 Engine Pressure Group".
Illustration 2 g02492016
Expandable rubber plug
Illustration 3 g02492019
Vented turn-tite plug
Plug the air inlet (3) with the expandable rubber plug and air outlet (4) with the vented turn-tite plug on the NRS cooler (1).
Make sure that the air pressure regulator is closed and connect compressed air to the pressure regulator.
Do not over-pressurize the cooler, stay within the recommended pressures.
Apply a minimum of 34.5 kPa (5 psi), but not more than 68.9 kPa (10 psi) of air pressure to the cooler.
While the NRS cooler is still pressurized, submerge the cooler in water that is at ambient temperature.
Allow the NRS cooler to settle in order for the air that is trapped to escape
Observe the NRS cooler for air bubbles that indicate a leak.
If no bubbles are observed, follow step 3.
Remove the NRS cooler from the water.
While the NRS cooler is still pressurized, use a soap solution to aid in finding the slow leaks.
Spray the NRS cooler with the soap solution on the inner and outer surfaces.
Observe the NRS cooler for the formation of bubbles, which indicate a leak.
Note the location or the origin of the leak. Record this information.
If no bubbles are detected after 30 seconds, the NRS cooler is reusable.
If the NRS cooler does not leak, the problem may be elsewhere in the cooling system or the