Cleaning EGR Cooler

See Service Bulletin SB894 on e-Tech Library for detailed EGR system maintenance interval information. SB894 EGR Maintenance Interval Update – Yanmar Common Rail Diesel Engines

The EGR cooler must be cleaned according to the maintenance inspection schedule for the engine to remain emissions compliant. If an EGR cooler remains in service longer than 3000 hours, the difficulty and time required to clean the EGR cooler increases.

The following procedure along with the Soot Scrubber cleaning solution, is the only approved method to clean the EGR cooler. Soot Scrubber and the black rubber stoppers are included in the EGR System Cleaning Kit (P/N 203-799).

    Important

  1. Always wear appropriate Personal Protective Equipment (PPE) when cleaning the EGR Cooler and the EGR system. This includes safety glasses, rubber gloves, and a respirator.

  2. Dispose of used soot scrubber solution in accordance with local environmental regulations. The used solution may contain heavy metals and petroleum products. The used solution should be considered hazardous waste unless declared otherwise by your local environmental agency.

      Notice
    • Equipment Damage
    • Never use the Soot Scrubber cleaning solution on any material except stainless steel. It will cause accelerated corrosive damage of the material, especially the aluminum body of the EGR Valve.

  1. Remove the EGR cooler from the engine.

  2. Use the two provided black rubber stoppers to plug coolant inlet and outlet.

  3. Thread two screws (use the two screws which mount the EGR cooler to the outlet tube) into the flange end. These serve to space the flanged end of the EGR cooler off of the bottom of the heated bath, allowing natural circulation during the chemical reaction of the Soot Scrubber on the deposits.

  4. Mix 1-part standard concentration Soot Scrubber with 3-parts water at 120 F. Use one quart Soot Scrubber for 1-gallon final volume.

    Note Thermo King recommends using the TK heated cleaning bath tool (P/N 204-2379) to keep the cleaning solution at 120 F.

  5. Orientate the EGR cooler vertically in the cleaning bath as shown () to allow the soot deposits to fall out and not get trapped in the EGR cooler. Continuously heat the solution to 120 F with the EGR cooler submerged.

  6. Soak for 2.5 hours.

  7. Drain the solution from the EGR cooler and visually inspect.

  8. Once the deposits are removed from the EGR cooler, rinse clean with water.

  9. Dry the EGR cooler and reinstall on the engine.

1. Plug coolant inlet and outlet ports. 3. Thread the two M8 screws which mount the EGR cooler to the outlet tube into flange end.
2. EGR Cooler    

Parent topic: Exhaust Gas Recirculation (EGR) System