3/25/24, 4:00 PM SIS 2.
Aftercooler - Remove and Install - Aftercooler Housing with 24 bolts (SENR1126-36)
SMCS - 1063 i06899723
Removal Procedure
PSP
202 -000A
1. Drain the coolant from the auxiliary water system into a suitable container for storage or
disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) -
08: 4/03/2 4FC7
Change".
0
SEN 0:16+ 5
© 2 R112 08:00
024 6
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Illustration 1
2. Remove tube assemblies (1) and tube assemblies (2).
c.
g02173968
Illustration 2 g02173971
3. Remove tube assemblies (3) and hose assemblies (4).
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Illustration 3 g02173972
4. Remove hose clamps (6) and hose (7). Remove bolts (9), elbow (5), and the O-ring seals.
Remove bolts (10), elbow (8), and the O-ring seal. Repeat for the remaining turbochargers.
Illustration 4 g02173973
5. Remove bolts (14). Use two technicians to remove cover (13). The weight of cover (13) is
approximately 32 kg (71 lb). Slide cover (13) from pipe (12). Remove the O-ring seal from the
aftercooler core. Remove bolts (11), pipe (12), and the O-ring seals. Repeat for the other cover.
Illustration 5 g02173975
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3/25/24, 4:00 PM SIS 2.0
6. Disconnect tube assembly (18) from elbow (16). Remove bolts (17) and disconnect the tube
assembly and the flange from elbow (16). Remove the O-ring seals. Remove bolts (15), elbow
(16), the adapter, and the O-ring seals.
Illustration 6 g02174147
7. Remove bolts (19) from tee (20) and the clamp assemblies. Remove bolts (22), flange (21),
and tee (20). Remove the adapters and the O-ring seals.
Illustration 7 g02174148
8. Remove bolts (23), cover (24), the gasket, the adapter, and the O-ring seals.
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Illustration 8 g02174212
9. Use two technicians to remove aftercooler core (25). The weight of aftercooler core (25) is
approximately 45 kg (100 lb). Remove the O-ring seal from the housing. Repeat for the other
aftercooler core.
Illustration 9 g02174219
10. Remove bolts (27). Use two technicians to remove housing (26). The weight of housing (26) is
approximately 26 kg (57 lb). Remove the O-ring seal from the air inlet manifold. Repeat for the
other housing.
Installation Procedure
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3/25/24, 4:00 PM SIS 2.0
Illustration 10 g06050585
1. With the aftercooler core laying on its side, install the seal. Ensure that it is fully seated. Tape
the sides with removable tape to ensure the seal stays in place during assembly.
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Illustration 11 g06050591
2. Use a proper lift devise when lifting the aftercooler core and top cover. Lower the aftercooler
core straight down while aligning the bolt holes as shown in illustration 11. Install the top
aftercooler seal, ensuring it is fully seated. Install the top cover straight down ensuring no tilt.
Illustration 12 g06160963
Note: Zero torque reference means to install the bolts to minimal resistance.
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3/25/24, 4:00 PM SIS 2.0
3. Install the O-ring seal into groove on the air inlet manifold. Install the lower housing onto the air
inlet manifold.
4. Install the bolts at zero torque, starting in the middle and using the pattern shown in Illustration
12. Using the pattern in Illustration 12, tighten the bolts to a torque of 24 N·m (18 lb ft) and
inspect the seal for proper seating, bubbles, or bulges.
5. Using the pattern in Illustration 12, again tighten the bolts to a torque of 47 N·m (35 lb ft) and
inspect for any bubbles or bulges.
6. Using the pattern in Illustration 12, again tighten the bolts to a torque of 105 ± 20 N·m
(77 ± 15 lb ft).
Illustration 13 g02174212
7. Install the O-ring seal on the housing. Use two technicians to install aftercooler core (25). The
weight of aftercooler core (25) is approximately 45 kg (100 lb). Repeat for the other aftercooler
core.
Illustration 14 g02173973
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8. Install the O-ring seals on the aftercooler cores. Use two technicians to install cover (13). The
weight of cover (13) is approximately 32 kg (71 lb).
9. Apply a light coat of glycerin to the O-ring seals. Install the O-ring seals, pipe (12), and bolts
(11) on the other cover. Use two technicians to install the other cover. Slide pipe (12) in cover
(13). Install bolts (14). Tighten the corner bolts to seat the O-ring seal. The remaining bolts will
be tightened later.
Illustration 15 g02174148
10. Apply a light coat of glycerin to the O-ring seals. Install the O-ring seals, the adapter, the
gasket, cover (24), and bolts (23). Do not tighten the bolts at this time.
Illustration 16 g02174147
11. Apply a light coat of glycerin to the O-ring seals. Install the O-ring seals, the adapters, tee (20),
flange (21), and bolts (22). Install the clamp assemblies and bolts (19). Do not tighten the
bolts at this time.
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3/25/24, 4:00 PM SIS 2.0
PSP
202 -000A
4
08: /03/2 4FC7
0
SEN 0:16+ 5
© 2 R112 08:00
Illustration 17 g02173975
12. Apply a light coat of glycerin to the O-ring seals. Install the O-ring seals, the adapter, elbow
024 6
(16), and bolts (15). Connect the tube assembly and the flange to elbow (16) and install bolts
(17). Connect tube assembly (18) to elbow (16). Do not tighten the bolts at this time.
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Illustration 18 g06160966
13. Using the pattern in Illustration 18, tighten the bolts to a torque of 24 N·m (18 lb ft).
14. Using the pattern in Illustration 18, again tighten the bolts to a torque of 47 N·m (35 lb ft).
15. Tighten the bolts for the water elbows.
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Illustration 19 g02173972
16. Install the O-ring seal, elbow (8), and bolts (10). Apply a light coat of glycerin to the O-ring
seals. Install the O-ring seals, elbow (5), and bolts (9). Install hose (7) and hose clamps (6).
Orient the hose clamps 180 degrees away from each other. Repeat for the remaining
turbochargers.
Illustration 20 g02173971
17. Install hose assemblies (4) and tube assemblies (3).
Illustration 21 g02173968
18. Install tube assemblies (2) and tube assemblies (1).
19. Refill the auxiliary water system with coolant. Refer to Operation and Maintenance Manual,
"Cooling System Coolant (ELC) - Change".
PSP-000A4FC7
2024/03/25
08:00:10+08:00
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3/25/24, 4:00 PM SIS 2.0
i06899723
© 2024 Caterpillar Inc.
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