CORE AS-AFTERCOOLER 2054655 - Caterpillar

Start By:a. remove hoodb. remove radiator assemblyc. air conditioner/heater box Shut off fuel at fuel tank and water separator. Drain the hydraulic tank.
Effective July 1, 1992 regulations prohibit the venting of any refrigerant into the atmosphere. Refer to Caterpillar publication SENR3334, SENR5664 and NEDG5065 for the proper procedure, equipment and tools to reclaim refrigerant from any Caterpillar machine.
Always wear goggles when working on air conditioning systems. The system is under pressure at all times, engine running or not. Escaping refrigerant R-12 (CCl2F2 Dichlorodifluoromethane) or refrigerant R-134A can cause freezing of human flesh.Do not smoke while working on air conditioning systems. INHALING REFRIGERANT R-12 OR REFRIGERANT R-134A THROUGH ANY SMOKING MATERIAL, ALTHOUGH NOT TOXIC OR FLAMMABLE, CAN GENERATE LETHAL PHOSGENE GAS AND CAUSE VIOLENT ILLNESS OR DEATH. ALSO, HEAT MUST NEVER BE APPLIED TO A CHARGED SYSTEM. See Air Conditioning And Heating Service Manual, SENR3334 and SENR5664, for more information on removal and installation of lines and refrigerant from the system.Purge the air conditioning system. See "Purging the System" in the Air Conditioning and Heating Service Manual, SENR3334 or SENR5664 for the correct procedure.
Mark all wires for location and identification purposes prior to disconnecting 1. Disconnect four electrical connectors (2). Remove one bolt, washer and clamp (1) holding wiring harness to flywheel housing. 2. Disconnect and cap fuel line (4) to the water separator.3. Remove one bolt, two washers and hose clamp (4) for the fuel line to the filter. 4. Disconnect and cap fuel line (5) to the fuel filter. 5. Remove four bolts (6) from drive shaft universal joint (7) to disconnect the drive shaft. 6. Disconnect two wires (8) to the starter solenoid.7. Disconnect three ground wires (10), (13) and (14) at the machine frame, starter, and the engine block.8. Remove nut and washer (12) and plastic cover (11).9. Disconnect solenoid wire (9) to the starter solenoid. 10. Disconnect cold starting aid tube (15).11. Disconnect electrical connector (16).12. Remove bolt, washer and clamp (17) from the frame and the wiring harness.13. Remove tie wrap (18) from the wiring harness. 14. Disconnect refrigerant line (19) at the air conditioning compressor.
At operating temperature, the hydraulic oil tank is hot and under pressure. Hot oil can cause burns. To prevent possible personal injury, release the pressure in the hydraulic system before and hydraulic lines or components are disconnected or removed.
15. Disconnect two tube assemblies (20) from the implement oil cooler. 16. Remove two bolts and washers (22) and remove implement oil cooler (21). 17. Remove two tie wraps (24) from the alternator wiring harness and disconnect alternator connections (23) from the alternator.18. Disconnect hose assembly (20). 19. Loosen clamp (25) at pipe (32).20. Remove two clamps (26), loosen clamp (27), and remove pipe (32).21. Loosen clamp (29) and remove hose (28) Hose (28) can be left attached to the turbocharger.22. Remove exhaust clamps (30) and remove pipe (31). 23. Loosen clamp (33) and remove heater hose (35) from water pump outlet valve (34). 24. Remove eight bolts and washers