EXCHANGER-HEAT 2066476 - Caterpillar

Table 1
Required Tools
Part Number Part Name Quantity
1U-5470
or
198-4240 Engine Pressure Group
or
Digital Pressure Indicator 1 Visual Inspection
Inspect the following parts:
Air lines
Hoses
Gasket joints
Pressurized air can cause personal injury. When pressurized air is used for cleaning, wear a protective face shield, protective clothing, and protective shoes.
Ensure that the constant torque hose clamps are tightened to the correct torque. Check the welded joints for cracks. Ensure that the brackets are in good condition and ensure that the brackets are tight. Use compressed air to clean any debris or any dust from the aftercooler core assembly. Inspect the core fins for the following conditions:
Damage
Debris
CorrosionUse a stainless steel brush to remove any corrosion. Ensure that you use soap and water.Note: When parts of the aftercooler system are repaired, perform a leak test in order to confirm that the repair has been successful.Inlet Manifold Pressure
Normal inlet manifold pressure with high exhaust temperature can be caused by blockage of the fins of the aftercooler core. Clean the fins of the aftercooler core. Refer to "Visual Inspection" for the cleaning procedure.Low inlet manifold pressure and high exhaust manifold temperature can be caused by any of the following conditions:Plugged air cleaner - Clean the air cleaner or replace the air cleaner, as required. Refer to the Operation and Maintenance Manual, "Engine Air Cleaner Element - Clean/Replace".Blockage in the air lines - Blockage in the air lines between the air cleaner and the turbocharger must be removed.Aftercooler core leakage - Visually inspect the aftercooler core in order to identify coolant leakage from the core. Refer to "Aftercooler Core Leakage" topic for the testing procedure.Inlet manifold leak - An inlet manifold leak can be caused by the following conditions: loose fittings and plugs, missing fittings and plugs, damaged fittings and plugs and leaking inlet manifold gasket.Measuring the Air Temperature and Air Pressure Across the Aftercooler
Remove all air leaks from the system to prevent engine damage. In some operating conditions, the engine can pull a manifold vacuum for short periods of time. A leak in the aftercooler or air lines can let dirt and other foreign material into the engine and cause rapid wear and/or damage to engine parts.
Illustration 1 g02027342
Test locations for the aftercooler temperature and pressure measurements (left side engine view)
(1) Port for measurements at the turbocharger compressor outlet
(2) Port for measurements at the outlet of the aftercooler Perform measurements for pressure and temperature at the locations that are shown Illustration 1. Perform the measurements while the engine is under a normal mode operation. Record the test results in the following Table:
Table 2
Aftercooler Temperature and Pressure Measurements
Parameter 100% Load 75% Load 50% Load
"Compressor Out Pressure" (Inches Hg(ABS))
"Inlet Manifold Pressure" (Inches Hg(ABS))
"Compressor Out Temperature" (°F)
"Aftercooler Air Outlet Temperature" (°F) Compare the results of the test to values that are given in Technical Marketing Information (TMI). Look for similar results. If a large change in the temperature or the pressure differential is noticed, there may be a problem in the aftercooler circuit.If a large change for the pressure differential