GEAR A. 4F4220 - Caterpillar

At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot water or steam. Any contact can cause severe burns. Look at the sight gauge to check the coolant level. The coolant level should be in the green range. If necessary, remove the fill cap only after the engine has been stopped and the cap is cool enough to remove with your bare hand. Remove the cooling system fill cap slowly to relieve pressure. Cooling system condition contains alkali that can cause personal injury. Avoid contact with the skin and eyes and do not drink. Allow cooling system components to cool before draining.
1. Drain the coolant from the engine in a suitable container for storage or disposal. Put identification on all lines, hoses and tubes for installation purposes. Cap and plug all lines, hoses and tubes to prevent foreign material from entering the system. 2. Remove bolts (1), washers and nuts that hold turbocharger tube (2) to the aftercooler housing. 3. Loosen clamps (3) on both sides of turbocharger tube (2). 4. Rotate turbocharger tube (2) out of the way. 5. Remove four bolts (4) and elbow (5) from the aftercooler housing. 6. Check the condition of O-ring (6) and replace if worn or damaged.7. Remove two adapters (7). 8. Remove four bolts (8) and elbow (9) from the aftercooler housing. 9. Remove tube (10). Check two O-ring seals (11) on tube (10) and replace if worn or damaged.10. Remove adaptors (12) from the aftercooler housing. 11. Remove 26 bolts (13) and washers and clips (14) and (15) from the aftercooler housing cover and remove the cover. 12. Remove aftercooler core (16) from the aftercooler housing. Check the condition of two O-ring seals (17) and the two aftercooler core gaskets, , if worn or damaged replace with new parts. Install in the reverse order.13. Tighten the aftercooler core cover bolts to a torque of 23 4 N m (17 3 lb ft). Tighten the bolts again after engine is operated to a torque of 23 4 N m (17 3 lb ft). Refer to the Topic "Lubricant Viscosities and Refill Capacities" in the Operation and Maintenance Manual for the proper filling procedure and the proper levels for the hydraulic system and the cooling system.