LINES GP-FUEL INJECTION 1638025 - Caterpillar

Note: Seal 149-2213 needs to be cut to match each plateNote: Ensure the proper order and orientation of the heat exchanger plates and the gaskets.Note: The gaskets on the heat exchanger plates should face the rear frame during installation.Note: Use Tooling (A) to ensure that the heat exchanger plates are properly aligned.Note: Ensure that the edges of the heat exchanger plates are properly aligned and the gaskets are in the proper grooves in the heat exchanger plates.Note: If the heat exchanger plates do not lay flat during installation on the rear frame, one side of Tooling (A) may be loosened and retightened to accommodate the heat exchanger plates.Note: If the heat exchanger plates appear stuck together or do not align during installation, the edges of the heat exchanger plates can be lightly lifted and adjusted.
Install heat exchanger plates (6) and the gaskets.
Install the liners and the collars in front frame (2). Install front frame (2).Note: The liners are installed from the front of the front frame.
Install Tooling (B) in the spacers. Ensure that Tooling (B) is securely installed. Apply Tooling (C) to the threads of the nut and the threads of the guide stud prior to installation.
Illustration 7 g02104418
Tighten the nuts on Tooling (B) evenly until the front frame contacts the spacers.Note: As the front frame lowers, the heat exchanger plates will slide along Tooling (A).Note: Check the heat exchanger plates, the gaskets, and the gasket tabs frequently during compression to ensure proper alignment. Ensure that the gaskets are not pinched during compression. A pinched gasket will be observed by the edges of the adjacent heat exchanger plates separating slightly.Note: If proper alignment of the heat exchanger plates is not achieved during compression, the front frame can be loosened and the heat exchanger plates lightly adjusted.
Illustration 8 g02104417
Remove Tooling (A) and install the spacers and bolts (5).
Illustration 9 g02104414
Illustration 10 g02105860
Remove Tooling (B) and install bolts (3) in spacers (4) through front frame (2).
Remove Tooling (B) and install bolts (1) in spacers (4) through front frame (2).
Tighten the bolts in a numerical sequence to a torque of 260 N m (190 lb ft).
Install the heat exchanger on the engine. Connect the elbows to the heat exchanger.
Fill the cooling system. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".Leak Checking the Heat Exchanger
Illustration 11 g02388416Note: Leak checking of the heat exchanger should be completed before installation on the engine.
Install Tooling (F), (G), and (H) on the ports of the heat exchanger.Note: Each circuit on the heat exchanger will require two Tooling (F), one Tooling (G), and one Tooling (H).
Attach an air hose to the end of Tooling (G) on the sea water (SW) circuit.
Verify that flow through is achieved on (SW).
Pressurize (SW) at 275 kPa (40 psi) and close off the circuit.
Close Tooling (G) on the end of jacket water (JW) circuit and separate circuit aftercooler circuit (SCAC).
Attach some hoses to the ends of Tooling (H) on (JW) and (SCAC). Place the ends of the hoses under water and check for bubbles