PLATE & FILM GP 3904506 - Caterpillar

Illustration 3 g00616450
Disconnect tube assemblies (3) from the ends of the aftercooler core. One tube is at the front and one tube is for the rear.
Illustration 4 g00601409
Install Tooling (A) into the top of air inlet cover (4).
Attach a suitable lifting device onto Tooling (A). The weight of air inlet cover (4) is approximately 11 kg (24 lb). Remove bolts (5). Remove air inlet cover (4). Note: Be careful not to damage the fins of the aftercooler core.
Illustration 5 g00601411
Attach a suitable lifting device onto aftercooler core (6). The weight of aftercooler core (6) is approximately 37 kg (82 lb). Lift aftercooler core (6) from the air inlet manifold. Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 2
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: Be careful not to damage the fins of the aftercooler core.
Illustration 6 g00601411
Inspect the top O-ring seal and the bottom O-ring seal of aftercooler core (6). If a seal is cut, scratched, or cracked, install a new seal. Temporarily secure the bottom seal with tape. Make sure that the tape can be removed after the aftercooler core is installed. Do not use an adhesive, a silicone lubricant, or any other lubricant for retention of the seal.
Attach a suitable lifting device onto aftercooler core (6). The weight of aftercooler core (6) is approximately 37 kg (82 lb). Position aftercooler core (6) onto the air inlet manifold. Ensure that the bottom seal is properly seated.
Illustration 7 g00601409
Install Tooling (A) in the top of air inlet cover (4). Attach a suitable lifting device onto Tooling (A). The weight of air inlet cover (4) is approximately 11 kg (24 lb).
Position air inlet cover (4) onto the aftercooler core. Ensure that the seal is seated between air inlet cover (4) and the aftercooler core.
Install bolts (5). Hand tighten bolts (5).
Illustration 8 g00747427
Bolt tightening sequence for engines with one aftercooler
(A) Front of the engine
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Bolt tightening sequence for engines with two aftercoolers
(A) Front of the engine
Tighten the bolts in the numerical sequence to a torque of 24 N m (18 lb ft).
Tighten the bolts in the numerical sequence to a torque of 47 N m (35 lb ft).
Remove the tape from the bottom seal.
Illustration 10 g00616450
Inspect the O-ring seals for tube assemblies (3). If a seal is cut, scratched, or cracked, install a new seal. Connect tube assemblies (3) to the ends of the aftercooler core. One tube is for the front and one tube is for the rear.
Illustration 11 g00601408
Inspect the O-ring seals for tube assemblies (2). If a seal is cut, scratched, or cracked, install a new seal. Install tube assemblies (2) between the air inlet cover of the aftercooler and the turbochargers.
Illustration 12 g00601406
Inspect the O-ring seals for tube assembly (1). If a seal is cut, scratched, or cracked, install a new seal. Install tube assembly (1).
Fill the cooling system with coolant. Refer to the Operation and Maintenance Manual, "Cooling System Coolant - Change".