TOOL KT-TURBO 1958104 - Caterpillar

Illustration 15 g03746796
Loosen bellows clamps around right-hand ATAAC outlet tube.
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Remove bellows, clamps, and ATAAC outlet tube.
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ATAAC core inlet
(3) 479-5370 Plug As
(4) 479-5369 Seal As
(8) ATAAC tube cutout represents callouts 6 and 7
(9) Plug assembly nut
(10) Pipe plug
(11) Seal assembly bolt
Lightly lubricate both plug assemblies (3) with oil.
Install one plug assembly (3) into ATAAC core inlet.Note: Always use the seal assembly during testing to secure the plug assembly in the ATAAC tube.
Install seal assembly (4) at the end of the ATAAC tube.Tighten seal assembly bolts (11) ... 55 10 N m (41 7 lb ft)
Install one plug assembly nut (9) to expand rubber.
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Lower ATAAC outlet
(1) 441-4895 Plug As
(2) 441-4896 Seal As
(8) ATAAC tube cutout represents callouts 6 and 7
(9) Plug assembly nut
(10) Pipe plug
(11) Seal assembly bolt
Lightly lubricate plug assembly (1) with oil.
Install one plug assembly (1) into lower ATAAC outlet.Note: Always use the seal assembly during testing to secure the plug assembly in the ATAAC tube.
Install seal assembly (2) at the end of the ATAAC inlet.Tighten seal assembly bolts (11) ... 55 10 N m (41 7 lb ft)
Install one plug assembly nut (9) to expand rubber.
Remove one pipe plug (10) from the end of one plug assembly .
Install pressure gauge into the end of the plug assembly.
Connect the air regulator to air supply and tune to 207 kPa (30 psi).Test Procedure
Pressurize the ATAAC to 207 kPa (30 psi).Note: Make sure the pressure gauge on the end of the plug assembly reads the same pressure as the regulated supply pressure.
Shut off the air supply.
Measure the decay over 15 seconds.Refer to Table 3 with results.Note: If decay is greater than 28 kPa (4 psi) in 15 seconds, perform steps 4 through 8 prior to replacing the ATAAC. If decay is less than 28 kPa (4 psi)in 15 seconds, perform step 9.
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Remove the grill panels.
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Pressurize the ATAAC to 207 kPa (30 psi).
Shut off the air supply.
Check ATAAC seams (12) for leakage with soapy water.
Check plug assemblies (1) and (3) for leakage with soapy water.
Repeat the test for the ATAAC on the other side of the machine.Aftercooler Salvage Procedure
It is possible to plug a leaking aftercooler tube in order to salvage the unit. To salvage the aftercooler unit follow the procedure given below:Note: The maximum of 2 to 3% of the total tubes only can be plugged, If more tubes need to be plugged, the unit cannot be salvaged.
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Locate the leaking tube (1) and mark for plugging.
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Tap tube hole with 14 mm (0.5 inch) tap. Clean newly tapped hole to remove all unwanted residue.
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Apply loctite thread sealant to the newly tapped hole and 14 mm (0.5 inch) hex pipe.
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Using a 7 mm (0.2 inch) allen wrench, thread the loctite coated plug into the newly tapped hole.
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Repeat step 2 through step 4 on opposite end (2) of leaking tube.