WINDSHIELD GP 6C8659 - Caterpillar

Table 1
Required Tools
Part Number Part Name Quantity
1U-5470
or
198-4240 Engine Pressure Group
or
Digital Pressure Indicator 1
FT-1984 Aftercooler Testing Group 1
FT-1438 Aftercooler Gp (DYNAMOMETER TEST) 1 Visual Inspection
Inspect the following parts at each oil change:
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. Refer to Torque Specifications, SENR3130, "Standard Torque for Constant Torque Hose Clamps" for the correct torque. Check the welded joints for cracks. Ensure that the brackets are tightened in the correct positions. Ensure that the brackets are in good condition. Use compressed air to clean any debris or any dust from the aftercooler core assembly. Inspect the fins of the aftercooler for the following conditions:
Damage
Debris
CorrosionUse a stainless steel brush to remove any corrosion.Note: When parts of the aftercooler system are repaired or replaced, a leak test is recommended.Inlet Manifold Pressure
Normal inlet manifold pressure with high exhaust temperature can be caused by blockage of the aftercooler core. Clean the aftercooler core.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 (Dual Element) - Clean/Replace".Blockage in the air lines - Blockage in the air lines between the air cleaner and the turbocharger must be removed.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.Air System Restriction
Pressure measurements should be taken at the inlet manifold and at the turbocharger outlet.Use the differential pressure gauge of the 1U-5470 Engine Pressure Group or use the 198-4240 Digital Pressure Indicator. Use the following procedure in order to measure the restriction of the aftercooler:
Connect the vacuum port of the differential pressure gauge to port (10).
Connect the pressure port of the differential pressure gauge to port (11).
Record the value. The air lines and the cooler core must be inspected for internal restriction when both of the following conditions are met:
Air flow is at a maximum level.
Total air pressure drop of the charged system exceeds 16.9 kPa (5 in Hg).If a restriction is discovered, proceed with the following tasks, as required:
Clean
Repair
ReplacementLeak Test for the Sea Water Cooling System
Test for Water Leaks
Remove the aftercooler core from the engine. Refer to Disassembly and Assembly, "Aftercooler and Aftercooler Core".
Thoroughly clean the aftercooler core.
Plug the fittings of the aftercooler core.
Pressurize the aftercooler core to 240 kPa (35 psi).
Spray the aftercooler core with a mixture of water and a soap solution. Look for air bubbles that form on the aftercooler core. Test for Air Leaks
The bottom opening of the aftercooler must be closed in order to perform the following pressure test. A cover may need to be fabricated in order to plug the opening.
Remove the