PLATE AS 9W0640 - Caterpillar

Remove Aftercooler Cores
1. Drain engine coolant.2. Remove air equalizer line (1). Remove turbocharger elbow-to-aftercooler housing mounting bolts (2) and clamps. Remove elbow-to-turbocharger retaining bolt and washers. Remove the elbow assembly. Cover the opening on the turbocharger.3. Disconnect governor linkage. Remove safety shutoff control cable hold down clamp retaining bolt from right aftercooler housing. Remove governor control channel assembly mounting bolts and spacers. Lay channel assembly aside. Remove air cleaner brace mounting bolt. Swing brace away from aftercooler housing.4. On Marine engines only, remove turbocharger heat shield water outlet lines. Remove the aftercooler housings sea water inlet lines. 5. To remove left aftercooler core only, disconnect the oil pressure gauge line (3) at the oil block. Remove the oil block mounting bolt (4). Remove the instrument panel mounting bolts (5). Remove the oil line and fuel line clamps retaining bolts. Lay gauge panel and oil block aside.6. On Marine engines only, remove the exhaust manifolds front water outlet lines. Remove aftercooler housings sea water outlet lines. Remove expansion tank-to-aftercooler housings support braces.7. Remove the tie bar from the cover assemblies. Remove the cover assembly-to-housing retaining bolts (6). Attach hoist and remove the cover assembly-weight 90 lbs. (41 kg). 8. Remove elbow (7). Slide the sleeve assembly away from the core. The sleeve cannot be removed without removing water temperature regulator housing. 9. Remove the elbow assembly (8). Remove the sleeve assembly (9).10. Attach a hoist and remove the aftercooler core-weight 90 lbs. (41 kg).Install Aftercooler Cores
1. Clean old gaskets from mating surfaces of aftercooler core, cover and housing.2. Install a new core-to-housing gasket. Attach hoist and install core (1) into the housing. 3. Lubricate the seals on the sleeve assemblies with clean SAE 30 engine oil. Position the inlet sleeve assembly (2) into the core.4. Install the outlet sleeve assembly.
Be sure that drain hole in sleeve assemblies is in downward position.
5. Install the water inlet and outlet elbow assemblies in front and rear of aftercooler housing and install the retaining bolts. 6. Install a new cover-to-core gasket. Attach hoist and install aftercooler core cover assembly (3). Position air cleaner brace on aftercooler housing. Install the cover retaining bolts. On later engines install the tie bar to the cover assemblies. 7. Position the elbow (4) into turbocharger and onto aftercooler housing. Install the retaining bolts, washers, and locks. Install the air equalizer line.8. On Marine engines only, install turbocharger heat shield water outlet lines.9. Position the governor control channel assembly on engine. Install the spacers and mounting bolts. Install the safety shutoff control cable hold-down clamp retaining bolt. Connect the governor linkage.10. On Marine engines only, install exhaust manifolds front water outlet lines. Install aftercooler housings sea water outlet lines. Install expansion tank support braces.11. To install the left aftercooler core, position the instrument panel on housing, and install retaining bolts. Position the oil block on housing and install the retaining bolt. Connect the oil pressure gauge line to oil block. Install the fuel line and oil line hold-down clamps