Usage:
1. Drain the heat exchanger by removing plug (1). If it is difficult to gain access to this plug, there are several others on the heat exchanger that can also be removed to drain the heat exchanger.
2. Remove two bolts (2) and remove two other bolts (5). All four of these bolts secure flanges that hold pipe (4). Remove bolt, nut and clamp (3) and slowly remove pipe (4). Pipe (4) may still have some water in it. Use caution to avoid spilling coolant on exhaust manifolds and shields.
3. Remove two bolts (7) and remove two other bolts (10). All four of these bolts also secure flanges that hold pipe (9). Slowly remove pipe (9). Remove two bolts (8) securing the flange on pipe (6).
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Use caution when removing the heat exchanger. In some applications, due to the angle of attachment necessary to remove the heat exchanger it can swing outward when the last bracket is removed. |
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4. Place alignment marks on the shell of the heat exchanger and the inner portion of the brackets. This will allow for easy pipe alignment during reassembly. Attach tooling A to the heat exchanger as illustrated. Remove eight bolts, two from each of the four bracket assemblies and remove each of the brackets (11).
5. Slowly remove the heat exchanger from the engine. Due to the design of the heat exchanger it will be heavier in the front than in the rear. Weight of the heat exchanger is 186 kg (410 lb).
NOTE: Installation of the heat exchanger is accomplished in the exact reverse order from removal.
NOTE: Prior to installation, lubricate the seal on the ends of pipe (4), (6), and (8) with clean oil to insure proper installation.
Disassemble And Assemble Heat Exchanger
Start By:
a. remove heat exchanger
1. Remove twelve bolts (1) securing the bonnet (2) to the shell of the heat exchanger. Remove bonnet (2). Remove four bolts (3) securing the adapter (4) to bonnet (2).
NOTE: It is not necessary to place alignment marks on the front bonnet and the shell of the heat exchanger. The shell of the heat exchanger contains an alignment pin and the bonnet contain a corresponding hole for the pin.
NOTE: For most applications involving disassembly of the heat exchanger, it is not necessary to remove adapter (4).
2. Remove gasket (5) and two rod assemblies (6).
3. Remove rod (8) from plug (7).
4. Remove twelve bolts (9) securing the other bonnet (10) to the heat exchanger and remove bonnet (10).
5. Remove rubber seal (11) from the inside of heat exchanger shell. Remove forty eight shims (12), four each from under each bolt. Remove plug (14) and remove rod (13) from the plug.
6. If it is necessary to remove the heat exchanger core from the shell it will be necessary to press it out from the end without a flange.
NOTE: Use caution when removing the heat exchanger core from the shell. The internal portion is constructed of soft metal and will crush easily.
NOTE: If it becomes necessary to clean the heat exchanger, remove both bonnets and run a long rod of smaller diameter than the core openings completely through the heat exchanger. If rod meets with resistance, do not force it. The internal core is constructed of soft metal and can puncture. Flush the heat exchanger with water and repeat the procedure until all core openings are clean and open.
NOTE: Assembly the heat exchanger is accomplished in the exact reverse order from disassembly.
7. If the core of the heat exchanger was removed from the shell it is important that the flange of the core be flush against the shell during reassembly.
8. After assembly of the bonnet (10) and shims (12) to the shell (16) of the heat exchanger measure the distance between the bottom of the bonnet and the top of the shell. With the proper number of shims the distance should be between 1.6 and 1.2 mm (.064 and .048 in).
9. Alignment pin (15) is located on the shell of the heat exchanger. This will allow proper alignment of bonnet (2)
End By:
a. install heat exchanger