69D and 769D Off-Highway Trucks and 771D Quarry Truck Caterpillar

Aftercooler - Remove

Usage:

769D 5SS

Removal Procedure

Start By:

Install the retaining ring and pin (body). Refer to Disassembly and Assembly, SENR1561, "Retaining Ring and Pin (Body) - Remove and Install".

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat^® products. Dispose of all fluids according to local regulations and mandates.

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Personal injury can result from hot coolant, steam and alkali.
At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.
Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand.

Cooling System Conditioner contains alkali. Avoid contact with skin and eyes.

Remove the protection cap assembly in order to relieve the pressure in the cooling system. Position a suitable container under the radiator. Drain the coolant from the radiator to a level below the aftercooler. Refer to Operation and Maintenance Manual, SEBU7092, "Cooling System Coolant (ELC) - Change".
Open the rear hood and the front hood.
Install the caps and plugs on all connections in order to avoid system contamination.
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Illustration 1 g00555622
Remove nut (4), the bolt and the two washers. Remove nut (3), the bolt and the two washers. Remove two bolts (2) and the washers. Position support (1) away from the inlet air elbow.
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Illustration 2 g00555628
Remove five bolts (5) and the washers from plate assembly (6). Remove plate assembly (6).
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Illustration 3 g00477441
Disconnect ether starting aid tube assembly (7) from the aftercooler cover (8).
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Illustration 4 g00555674
Disconnect two tube assemblies (9) and (10).
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Illustration 5 g00477443
Remove bolt (12) and the washer. Remove tube assembly (11).
Put identification on two bolts (14) and (15). Remove two bolts (14) and (15), the spacer and elbow (13).
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Illustration 6 g00555678
Disconnect tube assembly (19). Disconnect hose assembly (16). Remove two bolts (17). Remove manifold (18).
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Illustration 7 g00477446
Remove air inlet elbow (19) and gasket (20) (not shown) from the aftercooler cover (8).
Remove fifteen bolts (22) and the washers from aftercooler cover (8). Reposition wire harness (23), four clips (24) and bracket (21) out of the way.
Remove aftercooler cover (8). Remove gasket (25) (not shown) from the aftercooler housing.
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Illustration 8 g00477449
Remove eight bolts (26) and the washers.
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Illustration 9 g00477450
Remove two bolts (31), elbow (30), and the O-ring seal.
Remove two adapters (27) and O-ring seal (28).
Remove two adapters (29) and the O-ring seal.
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Illustration 10 g00477453
Attach a suitable lifting device to aftercooler core (32), as shown. Remove aftercooler core (32). Remove four O-ring seals (33).
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Illustration 11 g00477456
Remove eight bolts (35) and the washers. Remove aftercooler housing (34).
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Illustration 12 g00477480
Remove gasket (36).