M11 Series – Service Manual – 010-001   Aftercooler

Drain the cooling system. Refer to Procedure

008-018-005.

Loosen the hose clamps (1) and (2).

Remove the water inlet and outlet hoses from the aftercooler.

Remove the vent line connection.

Loosen the top turbocharger air inlet air connection hose clamp.

Remove the four capscrews and the air inlet connection elbow.

Remove the mounting capscrews.

Remove the aftercooler and gasket.

WARNING  When using a steam cleaner, wear protective clothing and safety glasses, or a face shield. Hot steam can cause serious personal injury.

Use steam to clean the aftercooler. Dry with compressed air.

Clean the gasket material from the rocker lever housing with a gasket scraper.

Visually inspect the aftercooler for cracks or damage.

Pressure test the aftercooler. Refer to Procedure

010-001-013.

With the aftercooler removed from the engine, install hose (1), hose clamps (2), and solid pipe plug (3) on the water outlet pipe.

Install hose (4), hose clamps (5), and the water inlet supply tube (6)
on the water inlet pipe.

Install hose (7), hose clamps (8), and air pressure gauge (9).

Connect the pressure gauge to a regulated air supply and apply air pressure.

Submerge the aftercooler in a tank of heated water.

If air bubbles appear, the core is damaged and the aftercooler

must
be replaced.

Remove the aftercooler from the water tank and dry with compressed air.

Remove the test equipment.

Install the aftercooler. Refer to Procedure

010-001-026.

Install two guide studs in the rocker lever housing.

Install a new gasket on the two guide studs.

Install the aftercooler.

Install and tighten the capscrews in the sequence shown.

NOTE: Be sure the air inlet hose is install on either the turbocharger compressor outlet or the air connection inlet before installing the air inlet connection to the aftercooler.

Install a new gasket and the air inlet connection elbow.

Install the air inlet hose an equal distance over the turbocharger compressor outlet and the aftercooler air inlet.

Tighten the hose clamp.

Install the inlet and outlet water hoses.

Tighten the hose clamps.

Install the vent line.

Fill the cooling system. Refer to Procedure

008-018-028.

Operate the engine to normal operating temperature and check for leaks.