Aftercooler Assembly Page 1 of 10

010-005 Aftercooler Assembly

Initial Check

A turbocharger or sea water

pump failure can cause
damage to the aftercooler
assembly.

If a turbocharger failure or a
sea water pump failure has
occurred, remove the
aftercooler element and
inspect the element and
housing for damage.

Inspect the zinc anodes to

make sure they are still in
one piece and have not
broken.

See the Inspect step within

this procedure.

Preparatory Steps

WARNING
Batteries can emit explosive
gases. To reduce the
possibility of personal injury,
always ventilate the
compartment before

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servicing the batteries. To

reduce the possibility of
arcing, remove the negative
(-) battery cable first and
attach the negative (-)
battery cable last.

WARNING
Fuel is flammable. Keep all
cigarettes, flames, pilot
lights, arcing equipment, and
switches out of the work
area and areas sharing
ventilation to reduce the
possibility of severe personal
injury or death when working
on the fuel system.

CAUTION

Use caution when

disconnecting or removing
fuel lines, replacing filters
and priming the fuel system
that fuel is not spilled or
drained into the bilge area.
Do not drop or throw filter
elements into the bilge area.
The fuel and fuel filters must
be discarded in accordance
with local environmental
regulations.

CAUTION

Zinc plugs expand and can

break off during removal.
Inspect the zinc plug to
make sure it is in one piece.
If not, it must be replaced
with a new zinc plug, and the
broken pieces must be
retrieved from the aftercooler
to prevent damage to
components downstream in
the sea water system.

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l Shut off the sea water

supply and return line(s).
Refer to the OEM
troubleshooting and
repair manual.
l Shut off the fuel supply
and return lines. Refer to
the OEM troubleshooting
and repair manual.
l Disconnect the battery
power from the engine.
Refer to Procedure 013-
009
l Drain the sea water by
removing the zinc plug at
the bottom of the
aftercooler assembly.
l Remove the aftercooler
air box drain plug and
drain the condensation
from the aftercooler
housing core.
l Loosen the aftercooler
top and bottom air
connection hose clamps.
l If necessary, remove the
four capscrews and the
aftercooler air discharge
connection.
l Disconnect the
aftercooler air inlet
connection.
l If necessary, remove the
fuel drain flex hoses at
the fuel cooler.
l Remove the fuel cooler
clip and mounting
capscrew.
l Remove the fuel cooler
lower molded sea water
hose from the aftercooler.
Support the cooler to
prevent damage to the
fuel lines.
l Loosen the hose clamp
on the upper water
transfer connection and
remove the aftercooler
sea water discharge
hose.

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Remove

NOTE: The rear engine

lifting bracket is secured
to the engine with the
aftercooler mounting
capscrews.

Loosen the aftercooler

mounting capscrews at the
flywheel housing (1), the
cylinder block (2), and the
cylinder head (3).

Remove the aftercooler

assembly.

Disassemble

Mark or note the aftercooler

inlet and outlet water
connection locations.

Remove the zinc plugs from

the upper water transfer
connection.

Remove the three

capscrews and the upper
water connection.

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CAUTION

The aftercooler core

assembly will slide out of
the cooler housing when
removing the lower
aftercooler water
connection. To reduce the
possibility of damaging the
core, lay the aftercooler
assembly on its side to
remove the connection and
the core.

Lay the aftercooler assembly

on its side.

The core assembly has two

flat sides which must be
orientated toward the
aftercooler air intake and
outlet sides of the aftercooler.

Remove the lower connection

cover and the core.

Remove the upper and lower

sealing o-rings.

Clean and Inspect for Reuse

WARNING
Wear appropriate eye and
face protection when using
compressed air. Flying
debris and dirt can cause
personal injury.

NOTE: The aftercooler core

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can be cleaned and tested by

a radiator cleaning facility.
Ultrasonic cleaning is the
preferred method of
cleaning.

Use soap and water to clean

the aftercooler and end caps.

Dry with compressed air.

Inspect the housing and caps

for cracks or other damage.

Inspect the aftercooler

housing for deterioration of
the sealing surfaces.

Assemble

Assemble the aftercooler in

a vertical position. Install the
aftercooler core into the
aftercooler housing. Align
the marks so one flat side of
the core is facing the air inlet
side of the housing.

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Install a new o-ring around

the lower core O.D. Install
the water end cap and
tighten the capscrews.

Torque
Value: 43 n.m [32 ft-lb]

Install a new o-ring around

the upper core O.D. Install
the water end cap and
tighten the capscrews.

Torque
Value: 43 n.m [32 ft-lb]

Install the zinc plugs and

tighten. Refer to Procedure
008-059

Pressure Test

WARNING
Wear appropriate eye and
face protection when using
compressed air. Flying
debris and dirt can cause
personal injury.

Pressure test the sea water

side of the aftercooler
assembly.

Apply 276 kPa [40 psi] air

pressure.

Lower the assembly into a tank

of water and check for leaks.

Completely dry the aftercooler

with compressed air.

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Install

Loosely install the

aftercooler assembly to the
flywheel housing first using
two mounting capscrews.

NOTE: The rear engine

lifting bracket is secured
by the aftercooler to
cylinder head mounting
capscrews. The aftercooler
bracket must be installed
on top of the lifting
bracket.

Install the upper capscrews

first. Be sure the aftercooler
bracket is installed on top of
the lifting bracket.

Install the aftercooler to

bracket mounting
capscrews.

Tighten all capscrews.

Torque Value:

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Aftercooler to Flywheel
Housing

1. 60 n.m [44 ft-lb]

Torque Value:
Aftercooler to Cylinder
Head

1. 77 n.m [57 ft-lb]

Torque Value:
Aftercooler to Bracket

1. 35 n.m [26 ft-lb]

Finishing Steps

l Install the fuel cooler

lower molded sea
water hose to the
aftercooler.
l Install the fuel cooler
clip and mounting
capscrew.
l If removed, install the
fuel drain flex hoses at
the fuel cooler.
l Connect the aftercooler
air inlet connection
from the turbocharger.
l Install the aftercooler
sea water discharge to
marine gear cooler
hose and tighten the
hose clamps.
l If removed, install the
four capscrews and the
aftercooler air
discharge to the intake
air connection.
l Tighten the aftercooler
top and bottom air

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connection hose
clamps.
l Connect the battery
power to the engine.
Refer to Procedure
013-009
l Open the sea water
supply and return line
(s). Refer to the OEM
troubleshooting and
repair manual.
l Open the fuel supply
and return lines. Refer
to the OEM
troubleshooting and
repair manual.

Operate the engine and

check for leaks.

Last Modified: 11-Mar-2013

Copyright © 2000-2010 Cummins Inc. All rights reserved.

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