Charge Air Cooler 5.05. 06.04.02.06 Mak Maintenance / Disassembly and reassembly a2 ae o ‘Spare parts list B1.05.06.9.7250, B1.05.09.9.8330 Personnel requirement: 2 Pers./ 1,00 Personnel qualification: skilled engine hand Heavy fuel and distillate fuel Operating mediut Maintenance: The charge air cooler must be removed and cleaned on the air side when the differential pressure before/after the cooler exceeds 1.5 times the test bench value, see engine documentation, chapter "Technical Engine Data” (AcceptanceTest Record) Auxiliary materials: Cleaning agent as recommended by the manufacturer, such as: * Vecom GmbH, Hamburg * * Drew Ameroid GmbH, Hamburg * * UNITOR chemicals * Molykote Paste "G-Rapid Plus” * * or equivalent product Procedure: 1 Disassembly 1.1 Loosen the bleeder bolts, or for engines with continual bleeding, ensure that the corresponding cock valves are open, remove the drain bolts (Fig. 1/5) and drain water from charge al cooler. 1.2 Remove the coolant feed and return lines(4) from the charge air cooler.Charge Air Cooler A505. 06.04.02.06 Mak Maintenance / Disassembly and reassembly M32. 1.3 Remove hexagon screws (Fig. 2/129) with extension sleeves (109). 1.4 Pull the charge air cooler (3) out of the housing (2) on exhaust gas side, suspend with hoist and lower into suitable container for cleaning. 1.8 Clean the charge air cooler in accordance with the manufacturer's instructions, see "engine do- cumentation, chapter "External Documentation”. 4.6 Inspect the housing, drain all condensation by opening the drain line. ACAUTION Follow the instructions contained in the handbook for the cleaning agent used, protect skin from contact with cleaning agents, wear rubber gloves, safety goggles and respi ratory protection if necessary! Ensure adequate ventilation!Charge Air Cooler A5.05, 06.04.02.06 Mak Maintenance / Disassembly and reassembly mg2 2 Assembly 2.1 Install charge air cooler in the reverse order as disassembly, 22 Slide charge air cooler (3) into the housing (2) carefully, Apply a light coat of Molykote paste "G-Rapid Plus” to the contact surfaces and threads of all bolts. 23 Insert hexagon screws (129) with extension sleeves (109). , 24 Tighten hexagon screws (128) one after the other to a torque of, M=190.Nm. 25 Attach coolant supply and return lines (4) to the charge air cooler. 2.6 Tighten drain bolts (5) and fil engine completely with coolant. 2.7 Tighten bleeder bolts or the corresponding cock valves tightly