F40154-3 Force EXHAUST PORT PLATE GASKET

Start By:
Remove the aftercooler. Refer to Disassembly and Assembly, "Aftercooler - Remove and Install".
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.
Personal injury can result from contact with refrigerant.This system is under pressure at all times, engine running or not. Heat should never be applied to a charged system. Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury.Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant.Always use caution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated area.Personal injury or death can result from inhaling refrigerant through a lit cigarette.Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death.Do not smoke when servicing air conditioners or wherever refrigerant gas may be present.Before any checks of the air conditioning and heating system are made, move the machine to a smooth horizontal surface. Lower all implements to the ground. Make sure the transmission is in neutral or park and that the parking brake is engaged. Keep all other personnel either away from the machine or where they can be seen.
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, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.
Drain the coolant from the cooling system into a suitable container. The capacity of the cooling system is 107 L (28.3 US gal).
Illustration 1 g00820508
Loosen two hose clamps (1). Remove three hoses (2) .
Illustration 2 g00820513
Remove two bolts (3) and reposition the hose assemblies and the wire assembly.
Illustration 3 g00820517
Remove tee fitting from tube assembly (6). Loosen hose clamp (4). Remove tube assembly (6) from radiator module (5). Remove the remaining tube assembly on the radiator.
Illustration 4 g00820476
Remove bolt (7) that secures bracket (8) to the radiator.
Illustration 5 g00820685
Remove three bolts (10) that secure windshield washer reservoir (9) .
Illustration 6 g00820698
Remove three bolts (11) that secure brackets (12) to fan guard (13) .
Illustration 7 g00820705
Remove four bolts (16) and nuts along the center of the shroud (15). Remove 12 bolts (14) along the outside of the shroud (15). Remove the upper and lower fan shrouds.
Illustration 8 g00820712
Disconnect two lines (18) that are connected to in-line refrigerant dryer (17) .
Remove four bolts (20) that secure the ether starting aid cylinder (19). Remove two bolt (21) that holds wire assembly (22). Remove bolt (23) that secures the ether starting aid tube assembly.