0438457 JOHNSON DECAL SET, 60 models

Start By:
Connect the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect" for the machine that is being serviced.
Remove the side panels and the side doors. Refer to Disassembly and Assembly, "Hood Side Panel and Side Door - Remove" for the machine that is being serviced.
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.
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. At operating temperature, the engine coolant is hot and under pressure.Steam can cause personal injury.Check the coolant level only after the engine has been stopped and the cooling system pressure cap is cool enough to touch with your bare hand.Remove the cooling system pressure cap slowly to relieve pressure.Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.
Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, hoses, and tubes. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.Note: Cleanliness is an important factor. Before the removal procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.
Drain the cooling system. Refer to Operation and Maintenance Manual, SEBU6471, "Cooling System Coolant (DEAC) - Change" for the correct procedure. The capacity of the cooling system is 36 L (9.5 US gal).
Illustration 1 g00682160
Remove bolts (1) and loosen hose clamps (3) .
Remove pipe (2) .
Illustration 2 g00682209
Disconnect tube assembly (4) from the aftercooler.
Illustration 3 g00682221
Loosen hose clamp (5) and remove bolts (7) .
Remove pipe (6) .
Loosen hose clamp (10) and remove bolts (8) .
Remove pipe (9) .
Illustration 4 g00682230
Remove bolts (11) and (12) from the aftercooler housing.
Remove aftercooler cover (13) and the gasket.
Illustration 5 g00682281
Remove aftercooler core (14) from the aftercooler housing.Installation Procedure
Note: Cleanliness is an important factor. Before installation, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.
Illustration 6 g00682281
Install aftercooler core (14) into the aftercooler housing.
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Install the gasket and aftercooler cover (13) .
Install bolts (11) and (12) to the aftercooler housing.
Illustration 8 g00682221
Note: Lubricate the bore lightly with glycerin.
Install pipe (9) .
Install bolts (8) and tighten hose clamp (10) .Note: Lubricate the bore lightly with glycerin.
Install pipe (6) .
Install bolts (7) and tighten hose clamp (5) .
Illustration 9 g00682209
Connect tube assembly (4) to the aftercooler.