Remove/install charge air cooler

AR09.41-G-6817B

Remove/install charge air cooler

22.06.2018

Engine

900.915/916, 902.923/924/935, 904.927/928, 906.935/955

Modification notes

30.05.2012

Drill out both bores in the mounting plates (arrows) of the carrier (14) from 17 mm to 21 mm, changed

Step 21

Shown on model 405.1

1

Radiator grill

2

Radiator

3

Charge air hose (black)

4

Charge air hose (red)

5

Charge air pipe

6

Charge air pipe

2

Radiator

11

Rubber bushing

7

Charge air cooler

12

Washer

8

Screw/bolt

13

Nut

9

Nut

14

Carrier

10

Screw/bolt

Pfeil

Mounting plate

7

Charge air cooler

18

Nut

14

Carrier

19

Screw/bolt

15

Screw/bolt

20

Rubber bushing

16

Rubber bushing

21

Washer

17

Washer

22

Nut

7

Charge air cooler

23

Bracket

24

Bracket

25

Cover



Remove

1

Raise and secure dumper flatbed

 See owner's manual.

2

Remove fan unit

AR20.40-G-5050B

3

Remove radiator grill (1) from engine radiator (2)

With CODE C47 (radiator grill at the rear)

4

Remove charge air hoses (3, 4)

 Close off openings for the charge air pipes (5, 6) and the charge air cooler (7).

5

Remove screw/bolts (8)

6

Unscrew both nuts (9)

7

Swivel engine radiator (2) to the rear and pull out cooler intermediate grille

With CODE M74 (radiator quick cleaning system Clean-Fix)

8

Remove screw/bolts (10), rubber mount (11), shims (12), nuts (13) and bushes

9

Remove screw/bolts (15), rubber mount (16), shims (17), nut (18) and bushes

10

Remove screw/bolt (19), rubber mount (20), shims (21), nut (22) and bushes

11

Remove charge air cooler (7)



Install

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

12

Install charge air cooler (7)

 Replace adhesive tape (length about 40 cm) above and below on the charge air cooler (7). Clean bonding surface beforehand.
If the charge air cooler (7) is replaced, both brackets (23, 24) and the cover (25) must be modified.

13

Push in cooler intermediate grille and swivel engine radiator (2) to the front

With CODE M74 (radiator quick cleaning system Clean-Fix)

14

Screw on both nuts (9)

 Replace nuts (9).

 Nut, engine radiator to charge air cooler at bottom

*BA20.20-N-1004-01K

15

Screw in both screw/bolts (8)

 Bolt, engine radiator to charge air cooler at top

*BA20.20-N-1003-01K

16

Install bush, screw/bolt (19), rubber mount (20), shims (21) and nut (22)


Only put on screw/bolt (19).
Warping or damage to the rubber mount (20) can occur otherwise.

 Replace rubber mount (20) and nut (22). Align the complete cooling module in such a way that the rubber mount (20) is installed free of tension.
The rubber mount (20) and shims (21) must be zero clearance.

17

Install bush, screw/bolt (15), rubber mount (16), shims (17) and nut (18)


Only put on screw/bolt (15).
Warping or damage to the rubber mount (16) can occur otherwise.

 Replace rubber mount (16) and nut (18). Align the complete cooling module in such a way that the rubber mount (16) is installed free of tension.
The rubber mount (20) and shims (21) must be zero clearance.

18

Install bushes, screw/bolts (10), rubber mount (11), shims (12) and nuts (13)


Only lay on screw/bolts (10).
Warping or damage to the rubber mount (11) can occur otherwise.

 Replace rubber mount (11) and nuts (13). Align the complete cooling module in such a way that the rubber mount (11, 16, 20) is installed free of tension.

19

Tighten screw/bolts (10)

 Bolt, charge air cooler to mounting support at bottom

*BA09.41-N-1004-03A

20

Tighten screw/bolts (15, 19)


First tighten down the screw/bolt (15), then tighten the screw/bolt (19).
Warping or damage to the rubber mount (16, 20) can occur otherwise.

 Bolt, charge air cooler to mounting support at top

*BA09.41-N-1003-03A



Check

21

Check rubber mount (16, 20) for crimped connection and distortion

 If an unstressed installation of the rubber mount (16, 20) is not possible, the bores in the mounting plates (arrows) of the carrier (14) must be drilled out from 17 mm to 21 mm.
Perform the following work:
Perform operation steps 8 to 10,
Drill out both bores in the mounting plates (arrows) of the carrier (14) from 17 mm to 21 mm, changed,
Perform operation steps 16 to 20.



Install

22

Install fan unit

AR20.40-G-5050B

23

Install charge air hoses (3, 4)

 Do not mix up the charge air hoses (3, 4).
The red charge air hose (4) is temperature-resistant and must always be installed between charge air pipe (6) and charge air cooler (7).

24

Attach radiator grill (1) to engine radiator (2)

With CODE C47 (radiator grill at the rear)

 Replace nuts.

25

Release and lower dumper flatbed

 See owner's manual.

 Charge air cooler

Number

Designation

Engine 900.91, 902.92/93, 904.92, 906.93/95

BA09.41-N-1003-03A

Bolt, charge air cooler to mounting support at top

M10

Nm

34

 Charge air cooler

Number

Designation

Engine 900.91, 902.92/93, 904.92, 906.93/95

BA09.41-N-1004-03A

Bolt, charge air cooler to mounting support at bottom

M10

Nm

55

 Radiator, coolant hoses

Number

Designation

Engine 900.915/916, 904.927/928

Engine 902.923/924/ 935, 906.935/955

BA20.20-N-1003-01K

Bolt, engine radiator to charge air cooler at top

Nm

15

15

 Radiator, coolant hoses

Number

Designation

Engine 900.915/916, 904.927/928

Engine 902.923/924/ 935, 906.935/955

BA20.20-N-1004-01K

Nut, engine radiator to charge air cooler at bottom

Nm

15

15