3500 and 3500B High Displacement Engines for Caterpillar Built Machines Aftercooler - Remove and Install - Aftercooler Housing with 12 bolts Caterpillar

Removal Procedure

1. Drain the coolant from the auxiliary water system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change".
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   Illustration 1	g02173968

2. Remove tube assemblies (1) and tube assemblies (2).
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   Illustration 2	g02173971

3. Remove tube assemblies (3) and hose assemblies (4).
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   Illustration 3	g02173972

4. Remove hose clamps (6) and hose (7). Remove bolts (9), elbow (5), and the O-ring seals. Remove bolts (10), elbow (8), and the O-ring seal. Repeat for the remaining turbochargers.
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   Illustration 4	g02173973

5. Remove bolts (14). Use two technicians to remove cover (13). The weight of cover (13) is approximately 32 kg (71 lb). Slide cover (13) from pipe (12). Remove the O-ring seal from the aftercooler core. Remove bolts (11), pipe (12), and the O-ring seals. Repeat for the other cover.
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   Illustration 5	g02173975

6. Disconnect tube assembly (18) from elbow (16). Remove bolts (17) and disconnect the tube assembly and the flange from elbow (16). Remove the O-ring seals. Remove bolts (15), elbow (16), the adapter, and the O-ring seals.
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   Illustration 6	g02174147

7. Remove bolts (19) from tee (20) and the clamp assemblies. Remove bolts (22), flange (21), and tee (20). Remove the adapters and the O-ring seals.
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   Illustration 7	g02174148

8. Remove bolts (23), cover (24), the gasket, the adapter, and the O-ring seals.
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   Illustration 8	g02174212

9. Use two technicians to remove aftercooler core (25). The weight of aftercooler core (25) is approximately 45 kg (100 lb). Remove the O-ring seal from the housing. Repeat for the other aftercooler core.
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   Illustration 9	g02174219

10. Remove bolts (27). Use two technicians to remove housing (26). The weight of housing (26) is approximately 26 kg (57 lb). Remove the O-ring seal from the air inlet manifold. Repeat for the other housing.

Installation Procedure

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Illustration 10	g06050585

1. With the aftercooler core laying on its side, install the seal. Ensure that it is fully seated. Tape the sides with removable tape to ensure the seal stays in place during assembly.
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   Illustration 11	g06050591

2. Use a proper lift devise when lifting the aftercooler core and top cover. Lower the aftercooler core straight down while aligning the bolt holes as shown in illustration 11. Install the top aftercooler seal, ensuring it is fully seated. Install the top cover straight down ensuring no tilt.
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   Illustration 12	g02174250

   Note: Zero torque reference means to install the bolts to minimal resistance.

3. Install the O-ring seal on the air inlet manifold. Install the bolts at zero torque, starting in the middle and using the pattern shown in illustration 12. Using the pattern in illustration 12. Torque the bolts to 50% 24 N·m (18 lb ft) Inspect the seal for proper seating, bubbles, or bulges. Finish torque to 100% 47 N·m (35 lb ft) and inspect for any bubbles or bulges.
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   Illustration 13	g02174212

4. Install the O-ring seal on the housing. Use two technicians to install aftercooler core (25). The weight of aftercooler core (25) is approximately 45 kg (100 lb). Repeat for the other aftercooler core.
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   Illustration 14	g02173973

5. Install the O-ring seals on the aftercooler cores. Use two technicians to install cover (13). The weight of cover (13) is approximately 32 kg (71 lb).

6. Apply a light coat of glycerin to the O-ring seals. Install the O-ring seals, pipe (12), and bolts (11) on the other cover. Use two technicians to install the other cover. Slide pipe (12) in cover (13). Install bolts (14). Tighten the corner bolts to seat the O-ring seal. The remaining bolts will be tightened later.
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   Illustration 15	g02174148

7. Apply a light coat of glycerin to the O-ring seals. Install the O-ring seals, the adapter, the gasket, cover (24), and bolts (23). Do not tighten the bolts at this time.
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   Illustration 16	g02174147

8. Apply a light coat of glycerin to the O-ring seals. Install the O-ring seals, the adapters, tee (20), flange (21), and bolts (22). Install the clamp assemblies and bolts (19). Do not tighten the bolts at this time.
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   Illustration 17	g02173975

9. Apply a light coat of glycerin to the O-ring seals. Install the O-ring seals, the adapter, elbow (16), and bolts (15). Connect the tube assembly and the flange to elbow (16) and install bolts (17). Connect tube assembly (18) to elbow (16). Do not tighten the bolts at this time.
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   Illustration 18	g02174347

10. Tighten the bolts for the covers in a numerical sequence to a torque of 24 N·m (18 lb ft). Tighten the bolts again in a numerical sequence to a torque of 47 N·m (35 lb ft).

11. Tighten the bolts for the water elbows.
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    Illustration 19	g02173972

12. Install the O-ring seal, elbow (8), and bolts (10). Apply a light coat of glycerin to the O-ring seals. Install the O-ring seals, elbow (5), and bolts (9). Install hose (7) and hose clamps (6). Orient the hose clamps 180 degrees away from each other. Repeat for the remaining turbochargers.
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    Illustration 20	g02173971

13. Install hose assemblies (4) and tube assemblies (3).
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    Illustration 21	g02173968

14. Install tube assemblies (2) and tube assemblies (1).

15. Refill the auxiliary water system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change".