3500 Engines Aftercooler - Remove and Install Caterpillar

Removal Procedure

1. Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".
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   Illustration 1	g01949540

2. Remove bolts (3) and strap (4).

3. Remove bolt (7) and loosen clamps (1). Remove air pipe (2). Remove the O-ring seals from air pipe (2).

4. Remove bolts (6), air inlet elbow (5), and the O-ring seal.

5. Repeat for the other side of the aftercooler.
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   Illustration 2	g01949543

6. Remove bolts (8) and disconnect elbow (9). Remove the O-ring seal.

7. Disconnect hose assembly (12). Remove bolts (10) and disconnect elbow (11). Remove the O-ring seal.

8. Remove bolts (13) and disconnect the flange. Remove the O-ring seals.

9. Remove bolts (14) and disconnect the flange. Remove the O-ring seals.
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   Illustration 3	g01949604

10. Attach Tooling (A) and a suitable lifting device to the top of air inlet cover (16). The weight of air inlet cover (16) is approximately 35 kg (77 lb).

11. Remove bolts (15), air inlet cover (16), and the seal.

    Note: Be careful not to damage the fins of the aftercooler core.

12. Attach a suitable lifting device onto aftercooler core (17). The weight of the 3508C aftercooler core is approximately 23 kg (51 lb). The weight of the 3512C aftercooler core is approximately 32 kg (71 lb). Remove aftercooler core (17). Remove the seal from adapter (19).

13. Remove bolts (18). Remove adapter (19) and the seal.

14. Attach a suitable lifting device onto aftercooler core (20). The weight of the 3508C aftercooler core is approximately 60 kg (132 lb). The weight of the 3512C aftercooler core is approximately 85 kg (187 lb). Remove aftercooler core (20). Remove the seal from the air inlet manifold.

    Note: Be careful not to damage the fins of the aftercooler core.

Installation Procedure

Note: Be careful not to damage the fins of the aftercooler cores.

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Illustration 4	g01949604

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Illustration 5	g01238547

1. Install the seal on the bottom of aftercooler core (20). Temporarily secure the bottom seal with tape. Make sure that the tape can be removed after the aftercooler core is installed. Do not use an adhesive, a silicone lubricant, or any other lubricant for retention of the seal.

2. Attach a suitable lifting device onto aftercooler core (20). The weight of the 3508C aftercooler core is approximately 60 kg (132 lb). The weight of the 3512C aftercooler core is approximately 85 kg (187 lb). Position aftercooler core (20) onto the air inlet manifold. Ensure that the bottom seal is properly seated.

3. Remove the tape that secured the bottom seal.

4. Install the seal and adapter (19) on top of aftercooler core (20).

5. Install bolts (18). Hand tighten bolts (18) to the following procedure:

   1. Tighten the bolts in the numerical sequence to a torque of 24 N·m (18 lb ft).

   2. Tighten the bolts in the numerical sequence to a torque of 47 N·m (35 lb ft).

6. Install the seal on adapter (19).

7. Attach a suitable lifting device onto aftercooler core (17). The weight of the 3508C aftercooler core is approximately 23 kg (51 lb). The weight of the 3512C aftercooler core is approximately 32 kg (71 lb). Position aftercooler core (17) onto adapter (19). Ensure that the bottom seal is properly seated.

8. Attach Tooling (A) and a suitable lifting device to the top of air inlet cover (16). The weight of air inlet cover (16) is approximately 35 kg (77 lb). Install the seal and air inlet cover (16).

9. Install bolts (15). Hand tighten bolts (15) to the following procedure:

   1. Tighten the bolts in the numerical sequence to a torque of 24 N·m (18 lb ft).

   2. Tighten the bolts in the numerical sequence to a torque of 47 N·m (35 lb ft).
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   Illustration 6	g01949543

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   Illustration 7	g06411012

10. Install the O-ring seals on the tube assembly. Lubricate the O-ring seals with Tooling (B). Connect the flange and install bolts (14). Ensure that there is no gap at position (X).

11. Install the O-ring seals on the elbow. Lubricate the O-ring seals with Tooling (B). Connect the flange and install bolts (13). Ensure that there is no gap at position (X).

12. Install the O-ring seal on elbow (11). Lubricate the O-ring seal with Tooling (B). Connect elbow (11) and install bolts (10). Connect hose assembly (12).

13. Install the O-ring seal on elbow (9). Lubricate the O-ring seal with Tooling (B). Connect elbow (9) and install bolts (8).
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    Illustration 8	g01949540

14. Install the O-ring seal, air inlet elbow (5), and bolts (6).

15. Install the O-ring seals on air pipe (2). Lubricate the O-ring seals with Tooling (B). Install air pipe (2). Tighten clamps (1) and install bolt (7).

16. Install strap (4) and bolts (3).

17. Repeat for the other side of the aftercooler.

18. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".