3500 and 3500B High Displacement Engines for Caterpillar Built Machines Aftercooler - Remove and Install - High Altitude Arrangement Caterpillar

Removal Procedure

Start By:

1. Remove the turbochargers. Refer to Disassembly and Assembly, "Turbocharger - Remove".

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	g02164395

2. Remove bolts (1), bellows assemblies (2), and the gaskets.
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   Illustration 2	g02165053

3. Remove bolts (3), bellows assembly (4), and the gaskets.

4. Remove bolts (10), the retainers, flange (11), and tube (9). Remove the O-ring seals.

5. Remove bolts (8), bolts (7), flanges (6), tee (5), the adapters, and the O-ring seals.
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   Illustration 3	g02165071

6. Remove sensor assembly (14) from tube assembly (18).

7. Remove bolts (13), the retainers, flange (12), tube assembly (18), and the O-ring seals.

8. Disconnect tube assembly (16) from elbow (17). Remove bolts (15), elbow (17), the adapter, and the O-ring seals.
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   Illustration 4	g02165103

9. Remove bolts (19), cover (20), the gasket, the adapter, and the O-ring seal.
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   Illustration 5	g02165107

10. Remove bolts (22). Use two technicians to remove cover assembly (21). The weight of cover assembly (21) is approximately 30 kg (66 lb). Remove the O-ring seal. Repeat for the other cover assembly.
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    Illustration 6	g02165574

    Note: Use care when removing the aftercooler core from the housing. Ensure that the couplings on the aftercooler core are not damaged during removal.

11. Use Tooling (A) to raise aftercooler core (23) from the housing. Use a suitable lifting device to remove aftercooler core (23). The weight of aftercooler core (23) is approximately 30 kg (66 lb). Remove the O-ring seals. Repeat for the other aftercooler core.
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    Illustration 7	g02165814

12. Remove bolts (25). Attach a suitable lifting device to housing (24). The weight of housing (24) is approximately 36 kg (80 lb). Remove housing (24) and the gasket. Repeat for the other housing.

Installation Procedure

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Illustration 8	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 9	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 10	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 11	g02165103

1. Apply a light coat of glycerin to the O-ring seals. Install the O-ring seal, the adapter, the gasket, cover (20), and bolts (19).
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   Illustration 12	g02165071

2. Apply a light coat of glycerin to the O-ring seals. Install the O-ring seals, the adapter, elbow (17), and bolts (15). Connect tube assembly (16) to elbow (17).

3. Apply a light coat of glycerin to the O-ring seals. Install O-ring seals, tube assembly (18), flange (12), the retainers, and bolts (13).

4. Install sensor assembly (14) in tube assembly (18).
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   Illustration 13	g02165053

5. Apply a light coat of glycerin to the O-ring seals. Install the O-ring seals, the adapters, tee (5), flanges (6), bolts (7), and bolts (8).

6. Apply a light coat of glycerin to the O-ring seals. Install the O-ring seals, tube (9), flange (11), the retainers, and bolts (10).

7. Install the gaskets, bellows assembly (4), and bolts (3). Tighten bolts (3) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
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   Illustration 14	g02164395

8. Install the gaskets, bellows assemblies (2), and bolts (1). Tighten bolts (1) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

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

End By:

1. Install the turbochargers. Refer to Disassembly and Assembly, "Turbocharger - Install".