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Aftercooler - Remove and Install (UENR0181-13)

SMCS - 1063 i07607429

Removal Procedure
Table 1
PIP
Required Tools
Tool Part Number Part Description Qty -
202 1059
3 9
A 439-3938 Link Bracket 2

00: 11/1 433

/
NOTICE

UE 3 4 : 3
18+
Keep all parts clean from contaminants.

N
Contaminants may cause rapid wear and shortened component
life.

©2 R 0
018 7:00
023 1
NOTICE
Cat
erp
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting, and

illa
repair of the product. Be prepared to collect the fluid with

rI
suitable containers before opening any compartment or
disassembling any component containing fluids.

Refer to Special Publication, PERJ1017, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain
fluids on Cat® products.
nc.
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Dispose of all fluids according to local regulations and

mandates.

Note: Different designs of aftercoolers are available for different applications. The following procedures describe the removal and
installation of a typical aftercooler.

Note: The 3508B and 3512B Engines have one aftercooler. The 3516B Engines have two aftercoolers. The following procedures
describe the removal and installation of only one aftercooler.

1. Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Disassembly and
Assembly, "Cooling System Coolant - Change".

Illustration 1 g00601406

2. Remove tube assembly (1). Cap the openings and/or plug of the openings.

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Illustration 2 g00601408

3. Remove tube assemblies (2) that are between the air inlet cover of the aftercooler and the turbochargers.

Illustration 3 g00616450

4. Disconnect tube assemblies (3) from the ends of the aftercooler core. One tube is at the front and one tube is for the rear.

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Illustration 4 g00601409

5. Install Tooling (A) into the top of air inlet cover (4).

6. Attach a suitable lifting device onto Tooling (A). The weight of air inlet cover (4) is approximately 11 kg (24 lb). Remove bolts (5).
Remove air inlet cover (4).
Note: Be careful not to damage the fins of the aftercooler core.

Illustration 5 g00601411

7. Attach a suitable lifting device onto aftercooler core (6). The weight of aftercooler core (6) is approximately 37 kg (82 lb). Lift

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aftercooler core (6) from the air inlet manifold.

Installation Procedure
Table 2

Required Tools
Tool Part Number Part Description Qty
A 439-3938 Link Bracket 2

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component

life.

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

Illustration 6 g00601411

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1. Inspect the top O-ring seal and the bottom O-ring seal of aftercooler core (6). If a seal is cut, scratched, or cracked, install a new
seal. 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 (6). The weight of aftercooler core (6) is approximately 37 kg (82 lb). Position
aftercooler core (6) onto the air inlet manifold.
Ensure that the bottom seal is properly seated.

Illustration 7 g00601409

3. Install Tooling (A) in the top of air inlet cover (4). Attach a suitable lifting device onto Tooling (A). The weight of air inlet cover (4)
is approximately 11 kg (24 lb).

4. Position air inlet cover (4) onto the aftercooler core.

Ensure that the seal is seated between air inlet cover (4) and the aftercooler core.

5. Install bolts (5). Hand tighten bolts (5).

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Illustration 8 g00747427
Bolt tightening sequence for engines with one aftercooler
(A) Front of the engine

Illustration 9 g00747429
Bolt tightening sequence for engines with two aftercoolers
(A) Front of the engine

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

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

8. Remove the tape from the bottom seal.

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Illustration 10 g00616450

9. Inspect the O-ring seals for tube assemblies (3). If a seal is cut, scratched, or cracked, install a new seal. Connect tube
assemblies (3) to the ends of the aftercooler core. One tube is for the front and one tube is for the rear.

Illustration 11 g00601408

10. Inspect the O-ring seals for tube assemblies (2). If a seal is cut, scratched, or cracked, install a new seal. Install tube assemblies
(2) between the air inlet cover of the aftercooler and the turbochargers.

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Illustration 12 g00601406

11. Inspect the O-ring seals for tube assembly (1). If a seal is cut, scratched, or cracked, install a new seal. Install tube assembly (1).

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

PIP-10599433
2023/11/13
00:33:31+07:00
i01135436
© 2023 Caterpillar Inc.

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