3508B, 3512B and 3516B Generator Set Engines Aftercooler

Aftercooler - Remove and Install

3508B, 3512B and 3516B Generator Set Engines [RENR5060]

3508B, 3512B and 3516B Generator Set Engines Air Inlet Manifold - Remove and Install

3508B, 3512B and 3516B Generator Set Engines Exhaust Manifold - Remove and Install

AIR INLET AND EXHAUST SYSTEM

AFTERCOOLER GP

3500B Engines Aftercooler - Remove and Install

3508B, 3512B and 3516B Generator Set Engines Aftercooler - Remove and Install

1.1. Removal Procedure

2.1. Installation Procedure

Removal Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	138-7573	Link Bracket	2

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat^® products. Dispose of all fluids according to local regulations and mandates.

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NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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

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".
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Illustration 1 g01115307
Remove bolts (1) and the retainers. Remove air pipes (2). Remove the O-ring seals from the air pipes.
If necessary, remove bolts (5) and remove adapters (4). Remove the O-ring seal from the adapters.
Remove bolts (7) and bolts (11). Remove adapter (8) and adapter (10) from the aftercooler cover. Remove the O-ring seals from the adapters.
Install Tooling (A) into the top of air inlet cover (3).
Attach a suitable lifting device onto Tooling (A). The weight of air inlet cover (3) is approximately 28 kg (62 lb). Remove bolts (6). Remove air inlet cover (3).
Note: Be careful not to damage the fins of the aftercooler core.
Note: The weight of the 3508B air inlet cover is approximately 28 kg (62 lb). The weight of the 3512B air inlet cover is approximately 35 kg (77 lb).
Install Tooling (A) into the top of air inlet cover (9).
Attach a suitable lifting device onto Tooling (A). The weight of air inlet cover (9) is approximately 33 kg (73 lb). Remove bolts (6). Remove air inlet cover (9).
Note: Be careful not to damage the fins of the aftercooler core.
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Illustration 2 g01115312
Remove hose assembly (15) from the aftercooler cores. Remove the O-ring seals from the hose assembly. Disconnect hose assembly (18) from the aftercooler core. Remove the O-ring seal from the hose assembly.
Disconnect tube assembly (12) and tube assembly (19). Remove the O-ring seals from the tube assemblies.
Remove tube (16) from the aftercooler cores. Remove the O-ring seals from the tube.
Attach a suitable lifting device onto aftercooler core (13). The weight of aftercooler core (13) is approximately 37 kg (82 lb). Remove aftercooler core (13) from the air inlet manifold. Remove seal (14) from the aftercooler core.
Note: Be careful not to damage the fins of the aftercooler core.
Note: The weight of the 3508B aftercooler core is approximately 37 kg (82 lb). The weight of the 3512B aftercooler core is approximately 52 kg (115 lb).
Attach a suitable lifting device onto aftercooler core (17). The weight of aftercooler core (17) is approximately 37 kg (82 lb). Remove aftercooler core (17) from the air inlet manifold. Remove seal (14) from the aftercooler core.
Note: Be careful not to damage the fins of the aftercooler core.

Installation Procedure

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Table 2
Required Tools
Tool	Part Number	Part Description	Qty
A	138-7573	Link Bracket	2
B	1U-6395	O-Ring Assembly Compound	-

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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 cores.

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Illustration 3	g01115763

Install seal (14) on the bottom of the aftercooler core (17). 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.
Attach a suitable lifting device onto aftercooler core (17). The weight of aftercooler core (17) is approximately 37 kg (82 lb). Position aftercooler core (17) onto the air inlet manifold. Ensure that the bottom seal is properly seated.
Note: The weight of the 3508B aftercooler core is approximately 37 kg (82 lb). The weight of the 3512B aftercooler core is approximately 52 kg (115 lb).
Install seal (14) on the bottom of aftercooler core (13). 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.
Attach a suitable lifting device onto aftercooler core (13). The weight of aftercooler core (13) is approximately 37 kg (82 lb). Position aftercooler core (13) onto the air inlet manifold. Ensure that the bottom seal is properly seated.
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Illustration 4 g01115909
Install seal (14) on top of the aftercooler core.
Install Tooling (A) into the top of air inlet cover (9).
Attach a suitable lifting device onto Tooling (A). The weight of air inlet cover (9) is approximately 28 kg (62 lb). Position air inlet cover (9) onto the aftercooler core. Ensure that the seal is seated between air inlet cover (9) and the aftercooler core.
Note: The weight of the 3508B air inlet cover is approximately 28 kg (62 lb). The weight of the 3512B air inlet cover is approximately 35 kg (77 lb).
Install Tooling (A) into the top of air inlet cover (3).
Attach a suitable lifting device onto Tooling (A). The weight of air inlet cover (3) is approximately 28 kg (62 lb). Position air inlet cover (3) onto the aftercooler core. Ensure that the seal is seated between air inlet cover (3) and the aftercooler core.
Install bolts (6). Hand tighten bolts (6) to the following procedure:
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Illustration 5 g01114393
Tighten the bolts in the numerical sequence to a torque of 24 N·m (18 lb ft).
Tighten the bolts in the numerical sequence to a torque of 47 N·m (35 lb ft).
Remove the tape that secured the bottom seal.
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Illustration 6 g01115761
Install the O-ring seal on adapter (4). Position adapter (4) on the cover and install bolts (5).
Install the O-ring seals on air pipes (2). Lubricate the O-ring seals with Tooling (B). Install air pipes (2) and install the retainers and bolts (1).
Install the O-ring seal on adapter (8). Install the O-ring seals on adapter (10). Lubricate the O-ring seals with Tooling (B). Position the adapters and install bolts (7) and bolts (11).
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Illustration 7 g01115772
Install the O-ring seal on tube assembly (12). Lubricate the O-ring seal with Tooling (B). Connect tube assembly (12) to the aftercooler core.
Install the O-ring seal on tube assembly (19). Lubricate the O-ring seal with Tooling (B). Connect tube assembly (19) to the aftercooler core.
Install the O-ring seals on tube (16). Lubricate the O-ring seals with Tooling (B). Install tube (16) to the aftercooler cores.
Install the O-ring seals on hose assembly (15) and install the hose assembly to the aftercooler. Install the O-ring seal on hose assembly (18) and install the hose assembly to the aftercooler.
Fill the cooling system with coolant. Refer to the Operation and Maintenance Manual, "Cooling System Coolant - Change".