G3516 Petroleum Engines Caterpillar

Aftercooler - Remove and Install

Usage:

Removal Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty.
A	447-3194	Lifting Eye Assembly	4
B		Loctite C5A Copper Anti-Seize	-

Start By:

Remove the throttle control valve. Refer to Disassembly and Assembly, "Throttle Control Valve - Remove".

Note: Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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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.

Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".
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Illustration 1 g06197467
Disconnect clamp (1) and swivel nut (3).
Remove bolts (2) and tube (4).
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Illustration 2 g06197083
Disconnect six clips (6) and remove tube (5).
Disconnect two tubes (8) and set off to the side.
Remove four bolts (7), eight bolts (9), and two elbows (10).
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Illustration 3 g06197133
Remove clip (11) and disconnect tube (12).
Remove four bolts (13) and bracket with tube (14).
Remove eight bolts (15) and actuator (16).
Remove eight bolts (17) and bracket (18).
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Illustration 4 g06197192
Remove clip (19) and disconnect tube (20).
Remove eight bolts (21) and four bolts (23) to remove tube and bracket (22).
Disconnect clamp (25) and remove tube (24).
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Illustration 5 g06197219
Remove two bolts (26), four bolts (27) , and elbow (28).
Remove four bolts (29), four bolts and clamp (31), and elbow (30).
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Illustration 6 g06197732
Remove two bolts (31) and remove the mounting group sensor and tube (32).
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Illustration 7 g06197735
Attach a suitable lifting device to the air cleaner (33). The air cleaner weighs approximately 35 kg (77 lb).
Disconnect four bolts (34), clamp (35), and remove air cleaner (33).
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Illustration 8 g06203323
Remove hose clamp (36), two U-bolts (38), and tube (37).
Remove three clamps (40) and tube (39).
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Illustration 9 g06203350
Disconnect clip (42) and remove tube (43).
Disconnect clip (46) and remove tubes (45) and (47).
Remove four bolts (44) and remove sensor and two brackets (41).
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Illustration 10 g06203568

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Illustration 11 g06203593
Attach Tooling A to the after cooler (48) at points (X).
Remove eight bolts (49) and remove after cooler (48).
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Illustration 12 g06206178

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Illustration 13 g06206207
Attach Tooling (A) and a suitable lifting device at positions (X). Aftercooler support weighs approximately 70 kg (154 lb).
Remove eight bolts (50), eight bolts (51), and aftercooler support.

Installation Procedure

Install the aftercooler in reverse order of removal
1. Apply Tooling (B) to the threads and bearing surfaces of eight bolts (21).
2. Tighten clamp (25) to a torque of 11 ± 3 N·m (97 ± 27 lb in).
3. Tighten two U-bolts (38) to a torque of 15 ± 2 N·m (133 ± 18 lb in).
4. Tighten clamp (40) to a torque of 16 ± 0.5 N·m (142 ± 4 lb in).