3508, 3512 and 3516 Generator Set Engines 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	g02007277

2. Remove bolts (1), elbow (2), the gasket and the O-ring seal.

3. Disconnect tube assembly (3) from adapter (6).

4. Remove bolts (4) and adapter (6).

5. Remove adapter (5), the sleeve, and the O-ring seal.

6. If necessary, remove bolt (7) and exhaust manifold (8).
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   Illustration 2	g02007993

7. Remove bolts (10) and adapter (9).

8. Remove adapter (11), the sleeve, and the O-ring seal.
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   Illustration 3	g02007995

9. Attach Tooling (A) and a suitable lifting device to aftercooler housing (13). For 3508 Engines, the weight of aftercooler housing (13) is approximately 28 kg (62 lb). For 3512 Engines, the weight of aftercooler housing (13) is approximately 70 kg (155 lb). For 3516 Engines, the weight of aftercooler housing (13) is approximately 109 kg (240 lb).

10. Remove bolts (12), aftercooler housing (13), and the gasket.

    Note: The following step is for 3508 and 3512 engines.

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    Illustration 4	g02007999

11. Attach Tooling (A) and a suitable lifting device to aftercooler core (14). For 3508 Engines, the weight of aftercooler core (14) is approximately 29 kg (64 lb). For 3512 Engines, the weight of aftercooler core (14) is approximately 52 kg (115 lb).

12. Remove bolts (15) and aftercooler core (14). Remove the O-ring seals, the ring, and connector (16).

    Note: The following step is for 3516 engines.

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    Illustration 5	g02011753

13. Attach Tooling (A) and a suitable lifting device to aftercooler cores (17). For 3516 Engines, the weight of each aftercooler core (17) is approximately 29 kg (64 lb).

14. Remove bolts (19), pipes (18), and the O-ring seals.

15. Remove cover (22).

16. Remove bolts (20) and each aftercooler core (17).

17. Remove the O-ring seals, the rings, and connectors (21).

Installation Procedure

1. Install aftercooler cores (17) and aftercooler core (14) in the reverse order of removal.

   1. Apply glycerin to the O-ring seals prior to installation.

   2. Ensure that connectors (21) and connector (16) are oriented properly during installation.

   3. If the aftercooler housings were disassembled and new gaskets were installed, trim the new gaskets even with the aftercooler housings.

   4. Tighten bolts (20) and bolts (15) to a torque of 32 ± 7 N·m (24 ± 5 lb ft).

   5. Tighten bolts (12) on the ends of aftercooler housing (13) to a torque of 55 ± 7 N·m (41 ± 5 lb ft).