G3612 & G3616 TWO STAGE AFTERCOOLOER Caterpillar


Disassembly and Assembly

Usage:


(1) Drain plug (for aftercooler first stage). (2) Vent line connection (for aftercooler first stage). (3) Drain plug (for aftercooler second stage). (4) Vent line connection (for aftercooler second stage).

1. Drain both coolant circuits of the aftercooler from any convenient drain location in the cooling system. The air vent plug should be opened to break the vacuum which may be caused by the out flowing coolant. Drain any remaining coolant in the aftercooler core by removing drain plugs (1,3) on the end of the aftercooler facing the front of the engine.


(5) Bolts (for cooling system tube to aftercooler). (6) Bolts (for cooling system tube). (7) Cooling system tubes.

2. Remove bolts (5) that hold the cooling system tubes to aftercooler. Remove bolts (6) that hold the other end of tubes. Remove all four cooling system tubes (7). Remove customer provided vent lines from vent line connection (2) for aftercooler first stage and vent line connection (4) for aftercooler second stage.


(8) Air inlet adapter bolts. (9, 10) Air Inlet adapters.

3. Remove air inlet adapters bolts (8). Remove air inlet adapters (9, 10) from the aftercooler.


(11,12,13,14) Inlet valve lubrication system tubes (right side).

4. Disconnect inlet valve lubrication system tubes (11,12,13,14) connected to the right side of the aftercooler housing.


(15) Inlet valve lubrication system tube (front). (16,17) Inlet valve lubrication system tubes (left side). (18) Inlet valve lubrication system tube (rear).

5. Disconnect inlet valve lubrication system tubes on the left side (16,17), front (15), and rear (18) of the aftercooler housing.


(19) Pressure module tube. (20) Air temperature sensor.

6. Disconnect pressure module tube (19) from the rear of the aftercooler housing and air temperature sensor (20) from the front of the aftercooler housing.


(21,22) Bolts (aftercooler cover to aftercooler core assembly). (23) Aftercooler cover. (24) Aftercooler core assembly. (25,26) Bolts (aftercooler core assembly to aftercooler housing). (27) Lifting holes. (28) Aftercooler housing. (29) Bolts (aftercooler housing to engine block).

7. Remove bolts (21,22) that hold aftercooler cover (23) to the aftercooler core assembly (24). Remove the aftercooler cover. The approximate weight of the aftercooler cover is 58 kg (128 lb).

8. Remove bolts (25,26) that hold aftercooler core assembly (24) to aftercooler housing (28). Lift the aftercooler core off the housing using the lifting holes (27) provided on the sides. The lifting hole thread size is M20 X 22. The approximate weight of the aftercooler core is 850 kg (1870 lb).

9. Remove bolts (29), washers and spacers that hold the aftercooler housing (28) to the engine block. Lift the aftercooler housing from the engine block. The approximate weight of the aftercooler housing is 280 kg (617 lb).


(2) Vent line connection (for aftercooler first stage). (4) Vent line connection (for aftercooler second stage). (30) Bolts (branch header). (31) Branch header. (32) Tubestack and sideplate assembly. (33) Return header.

10. Remove bolts (30) and washers. Remove branch header (31) from the tubestack and sideplate assembly (32).

11. Remove bolts, washers and return header (33) from the tubestack and sideplate assembly.

12. Install the return header and gasket onto the tubestack and sideplate assembly. Install the bolts and washers. Tighten the bolts to a torque of 55 ± 10 N·m (40 ± 7 lb ft).

13. Install the the branch header and gasket onto the tubestack and sideplate assembly. Install the bolts and washers. Tighten the bolts to a torque of 55 ± 10 N·m (40 ± 7 lb ft).

14. Install the aftercooler housing (28) and gasket onto the engine block. Install the bolts (29), washers and spacers. Tighten the bolts to a torque of 47 ± 9 N·m (35 ± 7 lb ft).

15. Install aftercooler core assembly (24) and gasket onto aftercooler housing (28). Install the bolts and washers. Tighten bolts (25) on the sides of the aftercooler core assembly to a torque of 47 ± 9 N·m (35 ± 7 lb ft). Tighten bolts (26) on the end to a torque of 25 ± 6 N·m (18 ± 4 lb ft).

16. Install aftercooler cover (23) and gasket. Install the bolts and washers. Tighten bolts (22) on the sides of the cover to a torque of 47 ± 9 N·m (35 ± 7 lb ft). Tighten bolts (21) on the end of the cover to a torque of 25 ± 6 N·m (18 ± 4 lb ft).

17. Connect the pressure module tube, and the air temperature sensor.

18. Connect the inlet valve lubrication system tubes.

19. Install the air inlet adapters and gaskets. Install the bolts, washers, and nuts. Tighten the bolts to a torque of 47 ± 9 N·m (35 ± 7 lb ft).

20. Install the cooling system tubes and gaskets. Install the bolts and washers. Tighten the bolts to a torque of 215 ± 40 N·m (160 ± 30 lb ft).

21. Install vent lines for first stage vent line connection (2) and second stage vent line connection (4). Vent lines should be provided by the customer as specified in the cooling system section of G3600 Application and Installation Guide.

22. Fill the cooling system to the correct level. Open vent plug from vent line connection (2) for air in first stage and vent plug from vent line connection (4) for venting air in second stage. See the G3600 Vee Industrial and EPG Gas Engines Operation & Maintenance Manual, SEBU6496.

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