Installation Of Energized Seals On 3600 High Performance Aftercoolers{1063} Caterpillar

Engines:

3612 (S/N: 9FR1-UP; 2NZ1-UP; 9RC1-UP)

3616 (S/N: 1FN1-UP; 1PD1-UP)

Introduction

This Special Instruction provides the procedure for installing the 130-1292 Seal for use in the 130-6262 Air Lines on 3600 Engines. The energized seal is used on the 130-1291 Pipe which is located between the turbocharger and the aftercooler. This Special Instruction also provides the procedures for the removal and installation of the High Performance Aftercooler.

Illustration 1	g00322563

Table 1

Required Tools And Parts
Item	Part Number	Description	Quantity
A	148-9707	Ring Compressor Pliers	2
B	148-9705	Seal Ring Compressor	2
C	148-6443	Ring Insert	1
D	148-6442	Ring	1
E	148-6444	Seal Installer	1
F	148-6445	Seal Driver	1
1	130-1292	Seals	4

Installation Of The 130-1292 Seal

Illustration 2	g00325103

Illustration 3	g00325104
Chamfer On Insert

1. Remove the two 6D-3033 Allen Head Screws from the 148-6443 Ring Insert (C). Place the 130-1291 Pipe (2) on a work bench. Install the insert in the top seal groove of the pipe (2). The insert has a chamfer on one side. It is important to install the insert with the chamfer toward the top of the pipe. This will allow the energized seal to slide evenly over the insert.

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Illustration 4	g00325105

2. When the insert (C) is installed, place the 148-6444 Seal Installer (E) onto the pipe. Lubricate the seal installer with glycerin.

3. Place the 130-1292 Seal (1) on the seal installer (E) with the energized spring toward the top of the pipe.

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Illustration 5	g00325106

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Illustration 6	g00325107

4. Use the 148-6442 Ring (D) in order to move the energized seal evenly onto the seal installer. Before you use the 148-6445 Seal Driver (F), notice that the seal driver has both a small inside diameter and a large inside diameter. Place the small inside diameter of the seal driver over the energized seal. The seal driver and the energized seal should be pushed down until the energized seal reaches the step (X) on the outside of the seal installer.

5. Invert the seal driver (F). Place the large diameter of the seal driver over the energized seal. The energized seal should be pushed down until the energized seal is located in the seal groove of the pipe (2) .

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Illustration 7	g00325108
This Illustration shows the seal driver with the large diameter on the bottom.

6. Continue to push the energized seal downward over the insert (C) until the seal reaches the lower seal groove (Y) .

7. Remove the seal driver (F) and the seal installer (E) .

8. Remove the 6D-3033 Allen Head Screws from the 148-6443 Ring Insert (C). Remove the insert from the seal groove in the pipe (2) .

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Illustration 8	g00325109

9. Put the seal installer (E) in position on the 130-1291 Pipe (2). Place the next energized seal (3) on the seal installer. Ensure that the energized spring is facing upward.

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Illustration 9	g00325110

10. Use the 148-6442 Ring (D) in order to move the energized seal evenly onto the seal installer. Before you use the 148-6445 Seal Driver (F), notice that the seal driver has both a small inside diameter and a large inside diameter. Place the small inside diameter of the seal driver over the energized seal. Push the seal driver and the energized seal downward until the energized seal reaches the step (X) on the outside of the seal installer.

11. Invert the seal driver (F). Place the large diameter of the seal driver over the energized seal. The energized seal should be pushed down until the energized seal is located in the seal groove of the pipe (2) .

12. Invert the 130-1291 Pipe (2). Repeat Steps 3 through 11 in order to install the remaining two energized seals on the opposite end of the pipe (2) .

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Illustration 10	g00325111

13. After the four energized seals are installed, place the 148-9705 Seal Ring Compressor (B) around two of the energized seals. Attach the 148-9707 Ring Compressor Pliers to the 148-9705 Seal Ring Compressor .

14. Squeeze the pliers in order to compress the energized seals into the seal grooves in the pipe (2) .

    Note: Ensure that the energized seals do not roll during the compression. The springs should be facing the end of the pipe.

15. Once the first seal retainer is installed, invert the air pipe (2). Install the second seal retainer and the pliers. Leave the seal retainers on the energized seals for approximately one hour.

16. Remove the pliers and the seal retainers.

    Note: Ensure that the seals have not been damaged and that the springs face the ends of the pipe. If any of the seals have been damaged, replace the energized seals.

Removal And Installation Of The High Performance Aftercooler

Removal Of The High Performance Aftercooler

1. Drain the coolant from the system before you begin work on the aftercooler.

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Illustration 11	g00325223

2. Remove the bolts (2) and washers from each end of the tube assembly (1). Remove the four retainers (3) .

3. Remove the tube assembly (1). Remove the gaskets from the ends of the tube assembly.

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Illustration 12	g00325224

4. Remove the four bolts (4) and washers.

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Illustration 13	g00325225

5. Remove the two bolts (5) and washers.

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Do not allow the bracket to fall when the bolts and washers are removed. Personal injury may result.

6. Remove the bracket (6) .

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Illustration 14	g00325226

7. Remove the bolts, nuts and washers (7) that connect the tubes (8) to the turbochargers.

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Illustration 15	g00325227

8. Remove the tubes (8) .

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Illustration 16	g00325228

9. Remove the air pipes (9) with the energized seals from the aftercooler housing (10) .

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Illustration 17	g00325229

10. Remove the eight bolts (11) and washers.

11. Remove the aftercooler housing (10) .

12. Remove the gasket (12) that is between the aftercooler housing (10) and the adapter (13) .

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Illustration 18	g00325230

13. Remove the eight bolts (14) and washers.

14. Remove the adapter (13) from the end of the aftercooler cover assembly (15) .

15. Remove the gasket (16) that is between the adapter (13) and the aftercooler cover assembly (15) .

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Illustration 19	g00325231

16. Remove four bolts (17) and washers.

17. Remove two retainers (19) .

18. Remove the flange (20), the orifice (18), and the plate (21) .

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Illustration 20	g00325232

19. Remove the bolts, nuts, and washers (23). Remove the clamp (22) .

20. Remove the two bolts (24) and washers.

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Illustration 21	g00325234

21. Remove the four bolts, washers, and spacers (25) .

22. Remove the two clamp assemblies (26) .

23. Remove the tube (27) .

24. Remove the ring and the O-ring seal from the end of the tube (27) .

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Illustration 22	g00325235

25. If necessary, remove the two brackets (28) .

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Illustration 23	g00325236

26. Remove the two bolts (29) from the tee connection (30) .

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Illustration 24	g00325237

27. Remove the bolts (31) and washers.

28. Remove the two flanges (32) and the tee connection (30) that is between the two aftercooler cores.

29. Remove the seals and the orifice from the end of the tee connection (30) .

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Illustration 25	g00325238

30. Remove the bolts (33), washers, bracket (34), and the bellows assembly (35) .

31. Remove the gaskets (36) from the ends of the bellows assembly.

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Illustration 26	g00325239

32. Remove the bolts (38), the washers, the flanges (37), and the tee adapter (39) .

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Illustration 27	g00325240

33. Remove the four bolts (40) .

34. Remove the elbow (41) .

35. Remove the O-ring seals from the elbow (41) .

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Illustration 28	g00325242

36. Remove the bolts (42) and washers that hold the aftercooler cover assembly to the aftercooler core assembly.

37. Remove the shims (43) that are between the aftercooler cover assembly and the aftercooler core assembly.

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Illustration 29	g00325244

38. Remove the shims (44) that are between the aftercooler core assembly and the aftercooler housing.

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Illustration 30	g00325245

39. Install two 1P-7409 Eyebolts , chains, and a suitable lifting device in order to lift the front aftercooler cover assembly (45). The weight of the front cover assembly is approximately 121 kg (267 lb).

40. Remove the front aftercooler cover assembly (45) from the front aftercooler core assembly (46) .

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Illustration 31	g00325246

41. Install two 1P-7409 Eyebolts , chains, and a suitable lifting device in order to lift the rear aftercooler cover assembly (47). The weight of the rear cover assembly is approximately 77 kg (170 lb).

42. Remove the bolts and washers. Remove the rear aftercooler cover assembly.

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Illustration 32	g00325247

43. Install two 1P-7409 Eyebolts , chains, and a suitable lifting device in order to lift the front aftercooler core assembly (49). The weight of the front core assembly is approximately 242 kg (534 lb).

44. Remove the front aftercooler core assembly (49) .

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Illustration 33	g00325248

45. Remove the seal (50), and the seal (51) from the front aftercooler core assembly (49) .

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Illustration 34	g00325249

46. Install two 1P-7409 Eyebolts , chains, and a suitable lifting device in order to lift the rear aftercooler core assembly (52). The weight of the rear core assembly is approximately 135 kg (298 lb).

47. Remove the rear aftercooler core assembly (52) .

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Illustration 35	g00325365

48. Remove the seal (53) and the seal (54) from the rear aftercooler core assembly (52) .

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Illustration 36	g00325250

49. Remove bolts (55), washers, and spacers from the front aftercooler housing (56) .

50. Remove the elbow and the tube from the front end of the front aftercooler housing (56) .

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Illustration 37	g00325251

51. Install two 1P-7407 Eyebolts , chains, and a suitable lifting device in order to lift the front aftercooler housing (56). The weight of the front housing is approximately 194 kg (428 lb).

52. Remove the front aftercooler housing (56) .

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Illustration 38	g00325252

53. Install two 1P-7407 Eyebolts , chains, and a suitable lifting device in order to lift the rear aftercooler housing (57). The weight of the front housing is approximately 88 kg (194 lb).

54. Remove the bolts, washers and spacers (58). Remove the rear aftercooler housing (57) .

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Illustration 39	g00325253

55. Remove the four gaskets (59) .

Installation Of The High Performance Aftercooler

Note: The sealing surface must be clean and free of oil and debris.

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Illustration 40	g00325253

1. Put four gaskets (59) into position on the cylinder block.

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Illustration 41	g00325252

2. Put bolts (58), washers, and spacers into position on the rear aftercooler housing (57) .

3. Install two 1P-7407 Eyebolts , chains, and a suitable lifting device in order to lift the rear aftercooler housing (57). The weight of the front housing is approximately 88 kg (194 lb).

4. Put the rear aftercooler housing (57) into position. See Illustration 41.

5. Remove the two 1P-7407 Eyebolts , chains, and the lifting device.

6. Tighten the bolts (58) to a torque of 50 ± 10 N·m (40 ± 7 lb ft).

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Illustration 42	g00325254

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Illustration 43	g00325251

7. Put the bolts (55), washers, and spacers into position on the front of the aftercooler housing (56) .

8. Install two 1P-7407 Eyebolts , chains, and a suitable lifting device in order to lift the front aftercooler housing (56). The weight of the front housing is approximately 194 kg (428 lb).

9. Put the front aftercooler housing (56) into position on the cylinder block.

10. Remove the two 1P-7407 Eyebolts , chains, and the lifting device.

11. Tighten the bolts (55) to a torque of 50 ± 10 N·m (40 ± 7 lb ft).

12. Install the elbow and the tube onto the front end of the front aftercooler housing.

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Illustration 44	g00325365

13. Install the seal (53) and the seal (54) onto the rear aftercooler core assembly (52) .

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Illustration 45	g00325249

14. Install two 1P-7409 Eyebolts , chains, and a suitable lifting device in order to lift the rear aftercooler core assembly (52). The weight of the rear core assembly is approximately 135 kg (298 lb).

15. Put the rear aftercooler core assembly (52) into position.

16. Remove the two 1P-7409 Eyebolts , chains, and the lifting device.

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Illustration 46	g00325248

17. Install two 1P-7409 Eyebolts , chains, and a suitable lifting device in order to lift the front aftercooler core assembly (49). The weight of the front core assembly is approximately 242 kg (534 lb).

18. Install the seal (50) and the seal (51) onto the front aftercooler core assembly (49) .

19. Put the front aftercooler core assembly (49) into position.

20. Remove the two 1P-7409 Eyebolts , chains, and the lifting device.

    Note: Ensure that both the front aftercooler core assembly and the rear aftercooler core assembly are centered on the aftercooler housings.

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Illustration 47	g00325246

21. Install two 1P-7409 Eyebolts , chains, and a suitable lifting device in order to lift the rear aftercooler cover assembly (47). The weight of the rear cover assembly is approximately 77 kg (170 lb).

22. Put the rear aftercooler cover assembly (47) into position. Install the bolts (48) and washers.

23. Remove the two 1P-7409 Eyebolts , chains, and the lifting device.

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Illustration 48	g00325245

24. Install two 1P-7409 Eyebolts , chains, and a suitable lifting device in order to lift the front aftercooler cover assembly (45). The weight of the front cover assembly is approximately 121 kg (267 lb).

25. Put the front aftercooler cover assembly (45) into position on the front aftercooler core assembly (46) .

26. Remove the two 1P-7409 Eyebolts , chains, and the lifting device.

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Illustration 49	g00325244

27. Install the shims (44) between the aftercooler core assembly and the aftercooler housing.

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Illustration 50	g00325242

28. Install the shims (43) between the aftercooler cover assembly and the aftercooler core assembly.

29. Install the bolts (42) and washers that hold the aftercooler cover assembly to the aftercooler core assembly.

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Illustration 51	g00325240

Note: Lubricate all O-ring seals moderately with glycerin before installation.

30. Put new O-ring seals into position on the elbow (41) .

31. Put the elbow (41) into position. Install the four bolts (40) .

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Illustration 52	g00325239

32. Put the tee adapter (39) into position with the flanges (37). Install the bolts (38) and washers.

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Illustration 53	g00325238

33. Put new gaskets (36) into position on the ends of the bellows assembly (35) .

34. Put the bellows assembly (35) into position on the aftercooler cover assemblies. Install the bracket (34), bolts (33), and washers.

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Illustration 54	g00325237

35. Install the seals and the orifice onto the end of the tee connection (30) .

36. Put the two flanges (32) and the tee connection (30) into position between the two aftercooler cores.

37. Install the bolts (31) and washers.

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Illustration 55	g00325236

38. Install the two bolts (29) and the tee connection (30) .

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Illustration 56	g00325235

39. If the two brackets (28) were removed, install the two brackets (28) in the original location.

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Illustration 57	g00325234

40. Put the ring and the O-ring seal into position on the end of the tube (27) .

41. Put the tube into position. See Illustration 57.

42. Install the two clamp assemblies (26) .

43. Install the four bolts (25), washers, and spacers.

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Illustration 58	g00325232

44. Install the two bolts (24) and washers.

45. Put the clamp (22) into position. Install the bolts (23), nuts, and washers.

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Illustration 59	g00325231

46. Put the flange (20), orifice (18), and plate (21) into the correct position.

47. Put the two retainers (19) into position. Install the four bolts (17) and washers.

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Illustration 60	g00325230

48. Put a new gasket (16) into position between the adapter (13) and the aftercooler cover assembly (15) .

49. Put the adapter (13) into position on the end of the aftercooler cover assembly (15). Install the eight bolts (14) and washers.

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Illustration 61	g00325229

50. Put a new gasket (12) into position between the aftercooler housing (10) and the adapter (13) .

51. Put the aftercooler housing (10) into position. Install the eight bolts (11) and washers.

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Illustration 62	g00325228

52. Put the air pipes (9) with the energized seals into position in the aftercooler housing (10) .

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Illustration 63	g00325227

53. Put the tubes into position. See Illustration 63.

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Illustration 64	g00325226

54. Install the bolts (7), nuts, and washers that connect the tubes (8) to the turbochargers.

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Illustration 65	g00325225

55. Put the bracket (6) into position. Install the two bolts (5) and washers.

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Illustration 66	g00325224

56. Install the four bolts (4) and washers.

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Illustration 67	g00325223

57. Put new gaskets into position on the ends of the tube assembly (1) .

58. Put the tube assembly (1) into position. Install the four retainers (3), bolts (2) and washers.

59. Fill the system with coolant to the normal operating level.