3512B Marine Auxiliary Engines Caterpillar

Removal Procedure

Start By:

1. Remove the air shutoff.

1. Drain the coolant from the cooling system into a suitable container for storage or for disposal.
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   Illustration 1	g00624685

2. Disconnect hose (1) from the aftercooler. Unless the hose will be replaced, leave the hose connected to the water temperature regulator housing.
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   Illustration 2	g00616450

3. Disconnect two water tubes (3) from the ends of the aftercooler. One tube is at the front of the aftercooler and one tube is as the rear of the aftercooler.
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   Illustration 3	g00601409

4. Install Tool (A) in the top of aftercooler cover (4).

5. Attach suitable chains and a lifting device to Tool (A). The weight of the aftercooler cover is approximately 11 kg (24 lb).

6. Remove bolts and washers (5). Remove the aftercooler cover.

7. Remove the seal from the joint that is between the cover and the aftercooler core. Discard the seal.
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   Illustration 4	g00601411

8. Use two people to remove aftercooler core (6) from the air inlet manifold. The weight of the aftercooler core is approximately 37 kg (82 lb). Be careful not to damage the fins of the aftercooler core.

9. Remove the seal from the joint that is between the air inlet manifold and the aftercooler core. Discard the seal.

Installation Procedure

1. Place new seals on the top and bottom of the aftercooler core. Temporarily secure the bottom seal with tape. Do not use an adhesive, a silicone lubricant, or any other lubricant for retention of the seal.
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   Illustration 5	g00601411

2. The weight of the aftercooler core is approximately 37 kg (82 lb). Use two people to lift aftercooler core (6) onto the air inlet manifold. Be careful not to damage the fins of the aftercooler core.

   Ensure that the bottom seal is properly seated.

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   Illustration 6	g00601409

3. Install Tool (A) in the top of aftercooler cover (4).

4. Attach suitable chains and a lifting device to Tool (A). The weight of the aftercooler cover is approximately 11 kg (24 lb).

5. Lift the aftercooler cover into position over the aftercooler core.

   Ensure that the seal is seated between the cover and the aftercooler core.

6. Install bolts (5). Hand tighten the bolts.
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   Illustration 7	g00280590
   Bolt tightening sequence

7. Tighten the bolts in the numerical sequence to a torque of 24 N·m (18 lb ft).

8. Tighten the bolts in the numerical sequence to a torque of 47 N·m (35 lb ft).

9. Remove the tape from the bottom seal.
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   Illustration 8	g00616450

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   Illustration 9	g00624633

10. Install new O-ring seals (B) and (C) for two water tubes (3) at the ends of the aftercooler. Lubricate the bore of seal (B) with glycerin.
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    Illustration 10	g00624685

11. Install a new O-ring seal for the elbow on hose (1) that is between the water temperature regulator housing and the aftercooler. Lubricate the bore of the seal with glycerin. Attach the hose to the aftercooler.

12. Fill the cooling system. For the proper coolant to use, see the Operation and Maintenance Manual.

End By:

1. Install the air shutoff.