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G3408C and G3412C Engines Caterpillar


Aftercooler - Remove

Usage:

G3408C 3WR

Removal Procedure

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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, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

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NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

  1. Drain the coolant from the aftercooler core and elbows into a suitable container for storage or disposal.
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    Illustration 1g00785310

  1. Remove four bolts (3), nuts (4), and the washers from air tube assembly (1) .

  1. Remove two bolts (5) and two plates (6) at turbocharger housing (7) .

  1. Disconnect tube assembly (2). Plug and cap all openings immediately.

  1. Remove air tube assembly (1) and the gasket.
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    Illustration 2g00785318

  1. Check the condition of two O-ring seals (8) on air tube assembly (1). If the O-ring seals are worn or damaged, use new parts for replacement.
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    Illustration 3g00785323

  1. Remove bolt (12), spacer (10), and the washers.

  1. Disconnect rod assembly (13) from throttle assembly (11) .

  1. Remove four bolts (9) and washers.

  1. Remove throttle assembly (11). Check the condition of the gasket under the throttle assembly. If the gasket is worn or damaged, use a new part for replacement.
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    Illustration 4g00785442

  1. Loosen wire harness (14) .

  1. Remove two bolts (16) and two spacers (17) from clips (15) .

  1. Remove twenty six bolts (20) and washers.

  1. Move two clips (19) out of the way.

  1. Remove aftercooler cover (18) and the gasket.
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    Illustration 5g00785343

  1. Loosen fitting (21) .

  1. Loosen two clamps (22). Remove tube adapter (23) and the two seals.
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    Illustration 6g00785352

  1. Disconnect tube assembly (25). Plug and cap all openings immediately.

  1. Remove two bolts (24) and washers.

  1. Remove elbow (26) with tube assembly (27), one plate and one adapter (28). Check the condition of the O-ring seal at the aftercooler housing. If the O-ring seal is worn or damaged, use a new part for replacement.
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    Illustration 7g00785362

  1. Disconnect tube assembly (29). Plug and cap all openings immediately.

  1. Remove two bolts (30) and washers.

  1. Remove elbow (31), one plate, one adapter, and one O-ring seal (32). Check the condition of the O-ring seal at the aftercooler housing. If the O-ring seal is worn or damaged, use a new part for replacement.
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    Illustration 8g00785367

  1. Remove ten bolts (33) and washers.
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    Illustration 9g00785369

  1. Attach chains and a suitable lifting device as shown and remove aftercooler core (34). The weight of the aftercooler core is approximately 59 kg (130 lb).

  1. If necessary, remove aftercooler housing (35) .
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    Illustration 10g00785410

  1. Remove four O-ring seals (36) on the extensions of aftercooler core (34). Check the condition of the O-ring seals. If the O-ring seals are worn or damaged, use new parts for replacement.

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