G3508B, G3512B, G3512B, G3516B and G3520B Petroleum Engines Caterpillar

Removal Procedure

Start By:

1. Remove the fuel control valve. Refer to Disassembly and Assembly, "Fuel Control Valve - Remove and Install".

2. Remove the throttle control valve. Refer to Disassembly and Assembly, "Throttle Control Valve - Remove".

1. Drain the coolant from the two-stage cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".
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   Illustration 1	g01684299

2. Attach Tooling (A) and a suitable lifting device to aftercooler (1). The weight of aftercooler (1) is approximately 323 kg (711 lb).

3. Support the air cleaner lines and remove U-bolts (5) from both sides. Remove bolts (3) and remove bracket (2).

4. Remove bolts (8), the retainers, the O-ring seals, and tube assembly (9).

5. Remove bolts (10), the retainers, the O-ring seals, and tube assembly (11).

6. Remove bolts (6), the washers, and tubes (7) from both sides of aftercooler (1).

7. Disconnect tube assembly (13). Remove bolts (4).

8. Remove bolts (12 ) from aftercooler (1) to the support assembly.
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   Illustration 2	g01684302

9. Remove bolts (17), the retainers, the O-ring seals, and tube assembly (18).

10. Remove bolts (19), the retainers, the O-ring seals, and tube assembly (20).

11. Disconnect tube assembly (14).

12. Remove bolts (16) and remove actuator assembly (15).

13. Remove aftercooler (1) from the engine.

Removal Procedure for TPC00140, ; TPC01002-01004, ; TPC01100-up, and ; GLF001100-up

Start By:

1. Remove the gas pressure regulator solenoid. Refer to Disassembly and Assembly, "Gas Pressure Regulator Solenoid - Remove".

2. Remove the fuel control valve. Refer to Disassembly and Assembly, "Fuel Control Valve - Remove and Install".

3. Remove the fuel control actuator. Refer to Disassembly and Assembly, "Fuel Control Actuator - Remove and Install".

1. Drain the coolant from the cooling system into a suitable container for storage or disposal.
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   Illustration 3	g01354966

2. Remove tube assembly (1).

3. Remove clamp (2) that fastens the harness assembly to the aftercooler.

4. Remove tube assembly (3).

5. Remove tube assembly (4).

6. Remove tube assembly (5).

7. Remove bolts (6), the washers, and the nuts to elbows (7).

8. Remove elbows (7) and the O-ring seals.
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   Illustration 4	g01354989

9. Remove clip assemblies (8) and (10) on each end of tube assembly (11).

10. Remove bolts (9) and reposition tube assembly (13).

11. Remove bolts (12) and reposition tube assembly (14).

12. Remove bolts (15), the washers, and the nuts on each side of the aftercooler.
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    Illustration 5	g01354990

13. Remove clip assembly (16) and remove tube assembly (18).

14. Remove bolts (22) and the gasket. Remove nuts (17) and the clamp assembly. Remove adapter (20).

15. Remove bolts (19) and (21) from the clip assemblies.

16. Remove bolts (23) and the gasket. Remove nuts (25) and the clamp assembly. Remove adapter (24).
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    Illustration 6	g01354991

17. Remove four nuts (28), the washers, and the bolts. Remove flange (29) and tube assembly (27).

18. Disconnect elbow (30).

19. Remove six bolts (31), the washers, and the nuts and remove bracket (32). Remove four bolts (34), the washers, and the nuts. Remove elbow (33).
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    Illustration 7	g01354992

20. Attach a suitable lifting device to aftercooler (35). The weight of aftercooler (35) is approximately 664 kg (1464 lb).

21. Remove bolts (36) and the washers on front side of the mounting plate and on the rear side mounting plate.

22. Remove aftercooler (35) from the engine.

Installation Procedure

1. Inspect the condition of the O-ring seals. Replace the gaskets and the seals, if necessary.
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   Illustration 8	g01684302

2. Attach Tooling (A) and a suitable lifting device to aftercooler (1). The weight of aftercooler (1) is approximately 323 kg (711 lb). Position aftercooler (1) on the engine.

3. Position actuator assembly (15) and install bolts (16).

4. Connect tube assembly (14).

5. Install the O-ring seals and the retainers on tube assembly (20) and install bolts (19).

6. Install the O-ring seals and the retainers on tube assembly (18) and install bolts (17).
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   Illustration 9	g01684299

7. Install bolts (12) in aftercooler (1) to the support assembly.

8. Install bolt (4). Connect tube assembly (13).

9. Position tubes (7) and install the washers and bolts (6) on both sides.

10. Install the O-ring seals and the retainers on tube assembly (11) and install bolts (10).

11. Install the O-ring seals and the retainers on tube assembly (9) and install bolts (8).

12. Position bracket (2) and install bolts (3). Install U-bolts (5).

13. Fill the two-stage cooling system to the correct level with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".

End By:

1. Install the throttle control valve. Refer to Disassembly and Assembly, "Throttle Control Valve - Remove".

2. Install the fuel control valve. Refer to Disassembly and Assembly, "Fuel Control Valve - Remove and Install".

Installation Procedure for TPC00140, ; TPC01002-01004, ; TPC01100-up, and ; GLF001100-up

1. Inspect the condition of the gaskets and O-ring seals. Replace the gaskets and the O-ring seals, if necessary.
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   Illustration 10	g01354992

2. Attach a suitable lifting device to aftercooler (35). The weight of aftercooler (35) is approximately 664 kg (1464 lb).

3. Position aftercooler (35) on the engine.

4. Install bolts (36) and the washers on front side of the mounting plate and on the rear side mounting plate.
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   Illustration 11	g01354991

5. Position elbow (33).

6. Install four bolts (34), the washers, and the nuts. Position bracket (32) and install six bolts (31), the washers, and the nuts.

7. Connect elbow (30).

8. Position tube assembly (27) and flange (29). Install the four bolts, the washers, and nuts (28).
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   Illustration 12	g01354990

9. Position adapter (24). Install the clamp assembly and install nuts (25). Install the gasket and bolts (23).

10. Position the clip assemblies and install bolts (21) and (19).

11. Position adapter (20). Install the clamp assembly and install nuts (17). Install the gasket and bolts (22).

12. Position tube assembly (18) and install clip assembly (16).
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    Illustration 13	g01354989

13. Install bolts (15), the washers, and the nuts on each side of the aftercooler.

14. Reposition tube assembly (14) and install bolts (12).

15. Reposition tube assembly (13) and install bolts (9).

16. Install clip assemblies (8) and (10) on each end of tube assembly (11).
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    Illustration 14	g01354966

17. Put the O-ring seals in position and install elbows (7).

18. Install bolts (6), the washers, and the nuts to elbows (7).

19. Install tube assembly (5).

20. Install tube assembly (4).

21. Install tube assembly (3).

22. Install clamp (2) that fastens the harness assembly to the aftercooler.

23. Install tube assembly (1).

24. Fill the coolant system to the correct level with coolant. Refer to Operation and Maintenance Manual for the correct procedure.

End By:

1. Install the fuel control actuator. Refer to Disassembly and Assembly, "Fuel Control Actuator - Remove and Install".

2. Install the fuel control valve. Refer to Disassembly and Assembly, "Fuel Control Valve - Remove and Install".

3. Install the gas pressure regulator solenoid. Refer to Disassembly and Assembly, "Gas Pressure Regulator Solenoid - Install".