3512B Generator Set Engine Caterpillar

Removal Procedure

1. Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Disassembly and Assembly, "Cooling System Coolant - Change".
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   Illustration 1	g01353326

2. Loosen clamp assemblies (5). Remove the bellows assembly and clamp assemblies (5). Discard the bellows assembly and clamp assemblies (5).

3. Remove bolts (1) and bolts (4). Remove air inlet elbow (2) and air pipe (3). Remove the O-ring seals from air inlet elbow (2) and air pipe (3).
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   Illustration 2	g01353355

4. Remove tube assembly (8).

5. Remove bolts (9) and bolts (12). Remove adapter (10) and adapter (11) from the air inlet covers. Remove the O-ring seals from the adapters.

6. Install Tooling (A) into the top of air inlet cover (7).

7. Attach a suitable lifting device onto Tooling (A). The weight of air inlet cover (7) is approximately 28 kg (62 lb). Remove bolts (6). Remove air inlet cover (7).

   Note: Be careful not to damage the fins of the aftercooler core.

   Note: The weight of the 3508C air inlet cover is approximately 28 kg (62 lb). The weight of the 3512C air inlet cover is approximately 35 kg (77 lb).

8. Install Tooling (A) into the top of air inlet cover (13).

9. Attach a suitable lifting device onto Tooling (A). The weight of air inlet cover (13) is approximately 28 kg (62 lb). Remove bolts (14). Remove air inlet cover (13).

   Note: Be careful not to damage the fins of the aftercooler core.

   Note: Some clamp assemblies must be loosened to remove the connectors.

10. Remove connector (16) and connector (17) from the aftercooler cores. Remove the O-ring seals from the connectors.

11. Attach a suitable lifting device onto aftercooler core (15). The weight of aftercooler core (15) is approximately 58 kg (130 lb). Remove aftercooler core (15) from the air inlet manifold. Remove the seals from aftercooler core (15).

    Note: Be careful not to damage the fins of the aftercooler core.

    Note: The weight of the 3508C aftercooler core is approximately 58 kg (130 lb). The weight of the 3512C aftercooler core is approximately 84 kg (185 lb).

12. Attach a suitable lifting device onto aftercooler core (18). The weight of aftercooler core (18) is approximately 58 kg (130 lb). Remove aftercooler core (18) from the air inlet manifold. Remove the seals from aftercooler core (18).

    Note: Be careful not to damage the fins of the aftercooler core.

Installation Procedure

Note: Be careful not to damage the fins of the aftercooler cores.

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Illustration 3	g01353355

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Illustration 4	g01353596

1. Install the seal on the bottom of aftercooler core (18). Apply a light amount of glycerin to the bore for the seal.

2. Attach a suitable lifting device onto aftercooler core (18). The weight of aftercooler core (18) is approximately 58 kg (130 lb). Position aftercooler core (18) onto the air inlet manifold. Ensure that the bottom seal is properly seated.

3. Install the seal on the bottom of aftercooler core (15). Apply a light amount of glycerin to the bore for the seal.

4. Attach a suitable lifting device onto aftercooler core (15). The weight of aftercooler core (15) is approximately 58 kg (130 lb). Position aftercooler core (15) onto the air inlet manifold. Ensure that the bottom seal is properly seated.

5. Install the O-ring seals on connector (17) and connector (16). Apply Tooling (B) to the O-ring seals. Install connector (17) and connector (16).

6. Install the seal on top of aftercooler core (18).

7. Install Tooling (A) into the top of air inlet cover (13).

8. Attach a suitable lifting device onto Tooling (A). The weight of air inlet cover (13) is approximately 28 kg (62 lb). Position air inlet cover (13) onto the aftercooler core. Ensure that the seal is seated between air inlet cover (13) and the aftercooler core.

   Note: The weight of the 3508C air inlet cover is approximately 28 kg (62 lb). The weight of the 3512C air inlet cover is approximately 35 kg (77 lb).

9. Install the seal on top of aftercooler core (15).

10. Install Tooling (A) into the top of air inlet cover (7).

11. Attach a suitable lifting device onto Tooling (A). The weight of air inlet cover (7) is approximately 28 kg (62 lb). Position air inlet cover (7) onto the aftercooler core. Ensure that the seal is seated between air inlet cover (7) and the aftercooler core.

12. Install bolts (14) and bolts (6). Hand tighten bolts (14) and bolts (6) according to the following procedure:

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

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

13. Install the O-ring seals on adapter (11) and adapter (10). Apply Tooling (B) to the O-ring seals. Install adapter (11), adapter (10), bolts (12), and bolts (9).

14. Install tube assembly (8).
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    Illustration 5	g01353326

15. Install the O-ring seals on air pipe (3) and air inlet elbow (2). Apply Tooling (B) to the O-ring seals. Install air pipe (3) and air inlet elbow (2). Install bolts (4) and bolts (1).

    Note: Ensure that the bellows assembly is in the proper orientation during installation. The direction of flow arrow must point in the correct direction. The spacing between the ridges of the bellows assembly should be equal.

16. Apply Tooling (C) to the threads, the bearing surfaces, and the inner surface of clamp assemblies (5). Install a new bellows assembly and new clamp assemblies (5). Tighten clamp assemblies (5) to a torque of 7.5 ± 1.0 N·m (65 ± 9 lb in). Lightly tap around the diameter of the clamp assemblies with a soft hammer. Tighten clamp assemblies (5) to a torque of 7.5 ± 1.0 N·m (65 ± 9 lb in).

17. Fill the cooling system with coolant. Refer to the Operation and Maintenance Manual, "Cooling System Coolant - Change".