3516C Locomotive Engines Caterpillar

Removal Procedure

1. Drain the coolant from the auxiliary water system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change".
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   Illustration 1	g02398258

2. Remove tube assemblies (1) and tube assemblies (2).
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   Illustration 2	g02398259

3. Remove hose clamps (4) and hose (5). Remove bolts (7), elbow (3), and the O-ring seals. Remove bolts (8), elbow (6), and the O-ring seal. Repeat for the remaining turbochargers.
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   Illustration 3	g02398260

4. Remove bolts (12). Use two technicians to remove cover (11). The weight of cover (11) is approximately 22 kg (49 lb). Slide cover (11) from pipe (10). Remove the seal from the aftercooler core. Remove bolts (9), pipe (10), and the O-ring seals. Repeat for the other cover.
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   Illustration 4	g02398261

5. Disconnect the tube assembly from elbow (14). Remove bolts (15) and disconnect the tube assembly and the flange from elbow (14). Remove the O-ring seals. Remove bolts (13), elbow (14), the adapter, and the O-ring seals. Repeat for the other side.
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   Illustration 5	g02398264

6. Remove bolts (19) from connector (18). Remove bolts (17), flange (16), and connector (18). Remove the O-ring seals.
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   Illustration 6	g02398266

7. Use two technicians to remove aftercooler core (20). The weight of aftercooler core (20) is approximately 23 kg (51 lb). Remove the seal from adapter (23). Remove bolts (21), bolts (22), adapter (23), and the seal from the aftercooler core. Repeat for the other side.
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   Illustration 7	g02398267

8. Remove bolts (27) from connector (26). Remove bolts (24), flange (25), and connector (26). Remove the O-ring seals. Repeat for connector (28).
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   Illustration 8	g02398782

9. Use two technicians to remove aftercooler core (29). The weight of aftercooler core (29) is approximately 60 kg (130 lb). Remove the seal from the air inlet manifold. Repeat for the other aftercooler core.

Installation Procedure

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Illustration 9	g02398782

Note: Temporarily secure the seals to the aftercooler core with tape. The tape will be removed after the bolts are tightened.

1. Install the seals on aftercooler core (29). Use two technicians to install aftercooler core (29). The weight of aftercooler core (29) is approximately 60 kg (130 lb). Repeat for the other aftercooler core.
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   Illustration 10	g02398267

2. Install the O-ring seals on connector (26). Apply a light coat of glycerin to the bore of the O-ring seals. Install connector (26), flange (25), and bolts (24). Install bolts (27) in connector (26). Repeat for connector (28).
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   Illustration 11	g02398266

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   Illustration 12	g02399820

   Note: Inspect the seals on the aftercooler core to ensure proper position.

3. Install adapter (23), bolts (22), and bolts (21). Use the following procedure to tighten bolts (22). Remove the tape from the seals on the aftercooler core after tightening bolts (22).

   1. Hand tighten the bolts.

   2. Tighten the bolts in a numerical sequence to a torque of 24 N·m (210 lb in).

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

   Note: Temporarily secure the seals to the aftercooler core with tape. The tape will be removed after the bolts are tightened.

4. Install the seals on aftercooler core (20). Use two technicians to install aftercooler core (20). The weight of aftercooler core (20) is approximately 23 kg (51 lb). Repeat for the other aftercooler core.
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   Illustration 13	g02398264

5. Install the O-ring seals on connector (18). Apply a light coat of glycerin to the bore of the O-ring seals. Install connector (18), flange (16), and bolts (17). Install bolts (19) in connector (18).
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   Illustration 14	g02398261

6. Install the O-ring seals on the adapter and elbow (14). Apply a light coat of glycerin to the bore of the O-ring seals. Install the adapter, elbow (14), and bolts (13). Connect the tube assembly and the flange to elbow (14) and install bolts (15). Connect the tube assembly to elbow (14). Repeat for the other side.
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   Illustration 15	g02398260

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   Illustration 16	g02399996

   Note: Inspect the seals on the aftercooler core to ensure proper position.

7. Use two technicians to install cover (11). The weight of cover (11) is approximately 22 kg (49 lb). Repeat for the other cover.

8. Install the O-ring seals on pipe (10). Apply a light coat of glycerin to the bore of the O-ring seals. Install pipe (10) and bolts (9).

9. Install bolts (12). Use the following procedure to tighten bolts (12). Remove the tape from the seals on the aftercooler core after tightening bolts (12).

   1. Hand tighten the bolts.

   2. Tighten the bolts in a numerical sequence to a torque of 24 N·m (210 lb in).

   3. Tighten the bolts again in a numerical sequence to a torque of 47 N·m (35 lb ft).
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   Illustration 17	g02398259

10. Apply Tooling (A) to the O-ring seals. Install the O-ring seal, elbow (6), and bolts (8). Install the O-ring seals, elbow (3), and bolts (7). Connect hose (5) and install hose clamps (4). Center hose clamps (4) within the markings on hose (5). Orient hose clamps (4) a minimum of 90 degrees apart from each other. Tighten hose clamps (4) to a torque of 10 ± 2 N·m (90 ± 18 lb in). Repeat for the remaining turbochargers.
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    Illustration 18	g02398258

11. Install tube assemblies (2) and tube assemblies (1).

12. Refill the auxiliary water system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change".