Installation Procedure for the Aftercooler on Certain 3512C Locomotive Engines {1059, 1063, 1064} Caterpillar

Engine

3512C (S/N: F2X1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

Required Parts

Installation Procedure

1. Drain the coolant from the 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	g06043468

2. Remove the following components:

   • Air support brackets

   • Compressor outlet tubes

   • Bellows

   • V-band clamps

3. Remove the O-rings from the compressor outlet tubes and store for reuse.

4. Discard the remaining components and associated hardware.

   Note: Do not discard the hardware used to attach the compressor outlet tubes to the inlet elbows.

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   Illustration 2	g06044262

5. Remove and discard the following components:

   • Inlet elbows

   • Straps

   • O-rings

   Keep the associated hardware for reuse.

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   Illustration 3	g06044270

6. Remove the turbocharger lines.

7. Set aside the 321-1289 Tube As, clamps, and associated hardware for reuse.

8. Discard the remaining turbocharger coolant lines and union cross.
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   Illustration 4	g06044284

9. Using a suitable lifting device, remove and discard the top air inlet cover. The cover weighs approximately 35 kg (77 lb).
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   Illustration 5	g06044293

10. Remove the elbow and clamps from the separate circuit aftercooler (SCAC) lines.
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    Illustration 6	g06044301

11. Remove and discard the tube assembly and the 261-7296 Bracket As.

12. Set aside all other brackets, clamps, and associated hardware for reuse.
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    Illustration 7	g06044326

13. Remove and discard the bolts and clamps.

    Note: Keep the washers for reuse.

14. Install the 388-3917 Flange onto the tube assembly.

15. Install the 388-6443 Ring onto the tube assembly.

16. Secure the 388-3917 Flange with two 165-3931 Bolts and the original washers.
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    Illustration 8	g06044368

17. Remove the jacket water line and bracket.
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    Illustration 9	g06044375

18. Using a suitable lifting device, remove and set aside the top aftercooler for reuse. The aftercooler weighs approximately 32 kg (71 lb).

19. Remove the seal from the adapter.

20. Discard the bolts.

    Note: Keep the washers for reuse.

21. Using a suitable lifting device, remove and set aside the bottom aftercooler for reuse. The aftercooler weighs approximately 85 kg (187 lb).

22. Remove the seal from the adapter.

23. Remove and set aside the O-ring plugs for reuse.
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    Illustration 10	g06044411

24. Remove the bolts from the inlet elbows.

25. Using a suitable lifting device, remove the air inlet manifold. The air inlet manifold weighs approximately 65 kg (143 lb).

Rework Procedure

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Illustration 11	g06044440
(1) 343-4579 Manifold (2) 348-7062 Seal

1. Prior to installing the seals on the air inlet manifold, temporarily install air inlet manifold (1). The intake manifold weighs approximately 77 kg (170 lb).

   The following locations on the plate will need to be marked.

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   Illustration 12	g06044446

2. The best way to mark the locations is with a center punch that fits inside the flanges of the air inlet manifold. When the locations have been marked, remove the air inlet manifold.

3. Drill the marked locations with an 11 mm drill bit.

   The plate is 3.05 mm (0.120 inch) thick. Ensure that the drill bit does not penetrate past the plate and damage the threads of the hole below it.

   If the drill does damage the threads use a thread chaser to clean up the threads.

4. Remove the shavings from the holes.

5. Using a suitable lifting device, install air intake manifold (1). The air intake manifold weighs approximately 77 kg (170 lb).

6. Secure air inlet manifold (1) to the plate with 1U-2812 Spacers and 10 261-5615 Bolts.

7. Install seal (2) into air inlet manifold (1).

Installation Procedure

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Illustration 13	g06044467
(1) 343-4579 Manifold (3) 483-2090 Aftercooler Core As (4) 6W-6672 Spacer (5) 0T-0065 Bolt

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Illustration 14	g06054144
Torque sequence

1. Using a suitable lifting device, install aftercooler core (3) onto air intake manifold (1). The intake manifold weighs approximately 188 kg (414 lb).

2. Secure aftercooler core (3) to air intake manifold (1) with 16 spacers (4) and 16 bolts (5).

   Torque bolts ... 24 N·m (18 lb ft)

   Torque bolts ... 47 N·m (35 lb ft)

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   Illustration 15	g06044512
   (3) 483-2090 Aftercooler Core As (5) 0T-0065 Bolt (6) 373-5443 Elbow (7) 167-4407 O-Ring Seal (8) 360-3680 Plug (9) 6V-6609 O-Ring Seal (10) 4P-5085 Cover (11) 5M-2894 Hard Washer (12) 153-9963 Ring (13) 245-6848 Clamp As (14) 1A-2029 Bolt (15) 9X-6458 Hard Washer (16) 9S-8752 Full Nut (17) 165-3931 Bolt (18) 447-4870 Tube (19) 8T-1919 O-Ring Seal (20) 388-6443 Ring (21) 388-3917 Flange (22) 446-0380 Elbow (23) 6V-5066 O-Ring Seal (24) 264-8272 Clamp As (25) 8N-0386 Flange (26) 4N-1320 Gasket (27) 091-0081 Spacer (28) 0S-1619 Bolt

3. Install plug (8) and one O-ring (9) into elbow (6).

4. Install two O-rings (7) into elbow (6).

   Note: Use O-ring retention compound on the O-rings.

5. Attach elbow (6) and cover (10) to aftercooler core (3) with two bolts (5) and two washers (11).

6. Install two O-rings (19) onto tube assembly (18).

7. Install tube assembly (18) into elbow (6).

   Note: Lubricate the O-rings and the bore of the elbow with glycerin.

8. Install ring (12) around tube assembly (16).

9. Install two clamp assemblies (13) loosely onto tube assembly (18). Use two bolts (14). four washers (15), and two nuts (16).

10. Attach clamp assemblies (13) to elbow (6) with two bolts (17) and two washers (15).

11. Install flange (21) onto tube assembly (18).

12. Install ring (20) onto tube assembly (18).

13. Install one O-ring (23) onto elbow (22).

14. Install flange (25) onto elbow (22).

    Note: Lubricate the O-ring and the bore of the elbow with.

15. Install two clamp assemblies (24) loosely onto elbow (22). Use two bolts (14). four washers (15), and two nuts (16).

16. Install elbow (22) onto tube assembly (18).

    Note: Lubricate the O-ring and the bore of the elbow with glycerin.

17. Secure flange (21) to elbow (22) with two bolts (17) and two washers (15).

18. Attach clamp assemblies (24) and flange (25) to the water pump with one gasket (26), two spacers (27), two bolts (17), two bolts (28), and two washers (11).
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    Illustration 16	g06044892
    (3) 483-2090 Aftercooler Core As (5) 0T-0065 Bolt (6) 373-5443 Elbow (7) 167-4407 O-Ring Seal (8) 360-3680 Plug (9) 6V-6609 O-Ring Seal (10) 4P-5085 Cover (11) 5M-2894 Hard Washer (12) 153-9963 Ring (13) 245-6848 Clamp As (14) 1A-2029 Bolt (15) 9X-6458 Hard Washer (16) 9S-8752 Full Nut (17) 165-3931 Bolt (19) 8T-1919 O-Ring Seal (20) 388-6443 Ring (21) 388-3917 Flange (29) 376-4868 Tube

19. Install plug (8) and one O-ring (9) into elbow (6).

20. Install two O-rings (7) into elbow (6).

    Note: Use O-ring retention compound on the O-rings.

21. Install two O-rings (19) onto tube assembly (18).

22. Install flange (21) onto tube assembly (18).

23. Install ring (20) onto tube assembly (29).

24. Install tube assembly (29) to the 298-2378 Adapter.

    Note: Lubricate the O-ring and the bore of the adapter with glycerin.

25. Secure flange (21) to adapter (30) with two bolts (17) and two washers (15).

26. Install elbow (6) onto tube assembly (18).

    Note: Lubricate the O-rings and the bore of the elbow with glycerin.

27. Attach elbow (6) and cover (10) to aftercooler core (3) with two bolts (5) and two washers (11).

28. Install ring (12) around tube assembly (16).

29. Install two clamp assemblies (13) loosely onto tube assembly (18). Use two bolts (14). four washers (15), and two nuts (16).

30. Attach clamp assemblies (13) to elbow (6) with two bolts (17) and two washers (15).
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    Illustration 17	g06044911
    (3) 483-2090 Aftercooler Core As (5) 0T-0065 Bolt (6) 373-5443 Elbow (7) 167-4407 O-Ring Seal (8) 360-3680 Plug (9) 6V-6609 O-Ring Seal (10) 4P-5085 Cover (11) 5M-2894 Hard Washer (12) 153-9963 Ring (19) 8T-1919 O-Ring Seal (30) 372-1625 Tube As

31. Install plug (8) and one O-ring (9) into elbow (6).

32. Install two O-rings (7) into elbow (6).

    Note: Use O-ring retention compound on the O-rings.

33. Install two O-rings (19) onto tube assembly (33).

34. Install tube assembly (30) into the regulator housing adapter.

    Note: Lubricate the O-rings and the bore of the adapter with glycerin.

35. Install ring (12) around tube assembly (30).

36. Install elbow (3) onto tube assembly (30).

    Note: Lubricate the O-rings and the bore of the elbow with glycerin.

37. Attach elbow (6) and cover (10) to aftercooler core (3) with two bolts (5) and two washers (11).

38. Secure tube assembly (30) to the engine with the original hardware.

39. Install one 8T-6765 Pipe Plug into tube assembly (30).
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    Illustration 18	g06055358
    (31) 490-0654 Bellows As (32) 1W-4658 Clamp

40. Remove the original two wastegate bellows if equipped.

    Note: Do not apply anti-seize on the inner V-band or screw/nut.

41. Install two bellow assemblies (21) with two clamps (32) per bellow assembly. Ensure proper bellow assembly alignment before torquing the locknuts.

    Torque clamps ... 8 ± 1 N·m (70 ± 9 lb in)

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    Illustration 19	g06044916
    (2) 348-7062 Seal (3) 483-2090 Aftercooler Core As (11) 5M-2894 Hard Washer (33) 363-1959 Cover (34) 109-7411 O-Ring Seal (35) 3B-1915 Bolt

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    Illustration 20	g06044488
    Torque sequence

42. Install one seal (2) into cover (33).

43. Install two O-rings (34) into cover (33).

44. Attach cover (33) to aftercooler core (3) with 20 bolts (35) and 20 washers (11).

    Torque bolts ... 47 N·m (35 lb ft)

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    Illustration 21	g06044919
    (11) 5M-2894 Hard Washer (33) 363-1959 Cover (36) 122-3374 Elbow (37) 0S-1588 Bolt

45. Attach two elbows (36) to cover (33) with four bolts (37) and four washers (11) per elbow.

    Torque bolts ... 47 N·m (35 lb ft)

46. Install one 8T-6764 Pipe Plug into each elbow (36).
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    Illustration 22	g06044994
    (37) 0S-1588 Bolt (38) 485-3706 Support (39) 485-3709 Support (40) 8M-9124 Washer

47. Attach support (38) to the 481-6767 Bracket As with four bolts (37) and four washers (40).

48. Attach support (39) to the 481-6767 Bracket As with four bolts (37) and four washers (40).
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    Illustration 23	g06045109
    (41) 344-0079 Bellows As (42) 434-6544 V Band Clamp

49. Apply Loctite® Antiseize to the threads, bearing surface, and inside diameter of v-band clamps (42).

50. Attach one bellow assembly (41) to each turbocharger with one clamp (42).

    Note: Orient the bellow assemblies such that the liner is at the compressor outlet end and the flow arrows point away from the compressor in the direction of flow.

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    Illustration 24	g06045194
    (28) 0S-1619 Bolt (38) 485-3706 Support (39) 485-3709 Support (43) 467-8183 Clamp (44) 9M-4594 Spacer (45) 2K-4973 Locknut

51. Place clamp (43) onto support (38) with the clamp arc downward.

52. Temporarily secure clamp (43) finger tight to support (38) with two bolts (28), four washers (44), and two lock nuts (45).

53. Place clamp (43) onto support (39) with the clamp arc downward.

54. Temporarily secure clamp (43) finger tight to support (39) with two bolts (28), four washers (44), and two lock nuts (45).
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    Illustration 25	g06057062

55. Loosen the bolts on the compressor housing and rotate the housing upward 7 degrees. Leave bolts loose until final assembly.

    Torque bolts after final assembly ... 40 ± 3 N·m (30 ± 2 lb ft)

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    Illustration 26	g06045200
    (46) 485-3708 Tube As (47) 6V-5103 O-Ring Seal

56. Install two O-rings (47) onto tube assembly (46).

57. Lubricate the O-rings and the bore of 122-3374 Elbow with clean engine oil.

58. Insert the O-ring end of tube assembly (46) into the 122-3374 Elbow.

59. Align the v-band flange of tube assembly (46) with the 344-0079 Bellows As.

    Note: The compressor outlet tube should be resting in the 467-8183 Clamp.

60. Remove the bolts, spacers, and lock nuts that held the 467-8183 Clamp temporarily in place.
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    Illustration 27	g06045203
    (28) 0S-1619 Bolt (43) 467-8183 Clamp (44) 9M-4594 Spacer (45) 2K-4973 Locknut (46) 485-3708 Tube As

61. Set clamp (43) on top of tube assembly (46).

62. Secure top clamp (43) to the bottom 467-8183 Clamp with four bolts (28), eight spacers (44), and four nuts (45).
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    Illustration 28	g06045537
    (47) 6V-5103 O-Ring Seal (48) 485-3707 Tube As

63. Install two O-rings (47) onto tube assembly (48).

64. Lubricate the O-rings and the bore of 122-3374 Elbow with clean engine oil.

65. Insert the O-ring end of tube assembly (48) into the 122-3374 Elbow.

66. Align the v-band flange of tube assembly (48) with the 344-0079 Bellows As.

    Note: The compressor outlet tube should be resting in the 467-8183 Clamp.

67. Remove the bolts, spacers, and lock nuts that held the 467-8183 Clamp temporarily in place.
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    Illustration 29	g06045605
    (28) 0S-1619 Bolt (43) 467-8183 Clamp (44) 9M-4594 Spacer (45) 2K-4973 Locknut (48) 485-3707 Tube As

68. Set clamp (43) on top of tube assembly (48).

69. Secure top clamp (43) to the bottom 467-8183 Clamp with four bolts (28), eight spacers (44), and four nuts (45).
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    Illustration 30	g06045610
    (42) 434-6544 V Band Clamp (46) 485-3708 Tube As (48) 485-3707 Tube As

70. Secure the 344-0079 Bellows As to tube assembly (46) with one v band clamp (42).

71. Secure the 344-0079 Bellows As to tube assembly (48) with one v band clamp (42).
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    Illustration 31	g06045632
    (43) 467-8183 Clamp (44) 9M-4594 Spacer (45) 2K-4973 Locknut (49) 491-2868 Bracket (50) 0L-1352 Bolt (51) 491-2870 Bracket

72. Attach two clamps (43), one bracket (49), and one bracket (51) to the 485-3707 Tube As with two bolts (50), four spacers (44), and two nuts (45).
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    Illustration 32	g06045635
    (43) 467-8183 Clamp (44) 9M-4594 Spacer (45) 2K-4973 Locknut (52) 0L-1143 Bolt

73. Attach the top clamp (43) to the bottom clamp (43) with two bolts (52), four spacers (44), and two nuts (45)
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    Illustration 33	g06045640
    ( 37) 0S-1588 Bolt (40) 8M-9124 Washer (49) 491-2868 Bracket (51) 491-2870 Bracket

74. Attach (49) to the 122-3374 Elbow with two bolts (37) and two washers (40).

75. Attach (51) to the 122-3374 Elbow with two bolts (37) and two washers (40).
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    Illustration 34	g06045678
    (43) 467-8183 Clamp (44) 9M-4594 Spacer (45) 2K-4973 Locknut (49) 491-2868 Bracket (50) 0L-1352 Bolt (51) 491-2870 Bracket

76. Attach two clamps (43), one bracket (49), and one bracket (51) to the 485-3708 Tube As with two bolts (50), four spacers (44), and two nuts (45).
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    Illustration 35	g06045681
    (43) 467-8183 Clamp (44) 9M-4594 Spacer (45) 2K-4973 Locknut (52) 0L-1143 Bolt

77. Attach the top clamp (43) to the bottom clamp (43) with two bolts (52), four spacers (44), and two nuts (45)
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    Illustration 36	g06045685
    ( 37) 0S-1588 Bolt (40) 8M-9124 Washer (49) 491-2868 Bracket (51) 491-2870 Bracket

78. Attach (49) to the 122-3374 Elbow with two bolts (37) and two washers (40).

79. Attach (51) to the 122-3374 Elbow with two bolts (37) and two washers (40).
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    Illustration 37	g06045700

80. Make sure that the bellows convolutions are parallel at all locations and that the 485-3708 Tube As is properly aligned with the 122-3374 Elbow.

    If the convolutions are not parallel, adjust the 481-6767 Bracket As and the 481-6768 Support until the bellows convolutions are parallel

81. Ensure the 434-6544 V Band Clamp are properly seated on the flanges.

    Torque v-band clamps ... 12 ± 1 N·m (106 ± 9 lb in)

82. Tighten the 467-8183 Clamp such that the bolts are drawn down evenly.

    Torque bolts ... 47 ± 9 N·m (35 ± 7 lb ft)

83. Tighten all remaining fasteners.

    Torque bolts ... 47 ± 9 N·m (35 ± 7 lb ft)

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    Illustration 38	g06045703

84. Make sure that the bellows convolutions are parallel at all locations and that the 485-3707 Tube As is properly aligned with the 122-3374 Elbow.

    If the convolutions are not parallel, adjust the 481-6767 Bracket As and the 481-6769 Support until the bellows convolutions are parallel

85. Ensure the 434-6544 V Band Clamp are properly seated on the flanges.

    Torque v-band clamps ... 12 ± 1 N·m (106 ± 9 lb in)

86. Tighten the 467-8183 Clamp such that the bolts are drawn down evenly.

    Torque bolts ... 47 ± 9 N·m (35 ± 7 lb ft)

87. Tighten all remaining fasteners.

    Torque bolts ... 47 ± 9 N·m (35 ± 7 lb ft)