Installation of the 519-5587 Aftercooler Core As on Certain G3500H Series Engines {1063} Caterpillar

Installation of the 519-5587 Aftercooler Core As on Certain G3500H Series Engines {1063}

Usage:

Engine: G3516H (S/N: NWH1-UP; NWJ1-UP; GLM1-UP; GLN1-UP); G3520H (S/N: GFP1-UP; GFR1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information. This Special Instruction covers the installation of the 519-5587 Aftercooler Core As.

Caterpillar Channel 1 Videos

For supplemental information on this procedure, refer to the following video. The previous training has been replaced with the video below.

Note: A CWS login is required to access Caterpillar Channel 1. Scan the QR code below with a QR enabled device or copy the link that follows.

Show/hide table




Illustration 1	g06306276

https://channel1.mediaspace.kaltura.com/media/Introduction+to+Visualization+Service+Procedures+%28VSP%29/1_92vjr92v

Safety Section

Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards, including human factors that can affect safety. This person should also have the necessary training, skills, and tools to perform these functions properly.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Cat dealers have the most current information available.

General Information

Graphic Color Description

Color-coding of targeted components, or sections of a part, is used to communicate a required action.

The descriptions below illustrate the different colors and what is represented when used in a graphic.

Show/hide table

(Blue) The primary component of focus for a particular step. Target or primary component to be installed or removed. Installation implied unless otherwise noted with a symbol.

Show/hide table

(Light Gray) Components used for reference.

Show/hide table

(Magenta) Any fastener, retainer, or electrical connector used to install or remove the primary component.

Graphic Symbol Description

This section includes all the symbol graphics used throughout the Visual Service Procedure (VSP), along with a brief description of what the symbol represents.

Show/hide table

Finger Tighten - To apply tension or torque with one digits and unaided by a tool or lever.

Show/hide table

Tighten - To make nearer to fully stretched, without slack, to apply tension or torque.

Torque Specifications

English (SAE) Fasteners

The following table has the recommended standard torque values.

Show/hide table

Table 1
Nuts and Bolts
Thread Size Inch	Standard Torque
1/4	12 ± 3 N·m (9 ± 2 lb ft)
5/16	25 ± 5 N·m (18 ± 5 lb ft)
3/8	47 ± 10 N·m (35 ± 5 lb ft)
7/16	70 ± 15 N·m (50 ± 10 lb ft)
1/2	105 ± 20 N·m (75 ± 15 lb ft)
9/16	160 ± 30 N·m (120 ± 20 lb ft)
5/8	215 ± 40 N·m (160 ± 30 lb ft)
3/4	370 ± 50 N·m (275 ± 37 lb ft)
7/8	620 ± 80 N·m (460 ± 60 lb ft)
1	900 ± 100 N·m (660 ± 75 lb ft)
1 1/8	1300 ± 150 N·m (960 ± 110 lb ft)
1 1/4	1800 ± 200 N·m (1320 ± 150 lb ft)
1 3/8	2400 ± 300 N·m (1780 ± 220 lb ft)
1 1/2	3100 ± 350 N·m (2280 ± 260 lb ft)

Metric (ISO) Fasteners

The following table has the recommended standard torque values.

Show/hide table

Table 2
Nuts and Bolts
Thread Size Metric	Standard Torque
M6	12 ± 3 N·m (9 ± 2 lb ft)
M8	30 ± 5 N·m (20 ± 5 lb ft)
M10	55 ± 10 N·m (40 ± 5 lb ft)
M12	100 ± 20 N·m (75 ± 15 lb ft)
M14	160 ± 30 N·m (120 ± 20 lb ft)
M16	240 ± 40 N·m (175 ± 30 lb ft)
M20	460 ± 60 N·m (340 ± 45 lb ft)
M24	800 ± 100 N·m (590 ± 75 lb ft)
M30	1600 ± 200 N·m (1180 ± 150 lb ft)
M36	2700 ± 300 N·m (2000 ± 220 lb ft)

Required Parts

There are parts that are required for only certain applications and do not apply to all the serial numbers listed above. Make sure to order the correct parts before trying to perform this Special Instruction.

Note:

Show/hide table

Table 3
G3516H Parts
Qty	Part Number	Part Name	Illustration Location (Step)
80	0S-1588	Bolts	Illustration 3 (2) Illustration 5 (1) Illustration 5 (2) Illustration 6 (1)
4	4L-3833	Gaskets	Illustration 9 (2)
4	6D-7128	O-Ring Seals	Illustration 9 (1)
1	6V-1454	O-Ring Seal	Illustration 9 (4)
3	6V-3250	O-Ring Seal	Illustration 9 (1)
2	7M-8485	O-Ring Seals	Illustration 15 (4)
4	8T-1919	O-Ring Seals	Illustration 9 (3)
2	9Y-6893	Gaskets	Illustration 15 (3)
80	107-7954	Spacers	Illustration 3 (2) Illustration 5 (1) Illustration 5 (2) Illustration 6 (1)
2	105-8180	Gaskets	Illustration 10 (1)
2	180-8424	O-Ring Seal	Illustration 9 (1)
1	214-7568	O-Ring Seal	Illustration 12 (5)
4	227-9012	Gaskets	Illustration 8 (1), (4) Illustration 10 (1)
1	228-7088	O-Ring Seal	Illustration 12 (2)
4	228-7089	O-Ring Seals	Illustration 12 (1) Illustration 13 (1)
1	228-7092	O-Ring Seal	Illustration 12 (4)
3	238-5080	O-Ring Seals	Illustration 12 (3) Illustration 13 (1)
1	357-8765	Gasket	Illustration 7 (1)
2	519-5853	Gaskets	Illustration 3 (1) Illustration 5 (1)
1	519-5587⁽¹⁾	Aftercooler Core As	N/A

Show/hide table

⁽¹⁾	This part is only needed if the aftercooler core assembly is being replaced.

Show/hide table

Table 4
G3520H Parts
Qty	Part Number	Part Name	Illustration Location (Step)
80	0S-1588	Bolts	Illustration 3 (2) Illustration 5 (1) Illustration 5 (2) Illustration 6 (1)
4	4L-3833	Gaskets	Illustration 9 (2)
4	6D-7128	O-Ring Seals	Illustration 9 (1)
1	6V-1454	O-Ring Seal	Illustration 9 (4)
3	6V-3250	O-Ring Seal	Illustration 9 (1)
2	7M-8485	O-Ring Seals	Illustration 15 (4)
2	8T-1919	O-Ring Seals	Illustration 9 (3)
2	9Y-6893	Gaskets	Illustration 15 (3)
2	105-8180	Gaskets	Illustration 10 (1)
80	107-7954	Spacers	Illustration 3 (2) Illustration 5 (1) Illustration 5 (2) Illustration 6 (1)
2	180-8424	O-Ring Seal	Illustration 9 (1)
1	214-7568	O-Ring Seal	Illustration 12 (5)
4	227-9012	Gaskets	Illustration 8 (1), (4) Illustration 10 (1)
1	228-7088	O-Ring Seal	Illustration 12 (2)
4	228-7089	O-Ring Seals	Illustration 12 (1) Illustration 13 (1)
1	228-7092	O-Ring Seal	Illustration 12 (4)
3	238-5080	O-Ring Seals	Illustration 12 (3) Illustration 13 (1)
1	357-8765	Gasket	Illustration 7 (1)
2	519-5853	Gaskets	Illustration 3 (1) Illustration 5 (1)
1	519-5587⁽¹⁾	Aftercooler Core As	N/A

Note: Some applications might need both types of gaskets depending upon the fuel valve faces and connections of the piping being used. Refer to Illustration 2 and Table 5 for more information.

Show/hide table




Illustration 2	g06178866
(1) Flat faced fuel valve (2) Raised faced fuel valve

Show/hide table

Table 5
Fuel Valve Gaskets
Qty	Part Number	Part Name	Illustration Location (Step)
3	452-2248⁽¹⁾	Gaskets	Illustration 11 (1)
3	5R-9779⁽²⁾	Gaskets	Illustration 11 (1)
3	168-4987⁽³⁾	Gaskets	Illustration 11 (1)

Show/hide table

⁽¹⁾	G3516H
⁽²⁾	G3516H
⁽³⁾	G3520H

Installation Procedure for Aftercooler Parts

Show/hide table




Illustration 3	g06175742

Show/hide table




Illustration 4	g06175754

Note: If brackets are already installed on the aftercooler, not all 40 bolts and washers will be needed . The torque remains the same for all bolts.

Start the torquing sequence at the center bolt of each side (1-4). Torque the remaining bolts using the numerical order shown. Retorque the center bolts again (1-4). Retorque the corner bolts in the following order (36,40,33,29,37,31,35,39,34,30,38,32).

Show/hide table




Illustration 5	g06175758

Show/hide table




Illustration 6	g06175768

Note: If brackets are already installed on the aftercooler, not all 40 bolts and washers will be needed . The torque remains the same for all bolts.

Show/hide table




Illustration 7	g06175785

Show/hide table




Illustration 8	g06175790

Show/hide table




Illustration 9	g06175813

Show/hide table




Illustration 10	g06175899

Show/hide table




Illustration 11	g06176132

Note: Some applications might need both types of gaskets depending upon the fuel valve faces and connections of the piping being used. Refer to Illustration 2 and Table 5 for more information.

Show/hide table