3512C and 3516C Marine Engines Caterpillar

Assembly Procedure

Note: The following story is for 369-2535 Sea Water Heat Exchanger Gp.

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Illustration 1	g06408616

1. Install liners (10) and collars (9) in the ports of the rear frame.

   Note: The liners are installed through the rear of the rear frame.

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   Illustration 2	g06408614

2. Install ring seals (8) into the grooves of top plate assembly (6).

   Note: Use tape to hold ring seals (8) in the grooves of the top plate assembly.

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   Illustration 3	g06408611

3. Install gaskets (7) onto plate assemblies (6).
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   Illustration 4	g06408605
   Typical Example

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   Illustration 5	g06409027
   (H) 376-0524 Plate Assembly (J) 375-7210 Plate Assembly (K) 375-7212 Plate Assembly (L) 375-7211 Plate Assembly (M) 375-7213 Plate Assembly (N) 375-7209 Plate Assembly (P) 375-7208 Plate Assembly

   Note: Ensure the proper order and orientation of the plate assemblies and the gaskets.

   Note: The gaskets on the plate assemblies should face the rear frame during installation.

   Note: Use Tooling (A) to ensure that the plate assemblies are properly aligned.

   Note: Ensure that the edges of the plate assemblies are properly aligned and the gaskets are in the proper grooves in the plate assemblies.

   Note: If the plate assemblies do not lay flat during installation on the rear frame, Tooling (A) may be loosened and retightened to accommodate the plate assemblies.

   Note: If the plate assemblies appear stuck together or do not align during installation, the edges of the plate assemblies can be lightly lifted and adjusted.

4. Install plate assemblies (6) and the gaskets.

5. Install the liners and the collars in front frame (5). Install front frame (5).

   Note: The liners are installed from the front of the front frame.

6. Install Tooling (A) in the spacers. Ensure that Tooling (A) is securely installed. Apply Tooling (C) to the threads of the nut and the threads of the guide stud prior to installation.
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   Illustration 6	g06408600
   Typical Example

7. Tighten the nuts on Tooling (A) evenly until the front frame contacts the spacers.

   Note: As the front frame lowers, the plate assemblies will slide along Tooling (A).

   Note: Check the plate assemblies, the gaskets, and the gasket tabs frequently during compression to ensure proper alignment. Ensure that the gaskets are not pinched during compression. A pinched gasket will be observed by the edges of the adjacent plate assemblies separating slightly.

   Note: If proper alignment of the plate assemblies is not achieved during compression, the front frame can be loosened and the plate assemblies lightly adjusted.

8. Remove Tooling (B).
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   Illustration 7	g06408598
   Typical Example

9. Install the spacers and bolts (4).
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   Illustration 8	g06408593
   Typical Example

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   Illustration 9	g06408588

10. Remove Tooling (A) and install bolts (1) in spacers (3) through the front frame.

11. Remove Tooling (A) and install bolts (2) in spacers (3) through the front frame.
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    Illustration 10	g06408617

12. Tighten the bolts in the sequence as shown in illustration 10. Tighten the bolts to a torque of 150 ± 7 N·m (111 ± 5 lb ft).

13. Install the heat exchanger on the engine. Connect the elbows to the heat exchanger.

14. Fill the cooling system. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure.

Leak Checking the Heat Exchanger

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Illustration 11	g06409046

Note: Leak checking of the heat exchanger should be completed before installation on the engine.

1. Install Tooling (E), (F), and (G) on the ports of the heat exchanger.

   Note: Each circuit on the heat exchanger will require two Tooling (E), one Tooling (F), and one Tooling (G).

   1. Attach an air hose to the end of Tooling (F) on the sea water (SW) circuit.

   2. Verify that flow through is achieved on (SW).

   3. Pressurize (SW) at 275 kPa (40 psi) and close off the circuit.

   4. Close Tooling (F) on the end of jacket water (JW) circuit and separate circuit aftercooler circuit (SCAC).

   5. Attach some hoses to the ends of Tooling (G) on (JW) and (SCAC). Place the ends of the hoses under water and check for bubbles with (SW) pressurized. A continuous stream of bubbles from the hoses would indicate an internal leakage in the heat exchanger. An internal leakage indicates that the heat exchanger was improperly assembled.

   6. Leave (SW) pressurized. Repeat Step 1a through Step 1c with the (JW).

   7. Leave (SW) and (JW) pressurized. Repeat Step 1a through Step 1c with the (SCAC).
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   Illustration 12	g06408620
   Top View

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   Illustration 13	g06409033
   Cross-section of Plate Assembly

2. With all circuits pressurized and closed off, submerge the entire heat exchanger and check for a continuous stream of bubbles from the heat exchanger. Bubbles may be present initially when the heat exchanger is submerged, but the bubbles should stop after a few minutes. It is common to see a stream of bubbles in a straight line at Locations (X). The bubbles should stop after a few minutes.

3. The gaskets on the heat exchanger plates contain weep holes at Locations (Y). As a result, bubbles may be present near Locations (Y). The bubbles should stop after a few minutes. Leave the entire heat exchanger submerged until bubbles stop coming from the weep holes.

   Note: Once the heat exchanger is installed on the engine and started, water may leak out of the weep holes. After a short time, the water leak will stop. This is not an indication of a faulty heat exchanger.