INSTRUMENT GP 3534755 - Caterpillar

Removal Procedure
Start By:
Remove the hood assembly. Refer to the Disassembly and Assembly, "Remove and Install Turbocharger Assembly".
Remove the turbocharger group. Refer to the Disassembly and Assembly, "Remove and Install Hood Group".
At operating temperature, the engine coolant is hot and under pressure.Steam can cause personal injury.Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand.Remove the fill cap slowly to relieve pressure.Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.
Release the pressure in the cooling system by slowly loosening the filler cap on the radiator. Drain the coolant from the radiator to a level below the aftercooler. Drain the coolant into a suitable container for storage or disposal.
Illustration 1 g00746532
Remove bolt (5), the washer and the spacer. Mark bolt (5) and mark the spacer for installation.
Remove bolt (2) and the washer that is holding the retaining clip. Mark bolt (2) for installation purposes.
Disconnect fuel line (1). Plug the fuel line connector.
Mark two bolts (3) for installation. Remove two bolts (3) and elbow (4) .
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Disconnect fuel line (8). Plug the fuel line connector.
Remove two bolts (7). Remove relief valve housing (6). Mark bolts (7) for installation.
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Loosen socket head bolt (12) (not shown) that is holding electrical connector (10) to electrical connector (9) .
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Remove two nuts (17) and remove ground wire (18) from bracket (11). Remove two bolts (16) and the washers. Identify bolts (16) for installation. Set bracket (11) with electrical connector (9) out of the way.
Remove six bolts (13). Remove elbow (14) and the O-ring seals (not shown).
Remove thirteen washers and bolts (19) from the aftercooler cover. Move the wire harness out of the way. Lift aftercooler cover (15) and the gasket from the aftercooler.
Illustration 5 g00747931
Remove eight bolts (21) and the washers.
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Remove two bolts (26), elbow (25) and the O-ring seal.
Remove two adapters (22) and O-ring seal (23) .
Remove two adapters (24) and the O-ring seal (not shown).
Illustration 7 g00747937
Attach the appropriate lifting device to the aftercooler core. Remove aftercooler core (27). The approximate weight of aftercooler (27) is 14.1 kg (31 lb). Remove O-ring seals (28) .
Illustration 8 g00747956
Remove the bolts (30) and the washers. Remove aftercooler housing (29). The approximate weight of aftercooler housing (29) is 7.85 kg (17 lb).
Illustration 9 g00747963
Remove aftercooler gasket (31) .