0777175 JOHNSON D.I. Blue

Table 1
Required Tools
Tool Part Number Part Description Qty
A 439-3938 Link Bracket 2
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, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".
Illustration 1 g01949540
Remove bolts (3) and strap (4).
Remove bolt (7) and loosen clamps (1). Remove air pipe (2). Remove the O-ring seals from air pipe (2).
Remove bolts (6), air inlet elbow (5), and the O-ring seal.
Repeat for the other side of the aftercooler.
Illustration 2 g01949543
Remove bolts (8) and disconnect elbow (9). Remove the O-ring seal.
Disconnect hose assembly (12). Remove bolts (10) and disconnect elbow (11). Remove the O-ring seal.
Remove bolts (13) and disconnect the flange. Remove the O-ring seals.
Remove bolts (14) and disconnect the flange. Remove the O-ring seals.
Illustration 3 g01949604
Attach Tooling (A) and a suitable lifting device to the top of air inlet cover (16). The weight of air inlet cover (16) is approximately 35 kg (77 lb).
Remove bolts (15), air inlet cover (16), and the seal.Note: Be careful not to damage the fins of the aftercooler core.
Attach a suitable lifting device onto aftercooler core (17). The weight of the 3508C aftercooler core is approximately 23 kg (51 lb). The weight of the 3512C aftercooler core is approximately 32 kg (71 lb). Remove aftercooler core (17). Remove the seal from adapter (19).
Remove bolts (18). Remove adapter (19) and the seal.
Attach a suitable lifting device onto aftercooler core (20). The weight of the 3508C aftercooler core is approximately 60 kg (132 lb). The weight of the 3512C aftercooler core is approximately 85 kg (187 lb). Remove aftercooler core (20). Remove the seal from the air inlet manifold.Note: Be careful not to damage the fins of the aftercooler core.Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
A 439-3938 Link Bracket 2
B 369-9450 Petro Amber Gel -
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: Be careful not to damage the fins of the aftercooler cores.
Illustration 4 g01949604
Illustration 5 g01238547
Install the seal on the bottom of aftercooler core (20). Temporarily secure the bottom seal with tape. Make sure that the tape can be removed after the aftercooler core is installed. Do not use an adhesive, a silicone lubricant, or any other lubricant for retention of the seal.
Attach a suitable lifting device onto aftercooler core (20). The weight of the 3508C aftercooler core is approximately 60 kg (132 lb). The weight of the 3512C aftercooler core is approximately 85 kg (187 lb). Position aftercooler core (20) onto the air inlet manifold. Ensure that the bottom seal is properly seated.
Remove the tape that secured the bottom seal.
Install the seal and adapter (19) on top of aftercooler core (20).
Install bolts (18). Hand tighten bolts (18) to the following procedure:
Tighten the bolts in the numerical sequence to a torque of 24 N m (18 lb ft).
Tighten the bolts in the numerical sequence to a torque of 47 N m (35 lb ft).
Install the seal on adapter (19).
Attach a suitable lifting device onto aftercooler core (17). The weight of the 3508C aftercooler core is approximately 23 kg (51 lb). The weight of the 3512C aftercooler core is approximately 32 kg (71 lb). Position aftercooler core (17) onto adapter (19). Ensure that the bottom seal is properly seated.
Attach Tooling (A) an