3BJ-00030-0 Tohatsu ASSEMBLY

Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7573 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.
Clamp assemblies MUST only be used once. Discard all clamp assemblies after use.
Bellows assemblies MUST only be used once. Discard all bellows assemblies after use.
Note: The 3508C and 3512C Engines have one aftercooler. The 3516C Engines have two aftercoolers. The following procedures describe the removal and installation of the 3516C aftercooler.
Drain the coolant from the cooling system into a suitable container for storage or for disposal.
Illustration 1 g01353326
Loosen clamp assemblies (5). Remove the bellows assembly and clamp assemblies (5). Discard the bellows assembly and clamp assemblies (5).
Remove bolts (1) and bolts (4). Remove air inlet elbow (2) and air pipe (3). Remove the O-ring seals from air inlet elbow (2) and air pipe (3).
Illustration 2 g01353355
Remove tube assembly (8).
Remove bolts (9) and bolts (12). Remove adapter (10) and adapter (11) from the air inlet covers. Remove the O-ring seals from the adapters.
Install Tooling (A) into the top of air inlet cover (7).
Attach a suitable lifting device onto Tooling (A). The weight of air inlet cover (7) is approximately 28 kg (62 lb). Remove bolts (6). Remove air inlet cover (7).Note: Be careful not to damage the fins of the aftercooler core.Note: The weight of the 3508C air inlet cover is approximately 28 kg (62 lb). The weight of the 3512C air inlet cover is approximately 35 kg (77 lb).
Install Tooling (A) into the top of air inlet cover (13).
Attach a suitable lifting device onto Tooling (A). The weight of air inlet cover (13) is approximately 28 kg (62 lb). Remove bolts (14). Remove air inlet cover (13).Note: Be careful not to damage the fins of the aftercooler core.Note: Some clamp assemblies may need to be loosened to remove the connectors.
Remove connector (16) and connector (17) from the aftercooler cores. Remove the O-ring seals from the connectors.
Attach a suitable lifting device onto aftercooler core (15). The weight of aftercooler core (15) is approximately 58 kg (130 lb). Remove aftercooler core (15) from the air inlet manifold. Remove the seals from aftercooler core (15).Note: Be careful not to damage the fins of the aftercooler core.Note: The weight of the 3508C aftercooler core is approximately 58 kg (130 lb). The weight of the 3512C aftercooler core is approximately 84 kg (185 lb).
Attach a suitable lifting device onto aftercooler core (18). The weight of aftercooler core (18) is approximately 58 kg (130 lb). Remove aftercooler core (18) from the air inlet manifold. Remove the seals from aftercooler core (18).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 138-7573 Link Bracket 2
B 1U-6395 O-Ring Assembly Compound -
C 5P-3931 Anti-Seize Compound -
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Clamp assemblies MUST only be used once. Discard all clamp assemblies after use.
Bellows assemblies MUST only be used once. Discard all bellows assemblies after use.
Note: Be careful not to damage the fins of the aftercooler cores.