GASKET 7N3642 - Caterpillar

Power ModulePM3516 (S/N: NBR1-UP)PMG3516 (S/N: JKK1-UP)Introduction
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.Safety Section
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, "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.
Required Parts
Table 1
Part Number Part Name Qty
3E-9860 Locknut 280
4M-6424 Bolt 96
5P-4116 Hard Washer 8
6V-8918 Bolt 12
7X-0440 Bolt 60
8C-3121 Bolt 124
8T-4224 Hard Washer 564
474-5626 Plate 16
474-5627 Plate 8
474-5628 Plate 4
474-5629 Plate 16
499-3431 Gasket 8
N/A Permatex® #80 Super Weatherstrip Adhesive - 81731 As Needed Removal Procedure
Illustration 1 g06061762
(1) Crankcase fumes disposal system outlet
(2) Remote-mount radiator (radiator assembly)
(3) Jacket Water (JW) lines
(4) Separate Circuit Aftercooler (SCAC) water lines
Illustration 2 g06061782
(5) Radiator core
Drain coolant from cooling system into a suitable container for storage or for disposal.
Remove the crankcase fumes disposal line (1) from the radiator assembly.
Remove the JW lines (3) from the radiator assembly.
Remove the SCAC water lines (4) from the radiator assembly.
Disconnect the wiring from the radiator assembly.
Illustration 3 g06061786
Radiator assembly
Remove the radiator assembly from the container.
Illustration 4 g06061812
Illustration 5 g06061819
Disconnect and remove the radiator vent lines at 5 locations shown in Illustrations 4 and 5.
Illustration 6 g06061873
Disconnect the 2 overflow hoses.
Disconnect the 2 fittings.
Illustration 7 g06061879
Remove the 3 bolts on each side of tanks.
Using a suitable lifting device, remove the tanks. The tanks weighs approximately 1334 N (300 lb).
Illustration 8 g06061898
Remove the 24 bolts from the top radiator core.
Illustration 9 g06061913
Install one lifting eye into each corner of the top radiator core.
Using a suitable lifting device, remove the top radiator core. The top radiator core weighs approximately 635 kg (1400 lb).Rework Procedure
Illustration 10 g06061919
Remove and set aside the following components of the top radiator core:
Core spacers
Tanks
Corner braces
Side memebers
Discard the core washers and all fastening hardware except the corner braces fastening hardware.
Place the cores on a flat, hard, and smooth surface.
Illustration 11 g06061944
Remove the old gasket material from the gasket side of core headers. Make sure that all the gasket joints are cleaned and free from debris.
Illustration 12 g06061949
Remove the old gasket material from the gasket side of tanks. Make sure that all the gasket joints are cleaned and free from debris.
Illustration 13 g06061964
Apply Permatex® #80 Super Weatherstrip Adhesive to the tank surfaces in a pattern shown in Illustration 13.
Illustration 14 g06061969
(6) 499-3431 Gasket
Install two gaskets (6) per tank with all the holes aligned.Note: The adhesive is used to hold the gasket in place during assembly.
Illustration 15 g06061972
Using a suitable lifting device, install the radiator core onto the tank. The radiator core weighs approximately 667 N (150 lb). This can be done manually using 2 people.Note: The cores must be held secure to prevent tipping or falling during the assembly process. The tanks and cores must be secured in