CATERPILLAR’ Renner: eeP Disassembly and Assembly G3508, G3512 and G3516 Engines NGA1-Up (Engine) NBA1-Up (Engine) N6B1-Up (Engine) N8B1-Up (Engine) N6C1-Up (Engine) N2NI1-Up (Engine) WPM1-Up (Engine) N2N1-Up (Engine) WPN1-Up (Engine) N2P1-Up (Engine) WPP1-Up (Engine) DLR1-Up (Engine) WPR1-Up (Engino) GNS1-Up (Engine) WPS1-Up (Engine) WPT1-Up (Engine) WPW1-Up (Engine) Paarliox001620 Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions property Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safely precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. The hazards are identified by the "Safety Alert Symbol’ and followed by a "Signal Word" such as “DANGER’, "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below. ‘The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. ‘The message that appears under the warning explains the hazard and can be either written or pictorially presented, ‘A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels Con the product and in this publication. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. ‘The warnings in this publication and on the product are, therefore, not all inclusive. You must not use this product in any manner different from that considered by this manual without first satisfying yourself that you have considered all safety rules and precautions applicable to the operation of the product in the location of use, including site-specific rules and precautions applicable to the worksite. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that you intend to use. The information, specifications, and illustrations in this publication are on the basis of information that ‘was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Cat dealers have the most current information available. When replacement parts are required for this product Caterpillar recommends using Cat re- placement parts or parts with equivalent speci- fications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to prema- ture failures, product damage, personal injury or death. In the United States, the maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair establishment or individual of the owner's choosing,RENR9709-03 2 Table of Contents Table of Contents Engine Oil Filter Housing - Assemble 81 Engine Oil Filter Housing - Install 83 Engine Oil and Water Pump Drive - Remove 84 Engine Oil and Water Pump Drive - Disassemble .. 85 Disassembly and Assem i v bly Section Engine Oil and Water Pump Drive - Assemble ..... 86 Electronic Control Module - Remove and Install... 6 Engine Oil andl Water Pump Drive - Install eo Gas Pressure Regulator Solenoid - Remove and Engine Oli Pan - Remove er ‘Retail 5 Engine Oil Pan - Disassemble 88 Electric Starting Motor - Remove and Install 6 Engine Ot eae 8 Air Starting Motor - Remove 7 Engine Oil Pan - Install 80 Ar Stating Motor Dissosambie 5 Engine Oil Sequence Valves - Remove and Install Air Starting Motor - Assemble 14 94 ar Starting Motor = netll 13 Drive Housing (Front) - Remove and Install 93 Gas Pressure Regulater - Remove (righ Vibration Damper - Remove and Install 96 ean, a Flywheel - Remove and Install 97 Gas Pressure Regulator - Disassemble 21 Fwnee! Housing - Remove §8 Gas Pressure Regulator - Assemble 22 eines! tlousing «Instat 89 Gas Pressure Regulator- Install (High Pressure) . 24 Crankshal Front Seal and Wear Sleeve - Remove, Fuel Control Actuator - Remove and Instal 4 Fuel Gontel Atiter- Remove and Install... 25 rankshef Front Sealand Wear Sieve - Inst Fuel Control Valve - Remove and Install 2% 208 Fuel Gontiol Valve - Remoce one Incl (Low Cranksiaft Rear Seal and Wear Sieeve - Remove Pressure) 2 105 Carburetor - Remove (High Pressure) a Crankshaft Rear Seal and Wear Sleeve - Install Carburetor - Disassemble (High Pressure) 28 108 Carburetor - Assemble (High Pressure) 29 Accessory Drive (Front) - Remove 10 Carburetor «instal (righ Freseure) 0 Accessory Drive (Front) - Disassemble 108 Exhaust Elbow - Remove and Install 31 Accessory Drive (Front) - Assemble 108 Exhaust Bypass Valve - Remove and install... 33 Accessory Drive (Front) - install ms Exhaust Manifold - Remove (Water Cooled) ....... 34 Gear Group (Rear) - Remove i Exhaust Manifold - Install (Water Cooled) 35 Gear Group (Rear) - Install M3 Eahaust Manifold - instal (Water 3 Crankcase Breather - Remove and install 115 Air Inlet Manifold - Remove and Install 38 Valve Gover and Spark Plug - Remove and Turbocharger - Remove 39 Install 7 Jurbochener - Diseosembie io Rocker Shaft and Push Rod - Remove "8 Juibochanger- Asserts ‘3 Rocker Shaft - Disassemble 119 Turbocharger. Inetall 4 Rocker Shaft - Assemble 120 Water Temperature Regulators - Remove 48 Rocker Shaft and Push Rod - Install 12h Water Temperature Regulators - Install o Nitrogen Oxide Sensor - Remove and Install... 122 Thermostatic Valve - Remove 50 Gylinder Head - Remove (24 Thermostatic Valve - Disassemble 51 Cylinder Head - Disassemble 126 ‘Thermostatic Valve - Assemble 52 Cylinder Head - Assemble 128 Thermostatic Valve - Install 52 Qylinder Head «Install 430 Water Punip- Remove 3 Spacer Plate - Remove and Install 131 Waster Pump -Ooscerbie at Piston Cooling Jets - Remove and Install 133 Water Pump - Assemble 26 Bearing Clearance - Check 13 Water Purp Inet ee Connecting Rod Bearings - Remove and install ‘Auxitary Water Purp - Remove 59 5 38 ‘Auxiliary Water Pump - Disassemble 61 Piston and Connecting Rods - Remove oe ‘Auxiliary Water Purp - Assemble 63 Piston and Connecting Rods - Install 139 Auxiliary Water Pump - stall 65 Cylinder Liner - Remove a Prelubrication Oil Pump - Remove and install. 67 Cylinder Liner - Install “ Engine Oil Pump - Remove 68 Camshat - Remove 14 Engine Oil Pump - Disassemble 68 Camshaft Install “r Engine oii Pump «Assemble, 6 Camshaft Bearings - Remove 15 Engine Oil Pump - Install ” Camshaft Bearings - Install 152 Engine Ol Cooler - Remove % Crankshaft Main Bearings - Remove 153 Engine Oil Cooter - Deascembic 3 Grankshaft Main Bearings - Install 155 Engine Oil Cooler - Assemble 75 Grankstiat - Remove 197 Engine Oil Cooler - Install 77 Crankshaft Install 188 Engine Oil Filter Housing - Remove 78 Engine Oil Filter Housing - Disassemble 794 RENR9709-03 Table of Contents Index Section Index 162RENR9709-03 5 Disassembly and Assembly Section Disassembly and Assembly Section ioasis4 Electronic Control Module - Remove and Install ‘SMCS Code: 1901-010 Removal Procedure 7 MUG es When servicing or repairing electric power gener- ation equipment: Make sure the unit is off-line (disconnected from utility and/or other generators power service), and either locked out or tagged DO NOT OPERATE. Remove all fuses. 1. Disconnect the battery, Refer to Operation and Maintenance Manual, "Battery or Battery Cable - Disconnect 901257238 stration 4 2, Disconnect hamess assemblies (4) from electronic control module (3) 3. Disconnect ground strap (1) 4, Remove bolts (2), the meunts, the spacers, and electronic contra! module (3). 5, If necessary, remove bolts (6) and bracket (6) Installation Procedure (901287238 stration 2 1. If necessary, position bracket (5) and install bolts (6). 2. Install electronic control module (3), the spacers, the mounts, and bolts (2) 3. Connect grounding strap (1). Position ground strap (1) between the bolt head and the washer. 4. Connect harness assemblies (4) to electronic contro! module (3). 5. Connect the battery. Refer to Operation and Maintenance Manual, "Battery or Battery Cable - Disconnect asoease Gas Pressure Regulator Solenoid - Remove and Install SMCS Code: 1270-010 Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life6 Disassembly and Assembly Section RENR9709-03 ‘mustration 3 01248600 1. Tum OFF the gas supply 2. Disconnect the hatness assembly from solenoid (2). 3. Remove solenoid (2) from gas pressure regulator (0). Installation Procedure NOTICE Keep all parts clean fram contaminants, Contaminants may cause rapid wear and shortened component life. IMustration 4 4, Install solenoid (2) on gas pressure regulator (1) 2. Connect the hamess assembly to solenoid (2) 3. Tum ON the gas supply. oases Electric Starting Motor - Remove and Install SMCS Code: 1453-010 Removal Procedure Iwustration 5 901284085 41. Remove fuses (1) from the interface box 2. Disconnect the batteries. ustration 6 901264073 Note: Before disconnecting the hamess assemblies, mark the items for the proper connections in order to, ‘ensure correct assembly. 3. Disconnect the harness assemblies from solenoid (2) and electric starting motor (3) Ifthe engine has two electric starting motors, disconnect the hamess assemblies between the solenoids and electric starting motors. 4, Attach a suitable lifting device to electric starting motor (3). The weight of electric starting motor (3) is approximately 30 kg (66 Ib)RENR9709-03 7 Disassembly and Assembly Section 5. Remove bolts (4). Remove electric starting motor, 3). Remove the gasket from the joint between electric starting motor (3) and the flywheel housing, Installation Procedure 1. Inspect the gasket for the joint between the electric starting motor and the flywhee! housing, Obtain a new gasket, if necessary. Wustration 7 901264073 2. Attach a suitable lifting device to electric starting motor (3). The weight of electric starting motor (3) ‘s approximately 30 kg (66 Ib). 3. Place the gasket in the cover for electric starting ‘motor (3). Lift electric starting motor (3) onto the mounting position, Install bolts (4) 4, Connect the hamess assemblies to solenoid (2) and electric starting motor (3) If the engine has two electric starting motors, connect the hamess assemblies between the solenoids and electric starting motors. 5. Connect the batteries, ‘oorz8406s 6. Install fuses (1) in the interface box. Air Starting Motor - Remove ‘SMCS Code: 1451-011 Removal Procedure NOTICE keep all parts clean from contaminants, Contaminants may cause rapid wear and shortened component life. Note: Several different air starting motors are available for use. The air starting motors can have different configurations for the air lines. Examples of removing two different air starting motors are described below. Removal of an Air Starting Motor Without the Air Tube Assemblies Attached ‘Tum OFF the supply of pressurized air. Purge the pressurized air from the air lines and the air starting motor. (901257808 Mustration 9 2, Disconnect hose assemblies (1). 3. Remove bolts (2). 4, Remove union nut (3) and air tube assemblies (4),8 Disassembly and Assembly Section RENR9709-03 IMiustration 10 roserees 5. Disconnect hose assembly (5). 6. Altach a suitable lifting device to air starting motor (6). The weight of air starting motor (6) is approximately 48 kg (106 Ib) 7. Remove bolts (7). Remove air starting motor (6). Remove the gasket from the joint between the cover of the air starting motor and the flywheel housing Removal of an Air Starting Motor With the Air Tube Assemblies Attached 4, Turn OFF the supply of pressurized ait. Purge the pressurized air from the air lines and the air starting motor. ea Iyatration 11 sproeaee2 2. Disconnect hamess assembly (8), 3. Disconnect the air supply tube from elbow (9). tiustration 12 woto4soa7 4, Attach a suitable lifting device to air starting motor (11), The weight of air starting motor (11) with the air tube assemblies is approximately 86 kg (190 Ib) 5. Remove bolts (10) and air starting motor (11). Remove the gasket from the joint between the cover of air starting motor (11) and the flywheel housing voass0009 Air Starting Motor - Disassemble SMCS Code: 1451-015 Disassembly Procedure Table 4 Required Tools _| Part Number | Part Description | Qty 1954 _| Retaining Ring Pliers 1 Plate a . 51.0 by 102.0 by6.0mm | > (2.00 by 4.00 by 025 nc) ah CG | 1P-1857 [Retaining Ring Pliers | 1 Start By: a. Remove the air starting motor. Refer to Disassembly and Assembly, "Air Starting Motor - Remove" NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened ‘component life:RENR9709-03 Note: Several different air starting motors are available for use, An example of disassembling a typical air starting motor gp is described below. ustration 13 00028087 1. Remove elbow (1) and bracket (2) from motor housing (3). tustration 14 soonasor2 2. To ensure correct assembly, mark the position of motor housing (3) in relation to gear case (6) Remove bolts (4). Remove gear case (6) and drive housing (5) as a unit stration 15 00025015 3. Use Tooling (A) to remove retaining ring (8) from drive gear (7). 9 Disassembly and Assembly Section Inustration 16 00625059 Personal injury can result from parts andlor cov- ers under spring pressure. Spring force will be released when covers are re- moved. Be prepared to hold spring loaded covers as the bolts are loosened. Note: Bolt (9) has left hand threads. 4, Remove bolt (9) and washer (10). Remove drive pinion (11), the spring sleeve, and the pinion spring, To ensure correct assembly, mark the position of drive housing (5) in relation to gear case (6). Remove bolts (12) and drive housing (6) from gear case (6). Mystration 17 ‘0002605 5. Remove O-ring seal (13) from drive housing (6).10 Disassembly and Assembly Section RENR9709-03 itustation 18, 901142879 Pe) ‘The drive shaft, the piston, and the drive gear are under a spring force. Slowly release the spring force before you remove these components. 6. Place Tooling (B) between drive gear (7) and piston (14). Use a suitable press to compress the return spring. Remove retaining ring (15) that holds the drive shaft and the piston in drive, housing (5) iusraton 19 oonaso8e 7. Slowly release the suitable press in order to remove the force of retum spring (16). Remove ‘Tooling (B). Remove retaining ring (15). Remove the drive gear, piston (14), and the drive shaft from drive housing (5) as a unit. Remove return spring (16) @—-ah itustation 20 sp0925089 8. Loosen the bolt for the drive gear with a 5/16 inch hex wrench until the bolt moves freely. Remove drive shaft (17) and piston (14) from drive gear (7) as a unit xc? stration 21 ooasioa 9. Remove bulkhead (18) from piston (14). Remove O-ring seals (19) from bulkhead (18) ho Iustration 22 909028002 40. Remove retaining ring (20) from piston (14. Remove the piston from drive shaft (17).RENR9709-03 4 Disassembly and Assembly Section a or BP Iustration 2% 00828005 11. Remove O-ring seal (22) and lip seal (21) from piston (14) a asteation 24 01052459 jury can result from parts and/or cov- ers under spring pressure. Spring force will be released when covers are re- moved. Be prepared to hold spring loaded covers as the bolts are loosened. 42, Remove retaining ring (31), cup (30), spring (29), driven clutch jaw (28), driving clutch jaw (27). bearing (26), washer (25), lockwasher (24), and bolt (23) from drive shaft (17) IMustraion 25 900028108 13. Remove retaining ring (32) and bearing (33) from drive shaft (17). Note: Note: Do not reuse retaining ring (32). Iusteaion 26 (900525108 14. Use Tooling (C) to remove lock ring (35). Remove ‘bearing (34) from gear case (6). stration 27 00025107 45. Remove spring seat (36) and bearing (37) from ‘drive housing (5).12 RENR9709-03, Disassembly and Assembly Section 0088510 00025148 tiystration 26, Mustration 34 16. Remove lip seal (38) from drive housing (5). 19. Loosen hex socket head bolt (43) and remove rotor clamp nut (42). Remove bearing (44) from rear end plate (45). Musvaton20SSS~*~« TT “Lae 17. To ensure correct assembly, mark the position Mustration 32 ‘os54 ‘of cover (39) in relation to motor housing (3). Remove cover (39) and remove the O-ring seal 20. Remove O-ring seal (46) and rear end plate (45). from motor housing (3). 00025152 Iustration 33 (0875116 ‘stration 30 24. Remove vanes (47) from rotor (48). 48.Remove bolt (41) and rotor pinion (40) from the rotor in the motor housing, 22. Remove rotor (48) from the motor housingRENR9709-03 13 Disassembly and Assembly Section ‘nustration 34 00825188 Mustiation 37 oooe28276 23. Use a suitable press to remove bearing (49) and 26. Remove O-ring seals (52) from rotor cylinder (63), front end plate (50) from rotor (48) as a unit, Wustration 38 aoir420%6 stration 35 000025157 27. Remove rotor cylinder (53) from motor housing 24, Remove bearing (49) from front en plate (50) (3). Remove O-ring seals (54) from the rotor oylinder. susration 36 en0825210 25. Remove washers (51) from front end plate (50).14 Disassembly and Assembly Section Air Starting Motor - Assemble SMCS Code: 1451-016 Assembly Procedure Table 2 Required Tools| Too! | Part Number | Part Description [A | 1P-1854 | Retaining Ring Pliers | Plate ing Pliers 1 RENR9709-03, (2.25 by 8.00 by0.25 inch) Driver Gp. 1 Bearing Lubricant 1P-0510 28-3230 NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened ‘component lif. ‘Mustration 39) 900828828 4. Install O-ring seals (54) on rotor oylinder (53) Install the rotor cylinder in motor housing (3). Orient pin (55) of the rotor cylinder with slot (56) in the motor housing, B : 51.0 by 102.0 by 60mm | 2 Inustation 40 {2.00 by 4.00 by .25:nchy | | 1-1657 ] Retaining Ring Piers 7 2. Install O-ring seals (52) onto rotor cylinder (53). Tube D : 57.0 by 203.0 by 6.0mm | 1 stration 41 0142056 3, Install rear end plate (45) on the shaft of rotor (48) 4, Install O-ring seal (46) over the shatt of the rotor. Itustration 42 oo1t4z900 5. Apply Tooling (F) to bearing (44). Install bearing (44) over the shaft of rotor (48) and into rear end plate (45). 6. Install rotor clamp nut (42) on the shaft of the rotor, Orient the shoulder of the nut toward the bearing,RENR9709-03 7. Tighten rotor clamp nut (42) in order to obtain a clearance of 0.03 to 0.08 mm (0.004 to 0.003 inch) between the rear end plate (45) and rotor (48). Measure the clearance with a feeler gauge. Tighten hex socket heat bolt (43) to secure rotor ‘clamp nut (42). Measure the clearance again DERE "900028856 8, Install rotor (48) into motor housing (3). Align pin (87) into the slot of the rear end plate. SUE 15 Disassembly and Assembly Section 10. Install front end plate (50) onto the rotor. Align ‘small hole (58) of front end plate onto rotor pin 659). stration 46 (90825967 11. Install washers (51) over the shaft of the rotor onto the front end plate. Iystration 47 0828960 12. Apply Tooling (F) to bearing (49). Use Tooling (E) ‘and a suitable press to install bearing (49) in the front end plate, Musteation 45 oor142008 9. Thoroughly lubricate vanes (47) with SAE 10W oil and install vanes (47) into the rotor. Mostration 48 00025176 43. Install rotor pinion (40). Install bolt (41). Tighten the bolt to a torque of 120 N-m (90 Ib ft)16 Disassembly and Assembly Section stration 49 ‘00825384 14, Install O-ring seal (60). Install cover (39) onto motor housing (3) IMustration 50 990925900 lustraion 51 900025501, 16. Apply Tooling (F) to bearing (33). install bearing (33) and new retaining ring (32) onto drive shaft (17). Use Tooling (D) and a suitable press to complete the installation of the new retaining ring Note: Note: Do not reuse retaining ring (32). RENR9709-03 © ® 3 Fi be OO © © stration 62 301062480 Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective oq} ment. 16. Install retaining ring (31), Install bolt (23), lockwasher (24), and washer (25) into drive shaft (17). Apply Tooling (F) to bearing (26) and install bearing (26) into the drive shaft. Install bolt (23), lockwasher (24), and washer (25) into drive shait (17). Apply Tooling (F) to bearing (26) and install the bearing into the drive shaft. Install driving clutch jaw (27), driven clutch jaw (28), spring (29), and cup (30) into the drive shatt, Install retaining ring (31). Thoroughly lubricate the drive assembly with SAE 0W oil A—® stration 53 epviaa0so 17. Use Tooling (E) to install lip seal (21) into piston (14). Install O-ring seal (22).RENR9709-03 7 Disassembly and Assembly Section “es _ O— et IMustration 54 ‘900825479 18. Install piston (14) onto the drive shaft (17). Install retaining ring (20) onto the piston Iustration 87 e074 i20 21. Use Tooling (E) to install lip seal (38) into drive housing (5), stration 85 19. Install O-ring seals (19) onto bulkhead (18). Install bulkhead (18) onto piston (14). ustation 86 corveait7 20. Install drive gear (7) onto drive shaft (17). Use @ 5/16 inch hex wrench to tighten the bolt of the ‘drive gear to 77 N-m (57 Ib ft). IMustration 58 oorTaaT28 22. Apply Tooling (F) to bearing (37) and install the bearing into the drive housing, 23. Install spring seat (36) into the drive housing, Oy oes a” ® stration 59) 0002508818 Disassembly and Assembly Section Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equip- ment. 24. Install return spring (16) onto the spring seat inside drive housing (5). 28. Install the drive gear, the piston, and the drive ‘shaft onto the return spring as a unit. Install retaining ring (18) over the piston. Place Tooling (B) between the drive gear and piston (14). Use a suitable press to compress return spring (16). Install retaining ring (18) into the groove of the drive housing. Slowly release the press and remove Tooling (B) tration 60 00828064 26. Install O-ring seal (13) to drive housing (6). Isteation 64 (00828108 27. Apply Tooling (F) to bearing (34) and instatt ‘bearing (34) into gear case (6). Use Tooling (C) to install Jock ring (35) RENR9709-03 stration 62 gorse 28. Install drive housing (5) on gear case (6). Make ‘sure that the shaft on the end of the drive gear is correctly engaged with the bearing in the gear case. Install bolts (12) and tighten to a torque of 36 Nim (27 Ib ft. Iustration 63 1900025470 29. Use Tooling (A) to install retaining ring (8). Mustraion 64 worseRENR9709-03 Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equip- ment. Note: Bolt (9) has left hand threads, 30, Install pinion spring (62), spring sleeve (61), and ‘rive pinion (11). Install washer (40) and bolt (9). Tighten bolt (9) to a torque of 110 im (80 Ib ft). Note: Bolt (9) has left hand threads. A ‘y IMustraion 65 00025012 34. Install gear case (6) and drive housing (5) onto motor housing (3). Install bolts (4) and tighten evenly to a torque of 80 N'm (60 Ib ft), Iustratio 68 0003601" 32. Install the gasket, elbow (1), and bracket (2) on ‘motor housing (3). 33. After you verify that the starting motor operates properly, attach the airlines to the starting motor. 19 Disassembly and Assembly Section Verify the Operation of the Air Starting Motor Use the follwing procedure to verify that the air starting motor is operating correctly. 1. Tum the drive pinion by hand in the direction of the rotation of the starting motor. The drive clutch must operate smoothly with a clicking sound 2. Tur the drive pinion in the opposite direction of the rotation of the starting motor. The drive pinion must turn by hand 3. Apply 345 kPa (50 psi) of air pressure in the inlet of the drive housing. The drive pinion must move away from the drive housing and air must come Out of the outlet of the drive housing, 4, Plug the outlet of the drive housing, Apply 1034 kPa (150 psi} of air pressure in the inlet of the drive housing. Ensure that no ait is leaking. Measure the dimension from the face of the drive pinion to the mounting face of the drive housing. The dimension must be 73.00 # 2.0 mm (2.874 + 0.08 inch). Remove the air pressure. Measure the dimension again. The dimension must be 44.5 + 2.0 mm (1.75 0.08 inch). Remove the plug from the outlet of the drive housing, 5. Apply 620 kPa (90 psi) of air pressure in the inlet of the drive housing, The starting motor must run smoothly, End By: a. Install the air starting motor. Refer to Disassembly and Assembly, “Air Starting Motor - Install” Air Starting Motor - Install SMCS Code: 1451-012 Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life Note: Several different air starting motors are available for use. The air starting motors can have different configurations for the air ines, Examples of installing two different air starting motors are provided below.20 Disassembly and Assembly Section Installation of an Air Starting Motor Without the Air Tube Assemblies. Attached Iusration 67 "900897643 4. Attach a suitable lifting device to air starting ‘motor (6). The weight of air starting motor (6) is approximately 48 kg (106 Ib) 2, Install a new gasket for the joint between the cover of the air starting motor and the flywhee! housing, Position the air starting motor and install bolts (7) 3. Connect hose assembly (5). twusvaton 62 ro 4, Install air tube assemblies (4) and union nut (3) 5, Install bolts (2). 6. Connect hose assemblies (1). RENR9709-03 Installation of an Air Starting Motor With the Air Tube Assemblies Attached ‘tustration 68 orosces7 1. Attach a suitable lifting device to air starting motor (11). The weight of air starting motor (11) with the air tube assemblies is approximately 86 kg (190 tb). 2. Install a new gasket for the joint between the cover of air starting motor (11) and the flywheel! housing. Position air starting motor (11) and install bolts (10) ‘stration 70 3. Connect the air supply tube to elbow (9) 4. Connect hamess assembly (8). 5. Tum ON the supply of pressurized air.RENR9709-03 sass Gas Pressure Regulator - Remove (High Pressure) SMCS Code: 1270-011 Removal Procedure Start By: a. Remove the gas pressure regulator solenoid. Refer to Disassembly and Assembly, "Gas Pressure Regulator Solenoid - Remove and instal” NOTICE Keep all parts clean from contaminants, Contaminants may cause rapid wear and shortened ‘component life. Mystration 74 1. Remove clamps (2) from the joint 2. Disconnect tube assembly (1) from the fitting on gas pressure regulator (4) 3. Remove bolts (3) and gas pressure regulator (4) iozesn007 Gas Pressure Regulator - Disassemble SMCS Code: 1270-015 Disassembly Procedure Start By: a. Remove the gas pressure regulator, Refer to Disassembly and Assembly, “Gas Pressure Regulator - Remove", 24 Disassembly and Assembly Section NOTICE Keep all parts clean from contaminants, Contaminants may cause rapid wear and shortened ‘component life. ‘Mustration 72 ‘900867827 ‘Types! example 4. Remove the bolts and fiting (1) ‘Mustration 73 "900807828 “Typical example 2, Remove O-ring seal (2) and orifice (3) lf iuecation 74 900507832 ‘Typical example22, Disassembly and Assembly Section RENR9709-03 3. Remove the bolts that hold the gas pressure regulator together. 4, Remove cover assembly (4), seat (5), spring (6), seat (7), and diaphragm (8) from housing (9). ustration 75 00587899 “Typical example 5. Remove the screws, the pin, lever (10), stem assembly (11), and holder (12), lustration 76 gp0se7e3s ‘Typical example 6. Remove bolt (13), heads (14), the head gasket and the pusher post from diaphragm (15) (900567830 Iusteation 77 ‘Typical example 7. Remove cap (16) and the gasket from cover assembly (4) | \ Iustration 78 00507840 “Typical example 8. Remove screw (17). Gas Pressure Regulator - Assemble SMCS Code: 1270-016 Assembly Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened ‘component life. | | Ta cam 4. Install screw (17)RENR9709-03, 23 Disassembly and Assembly Section | | Itustration 20 | 990587899 ‘Typical example 2. Install the gasket and cap (16) in cover assembly (4) tustation 81 ‘597835 Typical example 3. Install the pusher post, the head gasket, heads (14), end bolt (13) in diaphragm (18). Inustration 82 ‘Typieal example 4, Install holder (12), stem assembly (11), lever (10), the pin, and the screws. Iustration 83 gvose7ase ‘Typical example 5. Install diaphragm (8), seat (7), spring (6), seat (6), and cover assembly (4) in housing (9), 6. Install the bolts that hold the gas pressure regulator together. Ieteation 84 "900507628 Typical example 7. Install orifice (3) and O-ring seal (2) tystration 85 900807627 ‘Typical example 8. Install fiting (1) and the bolt.24 Disassembly and Assembly Section End By: a. Install the gas pressure regulator. Refer to Disassembly and Assembly, "Gas Pressure Regulator - Install’. Gas Pressure Regulator - Install (High Pressure) ‘SMCS Code: 270-012 Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. ‘901260862 Iustration 86 1. Install gas pressure regulator (4) and bolts (3) 2. Connect tube assembly (1) to the fitting on gas pressure regulator (4), 3. Install clamps (2) on the joint. End By: a. Install the gas pressure regulator solenoid, Refer to Disassembly and Assembly, "Gas Pressure Regulator Solenoid - Remove and Install’ RENR9709-03 Fuel Control Actuator - Remove and Install SMCS Code: 1909-010 Removal Procedure NOTICE Keep all parts clean from contaminants, Contaminants may cause rapid wear and shortened ‘component life IMusteation 87 012236 4. Disconnect the hamess assembly from fuel control actuator (2). 2, Remove bolt (3) and disconnect linkage (4) from fuel control actuator (2) 3. Remove bolts (1) from fuel control actuator (2). 4, Remove fuel control actuator (2) from the mounting plate, Installation Procedure NOTICE Keep all parts clean from contaminants, Contaminants may cause rapid wear and shortened component life.RENR9709-03 Iusteation 88 012736 4. Position fuel control actuator (2) on the mounting plate 2. Install bolts (1) in fuel control actuator (2) Note: Ensure that proper orientation is maintained during installation of linkage (4) 3. Place linkage (4) on fuet control actuator (2) and install bolt (3) 4, Connect the harness assembly to fuel control actuator (2). sonerss Fuel Control Actuator - Remove and Install SMCS Code: 1909-010 Removal Procedure NOTICE Keep all parts clean from contaminants, Contaminants may cause rapid wear and shortened component life IMustration 89 (o24s253 25 Disassembly and Assembly Section 1. Disconnect the harness assembly from fuel control actuator (1). 2. Remove bolt (2) and disconnect linkage (3) from fuel control actuator (1). 3. Remove bolts (4) from fuel control actuator (1) 4, Remove fuel control actuator (1) from the mounting plate. Installation Procedure NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear and shortened component life a FT Mustration 90 0269253 41. Position fuel control actuator (1) on the mounting plate. 2. Install bolts (4) in fuel control actuator (1) Note: Ensure that proper orientation is maintained during installation of linkage (3) 3. Place linkage (3) on fuel control actuator (1) and install bolt (2) 4, Connect the harness assembly to fuel control actuator (1).26 Disassembly and Assembly Section vons02 Fuel Control Valve - Remove and Install SMCS Code: 1909-010 Removal Procedure NOTICE Keep all parts clean from contaminants, Contaminants may cause rapid wear and shortened ‘component life. 1. Turn OFF the gas supply. 2. Turn the engine control switch to the OFF/RESET position, hustiation 91 01249040 3. Remove clamps (1) from the tube assembly. 4. Remove bolt (4) and disconnect linkage (3) from fuel control vaive (2) 5. Remove bolts (6) and flanges (5). 6. Remove fuel control valve (2). Installation Procedure NOTICE Keep all parts clean trom contaminants, Contaminants may cause rapid wear and shortened component life. RENR9709-03 901240040 Iusteaion 92 1. Inspect the condition of the O-ring seal on the bottom of fuel contral valve (2). Replace the O-ring seal, if necessary, 2, Install fue! control valve (2) with flanges (5) and bolts (6}. 3. Connect linkage (3) to fuel control valve (2) and install bolt (4), 4, Install clamps (1) on the tube assembly. 5. Turn ON the gas supply. 6. Turn the engine control switch to the AUTO or START position.RENR9709-03 27 Disassembly and Assembly Section Fuel Control Valve - Remove and Install (Low Pressure) SMCS Code: 1909-010 SIN: N6A1-Up SIN: N8A1-Up ‘SIN: N6B1-Up_ ‘SIN: N8B1-Up_ ‘SIN: N6C1-Up SIN: N2M1-Up SIN: N2N1-Up_ ‘SIN: N2P1-Up_ SIN: GNS1-Up ‘SIN: WPS1-Up Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life, 4. Turn OFF the gas supply. Iustation 93 01249489 2. Disconnect the hamess assembly from fuel control valve (2) 3. Remove bolts (1) and bolts (3). 4, Attach a suitable lifting device to fuel control valve (2). The weight of fuel control vaive (2) is approximately 68 kg (150 Ib). 5. Remove bolts (4) and fuel control valve (2) Remove the gaskets from the tube assemblies, Installation Procedure NOTICE Keep all parts clean from contaminants, Contaminants may cause rapid wear and shortened ‘component life. baa 90249800 Mustration 94 4. Attach a suitable lifting device to fuel controt valve (2). The weight of fuel control vaive (2) is approximately 68 kg (160 Ib). 2. install the gaskets on the tube assemblies. Place fuel control vaive (2) in position and install bolts, (4) 3. Install bolts (1) and bolts (3). Tighten the bolts to a torque of 115 + 20 Nem (85 + 15 Ib ft, 4, Connect the hamess assembly to fuel control valve (2) 5. Turn ON the gas supply. vo2a9oee2 Carburetor - Remove (High Pressure) SMCS Code: 1266-011 Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened ‘component life.28 Disassembly and Assembly Section RENR9709-03 Iustration 95 spose7oe2 Typical example 1. Turn OFF the gas supply. 2. Disconnect tube (2) and control rod (4) from carburetor (3). 3. Remove clamp (5) 4, Remove bolts (1) and the gasket. 5. Remove carburetor (3) and the gasket Carburetor - Disassemble (High Pressure) SMCS Cod: 266-015 Disassembly Procedure Start By: a. Remove the carburetor. Refer to Disassembly and ‘Assembly, “Carburetor - Remove" NoTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life, stration 96 900597237 Typical example 1. Remove adapter (1) and the gasket from base (2) Saw ba 900587238 Inustation 97 ‘Typical example DVT Personal injury can result from parts andlor cov- ers under spring pressure. Spring force will be released when covers are re- moved. Be prepared to hold spring loaded covers as the bolts are loosened. 2, Remove the screws, cover (5), spring (4), and air valve assembly (3).RENR9709-03, ‘Mustraion 98 00597799 Typiesl example 3. Remove sorews (6) and diaphragm (7). IMustration 99 9097204 ‘Typical example ‘4, Remove the setscrews and disc (10) from shaft (i) 5. Loosen the bolt and remove lever (8). 6. Loosen the set screw and remove stop assembly (8), Remove shaft (11). IMystration 100 (00507280 ‘Typical example 7. Remove the screws and mixer housing (12). 29 Disassembly and Assembly Section 8. Remove the bolts and base (13) from throttle assembly (14), Carburetor - Assemble (High Pressure) SMCS Code: 1266-016 Assembly Procedure NOTICE Keep all parts clean from contaminants, Contaminants may cause rapid wear and shortened component life Iustration 10% "900507280 ‘Typical example 1. Place base (13) on throttle assembly (14) and install the bolts, 2, Install the screws and mixer housing (12) on base. (13). stration 102 900887204 Typical example 3. Install shaft (11). Install stop assembly (9) and tighten the set screw.30 Disassembly and Assembly Section 4. Install lever (8) and tighten the bolt. 5. Install disc (10) and the setscrews on shaft (1). tustration 103, 900897298 Typical example 6. Install diaphragm (7) and sorews (6) stration 104) Typical example Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equip- ment. 7. Install air valve assembly (3), spring (4), cover (5), and the screws, RENR9709-03 Iystration 105 (00567237 Typical example 8. Install the gasket and adapter (1) on base (2) End By; ‘a. Install the carburetor. Refer to Disassembly and Assembly, “Carburetor - Install soao00e9 Carburetor - Install (High Pressure) SMCS Code: 1266-012 Installation Procedure NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear and shortened component life Isteaion 108 “Typical example 4. Position the gasket and carburetor (3) on the engine. 2, Install the gasket and bolts (1)RENR9709-03 34 Disassembly and Assembly Section 3. Install clamp (5). 4. Connect tube (2) and contro! rod (4) to carburetor (3), 5. Adjust the linkage on control rod (4). Refer to “Testing and Adjusting for the correct procedure. 6. Turn ON the gas supply. Exhaust Elbow - Remove and Install SMCS Cod 1060-010, Removal Procedure Table a Required Tools Part —_ Tool Number | _Part Description ‘A | 198-7873 | Link Bracket NOTE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened ‘component life, NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- rent containing fluids, Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Too! Catalog” for tools and supplies suitable to collect and contain fiuids on Caterpillar products. Dispose ofall fluids according to local regulations and mandates. 41. Turn the engine control switch to the OFF/RESET position. 2. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change” Ilustration 107 oiaee2te 3. Attach Tooling (A) and a suitable lilting device to exhaust elbow (1). The weight of exhaust elbow (1) is approximately 36 kg (80 Ib). ‘stration 108 | ‘901751046 4. Disconnect tube assembly (4) from exhaust elbow (1). 5. Remove bolts (2) and bolts (3). 901251046 Mustration 109 6. Disconnect tube assembly (5) from the exhaust ‘elbow and the exhaust bypass.32 Disassembly and Assembly Section Iustration #10 (01281057 7. Disconnect tube assembly (7) and tube assembly (9) from the exhaust bypass. Remove tube assembly (6) from exhaust elbow ), 9, Remove bolts (8). 10. Remove exhaust elbow (1) and the gaskets from the engine. Installation Procedure Required Tools Part Too! | Number Part Description | Qty A_ | 138-7578 | Link Bracket 2 NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened ‘component life. Iystation 111 901267288 RENR9709-03 4. Attach Tooling (A) and a suitable lifting device to exhaust elbow (1). The weight of exhaust elbow (1) is approximately 36 kg (80 Ib). Place the gaskets and exhaust elbow (1) in position Musteation 112 901281087 2. Install bolts (8). 3. Install tube assembly (6) on exhaust elbow (1). 4, Connect tube assembly (9) and tube assembly (7) to the exhaust bypass. 5. Connect tube assembly (5) to the exhaust elbow and the exhaust bypass. 901251046 Mustraion 114RENR9709-03, 6. Ensure that the gaskets between the adapters and the exhaust elbow are positioned correctly. Install bolts (2) and bolts (3). 7. Connect tube assembly (4) to exhaust elbow ('). 8. Fill the cooling system to the correct level with ‘coolant. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change" 9. Tum the engine control switch to the AUTO or START position ioasease Exhaust Bypass Valve - Remove and Install ‘SMCS Code: 1057-010 Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened ‘component life ‘01282236 Iustraion 115 4. Disconnect tube assembly (2) and clamp (3) from exhaust bypass valve (1). 33 Disassembly and Assembly Section Mustration 116 901281081 isconnect tube assembly (5) and tube assembly (6). 3. Remove bolts (4), exhaust bypass valve (1), and the gasket Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life, FESE|F ‘01261081 Imusteaion 117 41. Install the gasket, exhaust bypass valve (1), and bolts (4). 2. Connect tube assembly (5) and tube assembly (6),34 Disassembly and Assembly Section RENR9709-03 IMuseation 118 901282236 3. Connect tube assembly (2) and clamp (3) to exhaust bypass valve (1), soar Exhaust Manifold - Remove (Water Cooled) SMCS Code: 1059-011 Removal Procedure Start By: a. Remove the turbochargers. Refer to Disassembly and Assembly, "Turbocharger - Remove" b. Remove the aftercooler. Refer to Disassembly and Assembly, *Aftercooler - Remove and Install’. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened ‘component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- rnent containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates, 4. Turn OFF the gas supply. usteation 119 901251585 2. Disconnect tube assembly (2) from the fitting on the gas pressure regulator. 3. Remove clamp (1) from the joint IMustration 120 901251887 4, Disconnect tube assembly (2) and remove tube assembly (2) from the carburetor. 5. Remove clamp (3) and tube assembly (4) Iustration 121 "900506755, 6. Remove bolts (5) that hold the exhaust manifold fo the cylinder head.RENR9709-03, 35 Disassembly and Assembly Section lnustration 122 "900506756 7. Remove tube assemblies (6) that connect the exhaust manifold to the exhaust bypass. 8. Remove the bolts that hold the manifold for the exhaust bypass to the exhaust manifold. “he bolts are below tube assemblies (6). ‘stration 123) (900596757 9. Remove bolts (7) that hold the exhaust manifold to the water temperature regulator housing, 10. Remove bolts (8) that hold the adapters to the exhaust manifold, Isteaion 124 01251694 ustration 128 sorastese 41. Attach a suitable lifting device to exhaust ‘manifold (9). The weight of exhaust manifold (9) is approximately 287 kg (632 Ib). Remove bolts (10) that hold exhaust manifold (9) to the mounting bracket 42, Remove exhaust manifold (9). sasoztse Exhaust Manifold - Install (Water Cooled) SMCS Code: 1059-012 Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component lif. Mustration 126 gor25189236 Disassembly and Assembly Section RENR9709-03 ‘Mustration 127| ‘90125169 4. Attach a suitable lifting device to exhaust manifold (9). The weight of exhaust manifold (9) is approximately 287 kg (632 Ib). Position exhaust manifold (9) on the engine, Ensure that the ‘gaskets are in the proper position. 2. Install bolts (10). "900586757 IMustration 128, 3. Install bolts (7) and bolts (8). Iustraton 129 "900505756 4. Install tube assemblies (6). Install the bolts that hold the manifold for the exhaust bypass to the ‘exhaust manifold. The bolts are below tube assemblies (6). IMusteaion 130) 5. Install bolts (5), ‘Wustration 134 ‘o01251887 6. Install tube assembly (4) and clamp (3) 7. Connect tube assembly (2) to the carburetor. 901251505 stration 132. 8. Install clamp (1) 9. Connect tube assembly (2) to the gas pressure regulator 410. Turn ON the gas supply.RENR9709-03 End By: a. Install the aftercooler. Refer to Disassembly and Assembly, “Aftercooler - Remove and Install b. Install the turbochargers. Refer to Disassembly and Assembly, “Turbocharger - install” ‘2500878 Aftercooler - Remove and Install SMCS Code: 1063-010 Removal Procedure Table 5 Required Tools Part Too! Number Part Description | ty A | 138-7573 | Link Bracket 2 Start By: a. If necessary, remove the fuel control valve. Refer to Disassembly and Assembly, “Fuel Control Yalve = Remove and Install’, NOTICE Keep all parts clean from contaminants, Contaminants may cause rapid wear and shortened component life, NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- nent containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog’ for tools and supplies suitable to collect and contain fluids on Caterpillar products, Dispose of al fluids according to local regulations and mandates, 4, Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change’. 37 Disassembly and Assembly Section Mes EN ‘91250889 lusiration 133 2. Attach Tooling (A) and a suitable lifting device to aftercooler (1), The weight of aftercooler (1) is approximately 114 kg (250 Ib). 3. Remove bolts (2) and disconnect the tube assemblies. Remove bolts (3), retainers (4), tubes (7), and the O-ring seals. 4, Disconnect tube assembly (5) from aftercooler (1) Remove bolts (6) Vessration 134 5. Remove bolts (8). 6. Remove aftercooler (1) from the engine (901250872 stration 13538 Disassembly and Assembly Section RENR9709-03 7, Remove plate (10) and core assembly (9), if necessary, Installation Procedure Table 6 Required Tools a ace Toot | Number Part Descript ty ‘A_| 198-7573 | Link Bracket 2 NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 4. Inspect the condition of the O-ring seals. Replace the gaskets and the seals, if necessary. Iustravion 196 ‘901280872 2. Install core assembly (9) and plate (10), if necessary. ‘901250869 ystration 197 "901280839 Itustration 198 3. Attach Tooling (A) and a suitable lifting device to aftercooler (1). The weight of aftercooler (1) is. approximately 114 kg (250 Ib). Position aftercooler (1) on the engine. 4, Install bolts (8). 5. Install bolts (6) and connect tube assembly (5). 6. Place clean engine oil on the O-ring seals and connect tubes (7). 7, Install retainers (4) and bolts (3). Connect the tube assemblies and install bolts (2). 8. Fill the cooling system to the correct level with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change” End By: a, If necessary, install the fuel control vaive. Refer to Disassembly and Assembly, "Fuel Control Valve - Remove and Install’ ‘n2so1048 Air Inlet Manifold - Remove and Install SMCS Code: 1058-010 Removal Procedure Start By: a. Remove the aftercooler. Refer to Disassembly and Assembly, “Aftercooler - Remove and Install” NOTICE keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component lifeRENR9Q709-03 39 Disassembly and Assembly Section Mustration 139 4. Remove bolts (1) from the cylinder head and remove bolts (2) from air inlet manifold (7). 2. Remove air inlet elbows (3) from the engine, 3. Remove bolts (4) from cover (5) on air inlet manifold (7), 4, If necessary, remove air inlet adapter (6) and cover (5). Installation Procedure NOTICE Keep all parts clean from contaminants, Contaminants may cause rapid wear and shortened component life (9250805 lustration 140 4. Ifnecessary, install cover (5) and air inlet adapter (6) on air inlet manifold (7). 2. Install bolts (4). 3. Position air inlet elbows (3) on the engine. 4, Install bolts (2) in air inlet manifold (7) and install bolts (1) in the oylinder head End By: a, Install the aftercooler. Refer to Disassembly and Assembly, “Aftercooler - Remove and Install" Turbocharger - Remove SMCS Code: 1052-011 Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened ‘component life. NOTICE Care must be taken to ensure that fluids are contained ‘during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- nent containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Too! Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. 4. Drain the coolant from the cooling system to a level below the turbochargers into 2 suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling ‘System Coolant - Change’. Se Petia E om cipal eaten ores? tistration 441 2. Remove bolts (2) from each end of oil drain tube (4), Remove oil drain tube (4). 3. Remove tube assembly (3).40 Disassembly and Assembly Section 4, Remove bolts (1). stration 142. ‘901250350 5. Remove bolts (7) from the oil supply line. Remove the oil supply line and the gasket from the turbocharger. 6. Remove air inlet tube (5) and tube assembly (6) RENR9709-03 ia2soosas Turbocharger - Disassemble SMCS Code: 1052-015 Disassembly Procedure Required Tools | part | — yt toot |_Netor | pa ossernton A | 98-6963 | Holding Fixture [85-6849 | Fhiwe Asomby tt 1P-1089-[ Rtanng fing Phas | 1 Start By: a. Remove the turbocharger. Refer to Disassembly and Assembly, “Turbocharger - Remove" o1ascase stration 143 7. Attach a suitable lifting device to turbocharger (9). ‘The weight of turbocharger (9) is approximately 38 kg (84 Ib) 8. Remove nuts (8) that attach turbocharger (9) to the exhaust manifold. Remove turbocharger (9) from the engine. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened ‘component life Iustration 144 30125040 Note: This procedure is a typical disassembly procedure for a turbocharger. Cartridge assembly {3) is secured to compressor housing (1) and turbine housing (4) with clamp (2) and clamp (6). All turbochargers will have the same basic components,RENR9709-03 4 Disassembly and Assembly Section Typical example 1, Place the turbocharger on Tooling (A). Mark the turbocharger housings for the proper alignment during assembly. 2. Loosen clamp (2). Remove compressor housing (1) and clamp (2) ‘Mystration 146 ‘900503008 ‘Typical example 3. Loosen clamp (5) and remove cartridge assembly (3) from turbine housing (4). ‘stration 147, 00508007 “Typical example NOTICE Do Not place a side force on the shaft when the nut is removed or tightened. The shaft will bend and cause damage to the turbocharger. 4. Place the end of the turbine shaft in Tooling (B) Use a socket with a universal joint to remove the nut that holds compressor wheel (6). IMustration 148 Typical example 5. Use a suitable press to push the turbine shaft ‘out of compressor wheel (6) and the cartridge housing. Remove compressor wheel (6). ‘station 149 "900503075 ‘Typical example 6, Remove seal ring (8) and shroud (9) from turbine shaft (7),a2 Disassembly and Assembly Section stration 150) 90503020 “Typical example Mustration 151 050018 “Typical example 7. Bend the tabs of the locks away from bolts (10) and remove bolts (10). Note: Examine the position of the ail holes in the back plate assembly and the cartridge housing for the assembly procedure, 8. Remove back plate assembly (11). 9, Remove spacer (12) ftom back plate assembly ) IMustraton 152. ‘900583022 “Typical example RENR9709-03 10. Remove seal rings (13) from spacer (12) ustration 153 "900589028 ‘Typical example 11. Remove thrust collar (14) and seal ring (15). Iustration 154 900569825 ‘Typical example 12, Remove thrust bearing (16). istration 155 "900883062 Typical example Note: Place an identification mark on the bearings it the bearings are reusable. 43, Remove bearing (17) and the washer from the ‘cartridge housing,RENR9709-03 43 Disassembly and Assembly Section vo2s0o0ss Turbocharger - Assemble SMCS Code: 1052-016 Assembly Procedure Tote 8 Required Toole Part im Too! , Number | Part Description | | 99-6369. | Holding Fixture lstabon 156 08m @ | 95-6943 [Fite Assemby | 3 Typical example _C_|_1P-1853 | Retaining Ring Pliers 1 14. Use Tooling (C) to remove retaining rings (18) bp | t-s096 | Dial indicator 1 and (19) E | 6v-2055 | Grease i F | 40-9500 | auik Cure Primer [oF 0-8507 [Retaining Compound NOTICE Keep all parts clean from contaminants, Contaminants may cause rapid wear and shortened ‘component life 4. Ensure that all of the oil passages in the cartridge housing, the back plate assembly, and the bearing are clean, usta 157 ‘oosesees 2. Place clean engine oil on all of the parts for the cartridge assembly during the assembly 18. Remove bearing (20) and washer (21) Procedure, Note: Ensure that the round edge of the outside diameter of the snap rings 1 toward the bearing during installation, ‘Typical example Iusteaton 158 ‘oni257sa1 “Typical example 16. Use Tooling (C) to remove the lower retaining ring (22) from the cartridge housing IMustration 189) (00564729 ‘Typical example 3. Use Tooling (C) to install lower retaining ring (22) in the turbine end of the cartridge housing,44 Disassembly and Assembly Section RENR9709-03 4. Install washer (21) and bearing (20). Use Tooling (C) to install retaining ring (19). stration 160 00554195 ‘Typical example stration 163, (900504620 “Typical example 8, Install seal ring (15) in the groove of the cartridge, housing. IMustzation 164 1700584139 Typical example 5. Use Tooling (C) to install retaining ring (18), 6. install washer (23) and bearing (17) in the cartridge housing until washer (23) makes contact with retaining ring (18) ‘900504134 Iustration 162 “Typical example 7. Install thrust bearing (16) on the dowels in the cartridge housing. Ensure that the grooves in thrust bearing (16) are toward the outside. ystration 164) ‘Typical example 9. Install thrust collar (14) on the thrust bearing with the counterbore upward istration 168 "900508622 “Typical example 410. Install seal rings (13) on spacer (12). The gaps in the rings should be 180 degrees away from each other.RENR9709-03 stration 168 00504623 ‘Typical example 11. Install spacer (12) in back plate assembly (11). Inystration 167 0050642 Typical exampte onossaea7 Iusteation 168 ‘Typical example 12. Align oil passage (24) in the cartridge housing with oil passage (25) in back plate assembly (11), 13. Install back plate assembly (11) on the cartridge housing, Ensure that the spacer fits correctly in the counterbore of the thrust collar. 48 Disassembly and Assembly Section 14. Install the locks and the bolts on back plate ‘assembly (11), Tighten the bolts to a torque of 10 1 Nim (89+ 9 Ib in) rascal Mustration 169 ‘00809650 Typical example 45. install turbine shaft (7) in Tooling (B). Apply Tooling (E) in the groove for seal ring (8). Ensure that Tooling (E) fils half of the groove. This creates a-carbon dam under the seal ring 16. Install seal ring (8) and shroud (8). 17. Install the cartridge housing on the turbine shaft Hold the spacer in position. Ensure that the seal ring on the turbine is correctly placed in the cartridge housing, Mustration 170 00st “Typical example 18. Install compressor wheel (6).46 Disassembly and Assembly Section RENR9709-03, usteation 171 (900508673 Typical example NOTICE Do Not place a side force on the shaft when the nut is removed or tightened. The shaft will bend and cause damage to the turbocharger. 19. Place clean engine oil on the threads of the turbine shaft and on the face of compressor wheel (6) that Is under the nut. Tighten the nut to a torque of 16 + 2 Nem (1221 Ib ft. 1. Remove the nut. Apply Tooling (F) to the threads Of the turbine shaft 24. Apply Tooling (G) on the threads of the turbine shaft. Install the nut and tighten the nut to a torque of 4 N-m (36 Ib in). Turn the nut for an additional 120 degrees (1/3 turn) "00058467 stration 172 ‘Typical example 22, Place the cartridge assembly in a vise. Install Tooling (D) and check the end play of the shaft. The end play must rot be more than 0.165 + 0.085 mm (0.0065 0.0033 inch). tustraion 173 go0seeea0 ‘Typical example 23. Install turbine housing (4) on Tooling (A). Install the cartridge assembly and clamp (5) in turbine housing (4). Ensure that the marks on the housing and the cartridge are aligned 24. lnstall clamp (5). Tighten the clamp to a torque: of 14+ 1. Nm (10+ 1 Ib ft). Lightly tap the clamp with a soft hammer. Tighten the clamp to the same torque again (0594685 Iaeteation 174 | Typical example 25. Install clamp (2) and compressor housing (1) on the cartridge assembly. Install clamp (2). Tighten the clamp to a torque of 14+ 1N'm (10 £4 Ib ft) Lightly tap the clamp with @ soft hammer. Tighten the clamp to the same torque again. End By: a. Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Install”.RENR9709-03, Turbocharger - Install ‘SMCS Code: 1052-012 Installation Procedure ‘able @ Required Tools nay Part 7 Toot | Number Part Description | Qty ‘A_| 8P-3981 | Anti-Seize Compound | - NOTICE Keep all parts clean from contaminants, Contaminants may cause rapid wear and shortened ‘component life. 14. inspect the condition of the gaskets. Replace the gaskets, if necessary. 01250954 Iustration 175 2. Attach a suitable lifting device to turbocharger (9). ‘Tne weight of turbocharger (9) is approximately 38 kg (84 Ib). 3. Apply Tooling (A) to the studs on the exhaust ‘manifold. Install turbocharger (9) and nuts (8) that attach turbocharger (9) to the exhaust manifold Tighten nuts (8) to a torque of $4 5 Nem (40 £4 Ib) 47 Disassembly and Assembly Section lustration 176 90250555, 4, Install air inlet tube (5) and tube assembly (6). 5. Position the oil supply line and the gasket on the turbocharger. Install bolts (7) in the oil supply line. stration 47 6. Install bolts (1). 7. Install tube assembly (3) 8. Install oil drain tube (4) and bolts (2), 9. Fill the cooling system to the correct level with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change”48 Disassembly and Assembly Section RENR9709-03, Water Temperature Regulators - Remove SMCS Code: 1355-011 Removal Procedure Table 10 LC Required Tools [_ Part Tool |_ Number Part Description _| ty A_ | 198-7578 | Link Bracket 2 NOTICE Keep all parts clean from contaminants, Contaminants may cause rapid wear and shortened ‘component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the fiuid with suitable containers before open- ing any compartment or disassembling any compo- ent containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog’ for tools and supplies suitable to collect and contain fluids on Caterpillar, products. Dispose of all fluids according to local regulations and mandates, 4. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling ‘System Coolant - Change" IMustraton 178 ‘1251648 Typical example 2, Remove the bolts from retainers (2) and (6). 3. Remove the bolts from support bracket (4). 4, Remove tube (5) and the O-ring seals, 5. Remove the bolts from elbow (1). Remove elbow (1) and the gasket 6. Disconnect the harness assembly from pressure sensor (3). Remove the bolts from pressure sensor (3). Remove pressure sensor (3) Imustration 179) “Typical exampleRENR9709-03, 49 Disassembly and Assembly Section 7. Remove mounting straps (7) and (9) that hold the water temperature regulator housing te the engine oil filter housing. Remove plate (8) from the engine oil filter housing ioasasrs Water Temperature Regulators - Install SMCS Code: 1355-012 Installation Procedure rte Feared Tools Part Tool | Numer | Par Bosciption ty cA 138-757: Bracket | 2 “B | 19:0810 | Brver Group Cl stration 180) ‘901251650 Typical example 8. Altach Tooling (A) and a suitable lifting device to water temperature regulator housing (12). The weight of water temperature regulator housing (12)'8 approximately 59 kg (130 Ib). 9. Remove bolts (11) and water temperature regulator housing (12) from exhaust manifold (13) 40. Remove the O-ring seals from water temperature regulator housing (12) 11. Remove regulator housing (10) from water temperature regulator housing (12). stration 181 901251084 ‘Typical example 12. Remove water temperature regulators (14) from regulator housing (10). 13, Remove the valve assembly and the seals, if necessary, NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened ‘component life, 4. Install the valve assembly, if necessary. Ensure that the valve is flush with the surface of the housing 2. Use Tooling (B) to install the seals, if necessary Ensure that the lip of the sealis toward the inside of the housing ‘07251084 Iysteaion 182 ‘Typical example NOTICE If the water temperature regulator is installed incor- rectly, it will cause the engine to overheat 3, Install water temperature regulators (44) in regulator housing (10) with the spring upward,50 Disassembly and Assembly Section RENR9709-03 ‘Typical example 4, Install regulator housing (10) on water temperature. regulator housing (12). 5. Install the O-ring seals in water temperature regulator housing (12). ‘Attach Tooling (A) and a suitable lifting device to water temperature regulator housing (12). The weight of water temperature regulator housing (12)is approximately 89 kg (130 Ib). Position water temperature regulator housing (12) on the engine. 7. Install bolts (11) that attach water temperature regulator housing (12) to exhaust manifold (13). 00589055 Iustration 184 ‘Typical example 8. Install mounting straps (7) and (9). Install plate (8) on the engine oil filter housing. ‘901251848 9. Install a new gasket, elbow (1), and the bolts, 10. Install the O-ring seals and tube (5). Install retainers (2) and (6) with the bolts. 11. Install support bracket (4) and the bolts. 12. Install pressure sensor (3). Connect the harness ‘assembly to pressure sensor (3). 13. Fill the cooling system to the correct level with coolant. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change". Thermostatic Valve - Remove SMCS Code: 1355-011 Removal Procedure NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear and shortened ‘component life,RENR9709-03, 51 Disassembly and Assembly Section NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product, Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- nent containing fiuids Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog” for tools and supplies. suitable to collect and contain fluids on Caterpillar products. Dispose ofall fluids according to lecal regulations and mandates. 4. Disconnect the supply line to the auxiliary water pump. Plug all openings immediately. ‘Mustration 186 (901252008 Typical example 2, Remove clamps (3). 3. Remove bolts (1). Remove thermostatic valve (4) and bracket (2), ‘oorz52040 stration 187 4, Remove bolts (5) and separate thermostatic valve (4) from bracket (2). Thermostatic Valve - Disassemble SMCS Code: 1355-015 Disassembly Procedure Start By: a. Remove the thermostatic valve, Refer to Disassembly and Assembly, "Thermostatic Valve - Remove NOTICE Keep all parts clean from contaminants, Contaminants may cause rapid wear and shortened component lite, Iustraton 188 900500619 4. Remove tubes (1). Remove plug (6) 2. Remove remaining bolt (7), upper housing (2), O-ring seal (3), thermostat (4), and lower housing (5). Itustraion 199 ‘eo175707% 3. Remove retaining screw (10) and seal (8), if necessary.82 Disassembly and Assembly Section 4, Remove bolt (9) and plate (11), if necessary. inzs0276s Thermostatic Valve - Assemble SMCS Code: 1355-016 Assembly Procedure NOTICE Keep all parts clean from contaminants, Contaminants may cause rapid wear and shortened component life IMsteation 190 01262076 1. Install plate (11) and bolt (9), if necessary. 2, Install seal (8) and retaining sorew (10), if necessary. (900503670 IMustration 191 3. Assemble lower housing (5), thermostat (4). ‘O-ring seal (3), upper housing (2), and bolt (7) 4, Install plug (6) and tubes (1). RENR9709-03, End By: a, install the thermostatic valve, Refer to Disassembly and Assembly, “Thermostatic Valve - Install’. io2soa708 Thermostatic Valve - Install SMCS Code: 1355-012 Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened ‘component life. stration 192 oor2s70%8 4. Position bracket (2) on thermostatic valve (4) and install bolts (5) stration 193) 2. Position thermostatic valve (4) and bracket (2) on the engine and install bolts (1). 3. Install clamps (3). 4. Connect the supply line to the auxiiary water pumpRENR9709-03 lease Water Pump - Remove SMCS Code: 1361-011 Removal Procedure NOTICE Keep all parts clean from contaminants, Contaminants may cause rapid wear and shortened ‘component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- nent containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog’ for tools and supplies: suitable to collect and contain fluids on Caterpillar products, Dispose of alifluids according to local regulations and mandates, 4, Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling ‘System Coolant - Change’. 53 Disassembly and Assembly Section Mustration 194 901251960 2. Remove bolts (4) and the retainer from the water pump. 3. Remove the bolts and retainer (2} from elbow (1). 4, Remove the bolt from support bracket (6). Remove tube assembly (3) usteation 195 5. Attach a suitable lifting device to water pump (8). ‘The weight of water pump (8) is approximately 38 kg (85 Ib). Remove bolts (6), bolts (7), and. water pump (8).