15/10/2017 Advanced Full Text Search - SENR6419 - G3500 Engines

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Disassembly and Assembly

G3500 Engines
Media Number -SENR6419-14 Publication Date -01/03/2015 Date Updated -12/03/2015

i02559151

Exhaust Elbow - Remove and Install

SMCS - 1060-010

Part Number -
S/N - E8A1-UP

Part Number -
S/N - CRN1-UP

Part Number -
S/N - E6Z1-UP

Part Number -
S/N - ZAZ1-UP

Part Number -
S/N - TJ71-UP

Part Number -
S/N - CPG1-UP

Part Number -
S/N - 8PW1-UP

Part Number -
S/N - E621-UP

Part Number -
S/N - TJ21-UP

Part Number -
S/N - WC81-UP

Part Number -
S/N - E2C1-UP

Part Number -
S/N - 8LD1-UP

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Part Number -
S/N - E2E1-UP

Part Number -
S/N - E6N1-UP

Part Number -
S/N - WC21-UP

Part Number -
S/N - 9TG1-UP

Part Number -
S/N - 4EK1-UP

Part Number -
S/N - E6R1-UP

Part Number -
S/N - 6JW1-UP

Part Number -
S/N - E6W1-UP

Part Number -
S/N - CPY1-UP

Part Number -
S/N - CSZ1-UP

Part Number -
S/N - WC31-UP

Part Number -
S/N - 5JD1-UP

Part Number -
S/N - CSP1-UP

Part Number -
S/N - CPS1-UP

Part Number -
S/N - TJ41-UP

Part Number -
S/N - CRC1-UP

Part Number -
S/N - CPJ1-UP

Part Number -
S/N - 9AW1-UP

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Part Number -
S/N - 7NJ1-UP

Part Number -
S/N - E6Y1-UP

Part Number -
S/N - TJ61-UP

Part Number -
S/N - WC61-UP

Part Number -
S/N - WC71-UP

Part Number -
S/N - ZBA1-UP

Part Number -
S/N - E8C1-UP

Part Number -
S/N - 4WD1-UP

Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7573 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, 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.

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15/10/2017 Advanced Full Text Search - SENR6419 - G3500 Engines

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.

1. 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".

Illustration 1 g01282266

3. Attach Tooling (A) and a suitable lifting device to exhaust elbow (1) . The weight of exhaust elbow (1) is
approximately 36 kg (80 lb).

Illustration 2 g01251046

4. Disconnect tube assembly (4) from exhaust elbow (1) .

5. Remove bolts (2) and bolts (3) .

Illustration 3 g01251048

6. Disconnect tube assembly (5) from the exhaust elbow and the exhaust bypass.

Illustration 4 g01281057

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15/10/2017 Advanced Full Text Search - SENR6419 - G3500 Engines

7. Disconnect tube assembly (7) and tube assembly (9) from the exhaust bypass.

8. Remove tube assembly (6) from exhaust elbow (1) .

9. Remove bolts (8) .

10. Remove exhaust elbow (1) and the gaskets from the engine.

Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 2

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 5 g01282266

1. Attach Tooling (A) and a suitable lifting device to exhaust elbow (1) . The weight of exhaust elbow (1) is
approximately 36 kg (80 lb). Place the gaskets and exhaust elbow (1) in position.

Illustration 6 g01281057

2. Install bolts (8) .

3. Install tube assembly (6) on exhaust elbow (1) .

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4. Connect tube assembly (9) and tube assembly (7) to the exhaust bypass.

Illustration 7 g01251048

5. Connect tube assembly (5) to the exhaust elbow and the exhaust bypass.

Illustration 8 g01251046

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 (1) .

8. Fill the cooling system to the correct level with coolant. Refer to Operation and Maintenance Manual,
"Cooling System Coolant - Change".

9. Turn the engine control switch to the AUTO or START position.

Copyright 1993 - 2017 Caterpillar Inc. Sun Oct 15 2017 18:14:14 GMT-0500 (SA Pacific Standard Time)
All Rights Reserved.
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