CATERPILLAR 3500B Engine Disassembly & Assembly

° SENR6564-18 CATERPILLAR somes Disassembly and Assembly 3500B Engines OLE car ror 103 as7sx tbat Color_ Cvr (+4) 65# COVER Pgs: 220 PERFECT 4 2P, SHOLE 516 Dus 3P: NONE 06/02 we: 0 @ SENR6564 18Important Safety Information Most accidents tat involve product operation, maintenance and repair are caused by failure to obeerve bcie cafety rules or precautions. An accident can often he avoided hy recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skilis and tocls to perform these functions properly 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. Safety precautions and wamings 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 snown below: 7 Cy The sieaniny Uf this safety alert symbol is as fellows Attention! Become Alert! Your Satety 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 ere identified by “NOTICE” labels ‘on 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 nol use Uiis product in any manner different from that concidored by thie manual without first eaticfying yourself that you have considerad 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. Ifa tool, procedure, work method or operating technique that is not Specitically recommended by Caterpillar is used, you must satisfy yourself that itis safe for you and for others. You chould alco ensure that the product will not be damaged ar hecame unsafe by the operation, lubrication, maintenance or repair procedures that you intend to use. The information, specifications, and iluetrations in this publication are on the hasis af information that was available at the time that the publication was written, The specifications, torques, pressures, measurements, adjustments, ilustrations, and other items can change at any time, These changes can affect the service that is given to the product. Ubiain the complete and most current information before you Slart any juv. Cal dealers have the most current information available. When replacement parts are required for this product Caterpillar recommends using Cat replacement parts or parts with equivalent sp Juding, 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.SENRESEA18 3 Table of Contents Table of Contents Disassembly and Assembly Section Ar Starting Motor - Remove . Ai Starting Motor - Disassembie Alr Starting Motor - Assemble Air Sterting Motor - Install Electric Starting Motor - Remove and install ‘Attemator - Remove and Install. Electronic Control Module (Engine) - Remove ana Isla. : Fuel Filter Housing - Remove (Spin-on Fier Fuel Filter Housing - Remove Fuel Filter Housing - Remove Fuel Fitter Housing - Disasser Fitters). fal Filter Housing - Assembla (Spin-on Filters) 24 Fuel Filter Housing - install. see 2B Fuel Filter Housing - Install (Spin-on Fiters) Fuel Filter Housing - Install... Fuel Priming Pump - Remove and install. Fuel Transfer Pump - Remove ..... Fuel Transfer Pump - Disassemble Fuel Transfer Pump - Assembie Fuel Transfer Pump - Install Fuel Cooler - Remove and Install Air Cleaner - Remove and Install... Turbocharger - Remove (Center Mou “Turbocharger... anal Turbocharger - Remove (Rear Mounted. Turbocharger) PAS ‘Turbocharger - Remove (Rear Mounted ‘Turbocharger .... Turboctanges - Disassemble « ‘Turbocharger - Assemble ......... ‘Turbocharger - Install (Rear Mounted Turbocharger) a 4 Turbocharger - install (Rear Mounted Turbocharger) ‘Aftercooler = Remove and install”... ‘Arr Inlet Manifold - Remove and install Exhaust Elbow Romove and Inetall Exhaust Manifold - Remove and Install ........ Expansion Tank - Remove and Install ‘Water Temperature Regulators - Remove ... ‘Water Temperature Regulators - Install. ‘Water Pump - Remove ‘Nater Pump - Disassemble ‘Mater Pump - Assemble svater Pump - Install eter Pump (Geperate Circuit Afteroooler) Remove 64 ‘eter Pump (Separate Circuit Aftercooter) - Sisassemble ..... 65 ‘iat Pump (Separate Greil Anica) = - 687 69 Auxiiary Water Pump - Remove (Auxiliary Pump) «. ‘Auyiliary Water Purp - Remove (Aunilary Sea Water Pump) a ule Wer unis Bisassebie uiay Pump (Type 1)... ‘Auxiliary Water Pump - Disascomble (Auxiliary ba Water Pump) Auxiliary Water Pump - Disassemble (Auxiliary Bina (Type 2)). Auxiliary Wat (Auxiliary Pimp. (Type 1)... Auxiliary Water Pump - Assemble (Auxiliary Sea Water Pump) ‘Auxiliary Water Pump - Assemble (Auxillary Pump: (Type 2)... sity ise Bump ina cary Burg) 104 Aiary Water Purp - Insta (Auxiliary Sea Water Pump) on 105 Engine Oil Govier = Reiove on 100 Engine Oil Cooler - Disassemble... 107 Engine Oil Cooler - Assemble - 109 Engine Oil Cooler - Install. Mm Engine Oil Pump - Kemove m Engine Oil Pump - Disassemble . mer) 114 Engine Oil Pump - Install 116 Engine Cil Filter Housing - Remove 117 Engine Oil Filter Housing - Disassemble ne Engine Oil Filter Houeing Aecemble 120 Engine Oil Filter Housing - Install... 122 Engine Oil Filter Base - Remove (Spin-on Filters) Engine Oil Filer Base - Disassemble (Spin-on 123 Filters)... 124 Engine Gil Filter Base - Assemble (Spin-on Filters) . sevnntneses 124 Engine Gil Filter Base - install (Spin-on Filters) .. 125 Crgine Oil and Water Pump Drive - Remove ..... 125 Engine Oil and Water Pump Drive ~ Disassemble .. 126 Engine Oil and Water Pump Drive Assemble. 127 Engine Oil and Water Pump Drive ~ . 128 Engine Oil Pan - Remove ......... 129 Engine Oil Pan - Disassemble .. 130 Engine Oil Pan- Assemble... 131 Engine Oil Pan - install 12 Engine Oil Scavenge Pump - Remove... 193 Engine Oil Seavange Pump -Disassemie 134 Engine Oil Scavenge Pump - Assemble ........ 135 Engine Oil Scavenge Pump - install. 2137 Grankcase Breatner - Remove and Install... 138 Valve Cover - Remove and Install .. vs 130 Valve Cover Base - Remove and Install 140 Rocker Shaft and Push Rods Remove... 144 Rocker Shaft - Disassemble ik 142 Rocker Shafl - Assemble... 142 Rocker Shaft and Push Rods - install - 14a Electronic Unit Injector - Remove .. 145 Electronic Unit Injector - Insta... 145 Cylinder Head - Remove .... 147 Cylinder lead - Disassembie 448 Cylinder Head - Assemble : 1504 Table of Contents Cylinder Head - Insta. ‘Accessory Drive (Front) - Remove Accessury Drive (Front) - Disassemble .. Accessory Drive (Front) - Assemble Accessory Drive (Front) - Install ss Front Drive Housing - Remove and install. Vibration Damper - Remove and install Crankshaft Front Scal and Wear Sleeve Flywheel Remove and insiall =... Crankehaft Rear Seal and Wear Slave - Remove 169 169 Flywheel Housing - Remove wnnnnnnennne 474 Fiywheel Housing - Install 172 Engine Oi Sequence Valves - Remove and install 175 Gear Group (Rear - Remove a7 Gear Group (Reer) - Install. 179 Piston Croling Jats - Remove and Install... 184 Bearing Clearance - Check........... 182 Connecting Rod Bearings - Remove and install Crankshaft Main Bearings - Remove | Crankshaft Main Bearings - Install... Pistons and Connecting Rods - Remove .. Pistons and Connecting Rods - Insta. Gylinder Liner - Remove ft Cylinder Liner - Install Camshaft - Remove wan Camshaft Bearings - Remove .. ‘Camsnaft Bearings - Install Camshaft Install... Crankshaft - Remove ... Crankshaft - Install 0. Radiator Group - Remove . Radiator Group - Install Radiator Core - Remove Radiator Core - Install... Fan - Remove and Install Index Section Index Mttedbleebetereetrreete | 22 SFNRGSA4-18SFNRARAA18 Disassembly and Assembly Section Air Starting Motor - Remove SMCS Code: 1451-011 Removal Procedure NOTICE Keep all parts clean from contaminants, Contaminante may esuee-rapid wear and shortened component life. Note: Several different air starting motors are available for use. The starting motors can have different configurations for the air tube assemblies. Examples of removing two different air starting motors aro described below. Removal of an Air Starting Motor Without the Air Tube Assemblies Attached 1. lum oft tne supply of pressurized air. Purge tne pressurized air from the air tube assemblies ond the starting motor lkstration 1 2. Disconnect hose assemblics (1), 3. Remove bolts (2) . Remove U-boll (3) anid lube assemblies (4). 5 Disassembly and Assembly Section lllustration 2 sncsoreds 5. Disconnect hose assembly (5). 6. Attach a suitable lifing device onto air staring motor (6). The weiaht of air starting motor (6) is approximately 48 kg (106 Ib). 7. Remove bolts (7). Remove ai starting motor (6) Remove the gasket from the joint between the cover of air starting motor (6) and the flywinee! housing, Removal of an Air Starting Motor With the Air Tube Assemblies Attached 4. Tum off the supply of pressurized air. Purge the pressurized air from the air tube assemblies and the starting motor. ‘Ibustration 3 i Sasa 2, Disconnect hamess assembly (1). 3. Disconnect the tube assembly from elbow (2)6 Disassembly and Assembly Section Uustration 4 0018840 4, attach a sultabie tifting device onto alr starting motor (4). The weight of air starting motor (4) 15 approximately 86 kg (190 Ib). 5. Remove bolts (3). Remove air starting motor (4). Remove the gasket fui Une joint between Ure ‘cover of air starting motor (4) and the flywheel housing. ora2asie Starting Motor - Disassemble SMCS Code: 1451-015 Disassembly Procedure Table 1 Required Tools Part Toot | eit, | Part Description | aty A | 1P-1854 | Retaining Ring Phiers [4 Plate B 50.8 mm @inchesx |, 402 mm (4 inches) x6 | rim (0:25 inches) | 10-1857 [Retaining Ring Pliore | 1 Start Ry: a, Remove the air starting motor. Refer to Disassembly and Assembly, “Air Starting Motor Romove", NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened. ‘component life ‘SENR6564-18 Note: Several diferent air starting rotors are available for use. An example of dieseeembling a typical air startina motor is described below. Note: betore you disassemble the air starting motor, obtain @ complete set of these parts: gaskets, O-ring seals, seals, and vanes. stration 5 yooasr993 4. Remove elbow (1) and bracket (2) from motor housing (3). snustrawon 6 — 2. To ensure correct assembly, mark the position of motor housing (3) in relation to gear case (6). Remove bots (4). Remove gear case (6) and drive housing (6) a9 a unit. stration 7 00507605SFNRAAAAAR 3. Use Tooting (A) in order to remove ring (8) from drive gear (7) Note: Bull (9) ls left hand threads, 4 Remove bolt (9) and washer (10). Remove pinion (11), the sleeve, and the spring To ensure correct assembly, mark the position of drive housing (5) in relation to gear case (6). Remove bolts (12) and drive housing (5) from ‘gear case (6), (900587688 £ Remove O-ring seal (13) from drive housing (5). 7 Disassembly and Assembly Section PIMOE Ley ‘The drive shaft, the piston, and the drive gear are under a opring force. Slowly releaco the spring force before you remove these components, 6. Position Tooling (B) between drive gear (7) and piston (14). Use a suitable press in order to ‘compress the return spring. Remove the ring that holds the drive shaft and the piston in drive housing (5). IMustration 11 wo0serro8 Personal injury can result from being struck by parts propelled by a released spring force. ‘Make sure to wear all necessary protective equip- mont. Follow the recommended procedure and use all recommended tooling to release the spring force. 7. Slowly release the press in order to remove the force of return spring (16). Remove Tooling (0). Remove ring (18). Remove the drive gear, the piston, and the drive shaft from drive housing (5) a8 a unit. Remove retum spring (16). Muctration 12 (gse77118 SENR6564-18 Disassembly and Assembly Section ‘8. Loosen the bolt (not shown) until the bolt moves frooly. Remove drive ehaft (17) and piston (14) from drive gear (7) as a unit. “gu0587715 IMustration 18. 2 112, Remove O-nng seal (22) and seal (21) trom Mustration 13 906o7712 piston (14). 9. Remove bulkhead (18) from piston (14) inusraton 17 oOserrIe 10. Remove O-ring seals (19) from bulkhead (18) jparetnallinjsey aan rosui feora osina esr parts propelled by a released spring force. Make sure to wear all necessary protective equip- ment, Follow the recommended procedure and use all recommended tooling to release the spring force. 13, Remove the following parts from drive shaft (17) ring (31), cup (30), spring (28), aren ciuten jaw (28), driving cluten jew (27), bearing (26), wesher (25), lockwasher (24), and bait (23) Mustration 18 weoserria 41. Remove ring (20) from piston (14). Remove the piston from drive shaft (17).SENRASAA8 9 Disassembly and Assembly Section akewration 18 ‘Note: A new ring is always required for assembly :enen ring (82) is removed. 44. Remove ring (32) and bearing (33) from drive shaft (17), 00587719 *5.Lse Toalng (©) to remove ng 95), Remove 4} tom gear case (8) ‘bearing (34) 00587722 Imeeee 20 ove spring seat (36) and bearing (37) from housing (5). stration 24 s00807723 17. Remove seal (38) from drive housing (5). usteation 22 sp0se7724 18. To ensure correct assembly, mark the position of cover (39) in relation to motor trousiiny (3). Remove cover (39) and remove the O-ring seal from motor housing (3). ‘Mustration 23 419. Remove bolt (41) and rotor pinion (40) from the rotor in the motor housing10 Disassembly and Assembly Section ‘SENR6564-18 stration 24 900597726 20. Loosen bolt (43) and remove nut (42). Remove bearing (44) from rear end plate (4). Iyetention 75 24, Remove O-ring seal (46) and rear end piate (48). hateaion 26 901054287 22, Remove vanes (47) from rotor (48). Iestratin 27 * gooserr2a 23. Remove rotor (48) from motor housing (3). Imuetaon 28 900587780 24,Use a suitable press in order to remove bearing (49) and front ena pate (50) from rotor (46) as & unit. IMustration 29 007724 25. Remove bearing (49) from front end plate (50)SENRASAA.18 ‘Mestration 20 n0se7732 28. Remove washers (51) from front end plate (50). 1 Disassembly and Assembly Section " sors296i7 ig Motor - Assemble Assembly Procedure Table 2 Required Tools | Part Nantes | PartDescription | cry A_| 4P-1854 | Retaining Rina Piers 1. Plato 0.8 mm @ inches) x 102 2 mney som |? (0.25 inches) Toot noser73e 27.Remove O-ring seals (52) from rotor cylinder (53). ‘901008075 secration 32 28. Remove rotor cylinder (53) from motor housing 3). Remove O-ring seals (54) from rotor cylinder 38). [| qw-1807_| Retaining Ring Pers 1 Tube | OT mm (2.25 ind) n dlametee x8 mm (025 | 4 inch) thick wall x 203 mm @ inches) long 1P-0510 | Driver Group 28-3280 | Bearing Lubricant NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear end shortened component life. Note: Thoroughly clean all ofthe parts. Apply Tooling (F) to all of the bearings and the drive assembly. Before assembiy, coat all of the other parts with an SAE 10 grade of ol ® #108 iustration 33, Note: Check the O-ring seals for wear or for damage. Hf necessary, replace the O-ring seals.12 Disassembly and Assembly Section 4. Install O-ring seals (54) on rotor cylinder (53). Install rotor oylinder (63) into motor housing (2). Orient pin (55) of rotor cylinder (53) with slot (56) in motor housing (3). eel ‘0s86704 2. Install O-ring seal (52) onto rotor cylinder (53). IMesvaton 39 onnsaoas 3. Install rear end plate (45) on the shaft of rotor (48). p08 hnusreton 36 Note: Check the O-ring seal for wear or for damage. If necessary, replace the O-ring seal. 4, Inatell O-ring 2eal (46) over the shaft of rotor (48). ‘SENR6564-18 Mustration 37 ‘07054320 5. Install bearing (44) over the shatt of rotor (48). The bearing will fit into the rear end plate. eot0se324 stration 38, 6, Install 1uiur Glainp nut (42) on the siraft of rotor (48). Orient the shoulder of nut (12) toward the bearing, iustranon $3 g99seecor 7. Tighten the rotor clamp nut in order to obtain a clearance of 0.03 to 0.08 mm (0.001 to 0.003 inch) between the rear end piate and the rotor. Measure the clearance with a feeier gauge. Tighten hex. socket head bolt (43) into the rotor clamp nut. Measure the clearance again.SENRA5EA18 13 Disassembly and Assembly Section ‘ecratinn 40 o0seez07 Mustration 43 8. Install rotor (48) into rhotor housing (3). Align pin 11. Install washers (51) over the shatt ot the rotor (97) into the slot of the rear end plate. ‘onto the front end plate. a ‘Mesration 41 901084287 stration 44 gooseez2s & install vanes (47) into rotor (46). 12, Plave bearing (49) onto the front end plate. \masraion 42 ootosésar Mustation 45 enosseaas "201. sual front end plate (9U) onto rotor (48). Align 13. Use Tooling (E) and a suitable press in order to ‘=-all hole (58) of front end plate (50) onto rotor ‘complete the inetallation of bearing (19) : ae 9) ch)14 Disassembly and Assembly Section stration 46 ooseez27 114, Install rotor pinion (4U) with the nex head bolt. Tighten the bolt to @ torque of 120 N-m (80 Ib fi. SENR6564-18 Hustration 49 aseezs4 117. Use looling (V) with a suitable press in order to ‘complete the installation of the new ring. Mustraion 47 (20886230 Note: Check the O-ring seal for wear oF for damage. necessary, replace the O-ring seal. 15. Install O-ring seal (60) onto the rotor bearing that 's on the rear end plate. install cover (39) onto moter housing (3). ‘900588232 stration 48 4G. Install bearing (93) and new ring (32) onto crive ‘shaft (17). Mustration 50 7 Uy 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. 418, Install those parts into drive chaft (17): bolt (23), lockwasher (24). washer (25). bearing (26). driving clutch jaw (27), driven clutch jaw (28), spring (29), and cup ($0), Install nng (51).SFNRASBA-18 15 Disassembly and Assembly Section 21.Install O-ring seals (19) onto bulknead (16). crtion 54 se8242 poset ‘Macte: Check the O-ring séal for wear or for damage. aoe \f necessary, replace the O-ring seal, 22. Install bulkhead (18) onto piston (14). ‘3. Use Tooling (E) in order to install the seal into ‘pston (14). Ensure that the lip of the seal is Srented toward the outside of the piston. install ‘D-ring seal (22). stration 55 possess 23. Install dive gear (7) onto drive shaft (17). Tighten ie Bult (nol Shown) of the drive gear to a torque of 77 Nem (87 Ib ft), ‘tucraron 62 p0seents 22 lessiall piston (14) only the drive shaft (17). Install ‘ng (20) onto the piston. Mustration 66 24, Uce Tooling (E) in order to install the seal into ee drive housing (6). Ensure that the lip of the seal is esreicn 53 ni oriented toward the outside of the housing. ‘tesx=: Chook the © ring eeale for wear or for damage. \ "esessary, replace the O-ring seals.16 SENR6564-18 Disassembly and Assembly Section ‘stration 57 0eseezs7 25. Install bearing (37) nto the drive nousing. Improper assembly of parts that are spring loaded ‘ean cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equip- ment. 20. Install the drive gear, the piston, and the drive ‘shaft onto the return spring as @ unit. Install ring (15) over the piston. Place Tooling (©) detween te drive gear and tne piston. Use oe 8 cuitable prose in order to compress the return Mustration 58 eT spring. Install ring (18) into the groove of the drive housing. Siowly release the press. Remove Install spring seat (36) into the dnve nousing. Tooting (B). Mustration 59 g0ossezes stration 84 goosenz72 27. install return spring (16) onto the spring seat 28. Install bearing (34) into gear case (6). Use Tooling side Ure Urive housing. (C) in order to install the ring that retains the bearing in the gear cace.SI ng SENRASEA18 17 Disassembly and Assembly Section Bestration 62 een 30. Install drive housing (5) in gear case (6). Make Sure that the shaft on the end of the drive gear ie correatly engaged with tho bearing in the gear case. Tighten the bolts to a torque of 36 Nm (27 Ib ft). 31.Use Tooling (A) and install ring (8). amaneen O4 ‘wexe: Bolt (9) has left hand threads, SE rail these parts on the end of the drive sh ‘pren epring (62), epring cleove (61), drive pinion bolt (), and the washer. Tighten bolt (8) toa of 110 Nem (80 Ib ft). ‘stration 65 00598278 33. Install gear case (6) and drive housing (6) onto ‘over (3) a9 a unit. Tighten butts (4) evenly to a torque of 80 N-m (80 Ib ft). stration 66 34, Inctall the gacket, elbow (1), and bracket (2} on ‘motor housing (3). 35. After you verity that the starting motor operates ‘properly, attach the air lines to the starting motor, Verify the Operation of the Air Starting Motor Use the following procedure to verify that the air ‘starting motor is operating correctly: 4. 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. Tum the drive pinion in the opposite direction of the rotation of the starting motor. The drive pinion ‘must turn by hand. ‘Apply 945 KPa (50 psi) of air pressu af the drive housing The drive pi away from the drive housing and air must come ut ofthe outlet of the drive housing,18 Disassembly and Assembly Section 4. Plug the outlet of the drive housing. Apply. 1034 kPa (15U psi) in the inlet of ne drive housing, Ensure that no sir is leaking. Mcaoure 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 alt pressure, Measure the dimension ‘again. The dimension must bo 44.5 + 2.0 mm (4.75 + 0.08 inch). 5. Apply 620 kPa (90 psi) ot air pressure in the iniet Of ihe diive housing. The sterting motor must run smoothly End By: a. Install the air starting motor. Refer to Disassembly and Assambly, “Air Starting Motor - Install’ Air Starting Motor - Install SMCS Cada: 1451-012 Installation Procedure NOTICE Keep all parts clean trom contaminants. Contaminants may cause rapid wear and shortened ‘component life, Note: Several different air starting motors are available for use. The starting motors can have different configurations for the air tube assernblies. Cxamples of installing two different air etarting motors are provided below Installation of an Air Starting Motor Without the Air Tube Assemblie: Attached - etaton 67 ‘SENR6564-18 4. Attach a suitable lifting device to ir starung mutot (@). Thre weight of air starting motor (6) is approximately 48 kg (106 Ib) 2. Install a new gasket for the joint between the cover of air starting motor (6) and the flywheel housing. Position air starting motor (6). Inctall bolte (7). 3. Connect hose assembly (6). Mustration 68 4 install tube assemblies (4) and U-bolt (3). 5, Install bolts (2). &. Connect hoce aesemblies (1). Installation of an Air Starting Motor With the Air Tube Assemblies Attached tusvaion 08 o0etso40 1. Aitach a suitable lifting device to air starting motor (4). The weight of air starting motor (4) with the air Tube assemblies is approxittialely 66 ky (190 Ib).oF i SFNRAKA418 2. Install a new gasket for the joint between the cover of air starting motor (4) and the flywhiee! housing Position air starting rotor (4). install bolts (3). 7 2. Connect the tube aecemblios to elbow (2). & Connect harness assembly (1). iortzaase Electric Starting Motor - Remove and Install ‘SMCS Code: 1453-010 Removal Procedure 4 WarNinc Désconnect batteries before performance of any service work. inte: Before disconnecting the wires and electrical capies, mark the items for the proper connections in amter to ensure correct assembly. Marion 74 Snail *. Disconnect the wires and electrical cables from noid (1) and starting motor (2). 19 Disassembly and Assembly Section If the engine has two starting motors, disconnect Aire wires between Ure lwo solenoids and starting motors. 2. Attach a suitable hoist to the starting motor. The starting motor weighs approximately 30 kg (66 Ib). 3. Remove three halts (3). Remove the starting motor. Remove the gasket from the joint between the starting motor and the flywheel housing. Installation Procedure 4. Inspect the gasket for the joint between the. starting motor and the flywheel housing. Obtain a new gasket, if necessary. 2. Attach a suitable hoist to the starting motor. The starting motor weighs approximately 30 kg (66 Ib). ooseT Te istration 72 3. Place the gasket in the cover for the starting ‘motor. Lift the starting motor onto the mounting position. Install three bolts (3) 4. Conncot the wircs and clectrical cables to eolenoid (1) and starting motor (2). If the engine has two starting motors, connect the wires between tine lwo solenoids and starting motors. Alternator - Remove and Install SMCS Cod 405-010 Removal Procedure NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear and chortoned, ‘component life.20 Disassembly and Assembly Section SENR6564-18 stration 73 gee88021 4. Disconnect harness assemblies (2), (3), and (4) from alternator (6). 2. Loosen adjusting nuts (1) in order to provide slack for the belt. * goosssnzs Iustraton 75 1. Position alternator (5) on the support. install bolts (9) and (10) in order to hold alternator (5) in place. Bo not tighten the bolts at this fima 2. Install belt (8) on the pulley for the altermator. Iustration 74 poset 3. Remove nuts and washers (6) in order to remove belt guard (7). 4. Remove bett (8) from the pulley forthe alternator. 8, Remove boil (9) in order to disconect the altemator from the adjusting rod. 6. Remove bolt (10) in order to disconnect the alternator trom the support. Remove altemator (5). Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component lite. Wiateatinn 78 900880021 3. Adjust the belt tension. Refer to Specifications, Belt Tension Chart. In order to adjust the Delt tencion, turn adjusting nuts (1). Tighten adjusting ruts (1). 4, After the belt tension has been adjusted, install belt guard (7). Secure the bell guard lo bolls (9) and (10) with nuts and washers (6) 5. Connect harness assemblies (2), (3), and (4).| | | SFNRASRA-18 21 Disassembly and Assembly Section icaoeent7 Electronic Control Module (Engine) - Remove and Install SMCS Code: 1900-010 Removal Procedure NOTICE, 0p all parts clean from contaminants. ontaminants may cause rapid wear and shortened component if ‘Note: It the ECM is being replaced, download the personality module before you remove the ECM. Refer to Troubleshooting, “Replacing the FCM" ‘L Disconnect hamess assemblies (1). 2 Disconnect fuel hose assemblies (2). Immediately lace caps or plugs on the openings. 2 Support FOM (4), Remove bolts (3) & Remove ECM (4). - imstallation Procedure 1. Position ECM (4) on the engine. : 2. Install bolts (3) 3. Connect fuel hose assemblies (2). ‘4, Connect hamece accemblies (1). Fuel Filter Housing - Remove (Spin-on Filter) SMCS Gode: 1262-011 Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened ‘component life. NOTICE Care must be taken to eneure that fluide are contained during performance of inspection, maintenance, testing, adjusting and repair ofthe product. Be prepared to collect the fluid with suitable containers before open- ing any compertment or disassembling any compo ent containing Aids. Refer to Special Publication, NENG2500, “Caterpillar ‘Tools and Shop Products Gulde” for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates. 4. Shut OFT the fuel supply to the engine. NOTICE ‘Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a sultable cover over disconnected fuel system component.2 Disassembly and Assembly Section stration 70 gn10seeat 2, Disconnect tube assemblies (1) and tube ‘assembly (3) from fuel filter housing (2). 3. Remove bolts (4) that are located behind the fuel fiter housing 4. Remove fuel filter housing (2). vazranees Fuel Filter Housing - Remove SMCS Code: 1262-011 Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and, shortened component ii 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 open- ing any compartment or disassembling any component containing fluids Refer to Special Publication, NENG2500, ‘Caterpillar Dealer Seivice Tool Cateloy" for tools and supolies suitable to collect and contain fluide on Caterpillar products. Uispose of al tluids according to local regulations and mandates. SENR6564-18 41, Shut OFF the fuel supply to the engine, 2. Drain the fuel filter housing into a suitable ‘container for storage or for disposal. Refer to Operation and Maintenance Manual, “Fuel System ‘Secondary Filter - Replace” HT VIEW A-A. Iustration 80 gorsTs948 3. Disconnect sensor (4) and sensor (5). 4, Disconnect hose assembly (3). 5. Disconnect tube assembly (6) and tube assembly 0. 6. Attach a suitable lifting device onto fuel filter housings (2). The weight of fuel filter housings p) is approximately 30 kg (66 Ib). Remove bolts (1) 7. Remove fuel fter housings (2). Fuel Filter Housing - Remove SMCS Code: 1262-011 Removal Procedure : NOTICE Keep all parts clean from contaminants. ‘Contaminants may cause rapid wear and chortoned, ‘component life. 4. Shut OFF the fuel supply to the engine.am SENRG564-18 23 Disassembly and Assembly Section NONGE ‘Dare must be taken to ensure that fluids are contained Suring performance of inspection, maintenance, test- +5 adjusting and repair of the product. Be prepared to collect the fd with suitable containers before open- 2g any compartment or disassembling any compo sent containing fuide. Refer to Special Publication, NENG2500, “Caterpillar “ols and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of al fuids according to local regulations and daa es oosoess crenaates. 6. Disconnect tube assemblies (6). 2 Drain Ure fuel filer housing into a suitable container for storage or for diepossl 7. Remove bolts (6). 8. Attach a suitable lifting device onto fuel filter housing (4). The weight of fuel filter housing (4) is approximately 30 ky (6 Ib). Remove fuel filter housing (4). Fuel Filter Housi - Disassemble (Spin-on Filters) ‘SMCS Code: 1262-015 lena ar aves 7 NOT EG Ts eesonal injury can result from being struck by arts propelled by a released spring force. [Rake sure to wear all necessary protective equip- et, Fallow the recommended lure and use all secommended tooling to release the spring force. ‘2. Disconnect fuel pressure sensor (2). 4. Tisconnect hose assombly (3). 5, Femove cover (1). Disassembly Procedure Tables Required Tools Part Number A | 4az-o71A8 Tool Part Description | Qty Fitter Wrench 1 Start By: a. Remove the fuel fiter housing. Refer to Disassembly and Assembly, "Fuel Filter Housing = Remove”. b. Remove the fuel priming pump, if equipped. Refer 10 Disassembly and Assembly, “Fuel Priming Pump - Remove and Install” NOTICE Keep all parts clean from contaminants. ‘Contaminants may cause rapid wear and shortened ‘component life,24 Dicassembly and Assembly Section SFNRAS64-18 tmusiraion 83 spossezas 4. Remove bolts (1). Remove bracket (2) from the fuel filter housing. tration 84 2, Use Tooling (A) and remove fuel filters (3). ustton 85: 3. Remove bolts and nuts (4). 4, Separate adapter (5) and bases (6). Remove (O-ring seals (7) and (6) trom each base. Nota: Do nat disassemble valve (10). Do not change the setting of vaive (10). 5, Remove valve (10) and O-ring seals (8) from, adapter (6). Fuel Filter Housing - Assemble (Spin-on Filters) SMCS Gode: 1202-010 Assembly Procedure Tobie Required Tools ‘Tool_| PartNumber | Part Description | Qty A _| 187-2710 | Fiter Wrench 1 NOTICE Keep all parts clean from contaminants, Contaminants may cause rapid wear and shortened ‘component ie. Note: Inspect the O-ring seals before installation. Ifa seal is cut, scratched, or cracked, obtain a new seal for installation. To make installation easier. coat the bores for the seals with clean diese! fuel.aa SENR65A4.18 ‘900588248 1. Install O-ring seals (9) and valve (10) into adapter ©). 2. Install O-ring seals (7) and (8) into each base (6). 25 Disassembly and Assembly Section 4, Ensure that the sealing surface of the rfounting base is clean. Apply clean diesel fuel to the gaskets of new fusl fiters (3). Position fuel filters. (3). Use Tooling (A) and tighten fuel filters (3) until the gaskets contact the bases. Tighten fuel fiers (3) for an adattional one full turn (360 degrees). Do not overtighten fuel filters (2). 2 Assemble the fuel filter housing. Install bolts and nuts (4). ‘eosee2as 5. Position bracket (2) onto the fuel filter housing, Install botts (4) End By: 2. Inetall the fuel priming pump, if equipped. Refer to Disassembly and Assembly, “Fuel Priming Pump - Remove and Install”. b. Install he fuel filter housing, Refer to Disassembly and Assembly, “Fuel Filter Housing - Install. ieararaca Fuel Filter Housing - Install SMCS Code: 1262-012 Installation Procedure NOTICE Keep all parts clean from contaminants. ‘Contaminants may cause rapid wear and chortened ‘component life.26 Disassembly and Assembly Section VIEWA-A hasten 91 sora7a648 4. Attach a suitable iting device to fuel fiter housings (2). The weight of fuel fiter housings (2) {s approximately 30 kg (66 Ib). Posilion fue! filter housings (2) and inetall bolt (1). . Connect tube assembly (7) and tube assembly (6). . Connect hose assembly (9). 2 3. 4. Connect sensor (5) and sensor (4) $, Tum ON the fuel supply to the engine. 6 Remave the air from the fuel system. Refer to Operation and Maintenance Manual, “Fuel System ~- Prime". aos Fuel Filter Housing - Install (Spin-on Filters) if SMCS Code: 1262-012 Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. SENR6564-18 ‘ot08068 Muotration 02 1. Position fuel filter housing (2). 2. Install bolts (4) that are located behind fuel fier rousing (2). 3. Connect tube assemblies (1) and tube assembly 8). 4. Turn ON the fuel supply to the engine. voroseea Fuel Filter Housing - Install SMCS Code: 1262-012 Installation Procedure NOTICE ‘Keep all parts clean trom contaminants, Contaminants may cause rapid wear and shortened component life.SENRESE418 27 Disassembly and Assembly Section ‘Bestration 93, aan ‘tL Attach a suitable lifting device to fuel fitter nousing (4). The weight of fuel filter thousing (4) 'B approximately 20 kg (66 Ib). Position fuel filter housing (4) and install bolts (5). 2 Connect tube assemblies (6). — ‘2 nsall cover (1). & Connect hose aeeembly (3). . Connect fuel pressure sensor (2). - {%. Turn ON the fuel supply to the engine. RR the air from the fuel system. Refer to Testing and Adjusting, “Fuel System - Prime”. Fuel Priming Pump - Remove and Install ‘SMCS Code: 1258-010 Removal Procedure NOTICE Keep all parts clean from contaminants, Contaminants may cause rapid wear and shortened ‘component tife. . NOTICE Care mustbe taken to ensure that fuids are contained during performance of inepestion, maintenance, toct- ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any component containing fluids, Refer to Special Publication, NENG2500, “Caterpillar ‘Tools and Shop Products Guide" for tools and supplies: suitable to collect and contain fluids on Caterplliar products, Dispose of all fluids according to local regulations and mandates ‘1, Tum the tuel supply to the OFF position. Musiration 95 enesonsst 2. Remove bots (1) 3. Remove bolts (2). 4. Remove fuel priming pump (3). 5. Remove the gasket,28 Disassembly and Assembly Section Installation Procedure NOTICE Keep all parts clean from contaminants. Gontaminants may cause rapid wear and shortened ~ component life 0080055; stration 98 1. Position a new gasket and fuel priming pump (3). 2, Inctail bolte (2). 3. Install bolts (1). 44. Turn the fue! supply t Uns ON position waasor0e Fuel Transfer Pump - Remove SMCS Code: 1290-011 Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants way cause rapid wear and shortened component life. SENRAS&4.18 NOTICE ‘Care must be taken to cnoure thet fluids ere contained during performance of inspection, maintenance, test. ing, adjusting and repair ofthe product. Be prepared to collect the Tluid with suitable containers before open- ing any compartment or disassembling eny component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar ‘Too!s and Shop Progucts Guide" fortools and supplies suitable to collect and contain fiuids on Caterpillar products Dispose of al fluids according to local regulations and mandates, 4. Tum OFT the fuel supply to the engine. NOTICE Do not allow dirt o enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component. Mustration 97 haananail 2. Disconnect tube assembly (1). 3, Disconnect tube assembly (5). Disconnect tube assembly (4) that is hetween fuel transfer pump (3) and the fuel priming pump (if equipped) and/or the fuel filters. 4. Remove bolts (2) that hold fuel transfer pump (2) to the cover of the oil pump. 5. Kemove tuel transfer pump (3), the O-ring seal, and the drive coupling.(2) SENRESEAB love20r48 Fuel Transfer Pump - assemble ‘SMCS Code: 1256-015 Disassembly Procedure Sort By: & Remove the fuel transfer pump. Refer to Disassembly and Assembly, “Fuel Transfer Pump = Remove’ NOTICE ‘S220 all parts clean from contaminants. CGarzeminants may cause rapid wear and shortened s=mponent life. ‘orca 8 ‘1. Remove drive coupling (2) from the drive shaft. =move O-ring seal (1). sseersson 08 29 Disassembly and Assembly Section Matration 00 goroorise PCL) Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equip- ment, Follow the recommended procedure and use all recommended tooling to release the spring force. 2. Remove the following items from the bracket: cap &. washer (5), valve spring (4), and poppet valve Mustain 100 ooraor146 3. Remove bolts (7). Remove head (8) from plate (9).a 30 SENRESALAR Disassembly and Assembly Section ustration 104 ae Iustration 103 eorco7t9y 4. If check valve (10) will be replaced, remove the 6. Remove idler gear (12) and drive shaft (13) from ‘check valve from head (8). casing (14). Si stliiin é 9. I ee NAS “ HMI * Ses K 5 ‘Mustratinn 102 (901007788 Mustration 104 auiathnl 5, Remove plate (¥). Remove gasket (11), Remove 7. Remove casing (14) and sleeves (18) from bracke the Oving seal from the cide of the plate that is ~ (18), Remove the O-ting seal from casing (14). ‘opposite of gasket (11), if the bearings in plate (9) are damaged, the plate must be Teplaued. The beerings are onserviecable eeparately.1 ket ‘SENRESE+-18 6 a4 Disassembly and Assembly Section on [oa el testcation 105 en1007108 1 Remove gue ip sel (17) nd inner ip seal (18) from bracket (16). Moto: If the bearings in bracket (16) are damaged, ‘Be bracket must be replaced. The bearings are nonserviceable separately soseze749 Fuel Transfer Pump - Assemble ‘SMCS Code: 1256-016 Assembly Procedure Required Toole Poot [Partnumber | Part Description | Qty A | 1P-0510 Driver Group a NOTICE ‘Seep all paris clean trom contaminants. Contaminants may cause rapid wear and shortened samponent life. tustraton 108 0100708 4. Coat the lip seals for bracket (16) with clean engine oil, 2. Use Tooling (A) in order to install inner lip seal (18) and outer lip seal (17) into bracket (16). Note: If the bearings in bracket (16) are damaged, the bracket must be replaced. The bearings are nonservionable separately. IMustration 107 ‘gowworive 3. Install the O-ring scal onto casing (14). Inctall casing (14) and sleeves (15) onto bracket (16).20 ‘SENR6564-18 Disassembly and Assembly Section ” 28 Mlustretion 100 penny Mluctration 140. (901007954 4. Install idler gear (12) and drive shaft (13) into Note: Before you install check valve (10) in head 9 —— " 6. Install check valve (10) into head (8). i \ Ye 3) ~*~ RUPEE IEEE PILE VEEP WEPLLEELE AS CDF INNO g Ss t NO 4 / 6 l Mlustration 109, ae Note: If the bearings in plate (9) are damaged, the plate must be replaced. The beanngs are usration 111 nonserviceable separately. 7. Install haad (8) onta plate (9) 5. Install the O-ring seal into the side of the plate that is opposite of gasket (11). Install plate (9). Install 8, Install bolts (7). gasket (1).SENR6564-18 Mase aon 112 orcas Personal injury can resuit from parts andior cov- ex under spring pressure. ‘Spring force will be released when covers ara removed. ‘Be prepared to hold spring loaded covers as the ‘bois are loosened. ‘3. ‘otal the following items into the bracket: cap (6), ‘washer (5), valve spring (4), and poppet valve (3) herzer 13 gorournss O-ring seal (1). 33 Disassembly and Assembly Section 11. install drive coupling (2) onto the drive stiaft. End By: a. Install the fuel transfer pump. Refer to Disassembly and Assembly, “Fuel Iranter Pump - Install”. saoseio4 Fuel Transfer Pump - Install ‘SMCS Code: 1256-012 Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened ‘component life. Muctraton 114 00890571 4. Make sure that the O-ring seal is installed on fuel transfer pump (3). Position fuel transfer pump (3) conto the engine. Make sure thet the drive coupling is correctly engaged with the shaft of the engine cl pump. 2, Install bots (2) that secure fuel transfer pump (3) to the cover of the engine oil pump. 3. Connect tube assembly (4) that is between fuel transfer pump (3) and the fuel priming pump (it equipped) and/or the fuel fiters. 4, Connect tube assembly (5). ‘8. Connect tube assembly (1). 6. Turn ON the fuel supply to the engine.34 Disassembly and Assembly Section loessets Fuel Cooler - Remove and Install SMCS Code: 1712-010 Removal Procedure Start By: ‘a, Remove the fan. Refer to Disassembly and Assembly, "Fan - Remove and Install”, NOTICE Cate must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair ofthe product. Be preparedto collect the fluld with sultable containers before open- ing any compartment or disassembling any compo ‘nent containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog" for tuols and supplies: Suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids accoraing to local regulations and mandates, Fuel leaked oF spilled onto hat surfaces or elec- nts can cause a fire. To help pre- injury, turn the start switch off when iters or water separator elements. Cloan up fuel epille immedistoly. Noto: The cooling eyetom componente and weights may vary depending on your arrangement. 1. Tum the tue! supply to the OFF position station 135 eons 2. Disconnect hose assemblies (1). ‘SENR6564-18 3. Remove bolts (2) and fuel cooler (3). Installation Procedure ‘ovatsTis stration 116 1. Place fuel cooler (9) into position and install bolts 0) 2. Connect hose assemblies (1). ‘3. Turn the fuel cupply to the ON position, End By: a, Install the fan. Refer to Disassenibly aint Assembly, “Fan - Remove and Install". Air Cleaner - Remove and Install SMCS Code: 1051-010 Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid weer and shortened ‘component life, Note: Several differont types of air cleaners are available. The following procedures describe the removal and installation of a typical air cleaner.SENR6564-18 ration 117 0 ‘L Loosen clamps (1). Remove cover (23) and the ‘seal for the cover. flinte: For information on servicing the air cleaner ements, Refer to the Operation and Maintenance IMtsnual for the engine that is being serviced. 2 Remove the air cleaner olament. Loosen clamp (2) 44, Disconnect harness assembly (4). 5 Aztach a lifting device to air cleaner housing 3, The weight of air cleaner housing (5) is zpproximately 27 kg (60 tb) '& Remove bolts and washers (6) that attach air ‘deaner housing (5) to the bracket. Remove ait cleaner housing (6) lmstallation Procedure NOTICE ‘zee ail parts clean from contaminants. ‘Tomeminants may cause rapid wear wid shortened erponent life 35 Disassembly and Assembly Section 1. Attach a suitable iting device to air cledner housing (5). The weight of air cleaner housing (5) is approximately 27 kg (60 th). 2. Position air cleaner housing (5) on the air inlet of ‘the turbocharger. Install bolts and washers (6) that attach air cleaner houeing (6) to the bracket. 3. Install clamp (2). 4, Connect hainess assembly (4). Note: Before you install the air cleaner element, inspect the air cleaner element for cleaniiness and ‘good conatton. ' 55. Inctall the air cleaner alement 6. Inspect the seal of cover (3) for cleanliness and good condition. Install cover (3) with the sez Fasten clampe (1). Turbocharger - Remove (Center Mounted Turbocharger) SMCS Code: 1052-011 Removal Procedure NOTICE keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component ite. NOTICE Care must be taken to ensure that ulds are contained during performance of inepection, maintenance, teet- 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- Refer to Special Publication, NENG2500, “Caterpillar ‘Tools and Shop Products Guide" for tools and supplies suttable to collect and contain fluids on Caterpiiar products. Dispose of all fluids according to local regulations and mandates. 11. Drain the coolant trom tne cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change”.36 Disassembly and Assembly Section Musteation 110. oer! 2. Cut the wires in order to remove shield (1) from the connection of air inlet tube (2) and the turbocharger. Also, remove shield (1) from the connection of air inlet tube (2) and the air cleaner station 120 3, Looeen clampe (3) at both ends of air inlet tube (2). Mustraion 121 4, Remove nute (4) and the waehere, 5. Attach a suitable lifting device onto air inlet tube (2). The weight of air inlet tube (2) 1s approximately 23 kg (50 Ib), 6. Remove U-bolts (5) and supports (6). SENR6SAA.18 7. Remove air inlet tube (2) from tile turbocharger and from the ait cleaner stration 122 n0stssz= 8, Remove hose assembly (7). Mustraton 123 06r963t 9. Remove clamp (8) that attaches tube assembly (9) to the cylinder head. 10, Remove bolts (10). Remove tube assembly (8). DOA ss 11, Remove bolts (11) that attach turbocharger (12) to the altercooler nousing.38 Disassembly and Assembly Section SENR6584-18 Mustration 128 goostorzs 6. Kemove tube assembly (8). IWustration 190 soostseae 7. Remove cover (9). Disconnect thermocouple (10). 8. Remove the remaining shields from the turbochargers. msravon 131 ae 9, Remove bolts (11) from the exhaust inlet to the turbocharger. 40. Disconnect tube assembly (12). 11. Remove bolts (13) from the air outlet of the turbocharger. IMustration 132 sovere4se 12. Attach a suitable lifting device onto turbocharger (15). The weight of turbocharger (15) is approximately 65 kg (143 Ib), 413. Remove bolts (14) that attach turbocharger (15) to the exhaust elbow. Remove turbocnarger (19). inzaaras Turbocharger - Remove (Rear Mounted Turbocharger) SMCS Code: 1052-011 Removal Procedure Start By: a. Remove the air cleaner. Refer to Disassembly and Assembly, “Air Gleaner - Remove and Install’. NOTICE, Koop all parte clean from contaminants, Contaminants may cause rapid wear and shortened component ite, NOTICE are must be taken to ensure that fluids are contained during performance of inspection, maintenanuy, testing, adjusting and repairof the product. Be prepared to collect the fluid 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 anc mandates.SENRGSEA-18 +t. Drain the coolant from the cooling system into 2 sultable container for sturage ut fur disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change”. ta) poveones ‘Z. Diseonnect hase assemblies (1) and (2). 3k Disconnect tube assemblies (4) Remove tube assemblies (3), IRRELRE consas 52> a suitable lifting device to turbocharger (5). " waight of turbocharger (5) is approximately 7 I), Remove Dons (6). 39 Disassembly and Assembly Section 5. Remove bellows assembly (7) from exhalust elbow (8) and turbocharger (5). 5 9 Mstraton 136 ‘sorteeeor 6. Remove bolts (11) ard nuts (10). 7. Remove turbocharger (5) and gasket (9). voestas Turbocharger - Disassemble ‘SMCS Code: 1052-015 Disassembly Procedure ‘start By: a. Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove". NOTICE Keep all parts clean trom contaminants. Contaminants may cause rapid wear and shortened component life. Note: Different turbochargers are available for use with 3500B Engines. For some of the turbochargers, only te cartridge Is serviced. Further disassembly ie not possible.40 Disassembly and Assembly Section Hustraton 138 4. Mark the three turbocharger housings for alignment upon assembly. 2, Disconnect tube assembles (1) and (2). 3. Remove bolts (3) and (5) i 4, Remove turbine housing (4). 5. Use two people in order to remove cartridge assembly (6) from compressor housing (8). The weight of cartridge assembly (6) is approximately 30 kg (/0 ID). 6. Remove boits (7) SENR6564-18 Turbocharger - Assemble SMCS Code: 1052-016 loxesi715 Assembly Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened ‘component iif. Different uroochargers are available for use with 35008 Engines. For inetructions and torques for ‘your specific turbocharger, see the Specifications, “Tutbocnarger topic, The flowing procedure describes the assembly of a typical turbocharger. Note: Obtain new coals for aecembly. Thoroughly clean all of the parts. Unless other instructions are provided, coat the parts of the cartridge with clean ‘engine oil Iustration 139 991084008 1. Ensure that the following parts are aligned omeclly uporr assembly. lusLine housing (4), cartridge assembly (6), and compressor housing (8).eV SENRS564-18 a Disassembly and Assembly Section sien 140 2 Install bolts (7). 3 Use two people In order to install cartridge ‘aceombly (8) in compreceor housing (8). The weight of cartridge assembly (6) is approximately 30 kg (70 Ib). 4 Install turbine housing (4). install bolts (3) and (5). Refer to Specifications, “Turbocharger’ for the correct torque. & Connect tube assemblies (1) and (2). ‘End By: ‘& ‘nstall the turbocharger. Refer lu Disassembly and Aecombly, “Turbocharger - Inctall". ‘oenizoes ‘Turbocharger - Install (Rear Mounted Turbocharger) ‘SMCS Gode: 1052-012 ‘mstallation Procedure Tame = Required Tools Part Tool__Number Part Description | Qty + __4¢-5597_| Anti-Seize Compound 1 NOTICE Keep all perts clean from contaminants, Contaminants may cause rapid wear and shortened ‘component life. Note: Inspect the O-ring seals before instalation. Ifa ‘seal IS CUL, scratched, oF cracked, obtain a new seal {or inetallation, Hustration 141 41. Altech 2 suitable lifting device onto turbocharger (15). The weight of turbocharger (15) is approximately 65 kg (143 Ib). Apply Tooling (A) 10 bolts (14). Position turbocharger (15) and inotall bolts (14). Tighten bolts (14) to a torque of ‘544+5Nem (40 + 4 lb ft). masraton 142 2. Install bolts (13) 3. Connect tube assembly (12). 4. Apply Tooling (A) to bolts (11). install botte (14) and tighten bolts (11) to a torque of 54 #5 Nm (40 £4 tb fy). ‘5. Install te shield assemblies for the turbocharger and start the bolts. However, do not tighten the bolts until the shield assemblies are properly aligned‘SENR8564-18 Aateation 148 posts42 stration 146 00818997 6. Connect thermocouple (10). Install cover (9). 9. Install shield (4). 10. Attach tube aesembly (6) to both of the turbochargers. Install clamp (6). Mhatetion 144 00618423 T. Install tube assembly (8). smustravon 147 900810278 11. Position top of shield (2). Install bolts (1) and (3). 12. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, “Coulony System Coolant - Change". End By: ‘2. Install the air cleaner. Refer to Disassembly and Assembly. "Air Cleaner - Remave and Install” Iiyeeaion 145, 06 18408 8. Install tube assembly (7).SENRSSE4-18 Turbocharger - Install {Rear Mounted Turbocharger) ‘SMCS Code: 1052-012 installation Procedure me? Required Tools Part oot | Number Part Doscription | Qty | sP-0801 | Ani-Seize Compound = NOTICE scp all parte lean from contaminante. ‘Cantaminants may cause rapid wear and shortened ‘camponent ite aa3On 165 Peer |, dizach a suitable lftina device to turbocharaer (5). | The weight of turbocharger (5) is approximately 35 kg (77 Ib). Apply Tooling (A) to the threads of ‘Gots (11) and the bearing surfaces. Install gasket 1). Position turhacharger (5) an the engine seal bolts (11) and nuts (10). Use the following procedure in order to tighten nuts (10): ‘2 Tighten all of the nute on the joint to a enug fit. = Tighten one nut to a torque of 54 + 5 Nm 2404 ib ft). Tighten the diagonally opposed nut to 2 torque 3f 54 +5 Nm (40 + 4 Ib ft. ‘= Tighten the remaining nuts to a torque of 542.6 Nim (40 £4 Ib ft). Repeat Steps 1.b to 1.4. " 43 Disassembly and Assembly Section ‘Muatraton 440 conta90e8 2. Apply Tooling (A) to the threads of botts (6) and the bearing surfaces. Position bellows assembly (7) on exhaust elbow (6) and tuibudtrarye: (5). 3. Install bolts (6) and tighten the bolts to a torque of 5445 Nem (40 £4 Ib ft, 01199087 4. Install tube assemblies (3). Connect tube assemblies (4), Mustration 45 5. Connect hose assemblies (2) and (1).44 Disassembly and Assembly Section 6. Fill the cooling system with coolant. Refer to ‘Operation and Maintenance Manual, “Covlong System Coolant Change” End By: ‘stall Uwe ait leaner, Refer to Disassembly and Assembly, "Air Cleaner - Remove and Install” Turbocharger - Install (Center Mounted Turbocharger) SMCS Code: 1052-012 Install Table 8 in Procedure Required Tools Part Tool | Number ‘a | ac-5507 Part Description | Qty NOTICE Keep all parts clean from contaminants, Contaminants may cause rapid wear and shortened component iife, Note: Inspect ite O-1iny seals before installation. Ife eal ie cut, scratched, or cracked, obtain a new seal for installation. sustain 152 00618585 4. Apply Tooling (A) to bolts (13). Attach a lifting Gah tadechorger (13) the weight ct turbocharger (12) Is epproxiniataly 01 kg (194 Ib). Position turbocharger (12) and install botts (13). Tighten bolts (13) to a torque of 54 + 5 Nem (40 #4 Ib ft SFNRAS564-18 Imusteation #52 ores 2. Install bolts (11) that attach turbocharger (12) to the aftercooler housing. Mustration 154 ao 3. Install tube assembly (2). Install bolts (10). Install clamp (8) that attaches tube essembly (9) to the eylinder head Mustration 155 ere8t0 NOTICE A damaged hase assemily will reduice the service life of the turbocharger. Do not twist the hose assembly. To help prevent damage to the hose assembly, orient the position of the fuse esseinbly filing un the tur bocharger hofore you inetall the hose assembly.| sausrsicn 157 SENRE564-18 & Install hose assembly (7), emerson 458 01058625 &, Attach a suitable lifting device to air inlet tube (2). ‘The weight of ar inlet tube (2) 's approximately 23 kg (60 lb). Position air inlet tube (2) between ‘Fe turbocharger and the air cleaner. © ‘nstall supports (6). install U-bolts (5), nuts (4) and Tee westiers. 00519523 ™. iestall clamps (3) that attach air inlet tube (2) to shacharger 45 Disassembly and Assembly Section 8, Use wires to install shield (1) around thé connection of air inlet tube (2) and the turbocharger. 9. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change’ Aftercooler - Remove and Install ‘SMCS Code: 1063-010 Removal Procedure Table 9 Required Tools Toot | PartNumber | Part Description | Oty ‘A [100-7870 _| Link Drocket 2 NOTICE Keop all parts clean from contaminants. Contaminants may cause rapid wear and shortened ‘component ite. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair afthe product Re prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any component containing fluids. Refer to Special Publication. NENG2500. ‘Caterpillar ‘Tools and Shop Products Guide" for tools and supplies: suitable to collect and contain fluids on Caterpillar products. Dispose of al fluids according to local requlations and mandates. Note: Different designs of aftercoolers are available for different applications. The following procedures doseribe the removal and installation of a typical aftercooler. Note: Ine 35U8E and 35128 Engines nave one aftercooler. The 3516D Engines have two aftercoolers. The following procedures describe the ‘removal and installation of only one aftercooler. 4, Drain the coolant from the cooling system into suitable container for storage or for diepocal Refer to Disassembly and Assembly. “Cooling ‘System Coolant - Change”.46 Disassembly and Assembly Section SFNRG564-18 00sor408 usteation 159 2. Remove tube assembly (1). Cap the openings and/or plug of the openings. HWustraton 160 sncgorsoe 3, Remove tube assemblies (2) tat are between the air inlet cover of the aftercooler and the turbochargers. stration 161 eer04s0 nnact tube assemblies (3) fram the ands of the aftercooler core. One tube is atthe front and ‘one tube is for the rear. ustraion 162 5. Install Tooling (A) into the top of air inlet cover (4). 6. Attach a suitable lifting device onto Tooling (A). The weight of air inlet cover (4) is approximately 11 kg (24 Ib). Remove bolts (5). Remove air inlet cover (4) Note: Re careful not to damage the fins of the attercooler core. otretion 169 poset 7. Attach a suitable lifting device onto aftercooler ‘core (6). The weight of aftercooler core (6) is approximately 37 kg (62 Ib), Lift aftercouler core, (6) from the air inlet manifold. Installation Procedure Toble 10 Required Tools Tool Part Part Description | aty Number A_| 198-7578 | Link Bracket L2_ NOTICE Keep all parts clean trom contaminants. Contaminants may cause rapid wear and shortens ‘component life.SENRE564-18 - Note: Be careful not to damage the fins of the ‘=e rv00ler core. ). maszaton 164 esosorert ‘tL Inspect the top O-ring seal and the bottom j O-ring seal of aftercooler core (6) If a seal is. t ‘cut, scratched, or cracked, install a new seal. ‘Temporarily secure the bottom seal with tape. Make sure that the tape can be removed after the aftcroooler core ie inetalled. Do not ues an adhesive, a silicone lubricant, or any other ‘ubricant for retention of the seal. © Altacit a suilable ling device onto aftercooler +0r0 (6). The weight of aftercooler core (6) is approximately 37 ka (82 Ib). Position aftercooler ore (6) onto the air inlet manifold. Ensure that the bottom seal is properly scated. stall Tooling (A) in the top of air inlet cover (4). tach 2 suitable lifting device onto Tooling (A) Qty “Se weiaht of ar inlet cover (4) is approximately - eg 4b) 2. 4, =zition air inlet cover (4) onto the aterooolor ure thatthe seal is seated between air inlet Soret (4) ad the aftercouler core. tones . ~sll bolts (5). Hand tighten bolts (6). 47 Disassembly and Assembly Section iustration 166 gour474a7 Bolt tightening sequence for engines with one aftercooler (A) Front ofthe engine Iustration 167 0077429 Bolt ghtening sequence for engines with two aftercoclers (A) Front ofthe engine 66. lighten the bolts in the numerical sequence to a torque of 24 Nm (16 Ib ft. 7. Tighten the bolts in the numerical sequence to a torque of 47 N-m (35 Ib ft). 8. Romove the tape from the bottom eal. stration 188 ©. Inopect the O-ring ocale for tube aecomblcc (8). f a sealis cut, scratched, or cracked, install a new sseal. Connect tube assemblies (3) to the ends of the aftercooler core. One tube is for the front and ve lube for Une rear48 Disassembly and Assembly Section istration 409 soneare 10. Inspect the O-ring seais for tube assemblies (2) ifa seal is cut, scratched, or cracked, install & new seal, Install Lube assemblies (2) between the air iniat cover of the aftercooler and the turbochargers. stration 170 onnantane 41. Inspect the O-ring seals for tube assembly (1). If ‘a seal is cut, scratched, or cracked, install a new seal. install tube assembly (1). 42. Fill the cooling system with coolant. Refer fo the ‘Operation and Maintenance Manual, “Eooling ‘System Coolant - Change”. iozsanre 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’. SENRASAA8 NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. ‘stration 171 seoseesed tne exnaust neat sniela nas been removed for potograpiic purposes 1. Remove bolts (1) and the washers. Pry flanges (2) om tie elbows away from the air inlet manifold. Each cylinder has one elbow for inlet air Remove bolts (3). Nustration 172 00580880 3. al suitable lifting device to air inlet manifold (4). + Air inlet manifold (4) for a 3508R Engine weighs: approximately 49 kg (108 Ib). * Air inlet manifold (4) for a 35126 Engine weighs ‘epproximately 55 kg (121 Ib). * Air inlet manifold (4) for a 3516B Engine weighs approximately 94 kg (207 Ib). Romove air inlot manifold (4) |SENRGSEA-18 installation Procedure NOTICE ‘Keop all parte clean from contaminants, ‘Contaminants may cause rapid wear and shortened emponent life. ‘msramon 173 — 1% Alta a suitable litina device to sit inlet manifold ~ Air inlet menifold (4) for @ 9508B Engine weighs approximately 49 kg (108 tb) + Air inlet manifold (4) for a 3612B Engine weighs ‘approximately 65 kg (121 Ib). + Air inlet manifold (4) for a 3516B Engine weighs approximately 94 kg (207 Ib). air inlet manifold (4) onto the engine. ‘aaron 174 ‘gnc example “, mrsnall bolts (9). “u. IPScect the O-ring seals for flanges (2). Ifa seal is, ‘scratched, or cracked, install a new seal. 49 Disassembly and Assembly Section 41. Use washers and bolts (1) to install flangés (2) for the elbows. Each cylinder has one elbow for inlet air. End By: a. Install the aftercooler. Refer to Disassembly and Assembly, “Aftercaoler - Remove and Install’ ieeosae Exhaust Elbow - Remove and Install ‘SMCS Code: 1060-010 Removal Procedure Table 11 Required Toots Toot_| Part Number | Part Descrintion | Qty A__|_ 130-7573 | Link Bracket 2 ‘Start By: ‘a. Remove the turbochargers. Refer to Disassembly and Assembly, “Turbochager - Remove’. NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear and shortened ‘component Ife fy We ‘900615014 41, Install Tooling (A) in the top of exhaust elbow (1). Attach a suitable lifting device onto Tooling (A). ‘The weight of exhaust elbow (1) is approximately 4B kg (106 Ib). 2, Remove bolts (2). Lift exhaust elbow (1) from the engine.50 Disassembly and Assembly Section SENRAS64-18 006 016 Muetration 178 | 3. Remove the bolt and clamp (3). Remove bolts and clamps (4) rom each end of tube assembly (6). Romove tube aocombly (6). Inepect the ceale at the end of tube assembly (5). If the seals are damaged or deteriorated, obtain new seals for assembly, "900618017 4, Attach a suitable lifting device onto support bracket (7), The weight of support bracket (7) is approximately 117 kg (257 lb). Position eupport bracket (7) onto the engine. 2, Install bolts (6). 0a6ts017 Itstraton 477 4, Attach a suitable lifting device onto support bracket (7). The weight of support bracket (7) is approximately 117 kg (287 Ib). 5. Remove bolts (6). Remove support braeket (7). Installation Procedure Table 19 Required Toole Toot | PartNumber | Part Description | aty A__| 188-7578 | Link Bracket 2 NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. ‘ssension 179 00818016 Note: Ensure that the seals are installed in the ends of tube (5). 3. Position tube assembly (5) and install bolts and clamps (4) onto each end of tube assembly (5). Install the bolt ana clamp (3). stration 180 oostsore018 SENRESE4-18 4, Install Tooting (A) in the top of exhaust elbow (1) Attach a suitable liting device onto Tooling (A). “The weight of exhaust elbow (1) is approximately 48 kg (106 fb). Position exhaust ellow (1) 5. Install bolts (2) End By: a. Install the turbocharger. Refer to Disassembly and Assembly, “Turbocharger - Install’ soane020 Exhaust Manifold - Remove and Install SMCS Code: 1059-010 Removal Procedure Start By: a Remove the aftercooler. Refer to Disassembly and Assembly, “Aftercooler - Remove and Install”. '& Remove the air inlot manifold. Refer to Disassembly and Assembly. “Air Inlet Manifold - Remove and Install”. NOUCE Heep all parts clean from conteminants, ‘Contaminants may cause rapid wear and shortened component life. Note: is possible to remove the exhaust manifolds ‘wmout removing the air inlet manifold fist. However, he procedure is more difficult. The aftercooler ‘rast be removed before the exhaust manifolds are semoved, thutration 184 p0stes79 *. Remove bolts (1) and the washers from heat shield (2). 54 Disassembly and Assembly Section 2, Remove heat shield (2). tuetraton 162 20616500 3, Remove nuts (3) and the bolts that attach the ‘exhaust manifold to the elbow for the turbocharger. Remove the gasket Mystraton 183, goveresrs 4. Remove bolts (4), the nuts, and the washers that attach the exhaust manifold ta the cylinder heads. Remove gaskets (5). mustraton 104 0018635 5. atach a suitable lifting device to exhaust manifold62 Disassembly and Assembly Section Exhaust manifold (6) for 35088 Engines weighs ‘approximately 78 Kg (170 ID). Exhaust manifold (6) for 35128 Engines weighs approximately 125 kg (975 lb) Fxhaust manifold (6) for 35168 Engines weighs approximately 154 kg (340 Ib). 6. Lift extraust inanifuld (6) from the engine. Installation Procedure Table 13 L Required Tools Part Tool | Number Part Description Qty A_|_ 40-5597 _| Anti-Seize Compound 1 NOTICE keep all parts clean from contaminants. Contanuinants way cause rapid wear and shortened ‘component life, station 185 eee 1. Attach a suitable liting device to exhaust manifola ©). Exhaust manifold (6) for 3508B Engines weighs approximately 78 kg (170 Ib). Exhaust manifold (6) tor 35128 Engines welghs approximately 125 ky (276 Ib). Exhaust manifold (6) for 3546B Engines weighs approximately 154 kg (340 Ib) Position exhaust manitold (6) onto the engine. SENRB564-18 mustraton 186 00s 8818 3, Install new gaskets (5) for the joints between the exnaust manifold and the cylinder heads. Apply Tooling (A) to bolts (4). Install bolts (4), the mute, and the washers that attach the exhaust manifold to the cylinder head. Tighten bolts (4) to a torque of 55 +5 Nm (4124 Ib fi) lueteation 487 4. Install a new gasket for the joint between ‘We exhaust manifold and the elbow for the turbocharger. Apply Tooling (A) to bolte (3). Install balts(3) and the nuts. Tighten bolts (3) in ‘a diagonal pattern simultaneously to a torque of 55 +5 Nm (41 + 4 lb ft). usteaon 48R soneSENR6S64 18 5. Install heat shield (2) 6. Inatall bolts (1) and the washers for heat ahield (2) End By: listall the air inlet manifok, Refer to Disassembly ‘and Ascembly, “Air Inlet Manifold - Remove and Instalt’ b, Install the aftercooler. Reter to Disassembly and ‘Assembly, “ARtercooler - Remove and Install” Expansion Tank - Remove and Install SMCS Gode: 1354-010 Removal Procedure Tei 4 Required Tools Toot | PartNambor | Part Description | yy A | 130-7579 [Lik Brace z NOTICE Keep all parts olean 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 ofthe product. Be prepared to collect the fiuid with suitable containers before open- ing any compartment or disassembling any component containing fluids. o Refer to Special Puiblicatinn, NENG2500, “Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local reaulations and mandates. 1. Drain the coolant from the expansion tank into a Suitable contalner for storage or for disposal. 58 Disassembly and Assembly Section thsteation 420 2, Remove bolts (2) and the washers. Carefully slide flange (1) down tube (3). staan 190) ooseense 3. Remove bolts (4), elbow (6), and tube (3). stration 104 ot0ses 4, Remove bolts and washers (6). Remove flanges (6) and tubes (7)54 Disassembly and Assembly Section SFNRG564-18 ration 192 00598056, 5. Remove bolts (9) from the top of the expansion lank, Install Tooling (A) in the holes. 6. Attach a suitable lifting device onto Toolina (A). ‘The weight of the expansion tank is approximately 209 kg (460 ID} steaion 194 00sev086 4, Remove bolts (9) from the top of the expansion tank, Install Tooling (A) in the holes. 2, Attach a suitable iting device onto Tooling (A\. The weight ofthe expansion tank is approximately 209 kg (460 Ib). 0t0sec0# Austeation 193 7. Remove bolts (10) and the washers. Remove expansion tank (11), Installation Procedure Toble 15 Required To's Toot | PartNumber | Part Description | Qty A 198-7573 _| Link Bracket 2 NOTICE Keep all parts clean from contaminants, ‘Contaminants may cause rapid wear and shortened component life Imustration 195 ‘ot056804 3. Position expansion tank (11) and install bolts (10) and the washers 0586056 tustration 196 4. Remove Tooling (A). Install bolts (9) in the holes.SENRE564-18 55 Disassembly and Assembly Section shawraion 197 sot08se78 & Inspect the seais for flanges (8). Obtain new seals, i necessary. Lubricate the bores of flanges (8) figiily wilh ylyverin, Inset the seals into flanges °8). Install flanges (8) and tubes (7) with bolts (6). muaeraon 188 al & ‘repeet the O ring coal for tube (3). Obtain 2 now Suing seal, if necessary. Lubricate the bore of 0) bow (6) lightly with glycerin. Insert the O-ring ‘==21 into the bore of elbow (5). insert tube (3) into ag Bebe ofeow (0 | TL spect the seal forthe joint between elbow (6)and ‘re water pump. Obtain a new seal, if necessary. ace the seal onto the flange of elbow (5). Fasten ‘Bow (5) to the water pump with bolts (4). jes. tration 100 8. Inspect the gasket for the joint between flange (1) ‘and the expansion tank. Ubtain a new gasket, if necessary. Insert the gasket into flange (1). Carefully slide flange (1) up tube (3). Fasten flange(1) with bolts (2) and the washers. 9, Fl ie expansion tank to the Correct level proper coolant to uee, refer to the Operatic Maintenance Manual for the engine that is being serviced, 081080 Water Temperature Regulators - Remove ‘SMCS Code: 1355-011 Removal Procedure ewe 16 Required Tools Toot | Patt Part Deseriotion | Qty Number ‘A_| 136-7573 | Unk Bracket z NOTICE Keep all parts clean fom contaminents. Contaminants may cause rapid wear and shortened ‘component life.56 Disassembly and Assembly Section SENR6564-18 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 open- ing any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Caterpillar “Tools and Shop Products Guide” 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 cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change’. Drain the cooling system unti the level Of the coolant is below the exhaust manifolds. ‘mustraton 200 oon 2. Disconnect tube assembly (1) from the water temperature regulator housing. 3. Disconnect tube assemblies (2) from the water temperature regulator housing, tustration 202 ‘Typical example 4, Attach Tooling (A) and a suitable lifting device to water temperature regulator housing (4). Remove bolts (3), Remove water temperature regulator housing (4), ustraton 203 oposeT98 5. Remove water temperature regulators (6). Remove gasket (6) Visually inspect ferrule (7) and the seals for water temperature regulators (5). Obtain new parts for assembly, if necessary. soxeese75 Water Temperature Regulators - Install ‘SMCS Code: 1355-012 Installation Procedure Table 17 Required Toots Toot | PartNumber | Part Description | Qty [A_| 198-7573 |UnkBrecket | 2 8 221-0647 | SealinstallerGp | 1SENR6S64-18 NOTICE \ all parts clean from contaminants. ‘Sarteminants may cause rapid wear and shortened onent life. : 5 aoioseeb6 O-ring seals (4) and (5) 65 Disassembly and Assembly Section 2. Remove bolts (2) and gear (3) from shaft (1) sustraton 236 tent 3. Remove adapter (6) and adapter (7) from the housing. Remove the O-ring seal from adapter (7). Wustation 287 paiaieaes 4, Remove bolt (8) that holds impeller (9) on the shaft. station 23865 Disassembly and Assembly Section Personal injury can result from parts and/or covers under spring pressure. ‘Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened. 5. Use Tooling (A) in order to remove impeller (9) from the shaft. istration 230 ca 6. Remove spring (11) from carbon seal assembly (12). Remove carbon seal assembly (12) from shaft (10). DOIOS8815 Wustration 240 7. Remove bolts (13) that hold retaining washers (14) con the housing. Remove shaft (1) and washers (14), SENR6S64-18 istration 265 ‘oven 8. Remove bolts (15) that hold the shims and retaining washers (16) on the housing. Remove shaft (10), the shims, and washers (16) Mustration 242 one 9, Remove lip seal (17) from the housing. Mustration 243 o08ebes 10. Remove bearing (18)3 srosases Water Pump (Separate Circuit Aftercooler) - Assemble SMCS Code: 1363-016 Assembly Procedure “aie 22 B | 1P-0510 NOTICE ‘Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. aon 245 sonieati Ensure that the oil hole in bearing (18) is aligned with the oil passage in the housing. Use Tooling 8) and a suitable press in order to install bearing (18) in the housing. Bearing (18) must be 5 +.0.5 mm (0.06 + 0.02 inch) below the surface of the housing. The diameter of bearing (18) must 5¢ 75.000 + 0,055 mm (2.9527 + 0.0022 inch) er installation 67 Disassembly and Assembly Section tmustration 247 soroeeess 2. Lubricate the bore for lip seal (17) with clean ‘engine oil. Use Tooling (8) in order to install lip ‘seal (17) into the housing. Ensure that the lip of ‘seal (17) is toward the bearing, Imustration 248 shomeat 3. Install shaft (10). install retaining washers (16). the shims, and bolts (15) that hold shaft (10) in the housing68 Disassembly and Assembly Section SENR6564-18 Itustration 248 een 4. Lubricate the bearing in the housing with clean engine oil. Install shaft (1) and retaining washers (14), Install bolts (13) Hustaion 250 aeons 5. Place clean water on the inside diameter of carbon seal assembly (12) for lubrication. Use hand pressure and the too! that is supplied with the seal group in order to install carbon seal assembly (12). The face of carbon seal assembly (12) should make light contact with the shaft. tMystration 261 eee 6, Install spring (11) on shaft (10) and on carbon seal assembly (12) tmustration 262 ntoieses POG 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 impelier (9). Install bolt (8) and the washer. Tighten bolt (8) to a torque of 38 + 4 Nim (28 3 Ib f), Mustration 253 seep Note: Check the O-ring seal for wear or for damage. If necessary, replace the O-ring seal 8. Lubricate the bore for the O-ring seal with glycerin, Install the O-ring seal on adapter (7). Position adapter (7) in the housing and install adapter (8),cso 69 Disassembly and Assembly Section mesration 254 enna: mote: Check the O-ring seals for wear or for damage. Trecessary, replace the O-ring seals. % Position gear (3) on shaft (1) and install botts (2). Lubricate the bores for O-ring seals (4) and (6) with clean engine oil. Install O-ring seals (4) and 5) in the housing, ed By: & install the water pump. Refer to Disassembly and Assembly, “Water Pump (Separate Circuit Afercooler) - Install” snoesees Water Pump (Separate Circui Aftercooler) - Install SRC Code: 1263-012 installation Procedure se 23 Required Tools sol | PartNumber | _ Part Description & : 3/8 x 3 in guide pin 2.| NOTICE ==p all parts clean from contaminants. minants may cause rapid wear and shortened nent ie ‘mystration 255 41, Install Tooling (A) in the holes for mounting bolts (4). 2. Attach a suitable lifting device onto water pump (6). The weight of water pump (5) is approximately, 39 kg (86 Ib). Carefully lift water pump (5) onto Tooling (A). Position water pump (5) onto the engine. 3. Install mounting bolts (4). Remove Tooling (A) and install the remaining mounting bolts (4). 4. Install connector assembly (9). Install bolts (6), Install bolt (10), the nut, and the washer, 5. Position tube (8). install bolts (7) and the retainers. Imustration 256 6. Tighten bolts (3). Instail bolts (1) and (2),70 Disassembly and Assembly Section Auxiliary Water Pump - Remove (Auxiliary Pump) ‘SMCS Code: 1371-011 Removal Procedure Table 24 Tool | Number A_| 138-7573 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 open- ing any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Caterpillar ‘Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates, Remove the Check Valve 4. Drain the sea water from the system. 2, Disconnect the water lines from the check valve and from the auxiliary water pump. Remove the ‘gaskets from the joints between the water lines, the check valve, and the auxiliary water pump. SENR6S64-18 oor Istrauon 257 3. Remove the plugs from the bottom of the auxiliary water pump in order to drain the remaining water from the auxiliary water pump. After the water has drained, install the plugs. 4, Disconnect hose assembly (1) from the auxiliary ‘water pump. 5. Remove check valve (2) and hose assembly (1) a8 a unit. 6. Remove the gasket from the joint between the check valve and the auxiliary water pump. 7. Remove the studs for the check valve trom the holes around the outlet of the auxiliary water pump. Remove the Pump Iustration 258 * 1. Attach Tooling (A) and a suitable lifting device to auxiliary water pump (4), The weight of the auxiliary water pump is approximately 64 kg (140 Ib). Remove the slack from the suitable liking device. The auxiliary water pump must be. supported during removalSENRE5E4-18 ” Wile the auxiliary water pump is supported by De suitable liting device, remove bolts (3) and Se washers. Carefully move the shatt of the auxiliary water pump out of the front drive in order ‘© remove the auxiliary water pump from the front memesion 256 ee & Femove O-ring seal (5). Suxiliary Water Pump - Remove ‘Auxiliary Sea Water Pump) SECS Code: 1371-011 Femoval Procedure NOTICE “= al parts clean from contaminants, -srinants may cause rapid wear and shortened =reonent ife. =-ove the water lines from auxiliary water pump nm Disassembly and Assembly Section 2. Attach a suitable lifting device to auxiliary tater pump (1). The weight of the auxiliary water pump fs approximately 59 kg (130 Ib). 3. Remove the nuts and bolts that fasten auxiliary water pump (1) to housing (2). Remove auxiliary water pump (1). Wustration 261 enone 4, Remove bolts and washers (3) in order to remove housing (2). Ifnecessary, remove the bearing from the housing. 5. Remove the bolts and remove gear (4) from the accessory drive shaft72 Disassembly and Assembly Section Auxiliary Water Pump - Disassemble (Auxiliary Pump (Type 1)) ‘SMCS Code: 1361-015. Disassembly Procedure Table 26, ReqiiediToole Part Tool | Number Part Description Qty ‘Combination Puller (Two { a are) Jaw or Three Jaw) r |B | 193-8094 | Spline Socket a 1 joke 193-8100 | Socket (Impeller Nut) 1 [0 | 1P-0810 | onver Gp Tan] |= | 196-1452 | Retaining Fina Piers As | 1 F 152-7159 le aor Pn 1 [1s -w-7600 | sie anmer Pat Gp | 1 H | 1P-0074 | Side Hammer Puller Gp | 1 J = __ [M1035 Foreing Bons | 2 «|= | ex 1.25 Bots 2 Start By: a. Remove the auxiliary water pump. Refer to Disassembly and Assembly, “Auxiliary Water Pump - Remove” NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened ‘component life, Disassemble the Check Valve Note: if the hose assembly is leaking, the entire hose: assembly must be replaced. SENR6564-18 thstraion 263 fooeaeats 1. Remove hose assembly (1) from the body of check valve (2) Iuystration 268 FIMO Personal injury can result from parts andlor covers under spring pressure. ‘Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened. 2. Use Tooling (E) in order to remove retainer (3) from the body of check valve (2). 3. Remove spring (4) and disc (5) from the body of check valve (2)‘a7 SENR6S64-18 Disassemble the Pump ‘Restration 265 wien ‘4. Remove bolts (6) in order to remove cover (7). on ssre6 i Remove O-ring seal (8) from cover (7). Remove port plate (9), 73 Disassembly and Assembly Section Mustration 268 4, Remove nut (10) and the washer. Iustration 269 ie ‘5. Use Tooling (A) in order to remove impeller (11), stration 270 6. Remove bolts (12) from body (13). Note: Ring (14) and port plate (15) will remain inside when the body is removed,74 SENR6S64-18 Disassembly and Assembly Section naneavard (1055775 Imusvation 274 = 7. Use Tooling (J) in order to remove body (13), 40. Remove key (17) and shim (18) from shaft (19) ‘pOsSTa ‘90T088785 Imustraion 272 Imystration 275 8, Remove O-ring seal (16) from body (13). 11. Bend the tabs of lockwasher (20) away from the flats of locknut (21), o0ss7e3 mstravon 273 moieinn276 (seo70882 9, Remove ring (14) and port plate (15) from body (13). 12. Hold the driven end of the shaft with Tooling (8) Use Tooling (C) in order to loosen the locknut. Remove the focknut and the lockwasher from the shaft. Use @ new lockwasher upon assembly.SENR6SB4-18 season 277 or0seray stration 281 16. Use Tooling (D) and a suitable press in order to Temove the stationary segment of ceramic seal Pace body (23) in the downward position. (26) from body (23). =erove bolts and washers (24) that attach sang housing (26) to the body. stration 282 semzion 279 1088705 47, Remove ring (27) and the oui segment of ‘ceramic seal (28) from shaft (19) Js Tooling ec irene Re boar Boos 25) from body (23).76 Disassembly and Assembly Section SENR6564-18 jusvation 283 Roe) 18. Use an allen wrench to loosen the screws that hnold ring (29) to shaft (19). Remove the ring. stration 284 49, Remove O-ring seal (30) from shaft (19). 20. Place bearing housing (25) in a vise with the ‘driven end of the shaft in the upward position, Use ‘Tooling (E) in order to remove retaining ring (31) NOTICE Donotallow the shaftto fall when the shaftis removed from the bearing housing, ‘pot055808 imustration 286 24, Place bearing housing (25) and shaft (19) ina Suitable press, Orient the impeller end of the shaft in the upward position. Press the shaft out of the bearing housing, tuueteation 287 oiossar0 22. Place the shaft in a vise. Orient the driven end of the shaft in the upward position, Use Tooling (F) in order to remove nut (32) (not shown) from the shaft ‘108587 23. Place shaft (19) and bearing (33) in a suitable ‘press. Orient the driven end of the shaft in the ‘upward position. Press the shaft out of the bearing

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CATERPILLAR 3500B Engine Disassembly & Assembly

CATERPILLAR 3500B Engine Disassembly & Assembly