Installing a New Coolant Lines Gp on Certain G3512B Petroleum Engines{1071, 1380} Caterpillar


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Installing a New Coolant Lines Gp on Certain G3512B Petroleum Engines{1071, 1380} [REHS8659]
AIR INLET AND EXHAUST SYSTEM
INLET GP-AIR
Installing a New Coolant Lines Gp on Certain G3512B Petroleum Engines{1071, 1380}
1.1. Introduction
2.1. Parts Needed
3.1. Installing the 342-4469 Coolant Lines Gp and the 342-4479 Air Lines Gp
Engine:
G3512B (S/N: JHH1-UP)

Introduction

This Special Instruction provides the procedure in order to install the new water lines group for the G3512B Engines. Refer to following Tables for the coolant lines upgrade part numbers.

Parts Needed

Table 1
342-4469 Coolant Lines Gp    
Qty     Part    
2     0L-1351 Bolt    
2     0S-1594 Bolt    
1     1A-2029 Bolt    
2     1N-7284 Bolt    
2     2S-3567 Bolt    
2     3B-1915 Bolt    
3     3S-0127 Bolt    
1     4I-6141 Coupling As    
9     4P-7233 Grommet    
2     5G-1442 Gasket    
2     5K-9090 O-Ring Seal    
15     5M-2894 Hard Washer    
2     5P-7464 Clip    
2     5P-7465 Clip    
2     5P-9297 Clip    
2     6V-1249 Grommet    
1     6V-1581 Clip    
1     6V-1582 Clip    
1     6V-3251 O-Ring Seal    
1     6V-5063 O-Ring Seal    
2     6V-5064 O-Ring Seal    
2     6V-6609 O-Ring Seal    
1     6V-8635 Connector    
2     6V-8639 Connector    
1     6V-9007 Elbow    
1     6V-9830 Cap As    
4     6V-9851 Elbow    
1     7R-9570 Tee    
1     7W-3448 Elbow    
1     8C-6872 Connector    
9     8T-1887 Clip    
9     8T-1888 Clip    
1     8T-6758 Pipe Plug    
1     9S-4190 O-Ring Plug    
7     9S-8752 Full Nut    
4     9X-6458 Hard Washer    
1     130-7224 Adapter    
2     133-6934 Spacer    
15     180-8424 O-Ring Seal    
3     205-6716 Spacer    
2     243-1353 Spacer    
1     294-9072 O-Ring Seal    
1     434-7490 Adapter    
1     437-6980 Bracket    
1     437-6981 Bracket    
1     437-8491 Bracket    
1     438-0031 Tube As    
1     438-0032 Tube As    
1     438-0033 Tube As    
1     438-0034 Tube As    
1     438-8312 Hose As    

Table 2
342-4479 Air Lines Gp    
Qty     Part    
2     1A-2029 Bolt    
2     5M-2894 Hard Washer    
2     5P-9297 Clip    
2     6V-6609 O-Ring Seal    
2     7X-0732 Hard Washer    
1     8L-2786 O-Ring Seal    
1     8T-1715 Adapter    
1     9S-4185 O-Ring Plug    
1     005-4362 Elbow    
1     032-1268 Connector    
1     438-0035 Tube As    

Installing the 342-4469 Coolant Lines Gp and the 342-4479 Air Lines Gp




Illustration 1g03429244

  1. Remove the vent line and the fittings from the aftercooler and the exhaust bypass group shown in Illustration 1.



    Illustration 2g03429246

  1. Remove the water lines, the fittings, and the associated hardware shown in Illustration 2. Set aside the 6V-9830 Cap As and the 6V-9837 Swivel Tee for reuse.

    Leave the following parts attached to the engine:

    • The 8C-6871 Connectors on the exhaust bypass group

    • The front 322-3504 Adapter on the turbocharger

    • The rear turbocharger cooling line

  1. Remove the original 7W-3448 Elbow and the 130-7224 Adapter from the left-hand side of the aftercooler. Set aside the hardware for reuse.

    Due to modifications to the fitting size used, these two items will be replaced with a new 7W-3448 Elbow and a 130-7224 Adapter later in the installation procedure.




    Illustration 3g03429247

    (1) 8T-6758 Pipe Plug

  1. Remove the pipe plug from the rear of the aftercooler.

    Note: Use Loctite 567 on all pipe thread joints.

  1. Install pipe plug (1) into the rear of the aftercooler. The pipe plug is shorter to prevent the 438-0032 Tube As from rubbing on the plug.

  1. Remove the pipe plug from the water manifold.



    Illustration 4g03429252

    (2) 434-7490 Adapter

    (3) 6V-8639 Connector

    (4) 6V-6609 O-Ring Seal

    (5) 180-8424 O-Ring Seal

    (6) 6V-9007 Elbow

    (7) 6V-5063 O-Ring Seal

    (8) 294-9072 O-Ring Seal

    (9) 6V-8635 Connector

    (10) 6V-5064 O-Ring Seal

    (11) 5K-9090 O-Ring Seal

  1. Install two connectors (3) and one O-ring (4) per connector into adapter (2). Refer to Illustration 4 for the correct location of the connectors.

  1. Install one O-ring (5) into each connector (3) .

  1. Install one elbow (6) and one O-ring (7) into adapter (2). Refer to Illustration 4 for the correct location and orientation of the elbow.

  1. Install one O-ring (8) into elbow (6) .

  1. Install one connector (9) and one O-ring (10) into adapter (2). Refer to Illustration 4 for the correct location of the connector.

  1. Install one O-ring (11) into connector (9) .



    Illustration 5g03429253

    (9) 6V-8635 Connector

    (10) 6V-5064 O-Ring Seal

    (12) 4I-6141 Coupling As

  1. Install coupling assembly (12) and one O-ring (10) into the 111-8277 Manifold .

  1. Attach connector (9) and assembled parts to coupling assembly (12). Refer to Illustration 5 for the correct orientation.



    Illustration 6g03429256

    (3) 6V-8639 Connector

    (5) 180-8424 O-Ring Seal

    (13) 7R-9570 Tee

    (14) 6V-9830 Cap As

    (15) 438-0034 Tube As

    (16) 3S-0127 Bolt

    (17) 5M-2894 Hard Washer

    (18) 6V-9851 Elbow

    (19) 4P-7233 Grommet

    (20) 8T-1887 Clip

    (21) 8T-1888 Clip

    Note: Use Loctite 567 on all pipe thread joints.

  1. Install tee (13) into the 9Y-8283 Elbow of the aftercooler.

  1. Install elbow (18) and one O-ring (5) onto tee (13). Refer to Illustration 6 for the correct location and orientation of the elbow.

  1. Install cap assembly (14) and one O-ring (5) onto elbow (18) .

  1. Attach tube assembly (15) and one O-ring (5) to tee (13) .

  1. Attach tube assembly (15) to connector (3) .

    Note: Make sure that the O-ring is still in the connector.

  1. Install grommet (19) around tube assembly (15) .

  1. Install one clip (20) and one clip (21) around grommet (19) .

  1. Attach clips (20) and (21) to the aftercooler with one bolt (16) and one washer (17). Refer to Illustration 6 for the correct location of the bolt.



    Illustration 7g03429249

    (3) 6V-8639 Connector

    (5) 180-8424 O-Ring Seal

    (19) 4P-7233 Grommet

    (20) 8T-1887 Clip

    (21) 8T-1888 Clip

    (22) 438-0032 Tube As

    (23) 243-1353 Spacer

    (24) 2S-3567 Bolt

    (25) 8C-6872 Connector

    Note: Use Loctite 567 on all pipe thread joints.

  1. Install connector (25) into the 111-8276 Manifold .

  1. Attach tube assembly (22) and one O-ring (5) to connector (25)

  1. Attach tube assembly (22) to connector (3) .

    Note: Make sure that the O-ring is still in the connector.

  1. Install grommet (19) around tube assembly (22) .

  1. Install one clip (20) and one clip (21) around grommet (19) .

  1. Attach clips (20) and (21) to the aftercooler with one spacer (23), one bolt (24) and one washer (17) per set of clips. Refer to Illustration 7 for the correct location of the bolts.



    Illustration 8g03429251

    (19) 4P-7233 Grommet

    (20) 8T-1887 Clip

    (21) 8T-1888 Clip

    (22) 438-0032 Tube As

    (26) 3B-1915 Bolt

    (27) 9X-6458 Hard Washer

    (28) 9S-8752 Full Nut

    (29) 6V-1581 Clip

    (30) 6V-1582 Clip

  1. Install grommet (19) around tube assembly (22) .

  1. Install one clip (20) and one clip (22) around grommet (19). Refer to Illustration 8 for the correct orientation of the clips.

  1. Install one clip (29) and one clip (30) around the 328-2630 Tube As . Refer to Illustration 8 for the correct orientation of the clips.

  1. Attach clips (20) and (21) to clips (29) and (30) with one bolt (26), two washers (27), and one nut (28) .



    Illustration 9g03429258

    (6) 6V-9007 Elbow

    (11) 5K-9090 O-Ring Seal

    (17) 5M-2894 Hard Washer

    (26) 3B-1915 Bolt

    (27) 9X-6458 Hard Washer

    (28) 9S-8752 Full Nut

    (31) 438-8312 Hose As

    (32) 6V-1249 Grommet

    (33) 5P-7464 Clip

    (34) 5P-7465 Clip

    (35) 437-6980 Bracket

  1. Remove the original O-ring from the 322-3504 Adapter .

  1. Attach the straight end of hose assembly (31) and one O-ring (11) to the 322-3504 Adapter .

  1. Attach curved end of hose assembly (31) to elbow (6) .

    Note: Make sure that the O-ring is still in the elbow.

  1. Remove the inside lower bolt from the 347-9308 Bellows As . Refer to Illustration 9 for the correct bolt to remove.

  1. Attach bracket (35) loosely to the 347-9308 Bellows As with the original hardware.

  1. Install grommet (32) around hose assembly (31) .

  1. Install one clip (33) and one clip (34) around grommet (32) .

  1. Attach clips (33) and (34) loosely to bracket (35) with one bolt (26), two washers (27), and one nut (28) .

  1. Tighten all hardware that was left loose.

    Note: Do not kink hose assembly (31) .




    Illustration 10g03434236

    (32) 6V-1249 Grommet

    (33) 5P-7464 Clip

    (34) 5P-7465 Clip

  1. Remove the original grommet and clips. Set aside the hardware for reuse.

  1. Install grommet (32) around the original 342-4475 Hose As .

  1. Install one clip (33) and one clip (34) around grommet (32) .

  1. Attach clips (33) and (34) to the engine with the original hardware.



    Illustration 11g03429260

    (36) 9S-4190 O-Ring Plug

    (37) 6V-3251 O-Ring Seal

  1. Install plug (36) and one O-ring (37) into the 144-2980 Housing



    Illustration 12g03430459

    (5) 180-8424 O-Ring Seal

    (17) 5M-2894 Hard Washer

    (18) 6V-9851 Elbow

    (38) 437-6981 Bracket

    (39) 133-6934 Spacer

    (40) 1N-7284 Bolt

    (41) 438-0033 Tube As

  1. Remove two bolts from the top left-hand side of the aftercooler. Refer to Illustration 12 for the correct bolt location.

  1. Attach bracket (38) to the aftercooler with two spacers (39), two bolts (40), and two washers (17) .

  1. Remove the original O-ring from the 8C-6871 Connector on the right-hand side of the exhaust bypass group.

  1. Install elbow (18) and one O-ring (5) loosely onto the 8C-6871 Connector on the right-hand side of the exhaust bypass group.

  1. Install tube assembly (41) and one O-ring (5) loosely onto elbow (18) .



    Illustration 13g03430460

    (5) 180-8424 O-Ring Seal

    (14) 6V-9830 Cap As

    (17) 5M-2894 Hard Washer

    (19) 4P-7233 Grommet

    (20) 8T-1887 Clip

    (21) 8T-1888 Clip

    (27) 9S-8752 Full Nut

    (38) 437-6981 Bracket

    (41) 438-0033 Tube As

    (42) 6V-9837 Swivel Tee

    (43) 0S-1594 Bolt

    (44) 8C-6871 Connector

    (45) 7W-3448 Elbow

    (46) 5G-1442 Gasket

  1. Attach elbow (45) to the top left-hand side of the aftercooler with one gasket (46) and the original hardware.

    Note: Use Loctite 567 on all pipe thread joints.

  1. Install connector (44) into the 7W-3448 Elbow .

  1. Install swivel tee (42) and one O-ring (5) loosely onto connector (44) .

  1. Remove the original O-rings from swivel tee (42) .

  1. Install cap assembly (14) and one O-ring (5) onto the top of swivel tee (42) .

  1. Attach tube assembly (41) and one O-ring (5) loosely to swivel tee (42) .

  1. Install two grommets (19) around tube assembly (41) .

  1. Install one clip (20) and one clip (21) around each grommet (19) .

  1. Attach clips (20) and (21) to bracket (38) with one bolt (43), two washers (17), and one nut (27) per set of clips.

  1. Tighten all the connections that were left loose.



    Illustration 14g03430463

    (4) 6V-6609 O-Ring Seal

    (17) 5M-2894 Hard Washer

    (47) 005-4362 Elbow

    (48) 438-0035 Tube As

    (49) 8T-1715 Adapter

    (50) 5P-9297 Clip

    (51) 1A-2029 Bolt

    (52) 7X-0732 Hard Washer

    (53) 9S-4185 O-Ring Plug

    (54) 8L-2786 O-Ring Seal

  1. Remove the O-ring plug from the far left front port of the aftercooler. Refer to Illustration 14 for the correct location of the O-ring plug.

  1. Install adapter (49) and one O-ring (4) into the far left front port of the aftercooler.

  1. Install elbow (47) and one O-ring (4) into adapter (49) .

  1. Attach tube assembly (48) to elbow (47) .

  1. Install two clips (50) around tube assembly (48). Refer to Illustration 14 for the correct orientation of the clips.

  1. Attach clips (50) to the aftercooler with one bolt (51), one washer (17), and one washer (52) .

    Note: Washer (52) goes in between clips (50) and the aftercooler.

  1. Install plug (53) and one O-ring (54) into the aftercooler. Refer to Illustration 14 for the correct location of the plug.



    Illustration 15g03430464

    (17) 5M-2894 Hard Washer

    (19) 4P-7233 Grommet

    (20) 8T-1887 Clip

    (21) 8T-1888 Clip

    (28) 9S-8752 Full Nut

    (41) 438-0033 Tube As

    (48) 438-0035 Tube As

    (50) 5P-9297 Clip

    (56) 0L-1351 Bolt

    (57) 032-1268 Connector

    Note: Use Loctite 567 on all pipe thread joints.

  1. Install elbow (57) into the front of the exhaust bypass group.

  1. Attach tube assembly (48) to elbow (57) .

  1. Install two clips (50) around tube assembly (48) .

  1. Install two grommets (19) around tube assembly (41) .

  1. Install one clip (20) and one clip (21) around each grommet (19) .

  1. Attach clips (20) and (21) to clip (50) with one bolt (56), two washers (17), and one nut (27) per set of clips. Refer to Illustration 15 for the correct orientation of the clips.



    Illustration 16g03430465

    (5) 180-8424 O-Ring Seal

    (16) 3S-0127 Bolt

    (17) 5M-2894 Hard Washer

    (18) 6V-9851 Elbow

    (19) 4P-7233 Grommet

    (20) 8T-1887 Clip

    (21) 8T-1888 Clip

    (27) 9S-8752 Full Nut

    (44) 8C-6871 Connector

    (46) 5G-1442 Gasket

    (58) 205-6716 Spacer

    (59) 438-0031 Tube As

    (60) 437-8491 Bracket

    (61) 130-7224 Adapter

  1. Attach adapter (61) to the lower left-hand side of the aftercooler with one gasket (46) and the original hardware.

  1. Remove two bolts from the left-hand side of the aftercooler. Refer to Illustration 16 for the correct bolt location.

  1. Attach bracket (60) to the left-hand side of the aftercooler with two spacers (58), two bolts (16), and two washers (17) .

  1. Remove the original O-ring from the 8C-6871 Connector on the left-hand side of the exhaust bypass group.

  1. Install elbow (18) and one O-ring (5) loosely onto the 8C-6871 Connector on the left-hand side of the exhaust bypass group.

  1. Attach tube assembly (59) and one O-ring (5) loosely onto elbow (18) .

    Note: Use Loctite 567 on all pipe thread joints.

  1. Install connector (44) into adapter (61) .

  1. Attach elbow (18) and one O-ring (5) loosely to tube assembly (59) .

  1. Install elbow (18) and one O-ring (5) loosely onto connector (44) .

  1. Install one grommet (19) around tube assembly (59) .

  1. Install one clip (20) and one clip (21) around grommet (19) .

  1. Attach clips (20) and (21) to bracket (60) with one bolt (51), two washers (17), and one nut (27) .

  1. Tighten all the connections that were left loose.

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