Installation of the 422-9537 Repair Kit {1233} Caterpillar

Generator Set:

3512 (S/N: ZAF1-UP)

3512B (S/N: ZAH1-UP; ZAJ1-UP)

3516C (S/N: SBK1-UP)

C175-16 (S/N: WYB1-UP)

Engine:

3508 (S/N: ZAB1-UP; CNF1-UP; 8TL1-UP; 3HM1-UP; 9WN1-UP; 3PS1-UP; CAW1-UP; 5PW1-UP; 95Y1-UP; 96Y1-UP; 23Z1-UP; 68Z1-UP; 69Z1-UP; 70Z1-UP)

3508B (S/N: S2A1-UP; CNB1-UP; S2B1-UP; LPD1-UP; S2D1-UP; ZAD1-UP; S2E1-UP; S2F1-UP; BAG1-UP; 2BM1-UP; 3DM1-UP; 7SM1-UP; PTN1-UP; 6PN1-UP; C8R1-UP; 5PS1-UP; 1TW1-UP; 2HW1-UP; 3DW1-UP; 5KW1-UP; BGX1-UP; BPX1-UP)

3508C (S/N: TTA1-UP; TTB1-UP; F1X1-UP)

3512 (S/N: PTG1-UP; PTH1-UP; CMJ1-UP; YAK1-UP; 2WK1-UP; FDR1-UP; 3RS1-UP; 3WS1-UP; 6WW1-UP; 49Y1-UP; 50Y1-UP; 24Z1-UP; 65Z1-UP; 66Z1-UP; 67Z1-UP)

3512B (S/N: BRC1-UP; CMC1-UP; NSC1-UP; FDE1-UP; BLF1-UP; PTF1-UP; AAG1-UP; FFG1-UP; S2G1-UP; S2H1-UP; YAH1-UP; S2J1-UP; BRK1-UP; S2K1-UP; S2L1-UP; PTM1-UP; S2M1-UP; YAM1-UP; 7HM1-UP; 8EM1-UP; 8RM1-UP; BRN1-UP; S2N1-UP; YAN1-UP; 4TN1-UP; 4DR1-UP; 1PW1-UP; 2GW1-UP; 3ZW1-UP; 4AW1-UP; 5AW1-UP; 6GW1-UP; 2EZ1-UP)

3512C (S/N: TTC1-UP; TTE1-UP; TTF1-UP; MRG1-UP; SBG1-UP; TTG1-UP; MKH1-UP; LLK1-UP; SLM1-UP; TKP1-UP; T3P1-UP; T3R1-UP; RMS1-UP; T3S1-UP; NJT1-UP; E3W1-UP; T3W1-UP; E3X1-UP; F2X1-UP; E3Y1-UP)

3516 (S/N: CMD1-UP; 4MJ1-UP; 5MJ1-UP; CAL1-UP; YAL1-UP; ZAL1-UP; ZBL1-UP; GZR1-UP; YAS1-UP; YBS1-UP; 2TS1-UP; 3JS1-UP; 3SS1-UP; 3XS1-UP; 8TW1-UP; GZX1-UP; 25Z1-UP; 29Z1-UP; 71Z1-UP; 72Z1-UP; 73Z1-UP)

3516B (S/N: CPA1-UP; BMB1-UP; CDE1-UP; B5G1-UP; BPJ1-UP; BCK1-UP; LEK1-UP; TAK1-UP; CAN1-UP; CBN1-UP; FDN1-UP; 6HN1-UP; 7RN1-UP; 8CN1-UP; 8KN1-UP; 9AN1-UP; S2P1-UP; YAP1-UP; ZAP1-UP; ZBP1-UP; GAR1-UP; PBR1-UP; S2R1-UP; YAR1-UP; ZAR1-UP; ZBR1-UP; GZS1-UP; S2S1-UP; GZT1-UP; S2T1-UP; YAT1-UP; YBT1-UP; S2W1-UP; YAW1-UP; YBW1-UP; 1NW1-UP; 2FW1-UP; 2JW1-UP; 3CW1-UP; 4BW1-UP; 8NW1-UP; FDX1-UP; S2X1-UP; GZY1-UP; S2Y1-UP; S2Z1-UP)

3516C (S/N: PRC1-UP; SKC1-UP; TTD1-UP; PAG1-UP; TTH1-UP; SBJ1-UP; SCJ1-UP; SFJ1-UP; TTJ1-UP; SCK1-UP; SEK1-UP; SFK1-UP; SBM1-UP; TKR1-UP; JTS1-UP; TKS1-UP; TKT1-UP; WFT1-UP; SDX1-UP; TKX1-UP; T2X1-UP; TKY1-UP; E3Z1-UP; GS21-UP)

3606 (S/N: 8RB1-UP)

3608 (S/N: 6MC1-UP; 5PG1-UP; 8LL1-UP; 7WR1-UP)

3612 (S/N: 9RC1-UP; 9FR1-UP)

3616 (S/N: ZYD1-UP; 1PD1-UP; 1FN1-UP)

3618 (S/N: 2MW1-UP)

C175-16 (S/N: M6A1-UP; Y3A1-UP; A7B1-UP; M6B1-UP; WYC1-UP; P6L1-UP; P5P1-UP; R1X1-UP)

C175-20 (S/N: A7E1-UP)

C280-16 (S/N: NKB1-UP; TDX1-UP)

G3508 (S/N: 4WD1-UP; 9TG1-UP; CPJ1-UP; 2TJ1-UP; WPM1-UP; WPN1-UP; DLR1-UP; CPS1-UP; CPY1-UP)

G3508B (S/N: RBK1-UP)

G3512 (S/N: 5JD1-UP; 7NJ1-UP; CRN1-UP; CSP1-UP; WPP1-UP; WPR1-UP; GNS1-UP)

G3512B (S/N: JHH1-UP)

G3512E (S/N: GFM1-UP; NGS1-UP)

G3516 (S/N: L6A1-UP; ZBA1-UP; 8LD1-UP; L6E1-UP; L6F1-UP; CPG1-UP; L6G1-UP; 4EK1-UP; WPS1-UP; WPT1-UP; WPW1-UP; CSZ1-UP; ZAZ1-UP)

G3516B (S/N: ZBB1-UP; CSC1-UP; ZBC1-UP; CME1-UP; JEF1-UP; L6H1-UP; L6J1-UP; CEY1-UP; 7EZ1-UP)

G3516C (S/N: GSB1-UP; TJB1-UP; GZC1-UP; TJC1-UP; F6D1-UP; F6E1-UP; F6F1-UP; GZZ1-UP)

G3516E (S/N: F6G1-UP; GAS1-UP; SLY1-UP)

G3516H (S/N: GLM1-UP)

G3520B (S/N: GLF1-UP; GZP1-UP)

G3520C (S/N: GZA1-UP; GZB1-UP; GZJ1-UP; GZK1-UP; GZL1-UP; GZM1-UP; GZN1-UP; RLP1-UP; LGS1-UP)

G3520E (S/N: GZE1-UP; GZG1-UP; GZH1-UP)

G3606 (S/N: 3XF1-UP)

G3608 (S/N: 4WF1-UP)

G3612 (S/N: 1YG1-UP)

G3616 (S/N: 4CG1-UP)

Marine Engine:

C32 (S/N: RTK1-UP)

Petroleum Engine:

3508C (S/N: LLC1-UP; C8E1-UP; LLE1-UP; C8K1-UP)

3512C (S/N: LLA1-UP; LLB1-UP; LLF1-UP)

3516C (S/N: PES1-UP)

G3520B (S/N: TPC1-UP)

Power Module:

PM3516 (S/N: BPD1-UP; NBR1-UP)

PMG3516 (S/N: CFD1-UP; KAD1-UP; JKK1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you read this information and you understand this information.

This Special Instruction provides the installation procedure for the 422-9537 Repair Kit . The procedure must be followed in order to ensure the proper operation of the crankcase explosion relief valve.

The 422-9537 Repair Kit is used to repair the following crankcase explosion relief valves:

• The 8N-8509 Explosion Relief Valve

• The 1W-2834 Explosion Relief Valve

Table 1 lists the parts that are included in the 422-9537 Repair Kit .

Illustration 1	g03377727
Typical example (1) Large O-ring (2) Small O-ring (3) Cover (4) Valve plate (5) Valve spring (6) Spindle nut (7) Locknut (8) Upper spring cap (9) Lower spring cap (10) Carrier (11) Spider assembly (12) Wire screen (13) Spindle

Disassembly and Installation Procedure

For the following procedures, refer to Illustration 1.

Shut down the engine and allow the engine to cool. Remove the explosion relief valve from the engine.

Disassembly

1. Remove locknut (7) and cover (3).

2. Remove spindle nut (6). Hold valve spring (5) in order to ensure that the spring does not fly off the spindle.

3. Remove the following items: upper spring cap (8), valve spring (5), lower spring cap (9), small O-ring (2), large O-ring (1) and valve plate (4) .

Installation Procedure

Inspect wire screen (12) for any tears or holes. An open flame may escape through a damaged screen during an explosion. Replace the explosion relief valve if the wire screen is damaged.

1. Slide the new valve plate over the spindle. Ensure that the molded rubber seal seats on the carrier.

2. Lightly grease the spindle and the threads of the spindle. Install large O-ring (1) and small O-ring (2) .

3. Place lower spring cap (9) over the O-rings with the cup face toward valve plate (4) .

4. Place valve spring (5) over spindle (13). Ensure that the valve spring seats evenly on the lower spring cap.

5. Place upper spring cap (8) on top of the valve spring. Compress the valve spring by hand. Install spindle nut (6) onto the threads of spindle (13). Thread the nut until the opposite end of the nut is flush with the top of the spindle. With a wrench that holds the top of the spindle, tighten the spindle nut down eight complete turns.

6. Install cover (3) onto the spindle. The opening on the cover must face downward. Install locknut (7). Tighten the locknut. At the same time, center the valve plate on the carrier valve seat. Centering the valve plate ensures that the valve plate seats correctly on the valve seat. The cover should seat firmly on the flange of the carrier. The cover should be bowed slightly in order to provide tension.