Procedure to Install the 353-6981 Drive Coupling Assembly on Some G3500 Engines{5510} Caterpillar

Engine:

G3512E (S/N: SSR1-UP; NGS1-UP)

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

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

G3520B (S/N: TPC1-UP; GLF1-UP)

G3520C (S/N: GZA1-UP; GZB1-UP; MAD1-UP; GZJ1-UP; GZK1-UP; GZL1-UP; GZM1-UP; GZN1-UP; B9P1-UP; RLP1-UP; LGS1-UP; HAT1-UP; CWW1-UP; CWY1-UP)

G3520E (S/N: GZG1-UP; GZH1-UP; HAL1-UP; SXY1-UP)

Introduction

Do not perform any procedure that is outlined in this publication until you understand the information that is contained in this document.

A new drive coupling assembly for the compressor bypass is available for the engines that are listed above. The new 353-6981 Drive Coupling Assembly will compensate for thermal growth, movement from vibration and a slight misalignment in mounting.

Use the following instructions to remove the existing coupler for the compressor bypass and install the new coupler for the compressor bypass.

Required Parts

Table 1 lists the parts that are used for updating the existing coupling to the new 353-6981 Drive Coupling Assembly .

Table 2 lists the serviceable parts that are available for the new 353-6981 Drive Coupling Assembly .

Removal Procedure

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Illustration 1	g02112464
(1) Existing actuator assembly

1. Remove actuator assembly (1) from the engine.

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Illustration 2	g02112485
(1) Existing actuator assembly (2) Screw (3) Coupling (4) Valve assembly (5) Bolts (6) Bracket

2. Loosen screw (2) from coupling (3) .

3. Remove bolts (5) from bracket (6) .

4. Remove bracket (6) and valve assembly (4) from actuator assembly (1) .

Installation Procedure

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Illustration 3	g02112515
(7) 328-0756 Valve As (8) 328-0763 Spring Pin (9) 328-0762 Tooth

1. Install tooth (9) and spring pin (8) onto the shaft of valve assembly (7) .

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Illustration 4	g02112537
View of pin that is installed into tooth and shaft

2. Insert pin (8) until the pin is flush with the outside diameter of tooth (9) .

   Note: A drill bit with an outside diameter of 4.7 mm (0.185 inch) can be used in order to align the holes of the tooth with the holes in the shaft.

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Illustration 5	g02112700
(10) 223-1175 Torsion Spring

3. Install one end of spring (10) through pin (8) .

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Illustration 6	g02122536
(11) 328-0761 Yoke

4. Install yoke (11) onto the opposite end of spring (10). Rotate the yoke in a clockwise direction as you are installing yoke (11) onto tooth (9). The rotation will close the spring.

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Illustration 7	g02124415
(12) 328-0760 Adapter

5. Install a second spring (10) into the opposite end of yoke (11) .

6. Install adapter (12) onto the opposite end of spring (10). Rotate the adapter in a clockwise direction as you are installing adapter (12) onto yoke (11). The rotation will close the spring.

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Illustration 8	g02124455
(13) New valve assembly

7. Install the newly assembled valve assembly (13) onto bracket (6) .

   Torque for the four bolts ... 41 N·m (30 lb ft)

8. Rotate the actuator shaft in a clockwise direction until the stop is reached.

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Illustration 9	g02124515

9. Install new valve assembly (13) and bracket (6) onto actuator (1) by installing adapter (12) into coupling (3) .

   Note: Ensure that the arrow on the valve assembly is pointing in the direction of air flow.

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Illustration 10	g02124533

10. Reinstall the existing mounting hardware through the actuator and the bracket.

    Torque for the four bolts while the nuts are held from the opposite side. ... 45 N·m (33 lb ft)

11. Ensure that the actuator is against the CLOSED stop. Rotate the actuator shaft in a clockwise direction.

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Illustration 11	g02124562

12. Ensure that bolts (14) are facing the incoming air and that the arrow on the valve assembly follows the direction of air flow.

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Illustration 12	g02124537
(13) Valve assembly

13. Ensure that the plate in the valve assembly (13) is perpendicular to the direction of the air flow.

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Illustration 13	g02124557

14. Tighten screw (2) to a torque of 15 N·m (11 lb ft) while you are holding the plate in the valve assembly perpendicular to the direction of the air flow.

15. Reinstall the updated actuator assembly onto your engine.