- Engine:
- G3516 (S/N: 4EK1-UP; WPW1-UP)
Introduction
Do not perform any procedure that is outlined in this Special Instruction until the entire instruction has been read and understood.
This Special Instruction describes the assembly process for upgrading a G3516 Engine to ULB configuration. The configuration uses ADEM 3 technology, mass flow air fuel ratio control, and NOx sensors. The upgrade provides operation at maximum levels of 0.5 or 1.0 g/Hp-Hr of NOx emissions with higher altitude capability throughout the total speed range.
Note: Among other variables, emissions performance depends on engine setup and tuning, site parameters, and fuel quality.
This Special Instruction is an overview of the engine assembly process. Refer to Disassembly and Assembly, KENR8147-01 for detailed assembly instructions.
Rebuild and ULB Retrofit
Required Parts
A list of parts for your particular engine arrangement can be found at the following URL:
https://engines.cat.com/upgradekitsOnce you have accessed the web site, click the link that says "G3516 ULB Upgrade - Parts to Order".
Assembly Procedure
- Clean the cylinder block.
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| Illustration 1 | g02253733 |
- Check for blockage in the oil passages of the block.
- Install the O-Ring seals onto the cylinder liners.
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| Illustration 2 | g02244778 |
- Install the liners into the block. Check the cylinder liner projection. Refer to Systems Operation, Testing and Adjusting, KENR6892.
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| Illustration 3 | g02251213 |
Note: Lubricate the bores of the block with 266-9682 White Assembly Compound before installing liners.
- Install the camshaft bearings and check the camshaft bearing oil passages for alignment. Refer to Disassembly and Assembly, KENR8147.
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| Illustration 4 | g02251513 |
- Install all of the plugs into the cylinder block.
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| Illustration 5 | g02251394 |
- Install the main bearings into the block and the main bearing caps. Grease the bearings using 266-9682 White Assembly Compound .
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| Illustration 6 | g02251434 |
Note: Record the bearing numbers and the cylinder locations. Keep this information for future reference.
- Install the crankshaft.
- Install the main bearing caps and torque the bolts to specifications. Refer to Specifications, KENR6891.
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| Illustration 7 | g02251477 |
- Install the thrust plate.
- Measure end play of the crankshaft.
- Rotate the crankshaft. Make sure that the crankshaft will rotate freely.
- Assemble the pistons and the connecting rods.
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| Illustration 8 | g02251558 |
- Install the rings onto the pistons.
- Install the bearings onto the connecting piston rods and caps.
- Grease the bearings using 266-9682 White Assembly Compound .
- Clean and lubricate the cylinder liners with clean engine oil.
Note: Lubricate pistons and rings with clean engine oil before installing the components into the block.
- Install the pistons and the connecting rods into the cylinder liners.
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| Illustration 9 | g02256774 |
- Install the connecting rod bearing caps and torque the bolts to specifications. Refer to Specifications, KENR6891.
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| Illustration 10 | g02251635 |
- Install the counterweights and torque the new bolts to specifications. Refer to Specifications, KENR6891.
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| Illustration 11 | g02251673 |
- Rotate the crankshaft to the top center (TC) position.
- Install the piston cooling jets.
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| Illustration 12 | g02254113 |
- Install the 4P-7487 Engine Harness As through the cylinder block below the camshaft.
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| Illustration 13 | g02256794 |
- Install the camshafts. Pin the camshafts in place.
Note: Lubricate the camshaft bearings before installing the camshaft.
- Install the air intake plate assembly. Be sure to leave the bolts out of the marked holes until the assemblies are installed. Refer to Illustration 14. Refer to Disassembly and Assembly, KENR8147-01.
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| Illustration 14 | g02253317 |
(1) Bolts for the aftercooler mounting assembly. (2) Bolts for the adapter. (3) Bolts for the air cleaner mounting assembly. | |
- Install the covers for the cylinder block.
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| Illustration 15 | g02252076 |
- Install the dowels for the cylinder heads.
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| Illustration 16 | g02251753 |
- Install the spacer plates with gaskets, seals, water ferrules, and head gaskets.
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| Illustration 17 | g02251833 |
- Install the plugs into cylinder heads before installation onto the block.
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| Illustration 18 | g02253813 |
- Install the cylinder head and torque the bolts to specifications. Refer to Specifications, KENR6891.
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| Illustration 19 | g02251858 |
- Install the rear idler and cluster gears. Apply Locktite to the bolts and torque the bolts to specifications.
- Install the rear housing. Make sure to torque the bolts in sequence.
- Install the rear crankshaft seal assembly.
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| Illustration 20 | g02254654 |
- Install the front housing. Make sure to torque the bolts in sequence. Refer to Disassembly and Assembly, KENR8147-01.
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| Illustration 21 | g02256873 |
- Install the flywheel and torque the bolts to specifications. Refer to Specifications, KENR6891.
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| Illustration 22 | g02251993 |
Note: Torque the flywheel bolts in sequence. Refer to Disassembly and Assembly, KENR8147-01.
- Check the flywheel runout and end play. Refer to Systems Operation, Testing and Adjusting, KENR6892.
- Time the flywheel and pin the flywheel.
- Install the rear camshaft drive gears and torque the bolts to specifications. Refer to Specifications, KENR6891.
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| Illustration 23 | g02253833 |
- Remove the camshaft timing pins.
- Install the front crankshaft seal assembly.
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| Illustration 24 | g02253913 |
- Install the exhaust temperature sensors.
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| Illustration 25 | g02257336 |
- Install the valve cover bases.
- Install the push rods and valve bridges. Make sure that the push rods are aligned.
- Install the rocker arm assemblies.
- Torque the rocker arm assembly retaining bolts. Refer to Specifications, KENR6891.
- Adjust the valve lash. Refer to Systems Operation, Testing and Adjusting, KENR6892.
- Install the transformers.
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| Illustration 26 | g02252875 |
- Install the valve covers and the crankcase breathers.
- Install the air inlet elbows.
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| Illustration 27 | g02252894 |
- Assemble the oil cooler. Refer to Disassembly and Assembly.
- Install the oil coolers and the oil lines.
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| Illustration 28 | g02265097 |
- Install the exhaust manifolds, and the bellows. Cover the exhaust components with heat shields. Torque the bolts to specifications. Refer to Specifications, KENR6891.
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| Illustration 29 | g02252953 |
- Install the water manifolds.
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| Illustration 30 | g02255933 |
- Assemble the aftercooler as a group. Refer to Illustration 33 or Refer to Disassembly and Assembly, KENR8147-01.
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| Illustration 31 | g02255996 |
Note: Install the water manifold tee fitting before installing the aftercooler. Refer to Illustration 31.
- Install aftercooler into the base and the top housing. Torque the bolts to specifications. Refer to Specifications, KENR6891.
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| Illustration 32 | g02279193 |
- Install the aftercooler.
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| Illustration 33 | g02255674 |
- Install the engine oil pump.
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| Illustration 34 | g02254656 |
- Install the auxiliary water pump.
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| Illustration 35 | g02261854 |
- Install the front accessary drives.
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| Illustration 36 | g02257017 |
- Install the front auxiliary drive.
- Install the front gear group.
- Install the cover and the adapters on the front housing.
- Install the oil filter group and the related tubes.
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| Illustration 37 | g02254153 |
- Install the damper and the crankshaft pulley. Torque the bolts to specifications.
- Install the water temperature regulator housing and the related water lines.
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| Illustration 38 | g02263519 |
- Install the water lines from the water pump to the aftercooler. Refer to Illustration 55 and Illustration 56.
- Assemble the oil pan. Refer to Disassembly and Assembly, KENR8147-01.
- Install the oil pan assembly and the oil pump supply tube.
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| Illustration 39 | g02254633 |
- Install the dipstick.
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| Illustration 40 | g02254673 |
- Install the fittings into the block before installing the turbocharger support and the turbochargers.
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| Illustration 41 | g02253133 |
- Install the turbochargers and connect the turbochargers to the exhaust manifold piping.
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| Illustration 42 | g02262133 |
- Install the NOx sensor. Refer to Special Instruction, REHS3411 for detailed instructions on installing the NOx sensor. The NOx sensor must be installed correctly for proper operation.
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| Illustration 43 | g02327474 |
- Install the air lines from turbocharger to the aftercooler. Refer to Illustration 56.
- Install the oil lines for the turbochargers.
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| Illustration 44 | g02263973 |
- Install the water lines for the turbochargers.
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| Illustration 45 | g02264433 |
- Install the starting motors.
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| Illustration 46 | g02261455 |
- Install the alternator.
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| Illustration 47 | g02252273 |
- Install the heat shields that cover the turbochargers and the exhaust manifolds.
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| Illustration 48 | g02251956 |
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| Illustration 49 | g02252073 |
- Install the gas regulator bracket.
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| Illustration 50 | g02262193 |
- Install the gas regulator and the gas lines.
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| Illustration 51 | g02262593 |
- Install the inlet fuel heater.
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| Illustration 52 | g02265553 |
- Install all of the sensors on the engine.
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| Illustration 53 | g02251797 |
Locations of the engine sensors (left side engine view) (4) Intake manifold air temperature sensor (5) Intake manifold pressure sensor (6) Engine coolant temperature sensor (7) Pressure sensor for unfiltered oil (8) Pressure sensor for filtered oil (9) Engine oil temperature sensor (10) Engine coolant pressure sensor (outlet) (11) Throttle valve differential pressure sensor (12) Pressure switch for the prelubrication (13) Detonation sensors (left side) (14) Solenoid for the Gas Shutoff Valve (GSOV) (15) Engine speed/timing sensor | |
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| Illustration 54 | g02251814 |
Locations of the engine sensors (right side engine view) (16) Coolant pressure switch (inlet) (17) Air start solenoid (18) Solenoid for the prelube motor (19) Detonation sensors (right side) | |
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| Illustration 55 | g02265633 |
Locations of the engine components and lines (left side engine view) (20) Crankcase breather (21) Throttle valve (22) Auxiliary line (fresh water to aftercooler) (23) Auxiliary water pump (24) Auxiliary line (fresh water to aftercooler) (25) Gas regulator (26) Thermostatic valve (27) Gas shutoff solenoid valve (28) Inlet heater | |
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| Illustration 56 | g02265634 |
Locations of the engine components and lines (right side engine view). (29) Tube assembly (30) Tube from the turbo to the air cleaner (31) Water line to aftercooler (32) Two-stage aftercooler (33) Air cleaner (34) Water line to aftercooler (35) Turbo to aftercooler air line (36) Accumulator (37) Starter (38) Prelube pump | |
- Rebuild the control box and install the ECM in the control box.
- Install the control box and wire the panel.
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| Illustration 57 | g02251253 |
- Rebuild the interface box with the new harness.
- Install the interface box.
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| Illustration 58 | g02251873 |
For detailed information refer to the electrical schematic | |
- Install the pyrometer harness. Refer to Systems Operations, Testing and Adjusting, KENR5473.
- Install the detonation harness.
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| Illustration 59 | g02251693 |
Left side typical view | |
- Install the alternator harness.
- Install the dyno hardware. Refer to Special Instruction, REHS4724 for initial start-up procedures.
- Check the engine for loose or missing parts and bolts.
Register the Retrofit
Because retrofits to a prime product will change the configuration of the product, updating the configuration in SIMSi and AIMS is important. If the retrofit information is not provided, Caterpillar will not be able to provide important product updates.
The following information includes instructions on registering the updates and retrofits.
- When performing a retrofit installation, record the vital information in Table 1.
Note: If the procedure is performed by the customer, ask the customer to record the proper information.
Show/hide tableTable 1 Repair Date Product Serial Number Service Hours or Service Meter Units Removed Component Part Number (1) Removed Component Serial Number (1) Installed Component Part Number (2) 383-7682 Engine Conversion Ar Installed Component Serial Number (3) Show/hide table( 1 ) Only applies if a component is replaced by a retrofit component. If the product is an engine, and the product retrofit is a kit for upgrading the engine, disregard the "Removed Component" information. Refer to detailed instructions in Step 3 for more information. ( 2 ) Record the highest level retrofit kit, arrangement, or group part number. ( 3 ) Most retrofits will not have a serial number. Exceptions include emissions repower engines and diesel particulate filters.
- Update the product configuration by entering the information from Table 1 into SIMSi and AIMS.
Note: For retrofits that have a Caterpillar serial number, the AIMS application is "JIZ111-08". For retrofits that do not have a Caterpillar serial number, the AIMS application is "JIZ111-07".
- For detailed instructions on updating the product configuration, refer to Special Instruction, REHS5097, "Instructions to Register the Retrofit".