Retrofitting for Ultra Lean Burn (ULB) on a G3508 Engine{1000, 775E} Caterpillar

Engine:

G3508 (S/N: 9TG1-UP; WPM1-UP; WPN1-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 G3508 Engine to ULB configuration. The configuration uses ADEM 3 technology, mass flow air fuel ratio control, and NO_x sensors. The upgrade provides operation at maximum levels of 0.5 or 1.0 g/Hp-Hr of NO_x 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 for detailed assembly instructions.

Note: Refer to Reuse and Salvage Guidelines for parts reusability during this upgrade.

Rebuild and ULB Retrofit

Required Parts

A list of parts for your particular engine arrangement can be found at the following URL:

Once you have accessed the web site, click the link that says "G3508 ULB Upgrade - Parts to Order".

Once you have received the upgrade parts, the retro fit must be registered as a non-serialized component. Refer to ""Register the Retrofit" " for further instructions.

Assembly Procedure

Cylinder Block and Liners Installation

1. Install cylinder liners according to the following sequence.

   1. Clean the cylinder block.

   2. Check for blockage in the oil passages of the block.

   3. Install the O-Ring seals onto the cylinder liners.

   4. Lubricate the bores of the block with 266-9682 White Assembly Compound before installing liners.

   5. Install the liners into the block. Check the cylinder liner projection. Refer to Systems Operation, Testing and Adjusting, KENR6892.

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Illustration 1	g02251513

2. Install the camshaft bearings and check the camshaft bearing oil passages for alignment. Refer to Illustration 1 and Disassembly and Assembly, KENR8147.

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Illustration 2	g02251394

3. Install all of the plugs into the cylinder block.

Crankshaft Installation

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Illustration 3	g02251434

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Illustration 4	g02251477

1. Install the crankshaft according to the following sequence.

   1. Record the bearing numbers and the cylinder locations. Keep this information for future reference.

   2. Install the main bearings into the block and the main bearing caps. Grease the bearings using 266-9682 White Assembly Compound . Refer to Illustration 3.

   3. Install the crankshaft.

   4. Install the main bearing caps and torque the bolts to specifications. Refer to Illustration 4 and to Specifications, KENR6891.

   5. Install the thrust plate.

   6. Measure end play of the crankshaft.

   7. Rotate the crankshaft. Make sure that the crankshaft will rotate freely.

Piston Assembly and Installation

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Illustration 5	g02251558

1. Assemble the pistons and the connecting rods according to the following sequence.

   1. Install the rings onto the pistons.

   2. Install the bearings onto the connecting piston rods and caps.

   3. Grease the bearings using 266-9682 White Assembly Compound .

2. Install pistons according to the following sequence.

   1. Lubricate pistons and rings with clean engine oil before installing the components into the block.

   2. Clean and lubricate the cylinder liners with clean engine oil.

   3. Install the pistons into the cylinder liners.

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Illustration 6	g02251635

3. Install the connecting rod bearing caps and torque the bolts to specifications. Refer to Specifications, KENR6891.

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Illustration 7	g02251673

4. Install the counterweights and torque the new bolts to specifications. Refer to Specifications, KENR6891.

5. Rotate the crankshaft to the top center (TC) position.

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Illustration 8	g02254113

6. Install the piston cooling jets.

Camshaft Installation

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Illustration 9	g02699760

1. Install the 4P-9321 Wiring Harness through the cylinder block below the camshaft.

Note: Lubricate the camshaft bearings before installing the camshaft.

2. Install the camshafts. Pin the camshafts in place.

Air Intake Plate Installation

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Illustration 10	g02620478
(1) Bolt locations for the aftercooler mounting assembly

1. Install the air intake plate assembly. Be sure to leave all the bolts and spacers out of the aftercooler mounting assembly until aftercooler is installed. Refer to Illustration 10. Refer to Disassembly and Assembly, KENR8147.

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Illustration 11	g02620697
Side covers

2. Install the covers for the cylinder block.

Cylinder Head Installation

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Illustration 12	g02251753

1. Install the dowels for the cylinder heads.

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Illustration 13	g02251833

2. Install the spacer plates with gaskets, seals, water ferrules, and head gaskets.

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Illustration 14	g02253813

3. Install the plugs into cylinder heads before installation onto the block.

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Illustration 15	g02251858

4. Install the cylinder head and torque the bolts to specifications. Refer to Specifications, KENR6891.

Front and Rear Gear Housing Assembly

1. Install the rear idler and cluster gears. Apply Locktite to the bolts and torque the bolts to specifications.

2. Install the rear housing. Make sure to torque the bolts in sequence. Refer to Disassembly and Assembly, KENR8147.

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Illustration 16	g02254654

3. Install the rear crankshaft seal assembly.

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Illustration 17	g02256873

4. Install the front housing. Make sure to torque the bolts in sequence. Refer to Disassembly and Assembly, KENR8147.

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Illustration 18	g02251993

5. Install the flywheel and torque the bolts to specifications. Refer to Specifications, KENR6891. Make sure to torque the bolts in sequence.

6. Check the flywheel runout and end play. Refer to Systems Operation, Testing and Adjusting, KENR6892.

7. Time the flywheel and pin the flywheel.

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Illustration 19	g02253833

8. Install the rear camshaft drive gears and torque the bolts to specifications. Refer to Specifications, KENR6891. Make sure to torque the bolts in sequence. Refer to Disassembly and Assembly, KENR8147.

9. Remove the camshaft timing pins.

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Illustration 20	g02253913

10. Install the front crankshaft seal assembly.

Valve Covers Installation

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Illustration 21	g02621622
Exhaust temperature sensors

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Illustration 22	g02252875

1. Assemble the valve covers according to the following sequence.

   1. Install the exhaust temperature sensors.

   2. Install the valve cover bases.

   3. Install the push rods and valve bridges. Make sure that the push rods are aligned.

   4. Install the rocker arm assemblies.

   5. Torque the rocker arm assembly retaining bolts. Refer to Specifications, KENR6891.

   6. Adjust the valve lash. Refer to Systems Operation, Testing and Adjusting, KENR6892.

   7. Install the transformers.

   8. Install the valve covers and the crankcase breathers.

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Illustration 23	g02252894

2. Install the air inlet elbows.

Oil Cooler Installation

1. Assemble the oil cooler. Refer to Disassembly and Assembly, KENR8147.

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Illustration 24	g02621695

2. Install the oil coolers and the oil lines.

Water Manifold Installation

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Illustration 25	g02252953
Exhaust heat shields

1. 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 26	g02255933
Water manifolds

2. Install the water manifolds.

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Illustration 27	g02255996

3. Install the water T fitting

Aftercooler Installation

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Illustration 28	g02622302
Assemble aftercooler

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Illustration 29	g02622417

1. Install the aftercooler according to the following sequence.

   1. Install the water manifold tee fitting before installing the aftercooler. Refer to Illustration 27.

   2. Assemble the aftercooler as a group. Refer to Illustration 28 or refer to Disassembly and Assembly, KENR8147.

   3. Install aftercooler into the base and the top housing refer to Illustration 29. Torque the bolts to specifications. Refer to Specifications, KENR6891.

Oil and Water Pump Installation

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Illustration 30	g02254656

1. Install the engine oil pump.

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Illustration 31	g02261854

2. Install the auxiliary water pump.

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Illustration 32	g02257017
Auxiliary water pump gear

3. Install the front accessary drives.

4. Install the front auxiliary drive.

5. Install the front gear group.

6. Install the cover and the adapters on the front housing.

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Illustration 33	g02254153

7. Install the oil filter group and the related tubes.

8. Install the damper and the crankshaft pulley. Torque the bolts to specifications.

Cooling System Installation

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Illustration 34	g02263519

1. Install the water temperature regulator housing and the related water lines.

   1. Install the water lines from the water pump to the aftercooler.

Oil Pan

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Illustration 35	g02254633

1. Assemble the oil pan. Refer to Disassembly and Assembly, KENR8147.

2. Install the oil pan assembly and the oil pump supply tube.

3. Install the dipstick.

Turbochargers Installation

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Illustration 36	g02624136
(1) Turbocharger support (2) Turbocharger oil line fittings (3) Turbocharger oil lines (graphically shortened for illustrative purposes only)

1. Install the turbocharger according to the following sequence.

   1. Install the oil line fittings (2) into the block.

   2. Install the turbocharger support (1) .

   3. Loosely install the turbocharger oil lines (3) .

   4. Install the turbochargers.

   5. Tighten turbocharger oil lines

   6. Install the water lines for the turbochargers.

   7. Connect the turbochargers to the exhaust manifold piping.

   8. Install the air lines from turbocharger to the aftercooler. Refer to Illustration 42.

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Illustration 37	g02625078
(4) Mounting ring for the exhaust (5) Sensor (6) Sensor harness (7) Support clip for the harness (8) Mounting port for sensor (9) Cover for the sensor control unit (10) Tie-wraps (11) Slack in the harness

2. 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.

3. Install the heat shields that cover the turbochargers and the exhaust manifolds.

Starting Motor and Alternator Installation

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Illustration 38	g02261455

1. Install the starting motors.

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Illustration 39	g02252273

2. Install the alternator.

Gas Regulator and Fuel Heater Installation

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Illustration 40	g02262193

1. Install the gas regulator bracket.

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Illustration 41	g02625099

2. Install the gas regulator and the gas lines.

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Illustration 42	g02265553

3. Install the inlet fuel heater.

Engine Electrical Installation

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Illustration 43	g02646530
Locations of the engine sensors (left side engine view) (1) Manifold inlet air temperature sensor (2) Coolant temperature sensor (3) Unfiltered oil pressure sensor (4) Filtered oil pressure sensor (5) Coolant out pressure sensor (6) NOx Buffer (7) Oil temperature sensor (8) Exhaust temperature sensors (9) Solenoid for the Gas Shutoff Valve (GSOV) (10) Engine speed/timing sensor

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Illustration 44	g02625265
Locations of the engine sensors (right side engine view) (11) Turbo temperature sensor (12) Exhaust temperature sensors (13) Manifold inlet air temperature sensor (14) Coolant temperature sensor (15) Coolant inlet pressure switch connection (16) Prelube solenoid valve connection

1. Install all of the sensors on the engine. Refer to Schematic, KENR9034.

2. Rebuild the control box and install the ECM in the control box.

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Illustration 45	g02251253

3. Install the control box and wire the panel.

4. Rebuild the interface box with the new harness.

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Illustration 46	g02251873
For detailed information refer to the electrical schematic

5. Install the interface box.

6. Install the pyrometer harness. Refer to Systems Operations, Testing and Adjusting, KENR6892.

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Illustration 47	g02251693
Left side typical view

7. Install the detonation harness.

8. Install the alternator harness.

Final Assembly

1. Install the dyno hardware. Refer to Special Instruction, REHS5007 for initial start-up procedures.

2. 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.

1. 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.

   Note: When registering this upgrade, use 381-0873 Engine Conversion Ar for the part number to be registered.

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   Table 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)	381-0873
   Installed Component Serial Number (3)

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   ( 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.

2. 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".

3. For detailed instructions on updating the product configuration, refer to Special Instruction, REHS5097, "Instructions to Register the Retrofit".