- Engine:
- G3512 (S/N: 7NJ1-UP; WPP1-UP; WPR1-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 G3512 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 for detailed assembly instructions.
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:
https://engines.cat.com/upgradekitsOnce you have accessed the web site, click the link that says "G3512 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
- Install cylinder liners according to the following sequence:
- Clean the cylinder block.
- Check for blockage in the oil passages of the block.
- Install the O-Ring seals onto the cylinder liners.
- Lubricate the bores of the block with 266-9682 White Assembly Compound before installing liners.
- Install the liners into the block. Check the cylinder liner projection. Refer to Systems Operation, Testing and Adjusting, KENR6892.
- Install the camshaft bearings and check the camshaft bearing oil passages for alignment. Refer to Illustration 1 and Disassembly and Assembly, KENR8147.
Illustration 1 | g02251513 |
- Install all of the plugs into the cylinder block.
Illustration 2 | g02251394 |
Crankshaft Installation
- Install the crankshaft according to the following sequence:
- Record the bearing numbers and the cylinder locations. Keep this information for future reference.
- 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.
Show/hide tableIllustration 3 g02251434
- Install the crankshaft.
- Install the main bearing caps and torque the bolts to specifications. Refer to Illustration 4 and to Specifications, KENR6891.
Show/hide tableIllustration 4 g02251477
- Install the thrust plate.
- Measure end play of the crankshaft.
- Rotate the crankshaft. Make sure that the crankshaft will rotate freely.
Piston Assembly and Installation
- Assemble the pistons and the connecting rods according to the following sequence:
- 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 .
Illustration 5 | g02251558 |
- Install pistons according to the following sequence:
- Lubricate pistons and rings with clean engine oil before installing the components into the block.
- Clean and lubricate the cylinder liners with clean engine oil.
- Install the pistons into the cylinder liners.
- Install the connecting rod bearing caps and torque the bolts to specifications. Refer to Specifications, KENR6891.
Illustration 6 | g02251635 |
- Install the counterweights and torque the new bolts to specifications. Refer to Specifications, KENR6891.
Illustration 7 | g02251673 |
- Rotate the crankshaft to the top center (TC) position.
- Install the piston cooling jets.
Illustration 8 | g02254113 |
Camshaft Installation
- Install the camshafts according to the following sequence:
- Install the 4P-9322 Wiring Harness through the cylinder block below the camshaft.
Show/hide tableIllustration 9 g02678656
- Install the camshafts. Pin the camshafts in place.
Note: Lubricate the camshaft bearings before installing the camshaft.
Air Intake Plate Installation
- 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.
Illustration 10 | g02678627 |
(1) Bolt locations for the aftercooler mounting assembly |
- Install the covers for the cylinder block.
Illustration 11 | g02678621 |
Side covers |
Cylinder Head Installation
- Install the cylinder heads according to the following sequence:
- Install the dowels for the cylinder heads.
Show/hide tableIllustration 12 g02251753
- Install the spacer plates with gaskets, seals, water ferrules, and head gaskets.
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- Install the plugs into cylinder heads before installation onto the block.
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- Install the cylinder head and torque the bolts to specifications. Refer to Specifications, KENR6891.
Show/hide tableIllustration 15 g02251858
Front and Rear Gear Housing Assembly
- Install the front and rear gear housing assemblies according to the following sequence:
- 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. Refer to Disassembly and Assembly, KENR8147.
- Install the rear crankshaft seal assembly.
Show/hide tableIllustration 16 g02254654
- Install the front housing. Make sure to torque the bolts in sequence. Refer to Disassembly and Assembly, KENR8147.
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- Install the flywheel and torque the bolts to specifications. Refer to Specifications, KENR6891. Make sure to torque the bolts in sequence.
Show/hide tableIllustration 18 g02251993
- 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. Make sure to torque the bolts in sequence. Refer to Disassembly and Assembly, KENR8147.
Show/hide tableIllustration 19 g02253833
- Remove the camshaft timing pins.
- Install the front crankshaft seal assembly.
Show/hide tableIllustration 20 g02253913
Valve Covers Installation
- Assemble the valve covers according to the following sequence:
- Install the exhaust temperature sensors.
Show/hide tableIllustration 21 g02678623
Exhaust temperature sensors
- 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.
- Install the valve covers and the crankcase breathers.
- Install the air inlet elbows.
Illustration 22 | g02252894 |
Oil Cooler Installation
- Assemble the oil cooler. Refer to Disassembly and Assembly, KENR8147.
- Install the oil coolers and the oil lines.
Illustration 23 | g02678876 |
Water Manifold Installation
- Install the exhaust manifolds, and the bellows. Cover the exhaust components with heat shields. Torque the bolts to specifications. Refer to Specifications, KENR6891.
Illustration 24 | g02252953 |
Exhaust heat shields |
- Install the water manifolds.
Illustration 25 | g02255933 |
Water manifolds |
- Install the water T fitting
Illustration 26 | g02255996 |
Aftercooler Installation
- Install the aftercooler according to the following sequence:
- Install the water manifold tee fitting before installing the aftercooler. Refer to Illustration 26.
- Assemble the aftercooler as a group. Refer to Illustration 27 or refer to Disassembly and Assembly, KENR8147.
Show/hide tableIllustration 27 g02678676
- Install aftercooler into the base and the top housing refer to Illustration 28. Torque the bolts to specifications. Refer to Specifications, KENR6891.
Show/hide tableIllustration 28 g02678697
Oil and Water Pump Installation
- Install the engine oil pump.
Illustration 29 | g02254656 |
- Install the auxiliary water pump.
Illustration 30 | g02261854 |
- Install the front accessary drives.
Illustration 31 | g02257017 |
Auxiliary water pump gear |
- 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.
Illustration 32 | g02254153 |
- Install the damper and the crankshaft pulley. Torque the bolts to specifications.
Cooling System Installation
- Install the water temperature regulator housing and the related water lines.
- Install the water lines from the water pump to the aftercooler.
Illustration 33 | g02263519 |
Oil Pan
- Assemble the oil pan. Refer to Disassembly and Assembly, KENR8147.
Illustration 34 | g02254633 |
- Install the oil pan assembly and the oil pump supply tube.
- Install the dipstick.
Turbochargers Installation
- Install the turbocharger according to the following sequence:
- Install the oil line fittings into the block.
- Install the turbocharger support.
- Loosely install the turbocharger oil lines.
- Install the turbochargers.
- Tighten turbocharger oil lines
- Install the water lines for the turbochargers.
- Connect the turbochargers to the exhaust manifold piping.
- Install the air lines from turbocharger to the aftercooler.
- 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.
Illustration 35 | g02678699 |
(1) Mounting ring for the exhaust (2) Sensor (3) Slack in the harness (4) Tie-wraps (5) Sensor harness (6) Mounting port for sensor (7) Cover for the sensor control unit |
- Install the heat shields that cover the turbochargers and the exhaust manifolds.
Starting Motor and Alternator Installation
- Install the starting motors.
Illustration 36 | g02261455 |
- Install the alternator.
Illustration 37 | g02252273 |
Gas Regulator and Fuel Heater Installation
- Install the gas regulator bracket.
Illustration 38 | g02262193 |
- Install the gas regulator and the gas lines.
Illustration 39 | g02678778 |
- Install the inlet fuel heater.
Illustration 40 | g02265553 |
Engine Electrical Installation
- Install all of the sensors on the engine. Refer to Schematic, KENR9034.
Illustration 41 | g02678940 |
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 |
Illustration 42 | g02679056 |
Locations of the engine sensors (right side engine view) (11) Turbo temperature sensor (12) Exhaust temperature sensors (13) Coolant inlet pressure switch connection (14) Prelube solenoid valve connection |
- Rebuild the control box and install the ECM in the control box.
- Install the control box and wire the panel.
Illustration 43 | g02251253 |
- Rebuild the interface box with the new harness.
- Install the interface box.
Illustration 44 | g02251873 |
For detailed information refer to the electrical schematic |
- Install the pyrometer harness. Refer to Systems Operations, Testing and Adjusting, KENR6892.
- Install the detonation harness.
Illustration 45 | g02251693 |
Left side typical view |
- Install the alternator harness.
Final Assembly
- Install the dyno hardware. Refer to Special Instruction, REHS5007 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.
Note: When registering this upgrade, use 381-0874 Engine Conversion Ar for the part number to be registered.
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)     381-0874     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".