Installation of the 419-0893 Solenoid Valve Gp for Certain G3500 Petroleum Engines{1274, 5479} Caterpillar

Engine:

G3508B (S/N: RBK1-UP)

G3512B (S/N: JHH1-UP)

Introduction

The following procedure describes installation for the 419-0893 Solenoid Valve Gp .

The new solenoid valve group seals the gas supply from the engine during shutdown at high operating pressures. Sealing the gas at high operating pressures reduces restarting difficulty, or backfiring.

Required Parts

Tables 1 contains the parts needed for installation of the solenoid valve group.

Disassembly

1. Shut down the engine and shut off the gas supply to the fuel lines.

2. Purge fuel from the fuel lines and gas shutoff valve.

3. Remove the current gas shutoff valve (GSOV), fuel piping, fuel heater core, and fuel heater core bracket from the engine.

   Set aside the fuel heater core and associated hardware for reuse.

Installation

Illustration 1	g03655254
Typical G3508 ULB with the 419-0893 Solenoid Valve Gp (GSOV)

Illustration 2	g03655255
Typical G3512 ULB with the 419-0893 Solenoid Valve Gp (GSOV)

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Illustration 3	g03655257
(1) 443-7246 Tube As

1. Apply sealant to the threads of tube assembly (1) .

2. Install tube assembly (1) the pipe tee, so that when the fuel cooler core is installed the connection flanges are positioned horizontal.

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Illustration 4	g03655916
(2) 424-1117 Bracket

3. Install bracket (2) onto rail with the original hardware.

   Leave the bolts loose so the bracket can slide to facilitate mounting and installation of fuel heater and bolts.

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Illustration 5	g03655259
(1) 443-7246 Tube As (3) 425-3549 Gasket

4. Attach the fuel cooler core loosely to tube assembly (1) with one gasket (3) and the original hardware.

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Illustration 6	g03655918
(3) 425-3549 Gasket (4) 419-6617 Tube As

5. Attach tube assembly (4) loosely to the fuel cooler core with one gasket (3) and the original hardware.

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Illustration 7	g03655959
(4) 419-6617 Tube As (5) 419-0893 Solenoid Valve Gp (GSOV) (6) 420-8789 Gasket (7) 9X-8881 Bolt (8) 5P-8247 Hard Washer (9) 4K-0367 Full Nut

6. Attach GSOV (5) loosely to tube assembly (4) with one gasket (6), four bolts (7), four washers (8), and four nuts (9) .

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Illustration 8	g03655960
(5) 419-0893 Solenoid Valve Gp (GSOV) (6) 420-8789 Gasket (7) 9X-8881 Bolt (8) 5P-8247 Hard Washer (9) 4K-0367 Full Nut (10) 443-7245 Bracket (11) 9X-8883 Bolt (12) 424-0851 Flange

7. Attach bracket (10) and flange (12) loosely to GSOV (5) with one gasket (6), two bolts (7), two bolts (11), four washers (8), and four nuts (9). Refer to Illustration 8 for the correct location of the bracket and bolts.

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Illustration 9	g03655974
(1) 443-7246 Tube As (2) 424-1117 Bracket (4) 419-6617 Tube As

8. Attach tube assemblies (1) and (4) loosely to bracket (2) with the original hardware.

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Illustration 10	g03655975
(10) 443-7245 Bracket (13) 2H-3743 Bolt (14) 5P-8250 Washer

9. Attach bracket (10) to the flywheel housing with two bolts (13) and two washers (14) .

10. Snug the four 6V-8188 Nut for the fuel cooler core bracket to rail.

11. Check for assembly strain before torquing the rest of the bolts.

    a. Check the GSOV and fuel tube assembly for strain as the fuel heater bracket and GSOV bolts are tightened. If there is misalignment, loosen all of the bolts for the bracket to rail, fuel heater end plate, and the gas shut off valve bolts.

    b. Reposition above components to eliminate previous assembly strain. Leave the gas shut off valve and fuel heater end plate bolts loose.

    c. Hand tighten the fuel heater to fuel heater bracket first. Then tighten the fuel heater bracket to rail bolts.

    d. Check that the gas shut off valve and heater end plate bolts turn free by hand and not binding in the bolt holes. If the bolts can turn by hand, the fuel tubes are aligned.

12. Perform the final torque procedure for installation of the new gas shut off valve.

    a. Torque the fuel heater to fuel heater bracket bolts to 47 ± 9 N·m (35 ± 7 lb ft).

    b. Torque the fuel heater bracket to rail bolts to 105 ± 20 N·m (77 ± 15 lb ft).

    c. Torque the fuel heater end plate bolts to 47 ± 9 N·m (35 ± 7 lb ft).

    d. Torque the gas shut off valve bolts to 150 ± 20 N·m (111 ± 15 lb ft).

    e. Torque the GSOV bracket to flywheel housing bolts to 300 ± 50 N·m (221 ± 37 lb ft)

    f. Reconnect the fuel piping to the fuel supply and check for any leaks.