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Installation of Exhaust Shield Assemblies On Certain G3520C Engines {1059} Caterpillar


Installation of Exhaust Shield Assemblies On Certain G3520C Engines {1059}

Usage:

G3520C GZJ
Engine
G3520C (S/N: GZJ1-UP; HAT1-UP)

Introduction

Use the following procedures to install exhaust shields on G3520C Engines. Do not perform any procedure in this special instruction until you have read this special instruction and you understand this information.

Refer to Table 1 for the serial numbers and associated groups for installing the exhaust shield assemblies.

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Table 1
Group  Serial Number 
1  S/N:GZJ161-169,174-181,183-186,188,196-198,201,204-210,215,219-233,236,243-246,266,268,270-271,273-275,277-283,288-293,310,313 
2  S/N:GZJ234-235,257,259-260,262,265,267,284,294-307,311,314-319,321-363,369-381,385-409,411-421,424-428 
S/N:HAT102,200-205,207,209-211
3  S/N:GZJ429-473,476,478-491,493-495,498-553,600-620,624-665 
4  S/N:GZJ666-712 

Required Parts

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Table 2
Group 1 
Qty  Part Number 
8  0S-1595 Bolts 
2  1A-5822 Bolts 
4  3H-5825 Bolts 
4  5P-7128 High Temperature Bolts 
4  3E-6916 Full Nuts 
2  6V-3631 Full Nuts 
2  417-6722 Plates 
1  332-1462 Seal 
1  415-3125 Shield As 
1  415-3127 Shield As 
12  8C-8491 Hard Washers 
10  130-2321 Washers 
2  226-6575 Washers 
2  030-7949 Elbows 
6  0S-1594 Bolts 
4  7X-0818 Bolts 
12  4H-7655 Tube Clamps 
6  100-3237 Grommets 
1  318-8420 Hose As 
1  318-8421 Hose As 
6  9S-8752 Full Nuts 
2  5P-3456 O-Ring Seals 
2  311-3212 Tube As 
12  5M-2894 Hard Washers 
4  8T-4224 Hard Washers 
2  238-5081 O-Ring Seals 
1  344-9432 Shield As 
1  344-9433 Shield As 
1  344-9434 Shield As 
1  445-5974 Grid 
6  1A-1460 Bolts 
6  6V-1820 Bolts 
1  423-5408 Bracket 
1  423-5409 Bracket 
6  1F-7958 Full Nuts 
6  3E-4353 Hard Washers 
18  5P-8245 Hard Washers 
2  111-5822 Exhaust Gasket 
12  Fastener (if required) 

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Table 3
Group 2 
Qty  Part Number 
8  0S-1595 Bolts 
2  1A-5822 Bolts 
4  3H-5825 Bolts 
4  5P-7128 High Temperature Bolts 
4  3E-6916 Full Nuts 
2  6V-3631 Full Nuts 
2  417-6722 Plates 
1  332-1462 Seal 
1  415-3125 Shield As 
1  415-3127 Shield As 
12  8C-8491 Hard Washers 
10  130-2321 Washers 
2  226-6575 Washers 
2  030-7949 Elbows 
6  0S-1594 Bolts 
4  7X-0818 Bolts 
12  4H-7655 Tube Clamps 
6  100-3237 Grommets 
1  318-8420 Hose As 
1  318-8421 Hose As 
6  9S-8752 Full Nuts 
2  5P-3456 O-Ring Seals 
2  311-3212 Tube As 
12  5M-2894 Hard Washers 
4  8T-4224 Hard Washers 
2  238-5081 O-Ring Seals 
1  344-9432 Shield As 
1  344-9433 Shield As 
1  344-9434 Shield As 
1  445-5974 Grid 
2  111-5822 Exhaust Gasket 
12  Fastener (if required) 

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Table 4
Group 3 
Qty  Part Number 
8  0S-1595 Bolts 
2  1A-5822 Bolts 
4  3H-5825 Bolts 
4  5P-7128 High Temperature Bolts 
4  3E-6916 Full Nuts 
2  6V-3631 Full Nuts 
2  417-6722 Plates 
1  332-1462 Seal 
1  415-3125 Shield As 
1  415-3127 Shield As 
12  8C-8491 Hard Washers 
10  130-2321 Washers 
2  226-6575 Washers 
1  445-5974 Grid 
2  111-5822 Exhaust Gasket 
12  Fastener (if required) 

Note: For engines listed in group 1, refer to "Group 1 and 2 Installation Procedure", perform Steps 1 through 27.

Note: For engines listed in group 2, refer to "Group 1 and 2 Installation Procedure", perform Steps 2 through 22.

Note: For engines listed in group 3, refer to "Group 3 Installation Procedure".

Group 1 and 2 Installation Procedure

    Show/hide table
    Illustration 1g03742020
    Typical example of the 271-3830 Turbocharger Support Gp
    (1) 271-2347 Bracket
    (2) 271-2348 Bracket

  1. Remove brackets (1) and (2).
    Show/hide table
    Illustration 2g03742033
    (3) Clips
    (4) Tubes or hoses
    (5) Bracket
    (6) Tube assemblies
    (7) Brackets

  2. Remove tubes or hoses (4), clips (3), brackets (5) and (7), and tube assemblies (7).

    Note: Depending upon when your engine was built, tubes or hoses may be used. The drain tubes do not need to be removed.

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    Illustration 3g03742064
    (8) 415-3127 Shield As
    (9) 5P-7128 High Temperature Bolts
    (10) 8C-8491 Hard Washers
    (11) 3E-6916 Full Nuts

  3. Attach shield assembly (8) to the elbow using four bolts (9), eight washers (10), and four nuts (11).
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    Illustration 4g03742089
    (8) 415-3127 Shield As
    (12) 417-6722 Plate
    (13) 3H-5825 Bolt
    (14) 130-2321 Washers
    (15) 415-3125 Shield As
    (16) 1A-5822 Bolts
    (17) 226-6575 Washers
    (18) 6V-3631 Full Nut

  4. Attach shield assembly (15) to the elbow using four bolts (13) and four washers (14).

  5. Attach the top portion of shield assembly (15) to the elbow using two bolts (16), two washers (14), two washers (17), and two nuts (18).

  6. Attach plate (12) to shield assemblies (8) and (15) using four bolts (13) and four washers (14).
    Show/hide table
    Illustration 5g03743401
    (8) 415-3127 Shield As
    (12) 417-6722 Plate
    (13) 3H-5825 Bolt
    (14) 130-2321 Washers
    (15) 415-3125 Shield As

  7. Attach plate (12) to shield assemblies (8) and (15) using four bolts (13) and four washers (14).
    Show/hide table
    Illustration 6g03743448
    (19) 030-7949 Elbows
    (20) 318-8420 Hose As
    (21) 318-8421 Hose As

  8. Install two 238-5081 O-Ring Seal onto elbows (19) and install the elbows.

  9. Attach hose assemblies (20) and (21) to elbows (19).
    Show/hide table
    Illustration 7g03743785
    (20) 318-8420 Hose As
    (22) 4H-7655 Tube Clamps
    (23) 100-3237 Grommets
    (24) 0S-1594 Bolts
    (25) 5M-2894 Hard Washers
    (26) 9S-8752 Full Nuts
    (27) 311-3212 Tube As
    (28) 7X-0818 Bolts
    (29) 8T-4224 Hard Washers

  10. Install three grommets (23) onto hose assembly (20).

  11. Attach hose assembly (20) to the coolant tube using six clamps (22) over grommets (23).

  12. Secure the clamps using three bolts (24), six washers (25), and three nuts (26).

  13. Install one 5P-3456 O-Ring Seal into tube assembly (27).

  14. Attach tube assembly (27) to the turbocharger oil supply port using two bolts (28) and two washers (29).
    Show/hide table
    Illustration 8g03743857
    (21) 318-8421 Hose As
    (22) 4H-7655 Tube Clamps
    (23) 100-3237 Grommets
    (24) 0S-1594 Bolts
    (25) 5M-2894 Hard Washers
    (26) 9S-8752 Full Nuts
    (27) 311-3212 Tube As
    (28) 7X-0818 Bolts
    (29) 8T-4224 Hard Washers

  15. Install three grommets (23) onto hose assembly (21).

  16. Attach hose assembly (20) to the coolant tube using six clamps (22) over grommets (23).

  17. Secure the clamps using three bolts (24), six washers (25), and three nuts (26).

  18. Install one 5P-3456 O-Ring Seal into tube assembly (27).

  19. Attach tube assembly (27) to the turbocharger oil supply port using two bolts (28) and two washers (29).
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    Illustration 9g03743876
    (30) 344-9434 Shield As
    (31) 344-9433 Shield As
    (32) 344-9432 Shield As

  20. Install shield assemblies (30), (31), and (32).

  21. Disconnect the exhaust system above the engine.
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    Illustration 10g03743886
    (33) 445-5974 Grid

  22. Install grid (33) on top of the exhaust elbow. Use site-specific hardware to attach the grid to the elbow.

    Note: For engines listed in Group 2, connect the engine exhaust system after installing grid (33).

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    Illustration 11g06098926
    (34) 423-5408 Bracket
    (35) 423-5409 Bracket
    (36) 1A-1460 Bolts
    (37) 5P-8245 Hard Washers
    (38) 1F-7958 Full Nuts
    (39) 6V-1820 Bolts
    (40) 3E-4353 Hard Washers
    (41) 111-5822 Exhaust Gasket

  23. Install gasket (41) above and below the grid (33).

    Install bracket (34), attach the bracket to the exhaust elbow using three bolts (36), nine washers (37), and three nuts (38).

  24. Attach bracket (34) to the compressor housing using three bolts (39) and three washers (40). Tighten bolts (39) to 65 ± 5 N·m (48 ± 4 lb ft).

  25. Install bracket (35), attach the bracket to the exhaust elbow using three bolts (36), nine washers (37), and three nuts (38).

  26. Attach bracket (35) to the compressor housing using three bolts (39) and three washers (40). Tighten bolts (39) to 65 ± 5 N·m (48 ± 4 lb ft).

  27. Connect the exhaust system.

Group 3 Installation Procedure

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    Illustration 12g03744132
    (1) 344-9432 Shield As
    (2) 344-9434 Shield As
    (3) 344-9433 Shield As

  1. Remove shield assemblies (1), (2), and (3).
    Show/hide table
    Illustration 13g03744152
    (4) 415-3127 Shield As
    (5) 5P-7128 High Temperature Bolts
    (6) 8C-8491 Hard Washers
    (7) 3E-6916 Full Nuts

  2. Attach shield assembly (4) to the elbow using four bolts (5), eight washers (6), and four nuts (7).
    Show/hide table
    Illustration 14g03744163
    (4) 415-3127 Shield As
    (8) 417-6722 Plate
    (9) 3H-5825 Bolt
    (10) 130-2321 Washers
    (11) 415-3125 Shield As
    (12) 1A-5822 Bolts
    (13) 226-6575 Washers
    (14) 6V-3631 Full Nut

  3. Attach shield assembly (11) to the elbow using four bolts (9) and four washers (10).

  4. Attach the top portion of shield assembly (11) to the elbow using two bolts (12), two washers (10), two washers (13), and two nuts (14).

  5. Attach plate (8) to shield assemblies (4) and (11) using four bolts (9) and four washers (10).
    Show/hide table
    Illustration 15g03744167
    (4) 415-3127 Shield As
    (8) 417-6722 Plate
    (9) 3H-5825 Bolt
    (10) 130-2321 Washers
    (11) 415-3125 Shield As

  6. Attach plate (8) to shield assemblies (4) and (8) using four bolts (9) and four washers (10).
    Show/hide table
    Illustration 16g03744132
    (1) 344-9432 Shield As
    (2) 344-9434 Shield As
    (3) 344-9433 Shield As

  7. Reinstall shield assemblies (1), (2), and (3).

  8. Disconnect the exhaust system above the engine.
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    Illustration 17g06098929
    (15) 445-5974 Grid
    (16) 111-5822 Exhaust Gasket

  9. Install gasket (16) above and below the grid (15).

    Install grid (15) on top of the exhaust elbow. Use site-specific hardware to attach the grid to the elbow.

  10. Connect the exhaust system.

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