G3600 A4 Engines Caterpillar


Exhaust Bypass Valve

Usage:

G3612 BB2


Illustration 1g03821111
(3) 102-3457 Cover
(4) 102-6309 Thrust Washer
(5) 102-6311 Stop
(6) 6V-6753 High Temperature Bolt
(7) 8M-2295 Bolt

Table 1
Specification for 379-9020 Exhaust Bypass 
Item  Qty  Part  Specification Description 
416-4960 Tee As  Bore in housing for shaft bushings is 25.845 ± 0.013 mm (1.0175 ± 0.0005 inch).
Before assembly, outside diameter of 119-5929 Bushing is 25.898 ± 0.013 mm (1.0196 ± 0.0005 inch).
Diameter of shaft is 19.500 ± 0.013 mm (0.7677 ± 0.0005 inch)
30  5P-7128 High Temperature Bolt  Torque to 50 ± 10 N·m (37 ± 7 lb ft)
211-8175 Electronic Actuator Gp  A final adjustment of the linkage is required to ensure that the plate does not contact the housing when the plate is in the closed position. Fully extend the actuator to the closed position. With the plate in contact with the housing, shorten the length of the connecting rod by 2/3 turn. Lock the connecting rod in place. 
Install actuator (8) so the inlet port and outlet port are aligned. The ports on the actuator are stamped "Inlet" and "Outlet".
8H-3390 Full Nut  Torque to 200 ± 20 N·m (148 ± 15 lb ft)


Illustration 2g03821113
Detail of area A
(11) 379-9019 Shaft
(12) 4P-0394 Lever
(13) 5H-2532 Woodruff Key
(14) 6V-1943 High Temperature Bolt
(15) 119-5931 Spacer
(16) 133-8501 Cover As
(18) 102-1694 Plate

Table 2
Item  Qty  Part  Specification Description 
10  447-0674 Link  Torque to 10 ± 2 N·m (89 ± 18 lb in)
Use the following procedure in order to assemble the exhaust bypass valve and the actuator linkage.

1. Assemble the plate of the exhaust bypass valve to the shaft. Leave the mounting bolts loose. Assemble thrust washer (4) and axial stop (5). Tighten the axial stop bolt (6) to standard torque.
2. Install cover (3) and tighten the cover bolts (7).
3. Fully close the plate of exhaust bypass valve (18). Tighten mounting bolts (17) to 15 ± 3 N·m (133 ± 27 lb in). Bend the locking ends upward in order to secure the bolts in position. Install spacer (15) and cover assembly (16) onto the shaft. Make sure that the shaft can rotate freely. Tighten the bolts (14) for the cover assembly to standard torque. 
With the plate (18) of the exhaust bypass valve assembled to the shaft. Assemble the levers (12) to the shaft (11) of the exhaust bypass valve. Use the woodruff keys (13) in order to provide proper orientation. 
17  5P-9960 Bolt  Torque to 15 ± 3 N·m (133 ± 27 lb in)
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