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Assembly Procedure For Aftercooler Bonnet Group On Certain G3500 and CG170-16 Engines {1063} Caterpillar


Assembly Procedure For Aftercooler Bonnet Group On Certain G3500 and CG170-16 Engines {1063}

Usage:

G3520H GFP
Engine
G3516H (S/N: GLM1-UP; GLN1-UP)
G3520H (S/N: GFP1-UP; GFR1-UP)
Generator Set
CG170-16 (S/N: KSJ1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.

Dispose of all fluids according to local regulations and mandates.

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NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Assembly Procedure

Installation Procedure For G3516H and CG170-16 Aftercooler Bonnet Group

Required Parts

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Table 1
Qty  Part Number  Description 
10  0S-1588  Bolts 
47  0S-1594  Bolts 
6  0S-1625  Bolts 
2  105-8180  Gaskets 
2  165-3929  Bolts-Hex Head 
4  165-3931  Bolts-Hex Head 
2  1A-8537  Bolts 
4  1B-4367  Bolts 
1  214-7568  O-Ring Seal 
1  228-7088  O-Ring Seal 
2  227-9012  Gaskets 
1  228-7089  Seal-O-Ring-ORFS 
1  2T-2170  Adapter-Elbow 
3  325-6994  Clips-Half Slot 
3  325-6995  Clips-Half Tab 
3  353-7956  Grommets 
1  357-8769  Gasket 
1  362-1343  Housing-AFCLR 
4  3B-1915  Bolts 
8  3E-4352  Washers-Hard 
3  452-2248  Gaskets(1) 
1  471-1956  Hose As. 
1  471-1957  Bracket As 
12  4K-0367  Nuts-Full 
53  5M-2894  Washers-Hard 
24  5P-8247  Washers-Hard 
3  5R-9779  Gasket(2) 
8  6V-3940  Bolts-Hex Head 
1  6V-8641  Connector 
2  8M-9124  Washers-Hard 
12  8S-2332  Bolt-12 Point HD 
4  9S-8752  Nut-Full 
15  9X-6458  Washers-Hard 
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(1) Gasket is to only be used with the flat face fuel valve.
(2) Gasket as an option to be used with TJ raised face fuel valve.
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    Illustration 1g06073391
    (1) 0S-1588 Bolts
    (2) 5M-2894 Hard Washers
    (3) 0S-1594 Bolts
    (4) 362-1343 Aftercooler Housing
    (5) 357-8769 Gasket
    (6) 3B-1915 Bolts
    (7) 0S-1591 Bolts

  1. Install aftercooling housing (4) with gasket (5), washers (2), bolts (1), (3), (6), and (7).
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    Illustration 2g06073467
    (8) 227-9012 Gaskets
    (9) 8S-2332 Bolts

  2. Install throttle with bolts (9), and gaskets (8).
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    Illustration 3g06073476
    (10) 6V-3940 Bolts
    (11) 3E-4352 Hard Washers
    (12) 358-6239 Bracket As

  3. Secure throttle to bracket assembly (12) with bolts (10) and washers (11).
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    Illustration 4g06073509
    (3) 0S-1594 Bolts
    (10) 6V-3940 Bolts
    (11) 3E-4352 Hard Washers
    (13) 454-4732 Bracket
    (14) 9X-6458 Hard Washers
    (15) 362-1361 Bracket
    (16) 362-1360 Bracket

  4. Install brackets (13), (15), and (16) with bolts (3) and washers (14). Install bolts (10) and washers (11) into bracket (16).
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    Illustration 5g06154245
    (17) 1B-4367 Bolts
    (18) 5P-8247 Hard Washers
    (19) 4K-0367 Full Nuts
    (20) 452-2248 Gaskets
    (21) 1A-8537 Bolts
    (22) 0S-1625 Bolts
    (34) 5R-9779 Gaskets

    Note: Use 452-2248 Gasket for engines with flat face TJ.Use 5R-9779 Gasket as an option to be used with 418-7744 Gas Control Valve.

  5. Install gaskets (20) with bolts (17), (21), (22), washers (18), and nuts (19).
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    Illustration 6g06073934
    (1) 0S-1588 Bolts
    (2) 5M-2894 Hard Washers
    (23) 105-8180 Gaskets
    (24) 0S-1571 Bolts
    (25) 9S-8752 Full Nuts

  6. Install gaskets (23) with bolts (1), (24), washers (2), and nuts (25).
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    Illustration 7g06198343
    (3) 0S-1594 Bolts
    (14) 9X-6458 Hard Washers
    (26) 385-5780 Elbow As
    (27) 8M-9124 Washers
    (28) 325-6994 Clips
    (29) 325-6995 Clips
    (30) 353-7956 Grommets
    (31) 471-1956 Hose As
    (32) 471-1957 Bracket As
    (33) 6V-8641 Connector
    (34) 214-7568 O-Ring Seal
    (35) 228-7088 O-Ring Seal

  7. Install hose assembly (31) with elbow assembly (26) and connector assembly (33), (34), and (35).

  8. Install bracket assembly (32) with bolt (3) and washer (14).

  9. Secure hose assembly (31) with bolts (3), washers (14), (27), clips (28), (29), and grommets (30).

Installation Procedure For G3520H Aftercooler Bonnet Group

Required Parts

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Table 2
Qty  Part Number  Description 
8  0S-1588  Bolts 
35  0S-1594  Bolts 
8  0S-1625  Bolts 
8  1A-1135  Bolt 
6  1A-2029  Bolt 
2  105-8180  Gaskets 
2  165-3929  Bolts-Hex Head 
4  165-3931  Bolts-Hex Head 
2  168-4987  Gasket 
8  1A-8537  Bolts 
1  214-7568  O-Ring Seal 
2  227-9012  Gaskets 
1  228-7088  O-Ring Seal 
1  228-7089  O-Ring Seal 
1  2T-2170  Adapter-Elbow 
3  325-6994  Clips-Half Slot 
3  325-6995  Clips-Half Tab 
3  353-7956  Grommets 
1  357-8769  Gasket 
1  362-1343  Housing-AFCLR 
9  3B-1915  Bolts 
8  3E-4352  Washers-Hard 
1  471-1956  Hose As. 
1  471-1957  Bracket As 
24  4K-0367  Nuts-Full 
53  5M-2894  Washers-Hard 
48  5P-8247  Washers-Hard 
8  6V-3940  Bolts-Hex Head 
1  6V-8641  Connector 
2  8M-9124  Washers-Hard 
2  8S-2331  Bolt-12 Point HD 
10  8S-2332  Bolt-12 Point HD 
4  9S-8752  Nut-Full 
9  9X-6458  Washers-Hard 
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    Illustration 8g06072398
    (1) 0S-1594 Bolts
    (2) 5M-2894 Hard Washer
    (3) 3B-1915 Bolts
    (4) 362-1343 Aftercooler Housing
    (5) 357-8769 Gasket
    (6) 0S-1591 Bolts

  1. Install aftercooling housing (4) with gasket (5), washers (2) bolts (1), (3), and (6).
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    Illustration 9g06072573
    (7) 8S-2331 Bolts
    (8) 227-9012 Gaskets
    (9) 8S-2332 Bolts

  2. Install throttle with bolts (7), (9), and gaskets (8).
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    Illustration 10g06072825
    (10) 6V-3940 Bolts
    (11) 3E-4352 Hard Washers
    (12) 358-6239 Bracket As

  3. Secure throttle to bracket assembly (12) with bolts (10) and washers (11).
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    Illustration 11g06072906
    (10) 6V-3940 Bolts
    (11) 3E-4352 Hard Washers
    (13) 1A-2029 Bolts
    (14) 9X-6458 Hard Washers
    (15) 1A-8537 Bolts
    (16) 5P-8247 Hard Washers
    (17) 4K-0367 Full Nuts
    (18) 168-4987 Gaskets
    (19) 0S-1625 Bolts

  4. Install bracket to aftercooler housing with bolts (13) and washers (14).

  5. Install bolts (15) and (19) with gaskets (18), washers (16), and nuts (17).

  6. Install bolts (10) and washers (11) to bracket.
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    Illustration 12g06073080
    (2) 5M-2894 Hard Washers
    (20) 0S-1588 Bolts
    (21) 9S-8752 Full Nuts
    (22) 0S-1571 Bolts
    (23) 105-8180 Gaskets

  7. Install gaskets (23) with bolts (21), (22), washers (2), and nuts (21).
    Show/hide table
    Illustration 13g06198345
    (1) 0S-1594 Bolts
    (14) 9X-6458 Hard Washers
    (20) 0S-1588 Bolts
    (24) 385-5780 Elbow As
    (25) 8M-9124 Washers
    (26) 325-6994 Clips
    (27) 325-6995 Clips
    (28) 353-7956 Grommets
    (29) 471-1956 Hose As
    (30) 471-1957 Bracket As
    (31) 6V-8641 Connector
    (32) 214-7568 O-Ring Seal
    (33) 228-7088 O-Ring Seal

  8. Install hose assembly (29) with elbow assembly (24) and connector assembly (31), (32), and (33).

  9. Install bracket assembly (30) with bolt (1) and washer (14).

  10. Secure hose assembly (29) with bolts (20), washers (14), (25), clips (26), (27), and grommets (28).

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