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Installing Coolant Tubes and Clamps on Certain C175-16 Locomotive Engines {1307, 1380} Caterpillar


Installing Coolant Tubes and Clamps on Certain C175-16 Locomotive Engines {1307, 1380}

Usage:

C175-16 3A9
Engine
C175-16 (S/N: 3A91-UP; Y3A1-UP; KWT1-UP; R1X1-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.

Required Parts

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Table 1
Qty  Part Number  Part Name 
1  1T-1068  O-Ring Seal 
1  2Y-5829  Nut 
11  3E-4353  Hard Washer 
7  5P-8245  Hard Washer 
2  6A-5591  Bolt 
4  6V-1820  Bolt 
2  6V-3668  Bolt 
10  6V-3822  Bolt 
4  6V-4248  Bolt 
1  6V-4356  Clip 
1  6V-4357  Clip 
16  6V-5839  Washer 
2  6V-6707  O-Ring Seal 
9  6V-6782  Clip 
9  6V-6783  Clip 
3  6V-7673  Bolt 
1  6V-8149  Nut 
2  6V-8197  Bolt 
3  7D-1649  Hard Washer 
12  8T-0643  Bolt 
1  8T-7526  O-Ring Seal 
4  8T-7934  Hard Washer 
11  103-0892  Grommet 
2  208-6135  Clip 
2  208-6136  Clip 
1  216-8578  O-Ring Seal 
1  241-6174  Plug 
2  248-4097  Strap 
4  258-8738  O-Ring Seal 
4  259-4597  O-Ring Seal 
2  260-9153  Plug 
2  262-9990  O-Ring Seal 
2  269-7885  O-Ring Seal 
1  339-5623  Tube As 
2  344-9285  Ring 
4  344-9286  Ring 
1  348-8242  Tube As 
4  371-6761  Flange 
2  371-6762  Flange 
1  454-0707  Grommet 
1  477-2032  Bracket As 
1  477-2035  Bracket 
2  486-1380  Block 
3  486-1382  Block 
3  502-6652  Coupling Gp 
1  512-4970  Tube As 
1  512-4971  Tube 
1  516-4042  Bracket 
1  516-4043  Tube 

Installing the 516-4043 Tube

  1. Allow the engine to cool.

  2. Drain coolant from cooling system into a suitable container for storage or for disposal.
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    Illustration 1g06143274

  3. Drain oil from oil cooler bypass housing into a suitable container for storage or for disposal. Remove and set aside the M12 drain plug for reuse.

  4. Remove and discard the clip and associated hardware.

  5. Remove and discard the oil tube, clips, and associated hardware.

  6. Retain the 9Y-2099 Flange for reuse.
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    Illustration 2g06143279
    (1) 516-4042 Bracket
    (2) 6V-3668 Bolt
    (3) 5P-8245 Hard Washer

  7. Attach bracket (1) to the front housing with two bolts (2) and two washers (3).
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    Illustration 3g06143283
    (4) 516-4043 Tube
    (5) 344-9285 Ring
    (6) 371-6762 Flange

  8. Install flange 6 onto tube assembly (4). The large flange end goes toward the tube assembly double upset.

  9. Install ring 5 onto tube assembly (4). The large taper end goes toward the tube assembly double upset.
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    Illustration 4g06143284
    (4) 516-4043 Tube
    (7) 6V-6707 O-Ring Seal
    (8) 9Y-2099 Flange
    (9) 269-7885 O-Ring Seal

  10. Install one O-ring (9) onto tube assembly (4).

  11. Lubricate the bore of flange (8) and O-ring (9) with O-ring lubricant.

  12. Install flange (8) onto tube assembly (4) and O-ring (9).

  13. Install one O-ring (7) into flange (8). Use O-ring retention compound to hold the O-ring inside the flange.
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    Illustration 5g06143289
    (4) 516-4043 Tube
    (8) 9Y-2099 Flange
    (10) 8T-0643 Bolt
    (11) 6V-5839 Washer

  14. Attach tube assembly (4) and flange (8) to the engine with two bolts (10) and two washers (11).
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    Illustration 6g06143290
    (4) 516-4043 Tube
    (8) 9Y-2099 Flange
    (10) 8T-0643 Bolt
    (11) 6V-5839 Washer

  15. Attach tube assembly (4) and flange (8) to the oil cooler with two bolts (10) and two washers (11).
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    Illustration 7g06143296
    (1) 516-4042 Bracket
    (4) 516-4043 Tube
    (11) 6V-5839 Washer
    (12) 6V-3822 Bolt
    (13) 2Y-5829 Nut
    (14) 454-0707 Grommet
    (15) 6V-4356 Clip
    (16) 6V-4357 Clip

  16. Install one grommet (14) around tube assembly (4).

  17. Install one clip (15) and one clip (16) around grommet (14).

  18. Attach clips (15) and (16) to bracket (1) with one bolt (12), two washers (11), and one nut (13).

  19. Re-install the M12 drain plug into the bottom of the oil cooler bypass housing.

Installing the 512-4970 Tube As and the 512-4971 Tube

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Illustration 8g06143302

  1. Remove and discard the tube assemblies and associated hardware.
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    Illustration 9g06143312
    The 502-6652 Coupling Gp installed over both tube assemblies.
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    Illustration 10g06143314
    The 502-6652 Coupling Gp slid over onto one tube assembly.

  2. Remove 502-6652 Coupling Gp from the coolant tube assemblies. Slide the coupling past the end of the tubes. Make sure the gripper teeth are disengaged from the tubes.

    Note: Loosen the bolts alternately, but do not remove the bolts.

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    Illustration 11g06143308

  3. Remove and set aside the 215-9090 Elbow from the rear coolant tube assembly for reuse.

  4. Remove and set aside the 129-9454 Flange from the front and rear coolant tube assemblies for reuse.
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    Illustration 12g06143322
    (1) 248-4097 Strap
    (2) 6V-4248 Bolt
    (3) 6V-5839 Washer

  5. Attach two straps (1) to the inlet air manifolds with one bolt (2) and one washer (3) per strap.
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    Illustration 13g06143283
    (4) 512-4971 Tube
    (5) 344-9286 Ring
    (6) 371-6761 Flange

  6. Install flange 6 onto tube assembly (4). The large flange end goes toward the tube assembly double upset.

  7. Install ring 5 onto tube assembly (4). The large taper end goes toward the tube assembly double upset.
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    Illustration 14g06143284
    (4) 512-4971 Tube
    (7) 258-8738 O-Ring Seal
    (8) 129-9454 Flange
    (9) 259-4597 O-Ring Seal

  8. Install one O-ring (9) onto tube assembly (4).

  9. Lubricate the bore of flange (8) and O-ring (9) with O-ring lubricant.

  10. Install flange (8) onto tube assembly (4) and O-ring (9).

  11. Install one O-ring (7) into flange (8). Use O-ring retention compound to hold the O-ring inside the flange.
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    Illustration 15g06143328
    (4) 512-4971 Tube
    (8) 129-9454 Flange
    (10) 8T-0643 Bolt
    (11) 6V-5839 Washer

  12. Attach tube assembly (4) and flange (8) to the coolant elbow with two bolts (10) and two washers (11).
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    Illustration 16g06143337
    (4) 512-4971 Tube
    (12) 103-0892 Grommet
    (13) 6V-6782 Clip
    (14) 6V-6783 Clip
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    Illustration 17g06143358
    (1) 248-4097 Strap
    (12) 103-0892 Grommet
    (13) 6V-6782 Clip
    (14) 6V-6783 Clip
    (15) 6V-1820 Bolt
    (16) 3E-4353 Hard Washer

  13. Install one grommet (12) around tube (4).

  14. Install one clip (13) and one clip (14) around grommet (12).

  15. Attach clips (13) and (14) to strap (1) with one bolt (15) and one washer (16).
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    Illustration 18g06143361

  16. Slide the 502-6652 Coupling Gp over the end of tube (1) and out of the way.
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    Illustration 19g06143362
    (5) 344-9286 Ring
    (6) 371-6761 Flange
    (17) 512-4970 Tube As

  17. Install flange 6 onto tube assembly (17). The large flange end goes toward the tube assembly double upset.

  18. Install ring 5 onto tube assembly (17). The large taper end goes toward the tube assembly double upset.
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    Illustration 20g06143363
    (7) 258-8738 O-Ring Seal
    (8) 129-9454 Flange
    (9) 259-4597 O-Ring Seal
    (17) 512-4970 Tube As

  19. Install one O-ring (9) onto tube assembly (17).

  20. Lubricate the bore of flange (8) and O-ring (9) with O-ring lubricant.

  21. Install flange (8) onto tube assembly (17) and O-ring (9).

  22. Install one O-ring (7) into flange (8). Use O-ring retention compound to hold the O-ring inside the flange.
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    Illustration 21g06143368
    (8) 129-9454 Flange
    (10) 8T-0643 Bolt
    (11) 6V-5839 Washer
    (17) 512-4970 Tube As

  23. Attach tube assembly (17) and flange (8) to the housing with two bolts (10) and two washers (11).
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    Illustration 22g06143397
    (12) 103-0892 Grommet
    (13) 6V-6782 Clip
    (14) 6V-6783 Clip
    (17) 512-4970 Tube As
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    Illustration 23g06143402
    (12) 103-0892 Grommet
    (13) 6V-6782 Clip
    (14) 6V-6783 Clip
    (15) 6V-3822 Bolt
    (16) 3E-4353 Hard Washer

  24. Install one grommet (12) around tube (17).

  25. Install one clip (13) and one clip (14) around grommet (12).

  26. Attach clips (13) and (14) to the inlet air manifolds with one bolt (15) and one washer (16) per set of clips.
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    Illustration 24g06143409
    (4) 512-4971 Tube
    (17) 512-4970 Tube As
    Show/hide table
    Illustration 25g06044126
    A properly torqued coupling should have the coupling bars parallel and approximately a finger width apart.

  27. Make sure that tube assemblies (4) and (17) are aligned.

  28. Measure the length of the 502-6652 Coupling Gp.

  29. Mark half width of the 502-6652 Coupling Gp from center of gap on each tube assembly.

  30. Slide the 502-6652 Coupling Gp over and center coupling between these marks.

  31. Tighten the coupling bolts lightly alternating between each bolt. Refer to Illustration 25 for a properly torqued coupling.

    Torque bolts ... 12 N·m (106 lb in)

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    Illustration 26g06143412
    (17) 512-4970 Tube As
    (18) 260-9153 Plug
    (19) 262-9990 O-Ring Seal

  32. Install plug (18) and one O-ring (19) into tube assembly (17).
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    Illustration 27g06143417
    (17) 512-4970 Tube As
    (20) 216-8578 O-Ring Seal

  33. Install the original 215-9090 Elbow and one O-ring (20) into tube assembly (17).

Installing the 348-8242 Tube As and the 339-5623 Tube As

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Illustration 28g06143424

  1. Remove and set aside the clips with grommets and associated hardware for reuse.

  2. Remove and discard the tube assembly, clips without grommets, and associated hardware.
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    Illustration 29g06143427
    The 502-6652 Coupling Gp installed over both tube assemblies.
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    Illustration 30g06143428
    The 502-6652 Coupling Gp slid over onto one tube assembly.

  3. Remove and set aside the 359-9855 Coupling As from the coolant tube assemblies for reuse. Slide the coupling past the end of the tubes. Make sure the gripper teeth are disengaged from the tubes.

    Note: Loosen the bolts alternately, but do not remove the bolts.

  4. Remove and set aside the 129-9454 Flange from the coolant tube assembly for reuse.
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    Illustration 31g06143433
    (1) 477-2035 Bracket
    (2) 6A-5591 Bolt
    (3) 5P-8245 Hard Washer

  5. Attach bracket (1) to the flywheel housing with two bolts (2) and two washers (3).
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    Illustration 32g06143283
    (4) 348-8242 Tube As
    (5) 344-9286 Ring
    (6) 371-6761 Flange

  6. Install flange 6 onto tube assembly (4). The large flange end goes toward the tube assembly double upset.

  7. Install ring 5 onto tube assembly (4). The large taper end goes toward the tube assembly double upset.
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    Illustration 33g06143284
    (4) 348-8242 Tube As
    (7) 258-8738 O-Ring Seal
    (8) 129-9454 Flange
    (9) 259-4597 O-Ring Seal

  8. Install one O-ring (9) onto tube assembly (4).

  9. Lubricate the bore of flange (8) and O-ring (9) with O-ring lubricant.

  10. Install flange (8) onto tube assembly (4) and O-ring (9).

  11. Install one O-ring (7) into flange (8). Use O-ring retention compound to hold the O-ring inside the flange.
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    Illustration 34g06143456
    (4) 348-8242 Tube As
    (8) 129-9454 Flange
    (10) 8T-0643 Bolt
    (11) 6V-5839 Washer

  12. Attach tube assembly (4) and the original flange (8) to the housing with two bolts (10) and two washers (11).
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    Illustration 35g06143458
    (4) 348-8242 Tube As

  13. Slide the 502-6652 Coupling Gp over the end of tube assembly (4) and out of the way.
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    Illustration 36g06143470
    (1) 477-2035 Bracket
    (4) 348-8242 Tube As
    (12) 103-0892 Grommet
    (13) 6V-6782 Clip
    (14) 6V-6783 Clip
    (15) 6V-8197 Bolt
    (16) 5P-8245 Hard Washer
    (17) 6V-8149 Nut

  14. Install grommet (12) around tube assembly (4).

  15. Install one clip (13) and one clip (14) around grommet (12).

  16. Attach clips (13) and (14) to bracket (1) with one bolt (15), one washer (16), and one nut (17).
    Show/hide table
    Illustration 37g06143464

  17. Install the original grommet and clips around tube assembly (4).

  18. Secure the original clips to the engine with the original hardware.
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    Illustration 38g06143458
    (4) 348-8242 Tube As
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    Illustration 39g06044126
    A properly torqued coupling should have the coupling bars parallel and approximately a finger width apart.

  19. Make sure that tube assemblies (4) and the original tube assembly are aligned.

  20. Measure the length of the 502-6652 Coupling Gp.

  21. Mark half width of the 502-6652 Coupling Gp from center of gap on each tube assembly.

  22. Slide the 502-6652 Coupling Gp over and center coupling between these marks.

  23. Tighten the coupling bolts lightly alternating between each bolt. Refer to Illustration 25 for a properly torqued coupling.

    Torque bolts ... 12 N·m (106 lb in)

    Show/hide table
    Illustration 40g06143478

  24. Remove and discard the tube assembly, clips, and associated hardware.
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    Illustration 41g06143480
    The 502-6652 Coupling Gp installed over both tube assemblies.
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    Illustration 42g06143490
    The 502-6652 Coupling Gp bolts.
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    Illustration 43g06143491
    The 502-6652 Coupling Gp slid over onto one tube assembly.

  25. Remove and set aside the 502-6652 Coupling Gp from the coolant tube assemblies for reuse. Slide the coupling past the end of the tubes. Make sure the gripper teeth are disengaged from the tubes.

    Note: Loosen the bolts alternately, but do not remove the bolts.

  26. Remove and set aside the 129-9454 Flange from the coolant tube assembly for reuse.
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    Illustration 44g06143496

  27. Slide the 502-6652 Coupling Gp off of the tube assembly.
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    Illustration 45g06143593
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    Illustration 46g06143498
    (18) 486-1382 Block
    (19) 6V-7673 Bolt
    (20) 7D-1649 Hard Washer

  28. Attach three blocks (18) to the engine block with one bolt (19) and one washer (20) per block.

    Note: The tapped hole is offset from the through hole in block (18). Orient the tapped hole offset up.

    Note: The blocks use the same hole as the original clips.

    Show/hide table
    Illustration 47g06143501
    (12) 103-0892 Grommet
    (13) 6V-6782 Clip
    (14) 6V-6783 Clip
    (18) 486-1382 Block
    (21) 6V-3822 Bolt
    (22) 3E-4353 Hard Washer

  29. Install one grommet (12) around the original tube assembly.

  30. Install one clip (13) and one clip (14) around grommet (12).

  31. Attach clips (13) and (14) to block (18) with one bolt (21) and one washer (22).
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    Illustration 48g06143505
    (5) 344-9286 Ring
    (6) 371-6761 Flange
    (23) 339-5623 Tube As

  32. Install flange 6 onto tube assembly (23). The large flange end goes toward the tube assembly double upset.

  33. Install ring 5 onto tube assembly (23). The large taper end goes toward the tube assembly double upset.
    Show/hide table
    Illustration 49g06143506
    (7) 258-8738 O-Ring Seal
    (8) 129-9454 Flange
    (9) 259-4597 O-Ring Seal
    (23) 339-5623 Tube As

  34. Install one O-ring (9) onto tube assembly (23).

  35. Lubricate the bore of flange (8) and O-ring (9) with O-ring lubricant.

  36. Install flange (8) onto tube assembly (23) and O-ring (9).

  37. Install one O-ring (7) into flange (8). Use O-ring retention compound to hold the O-ring inside the flange.
    Show/hide table
    Illustration 50g06143509
    (8) 129-9454 Flange
    (10) 8T-0643 Bolt
    (11) 6V-5839 Washer
    (23) 339-5623 Tube As

  38. Attach tube assembly (23) and the original flange (8) to the housing with two bolts (10) and two washers (11).
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    Illustration 51g06143513
    (23) 339-5623 Tube As
    (24) 241-6174 Plug
    (25) 8T-7526 O-Ring Seal

  39. Install plug (24) and one O-ring (25) into tube assembly (23).
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    Illustration 52g06143516

  40. Slide the 502-6652 Coupling Gp over the end of the tube assembly (23).
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    Illustration 53g06143593
    Show/hide table
    Illustration 54g06143501
    (12) 103-0892 Grommet
    (13) 6V-6782 Clip
    (14) 6V-6783 Clip
    (18) 486-1382 Block
    (21) 6V-3822 Bolt
    (22) 3E-4353 Hard Washer
    (23) 339-5623 Tube As

  41. Install two grommets (12) around tube assembly (23).

  42. Install one clip (13) and one clip (14) around each grommet (12).

  43. Attach clips (13) and (14) to blocks (18) with one bolt (21) and one washer (22) per set of clips.
    Show/hide table
    Illustration 55g06143516
    Show/hide table
    Illustration 56g06044126
    A properly torqued coupling should have the coupling bars parallel and approximately a finger width apart.

  44. Make sure that tube assembly (4) and the original tube assembly are aligned.

  45. Measure the length of the 502-6652 Coupling Gp.

  46. Mark half width of the 502-6652 Coupling Gp from center of gap on each tube assembly.

  47. Slide the 502-6652 Coupling Gp over and center coupling between these marks.

  48. Tighten the coupling bolts lightly alternating between each bolt. Refer to Illustration 25 for a properly torqued coupling.

    Torque bolts ... 12 N·m (106 lb in)

    Show/hide table
    Illustration 57g06143596

  49. Remove and discard the clips, brackets, and associated hardware one set of clips at a time.
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    Illustration 58g06178191
    (12) 103-0892 Grommet
    (22) 3E-4353 Hard Washer
    (24) 208-6135 Clip
    (25) 208-6136 Clip
    (26) 6V-1820 Bolt
    (27) 486-1380 Block
    (28) 6V-4248 Bolt

  50. Install two blocks (27) to the air inlet manifolds with one bolt (28) and one washer (22) per block.

  51. Install one grommet (12) around the original tube assembly.

  52. Install one clip (24) and one clip (25) around grommet (12).

  53. Attach clips (24) and (25) to block (27) with one bolt (26) and one washer (22).

  54. Install one grommet (12) around the original tube assembly.

  55. Install one clip (24) and one clip (25) around grommet (12).

  56. Attach clips (24) and (25) to block (27) with one bolt (26) and one washer (22).
    Show/hide table
    Illustration 59g06143635
    Show/hide table
    Illustration 60g06143659

  57. Remove and discard the clips and associated hardware.
    Show/hide table
    Illustration 61g06143637

  58. Remove and discard the clips and associated hardware.
    Show/hide table
    Illustration 62g06143638
    Show/hide table
    Illustration 63g06143642

  59. Remove and discard the bracket and associated hardware. Set aside the 307-9758 Cover for reuse.
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    Illustration 64g06178193
    (12) 103-0892 Grommet
    (13) 6V-6782 Clip
    (14) 6V-6783 Clip
    (15) 6V-8197 Bolt
    (16) 5P-8245 Hard Washer
    (21) 6V-3822 Bolt
    (29) 477-2032 Bracket As
    (30) 8T-7934 Hard Washer

  60. Attach bracket (29), the original 307-9758 Cover, and one 1T-1068 O-Ring Seal to the front housing with four bolts (21) and four washers (30).

    Note: A new 1T-1068 O-Ring Seal should be used.

  61. Install one grommet (12) around the original tube assembly.

  62. Install one clip (13) and one clip (14) around grommet (12).

  63. Attach clips (13) and (14) to bracket (29) with one bolt (15) and one washer (16).

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