New Exhaust Manifold Brackets Are Now Used on Certain G3500 Engines {0635, 1061} Caterpillar

Engine

G3512H (S/N: GF51-149)

G3516H (S/N: NWH1-184; NWJ1-112; GLM1-188; GLN1-138)

G3520H (S/N: GFP1-195; GFR1-220)

Generator Set

CG170-16 (S/N: KSJ1-167)

Description Of Change: The new 523-8667 Bracket and 523-8668 Bracket provide more support to prevent fatigue cracks.

Adaptable To: The following changes are adaptable to the products within the listed serial numbers, and are effective with all products after the listed serial numbers.

Rework Procedure

Use the 512-6300 Plate As (Exhaust Spacer Tool) to align the exhaust elbow and manifolds.

Note: Ensure that the 512-6300 Plate As (Exhaust Spacer Tool) measures 111 mm (4.4 inch).

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Illustration 1	g06367766
(A) Bellow (B) Bellow (C) Elbow

1. Remove bellow (A) from elbow (C).

2. Remove the hardware for bellow (B) on the flange mating with the elbow.
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   Illustration 2	g06367811
   (C) Elbow (D) Nut (E) Washer (F) Bolt (G) Washer (1) 454-9488 Plate (2) 454-9486 Bracket (Left side) 454-9486 Bracket (Right side)

3. Remove 4 bolts (F) with 4 washers (G), 4 nuts (D), and 4 washers (E) that mount exhaust elbow (C) to bracket (2).
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   Illustration 3	g06367826
   (C) Elbow (D) Nut (E) Washer (F) Bolt (G) Washer (H) Bolt (K) Washer (1) 454-9488 Plate (2) 454-9486 Bracket (Left side) 454-9486 Bracket (Right side)

4. Remove 2 bolts (H) and 2 washers (K) from bracket (2).
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   Illustration 4	g06367850
   (C) Elbow (1) 454-9488 Plate (2) 454-9486 Bracket (Left side) 454-9486 Bracket (Right side) (3) 523-8667 Bracket (Left side) 523-8668 Bracket (Right side) (4) 0S-1590 Bolt (5) 198-4777 Hard Washer (6) 6L-3143 High Temperature Bolt (7) 226-6575 Washer (8) 6V-5766 Bolt (9) 6V-3631 Full Nut

5. Install bracket (3) to bracket (2) using 2 bolts (4) with 2 hard washers (5).

   1. Install 2 high temperature bolts (6) with 2 washers (7) through bracket (3), bracket (2), plate (1), and elbow (C).

   2. Loosely install 2 full nuts (9) and 2 washers (7) onto high temperature bolts (6).

6. Install 2 bolts (8) through bracket (2), plate (1), and elbow (C) using washer (7).

   1. Loosely install 2 full nuts (9) with 2 washers (7) onto bolts (8).
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   Illustration 5	g06378060
   (C) Elbow (1) 454-9488 Plate (L) Bolt (M) Washer

7. Remove 4 bolts (L) and 4 washers (M).
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   Illustration 6	g06378061
   (C) Elbow (1) 454-9488 Plate (10) Bolt (11) Washer

8. Install 4 bolts (10) to plate (1) using 4 washers (11).
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   Illustration 7	g06377019
   (B) Bellow (C) Elbow (L) Exhaust Manifold (T1) 512-6300 Plate As (Exhaust Spacer Tool)

9. Install exhaust spacer tool (T1) between elbow (C) and exhaust manifold (L).

   Note: Ensure that the 512-6300 Plate As (Exhaust Spacer Tool) measures 111 mm (4.4 inch).

10. Install bellow (B) onto the elbow using the 356-8647 Seal, 6 376-7739 Bolt, 12 107-7954 Spacer, and 6 3E-6916 Full Nut.
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    Illustration 8	g06367947
    (C) Elbow (1) 454-9488 Plate (2) 454-9486 Bracket (Left side) 454-9486 Bracket (Right side) (3) 523-8667 Bracket (Left side) 523-8668 Bracket (Right side) (6) 6L-3143 High Temperature Bolt (7) 226-6575 Washer (8) 6V-5766 Bolt (9) 6V-3631 Full Nut

11. Tighten 2 high temperature bolts (6) and 2 bolts (8).
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    Illustration 9	g06367766
    (A) Bellows (C) Elbow

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    Illustration 10	g06368007
    (A) Bellow (C) Elbow (12) 376-7739 Bolt (13) 107-7954 Spacer (14) 3E-6916 Full Nut

12. Remove the alignment tool and install bellow (A) onto elbow (C) using 2 356-8647 Seal, 4 bolts (12), 8 spacers (13), and 4 full nuts (14).

    Note: Ensure that the bellows are installed in the correct direction using new hardware.

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    Illustration 11	g06367988
    (15) Exhaust Shield

13. Install new exhaust shield (15) with cutout.