Installation of 106-5328 Conversion Arrangement For 3412 (825, 900, ; 1000 HP) Marine Engines With 9Z5359 Modification{1000, 1022} Caterpillar

Installation of 106-5328 Conversion Arrangement For 3412 (825, 900, & 1000 HP) Marine Engines With 9Z5359 Modification{1000, 1022}

Usage:

3412 Marine Engine38S

Introduction

This Special Instruction contains the necessary parts list and instructions for upgrading 3412 Marine Propulsion Engines rated at 825, 900, and 1000 HP. The Caterpillar Engine Service Representative should be consulted before ordering the parts for this conversion arrangement.

Miscellaneous items that are part of the engine installation into the vessel, but are not supplied by Caterpillar, may require modification or replacement because of the new components. This conversion arrangement provides the following components and associated hardware:

1. Water cooled turbochargers (turbine housings) and water cooled exhaust risers

2. Larger engine mounted heat exchanger with integral expansion tank

3. Deaerators

4. Air cleaners with positive crankcase pressure/oil separator system

5. Gilkes auxiliary water pump (optional).

General Information

A separate parts list and drawing is included for each group. In order to minimize the sorting of parts and to ease the installation of these components, it is strongly suggested that SEPARATE parts orders be placed for the parts in EACH group in the conversion. The parts list is for ONE engine except for 106-5344 Conversion Group for the Lower Cover. This group specifies parts specifically for the port and starboard engine. It will be necessary to place TWO separate parts orders for all of the other groups.

Repositioning Engine Components

The location of engine components must be carefully reviewed before starting the installation of the conversion arrangement. Inspect the following components closely.

1. The position of the turbochargers will require the exhaust piping to be moved rearward 61.9 mm (2.44 in), in order to maintain proper alignment of all the exhaust connections. Determine exactly which connection(s) need(s) to be repositioned to allow the piping to move straight back. Also inspect the exhaust hangers/brackets to make sure that the piping is correctly supported.

2. The new watercooled exhaust risers require water elbows and a connector from the bottom rear of each of the exhaust manifolds to the bottom of the risers. If the marine gear mounting brackets are also connected to the sides of the flywheel housing, the mounting brackets may need to be reworked to clear the new elbows and connectors.

3. If the marine gear oil cooler is connected to the engine mounted heat exchanger, a brass 90° elbow with 1"-11 1/2 NPTF thread and a barbed end for 19 mm (.75 in) I.D. coolant hose must be added to the right bottom side of the heat exchangers. Verify the I.D. of the hose.

Part Number Index

The 106-5328 Conversion Arrangement consists of the following groups.

Component Removal

1. Remove the heat exchanger, deaerators, auxiliary raw water pump, temperature regulator housings, brackets, hoses, elbows, clamps, connectors and other parts associated with the heat exchanger.

NOTE: Remove the auxiliary water pump only if it will be replaced. Do not remove the jacket water pump.

2. Remove the air cleaner elements, silencers, boots, brackets, and other related parts.

3. Remove the fuel lines as left-side and right-side groups.

4. Remove the aftercooler air inlet pipes and aftercooler cover. If necessary clean the aftercooler core.

5. Remove the heat insulation wrap from the turbochargers and risers.

6. Remove the turbocharger's oil/water lines and jacket water lines.

7. Remove the turbocharger support brackets, turbochargers, and exhaust risers.

8. Remove the rear lifting eye and rework to provide additional clearance.

Component Installation

Install the following groups:

1. 105-0268 Auxiliary Pump Group (optional)

2. 106-5360 Conversion Group (Aftercooler)

3. 106-5331 Conversion Group (Valve Cover)

4. 4P9219 Air Cleaner Group

5. 4P7924 Air Cleaner Mounting Group

6. 106-5344 Conversion Group (Lower Cover)

7. 106-5369 Conversion Group (Watercooled Exhaust Manifold)

8. 4P7473 Turbocharger Group

9. 4P7476 Turbocharger Oil Lines Group

10. 106-5379 Conversion Group (Turbocharger Water Lines)

11. 4P7477 Air Lines Group

12. 106-5400 Conversion Group (Heat Exchanger)

13. 7E1123 Lifting Eye Group

The following pages contain the conversion assembly procedures for each group along with a component drawing and parts list.

105-0268 Auxiliary Pump Group, Gilkes (Optional)

The 105-0268 Auxiliary Pump Group is optional for this conversion arrangement. This pump group is not required as part of the conversion in order to add the watercooled turbochargers, exhaust risers, heat exchanger and air cleaners.

If the optional 105-0268 Auxiliary Pump Group is NOT used, the 4P7987 Hose is not needed (part of 106-5400 Conversion Group). Order one 109-2169 Hose for the Jabsco Auxiliary Water Pump.

105-0268 Auxiliary Pump Group (Gilkes)

106-5360 Conversion Group (Aftercooler)

The 108-3593 Aftercooler Cover Group (1) is serviced as a complete assembly. Install a new gasket (2) and reuse the original bolts and washers to install aftercooler cover.

NOTE: If necessary, clean the aftercooler core.

106-5360 Conversion Group (Aftercooler)

106-5331 Conversion Group (Valve Cover) (Port Engine)

This conversion requires additional parts along with the original parts already on the engine. Additionally, one 7C9621 Plug, one 8C5196 Seal and one 6N2758 Rocker Arm Cover are needed. The right rear flat valve cover must be installed on the right rear to clear the bracket for the Air Cleaner Mounting Group. Reuse the original valve cover mounting bolts.

Port Engine

Reposition the adapters and plugs in the valve covers as follows.

1. Left front cover. Put the new 7C9621 Plug with 8C5196 Seal in the front and a 7C6514 Adapter in the rear of the valve cover. Install the breather onto the adapter.

2. Left rear cover. Put 7C9621 Plugs in both locations.

3. Right front cover. Put 7C6514 Adapters in both locations. Install oil filler plug onto front adapter and a breather onto the other adapter.

4. Right rear cover. Install a 6N2758 Rocker Arm Cover (no holes).

106-5331 Conversion Group (Port Engine)

106-5331 Conversion Group (Valve Cover) (Starboard Engine)

Starboard Engine

Reposition adapters and plugs in the valve covers as follows.

1. Left front cover. Put 7C6514 Adapters in both locations. Install oil filler plug on front adapter and a breather on the other adapter.

2. Left rear cover. Put 7C9621 Plugs in both locations.

3. Right front cover. Put the new 7C9621 Plug with 8C5196 Seal in the front and a 7C6514 Adapter in the rear of the valve cover. Install a breather on the adapter.

4. Right rear cover. Install a 6N2758 Rocker Arm Cover (no holes). Reuse the original valve cover mounting bolts.

106-5331 Conversion Group (Starboard Engine)

4P9219 Air Cleaner Group

A length of 5P1505 Hose (11), 185 cm (72.8 in), is used for drain lines from the air cleaners to the oil pan. The hose should be cut to the following lengths. One piece 150 mm (5.9 in) long and one piece 750 mm (29.5 in) long for the right side of the engine. One piece 150 mm (5.9 in) long and 800 mm (31.5 in) long for the left side of the engine.

The drain line on the right side of the starboard engine should be connected to the oil level gauge hole. All other connections should be made to the oil pan.

One-way check valves (13) are used in the drain lines. Arrows on the check valves must point in a downward direction.

4P9219 Air Cleaner Group (Part 1 of 2)

4P9219 Air Cleaner Group (Part 2 of 2)

4P7924 Air Cleaner Mounting Group

Install all parts as shown in the illustration.

4P7924 Air Cleaner Mounting Group

106-5344 Conversion Group (Lower Cover) (Starboard Engine)

On the 6I0391 Starboard Engine, the left side drain line is routed to the plug on the side of the oil pan. The right side drain line is routed to the right rear oil level gauge hole in the block. One 6I1809 Plug (2) and one 9M9647 Seal (1) is needed on the left side of the oil pan. One bolt and washer from the former plug should be used again.

106-5344 Conversion Group (Lower Cover) (Starboard Engine)

106-5344 Conversion Group (Lower Cover) (Port Engine)

On the 6I1788 Port Engine, the drain lines from the new air cleaners are routed downward to the plug on either side of the oil pan. Two 6I1809 Plugs (1) and two 9M9647 Seals (2) are needed, one for each side. The two bolts and washers from the former plugs should be used again.

106-5344 Conversion Group (Lower Cover) (Port Engine)

106-5369 Conversion Group (Watercooled Exhaust Manifold)

Additional clearance for the 4P7307 Bracket (10) and 4P7310 Bracket (12) must be provided by grinding material from the flywheel housing. These brackets support the 4P7221 Tube Assembly (6) and 4P7246 Water Supply Tube (11) from the cylinder heads to the exhaust risers.

Grind material from the flywheel housing for additional clearance.

Close-up view of flywheel housing after grinding.

The position of the turbochargers will require the exhaust piping to be moved rearward 61.9 mm (2.44 in). Refer to Item 1 in the "Repositioning Engine Components" section.

The eight 0T0102 Bolts (25), two 4N3955 Gaskets (26), eight 6N0561 Clips (27), and two 102-5933 Adapters (28) are required to adapt the exhaust system to the turbochargers.

106-5369 Conversion Group (Watercooled Exhaust Manifold)

4P7473 Turbocharger Group

Install all parts as shown in the illustration.

4P7473 Turbocharger Group

4P7476 Turbocharger Oil Lines Group

Install all parts as shown in the illustration.

4P7476 Turbocharger Oil Lines Group

106-5379 Conversion Group (Turbocharger Water Lines)

The 4V9643 Hose Assembly (12) to the left turbocharger is connected to the elbow on rear of the 4P9245 Adapter [(49) of 106-5400 Conversion Group] on left side of block. The 030-7924 Hose Assembly (18) to the right turbocharger is attached to the 009-4440 Connector [(67) of 106-5400 Conversion Group] on the rear of the oil cooler bonnet.

106-5379 Conversion Group (Turbocharger Water Lines)

4P7477 Air Lines Group

Install all parts as shown in the illustration.

4P7477 Air Lines Group

106-5400 Conversion Group (Heat Exchanger)

Install all parts as shown in the illustration. After installing the right side 4P7916 Tube Assembly (27), reuse the bolt, spacer, and nut to fasten the aftercooler water tube to the flange of the 4P7916 Tube Assembly.

If the optional 105-0268 Auxiliary Pump Group is NOT used, the 4P7987 Hose (20), is NOT needed. Order one 109-2169 Hose for the Jabsco Auxiliary Water Pump.

If marine gear oil cooler is connected to the engine mounted heat exchanger, a 90° elbow with 1" - 11 1/2NPTF threads and a barbed end for 19 mm (.75 in) I.D. coolant hose must be added to the right bottom side of the heat exchanger. Verify the I.D. of the hose.

Install 90° elbow into heat exchanger.

106-5400 Conversion Group (Heat Exchanger)

7E1123 Lifting Eye Group

The bolts, nuts, and washers listed in the 7E1123 Lifting Group are needed to mount the heat exchanger support bracket to the timing gear housing. The Pantroptic Engine's rear lifting eye must be modified, as shown below, to clear the left turbo compressor housing. Reuse the mounting hardware for the rear lifting eye.

Rework rear lifting eye as shown.