SETSCREW-SOCKET 8T8555 - Caterpillar

Engine: G3508 (S/N: 9TG1-UP; WPM1-UP; WPN1-UP)Introduction
Do not perform any procedure that is outlined in this Special Instruction until the entire instruction has been read and understood.This Special Instruction describes the assembly process for upgrading a G3508 Engine to ULB configuration. The configuration uses ADEM 3 technology, mass flow air fuel ratio control, and NOx sensors. The upgrade provides operation at maximum levels of 0.5 or 1.0 g/Hp-Hr of NOx emissions with higher altitude capability throughout the total speed range.Note: Among other variables, emissions performance depends on engine setup and tuning, site parameters, and fuel quality.This Special Instruction is an overview of the engine assembly process. Refer to Disassembly and Assembly, KENR8147 for detailed assembly instructions.Note: Refer to Reuse and Salvage Guidelines for parts reusability during this upgrade.Rebuild and ULB Retrofit
Required Parts
A list of parts for your particular engine arrangement can be found at the following URL:https://engines.cat.com/upgradekits
Once you have accessed the web site, click the link that says "G3508 ULB Upgrade - Parts to Order".Once you have received the upgrade parts, the retro fit must be registered as a non-serialized component. Refer to ""Register the Retrofit"" for further instructions.Assembly Procedure
Cylinder Block and Liners Installation
Install cylinder liners according to the following sequence.
Clean the cylinder block.
Check for blockage in the oil passages of the block.
Install the O-Ring seals onto the cylinder liners.
Lubricate the bores of the block with 266-9682 White Assembly Compound before installing liners.
Install the liners into the block. Check the cylinder liner projection. Refer to Systems Operation, Testing and Adjusting, KENR6892.
Illustration 1 g02251513
Install the camshaft bearings and check the camshaft bearing oil passages for alignment. Refer to Illustration 1 and Disassembly and Assembly, KENR8147.
Illustration 2 g02251394
Install all of the plugs into the cylinder block.Crankshaft Installation
Illustration 3 g02251434
Illustration 4 g02251477
Install the crankshaft according to the following sequence.
Record the bearing numbers and the cylinder locations. Keep this information for future reference.
Install the main bearings into the block and the main bearing caps. Grease the bearings using 266-9682 White Assembly Compound . Refer to Illustration 3.
Install the crankshaft.
Install the main bearing caps and torque the bolts to specifications. Refer to Illustration 4 and to Specifications, KENR6891.
Install the thrust plate.
Measure end play of the crankshaft.
Rotate the crankshaft. Make sure that the crankshaft will rotate freely.Piston Assembly and Installation
Illustration 5 g02251558
Assemble the pistons and the connecting rods according to the following sequence.
Install the rings onto the pistons.
Install the bearings onto the connecting piston rods and caps.
Grease the bearings using 266-9682 White Assembly Compound .
Install pistons according to the following sequence.
Lubricate pistons and rings with clean engine oil before installing the components into the block.
Clean and lubricate the cylinder liners with clean engine oil.
Install the pistons into the cylinder liners.
Illustration 6 g02251635
Install the connecting rod bearing caps and torque the bolts to specifications. Refer to Specifications, KENR6891.