VALVE GP-CONTROL 2597432 - Caterpillar

Washer Hard
2. Remove the items below.
a) Remove and do not reuse the sampling line hoses and 389-8631 Tubes that connect cylinder number 3, 9 and 13. Retain CCV line connected to cylinder number 3 for reuse.
b) Remove and do not reuse OMD Side covers and associated 392-0875 Sampling Funnels from clyinder number 3 and 13.
3. Disconnect hoses from Manifold assembly and do not reuse 388-0329 and 388-0330 Manifold Assemblies.
4. Remove and do not reuse 389-8625 Detector Mounting Bracket, 392-0872, 389-8627, 392-0873 and 389-8630 Manifold Mounting Brackets and 7N-6986 Bracket.
Note: Use Tier 2 installation for reference.
5. Remove OMD cover from cylinder number 9. Disassemble and do not reuse the sampling funnel from it. Install back the OMD cover and use 360-3692 Plug to close sampling port on the cover.
6. Install 373-6713 Side Cover to cylinder number 3 and connect the CCV line to port on cover. Install 1N-2914 Side Cover to cylinder number 13. The new OMD system will utilize only five sample points compared to the previous model.
Note: To be tightened to 35 +/- 5 NM. Install 272-0759 PIP Seal to OMD cover prior to installation
7. Assemble detector mount brackets (Image 2.3.1 and Image 2.3.2)
a) Install 419-5711 Lower Support Bracket to the engine block using 0L-2070 Bolts.
b) Install 1W-8129 Cast Bracket to engine the block using 165-3936 Bolts.
c) Mount the 419-5012 Main Detector Bracket to lower support and cast brackets.
Image2.3.1
Image2.3.2
8. Assemble the 389-8626 Plate to the main detector bracket using 7E-9324 Spring Mount. Install 335-8746 Detector, 144-0526 Regulator and 267-5286 Air filter Assembly. Connect the air filter outlet to regulator inlet using 399-0331 Hose. Connect the regulator outlet to detector air inlet using 390-9164 Hose. The detector head should be replaced with 425-9220 Detector Head. Note: Tighten to 28 +/- 7 N.m.
Note: The directional arrow on the air filter should point towards the rear of engine.
9. Install 388-0329 Rear manifold assembly, using 419-7167 and 419-7166 Brackets.
Install 388-0330 Front Manifold assembly, using 418-6624 and 418-6625 Brackets. The manifold assemblies are held up with 8T-1889 and 8T-1890 2-Piece Clip and 1A-2029 Bolt and 5M-2894 Washer. Be sure to use 5G-3676 grommet between the 2-piece clips.
10. Re-install hoses per layout shown in picture below. It is important to connect identified hoses to the OMD side covers and identified ports on the manifolds for proper functioning of the system. Connect the CCV Line Adapter to the port on cylinder number 3. Use 360-3692 Plug to seal unused ports on manifold.
11. Connect the 191-6502, 8I-3633, 2T-2170, 6V-8724, 6V-8730 Adapters, 0S-1618, 6V3918 Bolts, 117-3245, 418-5550, 390-9158, 390-9163, 416-1893, 389-8631, 197-4640, 389-8633, 390-9160, 390-9161, 419-6694 Hose Assembly and 389-8631, 396-9876 and 389-8632 Tube assemblies to the OMD cover on cylinder number 1, 5, 7, 9, 11 and 15
Note: Verify the fittings are turned in such way that hose are not stressed
Image2.4.1
12. Install the OMD exhaust line using 419-6694 Hose assembly, 419-5110 Plate, 8N-9993 Cover and 6V-3527 Adapter.
Image2.5.1
13. Connect a U-tube manometer at inspection cover.
14. Switch on the compressed air supply with inlet pressure in a