G3508 "A" to G3508 with ADEM 3 ECM Upgrade for Enhanced Performance of 1400 RPM Engines{1000, 1052, 1270, 191N} Caterpillar

Engine:

G3508 (S/N: 9TG1-UP)

Introduction

Do not perform any procedure that is outlined in this Special Instruction and do not order any parts until the entire instruction has been read and understood.

This Special Instruction describes the installation of the ADEM 3 Electronic Control Module (ECM) on G3508A Engines. The ADEM 3 electronic control improves performance and reliability by integrating the following functions:

• Governing of the engine

• Engine monitoring

• Air/fuel ratio control

• Ignition timing

• Detonation sensitive control

ADEM 3 is also known as A+ or A3 .

Whenever questions arise about this product or about this Special Instruction, consult your local Caterpillar dealer for the latest available information.

References

The following reference materials may be necessary for this procedure:

• Disassembly and Assembly Manual, SENR6419

• Systems Operation/Testing and Adjusting, KENR5473, "Exhaust Temperature Module"

• Special Instruction, REHS2558, "Installation and Start-up Procedure for G3500 A3 Engines"

• Troubleshooting, RENR9353, "Gas 3500 A3 Engines", "Nitrogen Oxide Sensor - Calibrate"

• Informational Release Memo, PELJ1004, "G3508 Engine Upgrade Conversion to ADEM III and AFRC with No_x Sensor Including Twin to Single Turbocharger"

System Description

Illustration 1	g01478972
Typical engine configuration (1) Nitrogen oxide sensor group (2) Electronic Control Module (ECM) (3) Exhaust Temperature Module (ETM) (4) Actuator for air/fuel ratio control (5) Engine's interface box (EIB) (6) Fuel valve

Illustration 2	g01479912
Engine's Interface Box (EIB) (7) Main system fuse (F3) (8) Throttle fuse (F4) (9) air/fuel ratio control fuse (F5) (10) Ground wire (11) Jumper wire (P200-C19) (12) - Battery (13) + Battery

Parts List

Conversion Arrangements for G3508 with Single Turbocharger

Table 1

Conversion Arrangements
Model	Conversion Arrangement	Description
G3508	452-9499	ADEM III with a Nox sensor
	330-1857	Single turbocharger configuration

The following items can be reused:

• Nuts

• Bolts

• Washers

• Clips

• Cable straps

• Pipe nipples

Note: Common hardware items that are called out in the illustrations in this document are listed as an aid for assembly. These items are not part of the conversion arrangement.

Refer to Table 2 for common fasteners and common hardware.

Table 2

Common Fasteners and Hardware
Quantity	Part Number	Description
Air Cleaner Gp
4	0L-1351	Bolt
9	1A-2029	Bolt
7	5M-2894	Hard Washer
2	5P-8245	Hard Washer
2	7B-3235	Bolt
Water Lines Gp
3	0L-2070	Bolt
5	0S-1594	Bolt
4	2A-4639	Bolt
3	2M-9780	O-Ring Seal
9	5M-2894	Hard Washer
1	5P-9299	Clip
1	7N-3368	Gasket
1	8M-0755	Connector
1	8S-4951	Cap
1	9S-8752	Full Nut
Turbocharger Oil Lines Gp
2	0S-1590	Bolt
2	0S-1594	Bolt
1	0S-1608	Bolt
1	2M-9780	O-Ring Seal
1	3B-1915	Bolt
1	4P-4460	Gasket
6	5M-2894	Hard Washer
2	5P-9890	O-Ring Seal
1	6V-4589	O-Ring Seal
1	7N-7559	Gasket
1	8L-2786	O-Ring Seal
2	8S-9191	Bolt
Aftercooler
34	0S-1594	Bolt
16	1A-2029	Bolt
2	3B-1915	Bolt
14	5M-2894	Hard Washer
4	9L-9132	Washer
Air Lines Gp
1	1A-2029	Bolt
3	1A-5822	Bolt
4	5P-8245	Hard Washer
1	7L-4302	Gasket
1	8T-6765	Pipe Plug
1	9X-6458	Hard Washer
1	9X-8874	Bolt
2	6V-6809	O-Ring Seal
Water Lines Gp
8	6V-9769	O-Ring Seal
4	1B-5355	Full Nut
Exhaust Manifold Gp
16	0L-2070	Bolt
2	0S-1587	Bolt
2	0S-1588	Bolt
8	0S-1591	Bolt
4	0V-0375	Bolt
3	1A-1460	Bolt
16	1D-4706	Bolt
8	1F-7958	Full Nut
30	3E-6916	Full Nut
44	5M-2894	Hard Washer
2	5P-7128	Bolt
32	5P-8245	Hard Washer
18	7L-6443	Bolt
44	8C-8491	Hard Washer
2	8M-2295	Bolt
1	8T-6765	Pipe Plug
1	9S-1366	Bolt
2	9S-1374	Bolt
10	9S-8752	Full Nut
4	9X-8873	Bolt
4	168-7800	Locknut
8	238-4665	Taperlock Stud

Note: All engines with electric starting motors must be converted to air starting motors prior to this conversion.

A list of options for G3508 Engines is available. Refer to Table 3.

Table 3

Options for G3508 Conversion Arrangement with Single Turbocharger
Qty	Part Number	Description	Remarks
1	317-5039	Control Box Gp	Remote advisor panel
1	251-9466	Wiring Harness	20 foot interconnect harness to remote advisor panel
1	251-9467	Wiring Harness	30 foot interconnect harness to the remote advisor panel
1	251-9468	Wiring Harness	50 foot interconnect harness to remote advisor panel
1	251-9513	Air Starting Lines Gp	Use with vane type air starting motor without prelube
1	273-3130	Air Starting Lines Gp	Use with turbine type air starting motor without prelube
1	273-3107	Electronic Control Wiring Gp	Wiring group for PL 1000E for use with remote advisor panel (1)
1	320-9979	Communication Installation Gp	Wiring group for PL 1000E (2)
1	273-3110	Electronic Control Wiring Gp	Wiring group for PL 1000T for use with remote advisor panel (3)
1	320-9980	Communication Installation Gp	Wiring group for PL 1000T (4)
1	325-6488	AFRC Conversion Gp	Use with engines with existing Air/Fuel Ratio Control (AFRC)
1	325-6492	AFRC Conversion Gp	Use with engines without existing AFRC

( 1 )	Order this part number if the CCM is not being replaced.
( 2 )	Order this part number if the CCM is not being replaced and the remote advisor panel is not being replaced.
( 3 )	Order this part number if the CCM is replaced.
( 4 )	Order this part number if the CCM is being replaced and the remote advisor panel is not being replaced.

The ECM flash files are listed in Table 4. The flash files can be downloaded from SIS.

Table 4

ECM Flash Files
1200 RPM and 1400 RPM Engines
G3508	319-6463 Engine Ratings Electronic Software Gp

Prepare the Engine

Take the following precautions:

• Disconnect the cables from the engine battery.

• Drain the engine coolant.

• Shut off the gas supply to the engine.

• Ensure that any source of electrical power is disconnected.

• Ensure that any source of hydraulic pressure or compressed air is relieved.

• Lock out the engine.

Remove the Existing Electronic Ignition System (EIS) Components

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Illustration 3	g01282629
EIS control module and interconnect harness

1. Remove engine harness (1) for the EIS control module. Remove all other external engine harnesses.

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Illustration 4	g01282399
EIS control module

2. Remove EIS control module (2) .

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Illustration 5	g01282598
Mounting plate for the EIS control module

3. Remove mounting plate (3) for the EIS control module.

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Illustration 6	g01282645
Remote panel

4. Remove the remote panel for the EIS (4) and the interconnect harness.

Remove the Gauge Panel

Illustration 7	g01249980

1. Remove gauge panel (1). Remove any mounting brackets, hoses, or metal tubing.

Remove the Sensors and Switches

1. Remove all existing sensors and switches from the engine. Examples of sensors that are removed are the following:
   • Exhaust Temperature sensors (thermocouples)

   • Differential oil pressure sensor

   • Manifold air temperature sensor

   • Intake manifold pressure sensor

   • Engine oil temperature sensor

   • Engine coolant temperature sensor

   • Engine oil pressure sensor

   Note: Refer to the 273-3117 Conversion Gp .

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Illustration 8	g01283178
Exhaust temperature sensor

2. Remove exhaust temperature sensor (1) at each cylinder. Do not plug these holes.

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Illustration 9	g01286288
(2) 9W-0532 Temperature Sensor Gp (3) 4P-5646 Elbow

3. Remove inlet air temperature sensor (2). Install a plug into the port for the inlet air temperature sensor. Apply pipe sealant to the threads of the plug.

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Illustration 10	g01282713
Manifold air pressure sensor

4. Remove manifold air pressure sensor (4) .

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Illustration 11	g01286062
Plug the orifice or cap the orifice for the manifold air pressure sensor.

5. Plug or cap connection (5) at the manifold air pressure sensor. Refer to Illustration 11.

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Illustration 12	g01282730
Coolant temperature sensor

6. Remove coolant temperature sensor (6) .

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Illustration 13	g01282792
Detonation sensor

7. Remove detonation sensors (7) from both the left side of the engine and the right side of the engine.

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Illustration 14	g01286108

8. Remove oil pressure sensor (8) .

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Illustration 15	g01286101
(9) 7W-6492 Pipe Plug

9. Install plug (9) into the orifice for the oil pressure sensor. Apply pipe sealant to the threads of the plug.

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Illustration 16	g01282805
Oil temperature sensor

10. Remove oil temperature sensor (10) from the side of the cylinder block.

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Illustration 17	g01286182
(11) 8T-6765 Pipe Plug

11. Install plug (11) into the orifice for the oil temperature sensor. Apply pipe sealant to the threads of the plug.

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Illustration 18	g01282852
Magnetic pickups

12. Remove magnetic pickups (12) from the flywheel housing. Remove the magnetic pickups from both the left side of the engine and the right side of the engine.

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Illustration 19	g01286083
(13) 5F-0304 Plugs (14) 4B-8407 Gasket

13. Install plugs (13) and gaskets (14) into the holes for the magnetic pickups.

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Illustration 20	g01282903
Speed-timing sensor

14. Remove existing speed-timing sensor (15) .

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Illustration 21	g01283038
Oxygen sensor

15. If the engine is equipped with an oxygen sensor, remove the oxygen sensor (16) from the adapter plate (17) .

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Illustration 22	g01283064
Adapter plate for the oxygen sensor

16. Remove the adapter plate (17) (if equipped) for the oxygen sensor. For certain applications, the exhaust stack may need support in order to access the adapter plate for the oxygen sensor.

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Illustration 23	g01283048
Buffer for the oxygen sensor

17. Remove buffer (18) (if equipped) for the oxygen sensor. Remove the bracket (if equipped) for the oxygen sensor.

18. Remove exhaust temperature sensors (19) (if equipped).

    Note: Illustration 24 shows a temperature sensor that attached to a gauge panel.

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Illustration 24	g01283114
Exhaust temperature sensor

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Illustration 25	g01283275
(11) 8T-6765 Pipe Plug

19. Plug any orifices that will not be used with the new A3 control system. The items could include tubes, sensors, or switches that were used with the previous system. Install plug (11) into the orifices for these devices. Apply pipe sealant to the threads of the plugs.

Remove the Engine Switches

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Illustration 26	g01319943
(1) Oil level regulator (2) Hose

1. Remove all of the temperature switches and all of the pressure switches.

2. Oil level regulator (2) remains on the engine. Hose (1) must be rerouted.

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Illustration 27	g01286321
Location for installation of new coolant pressure switch

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Illustration 28	g01286333
Hardware that has been removed

3. Remove any hardware (3) for the installation of the jacket water pressure switch. Refer to Illustrations 27 and Illustration 28.

Remove the Wiring Harnesses

1. Remove all the external wiring harnesses. The 4P-9321 Engine Harness As remains on the engine. This harness is the internal ignition system harness.

Remove the Governors, Actuators, and Linkages

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Illustration 29	g00805672
3161 Governor Typical example

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Illustration 30	g01046905
Throttle actuator Typical example

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Illustration 31	g01344696
Heinzmann actuator Typical example

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Illustration 32	g01250046
EG-3P actuator and linkage Typical example

1. Remove all governors, actuators, and linkages. Typical examples are shown in Illustrations 29 through 32.

Remove the Elbow for the Air Inlet Manifold

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Illustration 33	g01286468
The lifting eyebolt has been removed from the engine block in order to allow access to the flange. (1) 7N-5085 Flange (2) 7N-5079 Elbow

1. Remove elbow (2) for the air inlet manifold from the first cylinder. If necessary, remove the lifting eye in order to provide access to the elbow.

2. Flange (1) is reused. Note the orientation of the flange. The flange is marked TOP with raised letters.

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Illustration 34	g01286506
(3) 102-2674 Arrestor Assembly (1) 7N-5085 Flange

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Illustration 35	g01286525
Inlet elbow that has been removed

3. The flame arrestor is located behind the flange for the inlet elbow. Note the orientation of the flame arrestor.

Remove the Oil Bypass Valve Cover

1. Remove bypass valve cover (1). The bypass valve is located on the front of the engine on the upper left side. The bypass valve cover is fastened to the oil filter housing with one 0L-1143 Bolt and two 0S-1619 Bolts . Reuse these bolts.

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Illustration 36	g01286729
(1) 4W-8468 Bypass Valve Cover

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Illustration 37	g01286743
The cover is removed from the bypass valve. (2) 6V-8001 O-Ring Seal (3) 5P-4892 O-Ring Seals

2. Clean the mating surface between the bypass valve cover and the oil filter housing. Install new O-rings if the current O-rings need to be replaced.

Note: Install the new cover onto the oil bypass valve as soon as possible. The oil passages should not be left exposed to any contamination. Refer to ""Install the New Oil Bypass Valve Cover" ".

Remove the Air Start Lines and the Prelube Lines

1. Turn off the supply of pressurized air. Purge the pressurized air from the air tube assemblies and the starting motor.

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Illustration 38	g00597642

2. Remove hose assemblies (1) for the air start motor. Remove the prelube lines.

3. Remove bolts (2) .

4. Remove U-bolt (3) and tube assemblies (4) .

Remove the Transformers

1. Remove the valve covers.

2. Remove the connector from each transformer.

3. Remove bolt (1) and retainer (2) that secures the transformer to the cylinder head.

   Note: The bolt and the retainer should be reused with the new A3 transformer, if the engine is designed to Canadian Standards Association (CSA) specifications.

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Illustration 39	g01321404
Transformer and retainer

4. Lift the transformer out of the cylinder head.

5. Remove the remaining transformers from the engine in the same manner. The spark plugs may be reused.

   Note: Spark plugs that are used for the new A3 control system are the same spark plugs that were used previously. The spark plugs are not listed in the new conversion arrangements.

Illustration 40	g01282660
The valve cover and the transformer have been removed from the cylinder head.

Installation of the Components that are needed to Convert from Twin Turbocharger Configuration to Single Turbocharger Configuration

Remove the Air Cleaners and the Mounting Brackets

ReferenceDisassembly and Assembly, SENR6419, "Air Cleaner - Remove and Install".

Illustration 41	g01458581
Rear view (1) 0L-1351 Bolt (2) 5M-2894 Hard Washer (3) 8N-5254 Reducer Hose (4) 9Y-1704 Air Cleaner Support (5) 8N-3378 Air Cleaner Gp (6) 8N-9729 Air Cleaner Housing Cover (7) 1A-2029 Bolt (8) 5P-4869 Hose Clamp (9) 6H-1717 Bolt (10) 5P-8245 Hard Washer (11) 5P-3860 Hose Clamp (12) 9Y-1707 Bracket As (13) 9Y-1705 Bracket As

1. Remove the air cleaners. Remove all the supports and brackets that fasten the air cleaners to the engine. Refer to Illustration 41.

2. Remove the hoses and the hose clamps.

Note: The 8N-3378 Air Cleaner Gp will be reused.

Remove the Vent Lines and Fittings

ReferenceDisassembly and Assembly, SENR6419, "Turbocharger - Remove".

Illustration 42	g01458623
Top view (1) 121-3211 Tube As (2) 2N-8037 Elbow (3) 011-5224 Reducing Bushing (4) 7H-7055 Clip (5) 8S-4950 Cap (6) 116-2390 Tube As (7) 4S-3652 Union Tee (8) 116-2394 Tube As (9) 121-3209 Tube As (10) 116-2392 Tube As (11) 121-3210 Tube As (12) 030-8145 Flared Reducer (13) 5H-0275 Fitting Nut (14) 003-8581 Union Tee

1. Remove the tubes and the fittings that connect to the turbochargers.

2. Remove the tubes and the fittings that connect to the exhaust bypass valve. Refer to Illustration 42.

Remove the Water Lines for the Turbochargers and for the Exhaust Elbow

ReferenceDisassembly and Assembly, SENR6419, "Turbocharger - Remove".

Illustration 43	g01458730
Rear view (1) 001-7004 Flared Fitting (2) 006-2325 Flared Elbow (3) 090-3000 Flared Elbow (4) 6V-8649 Flared Elbow (5) 2W-7963 Tube As (6) 2W-7964 Tube As (7) 0S-1594 Bolt (8) 5M-2894 Hard Washer (9) 4W-2109 Retainer (10) 4W-2110 Retaining Ring (11) 7L-4773 O-Ring Seal

Illustration 44	g01458750
Top view (12) 8C-6874 Connector (13) 6V-9746 O-Ring Seal (14) 9X-2398 Elbow (15) 293-5522 Hose As (16) 293-5524 Hose As (17) 5K-9090 O-Ring Seal (18) 8C-6875 Connector (19) 293-5523 Hose As (20) 131-4863 Elbow

Illustration 45	g01458765
Right side view (21) 001-7042 Elbow (22) 7C-3917 Tube As (23) 2W-7977 Tube As (24) 7E-6761 Housing (25) 7N-3368 Gasket

1. Remove the tube assemblies, the elbows, and the fittings that connect to the turbochargers and to the exhaust elbow. Refer to Illustrations 43, 44, and 45.

Remove the Oil Lines from the Turbochargers

ReferenceDisassembly and Assembly, SENR6419, "Turbocharger - Remove".

Illustration 46	g01458812
Rear view and right side view (1) 0S-1571 Bolt (2) 5M-2894 Hard Washer (3) 1S-6595 Oil Supply Gasket (4) 1S-4810 Oil Drain Gasket (5) 0S-1594 Bolt (6) 9Y-1040 Turbocharger Tube Assembly (7) 5P-9890 O-Ring Seal (8) 1W-7214 Drain Elbow (9) 4P-0692 Clamp As (10) 9Y-1042 Oil Tube As (11) 9Y-1039 Drain Tube As (12) 6V-4589 O-Ring Seal (13) 9Y-1041 Oil Tube As (14) 9M-4584 Connector (15) 0L-2070 Bolt (16) 250-1498 Elbow As (17) 252-8374 Gasket

1. Remove the tube assemblies, the elbows, and the fittings for the oil lines that connect to the turbochargers.

2. Remove the clamps, the gaskets, and any hardware. Refer to Illustration 46.

Remove the Air Lines for the Aftercooler

ReferenceDisassembly and Assembly, SENR6419, "Aftercooler - Remove and Install".

Illustration 47	g01458898
Top view (1) 9Y-3009 Pipe (2) 5P-8245 Hard Washer (3) 9S-1366 Bolt (4) 7L-4302 Gasket (5) 1A-5822 Bolt (6) 5M-2894 Hard Washer (7) 0L-1351 Bolt (8) 4W-3851 Bracket (9) 2W-7111 Flange (10) 8T-6765 Pipe Plug (11) 4P-4878 Tube As (12) 032-1268 Flared Elbow (13) 6V-2695 O-Ring Seal (14) 9Y-3010 Pipe (15) 4W-9725 Gasket (16) 7B-3235 Bolt (17) 4W-9726 Flange

Remove the air lines for the aftercooler. Refer to Illustration 47.

Flange (17) should remain bolted to the aftercooler housing.

1. The following parts are reused:
   • 5P-8245 Hard Washer

   • 1A-5822 Bolt

   • 5M-2894 Hard Washer

   • 0L-1351 Bolt

   • 4W-3851 Bracket

   • 2W-7111 Flange

   • 4W-9725 Gasket

   • 7B-3235 Bolt

   • 4W-9726 Flange

Remove the Turbochargers

ReferenceDisassembly and Assembly, SENR6419, "Exhaust Elbow - Remove and Install". Disassembly and Assembly, SENR6419, "Turbocharger - Remove".

Illustration 48	g01458921
Top view (1) 168-7800 Locknut (2) 4W-1454 Exhaust Adapter (3) 121-5736 Gasket (4) 107-3127 Turbocharger Gp (5) 0S-1594 Bolt (6) 5M-2894 Hard Washer (7) 4W-1478 Exhaust Seal (8) 4W-1455 Exhaust Coupling (9) 4W-2359 Gasket

Remove all parts from the engine that are identified in Illustration 48.

Remove the Aftercooler

ReferenceDisassembly and Assembly, SENR6419, "Aftercooler - Remove and Install".

Illustration 49	g01459005
Aftercooler (1) 3K-0360 O-Ring Seal (2) 9S-4185 O-Ring Plug (3) 7E-3350 Front Housing (4) 7W-6492 Pipe Plug (5) 8T-6765 Pipe Plug (6) 3D-2824 O-Ring Seal (7) 9S-4183 O-Ring Plug (8) 152-5705 Gasket (9) 4W-9852 Rear Housing (10) 0S-1594 Bolt (11) 5M-2894 Hard Washer (12) 1A-2029 Bolt (13) 9L-9132 Washer (14) 4W-6493 Plate (15) Core Assembly

1. Remove the aftercooler from the engine. Refer to Illustration 49.

2. Leave front housing (3) and core assembly (15) bolted together. Leave the plugs in front housing (3) .

All of the components are reused except for the following parts:

• 8T-6765 Pipe Plug

• 152-5705 Gasket

• 4W-9852 Rear Housing

Remove the Throttle Actuator

ReferenceDisassembly and Assembly, SENR6419, "Fuel Control Actuator - Remove and Install".

Illustration 50	g01459120
Top view (1) 9M-1974 Hard Washer (2) 5S-0003 Nut (3) 4B-3388 Bolt

Illustration 51	g01459121
Rear view (4) 119-5092 Rod (5) 4F-2294 Jam Nut (6) 7E-9748 Rod End (7) 114-9269 Sleeve (8) 263-5007 Throttle Lever (9) 8L-4496 Jam Nut (10) 6V-9163 Rod End

Illustration 52	g01459122
Right side view (11) 5M-2894 Hard Washer (12) 0S-1591 Bolt (13) 091-0081 Spacer (14) 6V-2317 Bolt (15) 1A-2029 Bolt

1. Remove the throttle actuator and the throttle actuator linkage.

2. Remove all parts from the engine. All parts are reused. Refer to Illustration 50 through Illustration 52.

Remove the Carburetor

ReferenceDisassembly and Assembly, SENR6419, "Carburetor - Remove - High Pressure".Disassembly and Assembly, SENR6419, "Air Inlet Manifold - Remove and Install".

Illustration 53	g01459289
Right side view (1) 5P-8862 O-Ring Seal (2) 6V-5103 O-Ring Seal (3) 4W-9348 Flange (4) 4W-9002 Gasket (5) 0S-1587 Bolt (6) 5P-8245 Hard Washer (7) 1F-7958 Full Nut (8) 7E-4064 Carburetor Gp (9) 7W-7148 Coupling (10) 0S-1595 Bolt (11) 5P-8245 Hard Washer (12) 4W-7992 Gasket (13) 4P-8331 Adapter (14) 4W-9024 Gasket (15) 0S-1619 Bolt (16) 5M-2894 Hard Washer (17) 6W-6672 Spacer

1. Remove flange (3), carburetor (8), and inlet adapter (13) from the engine as a unit. Leave these components bolted together.

2. Remove bolts (15), washers (16), and spacers (17) in order to remove inlet adapter (13) from the engine. All parts that are removed will be reused except for gasket (14), seal (1), and seal (2). Refer to Illustration 53.

Remove the Exhaust Bypass Valve

ReferenceDisassembly and Assembly, SENR6419, "Exhaust Bypass Valve - Remove and Install".

Illustration 54	g01459469
Exhaust bypass valve (1) 9G-5127 Breather (2) 4H-0553 Fitting (3) 146-0758 Exhaust Bypass (4) 032-1268 Flared Elbow (5) 1B-5355 Full Nut (6) 7C-9710 Gasket

Remove nuts (5) in order to remove the exhaust bypass valve from the engine.

Nuts (5) and gasket (6) will not be reused.

Remove the Exhaust Manifolds

ReferenceDisassembly and Assembly, SENR6419, "Exhaust Manifold - Remove - Water Cooled".Disassembly and Assembly, SENR6419, "Exhaust Elbow - Remove and Install".

Illustration 55	g01459609
(1) 4W-7283 Exhaust Elbow (2) 4W-7274 Bracket (3) 4W-7273 Bracket (4) 1A-5822 Bolt (5) 6M-9613 Bolt (6) 2W-5958 Support (7) 0S-1595 Bolt (8) 7D-1649 Hard Washer (9) 7E-2900 Plate (10) 5P-2603 Taperlock Stud (11) 121-5736 Gasket (12) 9Y-1568 Housing (13) 7C-6239 Exhaust Tee Assembly (14) 0S-1594 Bolt (15) 7C-3921 Exhaust Seal Ring (16) 2W-5713 Adapter (17) 8T-6761 Pipe Plug (18) 290-7082 Manifold (19) 9Y-3838 Manifold (20) 0S-0509 Bolt (21) 5M-2894 Hard Washer (22) 1D-4706 Bolt (23) 7E-4127 Gasket (24) 0L-2070 Bolt (25) 6L-8562 Taperlock Stud (26) 3E-7428 Pipe Plug (27) 0S-1591 Bolt (28) 9S-8752 Full Nut (29) 9L-9132 Washer (30) 1W-2860 Bracket (31) 0V-0375 Bolt (32) 5P-8245 Hard Washer (33) 8T-6762 Pipe Plug (34) 9X-8874 Bolt (35) 1W-2430 V-Band Clamp (36) 7C-3920 Exhaust Seal

1. Remove the exhaust manifolds and the exhaust elbow from the engine. Refer to Illustration 55.

2. Remove two seals (37) and eight seals (38). These seals will not be reused. Refer to Illustration 56 and Illustration 57.

Illustration 56	g01459761
Front view (37) 6V-6809 O-Ring Seal

Illustration 57	g01459756
Right side view (38) 6V-9769 O-Ring Seal

Install the Exhaust Manifolds and the Turbocharger

Install the Exhaust Manifolds

Illustration 58	g01459799
Exhaust manifold and hardware (1) 8T-6761 Pipe Plug (2) 305-2617 Manifold (3) 306-5169 Exhaust Elbow (4) 0S-1591 Bolt (5) 5M-2894 Hard Washer (6) 9S-8752 Full Nut (7) 305-2618 Manifold (8) 1D-4706 Bolt (9) 0L-2070 Bolt (10) 7E-4127 Gasket (11) 168-3349 Pipe Plug (12) 9V-0999 Spacer (13) 5P-8245 Hard Washer (14) 0V-0375 Bolt (15) 313-6932 Bracket As (16) 305-2621 Exhaust Elbow (17) 305-2635 Bracket As (18) 1A-1460 Bolt (19) 1F-7958 Full Nut (20) 0S-1587 Bolt (21) 3E-6916 Full Nut (22) 8C-8491 Hard Washer (23) 8M-2295 Bolt (24) 7L-6443 Bolt (25) 5P-7128 Bolt (26) 4W-1478 Exhaust Seal (27) 303-9357 Coupling (28) 219-3234 Exhaust Seal (29) 121-5736 Gasket (30) 168-7800 Locknut (31) 2N-9288 Taperlock Stud (32) 6V-3631 Full Nut (33) 6L-3143 Bolt (34) 1L-4473 Terminal Bushing (35) 9X-8873 Bolt (36) 9S-1374 Bolt

Illustration 59	g01460227
Exhaust manifold and hardware (37) 313-9550 Taperlock Stud (38) 305-2620 Elbow (39) 229-5333 Exhaust Seal (40) 207-1364 Bellows As (41) 141-1751 Gasket (42) 141-1732 Housing (43) 5P-2603 Taperlock Stud (44) 141-1747 Shield (45) 0S-1588 Bolt (46) 4J-4382 Pipe Plug (47) 1W-7810 Outlet Gasket (48) 311-6494 Exhaust Elbow (49) 3E-2331 Plug (50) 109-1086 Spacer (51) 133-9315 Band Clamp (52) 135-0171 Exhaust Seal (53) 135-0172 Exhaust Seal Ring (54) 308-3813 Bracket As (55) 9S-1366 Bolt (56) 7W-2124 Bracket (57) 313-6930 Bracket As

1. Apply 5P-3931 Anti-Seize Compound on the following items for the exhaust manifold:
   • Threads of bolts

   • Plugs

   • Studs

   • Nuts

2. Install one elbow (38) onto the taperlock studs of left-hand manifold (2) and right-hand manifold (7). Install seal (39) onto each manifold.

3. Fasten the elbow to the manifold with washer (22) and nut (21) .

   Simultaneously tighten the diagonally opposite nuts to the following torque. ... 55 ± 5 N·m (41 ± 4 lb ft)

   Tighten the nuts to the following torque again. ... 55 ± 5 N·m (41 ± 4 lb ft)

4. Clean the mating surfaces of the cylinder heads and the exhaust manifolds.

5. Fasten the exhaust manifolds to the cylinder heads with 16 bolts (8), 16 bolts (9) and 32 washers (5). Use 8 gaskets (10) .

6. Apply 5P-3931 Anti-Seize Compound to the threads of the bolts.

   Torque ... 55 ± 5 N·m (41 ± 4 lb ft)

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Illustration 60	g01465427
(5) 5M-2894 Hard Washer (58) 1A-2029 Bolt (59) 0S-1590 Bolt (60) 9S-8752 Full Nut

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Illustration 61	g01465467
(61) 6V-6809 O-Ring Seal

7. Secure the exhaust manifold to the regulator housing. Use two new seals (61). Refer to Illustration 60 and Illustration 61.

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Illustration 62	g01465749
(62) 6V-9769 O-Ring Seal (63) 7E-8888 Elbow (64) 0S-1619 Bolt (65) 7E-8889 Tube (66) 5P-7204 O-Ring Seal (67) 1B-7182 Bolt (68) 7E-8890 Collar

8. Install the inlet tubes for the exhaust manifold. Refer to Illustration 62.

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Illustration 63	g01469871
(15) 313-6932 Bracket As (17) 305-2635 Bracket As (54) 308-3813 Bracket As (57) 313-6930 Bracket As

9. Install brackets (17), (15), (57), and (54). Refer to Illustrations 58, 59, and 63.

10. Assemble exhaust elbow (16) to bellows (40). Ensure that seals (39) have been installed.

    Simultaneously tighten the diagonally opposite nuts to the following torque. ... 55 ± 5 N·m (41 ± 4 lb ft)

    Tighten the nuts to the following torque again. ... 55 ± 5 N·m (41 ± 4 lb ft)

11. Install the assembled exhaust elbow (16) and bellows (40) to elbow (38). Ensure that seals (39) have been installed.

    Simultaneously tighten the diagonally opposite nuts to the following torque. ... 55 ± 5 N·m (41 ± 4 lb ft)

    Tighten the nuts to the following torque again. ... 55 ± 5 N·m (41 ± 4 lb ft)

12. Secure elbow (16) to bracket (17) with bolts (33), washers (13), and nuts (32) .

13. Install housing (42) and gasket (41). Secure housing (42) to exhaust elbow (16) at the front of the engine with bolts (24), washers (22) and nuts (21) .

    Torque ... 55 ± 5 N·m (41 ± 4 lb ft)

14. Secure housing (42) to exhaust elbow (16) at the rear of the engine with bolts (25) and nuts (21) .

    Torque ... 55 ± 5 N·m (41 ± 4 lb ft)

15. Install shield (44) to housing (42). Fasten the shield to the housing with bolts (45), washers (5), and nuts (6) .

    Torque ... 55 ± 5 N·m (41 ± 4 lb ft)

Install the Turbocharger

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Illustration 64	g01469845
(69) 305-4300 Turbocharger Gp

1. Install turbocharger (69) to exhaust elbow (16). Install gasket (29). Secure the turbocharger to the exhaust elbow with locknuts (30) .

   Torque ... 55 ± 5 N·m (41 ± 4 lb ft)

2. Assemble exhaust elbow (48), coupling (27), seal (26), and seal (28) .

3. Install the assembled parts to turbocharger (69). Fasten exhaust elbow (48) to bracket (54) with bolts (18), washers (13), and nuts (19) .

4. Install exhaust elbow (3) to exhaust elbow (48) and to housing (42). Secure exhaust elbow (3) to exhaust elbow (48) with clamp (51), seal (52), and seal (53) .

   Torque for the clamp ... 14 ± 1.5 N·m (10 ± 1 lb ft)

5. Secure exhaust elbow (3) to housing (42) with bolts (23), washers (22), and nuts (21). Ensure that gasket (47) has been installed.

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Illustration 65	g01477032

6. If necessary, loosen the clamp for the compressor housing in order to align the air inlet pipe. Refer to Illustration 65. After the air inlet pipe has been installed, tighten the clamp for the compressor housing.

   Torque ... 14 ± 1.5 N·m (10 ± 1 lb ft)

Install the Exhaust Bypass Valve

Illustration 66	g01461928
(1) Exhaust bypass valve (2) 5P-2603 Taperlock Stud (3) 7C-9710 Gasket (4) 141-1732 Housing

1. Install exhaust bypass valve (1) onto studs (2) of housing (4) .

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Illustration 67	g01461967
(5) 1B-5355 Full Nut

2. Use a new gasket (3) and new nuts (5) .

Install the Aftercooler

Illustration 68	g01469932
Top view (1) 5M-2894 Hard Washer (2) 3B-1915 Bolt (3) 152-5705 Gasket (4) 7E-3568 Aftercooler Core As (5) 0S-1594 Bolt (6) 7E-3350 Front Housing (7) 1A-2029 Bolt (8) 9S-4185 O-Ring Plug (9) 3K-0360 O-Ring Seal (10) 7W-6492 Pipe Plug (11) 305-2644 Housing

Illustration 69	g01469942
Right side view (12) 9S-4183 O-Ring Plug (13) 3D-2824 O-Ring Seal (14) 4W-6493 Plate (15) 9L-9132 Washer (16) 8T-6765 Pipe Plug

1. Reuse all of the components that were removed from the engine during disassembly except for the following parts:
   • 8T-6765 Pipe Plug

   • 152-5705 Gasket

   • 4W-9852 Rear Housing

2. The following new parts are used for installation of the aftercooler:
   • 305-2644 Housing

   • 152-5705 Gasket

   • 5M-2894 Hard Washer

   • 3B-1915 Bolt

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Illustration 70	g01470003
Left side view (1) 5M-2894 Hard Washer (2) 3B-1915 Bolt (3) 152-5705 Gasket (11) 305-2644 Housing

3. Refer to Illustrations 68, 69, and 70.

Install the Carburetor and the Inlet Adapter

Illustration 71	g01459289
Right side view (1) 5P-8862 O-Ring Seal (2) 6V-5103 O-Ring Seal (3) 4W-9348 Flange (4) 4W-9002 Gasket (5) 0S-1587 Bolt (6) 5P-8245 Hard Washer (7) 1F-7958 Full Nut (8) 7E-4064 Carburetor Gp (9) 7W-7148 Coupling (10) 0S-1595 Bolt (11) 5P-8245 Hard Washer (12) 4W-7992 Gasket (13) 4P-8331 Adapter (14) 4W-9024 Gasket (15) 0S-1619 Bolt (16) 5M-2894 Hard Washer (17) 6W-6672 Spacer

1. Install the carburetor and the inlet adapter onto the engine as a unit.

2. Fasten the carburetor and the inlet adapter to the inlet manifold with bolts (15), washers (16), and spacers (17). Install a new gasket (14) .

3. New seals (1) and (2) must be used with coupling (9) .

Install the Throttle Actuator

Table 5

Reference
Model	Part Number
G3508 high pressure	289-8546 Throttle Gp

Illustration 72	g01459120
Top view (1) 9M-1974 Hard Washer (2) 5S-0003 Nut (3) 4B-3388 Bolt

Illustration 73	g01459121
Rear view (4) 119-5092 Rod (5) 4F-2294 Jam Nut (6) 7E-9748 Rod End (7) 114-9269 Sleeve (8) 263-5007 Throttle Lever (9) 8L-4496 Jam Nut (10) 6V-9163 Rod End

Illustration 74	g01459122
Right side view (11) 5M-2894 Hard Washer (12) 0S-1591 Bolt (13) 091-0081 Spacer (14) 6V-2317 Bolt (15) 1A-2029 Bolt

1. Install the throttle actuator and the throttle actuator linkage.

2. Reuse all parts that were removed from the engine. Refer to Illustrations 72, 73, and 74.

Install the Water Lines for the Turbocharger

Illustration 75	g01470322
Rear view (1) 306-5173 Plate (2) 5P-5613 Flared Cross (3) 305-2654 Tube As (4) 5P-9299 Clip (5) 0S-1594 Bolt (6) 5M-2894 Hard Washer (7) 9S-8752 Full Nut (8) 8M-0755 Connector (9) 305-2658 Bracket (10) 3R-9704 Elbow (11) 8M-0744 Flared Nut (12) 8M-0745 Flared Reducer (13) 004-3099 Connector (14) 6K-3607 Connector (15) 2M-9780 O-Ring Seal (16) 5P-8196 Plug (17) 0L-2070 Bolt

Illustration 76	g01470335
Right side view (18) 7N-7878 Cover Plate (19) 241-3283 Gasket (20) 2M-3881 Lug (21) 2A-4639 Bolt (22) 180-5044 Cover (23) 247-0708 O-Ring Seal (24) 305-2652 Tube As (25) 7L-7262 Flared Elbow (26) 305-2653 Tube As (27) 306-5172 Tube As (28) 7F-2050 Locknut (29) 2P-1281 Union (30) 8S-4951 Cap (31) 8T-6761 Pipe Plug (32) 305-2650 Tube As (33) 305-2651 Tube As (34) 005-4173 Elbow (35) 144-2980 Housing (36) 7N-3368 Gasket

Illustration 77	g01470858
Top view

1. Install the water lines for the turbocharger. Refer to Illustrations 75, 76, and 77.

2. Lubricate threads and bearing surfaces before assembly with 5P-3931 Anti-Seize Compound . Lubricate O-ring seals with 1U-6396 O-Ring Assembly Compound .

Install the Oil Lines for the Turbocharger

Illustration 78	g01470695
Rear view (1) 5M-2894 Hard Washer (2) 8S-9191 Bolt (3) 6I-0805 Turbocharger Oil Adapter (4) 4P-4460 Gasket (5) 0S-1608 Bolt (6) 7N-7559 Gasket (7) 9Y-5814 Drain Elbow (8) 4K-8302 Clip (9) 305-2655 Hose As (10) 6K-3607 Connector (11) 6V-4589 O-Ring Seal (12) 9S-4190 O-Ring Plug (13) 2M-9780 O-Ring Seal (14) 8L-2786 O-Ring Seal (15) 030-7943 Elbow (16) 3B-1915 Bolt (17) 0S-1594 Bolt (18) 252-8374 Gasket (19) 4W-9890 Cover (20) 5P-9890 O-Ring Seal (21) 305-2649 Tube (22) 4W-2109 Retainer (23) 0S-1590 Bolt (24) 131-0484 Adapter

1. Install the oil lines for the turbocharger. Refer to Illustration 78.

2. Lubricate threads and bearing surfaces before assembly with 5P-3931 Anti-Seize Compound . Lubricate sealing surfaces with clean engine oil.

Install the Air Lines That Connect to the Turbocharger

Illustration 79	g01470878
Right side view (1) 6V-3917 O-Ring Seal (2) 305-2648 Air Pipe (3) 8T-6765 Pipe Plug (4) 0S-1585 Bolt (5) 5P-8245 Hard Washer (6) 4W-9726 Flange (7) 4W-9725 Gasket (8) 313-6939 Tube As (9) 032-1268 Flared Elbow (10) 5P-8245 Hard Washer (11) 1A-5822 Bolt (12) 2W-7111 Flange (13) 7L-4302 Gasket (14) 9X-6458 Hard Washer (15) 1A-2029 Bolt (16) 9X-8874 Bolt (17) 4W-3851 Bracket (18) 6V-2695 O-Ring Seal

1. Install the air lines for the turbocharger and for the aftercooler. Refer to Illustration 79.

2. Lubricate O-ring seals with 1U-6396 O-Ring Assembly Compound .

The following parts are new parts that are in the installation of the air lines:

• 6V-3917 O-Ring Seal

• 305-2648 Air Pipe

• 8T-6765 Pipe Plug

• 313-6939 Tube As

• 032-1268 Flared Elbow

• 6V-2695 O-Ring Seal

• 7L-4302 Gasket

Install the Exhaust Shields

Illustration 80	g01471335
Top view (1) 306-5187 Shield As (2) 306-5188 Shield As (3) 306-5183 Shield As (4) 226-3939 Spring (5) 306-5186 Shield As (6) 306-5185 Shield As (7) 306-5184 Shield As

Install the shields for the exhaust. Refer to Illustration 80.

Install the Air Cleaner

Illustration 81	g01471361
Front view (1) 8N-3378 Air Cleaner Gp (2) 8N-5254 Reducer Hose (3) 5P-4869 Hose Clamp (4) 305-2660 Tube (5) 162-2177 Hose (6) 311-6493 Support (7) 7W-5760 Fastener (8) 8N-9729 Air Cleaner Housing Cover (9) 9X-6458 Hard Washer (10) 1A-2029 Bolt

Illustration 82	g01471387
Left side view (11) 0L-1351 Bolt (12) 5M-2894 Hard Washer (13) 313-6933 Support As (14) 5P-8245 Hard Washer (15) 7B-3235 Bolt

Install the air cleaner. Refer to Illustration 81 and Illustration 82.

Note: Reuse the 8N-3378 Air Cleaner Gp .

Install the Components

Install the Transformers

1. Install the new transformers. Lubricate seals (2) with clean engine oil.

   Note: Spark plugs that are used for the new A3 control system are the same spark plugs that were used previously. The spark plugs are not listed in the new conversion arrangement.

   Note: The transformers must be changed in order to be compatible with the ADEM 3 control.

2. Secure the transformer with retainer (5) and bolt (4) .

   Note: If the engine was previously designed for CSA, the bolt and the retainer will already be installed in the engine. These parts can be removed and reused with the new A3 transformer.

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Illustration 83	g01320047
(1) 259-2078 Ignition Transformer Gp (2) 135-2651 Seal (3) 125-1372 O-Ring Seal

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Illustration 84	g01320079
(4) 5B-5059 Bolt (5) 134-4723 Retainer As

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Illustration 85	g01286639
The transformers have been installed into the cylinder head.

3. Connect each transformer to the internal harness connector.

4. Install the valve covers.

Install the Control Group and Mounting

1. Install the new ECM and the support bracket.

2. Remove any paint or oxidation from bracket (2) in order to ensure a good electrical contact.

Illustration 86	g01282608
Location for installation of the new ECM and support bracket

Illustration 87	g01431439
Mounting location for engines with single cooling circuit (1) 154-6713 Engine Electronic Control Gp (2) 251-9385 Bracket As (3) 2B-2694 Bolt (4) 8C-9987 Washer (5) 155-0576 Isolation Mount (6) 6I-1418 Spacer (7) 1D-4541 Bolt (8) 0S-1595 Bolt (9) 7D-1649 Hard Washer

Illustration 88	g01434688
Hardware for securing the engine harness (10) 9S-3232 Clip (11) 6B-6205 Spacer (12) 7X-0291 Bolt (13) 9L-9132 Washer (14) 9S-8752 Full Nut

Illustration 89	g01431440
View C-C (hardware for securing the engine harness) (15) 5P-8245 Hard Washer (16) 193-3973 Tie (17) 9X-8874 Bolt (18) 230-7732 Mount (19) 9F-4831 Spacer

Illustration 90	g01436858
Hardware at rear of support bracket (20) 4P-8134 Clip (21) 2S-2301 Spacer (22) 9N-0869 Hard Washer (23) 5S-0003 Nut

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Illustration 91	g01437897
ECM and support bracket (24) Ground strap

1. Install ground strap (24) between bolt head (3) and washer (4) .

Note: Install lockwashers (4) against the surface of the shock mounts in order to ensure a good electrical contact.

Illustration 92	g01435850
Front view

Install the Engine's Interface Box (EIB) and the Exhaust Temperature Module

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Illustration 93	g01288746
Location for the EIB

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Illustration 94	g01316633
(1) 1H-3338 Lockwasher (2) 8T-4205 Hard Washer (3) 6V-8185 Nut (4) 4M-5281 Bolt (5) 7X-6035 Grounding Strap (6) 104-6564 Mount (7) 1B-4971 Spacer (8) 5P-2675 Bolt (9) 0S-1588 Bolt (10) 5M-2894 Hard Washer (11) 251-9389 Bracket (12) 6V-8801 Nut (13) 8T-4896 Hard Washer (14) 4P-8134 Clip (15) 4L-6454 Bolt (16) 5S-7349 Bolt

Note: Washers (1) must be installed against shock mount (6).

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Illustration 95	g01502759
Engine interface box and exhaust temperature module

1. Install the bracket (11) for the EIB and the exhaust temperature module at the location that is shown in Illustration 93. Refer to Illustration 94 for the required hardware.

Install the New Elbow for the Inlet Air

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Illustration 96	g01253129
Top View (1) 175-6720 Elbow

1. Install new elbow (1). Reuse the existing bolts. An integral boss is cast into the side of the new elbow for the manifold air temperature sensor.

   Note: Removing the lifting eye may simplify the installation of the new air inlet elbow.

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Illustration 97	g01286614
New elbow and sensor (2) 102-2240 Temperature Sensor Gp (3) 8L-2786 O-Ring Seal (4) 153-8455 Manifold Gasket (5) 7N-5085 Flange (6) 7N-5089 Gasket

2. Clean the mating surfaces before installation. Install new gaskets or fabricate new gaskets. Install the flame arrestor. Install the raised portion of the flame arrestor toward the air inlet elbow. Ensure that the connecting flange is oriented properly. The flange is marked TOP with raised letters.

3. Install manifold air temperature sensor (2) and O-Ring seal (3) in the hole that is provided in the inlet elbow. Tighten the sensor to 20 ± 3 N·m (15 ± 2 lb ft).

Install the New Oil Bypass Valve Cover

The following part should be reused:

• Bolts

• Cover

• Spring

• Bypass valve

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Illustration 98	g01286905
(1) 4W-5592 Cover (2) 5P-4892 O-Ring Seal (3) 111-8639 Bypass Valve Cover (4) 2W-1635 Spring (5) 2W-1969 Bypass Valve

1. Replace the O-ring seals. Refer to Illustration 98.

2. Use the existing bolts in order to secure the bypass valve cover (3) .

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Illustration 99	g01286937
(6) 274-6719 Pressure Sensor (7) 9X-0262 Adapter (8) 6V-5048 O-Ring Seal

3. Install the filtered oil pressure sensor and the unfiltered oil pressure sensor (6). Each sensor uses an adapter (7) and an O-ring seal (8). The designation of each sensor is marked with raised letters on the bypass valve cover. Tighten the sensors to 10 ± 2 N·m (7 ± 1.5 lb ft).

Install Covers for the Governor Drive and the Accessory Drive

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Illustration 100	g01287117
Oil hole for governor drive (1) 8T-6757 Pipe Plug

1. Install covers for the governor drive and for the accessory drive. A plug (1) must be installed in the oil supply hole that is located in the engine block. Apply pipe sealant to the threads of the plug. Refer to 100.

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Illustration 101	g01287163
(3) 8N-9885 Drive Housing Gasket (4) 2W-5285 Cover (5) 9X-7371 O-Ring Seal (6) 7N-8374 Cover (7) 0S-1566 Bolt (8) 5P-8247 Hard Washer

2. Install cover (4) and gasket (3). Reuse the existing bolts. These items are required only when a Woodward EG-3P actuator is removed.

Note: If the engine is not equipped with accessory drive, use the 6I-1392 Accessory Drive Cover Gp .

3. Install cover (6) and O-ring seal (5). Fasten the cover with bolts (7) and hard washers (8). These items are required when either a Woodward 3161 governor or a EG-3P actuator is removed.

Install Actuators and the Actuator Linkage

Actuator for Air/Fuel Ratio Control (if equipped)

Table 6

Reference
Model	Part Number
G3508 high pressure	290-3419 Gas Pressure Regulator Gp

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Illustration 102	g01287680
(1) 0T-0055 Bolt (2) 7N-6986 Support (3) 0S-1619 Bolt (4) 1W-8129 Support

1. Install the supports for the air/fuel ratio control actuator. The top support bracket is fastened to the engine with two bolts (1). The lower support bracket is fastened to the engine with two bolts (3) .

   The supports for the air/fuel ratio control actuator are installed on the left side of the engine below the second cylinder .

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Illustration 103	g01481350
(5) 295-8941 Bracket As (6) 3B-1915 Bolt (7) 5M-2894 Hard Washer (8) 9S-8752 Full Nut (9) 0S-1591 Bolt (10) 091-0081 Spacer (11) 6V-2317 Bolt (12) 9M-1974 Hard Washer (13) 8M-9024 Hard Washer

2. Install bracket (5). Toward the top, use two bolts (6), two washers (7) and two nuts (8) in order to fasten the bracket to the supports. Toward the bottom, use two bolts (9), two washers (7) and two nuts (8) in order to fasten the bracket to the supports. Two hard washers (13) are used between the bracket and the bottom support.

3. Install the actuator onto the bracket. The actuator is fastened to the bracket with four bolts (11), four washers (12) and four spacers (10) .

Note: Install air/fuel ratio control if the engine does not currently have air/fuel ratio control. Refer to Illustrations 104, 105, and 106. The regulator assembly is installed below the number four cylinder.

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Illustration 104	g01482093
Rear view (14) 2W-2243 Clamp (15) 1A-2029 Bolt (16) 105-9267 Adapter (17) 6L-2849 Tube Joint (18) 254-1115 Actuator (19) 107-6318 Fuel Ratio Valve (20) 1N-3872 Support (21) 1A-5822 Bolt (22) 9F-7022 Bolt (23) 5P-0537 Hard Washer (24) 9S-8750 Nut (25) 164-0433 Plate

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Illustration 105	g01482354
Left side view (26) 5P-8116 Flared Elbow (27) 290-3410 Tube As (28) 290-3411 Tube As (29) 1P-4579 Half Flange (30) 0S-1587 Bolt (31) 5P-8245 Hard Washer (32) 3R-5387 Connector (33) 061-9593 Reducer Bushing (34) 6I-0327 Adapter (35) 4J-0524 O-Ring Seal (36) 4B-7770 Tee (37) 4B-9029 Pipe Nipple (38) 7E-3407 Gas Pressure Regulator (39) 6B-3156 Pipe Nipple (40) 3B-6486 Pipe Cap

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Illustration 106	g01483375
Top view (section of regulator valve)

4. Install the linkage for the actuator and for the fuel valve.

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Illustration 107	g01482633
(41) 263-5007 Throttle Lever (42) 1B-7182 Bolt (43) 5S-0003 Nut (44) 7E-9748 Rod End (45) 4F-2294 Jam Nut (46) 175-6830 Rod (47) 6V-9163 Rod End (48) 8L-4496 Jam Nut (49) 6S-7721 Lever (50) 0S-1571 Bolt

5. Install the levers for the fuel valve and for the actuator. Both the actuator and the fuel valve must be in the open position. Adjust the linkage at the points of attachment to the angles that are shown in Illustration 107. Provide equal engagement at each rod end.

Illustration 108	g01483533
Fuel regulator

Install the Remaining Sensors

• Jacket water pressure switch

• Exhaust temperature sensor

• Thermocouples for the Turbocharger

• Manifold air pressure sensor

• Jacket water pressure sensor

• Coolant temperature sensor

• Oil temperature sensor

• Speed-timing sensor

• Left detonation sensor

• Right detonation sensor

• Nitrogen oxide sensor

• Timing calibration sensor

• Prelube switch

Jacket Water Pressure Switch

1. Install the jacket water pressure switch. Refer to Illustration 109 for the parts that are needed to install the switch. Apply pipe sealant to the pipe plug, the reducer bushings, and the pipe nipple. Tighten the switch to 22 ± 3 N·m (16 ± 2 lb ft).

Illustration 109	g01290888
(1) 110-1168 Pressure Switch (2) 3B-7764 Reducer Bushing (3) 061-9593 Reducer Bushing (4) 4B-7770 Tee (5) 8T-6761 Pipe Plug (6) 3B-7749 Close Nipple

Illustration 110	g01290890
Jacket water pressure switch

Exhaust Temperature Sensors

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Illustration 111	g01290986
Exhaust temperature sensor The 241-9591 Temperature Sensor Gp is used for eight cylinders and for the left turbocharger inlet. (1) 241-9591 Temperature Sensor Gp

1. Install the exhaust temperature sensors. A new thermocouple (1) is installed at each cylinder.

Illustration 112	g01290988
(1) 241-9591 Temperature Sensor Gp (2) 5N-2126 Exhaust Adapter

Thermocouples for the Turbocharger

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Illustration 113	g01478392
Rear view Thermocouples for the turbocharger inlet temperature and for the turbocharger outlet temperature (1) 180-5420 Temperature Sensor Gp (Outlet temperature ) (2) 6B-5072 Reducing Bushing (3) 5N-2126 Adapter (4) 243-5752 Temperature Sensor Gp (5) 241-9591 Temperature Sensor Gp (inlet temperature for the left side)

1. Install the thermocouple for the turbocharger outlet (1). A new bushing (2) must be installed for the thermocouple of the turbocharger outlet. Apply pipe sealant to the threads of the bushings.

2. Install the thermocouple for the turbocharger inlet (4) and (5). Adapter (3) is used with the thermocouples for the turbocharger inlet temperature. Apply pipe sealant to the threads of the adapter.

Illustration 114	g01291017
(1) 180-5420 Temperature Sensor Gp (2) 6B-5072 Reducing Bushing

Illustration 115	g01478772
Left side view

Illustration 116	g01478857
Right side view

Manifold Air Pressure Sensor

Illustration 117	g01254649
Location for the manifold air pressure sensor (1) 276-6793 Pressure Sensor Gp (1) 290-4619 Sensor Buffer

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Illustration 118	g01291077
Manifold air pressure sensor (1) 276-6793 Pressure Sensor Gp (1) 290-4619 Sensor Buffer (2) 9X-0435 Adapter (3) 6V-5048 O-Ring Seal (4) 3B-7764 Bushing

1. Install the manifold air pressure sensor. A plug must be removed from the front of the cylinder block in order to install the sensor. Apply pipe sealant to adapter (2) and to bushing (4). Torque the sensor to 10 ± 2 N·m (7 ± 1 lb ft).

Jacket Water Pressure Sensor

1. Remove plug (1) from the exhaust manifold in order to install the jacket water pressure sensor.

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Illustration 119	g01291138
Location for the jacket water pressure sensor (turbocharged aftercooled engines)

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Illustration 120	g01344874
Location for the jacket water pressure sensor (naturally aspirated engines)

2. Install reducing bushing (4), adapter (2) and seal (3). Apply pipe sealant to the reducing bushing and to the adapter.

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Illustration 121	g01291139
(2) 9X-0435 Adapter (3) 6V-9027 O-Ring Seal (4) 162-6622 Reducing Bushing

3. Install jacket water pressure sensor (5). Torque the sensor to 10 ± 2 N·m (7 ± 1 lb ft).

Illustration 122	g01291140
(5) 276-6793 Pressure Sensor Gp

Coolant Temperature Sensor

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Illustration 123	g01291204
Coolant temperature sensor (1) 112-3231 Adapter (2) 6V-6609 O-Ring Seal (3) 264-4297 Temperature Sensor Gp

1. Install adapter (1), O-ring seal (2), and coolant temperature sensor (3). Apply pipe sealant to the threads of the adapter. Torque the sensor to 20 ± 3 N·m (15 ± 2 lb ft).

Oil Temperature Sensor

1. Remove plug (1) from the cylinder block in order to install the oil temperature sensor.

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Illustration 124	g01291215

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Illustration 125	g01291217
Oil temperature sensor (2) 112-3231 Adapter (3) 8L-2786 O-Ring Seal (4) 102-2240 Temperature Sensor Gp

2. Install adapter (2), O-ring seal (3), and oil temperature sensor (4). Apply pipe sealant to the threads of the adapter. Torque the oil temperature sensor to 20 ± 3 N·m (15 ± 2 lb ft).

Speed-Timing Sensor

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Illustration 126	g01291260
Location for installation of the speed-timing sensor (1) 273-5041 Speed Sensor Gp

1. Install speed-timing sensor (1). The slip head of the speed-timing sensor must extend a minimum of 4 mm (0.1575 inch) prior to installation. Torque the speed-timing sensor to 40 ± 5 N·m (29 ± 4 lb ft).

Detonation Sensors

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Illustration 127	g01254654
Typical example Location for the detonation sensor for the right side of the engine

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Illustration 128	g01291334
Location for the detonation sensor for the left side of the engine (1) 142-0215 Knock Sensor Group

1. Install the detonation sensors for the right side of the engine and for the left side of the engine. Refer to Illustration 127 and Illustration 128 for the location of the sensors. Torque the sensors to 15 ± 3 N·m (11 ± 2 lb ft).

Nitrogen Oxide Sensor

Table 7

Engine	Slack In Harness (A)  (1)	Slack In Harness (B)  (2)	Illustration
G3508	135 mm (5.3150 inch)	135 mm (5.3150 inch)	129, 130, and 131

( 1 )	The distance of the slack in the harness that is between the sensor and the support bracket
( 2 )	The distance of the slack in the harness that is between the buffer and the support bracket

Illustration 129	g01438808
Typical example (A) The distance of the slack in the harness that is between the sensor and the support bracket

Illustration 130	g01395328
Typical example (B) The distance of the slack in the harness that is between the buffer and the support bracket

Illustration 131	g01433088
G3508 (1) Adapter ring (2) Sensor (3) Support bracket (4) Sensor harness (5) Tie-wrap (A) The distance of the slack in the harness that is between the sensor and the support bracket (B) The distance of the slack in the harness that is between the buffer and the support bracket

1. Apply 5P-3931 Anti-Seize Compound to the threads of the sensor. Insert the sensor into the adapter ring for the exhaust. Tighten the sensor.

   Torque ... 50 ± 5 N·m (37 ± 4 lb ft)

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Illustration 132	g01513222
(6) 8-pin connector (7) Buffer (8) Harness to sensor (9) Mounting posts (10) Mounting plate

2. Install the buffer onto the two mounting posts. Verify that the buffer is flush with the mounting plate.

3. Replace the two spacers onto the mounting posts. Replace the cover for the buffer. The cover has a slot that is located over the pin on the mounting plate. This slot ensures that the cover for the buffer will align properly onto the mounting plate.

4. Replace the nuts and the washers onto the mounting posts. Tighten the nuts until the nuts are barely snug. This procedure allows movement of the cover for the buffer.

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Illustration 133	g01513234
(11) Tie-wrap (12) Tabs

5. Slide one of the tie-wraps over the wiring from the buffer to the 8-pin connector. Slide the other tie-wrap over the wiring from the buffer to the sensor. Ensure that the tie-wraps go around the metal tabs on the cover for the buffer. Pull the tab in order to tighten the tie-wrap as firmly as possible.

6. Tighten the nuts.

   Torque ... 5 ± 2 N·m (44 ± 18 lb in)

7. Pull the harness straight from the end of the sensor and mark the harness 135 mm (5.3150 inch) from the end of the sensor. Secure the harness to the support bracket at the marked location by using one of the included tie-wraps. Pull the tab in order to tighten the tie-wrap as firmly as possible.

   Note: Do not pull the sensor harness until the sensor harness is tight. Leave an arc of slack so that there is not any pull on the sensor.

8. Pull the sensor harness straight from the buffer. Verify that the slack in the harness from the point between the buffer and the support bracket is correct with the recommended slack. The slack is listed in Table 7. Secure the sensor harness to the support bracket near the buffer by using one of the included tie-wraps. Pull the tab in order to tighten the tie-wrap as firmly as possible.

9. Connect the 8-pin connector of the buffer to the engine harness.

Note: The sensor and the sensor buffer are integrated parts. The sensor and the sensor buffer must be replaced as a single component, if necessary.

Illustration 134	g01486215
Left side view (13) 304-4209 Nitrogen Oxide Sensor Gp (14) 311-6493 Support (15) 5M-2894 Hard Washer (16) 9S-8752 Full Nut (17) 0S-1594 Bolt (18) 4P-8134 Clip (19) 9X-6772 Cable Strap (20) 316-9297 Bracket As (21) 0S-1588 Bolt (22) 315-7845 Plate (23) 2B-2694 Bolt (24) 5S-0003 Nut (25) 8T-9655 Isolation Mount (26) 9N-0869 Hard Washer (27) 307-7359 Screw (28) 8T-4224 Hard Washer (29) 6V-8189 Nut

Illustration 135	g01486613
(30) 307-7356 Cover (31) 139-6535 Spring Pin (32) 7X-6315 Ground Strap

Illustration 136	g01483874
Nitrogen oxide sensor

Note: The nitrogen oxide sensor must be calibrated before the engine is put into service. Use the 156-1060 Emissions Analyzer Gp or the 156-1070 Emissions Analyzer Gp in order to calibrate the sensor. Refer to Operating Manual, NEHS0713, "156-1060 & 156-1070 GAS EMISSION ANALYZER " and Operating Manual, NEHS0714, "156-1060 & 156-1070 EMISSION ANALYZER GROUP POCKET CARD TOOL OPERATING TIPS".

Prelube Switch

1. Remove the knockout plug from the front door of the remote panel.

2. Remove the covering from the ends of the wires for the prelube. These wires are located in the remote panel.

3. Connect the wires to the terminals of the prelube switch. Refer to Illustration 137.

Illustration 137	g01319822
(1) 317-5039 Control Box Gp (2) 3E-1813 Push Button Switch (3) 150-1240 Pressure Switch

Wiring for the Air/Fuel Ratio Control

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Illustration 138	g01431264

1. Install the fuse holders for the air/fuel ratio control in the engine interface box.

2. Install fuse F4 (1) for the throttle actuator.

3. Install fuse F5 (2) for the air/fuel ratio control actuator.

4. Install jumper wire (3) (P200-C19).

Timing Calibration Connector and Service Tool Connector

The timing calibration connector and the service tool connector are part of the engine harness assembly. The timing calibration and the service tool connector are located at the left rear of the engine. Refer to Illustration 139.

Illustration 139	g01344886
(1) Service tool connector (2) Timing calibration connector

Install the Remote Advisor Panel (if equipped)

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Illustration 140	g01290823
Typical remote advisor panel support

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Illustration 141	g01316757
Remote advisor panel

1. Install the remote advisor panel.

2. The remote advisor panel must be installed within 50 feet of the engine.

Air Start Lines

Vane Type Air Starting Motor without Prelube

Illustration 142	g01347188
Vane type air starting motor without prelube (1) 8N-8451 Gasket (2) 8N-8446 Elbow (3) 9X-8875 Bolt (4) 3L-8893 Nipple-Close (5) 6V-8252 Pipe Union (6) 6B-3685 Elbow (7) 4P-8134 Clip (8) 9X-6772 Cable Strap (9) 0L-1143 Bolt (10) 8M-9024 Hard Washer (11) 6W-6672 Spacer (12) 4S-6399 Connector (13) 030-7961 Elbow (14) 298-4521 Bracket (15) 1H-2815 Pipe Nipple (16) 119-6284 Air Motor Lubricator Group (17) 5B-7666 Elbow (18) 5B-7442 Pipe Nipple (19) 5T-4373 Hose As (20) 6K-1972 Flared Elbow (21) 295-5743 Bracket (22) 9S-8752 Full Nut (23) 5L-2534 U-Bolt (24) 6L-5699 Pipe Nipple (25) 1L-2782 Pipe Tee (26) 8F-7800 Pipe Cap (27) 6F-5985 Hose As (28) 146-5215 Air Lines Strainer Gp (29) 5P-1076 Hard Washer (30) 0S-1573 Bolt (31) 4N-3411 Relay Valve Gp (32) 7J-8611 Pipe Elbow (33) 5P-2657 Elbow (34) 251-9396 Solenoid Valve Gp

Turbine Type Air Starting Motor without Prelube

Illustration 143	g01347623
Turbine type air starting motor without prelube (1) 3P-1823 Pipe Adapter (2) 2N-1931 Pipe Elbow (3) 003-4711 Pipe Nipple (4) 7N-2539 Hose As (5) 4P-8134 Clip (6) 0S-1571 Bolt (7) 8M-9024 Hard Washer (8) 2A-2677 Spacer (9) 9X-6772 Cable Strap (10) 0S-1590 Bolt (11) 6K-1972 Flared Elbow (12) 299-2408 Bracket (13) 9M-1974 Hard Washer (14) 1A-9579 Bolt (15) 6F-8857 Pipe Nipple (16) 5L-2534 U-Bolt (17) 9S-8752 Full Nut (18) 105-0428 Pipe Nipple (19) 6B-3685 Elbow (20) 143-5177 Pipe Nipple (21) 6L-5699 Pipe Nipple (22) 6F-5985 Hose As (23) 146-5215 Air Lines Strainer Gp (24) 5B-7666 Elbow (25) 6V-8252 Pipe Union (26) 3L-8993 Fitting (27) 4N-3411 Relay Valve Gp (28) 1L-2782 Pipe Tee (29) 8T-6760 Pipe Plug (30) 299-0698 Bracket (31) 251-9396 Solenoid Valve Gp

Install the Wiring Harnesses

Table 8

Reference
CSA Engines with Single Cooling Circuit
Model	Part Number
G3508	306-9152 Engine Wiring Gp

The letter designation and the description of the wiring harnesses that are used for G3508 CSA engines are listed in Table 9. The part numbers that are listed in Table 9 give detailed information about each wiring harness.

Table 9

Wiring Harnesses (CSA)
Harness Assembly	Part Number	Description
AC	337-0286	Engine Harness Assembly
AP	4P-9321	Wiring Harness
AR	273-3111	Control Harness As
AT	273-3103	Control Harness As
C	251-9471	Box Harness As
CC	298-8840	Power Harness As
F	N/A	Customer wiring
G	251-9446	Box Harness As
H	317-4461	Sensor Harness As
K	273-3121	Wiring Harness
T	251-9466	Interconnect harness 6 m (20 ft)
T	251-9467	Interconnect harness 9 m (30 ft)
T	251-9468	Interconnect harness 15 m (50 ft)

Orientation of the Fasteners for the Engine Harness

The following illustrations show the orientation of the clips for the wiring harnesses. The notations TOP, BOTTOM, RIGHT, LEFT, FRONT, and REAR are used in order to provide orientation for the clips. These positions are in reference to the current view, which shows the mounting orientation of the clips on the engine. These positions are not the customary views of the engine.

The harness must be tied to a clip with a tie strap. The tie straps must be installed through the appropriate slot in the clip. The tie straps must be tightened to the harness in order to prevent any rubbing of the harness on the clip. The clips must be oriented in order to minimize any contact between the wiring harness and the engine.

Reuse all existing washers.

Illustration 144	g01293103

Install the Engine Harness Assembly

Refer to Illustrations 145 through 148 in order to secure the wiring harness to the engine. Connectors for the engine harness are shown in Illustration 149.

Note: For more details on the connection of the thermocouple harness and for the exhaust temperature module, refer to ""Wiring for the Exhaust Temperature Module" ".

Illustration 145	g01493454
Left side view (1) 204-8000 Tie Anchor (2) 5M-2894 Hard Washer (3) 0S-1571 Bolt (4) 193-3973 Tie (5) 4W-9149 Spacer (6) 9X-6772 Cable Strap (7) 4P-7581 Clip (8) 0S-1594 Bolt (9) 251-9389 Bracket (10) 337-0286 Engine Harness As (11) 9S-8752 Full Nut (12) 9L-9132 Washer (13) 7X-0291 Bolt (14) 6B-6205 Spacer (15) 9S-3232 Clip (16) 9X-8874 Bolt (17) 5P-8245 Hard Washer (18) 230-7732 Mount (19) 9F-4831 Spacer (20) 4P-8134 Clip

Illustration 146	g01493473
Right side view (21) 0S-0509 Bolt (22) 9X-3495 Clip As (23) 7K-1181 Cable Strap

Illustration 147	g01493513
Rear view (24) 132-5789 Clip (25) 1F-7958 Full Nut (26) 4P-7429 Clip (27) 0S-1595 Bolt (28) 7W-2124 Bracket (29) 183-3108 Bracket

Illustration 148	g01493534
(30) 2S-2301 Spacer (31) 5S-0003 Nut (32) 9N-0869 Hard Washer (33) 0L-1351 Bolt (34) 2P-8977 Plate (35) 9X-6458 Hard Washer (36) 0L-1352 Bolt (37) 0S-1590 Bolt

Illustration 149	g01493553
Main engine harness connectors

Install the Thermocouple Wiring Harness

Table 10

Reference
Model	Part Number
G3508 with single turbocharger	317-4460 Pyrometer Wiring Gp

Note: For more details on the connection of the thermocouple harness and for the exhaust temperature module, refer to ""Wiring for the Exhaust Temperature Module" ".

Orientation of the Fasteners for the Thermocouple Harness

Refer to ""Orientation of the Fasteners for the Engine Harness" ".

The positions of the fasteners for securing the thermocouple harness to the engine are shown in Illustrations 150, 151, and 152.

Illustration 150	g01497053
Left side view (1) 3S-2093 Cable Strap (2) 5M-2894 Hard Washer (3) 0S-0509 Bolt (4) 4P-8134 Clip (5) 5N-2126 Adapter (6) 241-9591 Temperature Sensor Gp (7) 4P-7581 Clip (8) 9X-6772 Cable Strap

Illustration 151	g01497073
Right side view (9) 243-5752 Temperature Sensor Gp (10) 317-4461 Sensor Harness As

Illustration 152	g01497114
Rear view (11) 180-5420 Temperature Sensor Gp (12) 6B-5072 Reducing Bushing (13) 0S-1594 Bolt (14) 9S-8752 Full Nut (15) 9X-3495 Clip As

Install the Alternator Wiring Harness (if equipped)

Secure the alternator wiring harness to the engine. Refer to Illustrations 153 through 155.

Illustration 153	g01319109
G3516 Typical example

Illustration 154	g01501926
G3516 Typical example (1) 9X-6772 Cable Strap (2) 0S-0509 Bolt (3) 5M-2894 Hard Washer (4) 4P-7581 Clip (5) 0S-1588 Bolt (6) 4P-8134 Clip

Illustration 155	g01501953
(7) Fuse F5 (actuator for air/fuel ratio control) (8) Connection on the interconnect harness (9) 156-6175 Clip (10) 5P-0537 Hard Washer (11) 0S-1616 Bolt (12) 9S-8750 Nut (13) Test connector (14) 273-3127 Connector

Orientation of the Fasteners for the Alternator Wiring Harness

Refer to ""Orientation of the Fasteners for the Engine Harness" ".

The positions for the fasteners that secure the alternator wiring harness to the engine are shown in Illustrations 156 and Illustration 157.

Illustration 156	g01319292
G3516 Typical example

Illustration 157	g01319294

Visual Aids

The following illustrations are for use as a visual aid for securing the wiring harnesses.

Illustration 158	g01436890
Left side view (ECM)

Illustration 159	g01435850
Front view (ECM)

Illustration 160	g01436864
Hardware behind the support bracket for the ECM

Illustration 161	g01435928
Front view

Illustration 162	g01433009
Right side view

Illustration 163	g01435853
Right side view

Illustration 164	g01435870
Right side view

Illustration 165	g01435874
Right side view

Illustration 166	g01501975
Left side view

Illustration 167	g01501976
Left side view

Illustration 168	g01501977
Left side view

Illustration 169	g01435890
Left side view

Illustration 170	g01435895
Left side view

Illustration 171	g01435911
Left side view (harness for the throttle actuator)

Illustration 172	g01432542
Left side view (harness for the throttle actuator)

Illustration 173	g01436870
Top view (harness for throttle actuator )

Illustration 174	g01438279
Left side view (harness for the air/fuel ratio control actuator)

Illustration 175	g01438282
Left side view (harness for the air/fuel ratio control actuator)

Illustration 176	g01435940
Rear view (exhaust temperature module)

Illustration 177	g01501999
Rear view

Illustration 178	g01502001
Right side view

Illustration 179	g01504095
Alternator wiring harness

PL1000 Customer Communications Module

The PL1000E or the PL1000T Customer Communication Module (CCM) can be used with the G3508 ADEM 3 conversion. The following publications are available for detailed information on these modules.

• Special Instruction, REHS2362, "Installation Guide for the 256-7512 PL1000E Communications ECM"

• Systems Operation/Testing and Adjusting, RENR8091, "PL1000E Communication ECM"

• Special Instruction, REHS2125, "Installation Guide for the 256-7511 PL1000T Communications ECM"

• Systems Operation/Testing and Adjusting, RENR7945, "PL1000T Communication ECM "

Wiring for the Exhaust Temperature Module

ReferenceSystems Operation/Testing and Adjusting, KENR5473.

Illustration 180	g01431685
Typical example (1) 232-4674 Connector Seal (2) 288-4678 Connector As (3) 232-4675 Connector Seal (4) 288-4677 Connector As (5) Pyrometer display (6) Engine interface box (7) Main engine harness (8) Interconnect harness

Note: A sleeve must cover the following circuits of the interconnect harness that is located inside the interface box and the advisor panel:

• + Battery (P200-T4 RD)

• - Battery (P300-T39 BK)

• Keyswitch (P600-T18 WH)

• Push button for the prelube (C293-T26 BK)

• Prelube light (A320-T33 RD)

Illustration 181	g01431715
View B-B (9) 8T-9006 Bolt (10) 232-4673 Plug (11) 3S-2093 Cable Strap (12) 121-0199 Spiral Wrap (13) 237-4356 Adapter (14) 9X-6772 Cable Strap (15) Thermocouple harness

1. Five pins (pins 5 through 9) must be inserted into the 70-pin connector at the back of the exhaust temperature module. These five pins are located on two separate cables that break out from the main engine harness. Refer to Table 11. Refer to Illustrations 183 and Illustration 184.

2. A wrap-up sleeve must be installed over the power wires +B and - B at the 70-pin connector on the exhaust temperature module. Gather the five wires (pins 5 through 9) and ensure that the connector retaining screw is accessible for attaching to the exhaust temperature module. Use cable strap (11) in order to gather the wires inside the connector assembly. Install connector assembly (2), seal (1), connector assembly (4), seal (3), and adapter (13) .

3. Secure thermocouple harness (15) to main engine harness (7) with cable straps (14) in order to protect the connections at the 70-pin connector.

Illustration 182	g01431924
Remote panel (8) Interconnect harness

Note: The wrap must cover the following circuits for the interconnect harness that are located inside the interface box and the advisor panel:

• + Battery (P200-T4 RD)

• - Battery (P300-T39 BK)

• Keyswitch (P600-T18 WH)

• Push button for the prelube (C293-T26 BK)

• Prelube light (A320-T33 RD)

Table 11

70-pin Connector at the Back of the Exhaust Temperature Module
Pin	Description	Circuit Number
5	CAN Shield	D200-A8 CU
6	+ B	P600-A165 WH or RD
7	− B	P300-A164 BK
8	+ CAN	D200-A168 YL
9	- CAN	D200-A167 GN

Illustration 183	g01513854
Pins for the power and CAN data link on the exhaust temperature module connector (16) Socket connector

Illustration 184	g01431934
Pins for the power and CAN data link on the exhaust temperature module connector

Connect the Wiring From the Battery

Illustration 185	g01272958
Typical view of the engine (1) Engine interface box (2) Enclosures that are provided by the customer must be CSA approved enclosure.

Requirements for Engines That are Not Equipped With an Alternator

The customer is responsible for providing overcurrent protection for the battery circuit. The battery circuit must be protected by a CSA approved fuse. The maximum allowable rating of the fuse is 20 A.

Install the fuse in a fuse holder that is CSA approved. Mount the fuse holder in a CSA approved enclosure (2), if necessary. Mount the fuse holder or the enclosure as close as practical to interface box (1) .

Requirements for Engines That are Equipped With an Alternator

The customer is responsible for providing overcurrent protection for the charging circuit. The charging circuit includes the wiring from the battery and the wiring from the alternator. This wiring is connected at terminal 12 inside interface box (1). The circuit must be protected by a CSA approved fuse. The maximum allowable rating of the fuse is 60 A. This rating limits the charging current between the alternator and the battery. The gauge of the wiring from the battery may require a fuse rating that is lower than 60 A.

Install the fuse in a fuse holder that is CSA approved. Mount the fuse holder in a CSA approved enclosure (2), if necessary. Mount the fuse holder or the enclosure as close as practical to interface box (1).

Illustration 186	g01272967
Bottom view of the engine interface box (3) 50 mm (1.9685 inch) hole (4) 28 mm (1.1024 inch) hole (5) 28 mm (1.1024 inch) hole

Refer to Illustration 186. The bottom of the engine interface box has two holes (3) and (5) when the engine is shipped from the factory. Fabricate hole (4) if the engine is equipped with an alternator. Refer to Table 12.

Table 12

Holes in the Bottom of the Engine Interface Box
Hole	Size	Purpose
(3)	50 mm (1.9685 inch)	Wiring from the driven equipment
(4)	28 mm (1.1024 inch)	Hole for the wiring from the battery, which must be drilled out by the customer
(5)	28 mm (1.1024 inch)	Wiring from the alternator Route the wiring from the battery through this hole when the engine is not equipped with an alternator.

Perform the following procedure to make the connections from the battery.

1. Verify that the wiring from the battery is de-energized.

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Illustration 187	g01272968
Connections for the battery (6) Main fuse

2. Remove main fuse (6) .

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Illustration 188	g01272969
Hardware for connecting the wiring from the battery (7) 119-8044 Wire Ends (6 Gauge) (8) 4P-4891 Terminal Bushing (9) 273-3127 Connector

3. Use connector (9) and terminal bushing (8) to attach the wiring from the battery to the engine interface box.

4. Use a 139-2789 Ferrule Crimp Tool to crimp a wire end (7) to the end of each wire.

5. Connect wire ends (7) to the appropriate locations. Be sure to observe the polarity of the connections.

6. Connect the wiring to the battery.

   Note: Do not install main fuse (6) until all of the wiring from the driven equipment is connected to the engine.

Connect the Wiring From the Driven Equipment

Illustration 189	g01432607
Typical installations

Refer to Illustration 189. Make the electrical connections for the driven equipment at one of the following locations:

Engine Interface Box - All of the electrical connections for the driven equipment are made inside the engine interface box. The following connections are also made inside the engine interface box: switched power, unswitched power and prelube switch.

Interconnect Harness - The interconnect harness is connected to the engine interface box. All of the electrical connections for the driven equipment are made to the end of the interconnect harness.

Remote Advisor Panel - A remote advisor panel is connected to the engine interface box via an interconnect harness. All of the electrical connections for the driven equipment are made at a terminal strip inside the remote panel.

Table 13 lists the connections that are available at each of the locations. Review the Table before making the connections.

Note: The metal conduit must be provided by the customer. The metal conduit must be installed by the customer for all customer connections. The connections include the battery power and the interconnect harness. Customer installed conduit and wiring which is performed at the site must conform to all electrical codes. Customer installed wiring must conform to the standards of the Canadian Standards Association if CSA is one of the desired certifications.

Table 13

Connections for the Driven Equipment
Description	Engine Interface Box	Interconnect Harness	Remote Panel (Terminal Strip)	Function and Comments
Prelube ON	Terminal 1 on the Terminal Block	A320-T33 Cable 91-Red	33	This output indicates that the prelubrication is ON. The prelube indicator on the remote panel will illuminate when the prelubrication is ON.
"Manual Prelube" Input	Terminal 2 on the Terminal Block	C293-T26 Cable 91-White	26	This input must be connected to the keyswitch input via a switch. The manual prelube switch on the remote panel provides this connection.
Unswitched +Battery	Terminal 4 on the Terminal Block	P200-T4 Cable 105-Red	4	These connections provide the electrical power to the remote panel. Current flow through these connections must be limited to 5 A If the remote panel is not installed.
−Battery	Terminal 8 on the Terminal Block	P300-T39 Cable 105-Black	39
−Battery	Terminal 8 on the Terminal Block	P300-T40 Cable 91-Black	40
Keyswitch	Terminal 7 on the Terminal Block	P600-T18 Cable 105-White	18	This connection is the keyswitch input for the ECM. If a remote panel is not installed on the engine, the connection for the keyswitch must be powered when the engine control is in "COOLDOWN/STOP", "AUTO", or "START".
+5 VDC for the Input for the Desired Engine Speed	Terminal 6 on the Customer Connector	M170-T6 Cable 50-Red	6	An input for the desired engine speed is required. The input can be either 0 to 5 VDC or 4 to 20 mA. The method for the desired speed input must be selected with Cat ET. Terminals 6 and 8 provide a 5 VDC supply for the desired engine speed. These terminals must be connected to the potentiometer for the desired speed. Terminal 7 is the input for the desired engine speed. An input of 0 VDC causes the engine rpm to equal the value of the "Minimum High Idle Speed" parameter. An input of 5 VDC causes the engine rpm to equal the value of the "Maximum High Idle Speed" parameter.
Input for the Desired Engine Speed	Terminal 7 on the Customer Connector	M170-T7 Cable 50-White	7
Return for the Desired Engine Speed	Terminal 8 on the Customer Connector	M170-T8 Cable 50-Black	8
Shield for the Wiring for the Desired Engine Speed	Terminal 9 on the Customer Connector	M170-T9 Cable 50-Shield	9
"+" Input for the 4 to 20 mA Desired Speed Signal	Terminal 10 on the Customer Connector	M180-T10	10	An input for the desired engine speed is required. The input can be either 0 to 5 VDC or 4 to 20 mA. The method for the desired speed input must be selected with Cat ET. The 4 to 20 mA is an optional method for providing the desired engine speed input. If the 4 to 20 mA method is used to control the desired speed, the 0 to 5 VDC input must be disabled. The 4 to 20 mA input is an isolated input. The "+" input must be in the same circuit as the "-" input. An input of 4 mA causes the engine rpm to equal the value of the "Minimum High Idle Speed" parameter. An input of 20 mA causes the engine rpm to equal the value of the "Maximum High Idle Speed" parameter.
"-" Input for the 4 to 20 mA Desired Speed Signal	Terminal 12 on the Customer Connector	M180-T12	12
"Grid Status" Input	Terminal 11 on the Customer Connector	M120-T11	11	This input is not normally used in industrial applications. Primary governor gains are used when this input is not connected to the digital return. Auxiliary governor gains are used when this input is connected to the digital return.
Cat Data Link +	Terminal 13 on the Customer Connector	D100-T13	13	These connections provide the means for communicating the status of the engine control system, of various engine components, and of sensors. The Advisor Monitor Display on the remote panel is connected to these terminals. The Cat Data Link can be connected to the Customer Communication Module (CCM). For information on connecting the CCM, refer to the most recent literature for the CCM. When the Caterpillar Software for the CCM is loaded on a personal computer, the program uses the CCM in order to obtain engine information via this data link.
Cat Data Link −	Terminal 14 on the Customer Connector	D100-T14	14
Digital Return	Terminal 15 on the Customer Connector	P500-T15	15	This connection provides a return for various inputs.
Input for the "START" Mode	Terminal 16 on the Customer Connector	P615-T16	16	If these inputs are not wired correctly, the ECM will activate a diagnostic code. Typically, these inputs are connected to an engine control switch. Refer to "Inputs for the Engine's Mode of Operation" for additional information on these inputs. These inputs must be connected to a switch or to a logic device. The switch or a logic device must connect the inputs to the digital return. When terminal 24 is connected to the digital return, the ECM is in "STANDBY" mode. The engine mode of operation is determined by the "Input for the START Mode". When the "Input for the START Mode" is connected to the digital return, the normal sequence for start-up is initiated. When the "Input for the START Mode" is disconnected from the digital return, a normal shutdown is initiated. If the engine is running and the "Input for the Cooldown/STOP Mode" is connected to the digital return, the sequence for a normal shutdown is initiated.
Input for the "AUTO" Mode	Terminal 24 on the Customer Connector	P614-T24	24
Input for the "COOLDOWN/STOP" Mode	Terminal 31 on the Customer Connector	P613-T31	31
"Driven Equipment Ready" Input	Terminal 17 on the Customer Connector	M530-T17	17	This input indicates when the driven equipment is ready for operation. This input must be connected to the digital return in order for the engine to run. When this input is connected to the digital return, the engine can be started. When this input is not connected to the digital return, the engine will not crank. The ECM generates an event code if this input is not connected to the digital return within the programmed delay time. When the engine is running, this input normally continues to be connected to the digital return. If the engine is running and this input is disconnected from the digital return, the ECM immediately generates an event code. The ECM also de-energizes the GSOV. Because the cooldown is not performed, do not use this input for normal shutdown.
Keyswitch	Terminal 7 on the Terminal Block	P600-T18	18	When this input is connected to the +Battery, the ECM will power up. The Advisor Monitor Display on the remote panel will power up.
Normal Stop	Terminal 19 on the Customer Connector	M510-T19	19	This input must be connected to the digital return in order for the engine to run. This input is not recommended for normal shutdown. Connecting the "Input for the COOLDOWN/STOP Mode" to the digital return is the recommended method for initiating a normal shutdown. If the engine is not running and this input is not connected to the digital return, the engine will not crank. No diagnostic codes or event codes are provided for this condition. If the engine is running and this input is disconnected from the digital return, the ECM will remove power from the GSOV. The cooldown does not operate.
Output for Active Alarm	Terminal 20 on the Customer Connector	P697-T20	20	This output is activated if the ECM detects an alarm condition. When this output is activated, the output is connected to ground. Sinking 0.3 A output.
Idle/Rated Input	Terminal 22 on the Customer Connector	M190-T22	22	When this input is not connected to the digital return, the engine will run at the idle speed that has been programmed with Cat ET. When the engine oil pressure is greater than the setpoint for the engine speed and this terminal is connected to the digital return, the engine will run at rated speed.
Emergency Stop	Terminal 2 on the 2 Terminal Connector	C256-T23	23	These terminals must be connected in order for the engine to start. These terminals must remain connected in order for the engine to run. If the ECM is controlling the gas shutoff valve and this circuit is opened, the ECM de-energizes the gas shutoff valve. The fuel is immediately shut off. The ignition is immediately shut off. Additional emergency stop buttons may be added to the emergency stop circuit. For details, refer to "Wiring for the Emergency Stop Circuit".
	Terminal 28 on the Customer Connector	C256-T28	28
Output for Engine Failure	Terminal 25 on the Customer Connector	P698-T25	25	The ECM connects this terminal to ground when the ECM causes the engine to be shut down. Sinking 0.3 A output.
Input for Manual Prelube	Terminal 22 on the Customer Connector	C293-T26	26	This terminal is for the manual prelube. The logic of the ECM determines when prelube is required. The input for the manual prelube should be connected to the + Battery.
Gas Shutoff Valve	Terminal 5 on the Terminal Block	A330-T30 Cable109-Red	30	These connections are part of the circuit for the Gas Shutoff Valve (GSOV). For details on these terminals, refer to "Wiring for the Gas Shutoff Valve (GSOV)".
	Terminal 1 on the 2 Terminal Connector	A330-T37 Cable 109-White	37
+ CAN Data Link	Terminal 35 on the Customer Connector	D200-T35 Cable 45-Yellow	35	The Advisor Monitor Display on the remote panel is connected to these terminals.
- CAN Data Link	Terminal 36 on the Customer Connector	D200-T36 Cable 45-Green	36
CAN Data Link Shield	Terminal 38 on the Customer Connector	D200-T38 Cable 45-Shield	38
Spare	No Connection	P300-T41 Cable 109-Black	No Connection	Spare

Refer to the appropriate procedure in order to make the connections.

Engine Interface Box

Illustration 190	g01254409
Locations for connections inside the engine interface box

Wiring for the Emergency Stop Circuit

Illustration 191	g01254366
Options for the wiring for the emergency stop circuit (A) Only the engine emergency stop button is used. (B) The circuit contains an additional emergency stop button that is provided by the customer. (1) 155-2269 Connector Plug As and 8T-8730 Connector Socket (2) 8T-8729 Connector Pin

An emergency stop button is provided on the engine interface box. An additional emergency stop button may be connected to the circuit. Properly wire emergency stop buttons in order to stop the engine in case of an emergency situation. Wire the emergency stop circuit according to graphic (A) or graphic (B) in Illustration 191. Use 16 gauge wiring for this circuit.

The GSOV is immediately de-energized when an emergency stop button is activated. The ignition is disabled.

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NOTICE
Emergency shutoff controls are for EMERGENCY use ONLY. DO NOT use emergency shutoff devices or controls for normal stopping procedure.

Wiring for the Gas Shutoff Valve (GSOV)

The GSOV must be energize-to-run. The GSOV may be supplied by the customer or by Caterpillar. Usually, the GSOV is installed when the piping for the fuel is installed at the site. The GSOV is also called the fuel control relay.

The GSOV may be controlled by the engine control system or by the customer equipment. The recommended configuration is for the engine control system in order to control the GSOV. There will be fewer problems if this configuration is used. When the customer equipment controls the GSOV, the equipment must include the necessary logic. The logic ensures that the GSOV opens and the GSOV closes at the appropriate times.

The ECM can supply a maximum continuous current of 1.5 A to the GSOV. A relay must be installed if the GSOV requires a continuous current that is greater than 1.5 A.

When the engine control system controls the GSOV, the ECM supplies voltage to the GSOV. The valve opens in order to allow fuel to flow to the engine. When voltage is removed from the GSOV, the valve closes and the fuel flow stops.

The following section describes the two configurations for the circuit for the GSOV.

The GSOV is controlled by the engine control system. The customer may supply an additional switch in the electrical circuit for the GSOV. Refer to Illustration 192 for examples of these types of installations.

Illustration 192	g01254747
The GSOV is controlled by the engine control system. (A) Only the engine emergency stop button is used. (B) The circuit contains an additional emergency stop button that is provided by the customer. (1) 155-2269 Connector Plug As and 8T-8730 Connector Socket (3) 109-3038 Wire End

The GSOV is controlled by the customer equipment.

Refer to Illustration 193 for an example of this type of installation.

Illustration 193	g01254388
The GSOV is controlled by the customer' equipment. (1) 155-2269 Connector Plug As and 8T-8730 Connector Socket (3) 109-3038 Wire End

Wire the circuit for the gas shutoff valve according to the appropriate illustration. Use 16 gauge wiring for this circuit.

Illustration 194	g01432979
Routing of the harness for the gas shutoff valve

CAN Data Link

A termination resistor must be added to the CAN data link. Select one of the following locations for the resistor.

Inside of the Engine Interface Box - Use this location when the CAN data link does not extend past the engine interface box.

Outside of the Engine Interface Box - Use this location when the CAN data link extends past the engine interface box.

Illustration 195 describes a typical connection inside the engine interface box. Wire the connection according to SAE standards.

Illustration 195	g01254499
Typical installation for the termination resistor inside the engine interface box (2) 3 8T-8729 Connector Pins (4) 153-2707 Electrical Cable (5) 3E-3370 Connector Receptacle As (6) 174-3016 Plug As

Illustration 196 describes a typical connection outside the engine' interface box. Wire the connections according to SAE standards.

Illustration 196	g01254713
Typical installation for the termination resistor that is outside of the engine interface box (2) 3 8T-8729 Connector Pins (4) 153-2707 Electrical Cable (5) 3E-3370 Connector Receptacle As (6) 174-3016 Plug As (7) Splice (8) 119-3662 Heat Shrink Tube

Customer Connector

Make the connections to the customer connector according to the following procedure:

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Illustration 197	g01254403
Orientation of the customer connector

1. Route the wiring for the driven equipment into the engine interface box. Use 16 gauge wiring for the connections to the customer connector. The hardware that is used should provide a water tight connection at the hole in the engine interface box.

2. Crimp a 8T-8729 Connector Pin onto the end of each wire that will be inserted into the customer connector.

3. Make the connections to the customer connector according to Illustration 197 and Table 13. Insert each pin into the appropriate location on the customer connector. Pull on each wire in order to verify proper installation of the pin.

Terminal Block

Make the connections to the terminal block according to the following procedure:

1. Table 13 lists the functions that are available. Use 16 gauge wiring for the connections to the terminal block. Crimp a 109-3038 Wire End onto the end of each wire that will be inserted into the terminal block.

2. Make the connections according to Illustration 190 and Table 13.

Harness Connectors for the Engine Interface Box

Illustration 198	g01346883
Side view of engine interface box (1) Harness connectors

Note: Cut the tie strap that secures the harness to the harness clip. The harness clip is located on the side of the water regulator housing. Cutting the tie straps helps to ensure that strain will be relieved from the connector pins. This procedure will help prevent damage to the connectors.

Interconnect Harness

Interconnect harnesses of different lengths are available. Table 14 lists the interconnect harnesses that are available. The harnesses can be shortened, if necessary.

Table 14

Interconnect Harnesses
Part Number	Length	CSA	Braided
251-9466	6.1 m (20 ft)	Yes	No
251-9467	9.1 m (30 ft)	Yes	No
251-9468	15.2 m (50 ft)	Yes	No

Illustration 199	g01241390
The end of the interconnect harness for the engine interface box

Refer to Illustration 199. Pins and wire ends are crimped to the ends of the wires at one end of the interconnect harness. This end of the harness is for the engine interface box.

The interconnect harness must be routed through conduit. A 50 mm (2 inch) hole is provided for attaching the conduit to the engine interface box.

The following parts are provided with each interconnect harness:

Pieces of Heat Shrink Tube - Each piece of heat shrink tube is label ed with a wire identification. The tubes are used to identify each wire if the wire is cut to a shorter length.

14 Gauge Wire Ends, 16 Gauge Wire Ends, and 18 Gauge Wire Ends - These parts are only required if the remote advisor panel is used. A wire end will be crimped to the end of each wire. The crimp connects the wire to the terminal strip inside the remote advisor panel.

Note: A wrap-up sleeve is provided with the interconnect harness. A wrap-up sleeve must cover the following circuits for the interconnect harness. These circuits are located inside the engine interface box and the remote advisor panel:

• + Battery (P200-T4 RD)

• - Battery (P300-T39 BK)

• Keyswitch (P600-T18 WH)

• Push button for the prelube (C293-T26 BK)

• Prelube light (A320-T33 RD)

Perform the following procedure in order to connect the interconnect harness to the engine interface box:

1. Pull the harness through the conduit to the engine interface box. Be sure to orient the harness so that the wire ends with crimped terminals are inside the engine interface box.

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Illustration 200	g01432967
Connections on the terminal block (1) Fuse 4 is for the throttle actuator. The fuse for the throttle actuator is required for all engines. (2) Fuse 5 is for the air/fuel ratio control actuator. The fuse for the air/fuel ratio control actuator is required.

2. Make the connections to the terminal block first. Refer to Illustration 200 and Table 15. Each wire is labeled. Insert each wire end to the appropriate location on the terminal block. Pull on each wire in order to verify proper installation of the wire end.
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   Table 15

   Connections for the Terminal Block
   Interconnect Harness		Location on the Terminal Block
   Cable	Wire Identification
   91-Red	A320-T33 (1)	1
   91-White	C293-T26 (1)	2
   105-Red	P200-T4 (1)	4
   109-Red	A330-T30	5
   105-White	P600-T18 (1)	7
   105-Black	P300-T39 (1)	8
   91-Black	P300-T40
   91-Black	P300-T41	Spare

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   ( 1 )

   These circuits must be contained in the wrap-up sleeve at the engine interface box and at the remote advisor panel.

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Illustration 201	g01256097
Connections for the wiring to the customer connector

3. Refer to Illustration 201. Make the connections for wiring to the customer connector. Each wire is labeled. Insert each pin into the appropriate location on the connector. Pull on each wire in order to verify proper installation of the pin.

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Illustration 202	g01256115
Connections for the wires from the cables to the customer connector

4. Refer to Illustration 202. Connect the wiring from the cables to the customer connector. The wire in each cable is labeled. Insert each pin into the appropriate location on the connector. Pull on each wire in order to verify proper installation of the pin.

5. Connect the two terminal connectors on the interconnect harness to the two terminal connectors that are located inside the engine interface box. This connection is for the emergency stop circuit and the circuit for the GSOV.

6. Connect the wiring from the driven equipment to the end of the interconnect harness.

Remote Advisor Panel

Illustration 203	g01256226
Dimensions and components of the remote advisor panel (9) Advisor monitor display (10) Manual prelubrication switch and indicator (11) Emergency stop button (12) Engine control (13) Desired speed potentiometer (14) Service tool connector

The remote panel provides the following capabilities:

• Emergency stop

• Engine control

• Advisor monitor display

• Desired engine speed

• Manual prelubrication

• Indication of alarms, derates, and shutdowns via the advisor monitor display

Make the connections to the remote panel according to the following procedure:

1. Refer to "Interconnect Harness". Route the interconnect harness from the engine interface box to the remote advisor panel. Make the connections for the interconnect harness inside the engine interface box.

   Note: The wires and the cables that make up the interconnect harness may be cut to the appropriate length, if necessary. Do not cut all of the wires and the cables at the same time. Cut one wire and connect the wire to the appropriate location on the terminal strip. This practice is important when a cable that contains several wires is cut. The cable does not have an external marking that identifies the cable. Cut the cable. Then slide the appropriate heat shrink tube into the end of each wire in the cable. This technique helps to ensure that each connection is made correctly.

   Note: Each wire in the harness is identified with the circuit identification.

   1. Select a wire. Identify the location on the terminal strip for the wire. Refer to Table 16.

   2. Cut the wire to the appropriate length.

   3. Slide the appropriate heat shrink tube onto the end of the wire. Shrink the tube onto the wire.

   4. Attach the wire end that is the appropriate gauge onto the end of the wire.
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   Illustration 204	g01243294
   Location for the connections for the interconnect harness inside the remote panel

   5. Refer to Illustration 204. Make the connections for the interconnect harness on the left side of the terminal strip. Insert the wire end into the appropriate location on the terminal strip. Pull on the wire in order to verify that the connection is secure.

      Note: A wrap-up sleeve is provided with the interconnect harness. The wrap-up sleeve must cover the following circuits of the interconnect harness. These circuits are located on the inside of the engine interface box and the remote advisor panel:

      • + Battery (P200-T4 RD)

      • - Battery (P300-T39 BK)

      • Keyswitch (P600-T18 WH)

      • Push button for the prelube (C293-T26 BK)

      • Prelube light (A320-T33 RD)

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      Table 16

      Connections for the Interconnect Harness on the Terminal Strip
      Interconnect Harness Wire Identification	Gauge of the Wire End	Location on the Terminal Strip	Function
      P200-T4 (1) Cable 105-Red	16	4	+ Battery of the remote panel
      M170-T6 Cable 50-Red	16	6	Desired Engine Speed
      M170-T7 Cable 50-White	16	7	Desired Engine Speed
      M170-T8 Cable 50-Black	16	8	Desired Engine Speed
      M170-T9 Cable 50-Shield	16	9	Shield for the Desired Engine Speed
      M180-T10	16	10	Desired Engine Speed
      M120-T11	16	11	Grid Status
      M180-T12	16	12	Desired Engine Speed
      D100-T13	16	13	+ Cat Data Link
      D100-T14	16	14	- Cat Data Link
      P500-T15	16	15	Return
      P615-T16	16	16	Start Command
      M530-T17	16	17	Driven Equipment
      P600-T18 (1) Cable 105-White	14	18	Keyswitch
      M510-T19	16	19	Normal Stop
      P697-T20	16	20	Active Alarm
      SC01-T21	16	21	Spare
      M190-T22	16	22	Idle/Rated Input
      C256-T23	16	23	Emergency Stop
      P614-T24	16	24	Auto
      P698-T25	16	25	Engine Failure
      C293-T26 (1) Cable 91-White	16	26	Manual Prelube Input
      P696-T27	16	27	Crank Terminate
      C256-T28	16	Bottom 28	Emergency Stop
      M140-T29	16	29	Run Relay
      A330-T30 Cable 109-Red	16	30	Gas Shutoff Valve
      P613-T31	16	31	Cooldown/Stop
      M164-T32	16	32	Desired Timing
      A320-T33 (1) Cable 91-Red	16	33	Prelube ON
      D200-T35 Cable 45-Yellow	18	35	+ CAN Data Link
      D200-T36 Cable 45-Green	18	36	- CAN Data Link
      A330-T37 Cable 109-White	16	37	Gas Shutoff Valve
      D200-T38 Cable 45-Shield	18	38	CAN Data Link Shield
      P300-T39 (1) Cable 105-Black	14	39	−Battery
      P300-T40 Cable 91-Black	16	40
      P300-T41 Cable 109-Black	Unconnected		Spare

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      ( 1 )

      These circuits must be contained in the wrap-up sleeve at the engine interface box and at the remote advisor panel.

2. Perform the following procedure to connect the wiring from the driven equipment.

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Illustration 205	g01242443
Location for the customer connection inside the remote advisor panel

3. Refer to Illustration 205. Make the connections for the driven equipment on the right side of the terminal strip. Table 13 lists the connections that are available.

Wiring for the Emergency Stop Circuit

The circuit for the emergency stop buttons is complete when the remote panel is installed. An additional emergency stop button may be added to the circuit. Refer to Illustration 206. Remove the bridge and connect the additional button according to the Illustration.

Illustration 206	g01242557
Emergency stop circuit with an additional emergency stop button

Wiring for the Gas Shutoff Valve

The circuit for the emergency stop buttons is complete when the remote panel is installed. Refer to Illustration 206.

Illustration 207	g01256413
Circuit for the gas shutoff valve

Initial Start-up of the Engine

Refer to Special Instruction, REHS2558, "Installation and Initial Start-Up Procedure for G3500 A3 Engines".

Refer to Troubleshooting, RENR9353, "Gas 3500 A3 Engines", "Nitrogen Oxide Sensor - Calibrate".

Register the Retrofit

Because retrofits to a prime product will change the configuration of the product, updating the configuration in SIMSi and AIMS is important. If the retrofit information is not provided, Caterpillar will not be able to provide important product updates.

The following information includes instructions on registering the updates and retrofits.

1. When performing a retrofit installation, record the vital information in Table 17.

   Note: If the procedure is performed by the customer, ask the customer to record the proper information.

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   Table 17

   Repair Date
   Product Serial Number
   Service Hours or Service Meter Units
   Removed Component Part Number (1)
   Removed Component Serial Number (1)
   Installed Component Part Number (2)
   Installed Component Serial Number (3)

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   ( 1 )	Only applies if a component is replaced by a retrofit component. If the product is an engine, and the product retrofit is a kit for upgrading the engine, disregard the "Removed Component" information. Refer to detailed instructions in Step 3 for more information.
   ( 2 )	Record the highest level retrofit kit, arrangement, or group part number.
   ( 3 )	Most retrofits will not have a serial number. Exceptions include emissions repower engines and diesel particulate filters.

2. Update the product configuration by entering the information from Table 17 into SIMSi and AIMS.

   Note: For retrofits that have a Caterpillar serial number, the AIMS application is "JIZ111-08". For retrofits that do not have a Caterpillar serial number, the AIMS application is "JIZ111-07".

3. For detailed instructions on updating the product configuration, refer to Special Instruction, REHS5097, "Instructions to Register the Retrofit".