G3516 and G3512 Adem 3 with an Oxygen Sensor Upgrade to Air/Fuel Ratio Control and a Nitrogen Oxide Sensor{1408, 191N} Caterpillar

G3516 and G3512 Adem 3 with an Oxygen Sensor Upgrade to Air/Fuel Ratio Control and a Nitrogen Oxide Sensor{1408, 191N}

Usage:

Engine:: G3512 (S/N: WPP1-UP; WPR1-UP); G3516 (S/N: WPT1-UP; WPW1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you read this information and you understand this information.

This Special Instruction provides the procedure that is necessary for installing the nitrogen oxide sensor on 1200 rpm and 1400 rpm G3512 and G3516 Engines.

Air/fuel ratio control is required for this upgrade. The use of the remote advisor panel is highly recommended for this upgrade.

References

Special Instruction, REHS2558, "Installation and Initial Start-Up Procedure for G3500 A3 Engines".
Troubleshooting, RENR9353, "Gas 3500 A3 Engines", "Nitrogen Oxide Sensor - Calibrate".
Informational Release Memo, PELJ1001, "G3512 & G3516 ADEM III Engine Upgrade Conversion to Nitrogen Oxide Sensor"

Update Software

Ensure that the appropriate ADEM 3 flash file is correct for the air/fuel ratio control and for the nitrogen oxide sensor. Refer to Table 1.

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Table 1
G3500 Flash Files
Flash Files ⁽¹⁾	G3516	G3512
	317-5317	317-5319

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^( 1 )

The flash files can be downloaded from the Service Information System (SIS).

Required Parts

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Table 2
Engine Control Wiring
Engine Wiring Gp	G3516		G3512
	Part Number	Qty	Part Number	Qty
	305-4550 Engine Harness As	1	305-4551 Engine Harness As	1
Temperature Sensor Gp	243-5752 Temperature Sensor Gp	1	243-5752 Temperature Sensor Gp	1
	310-4796 Temperature Sensor Gp	1	310-4796 Temperature Sensor Gp	1
	5N-2126 Adapter	2	5N-2126 Adapter	2
	318-5027 Sensor Harness As	1	318-5025 Sensor Harness As	1

The parts that are listed above must be changed for the existing ADEM 3 engine wiring. Refer to Table 2 for the required parts for your application.

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Table 3
Updates for the Air/Fuel Ratio Control
	G3516	Qty	G3512	Qty
Nitrogen Oxide Sensor Mounting Gp	341-9401	1	341-9401	1
Nitrogen Oxide Sensor Wiring Gp	308-3821	1	308-3821	1
AFRC Conversion Gp	325-6491	1	325-6490	1

If the engine is currently equipped with air/fuel ratio control, refer to Table 3 for the required parts for your application.

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Table 4
Updates for the Air/Fuel Ratio Control
	G3516	Qty	G3512	Qty
Nitrogen Oxide Sensor Mounting Gp	341-9401	1	341-9401	1
Nitrogen Oxide Sensor Wiring Gp	308-3821	1	308-3821	1
AFRC Conversion Gp	325-6494	1	325-6493	1

If the engine is not currently equipped with air/fuel ratio control, refer to Table 4 for the required parts for your application.

If the installation has a remote advisor panel, ensure that the correct software is installed. The software monitors the NO_X data from the sensor. Refer to Table 5 for the required software for your application.

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Table 5
G3500 Flash Files
Flash Files ⁽¹⁾	G3516	G3512
	308-4785	308-4785

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^( 1 )

The flash files can be downloaded from the Service Information System (SIS).

If the installation does not have a remote advisor panel, a remote advisor panel is highly recommended. Ensure that the software that is listed in Table 5 is downloaded into the new remote advisor panel.

If the engine is equipped with prelube, refer to Table 6 for the required parts. Choose only one interconnect harness. The interconnect harnesses are available in the following lengths. 20 feet, 30 feet and 50 feet.

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Table 6
Remote Monitoring Panel For An Engine That Is Equipped With Prelube
G3516 and G3512
Part Number	Qty	Length
317-5038 Control Box	1
320-9978 Wiring Harness Fastener Gp	1
251-9466 Wiring Harness ⁽¹⁾	1	6 m (20 ft)
251-9467 Wiring Harness ⁽¹⁾	1	9 m (30 ft)
251-9468 Wiring Harness ⁽¹⁾	1	15 m (50 ft)

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^( 1 )

Choose only one interconnect harness.

If the engine is not equipped with prelube, refer to Table 7 for the required parts. Choose only one interconnect harness. The interconnect harnesses are available in the following lengths. 20 feet, 30 feet and 50 feet.

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Table 7
Remote Monitoring Panel For An Engine That Is Not Equipped With Prelube
G3516		G3512
Part Number	Qty	Part Number	Qty
317-5039 Control Box	1	317-5039 Control Box	1
320-9978 Wiring Harness Fastener Gp	1	320-9978 Wiring Harness Fastener Gp	1
251-9466 Wiring Harness ⁽¹⁾	1	251-9466 Wiring Harness ⁽¹⁾	1
251-9467 Wiring Harness ⁽¹⁾	1	251-9467 Wiring Harness ⁽¹⁾	1
251-9468 Wiring Harness ⁽¹⁾	1	251-9468 Wiring Harness ⁽¹⁾	1

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^( 1 )

Choose only one interconnect harness.

Installation Procedure

Wiring Harness and Sensors

Disconnect all the electrical connectors that connect to the engine harness and the wiring harness for the temperature sensors. Remove all the tie straps that secure the wiring harnesses to the engine.

Remove the engine wiring harness.

Remove the wiring harness for the temperature sensors.

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Illustration 1	g01290988
(1) Temperature Sensor Gp (2) Exhaust adapter

Remove the current temperature sensors from the engine. The temperature sensors are located in each of the cylinder heads and the temperature sensors are located on the turbocharger. Refer to Illustration 1.

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Illustration 2	g01291017
(1) Temperature Sensor Gp (2) Exhaust adapter (Typical Example)

Install the 5N-2126 Adapter into the cylinder heads. Apply pipe sealant to the threads of the adapter.

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Illustration 3	g01290988
(1) Temperature Sensor Gp (2) Exhaust adapter

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Illustration 4	g01291016

Install the new temperature sensors into the cylinder heads and install the temperature sensors into the turbochargers. Refer to Illustration 3 and Illustration 4.
Torque of the nut on the temperature sensor ... 12 ± 3 N·m (9 ± 2 lb ft)

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Illustration 5	g01435853

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Illustration 6	g01435870

Install the updated sensor harness assembly onto the engine. Use the existing clips to secure the harness to the engine. Refer to Illustration 5 and Illustration 6.

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Illustration 7	g01864437

Install the exhaust temperature module (3) onto the connector. Refer to Illustration 7.

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Illustration 8	g01864042
G3512 Left side view (4) Coolant pressure sensor (5) Throttle (6) Detonation sensor (7) Air/fuel ratio control (8) Power connector (9) Electronic interface connector (10) Prelube pressure switch (11) Gas shutoff valve connector (12) CAN'S resistor connector (13) Coolant temperature sensor connector (14) Filtered oil pressure sensor connector (15) Unfiltered oil pressure sensor connector

Connect the wiring harness to the ECM. Use tie straps and clips in order to secure the wiring harness to the engine.

Route the wiring harness along the left side of the engine. Use the existing harness clips and use tie straps in order to secure the wiring harness to the engine. Refer to Illustration 8.

Connect the following connectors that are located on the left side of the engine:
- Coolant pressure sensor (4)
- ProAct throttle (5)
- Detonation sensor (6)
- Air/fuel ratio control (7)
- Power connector (8)
- Electronic Interface Connector (9)
- Prelube pressure switch (10)
- Gas shutoff valve (11)
- CAN'S resistor (12)
- Coolant temperature sensor (13)
- Filtered oil pressure sensor (14)
- Unfiltered oil pressure sensor (15)

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Illustration 9	g01864455
Enlarged view shows a front view of the engine. (16) Intake manifold pressure sensor (17) Ignition wiring connection

Connect the harness to the following connectors that are located on the front of the engine:
- Intake manifold pressure sensor (16)
- Ignition wiring connection (17)
Refer to Illustration 9.

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Illustration 10	g01864460
Enlarged view shows a top view of the front of the engine. (18) Jacket water pressure sensor (19) Oil temperature sensor

Connect the harness to the following connectors that are located on the top front area of the engine:
- Jacket water pressure sensor (18)
- Oil temperature sensor (19)
Refer to Illustration 10.

Route the wiring harness around the rear of the engine.

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Illustration 11	g01864000
G3512 Enlarged view shows the right side of the engine. (20) Coolant pressure switch (21) Detonation sensor (22) Prelube solenoid valve connector (23) Air starting motor connector

Connect the harness to the remaining connectors on the right side of the engine. Refer to Illustration 11.

No _x Sensor

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Illustration 12	g01860294
The turbochargers are removed from the manifold group that is shown above. (1) Cover (2) Gasket (3) Exhaust Elbow

Remove the cover (1) and gasket (2) from the exhaust elbow (3) :

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Illustration 13	g01861196
The enlarged view shows the bottom side of the exhaust elbow. (4) Bolts (5) Washers (6) Brackets

Remove the bolts (4), washers (5) and brackets (6) from the bottom side of the exhaust manifold group: Refer to Illustration 13.

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Illustration 14	g01863073
(7) 9X-8875 Bolt (8) 5P-8245 Hard Washer (9) 341-0731 Bracket As (10) Bracket

Install the bracket assembly (9) on the bottom side of the exhaust elbow.

Install the brackets (10) that were removed in Step 1 to the bottom side of the new bracket assembly. Refer to Illustration 14.

Install the bolts (7) and the washer (8). Refer to Illustration 14.

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Illustration 15	g01861536
(11) 305-2632 Gasket (12) 305-0616 Ring Adapter (13) 179-1509 Cover (14) 0L-1143 Bolts (15) 5M-2894 Hard Washers (16) 8T-6765 Pipe plug

Install the new gasket (11) on the top surface of the exhaust elbow. To help ensure a proper seal, make sure that the top surface of the exhaust elbow is free of debris.

Install the adapter ring (12) on top of the gasket.

Install another gasket (11) on top of the ring adapter.

Install the cover (13) onto the top of the gasket.

Secure the adapter ring to the exhaust elbow by using the bolts (14) and washers (15) .

Install the pipe plug (16) into the top of the adapter ring cover.

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Illustration 16	g01864659
(17) Bolts

Remove the bolts (17) that secure the current shield that is located on the crossbar for the air cleaner. Refer to Illustration 16.

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Illustration 17	g01864794
(18) 317-9109 Shield

Install the shield (18) onto the crossbar for the air cleaner.

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Illustration 18	g01864659
(17) bolt

Install the 0S-1594 Bolt (17) into the new shield for the nitrogen oxide sensor.

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Illustration 19	g01863114
(19) 4P-8134 Clips (20) 1A-2029 Bolt (21) 5M-2894 Hard Washer (22) 9S-8752 Full Nut

Install the clip (19) to the mounting assembly for the sensor buffer. Use the following items in order to secure the clip to the bracket. bolt (20), hard washer (21) and nut (22). Refer to Illustration 19.

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Illustration 20	g01861754
(19) 4P-8134 Clip (20) 1A-2029 Bolt (21) 5M-2894 Hard Washer (22) 9S-8752 Full Nut

Install the clip (19) onto the shield. Use the following items in order to secure the clip to the bracket. bolt (20), washer (21) and nut (22). Refer to Illustration 20.

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)

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

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.

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

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Illustration 21	g01864473
(23) Tie-wrap (24) Tabs

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.

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

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.

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 8. 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.

Reconnect the 8-pin connector of the buffer to the engine harness.

Secure the wiring harness for the nitrogen oxide sensor to the clips that were installed in Step 17 and Step 17. Use 9X-6772 Cable Straps .

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Table 8
Engine	Slack In Harness (A) ⁽¹⁾	Slack In Harness (B) ⁽²⁾	Illustration
G3512	135 mm (5.3150 inch)	110 mm (4.3307 inch)	22, 23
G3516	135 mm (5.3150 inch)	110 mm (4.3307 inch)	22, 23

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^( 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

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Illustration 22	g01438808
Typical example (A) The distance of the slack in the harness that is between the sensor and the support bracket

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Illustration 23	g01395328
Typical example (B) The distance of the slack in the harness that is between the buffer and the support bracket

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".

Air/Fuel Ratio Control

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Illustration 24	g01864536
(1) Top support bracket (2) Bolts (3) Lower support bracket (4) Bolts

Install the supports for the actuator of the air/fuel ratio control. The top support bracket (1) is fastened to the engine with two bolts (2). The lower support bracket (3) is fastened to the engine with two bolts (4) .
The supports for the air/fuel ratio control actuator are installed at the following locations:
- The supports for the actuator are located on the left side of the engine below the sixth cylinder on G3512 Engines.
- The supports for the actuator are located on the left side of the engine below the eighth cylinder on G3516 Engines.

Install bracket (5). Use four bolts (6), four washers (7) and four nuts (9) in order to fasten the bracket to the supports.

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Illustration 25	g01854557
Installed bracket on G3512 Engines and G3516 Engines (5) 270-0378 Bracket (6) 3B-1915 Bolt (7) 5M-2894 Hard Washer (8) Mounting location for actuator

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Illustration 26	g01287734
Air/fuel ratio control actuator that is installed (9) 9S-8752 Full Nut (10) 9M-1974 Hard Washer (11) 6V-2317 Bolt (12) 091-0081 Spacer

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

Note: Install an air/fuel ratio control valve on the engines that do not have air/fuel ratio control.

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

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Illustration 27	g01450436
Linkage for the air/fuel ratio control actuator and the fuel valve (13) 263-5007 Throttle Lever (14) 1B-7182 Bolt (15) 9M-1974 Hard Washer (16) 5S-0003 Nut (17) 7E-9748 Rod End (18) 4F-2294 Jam Nut (19) (19) 119-5092 Rod (20) 6V-9163 Rod End (21) 8L-4496 Jam Nut (22) 6S-7721 Lever (23) 0S-1571 Bolt (24) 5M-2894 Hard Washer (25) 9S-8752 Full Nut

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Illustration 28	g01450635
Left side view (26) 6L-2849 Tube Joint (27) 6I-0236 Fuel Ratio Valve (28) 1P-4579 Half Flange (29) 0S-1587 Bolt (30) 5P-8245 Hard Washer (31) 6I-0327 Adapter (32) 4J-0524 O-Ring Seal

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Illustration 29	g01290801
Installed linkage for the air/fuel ratio control actuator

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 27. Provide equal engagement at each rod end.

Wiring for the Air/fuel Ratio Control

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Illustration 30	g01431264

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

Install fuse F4 (1) for the throttle actuator.

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

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

Install the Remote Advisor Panel

Remote Panel - A remote 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.

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Illustration 31	g01290823
Typical support for the remote monitoring panel

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Illustration 32	g01316757
Remote advisor panel

Install the remote advisor panel. Use hardware in order to secure the panel to a support stand.

Route the wiring harness from the engine to the remote advisor panel.

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

Wiring for the Remote Panel

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Illustration 33	g01256226
Dimensions and components of the remote 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:

Refer to "Interconnect Harness". Route the interconnect harness from the engine interface box to the remote 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.

Select a wire. Identify the location on the terminal strip for the wire. Refer to Table 9.

Cut the wire to the appropriate length.

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

Attach the wire end that is the appropriate gauge onto the end of the wire.

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Illustration 34	g01243294
Location for the connections for the interconnect harness inside the remote panel

Refer to Illustration 34. 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 sleeve is provided with the interconnect harness. The sleeve must cover the following circuits of the interconnect harness that are located inside the engine interface box and the remote 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 9
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 for the operation 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	Shield for the CAN Data Link
P300-T39 ⁽¹⁾ Cable 105-Black	14	39	−Battery
P300-T40 Cable 91-Black	16	40	−Battery
P300-T41 Cable 109-Black	Unconnected		Spare

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^( 1 )

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

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

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Illustration 35	g01242443
Location for the customer connection inside the remote panel

Refer to Illustration 35. Make the connections for the driven equipment on the right side of the terminal strip.

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 36. Remove the bridge and connect the additional button according to the Illustration.

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Illustration 36	g01242557
Emergency stop circuit with an additional emergency stop button

Prelube Switch

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

Remove the heat shrink tubing from the ends of the wires that control the prelube in the remote panel.

Connect the wires to the terminals of the prelube switch. Refer to Illustration 37.

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Illustration 37	g01319822
(1) 251-9444 Control Box (2) 3E-1813 Push Button Switch (3) 150-1240 Pressure Switch

Interconnect Harness

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.

Interconnect harnesses of different lengths are available. Table 10 lists the interconnect harnesses that are available. The harnesses can be shortened, if necessary.

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Table 10
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

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Illustration 38	g01241390
The end of the interconnect harness for the engine interface box

Refer to Illustration 38. 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 labeled 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 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 panel.

Note: A sleeve is provided with the interconnect harness. The sleeve must cover the following circuits of the interconnect harness that are inside the engine interface box and the inside 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:

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 39	g01432967
Connections on the terminal block (1) Fuse 4 is for the throttle actuator. Fuse 4 is required for all engines. (2) Fuse 5 is for the actuator of the AFRC. Fuse 5 is required for air/fuel ratio control.

Make the connections to the terminal block first. Refer to Illustration 39 and Table 11. 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 11
Connections for the Terminal Block
Interconnect Harness		Location on the Terminal Block
Cable Identification	Wire Identification	Location on the Terminal Block
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	8
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 40	g01256097
Connections for the wiring to the customer connector

Refer to Illustration 40. 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 41	g01256115
Connections for the wires from the cables to the customer connector

Refer to Illustration 41. 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.

Connect the two terminal connector on the interconnect harness to the two terminal connector inside the engine interface box. This connection is for the emergency stop circuit and the circuit for the GSOV.

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

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.

When performing a retrofit installation, record the vital information in Table 12.

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

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Table 12
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.

Update the product configuration by entering the information from Table 12 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".