Retrofitting for the Dynamic Gas Blending Capability on Certain 3512B and 3512C Engines {1000, 1250} Caterpillar

Engine

3512B (S/N: LN41-UP; LE61-UP; CTB1-UP; PTF1-UP; 4AW1-UP)

3512C (S/N: LN51-UP; LE81-UP; LLA1-UP; LLD1-UP; RMS1-UP)

Introduction

Note: Make sure that your generator set is in proper running order and up to date on all maintenance activities prior to installation or operation of Dynamic Gas Blending Capability (DGB). Check customer speed sensing and direct rack (if applicable) connections for quality connectivity and proper generator grounding.

Note: Make sure to copy the Product Status Report before starting the following procedure.

This Special Instruction provides the procedure in order to install an upgrade fuel kit for the 3512B and the 3512C Engines. Refer to following Tables for the upgrade fuel kit part numbers.

Refer to Systems Operation/Testing and Adjusting, KENR9743.

Refer to Troubleshooting, KENR9744.

Parts Needed

Table 1

241-0242 Power Harness As (if applicable)
Qty	Part
1	241-0242 Power Harness As

Table 2

262-6760 Fuel Injection Lines Gp3512B
Qty	Part
1	8N-6326 Tube As
1	386-6229 Elbow As

Table 3

373-1527 Electronic Control and Mounting Gp
Qty	Part
4	0T-0065 Bolt
4	1B-9575 Bolt
4	1D-4540 Bolt
4	2V-4387 Spacer
8	6I-1418 Spacer
8	8T-9655 Isolation Mount
2	9M-1974 Hard Washer
8	9N-0869 Hard Washer
4	9X-6458 Hard Washer
8	155-0576 Isolation Mount
4	190-4885 Spacer
1	231-7070 Bracket
1	353-8089 Electronic Control Module
1	417-6011 Electronic Control Module

Table 4

380-5440 Engine Wiring Gp
Qty	Part
1	0L-1352 Bolt
13	0S-1571 Bolt
1	0S-1585 Bolt
2	0S-1588 Bolt
5	0S-1594 Bolt
2	0S-1608 Bolt
19	1A-2029 Bolt
26	1A-9579 Bolt
2	3A-3692 Clip
2	3B-1915 Bolt
1	4P-7068 Bracket
3	4P-7429 Clip
23	4P-7581 Clip
47	4P-8134 Clip
4	4S-5719 Spacer
57	5M-2894 Hard Washer
12	5N-2126 Connector
4	6L-4428 Taperlock Stud
1	6V-1581 Clip
1	6V-1582 Clip
2	6V-9028 O-Ring Seal
2	6V-9330 Elbow
82	7K-1181 Cable Strap
1	8M-9024 Hard Washer
13	9C-5344 Spacer
28	9M-1974 Hard Washer
12	9S-8752 Full Nut
1	9X-0262 Adapter
3	034-3557 Locking Bolt
6	132-5789 Clip
6	195-2431 Detonation Sensor Gp
8	214-7566 O-Ring Seal
2	214-7568 O-Ring Seal
9	228-7100 O-Ring Seal
1	228-7101 O-Ring Seal
4	238-5080 O-Ring Seal
4	256-6453 Temperature Sensor
2	261-6847 Adapter
1	294-3313 Clip
1	305-6873 Pressure Sensor Gp
1	318-1181 Speed Sensor Gp
4	320-3060 Pressure Sensor
1	320-3061 Pressure Sensor
4	320-3063 Pressure Sensor
1	330-9739 Adapter
2	335-3999 Adapter
1	353-5439 Connector
2	353-5440 Adapter
5	353-5441 Elbow Adapter
1	461-1622 Wiring Harness
12	383-2990 Temperature Sensor Gp
2	415-2432 Temperature Sensor Gp

Table 5

415-7979 Sensor Harness As
Qty	Part
1	415-7979 Sensor Harness As

Table 6

386-4896 Engine Wiring Gp
Qty	Part
15	7K-1181 Cable Strap
2	132-5789 Clip
1	386-4897 Wiring Harness

Table 7

386-4901 Generator Wiring Gp
Qty	Part
1	386-4904 Engine Harness As

Table 8

388-5370 Fuel Lines Gp (Pipe Thread Design Gas Regulator) 3512C
Qty	Part
2	0S-1587 Bolt
6	0S-1591 Bolt
4	0S-1594 Bolt
2	1A-2029 Bolt
2	1F-7958 Full Nut
2	2A-4639 Bolt
2	3B-1915 Bolt
12	5M-2894 Hard Washer
6	5P-3860 Hose Clamp
2	5P-4869 Hose Clamp
2	5P-8211 O-Ring Seal
4	5S-0003 Nut
2	6V-1581 Clip
2	6V-1582 Clip
1	6V-1612 Bolt
5	7D-1649 Hard Washer
2	7K-1401 Clip
2	7K-1402 Bracket
4	7M-1599 Taperlock Stud
2	8B-4967 O-Ring Seal
4	9M-1974 Hard Washer
11	9S-8752 Full Nut
15	9X-6458 Hard Washer
1	105-8180 Gasket
1	145-5181 Spacer
2	255-6464 Joint
1	261-7951 Tube Joint
2	388-1299 Tube As
1	388-1302 Bracket
1	388-5372 Tube As
1	388-5374 Bracket
1	388-5375 Bracket
1	388-6418 Bracket
1	388-6419 Bracket
1	388-8893 Bracket As
1	388-8895 Bracket As
2	396-6986 Hose
2	396-6987 Reducer Hose
1	398-7716 Tube As
2	399-3106 Tube As

Table 9

390-4500 Cylinder Block Cover Gp
Qty	Part
36	1A-2029 Bolt
6	1C-2251 Bolt
1	2W-0752 Gasket
6	5L-5840 Washer
46	5M-2894 Hard Washer
2	9L-1480 Gasket
6	277-5833 Seal
5	349-6052 Camshaft Cover
1	374-1513 Camshaft Cover

Table 10

390-5453 Air Cleaner Mounting 3512B
Qty	Part
1	5N-7906 Support As
5	1A-2029 Bolt
9	5M-2894 Hard Washer

Table 11

390-5454 Air Cleaner Mounting 3512C
Qty	Part
2	0L-1351 Bolt
6	1A-2029 Bolt
8	5M-2894 Hard Washer
1	277-2265 Support As

Table 12

392-5541 Particle Sensor Gp (if applicable)
Qty	Part
3	0S-1588 Bolt
1	2T-2305 Elbow
1	3B-7738 Fitting
1	3B-7764 Bushing
1	4J-5477 O-Ring Seal
2	5M-2894 Hard Washer
1	6V-0267 Clip
1	6V-0268 Clip
1	6V-8397 O-Ring Seal
1	8C-6866 Connector
1	8T-6758 Pipe Plug
1	9L-1480 Gasket
1	9S-8752 Full Nut
2	9X-6458 Hard Washer
1	004-5933 Pipe Tee
1	174-5907 Clip
1	301-7944 Hose As

Table 13

397-8633 Gas Pressure Regulator Gp (Pipe Thread Design) (if applicable)
Qty	Part
8	0S-1585 Bolt
8	0S-1591 Bolt
8	2A-4639 Bolt
1	2L-6055 Pipe Cap
2	2M-4108 Gasket
6	3B-1915 Bolt
1	3B-7286 Pipe Nipple
3	3B-7296 Fitting
3	5B-5620 Bolt
20	5M-2894 Hard Washer
6	5P-8245 Hard Washer
3	5S-0003 Nut
1	6L-7322 Pipe Tee
1	6N-4543 Fitting
2	6V-8398 O-Ring Seal
2	7D-1649 Hard Washer
3	7X-7951 Union Elbow
4	8S-9191 Bolt
6	9M-1974 Hard Washer
10	9S-8752 Full Nut
1	9X-6138 Pipe Plug
16	9X-6458 Hard Washer
1	105-8180 Gasket
1	122-0089 Solenoid Valve Gp
2	122-8905 Elbow
1	210-2007 Gas Pressure Regulator Gp
2	265-5255 Plate
1	293-8396 Core
1	397-8628 Tube As
2	397-8629 Bracket
1	397-8631 Tube As
1	397-8632 Bracket
1	417-5543 Bracket As

Table 14

397-9400 Water Lines Gp (Pipe Thread Design Gas Regulator)
Qty	Part
1	0S-1571 Bolt
3	0S-1588 Bolt
3	0S-1594 Bolt
1	3B-6555 Elbow
1	4B-7770 Tee
2	4F-7391 O-Ring Seal
4	4J-5477 O-Ring Seal
4	4L-6454 Bolt
9	5M-2894 Hard Washer
7	5P-9297 Clip
1	6B-1628 Reducing Bushing
3	6V-0267 Clip
3	6V-0268 Clip
1	6V-3265 Clip
3	8C-6866 Connector
1	8C-6867 Connector
2	8S-9191 Bolt
4	8T-4896 Hard Washer
1	8T-6761 Pipe Plug
6	9S-8752 Full Nut
6	9X-6458 Hard Washer
1	005-8615 Pipe Nipple
1	196-9420 Ball Valve
2	265-5254 Plate
1	318-2484 Orifice
1	318-2485 Gasket
1	384-7876 Bracket
2	416-6524 Bracket
1	419-1797 Hose As
1	419-1798 Hose As

Table 15

398-7718 Air Lines Gp 3512C
Qty	Part
48	1T-0720 Bolt
24	2A-4639 Bolt
12	4S-5898 O-Ring Seal
72	5M-2894 Hard Washer
12	6V-5101 O-Ring Seal
12	7C-8199 Flange
24	153-8455 Manifold Gasket
10	370-7335 Air Inlet Elbow
2	370-7336 Air Inlet Elbow
12	371-5211 Flame Arrestor As

Table 16

399-3777 Fuel Lines Gp
Qty	Part
2	5P-8211 O-Ring Seal
2	8B-4967 O-Ring Seal
2	388-1301 Tube As

Table 17

416-7819 Precleaner Gp 3512C
Qty	Part
6	2H-3745 Bolt
12	5N-7919 Spacer
12	5P-8247 Hard Washer
6	5P-8250 Washer
6	8G-2077 Spacer
12	9X-8882 Bolt

Table 18

416-7820 Air Cleaner Gp 3512C
Qty	Part
2	0L-1351 Bolt
6	1A-2029 Bolt
2	5M-2894 Hard Washer
6	9X-6458 Hard Washer
1	277-2265 Support As

Table 19

417-3287 Precleaner Gp 3512B
Qty	Part
6	2H-3745 Bolt
12	5N-7919 Spacer
24	5P-8247 Hard Washer
6	5P-8250 Washer
12	9X-8882 Bolt
2	353-0248 Plate

Table 20

417-4387 Fuel System Parts Kit (if applicable)
Qty	Part
2	0S-1585 Bolt
2	1F-7958 Full Nut
2	1H-5514 Bolt
1	1L-4031 Service Tee
1	3B-6555 Elbow
1	4B-9030 Elbow
4	5K-9090 O-Ring Seal
2	5S-0003 Nut
4	7D-1649 Hard Washer
4	8C-6875 Connector
1	8T-6762 Pipe Plug
4	9M-1974 Hard Washer
2	9R-2860 Spacer
1	002-5743 Elbow
1	118-1656 Reducer Bushing
1	122-3201 Pipe Nipple
2	184-7211 Clip
2	196-9420 Ball Valve
1	397-9421 Hose As
1	397-9422 Hose As

Table 21

417-4388 Fuel System Parts Kit (if applicable)
Qty	Part
1	2T-2305 Elbow
1	4N-3411 Relay Valve Gp
1	5B-7642 Pipe Nipple
3	5B-7666 Elbow
1	5L-2534 U-Bolt
2	6V-8397 O-Ring Seal
4	7D-1649 Hard Washer
4	8S-9089 Bolt
4	9R-7882 Spacer
2	9S-8752 Full Nut
2	9X-6458 Hard Washer
1	105-0428 Pipe Nipple
1	152-0199 Adapter
1	391-3076 Bracket As

Table 22

417-4389 Fuel System Parts Kit (if applicable)
Qty	Part
1	2L-2811 Fitting
1	3J-7355 Flared Union
2	3L-1258 Pipe Nipple
1	5B-7643 Pipe Nipple
1	5B-7666 Elbow
2	6B-3685 Elbow
1	6F-5985 Hose As
1	6K-1972 Flared Elbow

Table 23

418-1393 Catalytic Converter Gp (if applicable)
Qty	Part
1	418-1393 Catalytic Converter Gp

Table 24

424-7719 Electronic Actuator Gp
Qty	Part
1	424-7719 Electronic Actuator Gp

Table 25

430-5919 Film
Qty	Part
1	419-0774 Film
1	444-0543 Film

Table 26

440-4790 Gas Pressure Regulator Gp (Bolted Flange Design) (if applicable)
Qty	Part
2	0S-1571 Bolt
10	0S-1585 Bolt
10	0S-1591 Bolt
2	1A-8537 Bolt
8	1F-7958 Full Nut
8	2A-4639 Bolt
2	3B-1915 Bolt
8	4K-0367 Full Nut
3	5B-5620 Bolt
20	5M-2894 Hard Washer
8	5P-8245 Hard Washer
16	5P-8247 Hard Washer
3	5S-0003 Nut
2	6V-8398 O-Ring Seal
18	7D-1649 Hard Washer
6	8S-9092 Bolt
4	8S-9191 Bolt
6	9M-1974 Hard Washer
10	9S-8752 Full Nut
16	9X-6458 Hard Washer
8	9X-8873 Bolt
1	105-8180 Gasket
1	122-8905 Elbow
1	211-5237 Connector
2	293-4056 Gasket
1	293-8396 Fuel Cooler Core
1	397-8632 Bracket
1	419-0893 Solenoid Valve Gp
2	420-8789 Gasket
2	425-3549 Gasket
1	435-0888 Gas Pressure Regulator Gp
1	440-4786 Bracket As
1	440-4788 Tube As
1	440-4791 Tube As
2	440-4792 Bracket
1	440-4794 Tube As
1	450-2989 Tube As
1	450-3143 Bracket As

Table 27

444-0554 Film
Qty	Part
1	443-5866 Film
1	444-0543 Film

Table 28

444-9249 Fuel Lines Gp (Bolted Flange Design Gas Regulator) 3512C
Qty	Part
2	0S-1587 Bolt
6	0S-1591 Bolt
4	0S-1594 Bolt
2	1A-2029 Bolt
2	1F-7958 Full Nut
2	2A-4639 Bolt
2	3B-1915 Bolt
12	5M-2894 Hard Washer
6	5P-3860 Hose Clamp
2	5P-4869 Hose Clamp
2	5P-8211 O-Ring Seal
4	5S-0003 Nut
2	6V-1581 Clip
2	6V-1582 Clip
1	6V-1612 Bolt
5	7D-1649 Hard Washer
2	7K-1401 Clip
2	7K-1402 Bracket
4	7M-1599 Taperlock Stud
2	8B-4967 O-Ring Seal
4	9M-1974 Hard Washer
11	9S-8752 Full Nut
15	9X-6458 Hard Washer
1	105-8180 Gasket
1	145-5181 Spacer
2	255-6464 Joint
1	261-7951 Tube Joint
2	388-1299 Tube As
1	388-1302 Bracket
1	388-5372 Tube As
1	388-5374 Bracket
1	388-5375 Bracket
1	388-6418 Bracket
1	388-6419 Bracket
1	388-8893 Bracket As
1	388-8895 Bracket As
2	396-6986 Hose
2	396-6987 Reducer Hose
2	399-3106 Tube As
1	444-9247 Tube As

Table 29

444-9250 Fuel Lines Gp (Bolted Flange Design Gas Regulator) 3512B
Qty	Part
3	0S-1585 Bolt
3	0S-1587 Bolt
6	0S-1591 Bolt
4	0S-1594 Bolt
6	1F-7958 Full Nut
4	2A-4639 Bolt
2	3B-1915 Bolt
12	5M-2894 Hard Washer
6	5P-3860 Hose Clamp
2	5P-4869 Hose Clamp
2	5P-8211 O-Ring Seal
4	5S-0003 Nut
2	6V-1581 Clip
2	6V-1582 Clip
1	6V-1612 Bolt
13	7D-1649 Hard Washer
3	7K-1401 Clip
3	7K-1402 Bracket
4	7M-1599 Taperlock Stud
2	8B-4967 O-Ring Seal
2	8N-5254 Reducer Hose
4	9M-1974 Hard Washer
11	9S-8752 Full Nut
15	9X-6458 Hard Washer
1	105-8180 Gasket
1	145-5181 Spacer
2	255-6464 Joint
1	261-7951 Tube Joint
1	388-1294 Tube As
2	388-1299 Tube As
1	388-1302 Bracket
2	388-1303 Bracket
1	388-1304 Bracket
2	388-3527 Bracket
1	389-0845 Bracket As
1	389-0848 Bracket As
2	396-6986 Hose
2	399-3106 Tube As
1	444-9247 Tube As

Table 30

451-6338 Water Lines Gp (Bolted Flange Design Gas Regulator)
Qty	Part
1	0S-1571 Bolt
3	0S-1588 Bolt
3	0S-1594 Bolt
1	3B-6555 Elbow
1	4B-7770 Tee
2	4F-7391 O-Ring Seal
4	4J-5477 O-Ring Seal
4	4L-6454 Bolt
9	5M-2894 Hard Washer
7	5P-9297 Clip
1	6B-1628 Reducing Bushing
3	6V-0267 Clip
3	6V-0268 Clip
1	6V-3265 Clip
3	8C-6866 Connector
1	8C-6867 Connector
2	8S-9191 Bolt
4	8T-4896 Hard Washer
1	8T-6761 Pipe Plug
6	9S-8752 Full Nut
6	9X-6458 Hard Washer
1	005-8615 Pipe Nipple
1	196-9420 Ball Valve
2	265-5254 Plate
1	318-2484 Orifice
1	318-2485 Gasket
1	384-7876 Bracket
2	416-6524 Bracket
1	419-1797 Hose As
1	419-1798 Hose As

Table 31

459-4911 Thermostatic Valve Gp
Qty	Part
2	3S-9643 Lip Type Seal
2	6V-1454 O-Ring Seal
2	204-6707 Water Temperature Regulator

Table 32

Package Components
Qty	Part
3	122-6588 Current Transformer As
3	154-3488 Transformer
1	267-9689 Filter Housing Cover
1	382-1791 Instrument Panel Box Gp

Table 33

Software
Qty	Part
1	433-6418 Engine Software (ISM)
1	491-2170 Engine Software (3512C NA ECM)
1	491-2171 Engine Software (3512C Non-Emission Certified Engine ECM)
1	486-0466 Engine Software (3512B US 49 States excluding California)

Table 34

Electro-Mechanical Control Panel (EMCP) 4.3 (if applicable)
Language	Software
French	462-7528 Generator Set Software Gp
German	462-7529 Generator Set Software Gp
Spanish	462-7530 Generator Set Software Gp
Italian	462-7531 Generator Set Software Gp
Portuguese	462-7532 Generator Set Software Gp
English	473-8904 Generator Set Software Gp
Dutch	462-7534 Generator Set Software Gp
Danish	462-7535 Generator Set Software Gp
Swedish	462-7536 Generator Set Software Gp
Finnish	462-7537 Generator Set Software Gp
Russian	462-7538 Generator Set Software Gp
Chinese	462-7539 Generator Set Software Gp
Japanese	462-7540 Generator Set Software Gp
Greek	462-7541 Generator Set Software Gp
Arabic	462-7542 Generator Set Software Gp
Turkish	462-7543 Generator Set Software Gp

Table 35

Electro-Mechanical Control Panel (EMCP) 4.4 (if applicable)
Language	Software
French	462-7544 Generator Set Software Gp
German	462-7545 Generator Set Software Gp
Spanish	462-7546 Generator Set Software Gp
Italian	462-7547 Generator Set Software Gp
Portuguese	462-7548 Generator Set Software Gp
English	473-8910 Generator Set Software Gp
Dutch	462-7550 Generator Set Software Gp
Danish	462-7551 Generator Set Software Gp
Swedish	462-7552 Generator Set Software Gp
Finnish	462-7553 Generator Set Software Gp
Russian	462-7554 Generator Set Software Gp
Chinese	462-7555 Generator Set Software Gp
Japanese	462-7556 Generator Set Software Gp
Greek	462-7557 Generator Set Software Gp
Arabic	462-7558 Generator Set Software Gp
Turkish	462-7559 Generator Set Software Gp

Copying the Product Status Report and the Injector Trim Codes

Copying the Product Status Report

1. Connect Cat® Electronic Technician (ET) 2012C or newer to the Electronic Control Module (ECM).
   Show/hide table

   Illustration 1	g03285257

2. Click on the "Information" tab and select the "Product Status Report", or click the "Product Status Report" button.

   The Product Status Report is for reference only.

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   Illustration 2	g03285338

3. Click on the "Create Report" button.
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   Illustration 3	g03285341

4. Click on the "Continue" button.
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   Illustration 4	g03285343

5. Wait for the report to download.
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   Illustration 5	g03285345

6. Click on the "Save As" button.

7. Save the file in a convenient location.

8. Click on the "Close Report" button.

Copying the Injector Trims Codes

Illustration 6	g03285599

1. Click on the "Service" tab.

2. Select "Calibrations".
   Show/hide table

   Illustration 7	g03285600

3. Click on "Injector Codes Calibration".
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   Illustration 8	g03285601

4. Click on the "File" tab.

5. Select "Print To File".
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   Illustration 9	g03285603

6. Change the file type to HTML.

7. Save the file in a convenient location.

8. Disconnect Cat ET from the ECM.

Verification of the Flame Arrestors

Illustration 10	g03612336
Typical engine with flame arrestors (1) 153-8455 Manifold Gasket (2) 371-5211 Flame Arrestor As

Illustration 11	g03646122
Typical engine without flame arrestors (3) 7N-5080 Manifold Gaskets (Paper Gaskets)

1. Verify if the flame arrestors are installed from the factory.

   If flame arrestors are installed from the factory proceed to Steps 16 through 23 of "Installing the 398-7718 Air Lines Gp".

   Note: The 153-8455 Manifold Gaskets (Metal Gaskets) are used on engines with the flame arrestors.

   If flame arrestors are not installed from the factory proceed to Step 1 of "Installing the 398-7718 Air Lines Gp".

   Note: The 7N-5080 Manifold Gaskets (Paper Gaskets) are used on engines without the flame arrestors.

Installing the 398-7718 Air Lines Gp

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Illustration 12	g02958259
Typical 3512C engine

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Illustration 13	g03551679
Typical control panel

1. Drain coolant from cooling system into a suitable container for storage or for disposal. The following components and associated hardware will be set aside for reuse during removal in the following steps:

   • Air cleaners

   • Air precleaners

   • Aftercooler assembly

   • Compressor pipes

2. Using a suitable lifting device, remove the control panel. The control panel weighs approximately 53 kg (118 lb).

3. Remove the wiring harnesses that attach to the control panel from the engine.

4. Using a suitable lifting device, remove the air cleaners and the precleaners. The air cleaners and the precleaners weigh approximately 95 kg (209 lb) per side.

   Note: The precleaner brackets are removed with the air cleaner and the precleaner assembly.

5. Remove the air cleaner brackets from the top of the flywheel housing.

6. Remove the compressor pipes from the aftercooler and the turbochargers.

7. Disconnect the water lines from the aftercooler core.

8. Disconnect the elbow flanges from the air inlet manifold and pry the elbow flanges away from the air inlet manifold.

9. Using a suitable lifting device, remove the aftercooler assembly. The aftercooler assembly weighs approximately 185 kg (408 lb).
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   Illustration 14	g02960621
   (1) 4S-5898 O-Ring Seal (2) 7C-8199 Flange (3) 6V-5101 O-Ring Seal (4) 370-7336 Air Inlet Elbow (5) 2A-4639 Bolt (6) 5M-2894 Hard Washer (7) 370-7335 Air Inlet Elbow (8) 1T-0720 Bolt (9) 153-8455 Manifold Gasket (10) 371-5211 Flame Arrestor As

10. Remove the 7C-7909 Elbows, 7C-7910 Elbow per each head.

11. Install one flame arrestor (10) with cylindrical side toward the air inlet elbow (4) and air inlet elbow (7). Use two gaskets (9), four bolts (8), and four washers (6) per each head.

12. Install one O-ring (3) per elbow onto elbows (4) and (7).

    Note: Lubricate the bore of flange (2) lightly with glycerin.

13. Install flange (2) onto elbows (4) and (7). Make sure to push the flanges back against the stops.

    Note: Lubricate the O-ring groove of flange (2) lightly with glycerin to hold O-ring in place.

14. Install one O-ring (1) into flange (2).

15. Install two bolts (5) and two washers (6) into the bolt holes of flange (2). The thread end of the bolts will be flush with the flanges.

16. Remove the pipe plug from the exhaust outlet port per cylinder head.
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    Illustration 15	g03089396
    (11) 5N-2126 Connector (12) 383-2990 Temperature Sensor Gp

    Note: The following steps will use parts from the 380-5440 Engine Wiring Gp.

17. Install connector (11) into exhaust outlet port of each cylinder head.

18. Install temperature sensor gp (12) into connector (11).

    Tighten the temperature sensor ... 12 ± 3 N·m (9 ± 2 lb ft)

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    Illustration 16	g03271297
    (13) 238-5080 O-Ring Seal (14) 256-6453 Temperature Sensor

19. Remove the coolant temperature sensor from the 111-9375 Housing.

20. Install temperature sensor (14) and one O-ring (13) into the 111-9375 Housing.

    Tighten the temperature sensor ... 20 ± 3 N·m (15 ± 2 lb ft)

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    Illustration 17	g03428320
    (13) 238-5080 O-Ring Seal (14) 256-6453 Temperature Sensor (15) 353-5440 Adapter

21. Remove the air inlet manifold temperature sensor from the 283-9599 Manifold.

22. Install adapter (15) into the 283-9599 Manifold.

    Note: Use Loctite 567 on all pipe thread joints.

23. Install temperature sensor (16) and one O-ring (13) into adapter (15).

    Tighten the temperature sensor ... 20 ± 3 N·m (15 ± 2 lb ft)

24. Using a suitable lifting device, install the aftercooler assembly. The aftercooler assembly weighs approximately 185 kg (408 lb).

25. Attach the air inlet elbow flanges to the air inlet manifold.

26. Attach the compressor pipes to the aftercooler and the turbochargers.

Installing the 390-4500 Cylinder Block Cover Gp

Change the camshaft covers to allow for the installation of the detonation sensors on specific cylinders. Additionally, relocate the crankcase pressure sensor to the right side of the engine with the engine wiring harness change.

Illustration 18	g03070899
(1) 2W-0752 Gasket (2) 1C-2251 Bolt (3) 5M-2894 Hard Washer (4) 374-1513 Camshaft Cover (5) 5L-5840 Washer (6) 1A-2029 Bolt (7) 277-5833 Seal (8) 349-6052 Camshaft Cover

Note: Washer (5) is installed under washer (3) on bolt (2).

Installing the Left-Hand Oil Service

Illustration 19	g03026107
(4) 374-1513 Camshaft Cover (8) 349-6052 Camshaft Cover

1. Install seal (7) into camshaft covers (4) and (8).

2. Remove the 8N-9992 Camshaft Covers and the 8N-9993 Camshaft Cover from cylinders 2, 6, and 10.

3. Remove the 7N-1875 Engine Oil Filler Gp from the 8N-9993 Camshaft Cover.

4. Install camshaft cover (4) onto cylinder 10. Use one bolt (2), five bolts (6), one washer (5), and six washers (3).

5. Install the 7N-1875 Engine Oil Filler Gp onto camshaft cover (4) use gasket (1) and the original hardware.

6. Install camshaft cover (8) onto cylinders 2 and 6. Use one bolt (2), five bolts (6), one washer (5), and six washers (3) per cover.

7. Remove the 8N-9992 Camshaft Cover from cylinder 1 or 5.

8. Remove the 8N-9993 Camshaft Cover from cylinder 4.

9. Install the 8N-9993 Camshaft Cover from cylinder 4 onto cylinder 1 or 5 use the original hardware.

10. Install one of the original 8N-9992 Camshaft Cover onto cylinder 4 use the original hardware.
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    Illustration 20	g03070957
    (8) 349-6052 Camshaft Cover

11. Remove the 8N-9992 Camshaft Covers from cylinders 3, 7, and 11.

12. Install camshaft cover (8) onto cylinders 3, 7, and 11. Use one bolt (2), five bolts (6), one washer (5), and six washers (3) per cover.

Installing the Right-Hand Oil Service

Illustration 21	g03471647
(4) 374-1513 Camshaft Cover (8) 349-6052 Camshaft Cover (9) Oil gauge assembly (Dipstick) (10) 9L-1480 Gasket

1. Install seal (7) into camshaft covers (4) and (8).

2. Remove the 8N-9992 Camshaft Covers from cylinders 3, 7, and 11.

3. Install camshaft cover (4) onto cylinder 7. Use one bolt (2), five bolts (6), one washer (5), and six washers (3) per cover.

4. Install camshaft cover (8) onto cylinders 3 and 11. Use one bolt (2), five bolts (6), one washer (5), and six washers (3) per cover.

5. Remove the 8N-9993 Camshaft Cover from cylinder 9.

6. Install one of the original 8N-9992 Camshaft Covers onto cylinder 9 use the original hardware.

7. Remove the 7N-1875 Engine Oil Filler Gp from the 8N-9993 Camshaft Cover.

8. Install the 7N-1875 Engine Oil Filler Gp onto camshaft cover (4) use gasket (1) and the original hardware.

9. Remove the 8N-9992 Camshaft Cover from cylinder 1 or 5.

10. Remove the 8N-9993 Camshaft Cover from cylinder 4.

11. Install the 8N-9993 Camshaft Cover from cylinder 4 onto cylinder 1 or 5 use the original hardware.

12. Install one of the original 8N-9992 Camshaft Cover onto cylinder 4 use the original hardware.

13. Remove oil gauge assembly (9) from the right-hand side of the oil pan. Set aside the hardware for reuse.

14. Remove the 4B-3140 Cover from the left-hand side of the oil pan. Set aside the hardware for reuse.

    Refer to Illustration 22 for the correct location of the cover.

15. Attach the 4B-3140 Cover to the right-hand side of the oil pan with one gasket and the original hardware.
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    Illustration 22	g03471652
    (8) 349-6052 Camshaft Cover (10) 9L-1480 Gasket (11) 4B-3140 Cover

16. Remove the 8N-9992 Camshaft Covers from cylinders 2, 6, and 10.

17. Install camshaft cover (8) onto cylinders 2, 6, and 10. Use one bolt (2), five bolts (6), one washer (5), and six washers (3) per cover.

18. Attach the oil gauge assembly to the left-hand side of the oil pan with one gasket (10) and the original hardware. Refer to Illustration 22 for the correct location.

Installing the 267-9689 Filter Housing Cover (if applicable)

Illustration 23	g02987620
(1) 267-9689 Filter Housing Cover

Note: The 267-9689 Filter Housing Cover can be installed on both left-hand and right-hand service engines.

1. Drain the fuel filter housing into a suitable container for storage or for disposal.

2. Remove the 267-9689 Filter Housing Cover and the 5D-5957 O-Ring Seal from the 278-1776 Fuel Filter Housing As.

3. Install cover (1) use the original O-ring and hardware.

Installing the 262-6760 Fuel Injection Lines Gp (if applicable)

Illustration 24	g03819949
S/N:4AW1-01089 3512B Engines with Adem 2 Electronic Control Modules (ECM) (1) 250-1496 Elbow (2) Tube assembly (3) 5p-4318 Elbow

1. Drain the fuel filter lines into a suitable container for storage or for disposal.

2. Remove tube assembly (2) from elbow (1) and (3).

3. Remove tube assembly (2) from the engine. Set aside associated hardware for reuse.

4. Remove elbow (3) from the fuel filter housing cover.
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   Illustration 25	g03819945
   (1) 250-1496 Elbow (4) 8N-6326 Tube As (5) 386-6229 Elbow As

5. Install elbow (5) into the fuel filter housing cover.

1. Attach tube assembly (4) to elbows (1) and (5).

2. Secure tube assembly (4) to the engine with the original hardware.

Installing the 459-4911 Thermostatic Valve Gp

Illustration 26	g03863639
(1) 204-6707 Water Temperature Regulator (2) 3S-9643 Lip Type Seal (3) 6V-1454 O-Ring Seal

1. Remove the adapter from the housing. Set aside associated hardware for reuse.

2. Remove and discard the two temperature regulators and four seals.

3. Install two regulators (1) into the housing with one lip type seal (2) and two O-ring (3) per regulator.

4. Attach the adapter to housing with the original hardware.

Installing the 380-5440 Engine Wiring Gp

Note: Use the 241-0242 Power Harness As with right-hand side alternator applications.

1. Remove the original wiring harness from the original mounting hardware.

   Note: Some of the original mounting hardware can be reused at your discretion.

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   Illustration 27	g03065381
   (1) 461-1622 Wiring Harness (2) 7K-1181 Cable Strap (3) 9C-5344 Spacer (4) 4P-8134 Clip (5) 0S-1571 Bolt (6) 5M-2894 Hard Washer

2. Install one spacer (3) and one clip (4) to the front bolt hole of each left-hand cylinder head. Use one bolt (5) and one washer (6) per cylinder head.

3. Install one spacer (3) and one clip (4) to the rear bolt hole of cylinder head 12 use one bolt (5) and one washer (6).

4. Secure engine wiring harness (1) to clip (4) use one cable strap (2) per clip.
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   Illustration 28	g03360908
   (1) 461-1622 Wiring Harness (2) 7K-1181 Cable Strap (4) 4P-8134 Clip (6) 5M-2894 Hard Washer (7) 4P-7581 Clip (8) 0S-1594 Bolt (9) 6L-4428 Taperlock Stud (10) 9S-8752 Full Nut (11) 4S-5719 Spacer (12) 034-3557 Locking Bolt (13) 352-3968 Clip

5. Remove the side cover mounting hardware of cylinder 8 from the engine block.

   Note: Engines with left-hand oil service will need to install the 377-2867 Circuit Breaker Panel Gp over the side cover of cylinder 10.

6. Install the original side cover of cylinder 8 or cylinder 10 to the engine block. Use four taper lock studs (9), four washers (6), and four nuts (10).

7. Install four spacers (11) onto taper lock studs (9) one per taper lock stud.

8. Install the 377-2867 Circuit Breaker Panel Gp onto taper lock studs (9) use four washers (6) and four nuts (10).

9. Install one clip (7) onto the camshaft cover of cylinder 10 use one bolt (8) and one washer (6).

10. Attach two clips (4) to the rear bolt holes of the side cover of cylinder 10. Alternatively the front bolt holes of the side cover of cylinder 12. Use one bolt (12) and one washer (6) per clip.

11. Install one clip (13) onto the bottom front bolt hole side cover of cylinder 10 use one bolt (12) and one washer (6).

12. Secure engine wiring harness (1) to clips (4), (7), and (13) use one cable strap (2) per clip.
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    Illustration 29	g03462957
    (1) 461-1622 Wiring Harness (2) 7K-1181 Cable Straps (4) 4P-8134 Clip (6) 5M-2894 Hard Washer (14) 1A-2029 Bolt (15) 4P-7429 Clip

13. Remove the two upper bolts and washers from the 140-6458 Bracket. Refer to Illustration 29 for the correct location.

14. Install two clips (15) onto the 140-6458 Bracket use the original hardware.

15. Remove the original bolts and washers from the round side of the 7N-4319 Cover. Refer to Illustration 29 for the correct location.

16. Attach clips (4) to the 7N-4319 Cover with one bolt (14) and one washer (6) per clip.

17. Remove the original bolts and washers from the flat side of the 7N-4319 Cover. Refer to Illustration 29 for the correct location.

18. Attach engine wiring gp (1), the bracket on the interface harness connector, to the 7N-4319 Cover with two bolts (14) and two washers (6).

19. Secure engine wiring harness (1) to clips (4) and (15) use one cable strap (2) per clip.

    Note: Leave the engine wiring harness loose on the rear of the engine until the fuel lines gp has been installed.

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    Illustration 30	g03066581
    (1) 461-1622 Wiring Harness (2) 7K-1181 Cable Strap (3) 9C-5344 Spacer (4) 4P-8134 Clip (5) 0S-1571 Bolt (6) 5M-2894 Hard Washer (16) 3B-1915 Bolt

20. Attach one spacer (3) and one clip (4) to the rear bolt hole of each right-hand cylinder head. Use one bolt (5) and one washer (6) per cylinder head.

21. Secure engine wiring harness (1) to clip (4) use one cable strap (2) per clip.

22. Remove the original bolt and washer from the top rear hole of the 7N-5336 Oil Filler Elbow.

23. Attach clip (4) to the 7N-5336 Oil Filler Elbow with one bolt (16) and one washer (6).

24. Secure engine wiring harness (1) to clip (4) use one cable strap (2).
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    Illustration 31	g03204762
    (1) 461-1622 Wiring Harness (2) 7K-1181 Cable Strap (4) 4P-8134 Clip (6) 5M-2894 Hard Washer (14) 1A-2029 Bolt (17) 273-5041 Speed Sensor Gp

25. Attach engine wiring harness (1) to the original the speed sensor (17).

26. Remove the original bolt and washer from the top rear bolt hole of camshaft cover cylinder 12.

27. Install clip (7) into the top rear bolt hole of camshaft cover cylinder 12 use one bolt (14) and one washer (6).

28. Secure engine wiring harness (1) to clip (4) use one cable strap (2).
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    Illustration 32	g03105365
    (18) 318-1181 Speed Sensor Gp

29. Remove the speed sensor gp from the top of the flywheel housing.

30. Install speed sensor gp (18) into flywheel housing.

    Note: The minimum clearance between the sensor and the teeth of the flywheel is 0.5 mm (0.020 inch).

    Tighten speed sensor jam nut ... 25 N·m (18 lb ft)

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    Illustration 33	g02967580
    Typical right-hand side fuel service engine (1) 461-1622 Wiring Harness (19) 320-3060 Pressure Sensor (20) 228-7100 O-Ring Seal (21) 256-6454 Temperature Sensor (22) 238-5080 O-Ring Seal (23) 353-5441 Elbow Adapter (24) 214-7566 O-Ring Seal (25) 330-9739 Adapter (26) 320-3061 Pressure Sensor (27) 228-7101 O-Ring Seal (28) 353-5439 Connector (29) 320-3063 Pressure Sensor

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    Illustration 34	g03280717
    Typical left-hand side fuel service engine. (1) 461-1622 Wiring Harness (19) 320-3060 Pressure Sensor (20) 228-7100 O-Ring Seal (21) 256-6454 Temperature Sensor (22) 238-5080 O-Ring Seal (23) 353-5441 Elbow Adapter (24) 214-7566 O-Ring Seal (25) 330-9739 Adapter (26) 320-3061 Pressure Sensor (27) 228-7101 O-Ring Seal (28) 353-5439 Connector (29) 320-3063 Pressure Sensor (30) 415-7979 Sensor Harness As

    Note: Use sensor harness (30) with left-hand side fuel service engines to connect engine harness (1) to the fuel and the oil sensors.

31. Remove the adapter and the pressure sensor from the unfiltered port (filter inlet) of the 112-4921 Engine Oil Filter Gp.

32. Install elbow adapter (23) and one O-ring (24) into the unfiltered port (filter inlet) of the 112-4921 Engine Oil Filter Gp.

33. Install pressure sensor (19) and one O-ring (20) into elbow (23).

    Tighten the pressure sensor ... 10 ± 2 N·m (7 ± 1 lb ft)

34. Remove the temperature sensor from the 208-0822 Water Lines Gp.

35. Install temperature sensor (21) and one O-ring (22) into the 208-0822 Water Lines Gp.

    Tighten the temperature sensor ... 20 ± 3 N·m (15 ± 2 lb ft)

36. Remove the adapter and pressure sensor from the inside port of the 111-0349 Module Bracket.

37. Install adapter (25) and one O-ring (24) into the inside port of the 111-0349 Module Bracket.

38. Install pressure sensor (26) and one O-ring (27) into adapter (25).

    Tighten the pressure sensor ... 10 ± 2 N·m (7 ± 1 lb ft)

39. Remove the adapter and pressure sensor from the outside port of the 111-0349 Module Bracket.

40. Install connector (28) and one O-ring (24) into the outside port of the 111-0349 Module Bracket.

41. Install pressure sensor (29) and one O-ring (20) into connector (28).

    Tighten the pressure sensor ... 10 ± 2 N·m (7 ± 1 lb ft)

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    Illustration 35	g03062398
    Typical right-hand side fuel service engine (1) 461-1622 Wiring Harness (19) 320-3060 Pressure Sensor (20) 228-7100 O-Ring Seal (23) 353-5441 Elbow Adapter (24) 214-7566 O-Ring Seal

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    Illustration 36	g03280696
    Typical left-hand side fuel service engine (19) 320-3060 Pressure Sensor (20) 228-7100 O-Ring Seal (23) 353-5441 Elbow Adapter (24) 214-7566 O-Ring Seal (30) 415-7979 Sensor Harness As

    Note: Use sensor harness (30) with left-hand side fuel service engines to connect engine harness (1) to the fuel and the oil sensors.

42. Remove the fuel lines from the fuel filter housing on the left-hand side fuel service engines.

43. Remove the adapters and pressure sensors from the 267-9689 Filter Housing Cover.

44. Install elbow adapters (23) and one O-ring (24) per elbow into the 267-9689 Filter Housing Cover.

45. Install pressure sensor (19) and one O-ring (20) per pressure sensor into each elbow adapter (22).

    Tighten the pressure sensors ... 10 ± 2 N·m (7 ± 1 lb ft)

46. Remove the adapter and the oil pressure sensor from the filtered port (block inlet) of the 112-4921 Engine Oil Filter Gp.

47. Install elbow adapter (23) and one O-ring (24) into the filtered port (block inlet) of the 112-4921 Engine Oil Filter Gp.

48. Install pressure sensor (19) and one O-ring (20) into elbow (22).

    Tighten the pressure sensor ... 10 ± 2 N·m (7 ± 1 lb ft)

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    Illustration 37	g03065377
    (1) 461-1622 Wiring Harness (2) 7K-1181 Cable Strap (4) 4P-8134 Clip (6) 5M-2894 Hard Washer (31) 0S-1588 Bolt (32) 0S-1585 Bolt (33) 132-5789 Clip (34) 8M-9024 Hard Washer

49. Remove the original bolt and washer from the rear hole of the 267-9689 Filter Housing Cover.

50. Attach clip (4) to the rear hole of the 267-9689 Filter Housing Cover with one bolt (31) and one washer (6).

51. Remove the original bolt and washer from the front bolt hole of the 2W-4334 Bar.

52. Attach clip (4) to the front bolt hole of the 2W-4334 Bar with one bolt (32) and one washer (6).

53. Remove the original bolt and washer from the front left bolt hole of the 112-4922 Fuel Filter Gp.

54. Attach clip (33) to the front left bolt hole of the 112-4922 Fuel Filter Gp with one bolt (15) and one washer (34).

55. Remove the original nut and washer from the front middle bolt of the 4W-6960 Housing Support.

56. Install clip (33) onto the front middle bolt of the 4W-6960 Housing Support use one washer (6) and one nut (10).

57. Secure engine wiring harness (1) to clip (4) and (33) use one cable strap (2) per clip.
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    Illustration 38	g03361553
    (1) 461-1622 Wiring Harness (2) 7K-1181 Cable Strap (4) 4P-8134 Clip (6) 5M-2894 Hard Washer (7) 4P-7581 Clip (8) 0S-1594 Bolt (35) 0L-1352 Bolt

58. Remove the original bolt and washer from the bottom rear bolt hole of the 7E-6017 Cover.

59. Attach clip (4) to the bottom rear bolt hole of the 7E-6017 Cover with one bolt (8) and one washer (6).

60. Remove the original bolt and washer from the middle bolt hole of the 4W-4313 Adapter.

61. Attach clip (7) to the middle bolt hole of the 4W-4313 Adapter with one bolt (35) and one washer (6).

62. Attach clip (4) to the 111-0349 Module Bracket with one bolt (8) and one washer (6).

63. Secure engine wiring harness (1) to clips (4) and (7) use one cable strap (2) per clip.
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    Illustration 39	g03065384
    (1) 461-1622 Wiring Harness (2) 7K-1181 Cable Strap (4) 4P-8134 Clip (6) 5M-2894 Hard Washer (10) 9S-8752 Full Nut (31) 0S-1588 Bolt (36) 6V-1581 Clip (37) 6V-1582 Clip

64. Install one clip (36) and one clip (37) around the 110-9538 Tube.

65. Attach one clip (4) to clips (36) and (37) with one bolt (31), two washers (6), and one nut (10).

66. Attach one clip (4) to the lower left bolt hole of the ECM with the original hardware.

67. Secure engine wiring harness (1) to brackets (4) use one cable strap (2) per clip.
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    Illustration 40	g03065380
    (1) 461-1622 Wiring Harness (2) 7K-1181 Cable Strap (4) 4P-8134 Clip (6) 5M-2894 Hard Washer (8) 0S-1594 Bolt (10) 9S-8752 Full Nut (38) 4P-7068 Bracket

68. Remove the 3B-1915 Bolt, the 9X-6458 Hard Washers, and the 9S-8752 Full Nut from the 111-5052 Bracket, the 6V-1867 Clip, and 6V-1868 Clip.

69. Attach bracket (38) to the 111-5052 Bracket, the 6V-1867 Clip, and 6V-1868 Clip with the original hardware.

70. Attach one clip (4) to bracket (38) with one bolt (8), two washers (6), and one nut (10).

71. Secure engine wiring harness (1) to clip (4) use one cable strap (2).
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    Illustration 41	g03062402
    (1) 461-1622 Wiring Harness (2) 7K-1181 Cable Strap (4) 4P-8134 Clip (7) 4P-7581 Clip (39) 1A-9579 Bolt (40) 9M-1974 Hard Washer (41) 383-2990 Temperature Sensor Gp

72. Remove the original bolt and washer from the upper left corner of each valve cover.

73. Install one clip (7) onto upper left corner of the valve cover. Use one bolt (39) and one washer (40) per each valve cover.

74. Remove the original bolt and washer from the lower left corner of each valve cover base.

75. Install one clip (4) onto lower left corner of the valve cover base. Use one bolt (39) and one washer (40) per each valve cover base.

76. Secure temperature sensor (41) and wiring harness (1) to clips (7). Use one cable strap (2) per clip.

77. Secure engine wiring harness (1) to clips (4) use one cable strap (2) per clip.
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    Illustration 42	g03062047
    Typical left-hand side engine view vO (1) 461-1622 Wiring Harness (2) 7K-1181 Cable Strap (4) 4P-8134 Clip (6) 5M-2894 Hard Washer (7) 4P-7581 Clip (8) 0S-1594 Bolt (42) 195-2431 Detonation Sensor Gp

78. Attach detonation sensors (42) to the engine under the camshaft covers on cylinders 2, 6, and 10.

    Tighten the detonation sensors ... 15 ± 3 N·m (11 ± 2 lb ft)

79. Attach detonation sensors (42) to engine wiring harness (1).

80. Attach one clip (7) to the camshaft covers on cylinders 4 and 8 with one bolt (8) and one washer (6) per clip. Orient clip (7) on cylinder 4 with ladder facing down.

81. Attach one clip (4) to the camshaft cover on cylinder 12 with one bolt (8) and one washer (6).

82. Secure engine wiring harness (1) and detonation sensors (42) to clips (4) and (7) with one cable strap (2) per clip.
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    Illustration 43	g03062049
    Typical right-hand side engine view (1) 461-1622 Wiring Harness (2) 7K-1181 Cable Strap (6) 5M-2894 Hard Washer (7) 4P-7581 Clip (8) 0S-1594 Bolt (42) 195-2431 Detonation Sensor Gp

83. Attach detonation sensors (42) to the engine under the camshaft covers on cylinders 3, 7, and 11.

    Tighten the detonation sensors ... 15 ± 3 N·m (11 ± 2 lb ft)

84. Attach detonation sensors (42) to engine wiring harness (1).

85. Attach one clip (7) to the camshaft covers on cylinders 1 and 5 with one bolt (8) and one washer (6) per clip.

    Note: The wiring for the detonation sensor on cylinder 11 does not attach to a clip.

86. Secure engine wiring harness (1) and detonation sensors (42) to clips (7) with one cable strap (2) per clip.
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    Illustration 44	g03062777
    Typical left-hand side engine view. (1) 461-1622 Wiring Harness (2) 7K-1181 Cable Strap (4) 4P-8134 Clip (6) 5M-2894 Hard Washer (8) 0S-1594 Bolt (39) 1A-9579 Bolt (40) 9M-1974 Hard Washer (43) 261-6847 Adapter (44) 415-2432 Temperature Sensor Gp (45) 3A-3692 Clip

87. Remove the adapter and the temperature sensor from the 172-0828 Exhaust Manifold.

88. Install adapter (43) into the 172-0828 Exhaust Manifold.

    Note: Lubricate the temperature sensor gp (44) with Loctite Nickel Anti Seize.

89. Install exhaust temperature sensor gp (44) into the adapter (43).

    Tighten the exhaust temperature sensor gp ... 45 ± 5 N·m (33 ± 4 lb ft)

90. Install one clip (45) around exhaust temperature sensor gp (44). Refer to Illustration 44 for the correct orientation of the clip.

91. Attach clip (45) to the cam cover on cylinder 10 with one bolt (8) and one washer (6).

92. Remove the original bolt and washer from the lower rear corner of the valve cover on cylinder 12.

93. Attach clip (4) to the lower rear corner of the valve cover on cylinder 12 with one bolt (39) and one washer (40).

94. Plug exhaust temperature sensor (44) into engine wiring harness (1).

95. Secure exhaust temperature sensor (44) to clip (4) with one cable strap (2).

96. Secure exhaust temperature sensor (44) to engine wiring harness (1) with cable straps (2) as needed.
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    Illustration 45	g03062778
    Typical right-hand side engine view. (1) 461-1622 Wiring Harness (4) 4P-8134 Clip (6) 5M-2894 Hard Washer (8) 0S-1594 Bolt (43) 261-6847 Adapter (44) 415-2432 Temperature Sensor Gp (45) 3A-3692 Clip

97. Remove the adapter and the temperature sensor from the 144-0723 Exhaust Manifold.

98. Install adapter (43) into the 144-0723 Exhaust Manifold.

    Note: Lubricate the temperature sensor gp (44) with Loctite Nickel Anti Seize.

99. Install exhaust temperature sensor gp (44) into the adapter (43).

    Tighten the exhaust temperature sensor gp ... 45 ± 5 N·m (33 ± 4 lb ft)

100. Install one clip (45) around exhaust temperature sensor gp (44). Refer to Illustration 45 for the correct orientation of the clip.

101. Attach clip (45) to the cam cover on cylinder 11 with one bolt (8) and one washer (6).

102. Plug exhaust temperature sensor (44) into engine wiring harness (1).

103. Secure exhaust temperature sensor (44) to clip (4) with one cable strap (2). Refer to Illustration 45 for the correct location.

104. Secure exhaust temperature sensor (44) to engine wiring harness (1) with cable straps (2) as needed.
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     Illustration 46	g03064299
     (22) 238-5080 O-Ring Seal (43) 256-6453 Temperature Sensor (47) 353-5440 Adapter

105. Remove the adapter and the temperature sensor from the 359-4123 Adapter.

     Note: Use Loctite 567 on all pipe thread joints.

106. Install adapter (47) into the 359-4123 Adapter.

107. Install temperature sensor (46) and one O-ring (22) into adapter (47).

     Tighten the temperature sensor ... 20 ± 3 N·m (15 ± 2 lb ft)

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     Illustration 47	g03428324
     (20) 228-7100 O-Ring Seal (23) 353-5441 Elbow Adapter (24) 214-7566 O-Ring Seal (29) 320-3063 Pressure Sensor

     Note: Installation of the crankcase pressure sensor can be on cylinder 1 or 5.

108. Remove the connector and crankcase pressure sensor from the 117-0066 Mounting Bracket.

109. Install elbow (23) and one O-ring (24) into the 117-0066 Mounting Bracket.

110. Install pressure sensor (29) and one O-ring (20) into connector (23).

     Tighten the pressure sensor ... 10 ± 2 N·m (7 ± 1 lb ft)

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     Illustration 48	g03645539
     (33) 132-5789 Clip (48) 9X-0262 Adapter (49) 6V-9028 O-Ring Seal (50) 305-6873 Pressure Sensor Gp

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     Illustration 49	g03645532
     (1) 461-1622 Wiring Harness (2) 7K-1181 Cable Strap (4) 4P-8134 Clip

111. Attach one clip (30) to the 397-8631 Tube As with the original 2A-4639 Bolt, 5M-2894 Hard Washers, and the 9S-8752 Full Nut. Refer to Illustration 49 for the correct location.

112. Attach one clip (33) to the 398-7716 Tube As with the original 2A-4639 Bolt, the 5M-2894 Hard Washers, and 9S-8752 Full Nut. Refer to Illustration 48 for the correct location.

113. Install two O-rings (49) onto adapter (48).

114. Install adapter (48) into the 397-8631 Tube As.

115. Install pressure sensor (50) onto adapter (48).

     Tighten the pressure sensor ... 10 ± 2 N·m (7 ± 1 lb ft)

116. Secure engine wiring harness (1) to clips (30) and (33) with one cable strap (2) per clip.
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     Illustration 50	g03469076
     Typical left-hand side engine view. (1) 461-1622 Wiring Harness (2) 7K-1181 Cable Strap (6) 5M-2894 Hard Washer (20) 228-7100 O-Ring Seal (29) 320-3063 Pressure Sensor (31) 0S-1588 Bolt (33) 132-5789 Clip (51) 6V-9330 Elbow (52) 335-3999 Adapter (53) 214-7568 O-Ring Seal

117. Remove the pressure sensor, the adapter, and the elbow from the air cleaner.

118. Install elbow (51) into the air cleaner.

119. Install adapter (52) and one O-ring (53) into elbow (51).

120. Install pressure sensor (29) and one O-ring (20) into adapter (53).

     Tighten the pressure sensor ... 10 ± 2 N·m (7 ± 1 lb ft)

121. Attach one clip (33) to the air cleaner with one bolt (31) and one washer (6).

122. Secure engine wiring harness (1) to clip (33) use one cable strap (2).
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     Illustration 51	g03469097
     Typical right-hand side engine view. (1) 461-1622 Wiring Harness (2) 7K-1181 Cable Strap (6) 5M-2894 Hard Washer (20) 228-7100 O-Ring Seal (29) 320-3063 Pressure Sensor (31) 0S-1588 Bolt (33) 132-5789 Clip (51) 6V-9330 Elbow (52) 335-3999 Adapter (53) 214-7568 O-Ring Seal

123. Remove the pressure sensor, the adapter, and the elbow from the air cleaner.

124. Install elbow (51) into the air cleaner.

125. Install adapter (52) and one O-ring (53) into elbow (51).

126. Install pressure sensor (29) and one O-ring (20) into adapter (53).

     Tighten the pressure sensor ... 10 ± 2 N·m (7 ± 1 lb ft)

127. Attach one clip (33) to the air cleaner with one bolt (31) and one washer (6).

128. Secure engine wiring harness (1) to clip (33) use one cable strap (2).
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     Illustration 52	g03469079
     Callout (56) is from the 373-1527 Electronic Control and Mounting Gp. (1) 461-1622 Wiring Harness (2) 7K-1181 Cable Strap (7) 4P-7581 Clip (54) 294-3313 Clip (55) 0S-1608 Bolt (56) 9X-6458 Hard Washer

     Note: The following steps will be performed during the installation of the 373-1527 Electronic Control and Mounting Gp.

129. Attach clip (54) to the 231-7070 Bracket with one bolt (55) and one washer (56).

130. Attach clip (7) to the 231-7070 Bracket with one bolt (55) and one washer (56).

131. Secure engine wiring harness (1) to clips (7) and (54) with one cable strap (2) per clip.
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     Illustration 53	g03119760
     (C) 7N-9738 Receptacle Housing (D) 238-8245 Connector Plug As

     Note: The following steps are only applicable with air starters.

132. Cut off the wires behind receptacle housing (C).

133. Strip back the insulation on the two wires.

134. Crimp the 9X-3402 Connector Socket onto each of the wires.

135. Install the crimped sockets into connector (D).

     Note: The connector is attached to the engine wiring harness.

Installing the 373-1527 Electronic Control and Mounting Gp

Illustration 54	g02979126
(1) 417-6011 Electronic Control Module

Illustration 55	g03023698
(2) 9M-1974 Hard Washer (3) 9N-0869 Hard Washer (4) 8T-9655 Isolation Mount (5) 6I-1418 Spacer (6) 2V-4387 Spacer (7) 1D-4540 Bolt

1. Remove the original engine electronic control from the 111-0349 Module Bracket.

2. Install electronic control module (1) onto the 111-0349 Module Bracket. Use four bolts (7), one washer (2), four washers (3), eight isolation mounts (4), four spacers (5), and four spacers (6).

   Note: The corner with ground wire will use washer (2).

   Note: Steps 3 through 10 use parts from the 397-9400 Water Lines Gp.

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   Illustration 56	g03105696
   (8) 8T-6761 Pipe Plug (9) 4B-7770 Tee (10) 196-9420 Ball Valve (11) 3B-6555 Elbow (12) 6B-1628 Reducing Bushing (13) 8C-6867 Connector (14) 005-8615 Pipe Nipple

3. Remove the pipe plug from the 7N-4944 Elbow.

4. Install pipe nipple (14) into the 7N-4944 Elbow.

5. Install the center hole of tee (9) onto the pipe nipple (14).

6. Install pipe plug (8) into the rear hole of tee (9).

7. Install ball valve (10) into the front hole of tee (9).

8. Install elbow (11) into ball valve (10).

9. Install reducing bushing (12) into elbow (11).

10. Install connector (13) into reducing bushing (12).
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    Illustration 57	g03475176
    Callout (20) is from the 380-5440 Engine Wiring Gp. (2) 9M-1974 Hard Washer (3) 9N-0869 Hard Washer (5) 6I-1418 Spacer (15) 353-8089 Electronic Control Module (16) 0T-0065 Bolt (17) 9X-6458 Hard Washer (18) 190-4885 Spacer (19) 231-7070 Bracket (20) 0S-1608 Bolt (21) 1B-9575 Bolt (22) 155-0576 Isolation Mount

    Note: Install the 195-2431 Detonation Sensor Gp before proceeding with the following steps.

11. Remove the rear cam cover bolts from cylinders 9 and 11.

    Note: The 4P-7581 Clip and the 294-3313 Clip will be installed on this step. Refer to steps 129 and 130 of the 380-5440 Engine Wiring Gp.

12. Attach bracket (19) to the engine. Use two bolts (16), two bolts (20), four washers (17), and four spacers (18). The spacers go in between the bracket and the cam covers.

13. Attach electronic control module (15) to bracket (19). Use four bolts (21), four washers (3), four spacers (5), and eight isolation mounts (22).

    Note: The corner with ground wire will use washer (2).

Installing the 397-8633 Gas Pressure Regulator Gp (Pipe Thread Design) (if applicable)

Illustration 58	g03021239
(1) 3B-7296 Fitting (2) 3B-7286 Pipe Nipple (3) 7X-7951 Union Elbow (4) 265-5255 Plate (5) 2M-4108 Gasket (6) 293-8396 Core (7) 0S-1591 Bolt (8) 5M-2894 Hard Washer

Note: Use Loctite 567 on all pipe thread joints.

1. Attach plates (4) to core (6). Use two gaskets (5), eight bolts (7), and eight washers (8).

   Note: Bolt holes in plates (4) facing the same direction.

2. Install fitting (1) into rear plate (4) with water the bonnets facing up and bolt holes in plates (4) facing toward the engine.

3. Install elbow union (3) onto fitting (1).

4. Install fitting (2) into front plate (4).

5. Install elbow union (3) onto fitting (2).
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   Illustration 59	g03021241
   (8) 5M-2894 Hard Washer (9) 0S-1585 Bolt (10) 7D-1649 Hard Washer (11) 397-8632 Bracket (12) 8S-9191 Bolt (13) 2A-4639 Bolt (14) 9X-6458 Hard Washer

6. Attach assembled parts to bracket (11) loosely with four bolts (13) and four washers (14).

7. Using a suitable lifting device, attach the bracket (11) to the engine below the side cover of cylinder 7 and to the oil pan. Use two bolts (9), two washers (10), four bolts (12), and four washers (8). The assembled parts weigh approximately 91 kg (200 lb).

   Note: There is no need to remove the oil cooler.

   Note: If, engine is equipped with air starters and there is interference with the air lines. Refer to "Installing the 417-4388 Fuel System Parts Kit (if applicable)" or "Installing the 417-4389 Fuel System Parts Kit (if applicable)".

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   Illustration 60	g02994736
   (9) 0S-1585 Bolt (14) 9X-6458 Hard Washer (15) 397-8629 Bracket (16) 3B-1915 Bolt (17) 9S-8752 Full Nut (18) 5P-8245 Hard Washer (19) 417-5543 Bracket As

8. Attach the bracket (19) to bracket (11) with six bolts (9) and six washers (18).

9. Attach brackets (15) to bracket (19) loosely. Use two bolts (16), four washers (14), and two nuts (17) per bracket.
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   Illustration 61	g02970964
   (1) 3B-7296 Fitting (3) 7X-7951 Union Elbow (20) 6N-4543 Fitting (21) 6L-7322 Pipe Tee (22) 2L-6055 Pipe Cap (23) 210-2007 Gas Pressure Regulator Gp

10. Install fitting (20) into the bottom of the gas regulator (23).

11. Install pipe tee (21) onto fitting (20).

12. Install fitting (1) onto bottom of the pipe tee (21).

13. Install cap (22) onto fitting (1).

14. Disconnect the front union elbow (3). Refer to Illustration 58.

15. Install the loose part of union elbow (3) into center hole of tee (21).

16. Install fitting (1) into top of gas regulator (23).

17. Install elbow union (3) onto fitting (1).
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    Illustration 62	g03021479
    (19) 417-5543 Bracket As (23) 210-2007 Gas Pressure Regulator Gp (24) 5B-5620 Bolt (25) 9M-1974 Hard Washer (26) 5S-0003 Nut (27) 9X-6138 Pipe Plug (28) 122-0089 Solenoid Valve Gp

18. Install pipe plug (27) into solenoid valve (28) on the side marked with the raised letters IN.

19. Install solenoid valve (28) onto elbow union (3).

20. Install gas regulator (23) loosely onto bracket (19). Use three bolts (24), six washers (25), and three nuts (26).

    Note: The bell side of the gas pressure regulator gp is up.

21. Connect both pieces of the front union (3) together.

    Note: The gas pressure regulator must be calibrated after the completion of the installation and gas supply is available. Refer to Testing and Adjusting, "Fuel Pressure (Gas System)" for instructions on setting the pressure regulator.

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    Illustration 63	g03021520
    (14) 9X-6458 Hard Washer (16) 3B-1915 Bolt (17) 9S-8752 Full Nut (29) 122-8905 Elbow (30) 6V-8398 O-Ring Seal (31) 397-8628 Tube As (32) 397-8631 Tube As

22. Install tube assembly (32) onto elbow union (3).

    Note: Union elbow (3) comes apart.

23. Attach tube assembly (32) to bracket (15) with two bolts (16), four washers (14), and two nuts (17).

    Note: Tighten all bolts that were left loose for alignment.

24. Install elbow (29) into tube assembly (32) and gas regulator (23).

25. Install one O-ring (30) per elbow into elbows (29).

26. Attach line (31) to elbows (29).
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    Illustration 64	g03022936
    (8) 5M-2894 Hard Washer (13) 2A-4639 Bolt (17) 9S-8752 Full Nut (33) 105-8180 Gasket

    Note: The parts called out are used for installing the 424-7719 Electronic Actuator Gp.

27. Refer to Illustration 75.

Installing the 440-4790 Gas Pressure Regulator Gp (Bolted Flange Design) (if applicable)

Illustration 65	g03685234
(1) 440-4791 Tube As (2) 293-8396 Core (3) 425-3549 Gasket (4) 440-4788 Tube As (5) 0S-1591 Bolt (6) 5M-2894 Hard Washer

1. Attach short elbow (1) to core (2) with one gasket (3), four bolts (5), and four washers (6).

2. Attach long elbow (4) to core (2) with one gasket (3), four bolts (5), and four washers (6).
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   Illustration 66	g03685235
   (6) 5M-2894 Hard Washer (7) 0S-1585 Bolt (8) 7D-1649 Hard Washer (9) 397-8632 Bracket (10) 8S-9191 Bolt (11) 2A-4639 Bolt (12) 9X-6458 Hard Washer

3. Attach assembled parts to bracket (9) loosely with four bolts (11) and four washers (12).

4. Remove the four bolts and four washers from the oil pan below the side cover of cylinder 7.

5. Using a suitable lifting device, attach the bracket (9) to the engine below the side cover of cylinder 7 and to the oil pan with two bolts (7), two washers (8), four bolts (10), and four washers (6). The assembled parts weigh approximately 91 kg (202 lb).
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   Illustration 67	g03685236
   (7) 0S-1585 Bolt (9) 397-8632 Bracket (13) 440-4786 Bracket As (14) 5P-8245 Hard Washer

6. Attach bracket (13) to bracket (9) with eight bolts (7) and eight washers (14).
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   Illustration 68	g03685237
   (13) 440-4786 Bracket As (15) 440-4792 Bracket (16) 0S-1591 Bolt (17) 9X-6458 Hard Washer (18) 9S-8752 Full Nut (19) 0S-1571 Bolt (20) 450-3143 Bracket As

7. Attach bracket (15) and bracket (20) to bracket (13) loosely with four bolts (19), eight washers (17), and four nuts (18).

8. Attach bracket (15) to bracket (13) loosely with four bolts (16), eight washers (17), and four nuts (18).
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   Illustration 69	g03685337
   (21) 435-0888 Gas Pressure Regulator Gp (22) 122-8905 Elbow (23) 6V-8398 O-Ring Seal

   Note: Use Loctite 567 on all pipe thread joints.

9. Install elbow (22) into the side port of gas regulator (21).

10. Install one O-ring (23) into elbow (22).
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    Illustration 70	g03685339
    (8) 7D-1649 Hard Washer (13) 440-4786 Bracket As (21) 435-0888 Gas Pressure Regulator Gp (24) 5B-5620 Bolt (25) 9M-1974 Hard Washer (26) 5S-0003 Nut (27) 293-4056 Gasket (28) 9X-8873 Bolt (29) 1F-7958 Full Nut

11. Install gas regulator (21) loosely onto bracket (13). Use three bolts (24), six washers (25), and three nuts (26).

    Note: The bell side of the gas pressure regulator group is up.

12. Attach gas pressure regulator (21) to the 440-4788 Tube As with one gasket (27), four bolts (28), eight washers (8), and four nuts (29).
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    Illustration 71	g03685407
    (8) 7D-1649 Hard Washer (15) 440-4792 Bracket (17) 9X-6458 Hard Washer (18) 9S-8752 Full Nut (21) 435-0888 Gas Pressure Regulator Gp (27) 293-4056 Gasket (28) 9X-8873 Bolt (29) 1F-7958 Full Nut (30) 450-2989 Tube As (31) 3B-1915 Bolt

13. Attach tube assembly (30) to gas pressure regulator (21) with one gasket (27), four bolts (28), eight washers (8), and four nuts (29).

14. Attach tube assembly (30) to bracket (15) with one two bolts (31), four washers (17), and two nuts (18).
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    Illustration 72	g03685458
    (22) 122-8905 Elbow (23) 6V-8398 O-Ring Seal (30) 450-2989 Tube As (32) 211-5237 Connector (33) 440-4794 Tube As

    Note: Use Loctite 567 on all pipe thread joints.

15. Install connector (32) into elbow (30).

16. Attach tube assembly (33) and one O-ring (23) to connector (32).

17. Attach tube assembly (33) to elbow (22).

    Note: Make sure that the O-ring is in the elbow.

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    Illustration 73	g03685523
    (34) 419-0893 Solenoid Valve Gp (35) 1A-8537 Bolt (36) 5P-8247 Hard Washer (37) 4K-0367 Full Nut (38) 420-8789 Gasket (39) 8S-9092 Bolt

18. Attach solenoid valve gp (34) to the 440-4791 Tube As loosely with one gasket (38), four bolts (39), eight washers (36), and four nuts (37).

    Note: The gas pressure regulator must be calibrated after the completion of the installation and gas supply is available. Refer to Testing and Adjusting, "Fuel Pressure (Gas System)" for instructions on setting the pressure regulator.

19. Attach solenoid valve gp (34) to the 450-3143 Bracket As and customer fuel supply loosely. Use one gasket (38), two bolts (35), two bolts (39), eight washers (36), and four nuts (37). Refer to Illustration 73 for the correct location of the bolts.
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    Illustration 74	g03685525
    (6) 5M-2894 Hard Washer (11) 2A-4639 Bolt (18) 9S-8752 Full Nut (40) 105-8180 Gasket

20. Tighten all the hardware that was left loose for installation except for outside bracket (15) and customer fuel supply connection.

    Note: The remaining parts called out are used for installing 424-7719 Electronic Actuator Gp.

21. Refer to Illustration 76.

Installing the 424-7719 Electronic Actuator Gp

Illustration 75	g03022937
(1) Installing the 424-7719 Electronic Actuator Gp

Illustration 76	g03684974
New design (1) 424-7719 Electronic Actuator Gp

1. Attach actuator (1) to 397-8631 Tube As or the 436-0492 Tube As with one 105-8180 Gasket, four 2A-4639 Bolts, eight 5M-2894 Hard Washers, and four 9S-8752 Full Nuts.

   Note: The actuator must be oriented correctly with respect to gas flow.

Installing the 397-9400 Water Lines Gp (Pipe Thread Design Gas Regulator)

Illustration 77	g02987617
(1) 4J-5477 O-Ring Seal (2) 8C-6866 Connector (3) 4L-6454 Bolt (4) 8T-4896 Hard Washer (5) 265-5254 Plate (6) 318-2484 Orifice (7) 4F-7391 O-Ring Seal (8) 318-2485 Gasket

Note: Use Loctite 567 on all pipe thread joints.

1. Install one O-ring (7) per plate into bottom of plates (5).

2. Attach plate (5) to front port of 293-8396 Core. Use two bolts (3) and two washers (4).

3. Attach plate (5) and orifice (6) to rear port of 293-8396 Core. Use one gasket (8), two bolts (3), and two washers (4).

4. Install connectors (2) into plates (5).

5. Install one O-ring (1) into each connector (2).
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   Illustration 78	g03105438
   (1) 4J-5477 O-Ring Seal (2) 8C-6866 Connector (9) 419-1798 Hose As (10) 5P-9297 Clip

6. Remove the 8T-6765 Pipe Plug from the front right side 154-1617 Manifold.

7. Install connector (2) into the front right side manifold.

8. Attach hose (9) and one O-ring (1) to connector (2).

9. Attach hose (9) to connector (2) on the front port of the 293-8396 Core.

   Note: Make sure that the O-ring is in the connector.

10. Remove the top rear 0S-1590 Bolt and the 5M-2894 Hard Washer from the left side 7E-6017 Cover.

11. Install one clip (10) around hose (9).

12. Attach clip (10) to the 7E-6017 Cover use the original hardware.
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    Illustration 79	g03462936
    (9) 419-1798 Hose As (10) 5P-9297 Clip (11) 0S-1588 Bolt (12) 9X-6458 Hard Washer (13) 9S-8752 Full Nut (14) 6V-0267 Clip (15) 6V-0268 Clip (16) 6V-3265 Clip (17) 0S-1594 Bolt (18) 5M-2894 Hard Washer (19) 0S-1571 Bolt (20) 384-7876 Bracket

13. Remove bottom outer bolt of oil cooler 7C-9217 Elbow.

14. Install bracket (20) use one bolt (19) and one washer (18).

15. Install one clip (10) around hose (9).

16. Attach clip (10) to bracket (20). Use one bolt (17), two washers (18), and one nut (13).

17. Remove inside bolt from 100-8075 Clamp As and 264-0450 Clamp As.

18. Install one clip (16) around hose (9).

19. Attach clip (16) to 100-8075 Clamp As and 264-0450 Clamp As with the original hardware.

20. Install three clips (14) and three clips (15) around oil 253-4775 Tube As.

21. Install three clips (10) around hose (9).

22. Attach each clip (10) to each clip (14) and (15). Use one bolt (11), two washers (12), and one nut (13) per clip assembly.
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    Illustration 80	g03024197
    (1) 4J-5477 O-Ring Seal (2) 8C-6866 Connector (10) 5P-9297 Clip (13) 9S-8752 Full Nut (17) 0S-1594 Bolt (18) 5M-2894 Hard Washer (21) 8C-6867 Connector (22) 419-1797 Hose As (23) 8S-9191 Bolt (24) 416-6524 Bracket

23. Attach hose (22) and one O-ring (1) to connector (21).

24. Attach hose (22) to connector (2) on the rear port of the 293-8396 Core.

    Note: Make sure that the O-ring is in the connector.

25. Remove one oil pan bolt located under the side cover of cylinder 9.

26. Attach one bracket (24) to the block under the side cover of cylinder 9 use one bolt (23) and one washer (18).

27. Install one clip (10) around hose (22).

28. Attach clip (10) to the bottom hole of the front bracket (24) use one bolt (17), two washers (18), and one nut (13).

29. Remove one oil pan bolt located under the side cover of cylinder 11.

30. Attach one bracket (24) to the block under the side cover of cylinder 11 use one bolt (23) and one washer (18).

31. Install one clip (10) around hose (22).

32. Attach clip (10) to the top hole of the rear bracket (24) use one bolt (17), two washers (18), and one nut (13).

Installing the 451-6338 Water Lines Gp (Bolted Flange Design Gas Regulator)

Illustration 81	g03863635
(1) 4J-5477 O-Ring Seal (2) 8C-6866 Connector (3) 4L-6454 Bolt (4) 8T-4896 Hard Washer (5) 265-5254 Plate (6) 318-2484 Orifice (7) 4F-7391 O-Ring Seal (8) 318-2485 Gasket

Note: Use Loctite 567 on all pipe thread joints.

1. Install one O-ring (7) per plate into bottom of plates (5).

2. Attach plate (5) to front port of 293-8396 Core. Use two bolts (3) and two washers (4).

3. Attach plate (5) and orifice (6) to rear port of 293-8396 Core. Use one gasket (8), two bolts (3), and two washers (4).

4. Install connectors (2) into plates (5).

5. Install one O-ring (1) into each connector (2).
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   Illustration 82	g03105438
   (1) 4J-5477 O-Ring Seal (2) 8C-6866 Connector (9) 419-1798 Hose As (10) 5P-9297 Clip

6. Remove the 8T-6765 Pipe Plug from the front right side 154-1617 Manifold.

7. Install connector (2) into the front right side manifold.

8. Attach hose (9) and one O-ring (1) to connector (2).

9. Attach hose (9) to connector (2) on the front port of the 293-8396 Core.

   Note: Make sure that the O-ring is in the connector.

10. Remove the top rear 0S-1590 Bolt and the 5M-2894 Hard Washer from the left side 7E-6017 Cover.

11. Install one clip (10) around hose (9).

12. Attach clip (10) to the 7E-6017 Cover use the original hardware.
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    Illustration 83	g03462936
    (9) 419-1798 Hose As (10) 5P-9297 Clip (11) 0S-1588 Bolt (12) 9X-6458 Hard Washer (13) 9S-8752 Full Nut (14) 6V-0267 Clip (15) 6V-0268 Clip (16) 6V-3265 Clip (17) 0S-1594 Bolt (18) 5M-2894 Hard Washer (19) 0S-1571 Bolt (20) 384-7876 Bracket

13. Remove bottom inside bolt of oil cooler 7C-9217 Elbow.

14. Install bracket (20) use one bolt (19) and one washer (18).

15. Install one clip (10) around hose (9).

16. Attach clip (10) to bracket (20). Use one bolt (17), two washers (18), and one nut (13).

17. Remove inside bolt from 100-8075 Clamp As and 264-0450 Clamp As.

18. Install one clip (16) around hose (9).

19. Attach clip (16) to 100-8075 Clamp As and 264-0450 Clamp As with the original hardware.

20. Install three clips (14) and three clips (15) around oil 253-4775 Tube As.

21. Install three clips (10) around hose (9).

22. Attach each clip (10) to each clip (14) and (15). Use one bolt (11), two washers (12), and one nut (13) per clip assembly.
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    Illustration 84	g03024197
    (1) 4J-5477 O-Ring Seal (2) 8C-6866 Connector (10) 5P-9297 Clip (13) 9S-8752 Full Nut (17) 0S-1594 Bolt (18) 5M-2894 Hard Washer (21) 8C-6867 Connector (22) 419-1797 Hose As (23) 8S-9191 Bolt (24) 416-6524 Bracket

23. Attach hose (22) and one O-ring (1) to connector (21).

24. Attach hose (22) to connector (2) on the rear port of the 293-8396 Core.

    Note: Make sure that the O-ring is in the connector.

25. Remove one oil pan bolt located under the side cover of cylinder 9.

26. Attach one bracket (24) to the block under the side cover of cylinder 9 use one bolt (23) and one washer (18).

27. Install one clip (10) around hose (22).

28. Attach clip (10) to the bottom hole of the front bracket (24) use one bolt (17), two washers (18), and one nut (13).

29. Remove one oil pan bolt located under the side cover of cylinder 11.

30. Attach one bracket (24) to the block under the side cover of cylinder 11 use one bolt (23) and one washer (18).

31. Install one clip (10) around hose (22).

32. Attach clip (10) to the top hole of the rear bracket (24) use one bolt (17), two washers (18), and one nut (13).

Installing the Air Cleaner Mounting

Installing the 390-5453 Air Cleaner Mounting on the 3512B

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Illustration 85	g03211918
(1) 5N-7906 Support As (2) 1A-2029 Bolt (3) 5M-2894 Hard Washer

1. Attach support (1) to the two bolt holes of the 140-0407 Exhaust Elbow use the original hardware.

Installing the 390-5454 Air Cleaner Mounting on the 3512C

Illustration 86	g03025918
(1) 277-2265 Support As (2) 0L-1351 Bolt (3) 5M-2894 Hard Washer

1. Attach support (1) to the lower two bolt holes of the 162-8864 Turbocharger Exhaust Elbow use two bolts (2) and two washers (3).

Installing the Fuel Lines

Installing the 444-9250 Fuel Lines Gp (Bolted Flange Design Gas Regulator) on the 3512B

Illustration 87	g03866762
399-3106 Tube As

Note: For a 1400-2300 BTU / SCF Lower Heating Value (LHV), order the 388-1301 Tube As.

Illustration 88	g03813840
(1) 388-1299 Tube As (2) 7M-1599 Taperlock Stud (3) 9M-1974 Hard Washer (4) 5S-0003 Nut (5) 399-3106 Tube As (6) 5P-8211 O-Ring Seal (7) 8B-4967 O-Ring Seal

Note: The 2B-2695 Bolt replaces the 7M-1599 Taperlock Stud.

1. Install two taperlock studs (2) into each tube assembly (1).

2. Install one O-ring seal (6) and one O-ring seal (7) onto tube assembly (5).

   Note: Lubricate the bore of tube assembly (1) lightly with glycerin.

3. Install tube assembly (5) into each tube assembly (1) use two washers (3) and two nuts (4).
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   Illustration 89	g03813848
   (8) 389-08458 Bracket As (9) 389-0845 Bracket As

4. Install bracket assembly (8) on the top right-hand side of the rear flywheel housing use the original hardware.

5. Attach bracket assembly (8) to the 5N-7916 Bracket use the original hardware.

6. Install bracket assembly (9) on the top right-hand side of the rear flywheel housing use the original hardware.

7. Attach bracket assembly (9) to the 5N-7916 Bracket use the original hardware.
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   Illustration 90	g03813850
   (1) 388-1299 Tube As (10) 5P-4869 Hose Clamp (11) 5P-3860 Hose Clamp (12) 396-6986 Hose (13) 8N-5254 Reducer Hose (14) 0S-1594 Bolt (15) 9X-6458 Hard Washer (16) 388-3527 Bracket (17) 0S-1591 Bolt (18) 9S-8752 Full Nut

8. Attach tube assembly (1) onto the compressor housing of the left turbocharger. Use one hose (12) and two hose clamps (11) with open end of tube facing the rear. Refer to Illustration 90 for correct orientation.

9. Install reducer hose (13) onto tube assembly (1) use hose clamp (11).

   Note: Hose clamp (10) is used to fasten reducer hose (13) to the air cleaner.

10. Install bracket (16) onto the left tube assembly (1) use two bolts (14) and two washers (15).

11. Attach bracket (16) to the 388-8893 Bracket As use two bolts (17), four washers (15), and two nuts (18).

12. Attach tube assembly (1) onto the compressor housing of the right turbocharger. Use hose (12) and two hose clamps (11) with open end of tube facing the rear. Refer to Illustration 90 for correct orientation.

13. Install reducer hose (13) onto tube assembly (1) use hose clamp (11).

    Note: Hose clamp (10) is used to fasten reducer hose (13) to the air cleaner.

14. Install bracket (16) onto the right tube assembly (1) use two bolts (14) and two washers (15).

15. Attach bracket (16) to the 388-8895 Bracket As use two bolts (17), four washers (15), and two nuts (18).
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    Illustration 91	g03863612
    (1) 388-1299 Tube As (15) 9X-6458 Hard Washer (17) 0S-1591 Bolt (18) 9S-8752 Full Nut (19) 255-6464 Joint (20) 388-1294 Tube As (21) 261-7951 Tube Joint (22) 444-9247 Tube As (23) 3B-1915 Bolt (24) 2A-4639 Bolt (25) 5M-2894 Hard Washer (26) 105-8180 Gasket (27) 6V-1581 Clip (28) 6V-1582 Clip

    Note: Fit tube assemblies loosely prior to final assembly.

16. Attach tube assembly (20) onto tube assemblies (1) use joint assemblies (19).

    Tighten the joint assemblies ... 12 ± 0.5 N·m (106 ± 4 lb in)

17. Attach tube assembly (22) to tube assembly (20) use joint assembly (21).

    Tighten the joint assembly ... 12 ± 0.5 N·m (106 ± 4 lb in)

18. Attach tube assembly (22) to the 424-7719 Electronic Actuator Gp use one gasket (26), four bolts (24), eight washers (25), and four nuts (18).

19. Attach tube assembly (22) to the 387-6744 Bracket use two bolts (23), four washers (15), and two nuts (18).

20. Install one clip (27) and one clip (28) around tube assembly (22).

21. Attach clips (27) and (28) to the bottom rear hole of the 5N-7916 Bracket use one bolt (23) and one washer (15).
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    Illustration 92	g03863613
    (15) 9X-6458 Hard Washer (17) 0S-1591 Bolt (18) 9S-8752 Full Nut (27) 6V-1581 Clip (28) 6V-1582 Clip (29) 388-1302 Bracket (30) 6V-1612 Bolt (31) 7D-1649 Hard Washer (32) 145-5181 Spacer

22. Attach bracket (29) to the top right-hand bolt hole of exhaust elbow support use one bolt (30), one washer (31), and one spacer (32).

23. Install one clip (27) and one clip (28) around tube assembly (20).

24. Attach clips (27) and (28) to bracket (29) use one bolt (17), two washers (15), and one nut (18).
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    Illustration 93	g03863614
    (31) 7D-1649 Hard Washer (33) 388-1304 Bracket (34) 388-1303 Bracket (35) 0S-1585 Bolt (36) 1F-7958 Full Nut (37) 0S-1587 Bolt (38) 7K-1401 Clip (39) 7K-1402 Bracket

25. Attach one bracket (33) to the left-hand side of the 5N-7906 Support As use one bolt (35), two washers (31), and one nut (36).

26. Attach two brackets (34) to the middle and right-hand side of the 5N-7906 Support As. Use one bolt (35), two washers (31), and one nut (36) per bracket.

27. Install three clips (38) and three brackets (39) around tube assembly (20).

28. Attach one clip (38) and one bracket (39) to the left-hand side bracket (33) use one bolt (37), two washers (31), and one nut (36).

29. Attach one clip (38) and one bracket (39) to the middle bracket (34) use one bolt (37), two washers (31), and one nut (36).

30. Attach one clip (38) and one bracket (39) to the right-hand side bracket (34) use one bolt (37), two washers (31), and one nut (37).

Installing the 388-5370 Fuel Lines Gp (Pipe Thread Design Gas Regulator) on the 3512C

Illustration 94	g03866762
399-3106 Tube As

Note: For a 1400-2300 BTU / SCF Lower Heating Value (LHV), order the 388-1301 Tube As.

Illustration 95	g03813840
(1) 388-1299 Tube As (2) 7M-1599 Taperlock Stud (3) 9M-1974 Hard Washer (4) 5S-0003 Nut (5) 399-3106 Tube As (6) 5P-8211 O-Ring Seal (7) 8B-4967 O-Ring Seal

Note: The 2B-2695 Bolt replaces the 7M-1599 Taperlock Stud.

1. Install two taperlock studs (2) into each tube assembly (1).

2. Install one O-ring seal (6) and one O-ring seal (7) onto tube assembly (5).

   Note: Lubricate the bore of tube assembly (1) lightly with glycerin.

3. Install tube assembly (5) into each tube assembly (1) use two washers (3) and two nuts (4).
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   Illustration 96	g03813841
   (8) 388-8893 Bracket As (9) 388-8895 Bracket As

4. Install bracket assembly (8) on the top left-hand side of the rear flywheel housing use the original hardware.

5. Attach bracket assembly (8) to the 5N-7916 Bracket use the original hardware.

6. Install bracket assembly (9) on the top right-hand side of the rear flywheel housing use the original hardware.

7. Attach bracket assembly (9) to the 5N-7916 Bracket use the original hardware.
   Show/hide table

   Illustration 97	g03813843
   (1) 388-1299 Tube As (10) 5P-4869 Hose Clamp (11) 5P-3860 Hose Clamp (12) 396-6986 Hose (13) 396-6987 Reducer Hose (14) 0S-1594 Bolt (15) 9X-6458 Hard Washer (16) 388-6418 Bracket (17) 388-6419 Bracket (18) 0S-1591 Bolt (19) 9S-8752 Full Nut

8. Attach tube assembly (1) onto the compressor of the left turbocharger. Use hump hose (12) and two hose clamps (11) with open end of tube facing the rear. Refer to Illustration 97 for correct orientation.

9. Install reducer hose (13) onto tube assembly (1) use hose clamp (11).

   Note: Hose clamp (10) is used to fasten reducer hose (13) to the air cleaner.

10. Install bracket (17) onto the left tube assembly (1) use two bolts (14) and two washers (15).

11. Attach bracket (17) to the 388-8893 Bracket As use two bolts (18), four washers (15), and two nuts (19).

12. Attach tube assembly (1) onto compressor of right turbocharger. Use hump hose (12) and two hose clamps (11) with open end of tube facing the rear. Refer to Illustration 97 for correct orientation.

13. Install bracket (16) onto the right tube assembly (1) use two bolts (14) and two washers (15).

14. Attach bracket (16) to the 388-8895 Bracket As use two bolts (18), four washers (15), and two nuts (19).
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    Illustration 98	g03863616
    (1) 388-1299 Tube As (15) 9X-6458 Hard Washer (18) 0S-1591 Bolt (19) 9S-8752 Full Nut (20) 255-6464 Joint (21) 398-7716 Tube As (22) 388-5372 Tube As (23) 261-7951 Tube Joint (24) 3B-1915 Bolt (25) 2A-4639 Bolt (26) 5M-2894 Hard Washer (27) 105-8180 Gasket (28) 6V-1581 Clip (29) 6V-1582 Clip

    Note: Fit tube assemblies loosely prior to final assembly.

15. Attach tube assembly (22) onto tube assemblies (1) use joint assemblies (20).

    Tighten the joint assemblies ... 12 ± 0.5 N·m (106 ± 4 lb in)

16. Attach tube assembly (21) to tube assembly (22) use joint assembly (23).

    Tighten the joint assemblies ... 12 ± 0.5 N·m (106 ± 4 lb in)

17. Attach tube assembly (21) to the 424-7719 Electronic Actuator Gp. Use one gasket (27), four bolts (25), eight washers (26), and four nuts (19).

18. Attach tube assembly (21) to the 387-6744 Bracket use two bolts (24), four washers (15), and two nuts (19).

19. Install one clip (28) and one clip (29) around tube assembly (21).

20. Attach clips (28) and (29) to the bottom rear hole of the 5N-7916 Bracket use one bolt (18) and one washer (15).
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    Illustration 99	g03813846
    (15) 9X-6458 Hard Washer (18) 0S-1591 Bolt (19) 9S-8752 Full Nut (28) 6V-1581 Clip (29) 6V-1582 Clip (30) 388-1302 Bracket (31) 6V-1612 Bolt (32) 7D-1649 Hard Washer (33) 145-5181 Spacer

21. Attach bracket (30) to the top right-hand bolt hole of exhaust elbow support use one bolt (31), one washer (32), and one spacer (33).

22. Install one clip (28) and one clip (29) around tube assembly (22).

23. Attach clips (28) and (29) to bracket (30) use one bolt (18), two washers (15), and one nut (19).
    Show/hide table

    Illustration 100	g03813847
    (15) 9X-6458 Hard Washer (19) 9S-8752 Full Nut (32) 7D-1649 Hard Washer (34) 1A-2029 Bolt (35) 388-5375 Bracket (36) 388-5374 Bracket (37) 7K-1401 Clip (38) 7K-1402 Bracket (39) 0S-1587 Bolt (40) 1F-7958 Full Nut

24. Install two clips (37) and two brackets (38) around tube assembly (22).

25. Attach clips (37) and brackets (38) to brackets (35) and (36) use two bolts (34), four washers (15), and two nuts (19).

26. Attach bracket (36) to left side of the 277-2265 Support As use one bolt (39), two washers (32), and one nut (40).

27. Attach bracket (35) to right side of the 277-2265 Support As use one bolt (39), two washers (32), and one nut (40).

Installing the Fuel Lines

Installing the 444-9249 Fuel Lines Gp (Bolted Flange Design Gas Regulator) on the 3512C

Illustration 101	g03866762
399-3106 Tube As

Note: For a 1400-2300 BTU / SCF Lower Heating Value (LHV), order the 388-1301 Tube As.

Illustration 102	g03813840
(1) 388-1299 Tube As (2) 7M-1599 Taperlock Stud (3) 9M-1974 Hard Washer (4) 5S-0003 Nut (5) 399-3106 Tube As (6) 5P-8211 O-Ring Seal (7) 8B-4967 O-Ring Seal

Note: The 2B-2695 Bolt replaces the 7M-1599 Taperlock Stud.

1. Install two taperlock studs (2) into each tube assembly (1).

2. Install one O-ring seal (6) and one O-ring seal (7) onto tube assembly (5).

   Note: Lubricate the bore of tube assembly (1) lightly with glycerin.

3. Install tube assembly (5) into each tube assembly (1) use two washers (3) and two nuts (4).
   Show/hide table

   Illustration 103	g03813841
   (8) 388-8893 Bracket As (9) 388-8895 Bracket As

4. Install bracket assembly (8) on the top left-hand side of the rear flywheel housing use the original hardware.

5. Attach bracket assembly (8) to the 5N-7916 Bracket use the original hardware.

6. Install bracket assembly (9) on the top right-hand side of the rear flywheel housing use the original hardware.

7. Attach bracket assembly (9) to the 5N-7916 Bracket use the original hardware.
   Show/hide table

   Illustration 104	g03813843
   (1) 388-1299 Tube As (10) 5P-4869 Hose Clamp (11) 5P-3860 Hose Clamp (12) 396-6986 Hose (13) 396-6987 Reducer Hose (14) 0S-1594 Bolt (15) 9X-6458 Hard Washer (16) 388-6418 Bracket (17) 388-6419 Bracket (18) 0S-1591 Bolt (19) 9S-8752 Full Nut

8. Attach tube assembly (1) onto the compressor of the left turbocharger. Use hump hose (12) and two hose clamps (11) with open end of tube facing the rear. Refer to Illustration 97 for correct orientation.

9. Install reducer hose (13) onto tube assembly (1) use hose clamp (11).

   Note: Hose clamp (10) is used to fasten reducer hose (13) to the air cleaner.

10. Install bracket (17) onto the left tube assembly (1) use two bolts (14) and two washers (15).

11. Attach bracket (17) to the 388-8893 Bracket As use two bolts (18), four washers (15), and two nuts (19).

12. Attach tube assembly (1) onto compressor of right turbocharger. Use hump hose (12) and two hose clamps (11) with open end of tube facing the rear. Refer to Illustration 97 for correct orientation.

13. Install bracket (16) onto the right tube assembly (1) use two bolts (14) and two washers (15).

14. Attach bracket (16) to the 388-8895 Bracket As use two bolts (18), four washers (15), and two nuts (19).
    Show/hide table

    Illustration 105	g03863616
    (1) 388-1299 Tube As (15) 9X-6458 Hard Washer (18) 0S-1591 Bolt (19) 9S-8752 Full Nut (20) 255-6464 Joint (21) 444-9247 Tube As (22) 388-5372 Tube As (23) 261-7951 Tube Joint (24) 3B-1915 Bolt (25) 2A-4639 Bolt (26) 5M-2894 Hard Washer (27) 105-8180 Gasket (28) 6V-1581 Clip (29) 6V-1582 Clip

    Note: Fit tube assemblies loosely prior to final assembly.

15. Attach tube assembly (22) onto tube assemblies (1) use joint assemblies (20).

    Tighten the joint assemblies ... 12 ± 0.5 N·m (106 ± 4 lb in)

16. Attach tube assembly (21) to tube assembly (22) use joint assembly (23).

    Tighten the joint assemblies ... 12 ± 0.5 N·m (106 ± 4 lb in)

17. Attach tube assembly (21) to the 424-7719 Electronic Actuator Gp. Use one gasket (27), four bolts (25), eight washers (26), and four nuts (19).

18. Attach tube assembly (21) to the 387-6744 Bracket use two bolts (24), four washers (15), and two nuts (19).

19. Install one clip (28) and one clip (29) around tube assembly (21).

20. Attach clips (28) and (29) to the bottom rear hole of the 5N-7916 Bracket use one bolt (18) and one washer (15).
    Show/hide table

    Illustration 106	g03813846
    (15) 9X-6458 Hard Washer (18) 0S-1591 Bolt (19) 9S-8752 Full Nut (28) 6V-1581 Clip (29) 6V-1582 Clip (30) 388-1302 Bracket (31) 6V-1612 Bolt (32) 7D-1649 Hard Washer (33) 145-5181 Spacer

21. Attach bracket (30) to the top right-hand bolt hole of exhaust elbow support use one bolt (31), one washer (32), and one spacer (33).

22. Install one clip (28) and one clip (29) around tube assembly (22).

23. Attach clips (28) and (29) to bracket (30) use one bolt (18), two washers (15), and one nut (19).
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    Illustration 107	g03813847
    (15) 9X-6458 Hard Washer (19) 9S-8752 Full Nut (32) 7D-1649 Hard Washer (34) 1A-2029 Bolt (35) 388-5375 Bracket (36) 388-5374 Bracket (37) 7K-1401 Clip (38) 7K-1402 Bracket (39) 0S-1587 Bolt (40) 1F-7958 Full Nut

24. Install two clips (37) and two brackets (38) around tube assembly (22).

25. Attach clips (37) and brackets (38) to brackets (35) and (36) use two bolts (34), four washers (15), and two nuts (19).

26. Attach bracket (36) to left side of the 277-2265 Support As use one bolt (39), two washers (32), and one nut (40).

27. Attach bracket (35) to right side of the 277-2265 Support As use one bolt (39), two washers (32), and one nut (40).

Installing the 444-9250 Fuel Lines Gp (Bolted Flange Design Gas Regulator) on the 3512B

Illustration 108	g03813838
399-3106 Tube As

Note: For a 1400-2300 BTU / SCF Lower Heating Value (LHV), order the 388-1301 Tube As.

Illustration 109	g03813840
(1) 388-1299 Tube As (2) 7M-1599 Taperlock Stud (3) 9M-1974 Hard Washer (4) 5S-0003 Nut (5) 399-3106 Tube As (6) 5P-8211 O-Ring Seal (7) 8B-4967 O-Ring Seal

Note: The 2B-2695 Bolt replaces the 7M-1599 Taperlock Stud.

1. Install two taperlock studs (2) into each tube assembly (1).

2. Install one O-ring seal (6) and one O-ring seal (7) onto tube assembly (5).

   Note: Lubricate the bore of tube assembly (1) lightly with glycerin.

3. Install tube assembly (5) into each tube assembly (1) use two washers (3) and two nuts (4).
   Show/hide table

   Illustration 110	g03813848
   (8) 389-08458 Bracket As (9) 389-0845 Bracket As

4. Install bracket assembly (8) on the top right-hand side of the rear flywheel housing use the original hardware.

5. Attach bracket assembly (8) to the 5N-7916 Bracket use the original hardware.

6. Install bracket assembly (9) on the top right-hand side of the rear flywheel housing use the original hardware.

7. Attach bracket assembly (9) to the 5N-7916 Bracket use the original hardware.
   Show/hide table

   Illustration 111	g03813850
   (1) 388-1299 Tube As (10) 5P-4869 Hose Clamp (11) 5P-3860 Hose Clamp (12) 396-6986 Hose (13) 8N-5254 Reducer Hose (14) 0S-1594 Bolt (15) 9X-6458 Hard Washer (16) 388-3527 Bracket (17) 0S-1591 Bolt (18) 9S-8752 Full Nut

8. Attach tube assembly (1) onto the compressor housing of the left turbocharger. Use one hose (12) and two hose clamps (11) with open end of tube facing the rear. Refer to Illustration 90 for correct orientation.

9. Install reducer hose (13) onto tube assembly (1) use hose clamp (11).

   Note: Hose clamp (10) is used to fasten reducer hose (13) to the air cleaner.

10. Install bracket (16) onto the left tube assembly (1) use two bolts (14) and two washers (15).

11. Attach bracket (16) to the 388-8893 Bracket As use two bolts (17), four washers (15), and two nuts (18).

12. Attach tube assembly (1) onto the compressor housing of the right turbocharger. Use hose (12) and two hose clamps (11) with open end of tube facing the rear. Refer to Illustration 90 for correct orientation.

13. Install reducer hose (13) onto tube assembly (1) use hose clamp (11).

    Note: Hose clamp (10) is used to fasten reducer hose (13) to the air cleaner.

14. Install bracket (16) onto the right tube assembly (1) use two bolts (14) and two washers (15).

15. Attach bracket (16) to the 388-8895 Bracket As use two bolts (17), four washers (15), and two nuts (18).
    Show/hide table

    Illustration 112	g03863612
    (1) 388-1299 Tube As (15) 9X-6458 Hard Washer (17) 0S-1591 Bolt (18) 9S-8752 Full Nut (19) 255-6464 Joint (20) 388-1294 Tube As (21) 261-7951 Tube Joint (22) 444-9247 Tube As (23) 3B-1915 Bolt (24) 2A-4639 Bolt (25) 5M-2894 Hard Washer (26) 105-8180 Gasket (27) 6V-1581 Clip (28) 6V-1582 Clip

    Note: Fit tube assemblies loosely prior to final assembly.

16. Attach tube assembly (20) onto tube assemblies (1) use joint assemblies (19).

    Tighten the joint assemblies ... 12 ± 0.5 N·m (106 ± 4 lb in)

17. Attach tube assembly (22) to tube assembly (20) use joint assembly (21).

    Tighten the joint assembly ... 12 ± 0.5 N·m (106 ± 4 lb in)

18. Attach tube assembly (22) to the 424-7719 Electronic Actuator Gp use one gasket (26), four bolts (24), eight washers (25), and four nuts (18).

19. Attach tube assembly (22) to the 387-6744 Bracket use two bolts (23), four washers (15), and two nuts (18).

20. Install one clip (27) and one clip (28) around tube assembly (22).

21. Attach clips (27) and (28) to the bottom rear hole of the 5N-7916 Bracket use one bolt (17) and one washer (15).
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    Illustration 113	g03863613
    (15) 9X-6458 Hard Washer (17) 0S-1591 Bolt (18) 9S-8752 Full Nut (27) 6V-1581 Clip (28) 6V-1582 Clip (29) 388-1302 Bracket (30) 6V-1612 Bolt (31) 7D-1649 Hard Washer (32) 145-5181 Spacer

22. Attach bracket (29) to the top right-hand bolt hole of exhaust elbow support use one bolt (30), one washer (31), and one spacer (32).

23. Install one clip (27) and one clip (28) around tube assembly (20).

24. Attach clips (27) and (28) to bracket (29) use one bolt (17), two washers (15), and one nut (18).
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    Illustration 114	g03863614
    (31) 7D-1649 Hard Washer (33) 388-1304 Bracket (34) 388-1303 Bracket (35) 0S-1585 Bolt (36) 1F-7958 Full Nut (37) 0S-1587 Bolt (38) 7K-1401 Clip (39) 7K-1402 Bracket

25. Attach one bracket (33) to the left-hand side of the 5N-7906 Support As use one bolt (35), two washers (31), and one nut (36).

26. Attach two brackets (34) to the middle and right-hand side of the 5N-7906 Support As. Use one bolt (35), two washers (31), and one nut (36) per bracket.

27. Install three clips (38) and three brackets (39) around tube assembly (20).

28. Attach one clip (38) and one bracket (39) to the left-hand side bracket (33) use one bolt (37), two washers (31), and one nut (36).

29. Attach one clip (38) and one bracket (39) to the middle bracket (34) use one bolt (37), two washers (31), and one nut (36).

30. Attach one clip (38) and one bracket (39) to the right-hand side bracket (34) use one bolt (37), two washers (31), and one nut (37).

Installing the 392-5541 Particle Sensor Gp (if applicable)

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Illustration 115	g03093498
(1) 6V-0267 Clip (2) 6V-0268 Clip (3) 301-7944 Hose As (4) 174-5907 Clip (5) 0S-1588 Bolt (6) 9X-6458 Hard Washer (7) 9S-8752 Full Nut (8) 2T-2305 Elbow (9) 6V-8397 O-Ring Seal (10) 3B-7764 Bushing (11) 5M-2894 Hard Washer (12) 9L-1480 Gasket

Note: Use Loctite 567 on all pipe thread joints.

1. Remove the metal particle detector gp. Set aside the following components for reuse.

   • Ball valve

   • Flange

   • Nipple reducer

   • Particle detector

   Note: Leave the flange, the nipple reducer, and the particle detector assembled.

2. Install the flange onto the oil pan use one gasket (12), two bolts (5), and two washers (11).

3. Install bushing (10) into the metal particle detector.

4. Install elbow (8) into bushing (10).

5. Attach hose (3) and one O-ring (9) to elbow (8).

6. Install one clip (1) and one clip (2) around the 7W-1929 Tube of the oil cooler.

7. Install one clip (4) around hose (3).

8. Attach clip (4) to clips (1) and (2) with one bolt (5), two washers (6), and one nut (7).
   Show/hide table

   Illustration 116	g03108058
   (3) 301-7944 Hose As (3) 4J-5477 O-Ring Seal (13) 8T-6758 Pipe Plug (14) 004-5933 Pipe Tee (15) 3B-7738 Fitting (16) 8C-6866 Connector (17) 4J-5477 O-Ring Seal

9. Install pipe tee (14) into the 7N-5413 Elbow.

10. Install pipe plug (13) into the rear port of pipe tee (14).

11. Install fitting (15) into the front port of pipe tee (14).

12. Install the original ball valve onto fitting (15). Refer to Illustration 116 for correct orientation.

13. Install connector (16) into the ball valve.

14. Attach hose (3) and one O-ring (17) to connector (16).

Installing the 417-4387 Fuel System Parts Kit (if applicable)

Note: Refer to 397-9423 Jacket Water Heater Mounting Gp for more information.

Illustration 117	g03122816
Typical right-side engine view. (1) 3B-6555 Elbow (2) 002-5743 Elbow (3) 196-9420 Ball Valve (4) 122-3201 Pipe Nipple (5) 4B-9030 Elbow (6) 8C-6875 Connector (7) 5K-9090 O-Ring Seal (8) 397-9422 Hose As (9) 9R-2860 Spacer (10) 184-7211 Clip (11) 1H-5514 Bolt (12) 9M-1974 Hard Washer (13) 5S-0003 Nut

Note: Use Loctite 567 on all pipe thread joints.

1. Remove the pipe plug from the rear hole of the 4B-7770 Tee from the 397-9400 Water Lines Gp.

2. Install elbow (2) into the rear hole of the tee facing away from the engine.

3. Install elbow (1) into elbow (2).

4. Install ball valve (3) into elbow (1).

5. Install pipe nipple (4) into ball valve (3).

6. Install elbow (5) onto pipe nipple (4).

7. Install connector (6) into elbow (5).

8. Attach hose (8) and one O-ring (7) to connector (6).

9. Install one clip (10) around hose (8).

10. Attach clip (10) to the genset base use one bolt (11), two washers (12), one spacer (9), and one nut (13).

    Note: Spacer (9) goes under clip (10).

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    Illustration 118	g03122817
    Typical left-side engine view. (6) 8C-6875 Connector (7) 5K-9090 O-Ring Seal (8) 397-9422 Hose As (9) 9R-2860 Spacer (10) 184-7211 Clip (11) 1H-5514 Bolt (12) 9M-1974 Hard Washer (13) 5S-0003 Nut (14) 0S-1585 Bolt (15) 7D-1649 Hard Washer (16) 1F-7958 Full Nut

11. Install the 375-2566 Jacket Water Heater Gp or the 375-4745 Jacket Water Heater Gp onto the genset base. Use two bolts (14), eight washers (15), and two nuts (16).

12. Install connector (6) into the rear port of the jacket water heater.

13. Attach hose (8) and one O-ring (7) to connector (6).

14. Install one clip (10) around hose (8).

15. Attach clip (10) to the genset base use one bolt (11), two washers (12), one spacer (9), and one nut (13).

    Note: Spacer (9) goes under clip (10).

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    Illustration 119	g03122821
    Typical left-side engine view. (3) 196-9420 Ball Valve (6) 8C-6875 Connector (7) 5K-9090 O-Ring Seal (17) 397-9421 Hose As (18) 1L-4031 Service Tee (19) 8T-6762 Pipe Plug (20) 118-1656 Reducer Bushing

16. Remove the pipe plug from the front left 7N-3298 Block Cover.

17. Install pipe tee (18) into the front left 7N-3298 Block Cover.

18. Install ball valve (3) into the center hole of pipe tee (18).

19. Install reducer bushing (20) into the end hole of pipe tee (18).

20. Install pipe plug (19) into reducer bushing (20).

21. Install connector (6) into ball valve (3).

22. Install connector (6) into the top port of the jacket water heater.

23. Attach hose (17) and one O-ring (7) per connector to connectors (6).

Installing the 417-4388 Fuel System Parts Kit (if applicable)

Note: Refer to 391-3077 Air Starting Lines Gp for more information.

Illustration 120	g03119137

Note: Use Loctite 567 on all pipe thread joints.

1. Remove the air starter from the engine. The air starter weighs approximately 44 kg (97 lb).

2. Remove the air hose from the relay valve and the starter.

3. Remove the 7W-9269 Air Starting Lines Gp. Set the following components aside for reuse:

   • Air hose

   • Lubricator
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   Illustration 121	g03114920
   (1) 5B-7666 Elbow (2) 5B-7642 Pipe Nipple

4. Install pipe nipple (2) into elbow (1).

5. Install elbow (1) into the lubricator.
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   Illustration 122	g03114921
   (3) 8S-9089 Bolt (4) 7D-1649 Hard Washer (5) 9R-7882 Spacer (6) 391-3076 Bracket As

6. Attach bracket assembly (6) to the air starter use four bolts (3), four washers (4), and four spacers (5).

7. Attach the preassembled parts to the 8N-8446 Elbow of the air starter.
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   Illustration 123	g03119379
   (2) 5B-7666 Elbow (7) 105-0428 Pipe Nipple (8) 4N-3411 Relay Valve Gp

8. Install pipe nipple (7) into elbow (2).

9. Install pipe nipple (7) into relay valve (8) on the side marked with the raised letters out.

10. Install elbow (2) into the relay valve with open port facing down.
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    Illustration 124	g03115077

11. Attach the preassembled parts to the lubricator.
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    Illustration 125	g03115079
    (9) 152-0199 Adapter (10) 6V-8397 O-Ring Seal (11) 2T-2305 Elbow (12) 5L-2534 U-Bolt (13) 9X-6458 Hard Washer (14) 9S-8752 Full Nut

12. Secure pipe nipple (7) to bracket assembly (6) use u-bolt (12), two washers (13), and two nuts (14).

13. Install adapter (9) into the port on the air starter.

14. Attach the air hose and one O-ring (10) to adapter (9).

15. Install elbow (11) into relay valve (8).

16. Attach the air hose and one O-ring (10) to relay valve (8).

17. Install the air starter back onto the engine. The air starter weighs approximately 44 kg (97 lb).

Installing the 417-4389 Fuel System Parts Kit (if applicable)

Note: Refer to 416-5386 Air Starting Lines Gp for more information.

Illustration 126	g03118682

Note: Use Loctite 567 on all pipe thread joints.

1. Remove the air starter from the engine. The air starter weighs approximately 44 kg (97 lb).

2. Remove the air hose from the relay valve.

3. Remove the 8N-8481 Air Starting Lines Gp. Set the following components aside for reuse:

   • Lubricator

   • Relay valve
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   Illustration 127	g03118136
   (1) 6B-3685 Elbow (2) 5B-7643 Pipe Nipple (3) 3L-1258 Pipe Nipple

4. Install elbow (1) onto pipe nipple (3).

5. Install pipe nipple (2) into elbow (1).

6. Install the lubricator onto pipe nipple (2).
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   Illustration 128	g03118139

7. Attach the preassembled parts to the 8N-8446 Elbow of the air starter.
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   Illustration 129	g03118140
   (1) 6B-3685 Elbow (3) 3L-1258 Pipe Nipple (4) 2L-2811 Fitting (5) 5B-7666 Elbow

8. Install pipe nipple (3) into elbow (5).

9. Install pipe nipple (3) into the relay valve on the side marked with the raised letters out.

10. Install fitting (4) into the relay valve.

11. Install elbow (1) onto fitting (4) with the open port facing down.
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    Illustration 130	g03118156

12. Install the preassembled parts into the lubricator.
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    Illustration 131	g03118158
    (6) 3J-7355 Flared Union (7) 6K-1972 Flared Elbow (8) 6F-5985 Hose As

13. Secure fitting (4) to bracket with the original hardware.

14. Install hose assembly (8) into elbow (1).

15. Install flared elbow (7) into the relay valve.

16. Attach the air hose to flared elbow (7).

17. Attach flared union (6) to the air hose.

18. Install the air starter back onto the engine. The air starter weighs approximately 44 kg (97 lb).

19. Attach flared union (6) to the customer air supply.

Installing the 382-1791 Instrument Panel Box Gp

Illustration 132	g03049257
(1) 382-1791 Instrument Panel Box Gp

Note: The installation of box (1) is customer and site specific and the long 386-4897 Wiring Harness and 386-4904 Engine Harness As allow for the mounting location to be convenient for the operator. Box (1) is 788.8 mm (31 inch) long, 518 mm (20.4 inch) tall, 187.8 mm (7.4 inch) wide, and weighs 53 kg (118 lb). The box is typically mounted with the four shock mounts on the top and four shock mounts on the bottom.

Note: The stand holding the 382-1791 Instrument Panel Box Gp in Illustration 132 is not included in the kit.

Note: Refer to Special Instruction, REHS7328, "Installation Instructions for 3500 Dynamic Gas Blending - Electrical and Generator" for further control panel mounting instructions.

Installing the 386-4896 Panel Wiring Gp

Illustration 133	g03066158
(1) 7K-1181 Cable Strap (2) 132-5789 Clip (3) 386-4897 Wiring Harness

1. Attach wiring harness (3) to the 376-4787 Engine Wiring Gp.

2. Remove the left upper 0S-1594 Bolt and the 5M-2894 Hard Washer from the left 7N-4319 Cover.

3. Attach one clip (2) to the left 7N-4319 Cover use the 0S-1594 Bolt and the 5M-2894 Hard Washer.

4. Attach wiring harness (3) to clip (2) use cable strap (1).

5. Attach wiring harness (3) to the 376-4787 Engine Wiring Gp use cable straps (1).
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   Illustration 134	g03066096
   (3) 386-4897 Wiring Harness

   Note: The stand holding the 382-1791 Instrument Panel Box Gp in Illustration 134 is not included in the kit.

6. Attach wiring harness (3) to the bottom front port of the 382-1791 Instrument Panel Box Gp.

7. Attach wiring harness (3) to the 339-2947 Electrical Conduit Gp use 14 cable straps (1).

8. Strap excess wiring harness (3) together with cable straps (1)

Installing the 386-4904 Engine Harness As

Illustration 135	g03066118
(1) 386-4904 Engine Harness As

Note: The stand holding the 382-1791 Instrument Panel Box Gp in Illustration 135 is not included in the kit.

Note: Wiring harness (1) attaches the 382-1791 Instrument Panel Box Gp and the genset. Refer to Special Instruction, REHS7328, "Installation Instructions for 3500 Dynamic Gas Blending - Electrical and Generator".

Installing the Precleaners (if applicable)

Installing the 416-7819 Precleaner Gp on the 3512C

Illustration 136	g03360627
Typical left-hand side air cleaner and precleaner. (1) 5P-4869 Hose Clamp (2) 1A-2029 Bolt (3) 5M-2894 Hard Washer (4) 5N-7919 Spacer (5) 9X-8892 Bolt (6) 5P-8247 Hard Washer (7) 8G-2077 Spacer (8) 2H-3745 Bolt (9) 5P-8250 Washer

1. Attach the 308-7312 Bracket As to the left-hand side precleaner to use six spacers (4), six bolts (5), and six washers (6).

2. Attach the 398-3609 Bracket As to the right-hand side precleaner to use six spacers (4), six bolts (5), and six washers (6).

3. Using a suitable lifting device, install the air cleaner and the precleaner assemblies. The air cleaner and the precleaner assemblies weigh approximately 95 kg (209 lb) per side.

4. Attach the air cleaners to the 277-2265 Support As with three bolts (2) and three washers (3) per air cleaner.

5. Attach the left-hand air cleaner to the 388-8893 Bracket As with two bolts (2) and two washers (3).

6. Attach the right-hand air cleaner to the 388-8895 Bracket As with three bolts (2) and three washers (3).

7. Attach the 308-7312 Bracket As to the lower left side of the flywheel housing. Use three spacers (7), three bolts (8), and three washers (9).

8. Attach the 398-3609 Bracket As to the lower right side of the flywheel housing. Use three spacers (7), three bolts (8), and three washers (9).

9. Fasten the 8N-5254 Reducer Hoses to the air cleaners use on hose clamp (1) per reducer hose.

Installing the 417-3287 Precleaner Gp on the 3512B

Illustration 137	g03366385
Typical left-hand side air cleaner and precleaner. (1) 1A-2029 Bolt (2) 5M-2894 Hard Washer (3) 5P-4869 Hose Clamp (4) 5N-7919 Spacer (5) 9X-8892 Bolt (6) 5P-8247 Hard Washer (7) 353-0248 Plate (8) 2H-3745 Bolt (9) 5P-8250 Washer

Note: Washers are installed on both sides of all the brackets

1. Attach the 310-3632 Bracket As to the left-hand side precleaner to use six spacers (4), six bolts (5), and six washers (6).

2. Attach the 398-3609 Bracket As to the right-hand side precleaner to use six spacers (4), six bolts (5), and six washers (6).

3. Using a suitable lifting device, install the air cleaner and the precleaner assemblies. The air cleaner and the precleaner assemblies weigh approximately 95 kg (209 lb) per side.

4. Attach the air cleaners to the 5N-7906 Support As with three bolts (2) and three washers (3) per air cleaner.

5. Attach the left-hand air cleaner to the 389-0848 Bracket As with two bolts (2) and two washers (3).

6. Attach the right-hand air cleaner to the 389-0845 Bracket As with three bolts (2) and three washers (3).

7. Attach the 310-3632 Bracket As to the lower left side of the flywheel housing. Use three spacers (7), three bolts (8), and three washers (9).

8. Attach the 398-3609 Bracket As to the lower right side of the flywheel housing. Use three spacers (7), three bolts (8), and three washers (9).

9. Fasten the 8N-5254 Reducer Hoses to the air cleaners use on hose clamp (1) per reducer hose.

Installing the 418-1393 Catalytic Converter Gp (if applicable)

Illustration 138	g03341963
Typical end view of the catalyst.

Illustration 139	g03011317
Typical side view of the 418-1393 Catalytic Converter Gp

Illustration 140	g03343683

1. Install the catalyst as close to the engine out exhaust elbow as possible. The catalyst weighs approximately 113 kg (250 lb).

   Note: Support the catalyst by the bottom of the catalyst bricks only. Do not support the weight of the catalyst by the flanges.

   Note: Refer to Application and Installation Guide, LEBW0018, "Dynamic Gas Blending" for the installation procedure of the catalyst.

Software Flash Instructions

Two software files need downloaded and installed by the dealer prior to beginning operation with Dynamic Gas Blending kits.

1. Download the 433-6418 Engine Ratings Electronic Software Gp free from the Service Information System (SIS).

   Note: All 3500 DGB engine ratings use the same Integrated Sensing Module (ISM) software.

2. Install the 433-6418 Engine Software on a blank ISM (A3).

3. Download one of the following engine Electronic Control Module (ECM) software free from the SIS:

   • The 491-2170 Engine Software (3512C NA ECM) is for use in North America.

   • The 491-2171 Engine Software (3512C ROW ECM) is for use outside the US.

   • The 486-0466 Engine Software (3512B US 49 States excluding California)

4. Install the correct software onto a blank ECM (A4).

   After the software is installed, it will be possible to run the engine as a diesel engine, but gas blending will not be available or functional.

Installing the Injector Trim Codes and Setting the FLS/FTS

Illustration 141	g03285604

1. Connect Cat ET to the ECM

2. Click on the "Service" tab.

3. Select "Calibrations".
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   Illustration 142	g03286182

4. Click on "Injector Codes Calibration".
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   Illustration 143	g03286196

5. Select the "Injector".
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   Illustration 144	g03286198

6. Enter the correct Injector Code that was previously saved.

7. Click the "Change" button.

8. Click the "OK" button.
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   Illustration 145	g03286199

9. Click the "Yes" button.

10. Continue the previous procedures until all Injector Trim Codes are calibrated to match the values saved from the original ECM.

11. Set both the FLS/FTS to zero. Refer to the engine information label.

Setting the Air Shutoffs Configuration and Calibration of the Engine Timing

Setting the Air Shutoffs Configuration

Illustration 146	g03357967
Default air shutoff not installed

Illustration 147	g03357984
Air shutoffs installed

1. Enable the air shutoffs.

Calibration of the Engine Timing

Note: The engine has to be out of "Cold Mode" and the "Direct Fuel Control Mode" disabled in order to calibrate the speed timing.

Illustration 148	g03286158

1. Click on the "Service" tab.

2. Select "Calibrations".
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   Illustration 149	g03286176

3. Click on "Timing Calibration".
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   Illustration 150	g03286178

4. Follow the Prompts.

5. Click the "Continue" button.

Software Enabled Attachments (SEA)

Illustration 151	g03342855
SEA not installed

Note: There is a significant charge for enabling the 428-6165 Premium Configuration feature. The charge will be billed to the license holder of the Cat ET performing the switch.

Note: The Gas Substitution SEA can only be enabled when the Direct Fuel Control Mode is set to Disabled. The Direct Fuel Control Mode can be re-enabled after the Gas Substitution SEA is installed.

Illustration 152	g03342857
SEA installed

1. Refer to Information Release Memo, PELJ0138, "Electronics & Electrical Systems" and Information Release Memo, PELJ1357, "Cat Electronics" for more information.

2. Disconnect CAT ET from the ECM

Installing the 430-5919 Film, 444-0554 Film, or the 485-3498 Film

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Illustration 153	g03813856
Typical 419-0774 Film (3512C NA)

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Illustration 154	g03860029
Typical 485-3492 Film (3512B US 49 States excluding California)

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Illustration 155	g03814974
Typical 443-5866 Film (Non-Emission Certified Engines)

1. Write in the correct information on the 419-0774 Film if applicable.

   Note: Caterpillar provides warranty for the alternative fuel conversion system of your kit for regulatory terms of 5 years/3000 hours, whichever comes first, in the U.S. and 12 months Caterpillar New Parts terms for rest of world provided there has been no abuse, neglect or improper maintenance of the kit or your engine.

2. Clean off the valve cover next to the valve cover with the engine certification film.

   Note: Do not obstruct the view of any other film.

3. Attach one of the following films to the valve cover.

   • 419-0774 Film (3512C NA)

   • 443-5866 Film (3512B and 3512C Non-Emission Certified Engines)

   • 485-3492 Film (3512B US 49 States excluding California)

4. Attach the 444-0543 Film to the valve cover on top of the previous film.

   Note: The 444-0543 Film is a protective film for the 449-0090 Film or the 443-5866 Film.

Startup Checklist

The following retrofit checklist is used before the dynamic gas blending is activated.

Table 36

Step	Description	Complete/Measured Values	Dealer sign-off	Customer sign-off
1	Confirm the air filter covers are removed.
2	Power on engine, check for any fault codes.
3	Check customer Input / Output connections, proper operation (direct rack, secondary gas shutoff valve).
4	Diesel-only startup, ensure proper engine/generator function.
5	Check voltage / current for each phase.
6	Check for leaks (cooling, lube, manifold area, exhaust).
7	Operate engine through as much load range as possible.
8	Confirm no excessive exhaust restriction (including catalyst).
9	Pull a Product Status Report.
10	Measure exhaust Diesel Oxidation Catalyst inlet temperature.
11	Check all temperatures.
12	Check all pressures.
13	Confirm E-stop works.
14	Supply gas system checks.
-	Clean, dry gas per Application and Installation Guide, LEBW4977, "Gaseous Fuels".
-	<10 ppm H2S present in gas (<50 ppm with a stainless steel aftercooler).
-	Gas pressure is (12 to 35 psig).
-	Meets required gas flow (per web calculator tool).
15	Regulator pressure is set properly (engine loaded and running) per procedure. Refer to Testing and Adjusting, "Fuel Pressure (Gas System)".
16	Check gas system for leaks.
17	Confirm Software Enabled Attachment works, blending enabled.
18	Enable Dynamic Gas Blending mode.
19	Set desired substitution percentage and check for fault codes (pressure within range, gas valves performance, etc.).
20	Inspect supply gas equipment for proper operation while gas is flowing.
21	Operate engine through as much load range as possible.
22	Monitor all pressure and temperatures.
23	Check engine operation during load steps; tune the engine governor accordingly (ECM or direct rack controller).
24	Operate engine paralleled with other DGB equipped engines with DGB enabled.
25	Check engine operation during load steps; tune the genset controller accordingly (EMCP or other controller).

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.

1. When performing a retrofit installation, record the vital information in Table 37.

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

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   Table 37

   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.
   (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 37 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".