Retrofitting for the Dynamic Gas Blending Capability on Certain 3516B Engines{1000, 1250} Caterpillar

Electric Power Generation:

3516B (S/N: ZAP1-UP)

Engine:

3516B (S/N: YAP1-UP; YAT1-UP; YBT1-UP; DD31-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 3516B Diesel Engine. 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

372-6100 Turbocharger Air Lines Gp
Qty	Part
64	1T-0720 Bolt
32	2A-4639 Bolt
16	4S-5898 O-Ring Seal
96	5M-2894 Hard Washer
16	6V-5101 O-Ring Seal
16	7C-8199 Flange
32	153-8455 Manifold Gasket
14	370-7335 Air Inlet Elbow
2	370-7336 Air Inlet Elbow
16	371-5211 Flame Arrestor As

Table 2

373-1527 Electronic Control and Mounting Gp
Qty	Part
4	0T-0065 Bolt
4	1B-9575 Bolt
4	6I-1418 Spacer
8	8T-9655 Isolation Mount
1	9M-1974 Hard Washer
4	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 Gp
1	417-6011 Electronic Control Module

Table 3

375-2566 Jacket Water Heater Gp
Qty	Part
1	375-2566 Jacket Water Heater Gp

Table 4

375-4745 Jacket Water Heater Gp
Qty	Part
1	375-4745 Jacket Water Heater Gp

Table 5

376-4787 Engine Wiring Gp
Qty	Part
4	0S-1594 Bolt
16	1A-2029 Bolt
2	3A-3692 Clip
32	4P-7581 Clip
28	4P-8134 Clip
22	5M-2894 Hard Washer
16	5N-2126 Connector
1	6V-1582 Clip
2	6V-9028 O-Ring Seal
100	7K-1181 Cable Strap
1	9X-0262 Adapter
8	195-2431 Detonation Sensor Gp
7	214-7566 O-Ring Seal
2	214-7568 O-Ring Seal
8	228-7100 O-Ring Seal
2	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	376-4892 Engine Wiring Gp
16	383-2990 Temperature Sensor Gp
2	415-2432 Temperature Sensor Gp

Table 6

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

Table 7

379-5145 Temperature Regulator Gp
Qty	Part
1	0S-1585 Bolt
2	0S-1591 Bolt
2	1F-7958 Full Nut
2	4W-0530 Retaining Ring
5	7D-1649 Hard Washer
2	8T-1919 O-Ring Seal
2	9S-8752 Full Nut
4	9X-6458 Hard Washer
2	9X-8873 Bolt
1	125-2780 Tube
1	379-5142 Bracket
1	379-5144 Tube
1	386-3398 Bracket
1	390-4498 Tube

Table 8

381-5733 Air Cleaner Mounting
Qty	Part
2	0S-1571 Bolt
14	0S-1588 Bolt
4	0S-1591 Bolt
11	0S-1595 Bolt
4	0T-0055 Bolt
4	2A-4639 Bolt
4	2B-2695 Bolt
12	5M-2894 Hard Washer
8	5P-1075 Hard Washer
4	5S-0003 Nut
11	7D-1649 Hard Washer
4	7M-1599 Taperlock Stud
2	7N-6986 Support
4	9M-1974 Hard Washer
10	9S-8752 Full Nut
22	9X-6458 Hard Washer
1	381-1062 Tube As
1	381-1063 Tube As
2	386-3396 Bracket
1	388-2132 Bracket
1	388-2133 Bracket

Table 9

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

Table 10

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

Table 11

390-2914 Cylinder Block Cover Gp
Qty	Part
40	1A-2029 Bolt
8	1C-2251 Bolt
8	5L-5840 Washer
48	5M-2894 Hard Washer
8	277-5833 Seal
4	349-6052 Camshaft Cover
4	374-1513 Camshaft Cover

Table 12

391-3977 Fuel Lines Gp
Qty	Part
2	0S-1591 Bolt
1	0S-1594 Bolt
4	2A-4639 Bolt
2	3B-1915 Bolt
12	5M-2894 Hard Washer
2	6V-1581 Clip
2	6V-1582 Clip
2	6V-4368 O-Ring Seal
8	9S-8752 Full Nut
5	9X-6458 Hard Washer
1	105-8180 Gasket
2	255-6464 Joint
1	391-2202 Bracket
1	391-2203 Bracket
1	398-7717 Tube As
2	399-3105 Tube As

Table 13

391-3080 Precleaner Gp
Qty	Parts
8	0S-1591 Bolt
12	0S-1592 Bolt
2	1A-1460 Bolt
2	1F-7958 Full Nut
4	2H-3743 Bolt
12	2S-7593 Hard Washer
4	5P-8250 Washer
4	7D-1649 Hard Washer
8	9X-6458 Hard Washer
1	382-5499 Support Bracket As
1	382-5500 Support Bracket As
2	386-3397 Bracket

Table 14

397-8633 Gas Pressure Regulator Gp (Pipe Thread Design) (if applicable)
Qty	Part
10	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
8	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 15

397-9380 Water Lines Gp
Qty	Part
1	0S-1571 Bolt
4	0S-1588 Bolt
3	0S-1594 Bolt
1	3B-6498 Elbow
1	3B-7749 Pipe Nipple
1	4B-7770 Tee
2	4F-7391 O-Ring Seal
4	4J-5477 O-Ring Seal
4	4L-6454 Bolt
11	5M-2894 Hard Washer
5	5P-9297 Clip
1	6B-1628 Reducing Bushing
3	6V-0267 Clip
3	6V-0268 Clip
3	6V-3265 Clip
3	8C-6866 Connector
1	8C-6867 Connector
4	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	397-9377 Bracket
1	397-9378 Hose As
1	397-9379 Hose As

Table 16

399-3107 Fuel Mixer Gp
Qty	Parts
2	6V-4368 O-Ring Seal
2	381-3558 Tube As

Table 17

416-4348 Fuel System Parts Kit
Qty	Parts
8	5P-4869 Hose Clamp
4	8N-8741 Hose
2	113-1328 Tube

Table 18

416-4349 Fuel System Parts Kit
Qty	Parts
8	3B-1915 Bolt
2	5P-0600 Hose Clamp
2	7E-8224 Reducer Hose
4	388-2134 Bracket

Table 19

417-4386 Fuel System Parts Kit
Qty	Part
3	1A-1460 Bolt
2	1B-2790 Bolt
2	1F-7958 Full Nut
1	1L-4031 Service Tee
1	4B-9030 Elbow
4	5K-9090 O-Ring Seal
1	5P-8245 Hard Washer
2	5S-0003 Nut
1	7D-4092 Clip
4	7D-1649 Hard Washer
1	7E-5639 Spacer
2	7G-1239 Spacer
4	8C-6875 Connector
1	8T-6762 Pipe Plug
4	9M-1974 Hard Washer
1	006-5707 Pipe Elbow
1	118-1656 Reducer Bushing
1	122-3201 Pipe Nipple
2	184-7211 Clip
2	196-9420 Ball Valve
1	307-8764 Hose As
1	307-9372 Hose As

Table 20

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

Table 21

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 22

444-0554 Film (Non-Emission Certified Engines)
Qty	Part
1	443-5866 Film
1	444-0543 Film

Table 23

Package Components
Qty	Part
1	267-9689 Filter Housing Cover
3	361-7019 Transformer
1	382-1791 Instrument Panel Box Gp
1	434-3073 Transformer Mounting

Table 24

Software
Qty	Part
1	433-6418 Engine Ratings Electronic Software Gp (ISM)
1	440-0165 Engine Ratings Electronic Software Gp (ECM)

Table 25

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 26

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).

   Note: The Product Status Report is for reference only.

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Illustration 1	g03285257

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

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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 Product Status 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".

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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.

Installing the 371-5211 Flame Arrestor As

Illustration 10	g02960536

Illustration 11	g03551679
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 inlet covers

   • Aftercooler assembly

   • Clamps

   • Compressor pipes

   • Inlet air pipe supports

   • Rubber hoses

   • Shields

2. Remove the wiring harnesses that attach the control panel to the engine.

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

4. Using a suitable lifting device, remove the air cleaners and the small air inlet pipes if applicable. The air cleaners and the air inlet pipes weigh approximately 49 kg (107 lb) per side.

5. Using a suitable lifting device, remove the air cleaners and the air shutoffs if applicable. The air cleaners and the air shutoffs weigh approximately 56 kg (123 lb) per side.

6. Using a suitable lifting device, remove the air precleaners. The air precleaners weigh approximately 40 kg (88 lb) apiece.

7. Remove the air cleaner and the precleaner mounting brackets.

8. Remove the air inlet pipes.

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Illustration 12	g03032057

9. Remove the compressor pipes and the air inlet elbows from the aftercooler and the turbochargers.

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Illustration 13	g03032223

10. Disconnect the water lines from each end of the aftercooler cores.

11. Disconnect the vent line from the front aftercooler core.

12. Disconnect the elbow flanges from the air inlet manifold. Pry the elbow flanges away from the air inlet manifold.

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Illustration 14	g03028581

13. Using a suitable lifting device, remove the aftercooler assembly. The aftercooler assembly weighs approximately 225 kg (496 lb).

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Illustration 15	g03028583
(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

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

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

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

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

17. 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 the flange (2) lightly with glycerin to hold the O-ring in place.

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

19. 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.

20. Remove the pipe plug from the exhaust outlet port of each cylinder head.

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Illustration 16	g03091418
The following parts are from the 376-4787 Engine Wiring Gp . (11) 5N-2126 Connector (12) 383-2990 Temperature Sensor Gp

Note: The following steps will use parts from the 376-4892 Engine Wiring Gp .

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

22. 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 17	g03272297
(13) 238-5080 O-Ring Seal (14) 256-6453 Temperature Sensor

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

24. 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 18	g03272438
(13) 238-5080 O-Ring Seal (14) 256-6453 Temperature Sensor (15) 353-5440 Adapter

25. Remove the air inlet manifold temperature sensor from the 283-9779 Manifold .

26. Install adapter (15) into the 283-9779 Manifold .

    Note: Use Loctite 567 on all pipe thread joints.

27. Install temperature sensor (14) and one O-ring (13) into adapter (15) .

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

28. Using a suitable lifting device, install the aftercooler assembly. The aftercooler assembly weighs approximately 225 kg (496 lb).

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

30. Attach the water lines to each end of the aftercooler cores.

31. Attach the vent line to the front aftercooler core.

32. Attach the compressor pipes and the air inlet elbows to the aftercooler and the turbochargers.

Installing the 390-2914 Cylinder Block Cover Gp

Illustration 19	g03052179
(1) 1C-2251 Bolt (2) 5M-2894 Hard Washer (3) 374-1513 Camshaft Cover (4) 5L-5840 Washer (5) 1A-2029 Bolt (6) 277-5833 Seal (7) 349-6052 Camshaft Cover

Note: Washer (4) is installed under washer (2) on bolt (1) .

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Illustration 20	g03052176
Typical right-side engine view (3) 374-1513 Camshaft Cover (7) 349-6052 Camshaft Cover

1. Install seal (6) into camshaft covers (3) and (7) .

2. Remove the 8N-9992 Camshaft Covers from cylinders 7 and 15.

3. Remove the 7N-5094 Drain Elbows from the 8N-9993 Camshaft Covers .

4. Remove the 8N-9993 Camshaft Covers from cylinders 3 and 11.

5. Remove the 8N-9993 Camshaft Cover with the crankcase pressure sensor from cylinder 4.

6. Install the 8N-9993 Camshaft Cover with the crankcase pressure sensor onto cylinder 1 or 5. Use one bolt (1), five bolts (5), one washer (4), and six washers (2) .

   Note: Leave the crankcase pressure sensor on cylinder 5 if already there.

7. Install the 8N-9992 Camshaft Cover onto cylinder 4 use one bolt (1), five bolts (5), one washer (4), and six washers (2) .

8. Install camshaft cover (3) onto cylinders 3 and 11 use one bolt (1), five bolts (5), one washer (4), and six washers (2) per cover.

9. Install camshaft cover (7) onto cylinders 7 and 15 use one bolt (1), five bolts (5), one washer (4), and six washers (2) per cover.

10. Attach the 7N-5094 Drain Elbows to camshaft cover (3) with the original gasket and hardware.

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Illustration 21	g03052196
Typical left-side engine view (3) 374-1513 Camshaft Cover (7) 349-6052 Camshaft Cover

11. Remove the 8N-9992 Camshaft Covers from cylinders 2 and 10.

12. Remove the 7N-5094 Drain Elbows from the 8N-9993 Camshaft Covers .

13. Remove the 8N-9993 Camshaft Covers from cylinders 6 and 14.

14. Install camshaft cover (3) onto cylinders 6 and 14 use one bolt (1), five bolts (5), one washer (4), and six washers (2) per cover.

15. Install camshaft cover (7) onto cylinders 2 and 10 use one bolt (1), five bolts (5), one washer (4), and six washers (2) per cover.

16. Attach the 7N-5094 Drain Elbows to camshaft cover (3) with the original gasket and hardware.

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

Illustration 22	g03046900
(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 original 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 376-4787 Engine Wiring Gp

Illustration 23	g03069861
(1) 376-4892 Engine Wiring Gp (2) 7K-1181 Cable Strap

Illustration 24	g03069937
(1) 376-4892 Engine Wiring Gp (2) 7K-1181 Cable Strap

Illustration 25	g03069940
(1) 376-4892 Engine Wiring Gp (2) 7K-1181 Cable Strap (3) 1A-2029 Bolt (4) 5M-2894 Hard Washer

1. Remove the cable straps and the engine wiring harness from the engine.

   Note: Leave the original mounting hardware on the engine.

2. Attach engine wiring harness (1) to the original clips. Use one cable strap (2) per clip.

3. Remove the 0S-1594 Bolts and the 5M-2894 Hard Washers from the flat side of the 7N-4319 Cover . Refer to Illustration 25.

4. Attach engine wiring harness (1), the bracket on the interface harness connector, to the 7N-4319 Cover with two bolts (3) and two washers (4) .

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Illustration 26	g03204777
(1) 376-4892 Engine Wiring Gp (2) 7K-1181 Cable Strap (5) 273-5041 Speed Sensor Gp

5. Attach engine wiring harness (1) to the original the speed sensor (5) .

6. Secure engine wiring harness (1) to the original clip use one cable strap (2) .

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Illustration 27	g03102486
(1) 376-4892 Engine Wiring Gp (6) 318-1181 Speed Sensor Gp

7. Remove the speed sensor from the top of the flywheel housing.

8. Install speed sensor (6) 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 28	g03050228
(1) 376-4892 Engine Wiring Gp (7) 320-3060 Pressure Sensor (8) 228-7100 O-Ring Seal (9) 256-6453 Temperature Sensor (10) 238-5080 O-Ring Seal (11) 353-5441 Elbow Adapter (12) 214-7566 O-Ring Seal (13) 330-9739 Adapter (14) 320-3061 Pressure Sensor (15) 228-7101 O-Ring Seal (16) 353-5439 Connector (17) 320-3063 Pressure Sensor

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Illustration 29	g03281718
(1) 376-4892 Engine Wiring Gp (7) 320-3060 Pressure Sensor (8) 228-7100 O-Ring Seal (9) 256-6453 Temperature Sensor (10) 238-5080 O-Ring Seal (11) 353-5441 Elbow Adapter (12) 214-7566 O-Ring Seal (13) 330-9739 Adapter (14) 320-3061 Pressure Sensor (15) 228-7101 O-Ring Seal (16) 353-5439 Connector (17) 320-3063 Pressure Sensor (18) 415-7979 Sensor Harness As

Note: Use sensor harness (18) with left-hand side fuel service engines to connect engine harness (1) to the fuel and the oil sensors.

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

10. Install elbow (11) and one O-ring (12) into the unfiltered port (filter inlet) of the 112-4921 Engine Oil Filter Gp .

11. Install pressure sensor (7) and one O-ring (8) into elbow (11) .

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

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

13. Install temperature sensor (9) and one O-ring (10) into the 208-0822 Water Lines Gp .

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

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

15. Install adapter (13) and one O-ring (12) into the inside port of the 111-0349 Module Bracket .

16. Install pressure sensor (14) and one O-ring (15) into adapter (13) .

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

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

18. Install connector (16) and one O-ring (12) into the outside port of the 111-0349 Module Bracket .

19. Install pressure sensor (17) and one O-ring (8) into connector (16) .

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

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Illustration 30	g03050229
(1) 376-4892 Engine Wiring Gp (2) 7K-1181 Cable Strap (7) 320-3060 Pressure Sensor (8) 228-7100 O-Ring Seal (11) 353-5441 Elbow Adapter (12) 214-7566 O-Ring Seal

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Illustration 31	g03281722
(2) 7K-1181 Cable Strap (7) 320-3060 Pressure Sensor (8) 228-7100 O-Ring Seal (11) 353-5441 Elbow Adapter (12) 214-7566 O-Ring Seal (18) 415-7979 Sensor Harness As

Note: Use sensor harness (18) with left-hand side fuel service engines to connect engine harness (1) to the fuel and the oil sensors.

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

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

22. Install elbow adapters (11) and one O-ring (12) per elbow into the 267-9689 Filter Housing Cover .

23. Install pressure sensor (7) and one O-ring (8) per sensor into each elbow adapter (11) .

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

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

25. Install elbow (11) and one O-ring (12) into the filtered port (block inlet) of the 112-4921 Engine Oil Filter Gp .

26. Install pressure sensor (7) and one O-ring (8) into elbow adapter (11) .

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

27. Secure engine wiring harness (1) to the original clips use one cable strap (2) per clip.

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Illustration 32	g03050227
The exhaust temperature sensor is always on the left-hand side of the head. (1) 376-4892 Engine Wiring Gp (2) 7K-1181 Cable Strap (19) 383-2990 Temperature Sensor Gp (20) 4P-7581 Clip

28. Secure wiring harness (1) and temperature sensor (19) to clips (20). Use one cable strap (2) per clip.

29. Secure wiring harness (1) to the original clips. Use one cable strap (2) per clip.

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Illustration 33	g03055083
Typical right-side engine view (1) 376-4892 Engine Wiring Gp (2) 7K-1181 Cable Strap (3) 1A-2029 Bolt (4) 5M-2894 Hard Washer (20) 4P-7581 Clip (21) 195-2431 Detonation Sensor Gp

30. Attach one detonation sensor (21) to the engine under the camshaft covers on cylinders 3, 7, 11, and 15.

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

31. Attach one clip (20) to the camshaft covers on cylinders 1, 5, and 9 with one bolt (3) and one washer (4). Orient clip (20) on cylinders 1 and 9 with ladder facing up.

    Note: The wiring for the detonation sensor on cylinder 15 is mounted to the 373-1527 Electronic Control and Mounting Gp

32. Secure engine wiring harness (1) and detonation sensors (21) to clips (20) with one cable strap (2) per clip.

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Illustration 34	g03053920
Typical left-side engine view (1) 376-4892 Engine Wiring Gp (2) 7K-1181 Cable Strap (3) 1A-2029 Bolt (4) 5M-2894 Hard Washer (20) 4P-7581 Clip (21) 195-2431 Detonation Sensor Gp

33. Attach one detonation sensor (21) to the engine under the camshaft covers on cylinders 2, 6, 10, and 14.

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

34. Attach one clip (20) to the camshaft covers on cylinders 4, 8, 12, and 16. Use one bolt (3) and one washer (4) .

35. Secure engine wiring harness (1) and detonation sensors (21) to clips (20) with one cable strap (2) per clip.

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Illustration 35	g03053921
Typical right-side engine view (1) 376-4892 Engine Wiring Gp (2) 7K-1181 Cable Strap (4) 5M-2894 Hard Washer (22) 261-6847 Adapter (23) 415-2432 Temperature Sensor Gp (24) 3A-3692 Clip (25) 0S-1594 Bolt

36. Remove the pipe plug from the 111-1830 Exhaust Manifold

37. Install adapter (22) into the 111-1830 Exhaust Manifold .

38. Lubricate the exhaust temperature sensor gp (23) with Loctite Nickel Anti Seize.

39. Install exhaust temperature sensor (23) into adapter (22) .

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

40. Install one clip (24) around exhaust temperature sensor gp (23). Refer to Illustration 35 for the correct orientation of the clip.

41. Attach clip (24) to the cam cover on cylinder 13 with one bolt (25) and one washer (4) .

42. Secure exhaust temperature sensor gp (23) to the original clip on the valve cover base of cylinder 11 with one cable strap (2) .

43. Secure exhaust temperature sensor gp (23) to engine wiring harness (1) with cable straps (2) as needed.

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Illustration 36	g03053923
Typical left-side engine view (1) 376-4892 Engine Wiring Gp (2) 7K-1181 Cable Strap (4) 5M-2894 Hard Washer (22) 261-6847 Adapter (23) 415-2432 Temperature Sensor Gp (24) 3A-3692 Clip (25) 0S-1594 Bolt

44. Remove the pipe plug from the 111-1832 Exhaust Manifold

45. Install adapter (22) into the 111-1832 Exhaust Manifold .

46. Lubricate the exhaust temperature sensor gp (23) with Loctite Nickel Anti Seize.

47. Install exhaust temperature sensor gp (23) into adapter (22) .

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

48. Attach clip (24) to the camshaft cover on cylinder 12 with one bolt (25) and one washer (4) .

49. Secure exhaust temperature sensor gp (23) to the original clips with one cable strap (2) per clip.

50. Secure exhaust temperature sensor gp (23) to engine wiring harness (1) with cable straps (2) as needed.

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Illustration 37	g03055080
(1) 376-4892 Engine Wiring Gp (2) 7K-1181 Cable Strap (9) 256-6453 Temperature Sensor (10) 238-5080 O-Ring Seal (26) 353-5440 Adapter

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

Note: Use Loctite 567 on all pipe thread joints.

52. Install adapter (26) into the 359-4123 Adapter .

53. Install temperature sensor (9) and one O-ring (10) into adapter (26) .

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

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Illustration 38	g03062045
(8) 228-7100 O-Ring Seal (11) 353-5441 Elbow Adapter (12) 214-7566 O-Ring Seal (17) 320-3063 Pressure Sensor

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

54. Remove the adapter and the pressure sensor from the 117-0066 Mounting Bracket .

55. Install elbow (11) and one O-ring (12) into the 117-0066 Mounting Bracket .

56. Install pressure sensor (17) and one O-ring (8) into elbow (11) .

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

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Illustration 39	g03062046
(27) 305-6873 Pressure Sensor Gp (28) 9X-0262 Adapter (29) 6V-9028 O-Ring Seal

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Illustration 40	g03601140
(2) 7K-1181 Cable Strap (30) 4P-8134 Clip

57. 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 40 for the correct location.

58. Install two O-rings (29) onto adapter (28) .

59. Install adapter (28) into the 397-8631 Tube As .

60. Install pressure sensor (27) onto adapter (28) .

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

61. Secure the engine wiring harness to clip (4) with one cable strap (2) .

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Illustration 41	g03609997
Typical right-side engine view (8) 228-7100 O-Ring Seal (17) 320-3063 Pressure Sensor (31) 335-3999 Adapter (32) 214-7568 O-Ring Seal

62. Remove the adapter and the pressure sensor from the 6V-9330 Elbow of the air cleaner.

63. Install adapter (31) and one O-ring (32) into the 6V-9330 Elbow .

64. Install pressure sensor (17) and one O-ring (8) into adapter (30) .

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

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Illustration 42	g03609996
Typical left-side engine view (8) 228-7100 O-Ring Seal (17) 320-3063 Pressure Sensor (31) 335-3999 Adapter (32) 214-7568 O-Ring Seal

65. Remove the adapter and the pressure sensor from the 6V-9330 Elbow of the air cleaner.

66. Install adapter (31) and one O-ring (32) into the 6V-9330 Elbow .

67. Install pressure sensor (17) and one O-ring (8) into adapter (30) .

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

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Illustration 43	g03609978
(2) 7K-1181 Cable Strap (20) 4P-7581 Clip (30) 4P-8134 Clip (33) 294-3313 Clip

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

68. Attach one clip (32) to the 231-7070 Bracket with the original 0T-0065 Bolt and the 9X-6458 Hard Washer . Refer to the Illustration 43 for the correct location.

69. Attach two clips (20) to the 231-7070 Bracket with the original 0T-0065 Bolt and the 9X-6458 Hard Washer . Refer to the Illustration 43 for the correct location.

70. Attach one clip (30) to the 231-7070 Bracket with the original 1B-9575 Bolt . Refer to the Illustration 43 for the correct location.

71. Secure engine wiring harness (1) to clips (20), (30), and (33). Use one cable strap (2) per clip.

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Illustration 44	g03121296
(C) 7N-9738 Receptacle Housing (D) 238-8245 Connector Plug As

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

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

73. Strip back the insulation on the two wires.

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

75. 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 45	g02979126
(1) 417-6011 Electronic Control Module

Illustration 46	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 old engine electronic control from the 111-0349 Module Bracket .

   Note: The mounting hardware will be reused except the isolation mounts.

2. Install electronic control module (1) use four bolts (7), one washer (2), four washers (3), four spacers (5), four spacers (6), and eight isolation mounts (4) .

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

   Note: Steps 3 through 11 use parts from the 397-9380 Water Lines Gp .

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Illustration 47	g03352263
(8) 005-8615 Pipe Nipple (9) 1L-4031 Service Tee (10) 196-9420 Ball Valve (11) 6B-1628 Reducing Bushing (12) 8C-6867 Connector (13) 3B-6555 Elbow (14) 3B-7749 Pipe Nipple (15) 8T-6761 Pipe Plug

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

4. Install pipe nipple (8) into the 7N-4944 Elbow .

5. Install elbow (13) onto pipe nipple (8) .

6. Install pipe nipple (14) into elbow (13) .

7. Install service tee (9) onto pipe nipple (14) .

8. Install pipe plug (15) into center port of service tee (9) .

9. Install ball valve (10) into service tee (9) .

10. Install reducer bushing (11) into ball valve (10) .

11. Install connector (12) into reducer bushing (11) .

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Illustration 48	g03046656
(2) 9M-1974 Hard Washer (3) 9N-0869 Hard Washer (5) 6I-1418 Spacer (16) 353-8089 Electronic Control Module (17) 190-4885 Spacer (18) 231-7070 Bracket (19) 0T-0065 Bolt (20) 9X-6458 Hard Washer (21) 1B-9575 Bolt (22) 155-0576 Isolation Mount

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

12. Remove the rear cam cover bolts from cylinders 13 and 15.

Note: The 4P-7581 Clips , 4P-8134 Clip , and the 294-3313 Clip will be installed on this step. Refer to Steps 68 and 71 of the 376-4787 Engine Wiring Gp .

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

14. Attach electronic control module (16) to bracket (18) with 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 381-5733 Air Cleaner Mounting

Illustration 49	g03033137
(1) 381-1063 Tube As (2) 381-1062 Tube As

Note: The following steps use parts that were removed during the 371-5211 Flame Arrestor As installation.

1. Install tube assemblies (1) and (2) to turbochargers with the following original parts:
   • Two 162-2177 Hoses

   • Two 8N-5254 Reducer Hoses

   • Two 5P-4869 Hose Clamps

   • Six 5P-3860 Hose Clamps

   • Four 321-5895 Shield As

2. Attach tube assemblies (1) and (2) to the 191-6015 Brackets with the original hardware.

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Illustration 50	g03035043
(3) 7M-1599 Taperlock Stud (4) 9M-1974 Hard Washer (5) 5S-0003 Nut

3. Install two studs (3) per tube assembly into tube assemblies (1) and (2) .

   Note: For kits shipped after June 2014, the kits will utilize four 2B-2695 Bolts and four 9M-1974 Hard Washers for this procedure.

4. Install one nut (5) and one washer (4) per stud loosely onto studs (3). The nuts and washers will be used with the 381-3558 Tube As from the 391-3977 Fuel Lines Gp .

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Illustration 51	g03035053
Typical right-hand side view. (6) 0S-1588 Bolt (7) 9X-6458 Hard Washer (8) 386-3396 Bracket (9) 0S-1595 Bolt (10) 7D-1649 Hard Washer

5. Attach bracket (8) on top of the right side flywheel housing with six bolts (9) and six washers (10) .

   Note: The bolts (6) and the washers (7) will be used during installation of air cleaner.

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Illustration 52	g03035047
Typical right-hand side view. (7) 9X-6458 Hard Washer (8) 386-3396 Bracket (11) 2A-4639 Bolt (12) 9S-8752 Full Nut (13) 388-2133 Bracket (14) 0T-0055 Bolt (15) 0S-1591 Bolt (16) 5M-2894 Hard Washer (17) 0S-1571 Bolt (18) 7N-6986 Support

6. Remove the bottom two bolts on the valve cover base of cylinder 15.

7. Install bracket (18) onto the valve cover base with two bolts (14) .

8. Attach bracket (13) to bracket (18) with one bolt (15), two bolts (17), six washers (16), and three nuts (12) .

   Note: The bolt (15) is used in the hole toward the rear of the engine.

9. Attach bracket (13) to bracket (8) with two bolts (11), four washers (7), and two nuts (12) .

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Illustration 53	g03035576
Typical left-hand side view. (6) 0S-1588 Bolt (7) 9X-6458 Hard Washer (8) 386-3396 Bracket (9) 0S-1595 Bolt (10) 7D-1649 Hard Washer

10. Attach bracket (8) on top of the left side flywheel housing with five bolts (9) and five washers (10). The rear center hole in Illustration 53 is used with the 379-5145 Temperature Regulator Gp .

    Note: The bolts (6) and the washers (7) will be used during installation of air cleaner.

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Illustration 54	g03035051
Typical left-hand side view. (7) 9X-6458 Hard Washer (8) 386-3396 Bracket (11) 2A-4639 Bolt (12) 9S-8752 Full Nut (14) 0T-0055 Bolt (15) 0S-1591 Bolt (16) 5M-2894 Hard Washer (18) 7N-6986 Support (19) 388-2132 Bracket

11. Remove the bottom two bolts of the valve cover base of cylinder 16.

12. Install bracket (18) onto the valve cover base with two bolts (14) .

13. Attach bracket (19) to bracket (18) with three bolts (15), six washers (16), and three nuts (13) .

14. Attach bracket (19) to bracket (8) with two bolts (11), four washers (7), and two nuts (12) .

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

Illustration 55	g03027776
(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 56	g03027779
(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. Remove the four bolts and four washers from the oil pan below the side cover of cylinder 7.

8. 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.

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Illustration 57	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

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

10. Attach brackets (15) to bracket (19) loosely with four bolts (16), eight washers (14), and four nuts (17) .

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Illustration 58	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

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

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

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

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

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

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

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

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

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Illustration 59	g03027781
(24) 5B-5620 Bolt (25) 9M-1974 Hard Washer (26) 5S-0003 Nut (27) 9X-6138 Pipe Plug (28) 122-0089 Solenoid Valve Gp

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

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

21. 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.

22. 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 60	g03027797
(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

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

    Note: Union elbow (3) comes apart.

24. 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.

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

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

27. Attach line (31) to elbows (29) .

28. 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.

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

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

31. Attach line (31) to elbows (29) .

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Illustration 61	g03027798
(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 .

32. Refer to Illustration 72.

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

Illustration 62	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 63	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 64	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 65	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 66	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 67	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 68	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 69	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 70	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 70 for the correct location of the bolts.

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Illustration 71	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 73.

Installing the 424-7719 Electronic Actuator Gp

Illustration 72	g03027877
New design (1) 424-7719 Electronic Actuator Gp

Illustration 73	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 397-9380 Water Lines Gp

Illustration 74	g03042778
(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 75	g03104317
(1) 4J-5477 O-Ring Seal (2) 8C-6866 Connector (9) 397-9378 Hose As (10) 5P-9297 Clip

6. Remove the 8T-6765 Pipe Plug from the front right side of the 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 76	g03042758
(9) 397-9378 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 (21) 397-9377 Bracket (22) 8S-9191 Bolt

13. Remove the center two oil pan bolts under the side cover cylinder 5.

14. Attach bracket (21) to the engine with two bolts (22) and two washers (18) .

15. Install clip (16) around hose (9) .

16. Attach clip (16) to bracket (21) with one bolt (17), two washers (18), and one nut (13) .

17. Remove the bottom outer bolt of the 7C-9217 Elbow .

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

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

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

21. Remove the rear bolt from the 100-8075 Clamp As and the 264-0450 Clamp As .

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

23. Attach clip (16) to 100-8075 Clamp As and 264-0450 Clamp As . Use the original hardware and one bolt (11). The original bolt is not used.

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

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

26. 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 77	g03042759
(1) 4J-5477 O-Ring Seal (2) 8C-6866 Connector (13) 9S-8752 Full Nut (16) 6V-3265 Clip (17) 0S-1594 Bolt (18) 5M-2894 Hard Washer (21) 397-9377 Bracket (22) 9S-8752 Full Nut (23) 8C-6867 Connector (24) 397-9379 Hose As

27. Attach hose (24) and one O-ring (1) to connector (23) .

28. Attach hose (24) to connector (2) on the rear port of the 293-8396 Core . Make sure that the O-ring is in connector (1) .

29. Remove the center two oil pan bolts under the side cover of cylinder 11.

30. Attach bracket (21) to the engine with two bolts (22) and two washers (18) .

31. Install clip (16) around hose (24) .

32. Attach clip (16) to bracket (21) with one bolt (17), two washers (18), and one nut (13) .

Installing the 391-3977 Fuel Lines Gp

Illustration 78	g03037297
(1) 399-3105 Tube As (2) 6V-4368 O-Ring Seal

Note: The two sets of mixing tubes provided are intended for use with specific ranges of gas quality. Installation is the same for both tube assemblies. The proper mixing tube to be used for optimal substitution performance should be determined by the Lower Heating Value (LHV) of the supply gas as calculated from a gas analysis. The LHV of a gas analysis can be calculated using Caterpillar Gas Engine Rating Pro (GERP). Once a LHV is determined, install the correct mixing tubes listed in reference to Table 27.

Table 27

LHV Range British Thermal Unit (BTU) / Standard Cubic Foot (SCF)	Part
450-1400 BTU / SCF	381-3558 Tube As
1300-2300 BTU / SCF	399-3105 Tube As

1. Install tube assembly (1) and one O-ring (2) per tube assembly into the air inlet tube assemblies. Use two 9M-1974 Hard Washers and two 5S-0003 Nuts per tube assembly (1) .

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Illustration 79	g03037277
(3) 255-6464 Joint (4) 398-7717 Tube As (5) 105-8180 Gasket (6) 2A-4639 Bolt (7) 5M-2894 Hard Washer (8) 9S-8752 Full Nut (9) 3B-1915 Bolt (10) 9X-6458 Hard Washer

2. Attach tube assembly (4) to tube assemblies (1) with joints (3) .

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

3. Attach tube assembly (4) to the 424-7719 Electronic Actuator Gp with one gasket (5), four bolts (6), eight washers (7), and four nuts (8) .

4. Attach tube assembly (4) to bracket 397-8629 Bracket with two bolts (9), four washers (10), and two nuts (8) .

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Illustration 80	g03037860
(4) 398-7717 Tube As (8) 9S-8752 Full Nut (10) 9X-6458 Hard Washer (11) 391-2203 Bracket (12) 0S-1594 Bolt (13) 6V-1581 Clip (14) 6V-1582 Clip (15) 0S-1591 Bolt

5. Attach bracket (11) to the 155-0540 Elbow with one bolt (12) and one washer (10) .

6. Install clips (13) and (14) around tube assembly (4) .

7. Attach clips (13) and (14) to bracket (11) with one bolt (15), two washers (10), and one nut (9) .

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Illustration 81	g03037862
(4) 398-7717 Tube As (8) 9S-8752 Full Nut (10) 9X-6458 Hard Washer (13) 6V-1581 Clip (14) 6V-1582 Clip (15) 0S-1591 Bolt (16) 391-2202 Bracket

8. Remove two 0S-1571 Bolts , four 5M-2894 Hard Washers , and two 9S-8752 Full Nuts from the 388-2133 Bracket and the 7N-6986 Support .

9. Attach bracket (16) to the 388-2133 Bracket and the 7N-6986 Support with the original hardware.

10. Install clips (13) and (14) around tube assembly (4) .

11. Attach clips (13) and (14) to bracket (16) with one bolt (15), two washers (10), and one nut (8) .

Installing the 391-3080 Precleaner Gp (if applicable)

Note: Use Loctite 567 on all pipe thread joints.

Illustration 82	g03039763
Typical right-hand side engine view. (1) 1A-1460 Bolt (2) 7D-1649 Hard Washer (3) 1F-7958 Full Nut (4) 386-3397 Bracket (5) 382-5500 Support Bracket As (6) 0S-1591 Bolt (7) 9X-6458 Hard Washer (8) 0S-1592 Bolt (9) 2S-7593 Hard Washer (10) 2H-3743 Bolt (11) 5P-8250 Washer

1. Attach the bracket (4) and bracket (5) to the upper flywheel housing with four bolts (6) and four washers (7)

   Note: Bracket (4) is installed on top of bracket (5) .

2. Attach bracket (4) to the 386-3396 Bracket with two bolts (1), four washers (2), and two nuts (3) .

3. Attach bracket (5) to the lower flywheel housing with two bolts (10) and two washers (11) .

   Note: Bolts (8) and washers (9) are used during the installation of the precleaners.

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Illustration 83	g03039764
Typical left-hand side engine view. (4) 386-3397 Bracket (6) 0S-1591 Bolt (7) 9X-6458 Hard Washer (8) 0S-1592 Bolt (9) 2S-7593 Hard Washer (10) 2H-3743 Bolt (11) 5P-8250 Washer (12) 382-5499 Support Bracket As

4. Attach bracket (4) and bracket (12) to the upper flywheel housing with four bolts (6) and four washers (7)

   Note: Bracket (4) is installed on top of bracket (12) .

5. Attach the bracket (12) to the lower flywheel housing with two bolts (10) and two washers (11) .

   Note: Bolts (8) and washers (9) are used during the installation of the precleaners.

Installing the 379-5145 Temperature Regulator Gp

Illustration 84	g03039217
(4) 4W-0530 Retaining Ring (6) 8T-1919 O-Ring Seal (10) 125-2780 Tube (12) 379-5144 Tube (14) 390-4498 Tube

1. Remove the original separate circuit aftercooler tube assemblies. Set the following components and associated hardware aside for reuse:
   • Clips

   • Spacers

   • Retainers

   • Tube joints

2. Install one O-ring seal (6) and one retaining ring (4) around tube assembly (14). Lubricate the O-ring seal with 1U-6395 O-Ring Assembly Compound .

3. Install tube assembly (14) into the 214-0729 Adapter with the original hardware.

4. Attach tube assembly (12) to tube assembly (14) with the 9S-9635 Tube Joint .

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

5. Install one O-ring seal (6) and one retaining ring (4) around tube assembly (10). Lubricate the O-ring seal with 1U-6395 O-Ring Assembly Compound .

6. Attach tube assembly (10) to the aftercooler and tube assembly (12) with the original 9S-9635 Tube Joint and hardware.

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

7. Secure tube assemblies (12) and (14) to the cam covers with the original clips and associated hardware.

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Illustration 85	g03038216
(2) 0S-1591 Bolt (3) 1F-7958 Full Nut (5) 7D-1649 Hard Washer (7) 9S-8752 Full Nut (8) 9X-6458 Hard Washer (9) 9X-8873 Bolt (13) 386-3398 Bracket

8. Attach bracket (13) to the 386-3396 Bracket with two bolts (9), four washers (5), and two nuts (3) .

9. Install the original clips around tube assembly (12) .

10. Attach the clips to bracket (13) with one bolt (2), two washers (8), and one nut (7) .

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Illustration 86	g03038359
(1) 0S-1585 Bolt (2) 0S-1591 Bolt (5) 7D-1649 Hard Washer (7) 9S-8752 Full Nut (8) 9X-6458 Hard Washer (11) 379-5142 Bracket

11. Install bracket (11) onto the top of the flywheel housing with one bolt (1) and one washer (5) .

12. Install the original clips around tube assembly (10) .

13. Attach bracket (11) to the clips with one bolt (2), two washers (8), and one nut (7) .

Installing the 416-4348 Fuel System Parts Kit (if applicable)

Note: Refer to 391-3078 Air Lines Gp for more detailed information.

Illustration 87	g03095801
(1) 5P-4869 Hose Clamp (2) 8N-8741 Hose (3) 113-1328 Tube

1. Install hoses (2) onto tube (3) with two clamps (1) .

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Illustration 88	g03095803
(1) 5P-4869 Hose Clamp

2. Install the assembled parts onto the 381-1062 Tube As and the 381-1063 Tube As with one clamp (1) per tube assembly.

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Illustration 89	g03095805
Typical right-hand side engine view. (1) 5P-4869 Hose Clamp (2) 8N-8741 Hose (4) 0S-1588 Bolt (5) 9X-6458 Hard Washer

3. Attach the air cleaner to the 386-3396 Bracket with seven bolts (4) and seven washers (5) .

4. Fasten hose (2) to the air cleaner with a clamp (1) .

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Illustration 90	g03095806
Typical left-hand side engine view. (1) 5P-4869 Hose Clamp (2) 8N-8741 Hose (4) 0S-1588 Bolt (5) 9X-6458 Hard Washer

5. Attach the air cleaner to the 386-3396 Bracket with seven bolts (4) and seven washers (5) .

6. Fasten hose (2) to the air cleaner with a clamp (1) .

Installing the 416-4349 Fuel System Parts Kit (if applicable)

Note: Refer to 389-0847 Air Shutoff Gp for more detailed information.

Illustration 91	g03045719
(1) 7E-8224 Reducer Hose (2) 5P-0600 Hose Clamp (3) 388-2134 Bracket

1. Remove the original reducer hoses and support brackets from the air cleaners.

2. Install two brackets (3) onto each of the air cleaners use the original hardware.

   Note: Leave brackets (3) loose for the installation of the air cleaners.

3. Install one reducer hose (1) onto each of the air cleaners use one hose clamp (2) per reducer hose.

4. Attach the air cleaners to the 386-3396 Brackets with the original hardware.

   Note: The bolts go in the three bottom holes of the bracket.

5. Fasten reducer hose (2) to the tube assemblies with the original 5P-4869 Hose Clamp .

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Illustration 92	g03046208
Typical right-hand side engine view. (3) 388-2134 Bracket (4) 3B-1915 Bolt

6. Attach brackets (3) to the air cleaner and the 386-3396 Brackets with four bolts (4) .

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Illustration 93	g03045721
Typical left-hand side engine view. (3) 388-2134 Bracket (4) 3B-1915 Bolt

7. Attach brackets (3) to the air cleaner and the 386-3396 Brackets with four bolts (4) .

8. Tighten the original hardware that was left loose for installation.

Installing the 417-4386 Fuel System Parts Kit

Note: Refer to 392-7072 Jacket Water Heater Lines Gp for more detailed information.

Illustration 94	g03042760
Typical right-hand side engine view. (1) 006-5707 Pipe Elbow (2) 196-9420 Ball Valve (3) 122-3201 Pipe Nipple (4) 4B-9030 Elbow (5) 8C-6875 Connector (6) 5K-9090 O-Ring Seal (7) 307-9372 Hose As (8) 7G-1239 Spacer (9) 184-7211 Clip (10) 1B-2790 Bolt (11) 9M-1974 Hard Washer (12) 5S-0003 Nut

Note: Use Loctite 567 on all pipe thread joints.

1. Remove the pipe plug from the center hole of the 1L-4031 Service Tee .

2. Install elbow (1) into the center hole of the 1L-4031 Service Tee .

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

4. Install pipe nipple (3) into ball valve (2) .

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

6. Install connector (5) into elbow (4) .

7. Attach hose (7) and one O-ring (6) to connector (5) .

8. Slide other end of hose assembly (7) under the engine to the other side.

9. Install clip (9) around hose assembly (7) .

10. Attach clip (9) to the genset base with one spacer (8), one bolt (10), two washers (11), and one nut (12) .

    Note: Spacer (8) goes under clip (9) .

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Illustration 95	g03044477
Typical left-hand side engine view. (5) 8C-6875 Connector (6) 5K-9090 O-Ring Seal (7) 307-9372 Hose As (8) 7G-1239 Spacer (9) 184-7211 Clip (10) 1B-2790 Bolt (11) 9M-1974 Hard Washer (12) 5S-0003 Nut (13) 1A-1460 Bolt (14) 7D-1649 Hard Washer (15) 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 (13), eight washers (14), and two nuts (15) .

12. Install connector (5) to the rear port of the jacket water heater gp.

13. Attach hose assembly (7) and one O-ring (6) to connector (5) .

14. Install clip (9) around hose assembly (7) .

15. Attach clip (9) to the genset base with one spacer (8), one bolt (10), two washers (11), and one nut (12) .

    Note: Spacer (8) goes under clip (9) .

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Illustration 96	g03044599
Typical left-hand side engine view. (2) 196-9420 Ball Valve (5) 8C-6875 Connector (6) 5K-9090 O-Ring Seal (13) 1A-1460 Bolt (16) 7D-4092 Clip (17) 307-8764 Hose As (18) 7E-5639 Spacer (19) 5P-8245 Hard Washer (20) 118-1656 Reducer Bushing (21) 8T-6762 Pipe Plug (22) 1L-4031 Service Tee

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

17. Install pipe tee (22) into the front left 7N-3298 Block Cover .

18. Install ball valve (2) into the center hole of pipe tee (22) .

19. Install reducer bushing (20) into the end hole of pipe tee (22) .

20. Install pipe plug (21) into reducer bushing (20) .

21. Install connector (5) into ball valve (2) .

22. Install connector (5) into the top port of the jacket water heater gp.

23. Attach hose assembly (17) and one O-ring (6) per connector to connectors (5). Refer to Illustration 96 for the correct orientation of the hose assembly.

24. Install one clip (16) around hose assembly (17) .

25. Attach clip (16) to the engine block between cylinder 6 and cylinder 8 with one spacer (18), bolt (13), and one washer (19) .

Installing the 382-1791 Instrument Panel Box Gp

Illustration 97	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 99 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 Engine Wiring Gp

Illustration 98	g03046905
(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 ladder clip (2) to the left 7N-4319 Cover with the original hardware.

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

5. Attach wiring harness (3) to the 376-478 Engine Wiring Gp with cable straps (1) .

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Illustration 99	g03046904
(3) 386-4897 Wiring Harness

Note: The stand holding the 382-1791 Instrument Panel Box Gp in Illustration 99 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 with 14 cable straps (1) .

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

Installing the 386-4901 Generator Wiring Gp

Illustration 100	g03046906
(1) 386-4904 Engine Harness As

Note: The stand holding the 382-1791 Instrument Panel Box Gp in Illustration 100 is not included in the kit.

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

1. Attach the precleaners to the 382-5499 Support Bracket As and the 382-5500 Support Bracket As . Refer to Illustration 83 for the correct hardware.

2. Attach the precleaners to the air cleaners with the original hardware.

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 Ratings Electronic Software Gp on a blank ISM (A3).

3. Download the 440-0165 Engine Ratings Electronic Software Gp free from the Service Information System (SIS).

4. Install the 440-0165 Engine Ratings Electronic Software Gp on 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.

   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 101	g03285604

1. Connect Cat ET to the ECM.

2. Click on the "Service" tab.

3. Select "Calibrations".

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Illustration 102	g03286182

4. Click on "Injector Codes Calibration".

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Illustration 103	g03286196

5. Select the "Injector".

6. Click the "Change" button.

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Illustration 104	g03286198

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

8. Click the "OK" button.

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Illustration 105	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

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Illustration 106	g03357967
Default air shutoff not installed

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Illustration 107	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 108	g03286158

1. Click on the "Service" tab.

2. Select "Calibrations".

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Illustration 109	g03286176

3. Click on "Timing Calibration".

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Illustration 110	g03286178

4. Follow the Prompts.

5. Click the "Continue" button.

Software Enabled Attachments (SEA)

Illustration 111	g03344246
SEA not installed

Note: There is a significant charge for enabling the Gas Substitution SEA 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 112	g03344248
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 444-0554 Film

Illustration 113	g03814974
Typical 443-5866 Film (Non-Emission Certified Engines)

1. 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.

2. Attach the 443-5866 Film to the valve cover.

3. Attach the 444-0543 Film to the valve cover on top of the 443-5866 Film .

   Note: The 444-0543 Film is a protective film for the 443-5866 Film .

Startup Checklist

The following retrofit checklist is used before the dynamic gas blending is activated.

Table 28

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.

Register the Retrofit

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

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

1. When performing a retrofit installation, record the vital information in Table 29.

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

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   Table 29

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

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

2. Update the product configuration by entering the information from Table 29 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".