Retrofitting for the Dynamic Gas Blending Capability on Certain 3516B Engines {1071, 1100, 1250, 1270, 1274, 1403, 1716, 1901, 1920} Caterpillar

Electric Power Generation

3516B GEN SET (S/N: ZAP1-UP)

Engine

3516B (S/N: LY31-UP; LY41-UP; DD91-UP; JCH1-UP; JCN1-UP; YAP1-UP; ZBP1-UP; YAR1-UP; ZAR1-UP; ZBR1-UP; YAT1-UP; YBT1-UP; LNW1-UP; YAW1-UP; YBW1-UP; LNZ1-UP)

Power Module

PM3516 (S/N: DD81-UP; 1HZ1-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 to install an upgrade fuel kit for the 3516B Engines. Refer to following Tables for the upgrade fuel kit part numbers.

Note: Make sure that the latest software file is downloaded from SIS web for the engine and Electronic Modular Control Panel (EMCP).

Safety

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Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand. Cooling System Conditioner contains alkali. Avoid contact with skin and eyes.

References

Reference: Operation and Maintenance Manual, SEBU9019

Reference: Systems Operation/Testing and Adjusting, M0086333

Reference: Troubleshooting, M0086332

Required Parts

Copying the Product Status Report and the Injector Trim Codes

Copying the Product Status Report

1. Connect Cat^® Electronic Technician (ET) 2016B or newer to the Electronic Control Module (ECM).
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   Illustration 1	g03285257

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

4. Click 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 the "Save As" button.

7. Save the file in a convenient location.

8. Click the "Close Report" button.

Copying the Injector Trims Codes

Illustration 6	g03285599

1. Click the "Service" tab.

2. Select "Calibrations".
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   Illustration 7	g03285600

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

4. Click 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 33 through 38 of "Installing the 465-8186 Flame Arrestor 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 465-8186 Flame Arrestor Gp".

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

Installing the 465-8186 Flame Arrestor Gp

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Illustration 12	g06266612

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

   • Cylinder heads

   • Exhaust manifolds

   • Fuel lines

   • Rocker mechanism

   • Rocker base

   • Valve mechanism cover

   • Water manifolds

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

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

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 13	g03032057

9. Remove the compressor pipes and the air inlet elbows from the aftercooler and the turbochargers.
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   Illustration 14	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 15	g03028581

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

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

15. Disconnect the fuel lines from the cylinder heads and the fuel manifolds.

16. Remove the fuel manifolds from the engine.

17. Using a suitable lifting device, remove the water manifold. The water manifold weighs approximately 35 kg (77 lb) per side.

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

19. Using a suitable lifting device, remove the exhaust manifold. The exhaust manifold weighs approximately 125 kg (275 lb) per side.

20. Using a suitable lifting device, remove the cylinder heads. Each cylinder heads weighs approximately 47 kg (104 lb).

21. Remove the 7C-7909 Elbows from 14 of the cylinder heads.

22. Remove the 7C-7910 Elbows from 2 of the cylinder heads.
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    Illustration 16	g06147949
    463-0919 Cylinder Head Gp (1) 443-5682 Pressure Sensor Gp (In Cylinder Pressure Sensor)

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    Illustration 17	g06148758
    (1) 443-5682 Pressure Sensor Gp (In Cylinder Pressure Sensor)

23. Visually inspect the port in the cylinder head.

    If cylinder heads were delivered with Tarp or Tarp-B applied, clean per the Engine News, SEBD9204, Uses, Characteristics, And Removal of Castrol Tarp®, Tarp-B®, And 4164® prior to installing on the engine. If the heads were delivered with a different rust preventer applied, clean appropriately prior to installing on the engine.

    Note: If the engine and DGB retrofit kit is going to be painted, ensure that all sensors, actuators, and wiring harnesses are installed and connected or ensure that any open holes or exposed connectors are fully masked. Paint in port threads will affect the sensor's tightening torque. Paint inside connectors may prevent a good electrical connection.

    Note: Use the 4C-5894 Tap (M10 X 1) to chase the damaged threads.

    1. Use the 264-4355 Nylon Brush to ensure that cleaning agent removes tarp in the cylinder pressure sensor threads. Do not use metal brushes. Any tarp left in the threads will affect the cylinder pressure sensor's tightening torque.

    2. Use the 266-2281 Nylon Brush to ensure that cleaning agent removes tarp from the cylinder pressure sensor seat. Do not use metal brushes. Any tarp left on the seat may cause premature sensor failure because of combustion gas leakage.

24. Use shop air to blow out the port in the cylinder head.

25. Clean the threads of the pressure sensor (1) with a nylon brush. Do not use steel or brass brushes.

26. Apply Loctite^® Anti-Seize to the threads of pressure sensor (1).

27. Hand-tighten sensor into port until seated. Use caution to avoid cross-threading. Do not use an impact wrench. Use caution to keep the pressure sensor tip from contacting any hard surfaces during installation.

28. Install pressure sensor (1) into each cylinder head.

    Torque pressure sensor ... 11.5 ± 1 N·m (8.5 ± .7 lb ft)

    For installation of ICPS, refer to Special Instruction, M0079018, Installation and Removal of the 443-5682 Pressure Sensor Gp (In Cylinder Pressure Sensor). This document is critical and highlights the proper torque specifications and sensor installation procedure.

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    Illustration 18	g06262638
    (2) 4S-5898 O-Ring Seal (3) 7C-8199 Flange (4) 6V-5101 O-Ring Seal (5) 370-7336 Air Inlet Elbow (6) 2A-4639 Bolt (7) 5M-2894 Hard Washer (8) 370-7335 Air Inlet Elbow (9) 1T-0720 Bolt (10) 153-8455 Manifold Gasket (11) 371-5211 Flame Arrestor As

29. Install 1 flame arrestor (11) with cylindrical side toward the air inlet elbow (5) and air inlet elbow (8). Use 2 gaskets (10), 4 bolts (9), and 4 washers (7) per each head.

30. Install 1 O-ring (4) per elbow onto elbows (5) and (8).

    Note: Lubricate the bore of flange (3) lightly with glycerin.

31. Install flange (3) onto elbows (5) and (8). Make sure to push the flanges back against the stops.

    Note: Lubricate the O-ring groove of flange (3) lightly with glycerin to hold O-ring in place.

32. Install 1 O-ring (2) into flange (3).

33. Install 2 bolts (6) and 2 washers (7) into the bolt holes of flange (3). The thread end of the bolts will be flush with the flanges.
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    Illustration 19	g06148258
    (12) 256-6453 Temperature Sensor (13) 238-5080 O-Ring Seal

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

35. Install temperature sensor (12) and 1 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 20	g06262639
    (12) 256-6453 Temperature Sensor (13) 238-5080 O-Ring Seal (14) 001-9440 Connector (15) 353-5440 Adapter

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

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

    Note: Use Loctite 567 on all pipe thread joints.

38. Install temperature sensor (12) and 1 O-ring (13) into adapter (15).

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

39. Install adapter (14) into the 283-9779 Manifold.

    Note: Use Loctite 567 on all pipe thread joints.

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

41. Using a suitable lifting device, install the cylinder heads. Each cylinder heads weighs approximately 47 kg (104 lb).

42. Using a suitable lifting device, install the exhaust manifold. The exhaust manifold weighs approximately 125 kg (275 lb) per side.

43. Using a suitable lifting device, install the water manifold. The water manifold weighs approximately 35 kg (77 lb) per side.

44. Install the fuel manifolds onto the engine.

45. Connect the fuel lines to the cylinder heads and the fuel manifolds.

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

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

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

Illustration 21	g06264311
(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 536-7928 Engine Wiring Gp

Note: Ensure that the wiring harnesses are properly routed to prevent rubbing and chaffing.

1. Remove the original wiring harness from the original mounting hardware.
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   Illustration 22	g06264953
   Left-hand side of engine

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   Illustration 23	g06265334
   Left-hand side front 4 cylinders (1) 536-9455 Engine Wiring Gp (2) 4P-7581 Clip (3) 7K-1181 Cable Strap (4) 533-6558 Engine Harness As (5) 132-5789 Clip (6) 4P-8134 Clip (7) 352-3968 Clip (8) 6W-6672 Spacer (9) 0L-2070 Bolt (10) 5M-2894 Hard Washer

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   Illustration 24	g06265311
   Left-hand side rear 4 cylinders (1) 536-9455 Engine Wiring Gp (2) 4P-7581 Clip (3) 7K-1181 Cable Strap (4) 533-6558 Engine Harness As (5) 132-5789 Clip (6) 4P-8134 Clip (7) 352-3968 Clip (8) 6W-6672 Spacer (9) 0L-2070 Bolt (10) 5M-2894 Hard Washer (11) 352-3964 Clip (12) 4S-5719 Spacer (13) 6L-4428 Taperlock Stud (14) 9S-8752 Full Nut (15) 522-1641 Speed Sensor Gp (17) 034-3557 Locking Bolt

2. Verify that the 478-3965 Sensor Harness As connectors are free liquid, debris, or damage.

3. Attach 1 478-3965 Sensor Harness As to each 443-5682 Pressure Sensor Gp.

4. Install 1 clip (2) to the rear outer bolt hole of the valve cover on cylinder 2 with the original hardware.

5. Install 1 clip (2) to the front outer bolt hole of the valve cover on cylinders 10, 12, and 16 with the original hardware.

6. Install 1 clip (5) to the front and rear oil tube assembly bracket and clip with the original hardware.

7. Install 1 clip (6) to the rear outer bolt hole of the valve cover on cylinder 16 with the original hardware.

8. Install 1 clip (6) to the front outer bolt hole of the rocker base cylinders 6, 8, 10, 12, 14, and 16 with the original hardware.

   On cylinder 8, the clip (6) goes under clip (7).

   On cylinder 14, the clip goes under the 7N-6986 Support.

9. Install 1 spacer (8) and 1 clip (6) to the front bolt hole of each left-hand cylinder head. Use 1 bolt (9) and 1 washer (10) per cylinder head.

10. Install 1 spacer (8) and 1 clip (6) to the rear bolt hole of cylinder head 16 use 1 bolt (9) and 1 washer (10).

11. Remove the side cover mounting hardware of cylinder 12 from the engine block.

    Note: Engines with left-hand oil service will need to install the 548-4776 Box over the side cover of cylinder 14.

12. Install the original side cover of cylinder 12 or cylinder 14 to the engine block. Use 4 taper lock studs (13), 4 spacers (12), 4 washers (10), and 4 nuts (14).

    1. Install 4 taper lock studs (13) into the engine block.

    2. Install the original side cover on taper lock studs (13).

    3. Install 4 spacers (12) onto taper lock studs (13) 1 per taper lock stud.

    4. Install the 548-4776 Box onto taper lock studs (13).

    5. Secure the side cover and the 548-4776 Box to the engine with 4 washers (10) and 4 nuts (12).

13. Install 2 clips (6) onto the rear bolt holes of camshaft cover of cylinder 12 use the original hardware.

14. Install 1 clip (2) onto the top rear bolt hole of camshaft cover cylinder 16 use the original hardware.

15. Install 1 clip (6) to the top front bolt hole of the side cover of cylinder 14 use 1 bolt (16) and 1 washer (10).

16. Install 1 clip (7) onto the bottom front bolt hole side cover of cylinder 14 use 1 bolt (17) and 1 washer (10).

17. Plug wiring harness (1) into the plug-in of each rocker arm base.

18. Plug wiring harness (4) into each 478-3965 Sensor Harness As.

19. Secure the 478-3965 Sensor Harness As and wiring harness (4) to clips (2), (5), and (7) with 1 cable strap (3) per clip.

20. Secure wiring harnesses (1) and (4) to clips (2), (6), and (11) use 1 cable strap (3) per clip.

21. Secure wiring harnesses (1) to clips (6) and (7) use 1 cable strap (3) per clip.

22. Remove the speed sensor from the side of the flywheel housing.

23. Install speed sensor (15) into the flywheel housing.

24. Plug speed sensor (15) into wiring harness (1).

25. Secure wiring harness (1) to clip (2) use 1 cable strap (3).
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    Illustration 25	g06265380
    (1) 536-9455 Engine Wiring Gp (3) 7K-1181 Cable Strap (4) 533-6558 Engine Harness As (18) 4P-7429 Clip (19) 0S-1621 Bolt (20) 2M-0849 Hard Washer

26. Install 4 clips (18) onto the flywheel housing use 4 bolts (19) and 4 washers (20).

27. Secure wiring harnesses (1) and (4) to clips (18) use 1 cable strap (3) per clip.
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    Illustration 26	g06265520
    Right-hand side of engine

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    Illustration 27	g06265528
    Right-hand side rear 4 cylinders (1) 536-9455 Engine Wiring Gp (2) 4P-7581 Clip (3) 7K-1181 Cable Strap (4) 533-6558 Engine Harness As (5) 132-5789 Clip (6) 4P-8134 Clip (7) 352-3968 Clip (8) 6W-6672 Spacer (9) 0L-2070 Bolt (10) 5M-2894 Hard Washer (11) 352-3964 Clip (21) 352-3966 Clip

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    Illustration 28	g06265539
    Right-hand side front 4 cylinders (1) 536-9455 Engine Wiring Gp (2) 4P-7581 Clip (3) 7K-1181 Cable Strap (4) 533-6558 Engine Harness As (6) 4P-8134 Clip (7) 352-3968 Clip (8) 6W-6672 Spacer (9) 0L-2070 Bolt (10) 5M-2894 Hard Washer (11) 352-3964 Clip

28. Attach 1 478-3965 Sensor Harness As to each 443-5682 Pressure Sensor Gp.

29. Install 1 clip (2) to the front outer bolt hole of the valve cover on cylinder 1 and 3 with the original hardware.

30. Install 1 clip (2) to the rear outer bolt hole of the valve cover on cylinders 5, 7, and 13 with the original hardware.

31. Install 1 clip (5) to the front outer bolt hole of the valve cover on cylinder 9 with the original hardware.

32. Install 1 clip (21) to the front outer bolt hole of the valve cover on cylinder 11 with the original hardware.

33. Install 1 clip (6) to the rear outer bolt hole of the valve cover on cylinder 11 with the original hardware.

34. Install 1 clip (6) to the rear outer bolt hole of the each rocker base with the original hardware.

    On cylinder 3, the clip (6) goes under clip (7).

    On cylinder 5, 13, and 15, the clip goes under the 7N-6986 Support The 7N-6986 Support and hardware for cylinder 15 are from the 545-7878 Fuel Lines Gp.

35. Install 2 clips (11) to the 7N-6986 Support use the original hardware.

36. Install 1 spacer (8) and 1 clip (6) to the rear bolt hole of each right-hand cylinder head. Use 1 bolt (9) and 1 washer (10) per cylinder head.

37. Plug wiring harness (1) into the plug-in of each rocker arm base.

38. Plug wiring harness (4) into each 478-3965 Sensor Harness As.

39. Plug wiring harness (1) into wiring harness (4).

40. Secure the 478-3965 Sensor Harness As to clips (2) and (7) with 1 cable strap (3) per clip.

41. Secure wiring harnesses (1) and (4) to clips (6) and (11) use 1 cable strap (3) per clip.
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    Illustration 29	g06147898
    (1) 536-9455 Engine Wiring Gp (22) 318-1181 Speed Sensor Gp

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

43. Install speed sensor (22) 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)

44. Plug speed sensor (22) into wiring harness (1).
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    Illustration 30	g06265677
    Right-hand side fuel service engine (1) 536-9455 Engine Wiring Gp (23) 320-3060 Pressure Sensor (24) 228-7100 O-Ring Seal (25) 256-6454 Temperature Sensor (26) 238-5080 O-Ring Seal (27) 353-5441 Elbow Adapter (28) 214-7566 O-Ring Seal (29) 353-5439 Connector (30) 320-3063 Pressure Sensor (31) 330-9739 Adapter (32) 320-3061 Pressure Sensor (33) 228-7101 O-Ring Seal

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    Illustration 31	g06265679
    Left-hand side fuel service engine (1) 536-9455 Engine Wiring Gp (23) 320-3060 Pressure Sensor (24) 228-7100 O-Ring Seal (25) 256-6454 Temperature Sensor (26) 238-5080 O-Ring Seal (27) 353-5441 Elbow Adapter (28) 214-7566 O-Ring Seal (29) 353-5439 Connector (30) 320-3063 Pressure Sensor (31) 330-9739 Adapter (32) 320-3061 Pressure Sensor (33) 228-7101 O-Ring Seal (34) 415-7979 Sensor Harness As

    Note: Use sensor harness (34) with left-hand side fuel service engines to connect engine harness (1) to the fuel and the oil sensors.

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

46. Install elbow adapter (27) and 1 O-ring (28) into the unfiltered port (filter inlet) of the 112-4921 Engine Oil Filter Gp.

47. Install pressure sensor (23) and 1 O-ring (24) into elbow adapter (27).

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

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

49. Install temperature sensor (25) and 1 O-ring (26) into the 208-0822 Water Lines Gp.

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

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

51. Install adapter (31) and 1 O-ring (28) into the inside port of the 111-0349 Module Bracket.

52. Install pressure sensor (32) and 1 O-ring (33) into adapter (31).

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

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

54. Install connector (29) and 1 O-ring (28) into the outside port of the 111-0349 Module Bracket.

55. Install pressure sensor (30) and 1 O-ring (24) into connector (29).

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

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    Illustration 32	g06265682
    Right-hand side fuel service engine (1) 536-9455 Engine Wiring Gp (23) 320-3060 Pressure Sensor (24) 228-7100 O-Ring Seal (27) 353-5441 Elbow Adapter (28) 214-7566 O-Ring Seal

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    Illustration 33	g06265683
    Left-hand side fuel service engine (23) 320-3060 Pressure Sensor (24) 228-7100 O-Ring Seal (27) 353-5441 Elbow Adapter (28) 214-7566 O-Ring Seal (34) 415-7979 Sensor Harness As

    Note: Use sensor harness (34) with left-hand side fuel service engines to connect engine harness (1) to the fuel and the oil sensors.

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

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

58. Install elbow adapters (27) and 1 O-ring (28) per elbow into the 267-9689 Filter Housing Cover.

59. Install pressure sensor (23) and 1 O-ring (24) per pressure sensor into each elbow adapter (27).

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

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

61. Install elbow adapter (27) and 1 O-ring (28) into the filtered port (block inlet) of the 112-4921 Engine Oil Filter Gp.

62. Install pressure sensor (23) and 1 O-ring (24) into elbow (27).

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

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    Illustration 34	g06265688
    (1) 536-9455 Engine Wiring Gp (3) 7K-1181 Cable Strap (6) 4P-8134 Clip (18) 4P-7429 Clip

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

64. Attach clip (6) to the rear hole of the 267-9689 Filter Housing Cover with original hardware.

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

66. Attach clip (18) to the front bolt hole of the 2W-4334 Bar with the original hardware.

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

68. Attach clip (6) to the front left bolt hole of the 112-4922 Fuel Filter Gp with the original hardware.

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

70. Install clip (6) onto the front middle bolt of the 4W-6960 Housing Support with the original hardware.

71. Secure wiring harness (1) to clip (6) and (18) use 1 cable strap (3) per clip.
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    Illustration 35	g06265736
    (1) 536-9455 Engine Wiring Gp (2) 4P-7581 Clip (3) 7K-1181 Cable Strap (6) 4P-8134 Clip (10) 5M-2894 Hard Washer (35) 0L-1352 Bolt (36) 0S-1594 Bolt

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

73. Attach clip (6) to the bottom rear bolt hole of the 7E-6017 Cover with the original hardware.

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

75. Attach clip (2) to the middle bolt hole of the 4W-4313 Adapter with 1 bolt (35) and 1 washer (10).

76. Attach clip (6) to the 111-0349 Module Bracket with 1 bolt (36) and 1 washer (10).

77. Secure wiring harness (1) to clips (2) and (6) use 1 cable strap (3) per clip.
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    Illustration 36	g06266343
    (1) 536-9455 Engine Wiring Gp (3) 7K-1181 Cable Strap (6) 4P-8134 Clip (10) 5M-2894 Hard Washer (14) 9S-8752 Full Nut (36) 0S-1594 Bolt (37) 0S-1588 Bolt (38) 6V-1581 Clip (39) 6V-1582 Clip (40) 4P-7068 Bracket

78. Install 1 clip (38) and 1 clip (39) around the 110-9538 Tube.

79. Attach 1 clip (6) to clips (38) and (39) with 1 bolt (37), 2 washers (10), and 1 nut (14).

80. Attach 1 clip (11) to the lower left bolt hole of the ECM with the original hardware.

81. 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.

82. Attach bracket (40) to the 111-5052 Bracket, the 6V-1867 Clip, and 6V-1868 Clip with the original hardware.

83. Attach 1 clip (6) to bracket (40) with 1 bolt (36), 2 washers (10), and 1 nut (14).

84. Secure wiring harness (1) to clips (6) and (11) use 1 cable strap (3) per clip.
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    Illustration 37	g06266351
    Left-hand side engine view (1) 536-9455 Engine Wiring Gp (3) 7K-1181 Cable Strap (10) 5M-2894 Hard Washer (11) 132-5789 Clip (36) 0S-1594 Bolt (41) 261-6847 Adapter (42) 415-2432 Temperature Sensor Gp (43) 3A-3692 Clip

85. Remove the adapter and the temperature sensor from the 115-0556 Exhaust Manifold.

86. Install adapter (41) into the 115-0556 Exhaust Manifold.

    Note: Lubricate the temperature sensor gp (42) with Loctite Nickel Anti Seize.

87. Install exhaust temperature sensor gp (42) into the adapter (41).

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

88. Install 1 clip (43) around exhaust temperature sensor gp (42). Refer to Illustration 37 for the correct orientation of the clip.

89. Attach clip (43) to the camshaft cover on cylinder 12 with 1 bolt (36) and 1 washer (10).

90. Plug exhaust temperature sensor (43) into wiring harness (1).

91. Secure exhaust temperature sensor (43) to clip (11) with 1 cable strap (3). Refer to Illustration 37 for the correct location.

92. Secure exhaust temperature sensor (43) to wiring harness (1) with cable straps (3) as needed.
    Show/hide table

    Illustration 38	g06266363
    Right-hand side engine view (1) 536-9455 Engine Wiring Gp (3) 7K-1181 Cable Strap (10) 5M-2894 Hard Washer (36) 0S-1594 Bolt (41) 261-6847 Adapter (42) 415-2432 Temperature Sensor Gp (43) 3A-3692 Clip

93. Remove the adapter and the temperature sensor from the 155-0554 Exhaust Manifold.

94. Install adapter (41) into the 155-0554 Exhaust Manifold.

    Note: Lubricate the temperature sensor gp (42) with Loctite Nickel Anti Seize.

95. Install exhaust temperature sensor gp (42) into the adapter (41).

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

96. Install 1 clip (43) around exhaust temperature sensor gp (42). Refer to Illustration 38 for the correct orientation of the clip.

97. Attach clip (43) to the camshaft cover on cylinder 15 with 1 bolt (36) and 1 washer (10).

98. Plug exhaust temperature sensor (42) into wiring harness (1).

99. Secure exhaust temperature sensor (42) to clip (3) with 1 cable strap (3). Refer to Illustration 38 for the correct location.

100. Secure exhaust temperature sensor (42) to wiring harness (1) with cable straps (3) as needed.
     Show/hide table

     Illustration 39	g06266373
     (1) 536-9455 Engine Wiring Gp (25) 256-6453 Temperature Sensor (26) 238-5080 O-Ring Seal (47) 353-5440 Adapter

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

     Note: Use Loctite 567 on all pipe thread joints.

102. Install adapter (44) into the 359-4123 Adapter.

103. Install temperature sensor (25) and 1 O-ring (26) into adapter (43).

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

104. Plug wiring harness (1) into temperature sensor (25).
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     Illustration 40	g06266379
     (1) 536-9455 Engine Wiring Gp (3) 7K-1181 Cable Strap (6) 4P-8134 Clip (24) 228-7100 O-Ring Seal (27) 353-5441 Elbow Adapter (28) 214-7566 O-Ring Seal (30) 320-3063 Pressure Sensor

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

106. Attach clip (6) to the top front bolt of the camshaft cover on cylinder 8 with the original hardware.

107. Install elbow (30) and 1 O-ring (31) into the 117-0066 Mounting Bracket.

108. Install pressure sensor (33) and 1 O-ring (27) into elbow (30).

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

109. Plug wiring harness (1) into pressure sensor (33).

110. Secure wiring harness (1) to clip (6) with 1 cable strap (3).

     Note: If the engine does not have a prelubrication pump, cable strap the wiring harness up as needed.

     Show/hide table

     Illustration 41	g06266387
     (3) 7K-1181 Cable Strap (4) 533-6558 Engine Harness As (6) 4P-8134 Clip (28) 214-7566 O-Ring Seal (45) 9X-0262 Adapter (46) 305-6873 Pressure Sensor Gp

111. Install 2 O-rings (28) onto adapter (45).

112. Install adapter (45) into the 450-2989 Tube As.

113. Install pressure sensor (46) onto adapter (45).

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

114. Plug wiring harness (4) into pressure sensor (45).

115. Secure wiring harness (4) to clips (6) with 1 cable strap (3) per clip.
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     Illustration 42	g06266396
     (3) 7K-1181 Cable Strap (4) 533-6558 Engine Harness As (5) 132-5789 Clip (6) 4P-8134 Clip (9) 5M-2894 Hard Washer (23) 320-3060 Pressure Sensor Gp (24) 228-7100 O-Ring Seal (47) 352-3969 Clip

     Show/hide table

     Illustration 43	g06151721
     (3) 7K-1181 Cable Strap (4) 533-6558 Engine Harness As (6) 4P-8134 Clip

116. Attach clip (47) to the top front bolt of the camshaft cover on cylinder 11 with the original hardware. Refer to Illustration 42 for the correct location.

117. Attach 1 clip (6) to the 450-2989 Tube As with the original 2A-4639 Bolt, 5M-2894 Hard Washers, and the 9S-8752 Full Nut. Refer to Illustration 42 for the correct location.

118. Attach 2 clips (5) to the 545-7880 Tube As and the 440-4792 Bracket with the original 3B-1915 Bolt, the 5M-2894 Hard Washers, and 9S-8752 Full Nut per clip. Refer to Illustration 42 for the correct location.

119. Attach 2 clips (6) to the 440-4786 Bracket As and the 440-4792 Bracket with the original 0S-1571 Bolt, the 9X-6458 Hard Washers, and 9S-8752 Full Nut per clip. Refer to Illustration 42 for the correct location.

120. Install pressure sensor (23) and 1 O-ring (24) into the 561-0592 Flange.

121. Secure wiring harness (4) to clips (5) and (6) with 1 cable strap (3) per clip.
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     Illustration 44	g06266408
     (1) 536-9455 Engine Wiring Gp (3) 7K-1181 Cable Strap (24) 228-7100 O-Ring Seal (30) 320-3063 Pressure Sensor (48) 155-2078 Connector (49) 335-3999 Adapter (50) 214-7568 O-Ring Seal

122. Remove the pressure sensors and the adapters from the air cleaners.

     Note: Use Loctite 567 on all pipe thread joints.

123. Install connector (48) into each air cleaner.

124. Install adapter (49) and 1 O-ring (50) into each connector (48).

125. Install pressure sensor (30) and 1 O-ring (24) into each adapter (49).

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

126. Secure wiring harness (1) to clips (6) use 1 cable strap (3) per clip.
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     Illustration 45	g06266619
     Callouts (51), (52), and (53) are from the 513-2185 Electronic Control and Mounting Gp. (2) 4P-7581 Clip (3) 7K-1181 Cable Strap (4) 533-6558 Engine Harness As (51) 294-3313 Clip (52) 0T-0065 Bolt (53) 9X-6458 Hard Washer

     Note: The following steps will be performed during the installation of the 513-2185 Electronic Control and Mounting Gp.

127. Attach clip (51) to the 231-7070 Bracket with 1 bolt (52) and 1 washer (53).

128. Attach clip (6) to the 231-7070 Bracket with 1 bolt (52) and 1 washer (53).

129. Secure wiring harness (4) to clips (6) and (51) with 1 cable strap (3) per clip.
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     Illustration 46	g03119760
     (C) 7N-9738 Receptacle Housing (D) 238-8245 Connector Plug As

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

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

131. Strip back the insulation on the 2 wires.

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

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

     Note: The connector is attached to the wiring harness.

Installing the 513-2185 Electronic Control and Mounting Gp

Illustration 47	g06264786
Callout (5) is from the 536-7928 Engine Wiring Gp. (1) 289-1525 Engine Electronic Control Gp (2) 458-2971 Inductor Assembly (3) 526-2180 Wiring Harness (4) 352-3964 Clip (5) 9M-1974 Hard Washer (6) 9N-0869 Hard Washer (7) 8T-9655 Isolation Mount (8) 6I-1418 Spacer (9) 2V-4387 Spacer (10) 1D-4540 Bolt

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

2. Remove the ground wire from the electronic control module (1). Set hardware aside for reuse.

3. Attach wiring harness (3) to electronic control module (1) with the original hardware.

4. Install electronic control module (1) onto the 111-0349 Module Bracket. Use 4 bolts (10), 1 washer (5), 4 washers (6), 8 isolation mounts (7), 4 spacers (8), and 4 spacers (9).

   Note: On the corner where wiring harness (3) was attached, the wiring harness goes in between washer (6) and spacer (8).

   Note: Clip (4) goes between washer (5) and washer (6).

5. Plug inductor assembly (2) into wiring harness (3).
   Show/hide table

   Illustration 48	g06264812
   (2) 458-2971 Inductor Assembly (11) 132-5789 Clip (12) 5M-3062 Bolt (13) 8T-4896 Hard Washer (14) 7K-1181 Cable Strap

6. Attach clip (11) to the 111-0349 Module Bracket with 1 bolt (12) and 1 washer (13).

7. Secure inductor assembly (2) to clip (11) with 1 cable strap (14).
   Show/hide table

   Illustration 49	g06264842
   Callout (17) is from the 536-7928 Engine Wiring Gp. (15) 231-7070 Bracket (16) 190-4885 Spacer (17) 4P-7581 Clip (18) 294-3313 Clip (19) 0T-0065 Bolt (20) 9X-6458 Hard Washer

8. Remove the rear camshaft cover bolts from cylinders 13 and 15.

9. Attach bracket (15), 2 clips (17), and 1 clip (18) to the engine with 4 spacers (16), 4 bolts (19), and 4 washers (20). The spacers go in between the bracket and the camshaft covers.
   Show/hide table

   Illustration 50	g06264867
   (5) 9M-1974 Hard Washer (6) 9N-0869 Hard Washer (8) 6I-1418 Spacer (9) 2V-4387 Spacer (10) 1D-4540 Bolt (15) 231-7070 Bracket (21) 491-6842 Electronic Control Module (22) 155-0576 Isolation Mount

10. Attach electronic control module (21) to bracket (15) with 4 bolts (10), 4 washers (6), 4 spacers (8), and 8 isolation mounts (22).

    Note: The corner with ground wire will use the 9M-1974 Hard Washer.

Installing the 541-3615 Gas Pressure Regulator Gp

Illustration 51	g06262950
(1) 397-8632 Bracket (2) 541-3102 Tube As (3) 432-9907 Clamp As (4) 7X-0456 Bolt (5) 7X-0589 Hard Washer

1. Attach tube assembly (2) to bracket (1) with 2 clamp assemblies (3), 4 bolts (4), and 4 washers (5).
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   Illustration 52	g06263007
   (1) 397-8632 Bracket (6) 0S-1585 Bolt (7) 7D-1649 Hard Washer (8) 8S-9191 Bolt (9) 5M-2894 Hard Washer

2. Remove the 4 bolts and four washers from the oil pan below the side cover of cylinder 11.

3. Using a suitable lifting device, attach the bracket (1) to the engine below the side cover of cylinder 1 and to the oil pan with 2 bolts (6), 2 washers (7), 4 bolts (8), and 4 washers (8). The assembled parts weigh approximately 91 kg (202 lb).
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   Illustration 53	g06263015
   (1) 397-8632 Bracket (6) 0S-1585 Bolt (10) 440-4786 Bracket As (11) 5P-8245 Hard Washer

4. Attach bracket (10) to bracket (1) with 8 bolts (6) and 8 washers (11).
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   Illustration 54	g06263022
   (10) 440-4786 Bracket As (12) 440-4792 Bracket (13) 165-3929 Bolt (14) 9X-6458 Hard Washer (15) 9S-8752 Full Nut (16) 165-3931 Bolt (17) 450-3143 Bracket As

5. Attach bracket (12) and bracket (17) to bracket (10) loosely with 4 bolts (16), 4 washers (14), and 2 nuts (15).

6. Attach bracket (12) to bracket (10) loosely with 2 bolts (13), 4 washers (14), and 2 nuts (15).
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   Illustration 55	g06263036
   (7) 7D-1649 Hard Washer (10) 440-4786 Bracket As (18) 5B-5620 Bolt (19) 9M-1974 Hard Washer (20) 5S-0003 Nut (21) 435-0888 Gas Pressure Regulator Gp (22) 2B-0947 Bolt (23) 1F-7958 Full Nut (24) 420-8789 Gasket

7. Install gas regulator (21) loosely onto bracket (10). Use 3 bolts (18), 6 washers (19), and 3 nuts (20).

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

8. Attach gas pressure regulator (21) to the 541-3102 Tube As with 1 gasket (24), 4 bolts (22), 8 washers (7), and 4 nuts (23).
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   Illustration 56	g06263055
   (7) 7D-1649 Hard Washer (12) 440-4792 Bracket (14) 9X-6458 Hard Washer (15) 9S-8752 Full Nut (21) 435-0888 Gas Pressure Regulator Gp (22) 2B-0947 Bolt (23) 1F-7958 Full Nut (24) 420-8789 Gasket (25) 450-2989 Tube As (26) 3B-1915 Bolt

9. Attach tube assembly (25) to gas pressure regulator (21) with 1 gasket (24), 4 bolts (22), 8 washers (7), and 4 nuts (23).

10. Attach tube assembly (25) to bracket (12) with 2 bolts (26), 4 washers (14), and 2 nuts (15).
    Show/hide table

    Illustration 57	g06263072
    (21) 435-0888 Gas Pressure Regulator Gp (25) 450-2989 Tube As (27) 211-5237 Connector (28) 6V-8398 O-Ring Seal (29) 440-4794 Tube As (30) 122-8905 Elbow

    Note: Use Loctite 567 on all pipe thread joints.

11. Install connector (27) into tube assembly (25).

12. Install elbow (30) into gas pressure regulator (21).

13. Attach tube assembly (29) and 1 O-ring (28) to connector (27).

14. Attach tube assembly (29) and 1 O-ring (28) to elbow (30).
    Show/hide table

    Illustration 58	g06263081
    (24) 420-8789 Gasket (31) 489-1434 Solenoid Valve Gp (32) 1A-8537 Bolt (33) 5P-8247 Hard Washer (34) 4K-0367 Full Nut (35) 8S-9092 Bolt (36) 0S-1625 Bolt (37) 561-0592 Flange (38) 9X-6138 Pipe Plug

15. Attach solenoid valve gp (31) to the 541-3102 Tube As loosely with 1 gasket (24), 4 bolts (35), 8 washers (33), and 4 nuts (34).

    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.

16. Attach solenoid valve gp (31) and flange (37) to the 450-3143 Bracket As. Use 1 gasket (24), 2 bolts (32), 2 bolts (36), 8 washers (33), and 4 nuts (34). Refer to Illustration 58 for the correct location of the bolts.

17. Install pipe plug (38) into flange (37).
    Show/hide table

    Illustration 59	g06263092
    (9) 5M-2894 Hard Washer (12) 440-4792 Bracket (15) 9S-8752 Full Nut (39) 2A-4639 Bolt (40) 105-8180 Gasket

18. Tighten all the hardware that was left loose for installation except for outside bracket (12).

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

19. Refer to Illustration 60.

Installing the 424-7719 Electronic Actuator Gp

Illustration 60	g06263095
(1) 424-7719 Electronic Actuator Gp (2) 105-8180 Gasket (3) 2A-4639 Bolt (4) 5M-2894 Hard Washer (5) 9S-8752 Full Nut

1. Attach actuator (1) to 450-2989 Tube As with 1 gasket (2), 4 bolts (3), 8 washers (4), and 4 nuts (5).

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

2a

Installing the 547-8143 Air Lines Gp

Illustration 61	g06263824
(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:

   • 2 162-2177 Hoses

   • 2 8N-5254 Reducer Hoses

   • 2 5P-4869 Hose Clamps

   • 6 5P-3860 Hose Clamps

   • 4 321-5895 Shield As

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

   Illustration 62	g06263818
   (3) 2B-2695 Bolt (4) 9M-1974 Hard Washer

3. Install 2 bolts (3) and 2 washers (4) per tube assembly into tube assemblies (1) and (2). The bolts and washers will be used with the 381-3558 Tube As from the 545-7878 Fuel Lines Gp.

Installing the 545-7878 Fuel Lines Gp

Illustration 63	g06263836
(1) 399-3105 Tube As (2) 447-7206 O-Ring Seal

Note: The 2 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 12.

1. Install tube assembly (1) and 1 O-ring (2) per tube assembly into the air inlet tube assemblies. Use 2 2B-2695 Bolts and 2 9M-1974 Hard Washers per tube assembly (1).
   Show/hide table

   Illustration 64	g06263842
   (3) 255-6464 Joint (4) 442-5391 Tube As (5) 216-2285 Tube Joint (6) 545-7880 Tube As (7) 105-8180 Gasket (8) 2A-4639 Bolt (9) 5M-2894 Hard Washer (10) 9S-8752 Full Nut (11) 3B-1915 Bolt (12) 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 tube assembly (6) with joint (5).

4. Attach tube assembly (6) to the 424-7719 Electronic Actuator Gp with 1 gasket (7), 4 bolts (8), 8 washers (9), and 4 nuts (10).

5. Attach tube assembly (6) to the 440-4792 Bracket with 2 bolts (11), 4 washers (12), and 2 nuts (10).
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   Illustration 65	g06263855
   (13) 545-7879 Bracket As (14) 4S-5882 Bolt (15) 5P-8245 Hard Washer (16) 8T-8917 Bolt

6. Attach bracket (13) to the flywheel housing with 2 bolts (14), 2 bolts (16), and 4 washers (15).
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   Illustration 66	g06263860
   (4) 442-5391 Tube As (10) 9S-8752 Full Nut (12) 9X-6458 Hard Washer (13) 545-7879 Bracket As (17) 7K-1401 Clip (18) 7K-1402 Bracket (19) 165-3929 Bolt (20) 442-6224 Bracket

7. Attach bracket (20) to bracket (13) with 2 bolts (19), 4 washers (12), and 2 nuts (10).

8. Install 1 clip (17) and 1 bracket (18) around tube assembly (4).

9. Attach clip (17) and bracket (18) to bracket (20) with 1 bolt (19), 2 washers (12), and 1 nut (10).
   Show/hide table

   Illustration 67	g06263864
   (4) 442-5391 Tube As (10) 9S-8752 Full Nut (12) 9X-6458 Hard Washer (13) 545-7879 Bracket As (17) 7K-1401 Clip (18) 7K-1402 Bracket (19) 165-3929 Bolt (20) 442-6224 Bracket (21) 442-6223 Bracket (22) 165-3931 Bolt (23) 442-6225 Bracket

10. Attach bracket (21) and bracket (25) to bracket (13) with 2 bolts (24), 4 washers (12), and 2 nuts (10).

11. Install 1 clip (17) and 1 bracket (18) around tube assembly (4).

12. Attach clip (17) and bracket (18) to bracket (21) with 1 bolt (19), 2 washers (12), and 1 nut (10).
    Show/hide table

    Illustration 68	g06264349
    (6) 545-7880 Tube As (10) 9S-8752 Full Nut (12) 9X-6458 Hard Washer (19) 165-3929 Bolt (23) 442-6225 Bracket (24) 6V-1581 Clip (25) 6V-1582 Clip

13. Install 1 clip (24) and 1 clip (25) around tube assembly (6).

14. Attach clips (24) and (25) to bracket (23) with 1 bolt (19), 2 washers (12), and 1 nut (10).
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    Illustration 69	g06264405
    (6) 545-7880 Tube As (9) 5M-2894 Hard Washer (10) 9S-8752 Full Nut (12) 9X-6458 Hard Washer (19) 165-3929 Bolt (23) 442-6225 Bracket (24) 6V-1581 Clip (25) 6V-1582 Clip (26) 391-2202 Bracket (27) 0T-0055 Bolt (28) 7N-6986 Support (29) 0S-1588 Bolt

15. Attach support (28) to cylinder head 15 with 2 bolts (27).

16. Attach bracket (26) to support (28) with 2 bolts (29), 4 washers (9), and 2 nuts (10).

17. Install 1 clip (24) and 1 clip (25) around tube assembly (6).

18. Attach clips (24) and (25) to bracket (26) with 1 bolt (19), 2 washers (12), and 1 nut (10).

Software Flash Instructions

Two software files need downloaded from the Service Information System (SIS) and installed by the dealer prior to beginning operation with Dynamic Gas Blending kits.

1. Download Software

   1. Download 1 of the following Engine Software (A4) based on your application:

      • 3516B Switchable - 555-0163 Engine Software

      • 3516B 50 Hz - 555-0165 Engine Software

      • 3516B 60 Hz - 555-0167 Engine Software

      • 3516B HD 50 Hz - 555-0171 Engine Software

   2. Download the 533-1342 Engine Software (A6:P1)

2. Install Software

   1. Install the Engine Software on a blank ECM (A4).

   2. Install the 533-1342 Engine Software onto a blank ECM (A6:P1)

Note: 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.

Note: Make sure that the latest software file is downloaded from SIS web, changes could have occurred after publication.

Installing the Injector Trim Codes and Setting the FLS/FTS

Illustration 70	g03285604

1. Connect Cat ET to the ECM

2. Click the "Service" tab.

3. Select "Calibrations".
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   Illustration 71	g03286182

4. Click "Injector Codes Calibration".
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   Illustration 72	g03286196

5. Select the "Injector".
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   Illustration 73	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 74	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 75	g03357967
Default air shutoff not installed

Illustration 76	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 to calibrate the speed timing.

Illustration 77	g03286158

1. Click the "Service" tab.

2. Select "Calibrations".
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   Illustration 78	g03286176

3. Click "Timing Calibration".
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   Illustration 79	g03286178

4. Follow the Prompts.

5. Click the "Continue" button.

Software Enabled Attachments (SEA)

Illustration 80	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 81	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

Startup Checklist

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

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 14.

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

   Show/hide table

   Table 14

   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)

   Show/hide table

   (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 14 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".