Installation of the Water-Cooled Throttle for G3500C and G3500E Generator Set Engines{1265} Caterpillar

Engine:

G3516C (S/N: GSB1-UP; TJB1-UP; GZC1-UP; TJC1-UP; GZZ1-UP)

G3516E (S/N: GAS1-UP; SLY1-UP)

G3520 (S/N: HET1-UP)

G3520C (S/N: GZA1-UP; GZB1-UP; MAD1-UP; GZJ1-UP; GZK1-UP; GZL1-UP; GZM1-UP; GZN1-UP; B9P1-UP; RLP1-UP; LGS1-UP; HAT1-UP; CWW1-UP; CWY1-UP)

G3520E (S/N: GZG1-UP; GZH1-UP; HAL1-UP; SXY1-UP)

Introduction

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

This Special Instruction describes the installation procedure for a water-cooled throttle body for certain gas engines. The water-cooled throttle body ensures that the throttle body and actuator remain at an acceptable temperature.

Required Parts

Refer to Table 19 for a list of required parts that are used for all engine configurations included in this article. Table 1 to Table 18 list the specific serial numbers associated with each group. Additional parts that are unique to each individual group are located below in Table 20 to Table 37.

Table 1

Serial Numbers Effective for Group 1

S/N:GAS00170

S/N:GSB00113-00114

S/N:GSB00117-00123

S/N:GZC00211-00234

S/N:GZZ00193

S/N:GZZ00196

S/N:GZZ00198

S/N:GZZ00200

S/N:GZZ00203

S/N:GZZ00207

S/N:GZZ00217-218

S/N:GZZ00220

S/N:GZZ00267-268

S/N:GZZ00288

S/N:GZZ00330-00331

S/N:TJC00818-00819

Table 2

Serial Numbers Effective for Group 2

S/N:GZB00224-00225

S/N:GZB00227-00228

S/N:GZN00211-00215

S/N:GZN00221-00222

S/N:GZN00241-00242

S/N:GZN00244

S/N:GZN00250-00251

S/N:GZN00253-00254

S/N:GZN00257

S/N:GZN00261

S/N:GZN00272-00273

S/N:GZN00288

S/N:GZN00292

S/N:GZN00296-00297

S/N:GZN00299-00300

S/N:GZN00302-00303

S/N:GZN00305-00306

S/N:GZN00319

S/N:GZN00323

S/N:GZN00325

S/N:GZN00356

S/N:GZN00358-00359

S/N:GZN00389

S/N:GZN00391

S/N:GZN00444-00445

S/N:GZN00448

S/N:GZN00451

S/N:GZN00454

S/N:GZN00481-00484

S/N:GZN00489

S/N:GZN00498-00500

S/N:GZN00509-00510

S/N:GZN00515

S/N:GZN00517-00518

S/N:GZN00522

S/N:GZN00524

S/N:GZN00542-00543

S/N:GZN00545

S/N:GZN00553

S/N:GZN00559

S/N:GZN00563

S/N:GZN00567

S/N:GZN00571-00572

S/N:GZN00576-00578

S/N:GZN00586

S/N:GZN00590

S/N:GZN00596

S/N:GZN00598

S/N:GZN00600

S/N:GZN00612

S/N:GZN00617-00618

S/N:GZN00623-00624

S/N:GZN00625

S/N:GZN00628-00636

S/N:GZN00638

S/N:GZN00640

S/N:GZN00642-00647

S/N:GZN00649-00652

S/N:GZN0000654

S/N:GZN00656

S/N:GZN00658-00659

S/N:GZN00668

S/N:GZN00670-00673

S/N:GZN00675-00676

S/N:GZN00678-00681

S/N:GZN00683-00684

S/N:GZN00686

S/N:GZN00688

S/N:GZN00691

S/N:GZN00693-00696

S/N:GZN00698

S/N:GZN00700-00701

S/N:GZN00705

S/N:GZN00723-00724

S/N:GZN00749-00750

S/N:GZN00756-00757

S/N:GZN00762-00765

Table 3

Serial Numbers Effective for Group 3
S/N:GZH00112-00113
S/N:GZH00116
S/N:GZH00127
S/N:GZH00129
S/N:GZH00133
S/N:GZH00140
S/N:GZH00144-00145
S/N:GZH00150
S/N:GZH00158-00162
S/N:SXY00101-00102

Table 4

Serial Numbers Effective for Group 4
S/N:CWW00106-00109
S/N:CWW00116
S/N:CWW00118
S/N:CWW00123-00124
S/N:CWW00126
S/N:CWW00128
S/N:CWW00131
S/N:CWW00203-00205
S/N:CWW00209
S/N:CWW00212
S/N:CWW00214
S/N:CWW00217-00218
S/N:CWW00220
S/N:CWW00227
S/N:CWW00230
S/N:CWW00232
S/N:CWW00234
S/N:CWW00239-00240
S/N:CWW00242
S/N:CWW00246
S/N:CWW00248
S/N:CWW00250
S/N:CWW00252
S/N:CWW00254-00258
S/N:CWW00265-00267
S/N:CWW00272-00275
S/N:CWW00278-00282
S/N:CWW00284-00286
S/N:CWW00291
S/N:CWW00296-00301
S/N:GZN00803-00804

Table 5

Serial Numbers Effective for Group 5
S/N:GAS00116
S/N:GAS00118
S/N:GAS00121-00122
S/N:GAS00127
S/N:GAS00131
S/N:GAS00135
S/N:GAS00137-00138
S/N:GAS00140
S/N:GAS00147
S/N:GAS00150
S/N:GAS00158
S/N:GAS00168
S/N:GAS00169
S/N:GAS00171-00172
S/N:GAS00179-00180
S/N:GAS00183
S/N:GAS00188
S/N:GAS00194-00195
S/N:GAS00199
S/N:GAS00201
S/N:GAS00209
S/N:GAS00212-00213
S/N:GAS00218-00219
S/N:GAS00224
S/N:GAS00227
S/N:GAS00229-00230
S/N:GAS00232-00233
S/N:GAS00238
S/N:GAS00243-00246
S/N:GAS00254
S/N:GAS00261
S/N:GAS00269
S/N:GZZ00114-00117
S/N:GZZ00119-00141
S/N:GZZ00143-00145
S/N:GZZ00148
S/N:GZZ00150-00173
S/N:GZZ00180-00181
S/N:GZZ00183-00192
S/N:GZZ00195
S/N:GZZ00197
S/N:GZZ00199
S/N:GZZ00201-00202
S/N:GZZ00204-00206
S/N:GZZ00208-00216
S/N:GZZ00219
S/N:GZZ002221-00222
S/N:GZZ002224-00226
S/N:GZZ00228-00231
S/N:GZZ00233-00239
S/N:GZZ00242-00253
S/N:GZZ00257-00258
S/N:GZZ00260-00266
S/N:GZZ00269-00281
S/N:GZZ00285-00287
S/N:GZZ00291-00292
S/N:GZZ00294-00319
S/N:GZZ00321-00329
S/N:GZZ00332-00340
S/N:SLY00106-00107
S/N:TJB00102
S/N:TJB00105
S/N:TJB00107-00109

Table 6

Serial Numbers Effective for Group 6
S/N:GZJ00161-00197
S/N:GZJ00199-00204
S/N:GZJ00210-00215
S/N:GZJ00217-00221
S/N:GZJ00226-00227
S/N:GZJ00229
S/N:GZJ00231-00232
S/N:GZJ00234-00242
S/N:GZJ00244-00277
S/N:GZJ00282-00291
S/N:GZJ00294-00307
S/N:GZJ00309-00316
S/N:GZJ00326-00327
S/N:GZJ00329-00330
S/N:GZJ00333
S/N:GZJ00335-00338
S/N:GZJ00340-00341
S/N:GZJ00343-00344
S/N:GZJ00346-00348
S/N:GZJ00350
S/N:GZJ00355
S/N:GZJ00358
S/N:GZJ00360-00363
S/N:GZJ00365-00368
S/N:GZJ00375
S/N:GZJ00381-00382
S/N:GZJ00384
S/N:GZJ00386
S/N:GZJ00388
S/N:GZJ00390-00391
S/N:GZJ00393-00396
S/N:GZJ00403-00404
S/N:GZJ00406
S/N:GZJ00414-00419
S/N:GZJ00422-00423
S/N:GZJ00426-00433
S/N:GZJ00445-00448
S/N:GZJ00450-00451
S/N:GZJ00455-00457
S/N:GZJ00463-00471
S/N:GZJ00475-00476
S/N:GZK00151-00164
S/N:GZK00166
S/N:GZK00168-00170
S/N:GZK00173-00175
S/N:GZK00177-00183
S/N:MAD00200

Table 7

Serial Numbers Effective for Group 7
S/N:LGS00150
S/N:LGS00154-00155
S/N:LGS00158-00168

Table 8

Serial Numbers Effective for Group 8
S/N:CWW00103-00105
S/N:CWW00110-00115
S/N:CWW00117
S/N:CWW00119-00122
S/N:CWW00125
S/N:CWW00127
S/N:CWW00129-00130
S/N:GZN00217
S/N:GZN00223-00225
S/N:GZN00233-00240
S/N:GZN00247-00248
S/N:GZN00274-00277
S/N:GZN00279-00281
S/N:GZN00284
S/N:GZN00287
S/N:GZN00289
S/N:GZN00313-00314
S/N:GZN00316
S/N:GZN00361
S/N:GZN00363
S/N:GZN00366
S/N:GZN00386
S/N:GZN00387
S/N:GZN00490-00491
S/N:GZN00604

Table 9

Serial Numbers Effective for Group 9
S/N:B9P00101-00104
S/N:B9P00200-00205
S/N:B9P00207
S/N:B9P00209
S/N:B9P00213-00214
S/N:CWY00201-00206
S/N:CWY00208-00210
S/N:CWY00212-00221
S/N:GZG00111
S/N:GZL00141-00145
S/N:HET00150
S/N:SXY00100

Table 10

Serial Numbers Effective for Group 10

S/N:RLP00151-00152

S/N:RLP00156-00161

S/N:RLP00163-00164

S/N:RLP00166-00167

S/N:RLP00170-00171

S/N:RLP00175-00184

S/N:RLP00186-00188

S/N:RLP00190

S/N:RLP00193-00194

S/N:RLP00196

S/N:RLP00198-00200

S/N:RLP00202-00203

S/N:RLP00206

S/N:RLP00208-00210

Table 11

Serial Numbers Effective for Group 11
S/N:HAT00102

Table 12

Serial Numbers Effective for Group 12
S/N:MAD00101-00102

Table 13

Serial Numbers Effective for Group 13
S/N:CWW00200-00202
S/N:CWW00208
S/N:CWW00210-00211
S/N:CWW00219
S/N:CWW00222-00226
S/N:CWW00235-00238
S/N:CWW00243
S/N:CWW00245
S/N:CWW00247
S/N:CWW00249
S/N:CWW00251
S/N:CWW00253
S/N:CWW00259
S/N:CWW00260-00264
S/N:CWW00268-00271
S/N:CWW00276-00277
S/N:GZB00203-00205
S/N:GZB00207-00208
S/N:GZB00211-00219
S/N:GZB00221
S/N:GZB00223
S/N:GZB00229
S/N:GZN00227
S/N:GZN00229-00232
S/N:GZN00245-00246
S/N:GZN00249
S/N:GZN00262-00271
S/N:GZN00278
S/N:GZN00283
S/N:GZN00285-00287
S/N:GZN00289-00291
S/N:GZN00294-00295
S/N:GZN00298
S/N:GZN00301
S/N:GZN00308-00309
S/N:GZN00311
S/N:GZN00318
S/N:GZN00321-00322
S/N:GZN00329-00334
S/N:GZN00336-00341
S/N:GZN00343-00349
S/N:GZN00352-00353
S/N:GZN00355
S/N:GZN00357
S/N:GZN00364-00365
S/N:GZN00367-00371
S/N:GZN00373
S/N:GZN00378-00380
S/N:GZN00382-00385
S/N:GZN00394-00411
S/N:GZN00413
S/N:GZN00415-00416
S/N:GZN00418-00425
S/N:GZN00427-00428
S/N:GZN00430
S/N:GZN00432-00434
S/N:GZN00436-00439
S/N:GZN00441-00442
S/N:GZN00447
S/N:GZN00449-00450
S/N:GZN00455-00457
S/N:GZN00460
S/N:GZN00463-00468
S/N:GZN00470
S/N:GZN00472-00473
S/N:GZN00475
S/N:GZN00479-00480
S/N:GZN00483-00492
S/N:GZN00494
S/N:GZN00496-00497
S/N:GZN00501-00507
S/N:GZN00512-00513
S/N:GZN00516
S/N:GZN00519-00520
S/N:GZN00523
S/N:GZN00525-00526
S/N:GZN00536-00540
S/N:GZN00544
S/N:GZN00546-00547
S/N:GZN00549-00550
S/N:GZN00554-00556
S/N:GZN00558
S/N:GZN00560-00562
S/N:GZN00564-00565
S/N:GZN00570
S/N:GZN00573-00575
S/N:GZN00579
S/N:GZN00583-00585
S/N:GZN00587
S/N:GZN00589
S/N:GZN00592-00595
S/N:GZN00603
S/N:GZN00607-00609
S/N:GZN00613-00616
S/N:GZN00619-00622
S/N:GZN00626-00627
S/N:GZN00653
S/N:GZN00655
S/N:GZN00657
S/N:GZN00660-00667
S/N:GZN00669
S/N:GZN00687
S/N:GZN00689-00690
S/N:GZN00697
S/N:GZN00699
S/N:GZN00703
S/N:GZN00706-00707
S/N:GZN00710-00714
S/N:GZN00716
S/N:GZN00718-00722
S/N:GZN00725-00731
S/N:GZN00733-00736
S/N:GZN00738-00741
S/N:GZN00743
S/N:GZN00746-00747
S/N:GZN00751-00752
S/N:GZN00754-00755
S/N:GZN00758-00761
S/N:GZN00766
S/N:GZN00769-00774
S/N:GZN00776-00780
S/N:GZN00783-00789
S/N:GZN00791-00797
S/N:GZN00799-00802
S/N:GZN00805

Table 14

Serial Numbers Effective for Group 14

S/N:GZA00191-00192

S/N:GZA00194-00216

S/N:GZM00131-00161

S/N:GZM00163-00165

S/N:GZM00167-00169

S/N:GZM00171-00181

S/N:GZM00184-00193

S/N:GZM00196-00204

S/N:GZM00208

Table 15

Serial Numbers Effective for Group 15
S/N:RLP00213-00214
S/N:RLP00224
S/N:RLP00226-00235

Table 16

Serial Numbers Effective for Group 16
S/N:HAL00100

Table 17

Serial Numbers Effective for Group 17
S/N:B9P00206
S/N:B9P00208
S/N:B9P00210-00212

Table 18

Serial Numbers Effective for Group 18
S/N:HAT00200-00203
S/N:HAT00205-00211

Table 19

Required Parts for All Engines
Qty	Part Number	Part Description
4	0S-1587	Bolts
1	0S-1590	Bolt
4	0S-1591	Bolts
2	0S-1594	Bolts
6	1A-5822	Bolts
2	1F-7958	Full Nut
4	1L-2731	Tube Clamps
1	239-8100 (1)	Throttle Gp
1	264-7830	Bracket
1	360-7990	Gasket
1	363-7478	Bracket As
1	363-7479	Bracket As
1	363-8642	Tube As
1	363-8643	Tube As
1	363-8644	Tube As
1	364-1913	Bracket As
1	367-5997 (2)	Tee As
2	3J-1907	O-Ring Seals
6	3K-0360	O-Ring Seals
1	4K-0367	Full Nut
4	5M-2894	Hard Washers
18	5P-8245	Hard Washers
2	5P-8247	Hard Washers
2	6H-1717	Bolts
1	6M-9149	Bolt
2	6V-3265	Clips
2	6V-3940	Bolts
1	6V-8397	O-Ring Seal
4	6V-8398	O-Ring Seals
2	6V-8625	Elbows
1	6V-8723	Elbow
2	6V-8733	Unions
2	6V-9002	Elbows
7	6V-9746	O-Ring Seals
2	7J-9108	Seals
2	7M-8485	O-Ring Seals
2	7N-2597	Spacers
2	8C-6873	Connectors
1	8C-6920	Elbow
4	8M-9124	Washers
2	8T-1718	Elbows
1	9S-4191	O-Ring Plug
2	9S-8752	Full Nut
2	9S-9334	O-Ring Plugs
4	9X-6458	Hard Washers
4	9X-8873	Bolts

( 1 )	This group contains the following parts: 305-0580 Wiring Harness , and 362-6537 Throttle
( 2 )	Assembly consists of the following parts: 363-7918 Tee , 3K-0360 O-Ring Seal , 6V-8397 O-Ring Seal and 6V-9746 O-Ring Seal

Table 20

Required Parts for G3516C and G3516E Generator Set Engines (With Engine Driven SCAC Pump) Group 1
Qty	Part Number	Part Description
1	418-6827	Hose As
1	418-6828	Hose As
4	3H-8683	Clip
4	353-7953	Grommet
2	2A-2677	Spacer
2	5M-2894	Hard Washer
2	0L-2070	Bolt
1	215-4796	Tube As
1	210-6274	Tube
2	365-0682	Connector
2	8T-1919	O-Ring Seal
3	8T-6766	Pipe Plug
1	206-4181	Bracket As
1	207-5097	Plate
1	363-8645	Tube As
1	363-8646	Tube As
1	365-0682	Connector

Table 21

Required Parts for G3520C and G3520E Generator Set Engines (Single Turbo Without Engine Driven SCAC Pump) Group 2
Qty	Part Number	Part Description
1	418-1233	Hose As
1	418-1234	Hose As
2	6v-8733	Union
2	7X-7902	Elbow
1	0L-2070	Bolt
1	5M-2894	Hard Washer
1	363-8651	Bracket As
1	9S-1366	Bolt
1	1F-7958	Full Nut
2	5P-8245	Hard Washer
2	3H-8683	Clip
2	2A-2677	Spacer
2	353-7953	Grommet
1	201-1484	Bracket As
1	363-8645	Tube As
1	363-8646	Tube As
1	364-6074	Tube As
1	364-6075	Tube As

Table 22

Required Parts for G3520C and G3520E Generator Set Engines (Twin Turbo Without Engine Driven SCAC Pump) Group 3
Qty	Part Number	Part Description
1	418-1233	Hose As
1	418-1234	Hose As
2	6v-8733	Union
2	7X-7902	Elbow
1	0L-2070	Bolt
1	5M-2894	Hard Washer
1	363-8651	Bracket As
1	9S-1366	Bolt
1	1F-7958	Full Nut
2	5P-8245	Hard Washer
2	3H-8683	Clip
2	2A-2677	Spacer
2	353-7953	Grommet
1	206-4181	Bracket As
1	207-5097	Plate
1	363-8645	Tube As
1	363-8646	Tube As
1	364-6074	Tube As
1	364-6075	Tube As

Table 23

Required Parts for G3520C and G3520E Generator Set Engines (Single Turbo With Engine Driven SCAC Pump) Group 4
Qty	Part Number	Part Description
1	418-1233	Hose As
1	418-1234	Hose As
2	6v-8733	Union
2	7X-7902	Elbow
1	0L-2070	Bolt
1	5M-2894	Hard Washer
1	363-8651	Bracket As
1	9S-1366	Bolt
1	1F-7958	Full Nut
2	5P-8245	Hard Washer
2	3H-8683	Clip
2	2A-2677	Spacer
2	353-7953	Grommet
1	8T-8899	Elbow
1	201-1484	Bracket As
1	206-4181	Bracket As
1	207-5097	Plate
1	363-8645	Tube As
1	363-8646	Tube As
1	365-0682	Connector

Table 24

Required Parts for G3516C and G3516E Generator Set Engines (Without Engine Driven SCAC Pump) Group 5
Qty	Part Number	Part Description
1	418-1233	Hose As
1	418-1234	Hose As
2	6V-8733	Union
2	7X-7902	Elbow
1	0L-2070	Bolt
1	5M-2894	Hard Washer
1	9S-1366	Bolt
1	1F-7958	Full Nut
2	5P-8245	Hard Washer
2	3H-8683	Clip
2	2A-2677	Spacer
2	353-7953	Grommet
4	0S-1585	Bolt
1	205-7879	Elbow
1	205-7880	Elbow
1	206-4181	Bracket As
1	207-5097	Plate
1	363-8645	Tube As
1	363-8646	Tube As
1	364-1914	Tube As
1	364-1915	Tube As
1	365-0682	Connector

Table 25

Required Parts for G3520C Generator Set Engines (Twin Turbo Landfill) Group 6
Qty	Part Number	Part Description
1	437-7369	Hose As
1	439-0805	Hose As
2	367-6006	Connector As
4	3H-8683	Clip
4	353-7953	Grommet
3	5M-2894	Hard Washer
1	0S-1590	Bolt
1	0L-2070	Bolt
1	9S-8752	Full Nut
2	2A-2677	Spacer
1	236-5182	Tube As
1	7J-8902	Bolt
2	235-3958	Support As
1	235-3972	Support As
1	235-5648	Plate
1	364-1905	Tube As
	364-1906	Tube As

Table 26

Parts Required for G3520C Generator Set Engines (Single Turbo) Group 7
Qty	Part Number	Part Description
1	437-7369	Hose As
1	439-0805	Hose As
2	367-6006	Connector As
4	3H-8683	Clip
4	353-7953	Grommet
3	5M-2894	Hard Washer
1	0S-1590	Bolt
1	0L-2070	Bolt
1	9S-8752	Full Nut
2	2A-2677	Spacer
1	236-5182	Tube As
2	0S-1571	Bolt
2	186-3467	Gasket
2	235-3958	Support As
1	235-3972	Support As
2	235-5537	Gasket
1	276-2341	Tube As
1	306-6581	Bracket As
1	306-9208	Bracket
1	364-1905	Tube As
1	364-1906	Tube As

Table 27

Required Parts for G3520C and G3520E Generator Set Engines (Single Turbo With Engine Driven SCAC Pump) Group 8
Qty	Part Number	Part Description
2	0L-2070	Bolt
2	2A-2677	Spacer
4	353-7953	Grommet
2	367-6006	Connector As
4	3H-8683	Clip
1	437-7371	Hose As
1	439-4508	Hose As
2	5M-2894	Hard Washer
1	200-6441	Tube As
1	365-0682	Connector
1	363-8645	Tube As
1	363-8646	Tube As
1	201-1484	Bracket As
1	206-4181	Bracket As
1	207-5097	Plate
1	8T-8899	Elbow

Table 28

Required Parts for G3520C and G3520E Generator Set Engines (Twin Turbo With Engine Driven SCAC Pump) Group 9
Qty	Part Number	Part Description
2	0L-2070	Bolt
2	2A-2677	Spacer
4	353-7953	Grommet
2	367-6006	Connector As
4	3H-8683	Clip
1	437-7371	Hose As
1	439-4508	Hose As
2	5M-2894	Hard Washer
1	200-6441	Tube As
1	8T-8899	Elbow
1	206-4181	Bracket As
1	207-5097	Plate
1	363-8645	Tube As
1	363-8646	Tube As
1	365-0682	Connector

Table 29

Required Parts for G3520C Generator Set Engines (Coal Mine Methane) Group 10
Qty	Part Number	Part Description
2	0L-2070	Bolt
2	2A-2677	Spacer
4	353-7953	Grommet
2	367-6006	Connector As
4	3H-8683	Clip
1	437-7371	Hose As
1	439-4508	Hose As
2	5M-2894	Hard Washer
1	200-6441	Tube As
1	364-6072	Tube As
1	364-6073	Tube As
1	364-1905	Tube As
1	364-1906	Tube As
1	306-6581	Bracket As
1	306-9208	Bracket
1	276-2341	Tube As
2	235-3958	Support As
1	235-3972	Support As
2	235-5537	Gasket
2	186-3467	Gasket
1	8T-8899	Elbow
2	0S-1571	Bolt

Table 30

Required Parts for G3520C Landfill Engines (S/N: HAT) Group 11
Qty	Part Number	Part Description
2	0L-2070	Bolt
2	2A-2677	Spacer
4	353-7953	Grommet
2	367-6006	Connector As
4	3H-8683	Clip
1	437-7371	Hose As
1	439-4508	Hose As
2	5M-2894	Hard Washer
1	200-6441	Tube As
1	7J-8902	Bolt
2	235-3958	Support As
1	235-3972	Support As
1	235-5648	Plate
1	364-1905	Tube As
1	364-1906	Tube As
1	364-6073	Tube As

Table 31

Required Parts for G3520C Generator Set Engines (Twin Turbo Landfill) Group 12
Qty	Part Number	Part Description
2	0L-2070	Bolt
2	2A-2677	Spacer
4	353-7953	Grommet
2	367-6006	Connector As
4	3H-8683	Clip
1	437-7371	Hose As
1	439-4508	Hose As
2	5M-2894	Hard Washer
1	200-6441	Tube As
1	7J-8902	Bolt
2	235-3958	Support As
1	235-3972	Support As
1	235-5648	Plate
1	364-1905	Tube As
1	364-1906	Tube As

Table 32

Required Parts for G3520C and G3520E Generator Set Engines (Single Turbo With Engine Driven SCAC Pump) Group 13
Qty	Part Number	Part Description
2	0L-2070	Bolt
2	2A-2677	Spacer
4	353-7953	Grommet
2	367-6006	Connector As
4	3H-8683	Clip
1	437-7371	Hose As
1	439-4508	Hose As
2	5M-2894	Hard Washer
1	200-6441	Tube As
1	365-0682	Connector
1	363-8645	Tube As
1	363-8646	Tube As
1	201-1484	Bracket As
1	206-4181	Bracket As
1	207-5097	Plate
1	8T-8899	Elbow

Table 33

Required Parts for G3520C and G3520E Generator Set Engines (Twin Turbo With Engine Driven SCAC Pump) Group 14
Qty	Part Number	Part Description
2	0L-2070	Bolt
2	2A-2677	Spacer
4	353-7953	Grommet
2	367-6006	Connector As
4	3H-8683	Clip
1	437-7371	Hose As
1	439-4508	Hose As
2	5M-2894	Hard Washer
1	200-6441	Tube As
1	8T-8899	Elbow
1	206-4181	Bracket As
1	207-5097	Plate
1	363-8645	Tube As
1	363-8646	Tube As
1	365-0682	Connector

Table 34

Required Parts for G3520C Generator Set Engines (Coal Mine Methane) Group 15
Qty	Part Number	Part Description
2	0L-2070	Bolt
2	2A-2677	Spacer
4	353-7953	Grommet
2	367-6006	Connector As
4	3H-8683	Clip
1	437-7371	Hose As
1	439-4508	Hose As
2	5M-2894	Hard Washer
1	200-6441	Tube As
1	364-6072	Tube As
1	364-6073	Tube As
1	364-1905	Tube As
1	364-1906	Tube As
1	306-6581	Bracket As
1	306-9208	Bracket
1	276-2341	Tube As
2	235-3958	Support As
1	235-3972	Support As
2	235-5537	Gasket
2	186-3467	Gasket
1	8T-8899	Elbow
2	0S-1571	Bolt

Table 35

Required Parts for G3520C and G3520E Generator Set Engines (Twin Turbo With Engine Driven SCAC Pump) Group 16
Qty	Part Number	Part Description
1	418-1233	Hose As
1	418-1234	Hose As
2	6v-8733	Union
2	7X-7902	Elbow
1	0L-2070	Bolt
1	5M-2894	Hard Washer
1	363-8651	Bracket As
1	9S-1366	Bolt
1	1F-7958	Full Nut
2	5P-8245	Hard Washer
2	3H-8683	Clip
2	2A-2677	Spacer
2	353-7953	Grommet
1	8T-8899	Elbow
1	206-4181	Bracket As
1	207-5097	Plate
1	363-8645	Tube As
1	363-8646	Tube As
1	365-0682	Connector

Table 36

Required Parts for G3520C and G3520E Generator Set Engines (Twin Turbo Without Engine Driven SCAC Pump) Group 17
Qty	Part Number	Part Description
2	0L-2070	Bolt
2	2A-2677	Spacer
4	353-7953	Grommet
2	367-6006	Connector As
4	3H-8683	Clip
1	437-7371	Hose As
1	439-4508	Hose As
2	5M-2894	Hard Washer
1	200-6441	Tube As
1	364-6074	Tube As
1	364-6075	Tube As
1	363-8645	Tube As
1	363-8646	Tube As
1	206-4181	Bracket As
1	207-5097	Plate

Table 37

Required Parts for G3520C Landfill Engines (S/N: HAT) Group 18
Qty	Part Number	Part Description
1	437-7369	Hose As
1	439-0805	Hose As
2	367-6006	Connector As
4	3H-8683	Clip
4	353-7953	Grommet
3	5M-2894	Hard Washer
1	0S-1590	Bolt
1	0L-2070	Bolt
1	9S-8752	Full Nut
2	2A-2677	Spacer
1	236-5182	Tube As
1	364-6073	Tube As
1	364-1905	Tube As
1	364-1906	Tube As
2	235-3958	Support As
1	235-3972	Support As
1	235-5648	Plate
1	7J-8902	Bolt

Installation of Throttle and Related Components for G3516C and G3516E Generator Set Engines (With Engine Driven SCAC Pump) Group 1

1. Disconnect battery connections, or turn the master disconnect switch to the OFF position.

2. Drain the coolant from the second stage aftercooler circuit. Also, drain jacket water coolant to a level that is below the first stage aftercooler.

3. Remove the current throttle control valve. Refer to Disassembly and Assembly, "Throttle Control Valve - Remove" for more information.

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Illustration 1	g02381130
(1) 9S-9334 O-Ring Plug (2) 7M-8485 O-Ring Seal

4. Install plugs (1) with O-rings (2) into the aftercooler ports. Refer to Illustration 1.

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Illustration 2	g02404003
(3) 207-5097 Plate (4) 206-4181 Bracket As (5) 0S-1587 Bolt (6) 5P-8245 Hard Washer (7) 363-7478 Bracket As (8) 6H-1717 Bolt (9) 363-7479 Bracket As (10) 1A-5822 Bolt (11) 1F-7958 Full Nut (12) 7N-2597 Spacer

5. Remove the current bracket and install new bracket (4). Install bolts (5) with washers (6) into the two holes in the plate that are located near the turbochargers. Refer to Illustration 2.

   Note: Do not tighten the bolts until all bolts are installed into the plate.

6. Install bracket (3) onto plate (4) .

7. Position bracket (7) over the four holes that are located on plate near the throttle body. Install bolts (5) with washers (6) through bracket. Install bolts (8) with washers (6) through bracket (7) and plate (4) .

8. Install the new water-cooled throttle. Refer to Disassembly and Assembly, "Throttle Control Valve - Install" for more information. use the Steps below to install additional brackets onto the throttle housing.
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   Illustration 3	g02440576
   (13) 364-1913 Bracket As (14) 264-7830 Bracket (15) 360-7990 Gasket

   1. Install gasket (15) onto the throttle housing before the throttle is installed onto the engine.

   2. Insert the bolt that is located in the 12 o'clock position, through bracket (13), and install bolts into the throttle housing. Refer to Illustration 3 and Illustration 6 for the location of the brackets and bolts.

   3. Insert the bolts that are located in the 10 o'clock and 11 o'clock positions through bracket (14). Install the bolts into the air lines group housing.
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   Illustration 4	g02454037
   (16) Jumper harness

   4. Connect the connector of jumper harness (16) to the current engine wiring harness.

Installation of Throttle Coolant Supply Lines and Related Components

Illustration 5	g03525343
(13) 364-1913 Bracket As (14) 264-7830 Bracket (17) 6V-8398 O-Ring Seal (18) 3K-0360 O-Ring Seal (19) 6V-9002 Elbow (20) 0S-1594 Bolt (21) 9X-6458 Hard Washer (22) 9S-8752 Full Nut (23) 6V-3265 Clip (24) 6M-9149 Bolt (25) 5P-8247 Hard Washer (26) 363-8643 Tube As (27) 363-8642 Tube As (28) 6V-8625 Elbow (29) 6V-8723 Elbow (30) 363-8644 Tube As (31) 363-8645 Tube As (32) 363-8646 Tube As (33) 6V-8397 O-Ring Seal (34) 4K-0367 Full Nut

Illustration 6	g03525396
(17) 6V-8398 O-Ring Seal (18) 3K-0360 O-Ring Seal (27) 363-8642 Tube As (28) 6V-8625 Elbow (35) 367-5997 Tee As (36) 6V-9746 O-Ring Seal (37) 8C-6920 Elbow (38) 9S-4191 O-Ring Plug (39) 3J-1907 O-Ring Seal

1. Install elbows (19) with O-rings (18) into the throttle housing. Refer to Illustration 5 for proper orientation of the elbows.

2. Install O-rings (17) into the groove of elbow (19) .

3. Install tube (26) between the two elbows, and tighten the fittings.

4. Install elbow (29) with O-ring seal (18) into aftercooler housing.

5. Install O-ring seal (33) into the groove of elbow (29) .

6. Install tee (35) into the throttle housing. Orient tee (35) with the smaller threads of the adapter directed toward the front of the engine.

7. Install plug (38) with O-ring (39) into the port that is located at the top of tee (35). Alternatively, a connection can be attached to the expansion tank for the SCAC vent.

8. Install clips (23) onto tube (30), and install tube between the two elbows. Refer to Illustration 5 for the proper orientation of tube (30) .

9. Position clip (23) over the hole in bracket (14) that is closest to the throttle housing. Install bolt (20) with washer (21) through the clip and bracket. Install nut (22) with washer (21) onto the bolt, and tighten the bolt.

10. Position clip (23) over the hole in bracket (13). Install bolt (20) with washer (21) through the clip and bracket. Install nut (22) with washer (21) onto the bolt, and tighten the bolt.

11. Tighten the fittings on tube (30) .

12. Install elbow (28) with O-ring seal (18) into the right side of the throttle housing.

13. Install O-ring seal (17) into the groove in the elbow.

14. Install elbow (28) with O-ring seal (18) into the left side of the throttle housing.

15. Install O-ring seal (17) into the groove in the elbow.

16. Install tube (27) between the two elbows. Refer to Illustration 5 and Illustration 6 for proper orientation of tube (27) .

17. Install elbow (37) with O-ring seal (18) into the left side of the throttle housing. Refer to Illustration 6 for proper orientation of elbow (37) .

18. Install tube (32) onto elbow (37) .

19. Install tube (31) onto tee (35) .

Installation Procedure for the 210-6273 Water Lines Gp

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Illustration 7	g03525456
(36) 6V-9746 O-Ring Seal (40) 6V-8733 Union (41) 365-0682 Connector (42) 418-6828 Hose As (43) 418-6827 Hose As (44) 215-4796 Tube As (45) 210-6274 Tube

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Illustration 8	g03525617
(46) 363-8651 Bracket As (47) 3H-8683 Clip (48) 353-7953 Grommet (49) 0L-2070 Bolt (50) 5M-2894 Hard Washer (51) 2A-2677 Spacer (52) 8M-9124 Washer (53) 9S-1366 Bolt

1. Install o-ring seal (36) and union (40) onto the end of hose assembly (43) as shown in Illustration 7. On the other end of hose assembly (43), install o-ring seal (36) with connector (41) .

2. Install o-ring seal (36) with connector (41) onto hose assembly (42) .

3. Install tube assembly (45) and tube (44) onto the engine as shown in Illustration 7.

4. Connect hose assemblies (42) and (43) to tube assembly (44) and tube (45) as shown in Illustration 7.

5. Install grommet (48) onto hose assemblies (42) and (43) .

6. Install clips (47) onto grommets (48) and secure to bracket assembly (46). Use bolt (49) with hard washer (50), (52), and spacer (51) as shown in Illustration 8.

7. Attach bracket assembly (46) to the engine using bolt (53) .

8. Fill the aftercooler circuit with coolant. Also, fill the jacket water coolant to the proper level. Loosen the plug that is located on the tee when the SCAC is filled in order to allow air to vent from the SCAC system.

Installation of Throttle and Related Components for G3520C and G3520E Generator Set Engines (Single Turbo Without Engine Driven SCAC Pump) Group 2

1. Disconnect the battery connections, or turn the master disconnect switch to the OFF position.

2. Drain the coolant from the second stage aftercooler circuit. Also, drain jacket water coolant to a level that is below the first stage aftercooler.

3. Remove the current throttle control valve. Refer to Disassembly and Assembly, "Throttle Control Valve - Remove" for more information.

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Illustration 9	g03526046
(1) 9S-9334 O-Ring Plug (2) 7M-8485 O-Ring Seal

4. Install plugs (1) with O-rings (2) into the aftercooler ports. Refer to Illustration 9.

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Illustration 10	g03526048
(3) 201-1484 Bracket As (4) 0S-1587 Bolt (5) 5P-8245 Hard Washer (6) 6H-1717 Bolt (7) 1A-5822 Bolt (8) 1F-7958 Full Nut (9) 7N-2597 Spacer (10) 363-7479 Bracket As (11) 363-7478 Bracket As

5. Remove the current bracket and install new bracket (3). Install bolts (4) with washers (5) into the two holes in the plate that are located near the turbochargers. Refer to Illustration 10.

   Note: Do not tighten the bolts until all bolts are installed into the plate.

6. Position bracket (11) over the four holes that are located on bracket (3) near the throttle body. Install bolts (4) with washers (5) through bracket (11). Install bolts (6) with washers (5) through bracket (11) .

7. Install the new water-cooled throttle. Refer to Disassembly and Assembly, "Throttle Control Valve - Install" for more information. Use the Steps below to install additional brackets onto the throttle housing.
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   Illustration 11	g03526078
   (12) 364-1913 Bracket As (13) 264-7830 Bracket (14) 360-7990 Gasket

   1. Install gasket (14) onto the throttle housing before the throttle is installed onto the engine. Refer to Illustration

   2. Insert the bolt that is located in the 12 o'clock position, through bracket (12), and install bolts into the throttle housing. Refer to Illustration 11 for the location of the brackets and bolts.

   3. Insert the bolts that are located in the 10 o'clock and 11 o'clock positions through bracket (13). Install bolts into the air lines group housing.
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   Illustration 12	g02453259
   (15) Jumper harness

   4. Connect the jumper harness (15) that is attached to the new throttle, to the current engine wiring harness. Refer to Illustration 12.

   5. Place aftercooler bracket (10) into position. Install bolts that were removed in Step 3 onto the front end of the aftercooler bracket. Also, install bolts through aftercooler bracket (10), spacer (9), and aftercooler housing. Install nut (8) with washer (5) onto the end of bolt (7). Tighten the bolts and nuts

Installation of Throttle Coolant Supply Lines and Related Components

Illustration 13	g03526179
(12) 364-1913 Bracket As (13) 264-7830 Bracket (16) 6V-8398 O-Ring Seal (17) 3K-0360 O-Ring Seal (18) 6V-9002 Elbow (19) 0S-1594 Bolt (20) 9X-6458 Hard Washer (21) 9S-8752 Full Nut (22) 6V-3265 Clip (23) 6M-9149 Bolt (24) 5P-8247 Hard Washer (25) 363-8643 Tube As (26) 363-8642 Tube As (27) 6V-8625 Elbow (28) 6V-8723 Elbow (29) 363-8644 Tube As (30) 363-8646 Tube As (31) 363-8645 Tube As (32) 6V-8397 O-Ring Seal

Illustration 14	g03526180
(16) 6V-8398 O-Ring Seal (17) 3K-0360 O-Ring Seal (18) 6V-9002 Elbow (26) 363-8642 Tube As (27) 6V-8625 Elbow (33) 367-5997 Tee As (34) 6V-9746 O-Ring Seal (35) 8C-6920 Elbow (36) 9S-4191 O-Ring Plug (37) 3J-1907 O-Ring Seal

1. Install elbows (18) with O-rings (17) into the throttle housing. Refer to Illustration 13.

2. Install O-rings (16) into the groove of elbows (18) .

3. Install tube (25) between the two elbows, and tighten the fittings.

4. Install elbow (28) with O-ring seal (17) into aftercooler housing. Install tee (33) into the throttle housing. Orient tee (33) with the smaller threads of the adapter directed toward the front of the engine.

5. Install plug (36) with O-ring (37) into the top of the tee assembly, and tighten the plug. Alternatively, a connection can be attached to the expansion tank for the SCAC vent.

6. Install clips (22) onto tube (29), and install tube between the two elbows. Refer to Illustration 13 for the proper orientation of tube (29) .

7. Position clip (22) over the hole in bracket (13) that is closest to the throttle housing. Install bolt (19) with washer (20) through the clip and bracket. Install nut (21) with washer (20) onto the bolt, and tighten the bolt.

8. Position clip (22) over the hole in bracket (3). Install bolt (19) with washer (20) through the clip and bracket. Install nut (21) with washer (20) onto the bolt, and tighten the bolt.

9. Tighten the fittings on tube (29) .

10. Install elbow (27) with O-ring seal (17) into the right side of the throttle housing.

11. Install O-ring seal (16) into the groove in the elbow.

12. Install elbow (27) with O-ring seal (17) into the left side of the throttle housing.

13. Install O-ring seal (16) into the groove in the elbow.

14. Install tube (26) between the two elbows. Refer to Illustration 13 and Illustration 14 for proper orientation of tube (26) .

15. Install elbow (35) with O-ring seal (34) into the left side of the throttle housing. Refer to Illustration 14 for proper orientation of elbow (35) .

16. Install tube (30) onto elbow (35) .

17. Install tube (31) onto tee (33) .

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Illustration 15	g03526189
View A-A (38) 1L-2731 Tube Clamp (39) 0S-1591 Bolt (40) 5M-2894 Hard Washer (41) 8M-9124 Washer (42) 363-8651 Bracket As (43) 1A-5822 Bolt

18. Install clamps (38) onto tubes. Refer to Illustration 15.

19. Install bracket (43) onto the aftercooler housing. Use the current bolts in order to secure the bracket.

20. Install hard washer (41) between the clamps and the bracket.

21. Install bolts (39) with washer (40) through the clamps and the hard washer. Thread the bolt into the bracket and tighten the bolt. Refer to Illustration 15

Installation Procedure for the 200-6438 Water Lines Gp

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Illustration 16	g03526200
(43) 6V-9746 O-Ring Seal (44) 6V-8733 Union (45) 418-1233 Hose As (46) 418-1234 Hose As (47) 7X-7902 Elbow

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Illustration 17	g03526239
(48) 363-8651 Bracket As (49) 3H-8683 Clip (50) 353-7953 Grommet (51) 0L-2070 Bolt (52) 5M-2894 Hard Washer (53) 2A-2677 Spacer (54) 8M-9124 Washer (55) 9S-1366 Bolt

1. Install o-ring seal (43) with union (44) onto one end of hose assemblies (45) and (46).

2. On hose assembly (45) install o-ring seal (43) with elbow (47) and attach to the engine as shown in Illustration 16.

3. On hose assembly (46) install o-ring seal (43) with elbow (47) and attach to the engine as shown in Illustration 16.

4. Install grommet (50) onto hose assemblies (45) and (46) .

5. Install clips (49) onto grommets (50) and secure to bracket assembly (48). Use bolt (51) with hard washer (52), (54), and spacer (53) as shown in Illustration 19.

6. Attach bracket assembly (48) to the engine using bolt (55) .

Installation Procedure for the 200-6438 Water Aftercooler Gp

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Illustration 18	g03526257
(43) 6V-9746 O-Ring Seal (44) 6V-8733 Union (45) 418-1233 Hose As (46) 418-1234 Hose As (47) 7X-7902 Elbow

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Illustration 19	g03526239
(48) 363-8651 Bracket As (49) 3H-8683 Clip (50) 353-7953 Grommet (51) 0L-2070 Bolt (52) 5M-2894 Hard Washer (53) 2A-2677 Spacer (54) 8M-9124 Washer (55) 9S-1366 Bolt

1. Install o-ring seal (43) with union (44) onto one end of hose assemblies (45) and (46).

2. On hose assembly (45) install o-ring seal (43) with elbow (47) and attach to the engine as shown in Illustration 18.

3. On hose assembly (46) install o-ring seal (43) with elbow (47) and attach to the engine as shown in Illustration 18.

4. Install grommet (50) onto hose assemblies (45) and (46) .

5. Install clips (49) onto grommets (50) and secure to bracket assembly (48). Use bolt (51) with hard washer (52), (54), and spacer (53) as shown in Illustration 19.

6. Attach bracket assembly (48) to the engine using bolt (55) .

Installation of Throttle and Related Components for G3520C and G3520E Generator Set Engines (Twin Turbo Without Engine Driven SCAC Pump) Group 3

1. Drain the coolant from the second stage aftercooler circuit. Also, drain jacket water coolant to a level that is below the first stage aftercooler.

2. Remove the current throttle control valve. Refer to Disassembly and Assembly, "Throttle Control Valve - Remove" for more information.

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Illustration 20	g02381130
(1) 9S-9334 O-Ring Plug (2) 7M-8485 O-Ring Seal

3. Install plugs (1) with O-rings (2) into the aftercooler ports. Refer to Illustration 20.

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Illustration 21	g02404003
(3) 207-5097 Plate (4) 206-4181 Bracket As (5) 0S-1587 Bolt (6) 5P-8245 Hard Washer (7) 363-7478 Bracket As (8) 6H-1717 Bolt (9) 363-7479 Bracket As (10) 1A-5822 Bolt (11) 1F-7958 Full Nut (12) 7N-2597 Spacer

4. Remove the current bracket and install new bracket (4). Install bolts (5) with washers (6) into the two holes in the plate that are located near the turbochargers. Refer to Illustration 21.

   Note: Do not tighten the bolts until all bolts are installed into the plate.

5. Install plate (3) onto bracket (4). Use the four bolts that were previously removed in order to secure bracket (4) .

6. Position bracket (7) over the four holes that are located on plate near the throttle body. Install bolts (5) with washers (6) through bracket. Install bolts (8) with washers (6) through bracket. Refer to Illustration 21.

7. Place the aftercooler bracket into the proper position. Install the bots that were removed in Step 2 onto the front end of the aftercooler bracket. Also, install bolt (10) through aftercooler bracket (9), spacer (12), and aftercooler housing. Install nut (11), with washer (6) onto the end of bolt (10). Tighten the nuts and bolts.

8. Install the new water-cooled throttle. Refer to Disassembly and Assembly, "Throttle Control Valve - Install" for more information. use the Steps below to install additional brackets onto the throttle housing.
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   Illustration 22	g02440576
   (13) 364-1913 Bracket As (14) 264-7830 Bracket (15) 360-7990 Gasket

   1. Install gasket (15) onto the throttle housing before the throttle is installed onto the engine.

   2. Insert the bolt that is located in the 12 o'clock position, through bracket (13), and install bolts into the throttle housing. Refer to Illustration 22 and Illustration 22 for the location of the brackets and bolts.

   3. Insert the bolts that are located in the 10 o'clock and 11 o'clock positions through bracket (14). Install the bolts into the air lines group housing.
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   Illustration 23	g02453918
   (16) Jumper harness

   4. Connect the jumper harness (16) that is attached to the new throttle, to the current engine wiring harness. Refer to Illustration 23.

Installation of Throttle Coolant Supply Lines and Related Components

Illustration 24	g03526339
(17) 6V-8398 O-Ring Seal (18) 3K-0360 O-Ring Seal (19) 6V-9002 Elbow (20) 0S-1594 Bolt (21) 9X-6458 Hard Washer (22) 9S-8752 Full Nut (23) 6V-3265 Clip (24) 6M-9149 Bolt (25) 5P-8247 Hard Washer (26) 363-8643 Tube As (27) 363-8642 Tube As (28) 6V-8625 Elbow (29) 6V-8723 Elbow (30) 363-8644 Tube As (31) 363-8645 Tube As (32) 363-8646 Tube As (33) 6V-8397 O-Ring Seal

Illustration 25	g02467363
(17) 6V-8398 O-Ring Seal (18) 3K-0360 O-Ring Seal (27) 363-8642 Tube As (28) 6V-8625 Elbow (34) 367-5997 Tee As (35) 6V-9746 O-Ring Seal (36) 8C-6920 Elbow (37) 9S-4191 O-Ring Plug (38) 3J-1907 O-Ring Seal

1. Install elbows (19) with O-rings (18) into the throttle housing. Refer to Illustration 24 for the proper orientation of the elbows (19) .

2. Install O-rings (17) into the groove of elbow (19) .

3. Install tube (26) between the two elbows, and tighten the fittings.

4. Install elbow (29) with O-ring seal (18) into aftercooler housing.

5. Install O-ring seal (33) into the groove of elbow (29) .

6. Install tee (34) into the throttle housing. Orient tee (34) with the smaller threads of the adapter directed toward the front of the engine.

7. Install plug (37) with seal (38) into the port that is located on the top of the tee assembly. Alternatively, a connection can be attached to the expansion tank.

8. Install clips (23) onto tube (30), and install tube between the two elbows. Refer to Illustration 24 for the proper orientation of tube (30) .

9. Position clip (23) over the hole in bracket (14) that is closest to the throttle housing. Install bolt (20) with washer (21) through the clip and bracket. Install nut (22) with washer (21) onto the bolt, and tighten the bolt.

10. Position clip (23) over the hole in bracket (13). Install bolt (20) with washer (21) through the clip and bracket. Install nut (22) with washer (21) onto the bolt, and tighten the bolt.

11. Tighten the fittings on tube (30) .

12. Install elbow (28) with O-ring seal (18) into the right side of the throttle housing.

13. Install O-ring seal (17) into the groove in the elbow.

14. Install elbow (28) with O-ring seal (18) into the left side of the throttle housing.

15. Install O-ring seal (17) into the groove in the elbow.

16. Install tube (27) between the two elbows. Refer to Illustration 24 and Illustration 25 for proper orientation of tube (27) .

17. Install elbow (36) with O-ring seal (15) into the left side of the throttle housing. Refer to Illustration 25 for proper orientation of elbow (36) .

18. Install O-ring seal (35) into the groove of the elbow.

19. Install tube (32) onto elbow (36) .

20. Install tube (31) onto adapter (34) .

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Illustration 26	g02471700
View A-A (39) 1L-2731 Tube Clamp (40) 0S-1591 Bolt (41) 5M-2894 Hard Washer (42) 8M-9124 Washer

21. Install clamps (39) onto the tubes.

22. Install bracket (49) onto the aftercooler housing. Use the current bolts in order to secure the bracket.

23. Install hard washer (42) between the clamps and the aftercooler housing.

24. Install bolt (40) with washer (41) through the clamps and hard washer. Tighten the bolts.

Installation Procedure for Coolant Supply Lines of 200-6438 Water Aftercooler Gp

Note: This configuration is for the standard flow SCAC. Coolant enters on the side of the odd-numbered cylinder banks.

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Illustration 27	g03526257
(43) 6V-9746 O-Ring Seal (44) 6V-8733 Union (45) 418-1233 Hose As (46) 418-1234 Hose As (47) 7X-7902 Elbow

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Illustration 28	g03526239
(48) 363-8651 Bracket As (49) 3H-8683 Clip (50) 353-7953 Grommet (51) 0L-2070 Bolt (52) 5M-2894 Hard Washer (53) 2A-2677 Spacer (54) 8M-9124 Washer (55) 9S-1366 Bolt

1. Install o-ring seal (43) with union (44) onto one end of hose assemblies (45) and (46).

2. On hose assembly (45) install o-ring seal (43) with elbow (47) and attach to the engine as shown in Illustration 18.

3. On hose assembly (46) install o-ring seal (43) with elbow (47) and attach to the engine as shown in Illustration 18.

4. Install grommet (50) onto hose assemblies (45) and (46) .

5. Install clips (49) onto grommets (50) and secure to bracket assembly (48). Use bolt (51) with hard washer (52), (54), and spacer (53) as shown in Illustration 19.

6. Attach bracket assembly (48) to the engine using bolt (55) .

7. Fill the aftercooler circuit with coolant. Also, fill the jacket water coolant to the proper level. Loosen the plug located on the tee when the SCAC is filled in order to allow air to vent from the SCAC system.

Installation Procedure for the 369-1042 Water Lines Gp

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Illustration 29	g03526200
(43) 6V-9746 O-Ring Seal (44) 6V-8733 Union (45) 418-1233 Hose As (46) 418-1234 Hose As (47) 7X-7902 Elbow

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Illustration 30	g03526239
(48) 363-8651 Bracket As (49) 3H-8683 Clip (50) 353-7953 Grommet (51) 0L-2070 Bolt (52) 5M-2894 Hard Washer (53) 2A-2677 Spacer (54) 8M-9124 Washer (55) 9S-1366 Bolt

1. Install o-ring seal (43) with union (44) onto one end of hose assemblies (45) and (46).

2. On hose assembly (45) install o-ring seal (43) with elbow (47) and attach to the engine as shown in Illustration 18.

3. On hose assembly (46) install o-ring seal (43) with elbow (47) and attach to the engine as shown in Illustration 18.

4. Install grommet (50) onto hose assemblies (45) and (46) .

5. Install clips (49) onto grommets (50) and secure to bracket assembly (48). Use bolt (51) with hard washer (52), (54), and spacer (53) as shown in Illustration 19.

6. Attach bracket assembly (48) to the engine using bolt (55) .

7. Fill the aftercooler circuit with coolant. Also, fill the jacket water coolant to the proper level. Loosen the plug located on the tee when the SCAC is filled in order to allow air to vent from the SCAC system.

Installation of Throttle and Related Components for G3520C and G3520E Generator Set Engines (Single Turbo With Engine Driven SCAC Pump) Group 4

1. Drain the coolant from the second stage aftercooler circuit. Also, drain jacket water coolant to a level that is below the first stage aftercooler.

2. Remove the current throttle control valve. Refer to Disassembly and Assembly, "Throttle Control Valve - Remove" for more information.

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Illustration 31	g02381130
(1) 9S-9334 O-Ring Plug (2) 7M-8485 O-Ring Seal

3. Install plugs (1) with O-rings (2) into the aftercooler ports. Refer to Illustration 31.

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Illustration 32	g02456983
View of 201-1483 Control Mounting Gp (3) 0S-1587 Bolt (4) 5P-8245 Hard Washer (5) 6H-1717 Bolt (6) 1A-5822 Bolt (7) 1F-7958 Full Nut (8) 7N-2597 Spacer (9) 363-7479 Bracket As (10) 363-7478 Bracket As (11) 201-1484 Bracket As

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Illustration 33	g02456839
View of 206-4180 Control Mounting Gp (3) 0S-1587 Bolt (4) 5P-8245 Hard Washer (5) 6H-1717 Bolt (6) 1A-5822 Bolt (7) 1F-7958 Full Nut (8) 7N-2597 Spacer (9) 363-7479 Bracket As (10) 363-7478 Bracket As (12) 207-5097 Plate (13) 206-4181 Bracket As

4. Install the 201-1483 Control Mounting Gp . Use the following Steps. Refer to Illustration 32.

   Note: Do not tighten the bolts until all bolts are installed into the plate.

   1. Remove the current plate and install bracket (11). Install bolts (3) with washers (4) into the two holes in the plate that are located near the turbochargers.

   2. Position bracket (10) over the four holes that are located on plate near the throttle body. Install bolts (3) with washers (4) through bracket (10) and thread the bolt into the bracket. Install bolts (5) with washers (4) through the bracket.

5. Install the 206-4180 Control Mounting Gp . Use the following Steps. Refer to Illustration 33.

   Note: Do not tighten the bolts until all bolts are installed into the plate.

   1. Remove the current plate and install bracket (13). Install bolts (3) with washers (4) into the two holes in the plate that are located near the turbochargers.

   2. Install plate (12) onto bracket (13) .

   3. Position bracket (10) over the four holes that are located on plate near the throttle body. Install bolts (3) with washers (4) through bracket (10) and thread the bolt into the bracket. Install bolts (5) with washers (4) through the bracket.

6. Install the new water-cooled throttle. Refer to Disassembly and Assembly, "Throttle Control Valve - Install" for more information. use the Steps below to install additional brackets onto the throttle housing.
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   Illustration 34	g02431407
   (14) 364-1913 Bracket As (15) 264-7830 Bracket (16) 360-7990 Gasket

   1. Install gasket (16) onto the throttle housing before the throttle is installed onto the engine. Refer to Illustration

   2. Insert the bolt that is located in the 12 o'clock position, through bracket (14), and install bolts into the throttle housing. Refer to Illustration 34 and Illustration 37 for the location of the brackets and bolts.

   3. Insert the bolts that are located in the 10 o'clock and 11 o'clock positions through bracket (15). Install the bolts into the air lines group housing.
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   Illustration 35	g02453916
   (17) Jumper harness

   4. Connect the jumper harness (17) that is attached to the new throttle, to the current engine wiring harness. Refer to Illustration 35.

7. Position aftercooler bracket (9) into the proper position. Install the bolts that were removed in Step 2 onto the front end of the aftercooler bracket. Also install bolts through aftercooler bracket (9), spacer (8) and aftercooler housing. Install nut (7) with washer (4) onto the end of bolt (6). Tighten the nuts and bolts. Refer to Illustration 32 and Illustration 33.

Installation of Throttle Coolant Supply Lines and Related Components

Illustration 36	g03526437
(14) 364-1913 Bracket As (15) 264-7830 Bracket (18) 6V-8398 O-Ring Seal (19) 3K-0360 O-Ring Seal (20) 6V-9002 Elbow (21) 0S-1594 Bolt (22) 9X-6458 Hard Washer (23) 9S-8752 Full Nut (24) 6V-3265 Clip (25) 6M-9149 Bolt (26) 5P-8247 Hard Washer (27) 363-8643 Tube As (28) 363-8642 Tube As (29) 6V-8625 Elbow (30) 6V-8723 Elbow (31) 363-8644 Tube As (32) 363-8645 Tube As (33) 363-8646 Tube As (34) 6V-8397 O-Ring Seal

Illustration 37	g02457518
(18) 6V-8398 O-Ring Seal (19) 3K-0360 O-Ring Seal (28) 363-8642 Tube As (29) 6V-8625 Elbow (35) 367-5997 Tee As (36) 6V-9746 O-Ring Seal (37) 8C-6920 Elbow (38) 9S-4191 O-Ring Plug (39) 3J-1907 O-Ring Seal

1. Install elbows (20) with O-rings (19) into the throttle housing.

2. Install O-rings (18) into the groove of elbow (20) .

3. Install tube (27) between the two elbows, and tighten the fittings.

4. Install elbow (30) with O-ring seal (19) into aftercooler housing.

5. Install O-ring into the groove of elbow (30) .

6. Install tee (35) into the throttle housing. Orient tee (35) with the smaller threads of the adapter directed toward the front of the engine.

7. Install plug (38) with O-ring seal (39) into the top of the tee assemble, and tighten the plug. Alternatively, a connection can be attached to the expansion tank for the SCAC vent.

8. Install clips (24) onto tube (31), and install tube between the two elbows. Refer to Illustration 37 for the proper orientation of tube (31) .

9. Position clip (24) over the hole in bracket (15) that is closest to the throttle housing. Install bolt (21) with washer (22) through the clip and bracket. Install nut (23) with washer (22) onto the bolt, and tighten the bolt.

10. Position clip (24) over the hole in bracket (14). Install bolt (21) with washer (22) through the clip and bracket. Install nut (23) with washer (22) onto the bolt, and tighten the bolt.

11. Tighten the fittings on tube (31) .

12. Install elbow (29) with O-ring seal (19) into the right side of the throttle housing.

13. Install O-ring seal (18) into the groove in the elbow.

14. Install elbow (29) with O-ring seal (19) into the left side of the throttle housing.

15. Install O-ring seal (18) into the groove in the elbow.

16. Install tube (28) between the two elbows. Refer to Illustration 37 and Illustration 37 for proper orientation of tube (28) .

17. Install elbow (37) with O-ring seal (36) into the left side of the throttle housing.

18. Install tube (33) onto elbow (37) .

19. Install tube (32) onto tee (35) .

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Illustration 38	g03526456
View A-A (40) 1L-2731 Tube Clamp (41) 0S-1591 Bolt (42) 5M-2894 Hard Washer (43) 8M-9124 Washer (44) 363-8651 Bracket As

20. Install clamps (40) onto tubes (32) and (33) .

21. Install bracket (44) onto the aftercooler housing. Use the current bolts in order to secure the bracket.

22. Install hard washer (43) between the clamps and the aftercooler housing.

23. Install bolt (41) with washer (42) through the clamps and the hard washer, and tighten the bolt.

Installation Procedure for Coolant Supply Lines of 200-6438 Water Aftercooler Gp

Note: This configuration is for the standard flow SCAC. Coolant enters on the side of the odd-numbered cylinder banks.

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Illustration 39	g03526498
(45) 6V-9746 O-Ring Seal (46) 6V-8733 Union (47) 418-1233 Hose As (48) 418-1234 Hose As (49) 7X-7902 Elbow

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Illustration 40	g03526499
(50) 363-8651 Bracket As (51) 3H-8683 Clip (52) 353-7953 Grommet (53) 0L-2070 Bolt (54) 5M-2894 Hard Washer (55) 2A-2677 Spacer (56) 8M-9124 Washer (57) 9S-1366 Bolt

1. Install o-ring seal (45) with union (46) onto one end of hose assemblies (47) and (48).

2. On hose assembly (48) install o-ring seal (45) with elbow (49) and attach to the engine as shown in Illustration 39.

3. On hose assembly (47) install o-ring seal (45) with elbow (49) and attach to the engine as shown in Illustration 39.

4. Install grommet (52) onto hose assemblies (47) and (48) .

5. Install clips (51) onto grommets (52) and secure to bracket assembly (50). Use bolt (53) with hard washer (54), (56), and spacer (55) as shown in Illustration 40.

6. Attach bracket assembly (50) to the engine using bolt (57) .

7. Fill the aftercooler circuit with coolant. Also, fill the jacket water coolant to the proper level. Loosen the plug located on the tee when the SCAC is filled in order to allow air to vent from the SCAC system.

Installation Procedure for the 369-1042 Water Lines Gp

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Illustration 41	g03526557
(45) 6V-9746 O-Ring Seal (46) 6V-8733 Union (47) 418-1233 Hose As (48) 418-1234 Hose As (49) 7X-7902 Elbow

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Illustration 42	g03526499
(50) 363-8651 Bracket As (51) 3H-8683 Clip (52) 353-7953 Grommet (53) 0L-2070 Bolt (54) 5M-2894 Hard Washer (55) 2A-2677 Spacer (56) 8M-9124 Washer (57) 9S-1366 Bolt

1. Install o-ring seal (45) with union (46) onto one end of hose assemblies (47) and (48).

2. On hose assembly (47) install o-ring seal (45) with elbow (49) and attach to the engine as shown in Illustration 41.

3. On hose assembly (48) install o-ring seal (45) with elbow (49) and attach to the engine as shown in Illustration 41.

4. Install grommet (52) onto hose assemblies (47) and (48) .

5. Install clips (51) onto grommets (52) and secure to bracket assembly (50). Use bolt (53) with hard washer (54), (56), and spacer (55) as shown in Illustration 42.

6. Attach bracket assembly (50) to the engine using bolt (57) .

7. Fill the aftercooler circuit with coolant. Also, fill the jacket water coolant to the proper level. Loosen the plug located on the tee when the SCAC is filled in order to allow air to vent from the SCAC system.

Installation of Throttle and Related Components for G3516C and G3516E Generator Set Engines (Without Engine Driven SCAC Pump) Group 5

1. Disconnect battery connections, or turn the master disconnect switch to the OFF position.

2. Drain the coolant from the second stage aftercooler circuit. Also, drain jacket water coolant to a level that is below the first stage aftercooler.

3. Remove the current throttle control valve. Refer to Disassembly and Assembly, "Throttle Control Valve - Remove" for more information.

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Illustration 43	g02381130
(1) 9S-9334 O-Ring Plug (2) 7M-8485 O-Ring Seal

4. Install plugs (1) with O-rings (2) into the aftercooler ports. Refer to Illustration 43.

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Illustration 44	g02404003
(3) 207-5097 Plate (4) 206-4181 Bracket As (5) 0S-1587 Bolt (6) 5P-8245 Hard Washer (7) 363-7478 Bracket As (8) 6H-1717 Bolt (9) 363-7479 Bracket As (10) 1A-5822 Bolt (11) 1F-7958 Full Nut (12) 7N-2597 Spacer

5. Remove the current bracket and install new bracket (4). Install bolts (5) with washers (6) into the two holes in the plate that are located near the turbochargers. Refer to Illustration 44.

   Note: Do not tighten the bolts until all bolts are installed into the plate.

6. Install plate (3) onto bracket (4) .

7. Position bracket (7) over the four holes that are located on plate near the throttle body. Install bolts (5) with washers (6) through bracket (7). Install bolts (6) with washers (8) through bracket (7) and bracket (4) .

8. Install the new water-cooled throttle. Refer to Disassembly and Assembly, "Throttle Control Valve - Install" for more information. use the Steps below in to install additional brackets onto the throttle housing.
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   Illustration 45	g02440576
   (13) 364-1913 Bracket As (14) 264-7830 Bracket (15) 360-7990 Gasket

   1. Install gasket onto the throttle housing

   2. Insert the bolt that is located in the 12 o'clock position, through bracket (13), and install bolts into the throttle housing. Refer to Illustration 45 for the location of the brackets and bolts.

   3. Insert the bolts that are located in the 10 o'clock and 11 o'clock positions through bracket (14). Install the bolts into the air lines group housing.
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   Illustration 46	g02454037
   (16) Jumper harness

   4. Connect the connector of the jumper harness (16) to the current engine wiring harness.

Installation of Throttle Coolant Supply Lines and Related Components

Illustration 47	g03526597
(13) 363-8651 Bracket As (14) 264-7830 Bracket (17) 6V-8398 O-Ring Seal (18) 3K-0360 O-Ring Seal (19) 6V-9002 Elbow (20) 0S-1594 Bolt (21) 9X-6458 Hard Washer (22) 9S-8752 Full Nut (23) 6V-3265 Clip (24) 6M-9149 Bolt (25) 5P-8247 Hard Washer (26) 363-8643 Tube As (27) 363-8642 Tube As (28) 6V-8625 Elbow (29) 6V-8723 Elbow (30) 363-8644 Tube As (31) 363-8645 Tube As (32) 363-8646 Tube As (33) 6V-8397 O-Ring Seal

Illustration 48	g02467377
(17) 6V-8398 O-Ring Seal (18) 3K-0360 O-Ring Seal (27) 363-8642 Tube As (28) 6V-8625 Elbow (34) 367-5997 Tee As (35) 6V-9746 O-Ring Seal (36) 8C-6920 Elbow (37) 9S-4191 O-Ring Plug (38) 3J-1907 O-Ring Seal

1. Install elbows (19) with O-rings (18) into the throttle housing. Refer to Illustration 48 for proper orientation of the elbows.

2. Install O-rings (17) into the groove of elbow (19) .

3. Install tube (26) between the two elbows, and tighten the fittings.

4. Install elbow (29) with O-ring seal (18) into aftercooler housing.

5. Install O-ring seal (33) into groove of elbow (29) .

6. Install tee (34) into the throttle housing. Orient tee (34) with the smaller threads of the adapter directed toward the front of the engine.

7. Install plug (37) with O-ring (38) into the port that is located at the top of tee (33). Alternatively, a connection can be attached to the expansion tank for the SCAC vent.

8. Install clips (23) onto tube (30), and install tube between the two elbows. Refer to Illustration 48 for the proper orientation of tube (30) .

9. Position clip (23) over the hole in bracket (14) that is closest to the throttle housing. Install bolt (17) with washer (18) through the clip and bracket. Install nut (21) with washer (22) onto the bolt, and tighten the bolt.

10. Position clip (23) over the hole in bracket (13). Install bolt (17) with washer (18) through the clip and bracket. Install nut (21) with washer (22) onto the bolt, and tighten the bolt.

11. Tighten the fittings on tube (30) .

12. Install elbow (28) with O-ring seal (18) into the right side of the throttle housing.

13. Install O-ring seal (17) into the groove in the elbow.

14. Install elbow (28) with O-ring seal (18) into the left side of the throttle housing.

15. Install O-ring seal (17) into the groove in the elbow.

16. Install tube (27) between the two elbows. Refer to Illustration 48 and Illustration 48 for proper orientation of tube (27) .

17. Install elbow (36) with O-ring seal (18) into the left side of the throttle housing. Refer to Illustration 48 for proper orientation of elbow (36) .

18. Install tube (32) onto elbow (36) .

19. Install tube (31) onto tee (34) .

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Illustration 49	g03526618
View A-A (39) 1L-2731 Tube Clamp (40) 0S-1591 Bolt (41) 5M-2894 Hard Washer (42) 8M-9124 Washer (43) 363-8651 Bracket As

20. Install clamps (39) that are onto tubes (31) and (32). Refer to Illustration 49.

21. Install bracket (43) onto the aftercooler housing. Use the current bolts in order to secure the bracket.

22. Install washer (42) between the clamps and the aftercooler housing.

23. Install bolt (40) with washer (41) though the clamps and the washer. Tighten the bolts.

Installation Procedure for 251-8246 Water Lines Gp

Note: This configuration is for the standard flow SCAC. Coolant enters the engine on the side of the odd-numbered cylinder banks.

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Illustration 50	g03527800
(35) 6v-9746 O-Ring Seal (44) 6V-8733 Union (45) 7X-7902 Elbow (46) 418-1233 Hose As (47) 418-1234 Hose As (48) 205-7880 Elbow (49) 205-7879 Elbow

1. Install o-ring seal (35) with elbow (45) on one end of hose assembly (46) and (47) .

2. On the other end of the hose assemblies install o-ring seal (35) with union (44) .

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Illustration 51	g03527844
Rear view of engine (10) 5P-8245 Hard Washer (50) 7W-6492 Pipe Plug (51) 0S-1585 Bolt

3. Install bolts (51) with hard washer (10) into the elbows at the rear of the aftercooler housing.

4. Install pipe plug (50) into the elbows at the rear of the aftercooler housing.

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Illustration 52	g03527875
(52) 0L-2070 Bolt (53) 5M-2894 Hard Washer (54) 2A-2677 Spacer (55) 353-7953 Grommet (56) 3H-8683 Clip (57) 363-8651 Bracket As (58) 9S-1366 Bolt (59) 8M-9124 Washer

5. Install grommet (55) onto hose assemblies (46) and (47) .

6. Install clip (56) onto grommet (55). Attach clip (56) to bracket assembly (57) using bolt (52) with hard washer (53), (59) and spacer (54) .

7. Install bracket assembly (57) to the engine using bolt (58) .

8. Fill the aftercooler circuit with coolant. Also, fill the jacket water coolant to the proper level. Loosen the plug that is located on the tee when the SCAC is filled in order to allow air to vent from the SCAC system.

Installation Procedure for 369-1043 Water Lines Gp

Note: This configuration is for the reversed flow SCAC. Coolant enters the engine on the side of the even-numbered cylinder banks.

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Illustration 53	g03527800
(35) 6v-9746 O-Ring Seal (44) 6V-8733 Union (45) 7X-7902 Elbow (46) 418-1233 Hose As (47) 418-1234 Hose As (48) 205-7880 Elbow (49) 205-7879 Elbow

1. Install o-ring seal (35) with elbow (45) on one end of hose assembly (46) and (47) .

2. On the other end of the hose assemblies install o-ring seal (35) with union (44) .

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Illustration 54	g03527844
Rear view of engine (10) 5P-8245 Hard Washer (50) 7W-6492 Pipe Plug (51) 0S-1585 Bolt

3. Install bolts (51) with hard washer (10) into the elbows at the rear of the aftercooler housing.

4. Install pipe plug (50) into the elbows at the rear of the aftercooler housing.

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Illustration 55	g03527875
(52) 0L-2070 Bolt (53) 5M-2894 Hard Washer (54) 2A-2677 Spacer (55) 353-7953 Grommet (56) 3H-8683 Clip (57) 363-8651 Bracket As (58) 9S-1366 Bolt (59) 8M-9124 Washer

5. Install grommet (55) onto hose assemblies (46) and (47) .

6. Install clip (56) onto grommet (55). Attach clip (56) to bracket assembly (57) using bolt (52) with hard washer (53), (59) and spacer (54) .

7. Install bracket assembly (57) to the engine using bolt (58) .

8. Fill the aftercooler circuit with coolant. Also, fill the jacket water coolant to the proper level. Loosen the plug that is located on the tee when the SCAC is filled in order to allow air to vent from the SCAC system.

9. Fill the aftercooler circuit with coolant. Also, fill the jacket water coolant to the proper level. Loosen the plug that is located on the tee when the SCAC is filled in order to allow air to vent from the SCAC system.

Installation of Throttle and Related Components for G3520C Generator Set Engines (Twin Turbo Landfill) Group 6

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Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure.

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NOTICE
When refilling the aftercooling system, open the vent plug on the aftercooler, to allow the aftercooler to fill. Failure to do this will cause an air lock and engine damage.

1. Disconnect battery connections or turn the master disconnect switch to the OFF position.

2. Drain the coolant from the second stage aftercooler circuit. Also, drain jacket water coolant to a level that is below the first stage aftercooler.

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Illustration 56	g02371778
(1) Fuel Valve (2) 235-3972 Support As (3) 235-3958 Support As

3. Remove the current throttle control valve. Refer to Disassembly and Assembly, "Throttle Control Valve - Remove" for more information.

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Illustration 57	g02425896
(4) 9S-9334 O-Ring Plug (5) 7M-8485 O-Ring Seal

4. Install plugs (4) with O-rings (5) into the aftercooler ports. Refer to Illustration 57.

5. Remove the current fuel valve support bracket. Retain bolts and washers for reuse.

6. Install supports (3) into position on each side of the aftercooler housing. Install support bracket (2) into position. Install bolts with washers that were previously removed, through the support bracket, and tighten the bolts. Refer to Illustration 56.

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Illustration 58	g02373557
Right side view of the engine (6) 363-7479 Bracket As (7) 1F-7958 Full Nut (8) 5P-8245 Hard Washer (9) 1A-5822 Bolt (10) 7N-2597 Spacer (11) 235-5648 Plate (12) 0S-1587 Bolt (13) 363-7478 Bracket As (14) 6H-1717 Bolt

7. Remove the current plate and install new plate (11). Install bolts (12) with washers (8) into the two holes in the plate that are located near the turbochargers. Refer to Illustration 58.

   Note: Do not tighten the bolts until all bolts are installed into the plate.

8. Position bracket (13) over the four holes that are located on plate (11) near the throttle body. Install bolts (12) with washers (8) through bracket (13) and plate (11). Thread the bolt into brackets that are located on the engine. Refer to Illustration 58.

9. Install the new water-cooled throttle. Refer to Disassembly and Assembly, "Throttle Control Valve - Install" for more information. Use the Steps below in order to install additional brackets onto the throttle housing.
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   Illustration 59	g02425019
   (15) 364-1913 Bracket As (16) 264-7830 Bracket (17) 360-7990 Gasket

   1. Install gasket (17) onto the throttle housing before the throttle is installed onto the engine. Refer to Illustration 59.

   2. Insert the bolt that is located in the 12 o'clock position, through bracket (15), and install bolts into the throttle housing. Refer to Illustration 59 for the location of the brackets.

   3. Insert the two bolts that are located in the 10 o'clock and 11 o'clock positions, through bracket (16). Install bolts into the air lines group housing.
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   Illustration 60	g02453134
   (18) Jumper harness

   4. Connect the jumper harness (18) connector that is attached to the new throttle to the current engine wiring harness. Refer to Illustration 60.

10. Place aftercooler bracket (6) into position. Install the bolts that were removed in Step 3 onto the front end of the aftercooler bracket. Also, install bolts through aftercooler bracket (6), spacer (10), and aftercooler housing. Install nut (7) with washer (8) onto the end of bolt (9). Tighten the nuts and bolts.

Installation of Throttle Coolant Supply Lines and Related Components

Illustration 61	g02593599
Right side view of the throttle housing (15) 364-1913 Bracket As (16) 264-7830 Bracket (19) 6V-8398 O-Ring Seal (20) 3K-0360 O-Ring Seal (21) 6V-9002 Elbow (22) 0S-1594 Bolt (23) 9X-6458 Hard Washer (24) 9S-8752 Full Nut (25) 6V-3265 Clip (26) 6M-9149 Bolt (27) 5P-8247 Hard Washer (28) 363-8643 Tube As (29) 363-8642 Tube As (30) 6V-8625 Elbow (31) 6V-8723 Elbow (32) 363-8644 Tube As (33) 364-1905 Tube As (34) 364-1906 Tube As (35) 6V-8397 O-Ring Seal (53) 4K-0367 Full Nut

Illustration 62	g02373957
Left side view of the throttle housing (19) 6V-8398 O-Ring Seal (20) 3K-0360 O-Ring Seal (29) 363-8642 Tube As (30) 6V-8625 Elbow (36) 367-5997 Tee As (37) 6V-9746 O-Ring Seal (38) 8C-6920 Elbow (39) 9S-4191 O-Ring Plug (40) 3J-1907 O-Ring Seal

1. Install elbows (21) with O-rings (20) into the throttle housing.

2. Install O-rings (19) into the groove of elbow (21) .

3. Install tube (28) between the two elbows, and tighten the fittings.

4. Install elbow (31) with O-ring seal (20) into aftercooler housing.

5. Install O-ring seal (35) into the groove of elbow (31) .

6. Install tee (36) into the throttle housing. Orient tee (36) with the smaller threads of the adapter directed toward the front of the engine.

7. Install plug (39) with O-ring seal (40) into the top of the tee assembly, and tighten the plug. Alternatively, a connection can be attached to the expansion tank for the SCAC vent.

8. Install clips (25) onto tube (32), and install tube between the two elbows. Refer to Illustration 61 for the proper orientation of tube (32) .

9. Position clip (25) over the hole in bracket (16) that is closest to the throttle housing. Install bolt (22) with washer (23) through the clip and bracket. Install nut with washer onto the bolt, and tighten the bolt.

10. Position clip (25) over the hole in bracket (15). Install bolt (22) with washer (23) through the clip and bracket. Install nut (24) with washer (23) onto the bolt, and tighten the bolt.

11. Tighten the fittings on tube (32) .

12. Install elbow (30) with O-ring seal (20) into the right side of the throttle housing.

13. Install O-ring seal (19) into the groove in the elbow.

14. Install elbow (30) with O-ring seal (19) into the left side of the throttle housing.

15. Install O-ring seal (19) into the groove in the elbow.

16. Install tube (29) between the two elbows. Refer to Illustration 61 and Illustration 62 for proper orientation of tube (29) .

17. Install elbow (38) with O-ring seal (37) into the left side of the throttle housing. Refer to Illustration 62 for proper orientation of elbow (38) .

18. Install tube (33) onto elbow (38) .

19. Install tube (34) onto adapter (36) .

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Illustration 63	g02438557
View A-A (41) 1L-2731 Tube Clamp (42) 0S-1571 Bolt (43) 5M-2894 Hard Washer (44) 8M-9124 Washer

20. Install clamps (41) onto tubes.

21. Install hard washer (43) between the clamps and aftercooler housing.

22. Install bolt (42) with washer (43) through the clamps and the hard washer. Tighten the bolt.

Installation Procedure for the 236-5181 Water Lines Gp

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Illustration 64	g03527996
(37) 6V-9746 O-Ring Seal (45) 6V-8733 Union (46) 439-0805 Hose As (47) 437-7369 Hose As (48) 236-5182 Tube As

1. Install o-ring seal (37) with union (45) onto the end of hose assemblies (46) and (47). Install tube assembly (48) onto the engine as shown in Illustration 64.

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Illustration 65	g03528037
(37) 6V-9746 O-Ring Seal (49) 365-0682 Connector (50) 0L-2070 Bolt (51) 5M-2894 Hard Washer (52) 2A-2677 Spacer (53) 9S-8752 Full Nut (54) 353-7953 Grommet

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Illustration 66	g03528124
(55) 0L-2070 Bolt (56) 5M-2894 Hard Washer (57) 2A-2677 Spacer (58) 353-7953 Grommet (59) 3H-8683 Clip (60) 363-8651 Bracket As (61) 9S-1366 Bolt (62) 8M-9124 Washer

2. Install connector (49) with o-ring seal (37) into the tube assembly.

3. Install grommet (58) onto hose assemblies (46) and (47) .

4. Install clips (59) onto grommets (58). Attach the clip to bracket assembly (60) using bolt (55) with hard washer (56), (62), and spacer (57) .

5. Attach bracket assembly (60) to the engine using bolt (61) .

6. Fill the aftercooler circuit with coolant. Also, fill the jacket water coolant to the proper level. Loosen the plug that is located on the tee when the SCAC is filled in order to allow air to vent from the SCAC system.

Installation of Throttle and Related Components for G3520C Generator Set Engines (Single Turbo) Group 7

1. Disconnect battery connections, or turn the master disconnect switch to the OFF position.

2. Drain the coolant from the second stage aftercooler circuit. Also, drain jacket water coolant to a level that is below the first stage aftercooler.

3. Remove the tube that is connected to the fuel control valve and the air inlet. Retain the bolts that were removed for reuse.

4. Remove the current fuel valve support brackets. Retain bolts and washers for reuse.

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Illustration 67	g02476652
(1) Fuel Valve (2) 276-2343 Support As (3) 235-3958 Support As

5. Install new support assemblies (3) into position on each side of the aftercooler housing. Install support bracket (2) into position. Install bolts with washers that were previously removed, through the support bracket and tighten the bolts. Refer to Illustration 67.

6. Install the fuel control valve onto support bracket. Refer to Disassembly and Assembly, "Fuel Control Valve - Remove and Install" for more information.

7. Remove the current throttle control valve. Refer to Disassembly and Assembly, "Throttle Control Valve - Remove" for more information.

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Illustration 68	g02435958
(4) 9S-9334 O-Ring Plug (5) 7M-8485 O-Ring Seal

8. Install plugs (4) with O-rings (5) into the aftercooler ports. Refer to Illustration 68.

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Illustration 69	g02436058
(6) 306-9208 Bracket (7) 0S-1587 Bolt (8) 5P-8245 Hard Washer (9) 363-7478 Bracket As (10) 6H-1717 Bolt (11) 363-7479 Bracket As (12) 1A-5822 Bolt (13) 1F-7958 Full Nut (14) 7N-2597 Spacer

9. Remove the current plate and install new plate (6). Install bolts (7) with washers (8) into the two holes in the plate that are located near the turbochargers. Refer to Illustration 69.

   Note: Do not tighten the bolts until all bolts are installed into the plate.

10. Position bracket (9) over to four holes that are located on the plate near the throttle body. Install bolts (7) with washers (8) through bracket (9) and thread the bolts into the bracket. Install bolts (10) with washer (8) through bracket (9) and bracket (6) .

11. Install new water-cooled throttle. Refer to Disassembly and Assembly, "Throttle Control Valve - Install" for more information. Use the Steps that are listed below in order to install additional brackets onto the throttle housing.
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    Illustration 70	g02435876
    (15) 364-1913 Bracket As (16) 264-7830 Bracket (17) 360-7990 Gasket

    1. Install gasket (17) onto the throttle housing before the throttle is installed onto the engine. Refer to Illustration 70.

    2. Insert the bolt that is located in the 12 o'clock position, through bracket (15), and install bolts into the throttle housing. Refer to Illustration 70 and Illustration 73 for the location of the brackets and bolts.

    3. Insert the bolts that are located in the 10 o'clock and 11 o'clock positions through bracket (16). Install the bolts into the air lines group housing.
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    Illustration 71	g02455096
    (18) Jumper harness

    4. Connect the connector of the jumper harness (18) to the current engine wiring harness.

12. Place aftercooler bracket (11) into the proper position. Install the bolts that were removed in Step 7 onto the front end of the aftercooler bracket. Install bolt (12) through aftercooler bracket (11), spacer (14), and the aftercooler housing. Install nut (13) with washer (8) onto the end of the bolt. Tighten the nuts and bolts.

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Illustration 72	g02392717
(19) 306-6581 Bracket As (20) 186-3467 Gasket (21) 235-5537 Gasket (22) 276-2341 Tube As

13. Remove the current bracket that supports air inlet tube.

14. Install bracket (19). Use the current bolts in order to secure the bracket.

15. Install gasket (21) onto the fuel control valve.

16. Install end of tube (22) onto the end of the fuel control valve. Install the bolts that were previously removed through the flange of tube, and the flange of the fuel control valve. Install the nuts with washers onto the end of the bolts, and tighten the bolts.

17. Install gasket (20) onto the bellows.

18. Install the opposite end of tube (22) onto the bellows. Install the bolts through the flange of the tube and the flange of the bellows. Install the nuts with the washers onto the end of the bolts.

19. Install the current u-bolt over the tube. Install the current nuts with washer onto the u-bolt. Tighten the nuts.

Installation of Throttle Coolant Supply Lines and Related Components

Illustration 73	g02594214
Right side view of the throttle housing (15) 364-1913 Bracket As (16) 264-7830 Bracket (23) 6V-8398 O-Ring Seal (24) 3K-0360 O-Ring Seal (25) 6V-9002 Elbow (26) 0S-1594 Bolt (27) 9X-6458 Hard Washer (28) 9S-8752 Full Nut (29) 6V-3265 Clip (30) 6M-9149 Bolt (31) 5P-8247 Hard Washer (32) 363-8643 Tube As (33) 363-8642 Tube As (34) 6V-8625 Elbow (35) 6V-8723 Elbow (36) 363-8644 Tube As (37) 364-1905 Tube As (38) 364-1906 Tube As (39) 6V-8397 O-Ring Seal (58) 4K-0367 Full Nut

Illustration 74	g02436809
Left side view of the throttle housing (23) 6V-8398 O-Ring Seal (24) 3K-0360 O-Ring Seal (34) 6V-8625 Elbow (40) 367-5997 Tee As (41) 6V-9746 O-Ring Seal (42) 8C-6920 Elbow (43) 9S-4191 O-Ring Plug (44) 3J-1907 O-Ring Seal

1. Install elbows (25) with O-rings (24) into the throttle housing. Refer to Illustration 73 for the proper orientation of the elbows.

2. Install O-rings (23) into the groove of elbows (25) .

3. Install tube (32) between the two elbows, and tighten the fittings.

4. Install elbow (35) with O-ring seal (24) into aftercooler housing.

5. Install O-ring seal (39) into the groove of elbow (35) .

6. Install tee (40) into the throttle housing. Orient tee (40) with the smaller threads of the adapter directed toward the front of the engine.

7. Install plug (43) with O-ring seal (44) into the top of the tee assembly, and tighten the plug. Alternatively, a connection can be attached to the expansion tank for the SCAC vent.

8. Install clips (29) onto tube (36), and install tube between the two elbows. Refer to Illustration 73 for the proper orientation of tube (36) .

9. Position clip (29) over the hole in bracket (15) that is closest to the throttle housing. Install bolt (26) with washer (27) through the clip and bracket. Install nut with washer onto the bolt, and tighten the bolt.

10. Position clip (29) over the hole in bracket (16). Install bolt (26) with washer (27) through the clip and bracket. Install nut (28) with washer (27) onto the bolt, and tighten the bolt.

11. Tighten the fittings on tube (36) .

12. Install elbow (34) with O-ring seal (24) into the right side of the throttle housing.

13. Install O-ring seal (23) into the groove in the elbow.

14. Install elbow (34) with O-ring seal (24) into the left side of the throttle housing.

15. Install O-ring seal (23) into the groove in the elbow.

16. Install tube (33) between the two elbows. Refer to Illustration 73 and Illustration 74 for proper orientation of tube (33) .

17. Install elbow (42) with O-ring (24) into the left side of the throttle housing. Refer to Illustration 74 for proper orientation of the elbow.

18. Install O-ring (23) into the groove of elbow (42) .

19. Install tube (37) onto elbow (42) .

20. Install tube (38) onto tee (40) .

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Illustration 75	g02437016
View A-A (45) 1L-2731 Tube Clamp (46) 0S-1571 Bolt (47) 5M-2894 Hard Washer (48) 8M-9124 Washer

21. Install clamps (45) onto tubes (37) and (38) .

22. Install hard washer (48) between the clamps and the aftercooler housing.

Installation Procedure for the 236-5181 Water Lines Gp

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Illustration 76	g03528160
(37) 6V-9746 O-Ring Seal (49) 6V-8733 Union (50) 439-0805 Hose As (51) 437-7369 Hose As (52) 236-5182 Tube As

1. Install o-ring seal (37) with union (49) onto one end of hose assemblies (50) and (51) .

2. Install tube assembly (52) onto the engine as shown in Illustration 76.

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Illustration 77	g03528179
(37) 6V-9746 O-Ring Seal (53) 365-0682 Connector (54) 0L-2070 Bolt (55) 5M-2894 Hard Washer (56) 2A-2677 Spacer (57) 9S-8752 Full Nut (58) 353-7953 Grommet (59) 3H-8683 Clip

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Illustration 78	g03528196
(60) 0L-2070 Bolt (61) 5M-2894 Hard Washer (62) 2A-2677 Spacer (63) 353-7953 Grommet (64) 3H-8683 Clip (65) 363-8651 Bracket As (66) 9S-1366 Bolt (67) 8M-9124 Washer

3. Install connector (53) with o-ring seal (37) into the tube assembly.

4. Install grommets (64) onto hose assemblies (50) and (51) .

5. Install clips (64) onto grommets (64) .

6. Attach the clips to bracket assembly (65) using bolt (60) with hard washers (61), (67), and spacer (62) .

7. Attach bracket assembly (65) to the engine using bolt (66) .

8. Fill the aftercooler circuit with coolant. Also, fill the jacket water coolant to the proper level. Loosen the plug that is located on the tee when the SCAC is filled in order to allow air to vent from the SCAC system.

Installation of Throttle and Related Components for G3520C and G3520E Generator Set Engines (Single Turbo With Engine Driven SCAC Pump) Group 8

1. Drain the coolant from the second stage aftercooler circuit. Also, drain jacket water coolant to a level that is below the first stage aftercooler.

2. Remove the current throttle control valve. Refer to Disassembly and Assembly, "Throttle Control Valve - Remove" for more information.

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Illustration 79	g02381130
(1) 9S-9334 O-Ring Plug (2) 7M-8485 O-Ring Seal

3. Install plugs (1) with O-rings (2) into the aftercooler ports. Refer to Illustration 79.

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Illustration 80	g02456983
View of 201-1483 Control Mounting Gp (3) 0S-1587 Bolt (4) 5P-8245 Hard Washer (5) 6H-1717 Bolt (6) 1A-5822 Bolt (7) 1F-7958 Full Nut (8) 7N-2597 Spacer (9) 363-7479 Bracket As (10) 363-7478 Bracket As (11) 201-1484 Bracket As

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Illustration 81	g02456839
View of 206-4180 Control Mounting Gp (3) 0S-1587 Bolt (4) 5P-8245 Hard Washer (5) 6H-1717 Bolt (6) 1A-5822 Bolt (7) 1F-7958 Full Nut (8) 7N-2597 Spacer (9) 363-7479 Bracket As (10) 363-7478 Bracket As (12) 207-5097 Plate (13) 206-4181 Bracket As

4. Install the 201-1483 Control Mounting Gp . Use the following Steps. Refer to Illustration 80.

   Note: Do not tighten the bolts until all bolts are installed into the plate.

   1. Remove the current plate and install bracket (11). Install bolts (3) with washers (4) into the two holes in the plate that are located near the turbochargers.

   2. Position bracket (10) over the four holes that are located on plate near the throttle body. Install bolts (3) with washers (4) through bracket (10) and thread the bolt into the bracket. Install bolts (5) with washers (4) through the bracket.

5. Install the 206-4180 Control Mounting Gp . Use the following Steps. Refer to Illustration 81.

   Note: Do not tighten the bolts until all bolts are installed into the plate.

   1. Remove the current plate and install bracket (13). Install bolts (3) with washers (4) into the two holes in the plate that are located near the turbochargers.

   2. Install plate (12) onto bracket (13) .

   3. Position bracket (10) over the four holes that are located on plate near the throttle body. Install bolts (3) with washers (4) through bracket (10) and thread the bolt into the bracket. Install bolts (5) with washers (4) through the bracket.

6. Install the new water-cooled throttle. Refer to Disassembly and Assembly, "Throttle Control Valve - Install" for more information. use the Steps below to install additional brackets onto the throttle housing.
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   Illustration 82	g02431407
   (14) 364-1913 Bracket As (15) 264-7830 Bracket (16) 360-7990 Gasket

   1. Install gasket (16) onto the throttle housing before the throttle is installed onto the engine. Refer to Illustration

   2. Insert the bolt that is located in the 12 o'clock position, through bracket (14), and install bolts into the throttle housing. Refer to Illustration 82 and Illustration 84 for the location of the brackets and bolts.

   3. Insert the bolts that are located in the 10 o'clock and 11 o'clock positions through bracket (15). Install the bolts into the air lines group housing.
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   Illustration 83	g02453916
   (17) Jumper harness

   4. Connect the jumper harness (17) that is attached to the new throttle, to the current engine wiring harness. Refer to Illustration 83.

7. Position aftercooler bracket (9) into the proper position. Install the bolts that were removed in Step 2 onto the front end of the aftercooler bracket. Also install bolts through aftercooler bracket (9), spacer (8) and aftercooler housing. Install nut (7) with washer (4) onto the end of bolt (6). Tighten the nuts and bolts. Refer to Illustration 80 and Illustration 81.

Installation of Throttle Coolant Supply Lines and Related Components

Illustration 84	g02594156
(14) 364-1913 Bracket As (15) 264-7830 Bracket (18) 6V-8398 O-Ring Seal (19) 3K-0360 O-Ring Seal (20) 6V-9002 Elbow (21) 0S-1594 Bolt (22) 9X-6458 Hard Washer (23) 9S-8752 Full Nut (24) 6V-3265 Clip (25) 6M-9149 Bolt (26) 5P-8247 Hard Washer (27) 363-8643 Tube As (28) 363-8642 Tube As (29) 6V-8625 Elbow (30) 6V-8723 Elbow (31) 363-8644 Tube As (32) 363-8645 Tube As (33) 363-8646 Tube As (34) 6V-8397 O-Ring Seal (53) 4K-0367 Full Nut

Illustration 85	g02457518
(18) 6V-8398 O-Ring Seal (19) 3K-0360 O-Ring Seal (28) 363-8642 Tube As (29) 6V-8625 Elbow (35) 367-5997 Tee As (36) 6V-9746 O-Ring Seal (37) 8C-6920 Elbow (38) 9S-4191 O-Ring Plug (39) 3J-1907 O-Ring Seal

1. Install elbows (20) with O-rings (19) into the throttle housing.

2. Install O-rings (18) into the groove of elbow (20) .

3. Install tube (27) between the two elbows, and tighten the fittings.

4. Install elbow (30) with O-ring seal (19) into aftercooler housing.

5. Install O-ring into the groove of elbow (30) .

6. Install tee (35) into the throttle housing. Orient tee (35) with the smaller threads of the adapter directed toward the front of the engine.

7. Install plug (38) with O-ring seal (39) into the top of the tee assemble, and tighten the plug. Alternatively, a connection can be attached to the expansion tank for the SCAC vent.

8. Install clips (24) onto tube (31), and install tube between the two elbows. Refer to Illustration 84 for the proper orientation of tube (31) .

9. Position clip (24) over the hole in bracket (15) that is closest to the throttle housing. Install bolt (21) with washer (22) through the clip and bracket. Install nut (23) with washer (22) onto the bolt, and tighten the bolt.

10. Position clip (24) over the hole in bracket (14). Install bolt (21) with washer (22) through the clip and bracket. Install nut (23) with washer (22) onto the bolt, and tighten the bolt.

11. Tighten the fittings on tube (31) .

12. Install elbow (29) with O-ring seal (19) into the right side of the throttle housing.

13. Install O-ring seal (18) into the groove in the elbow.

14. Install elbow (29) with O-ring seal (19) into the left side of the throttle housing.

15. Install O-ring seal (18) into the groove in the elbow.

16. Install tube (28) between the two elbows. Refer to Illustration 84 and Illustration 85 for proper orientation of tube (28) .

17. Install elbow (37) with O-ring seal (36) into the left side of the throttle housing.

18. Install tube (33) onto elbow (37) .

19. Install tube (32) onto tee (35) .

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Illustration 86	g03528257
View A-A (40) 1L-2731 Tube Clamp (41) 0S-1591 Bolt (42) 5M-2894 Hard Washer (43) 8M-9124 Washer (44) 363-8651 Bracket As

20. Install clamps (40) onto tubes (32) and (33) .

21. Install bracket (52) onto the aftercooler housing. Use the current bolts in order to secure the bracket.

22. Install hard washer (43) between the clamps and the aftercooler housing.

Installation Procedure for the 200-6443 Water Lines Gp

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Illustration 87	g03528239
(45) 200-6441 Tube As

1. Install tube assembly (45) to the engine as shown in Illustration 87.

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Illustration 88	g03528277
(36) 6V-9746 O-Ring Seal (46) 365-0682 Connector

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Illustration 89	g03528279
(36) 6V-9746 O-Ring Seal (47) 6V-8733 Union (48) 437-7371 Hose As (49) 439-4508 Hose As

2. Install connectors (46) with o-ring seals (36) onto the end of hose assemblies (48) and (49) as shown in Illustration 99.

3. Install o-ring seals (36) with unions (47) onto the other ends of hose assemblies (48) and (49.)

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Illustration 90	g03528481
(50) 5M-2894 Hard Washer (51) 2A-2677 Spacer (52) 8M-9124 Washer (53) 0L-2070 Bolt (54) 363-8651 Bracket As (55) 9S-1366 Bolt (56) 353-7953 Grommet (57) 3H-8683 Clip

4. Install grommets (56) on hose assemblies (48) and (49) .

5. Attach clips (57) to grommets (56) and attach to bracket assembly (54). Attach the clips to the bracket assembly using bolt (53) with hard washer (50), (52), and spacer (51) .

6. Attach bracket assembly (54) to the engine using bolt (55) .

7. Fill the aftercooler circuit with coolant. Also, fill the jacket water coolant to the proper level. Loosen the plug that is located on the tee when the SCAC is filled in order to allow air to vent from the SCAC system.

Installation of Throttle and Related Components for G3520C and G3520E Generator Set Engines (Twin Turbo With Engine Driven SCAC Pump) Group 9

1. Disconnect battery connections, or turn the master disconnect switch to the OFF position.

2. Drain the coolant from the second stage aftercooler circuit. Also, drain jacket water coolant to a level that is below the first stage aftercooler.

3. Remove the current throttle control valve. Refer to Disassembly and Assembly, "Throttle Control Valve - Remove" for more information.

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Illustration 91	g02381130
(1) 9S-9334 O-Ring Plug (2) 7M-8485 O-Ring Seal

4. Install plugs (1) with O-rings (2) into the aftercooler ports. Refer to Illustration 91.

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Illustration 92	g02404003
(3) 207-5097 Plate (4) 206-4181 Bracket As (5) 0S-1587 Bolt (6) 5P-8245 Hard Washer (7) 363-7478 Bracket As (8) 6H-1717 Bolt (9) 363-7479 Bracket As (10) 1A-5822 Bolt (11) 1F-7958 Full Nut (12) 7N-2597 Spacer

5. Remove the current bracket and install new bracket (4). Install bolts (5) with washers (6) into the two holes in the plate that are located near the turbochargers. Refer to Illustration 92.

   Note: Do not tighten the bolts until all bolts are installed into the plate.

6. Install bracket (3) onto plate (4) .

7. Position bracket (7) over the four holes that are located on plate near the throttle body. Install bolts (5) with washers (6) through bracket. Install bolts (6) with washers (8) through bracket. Refer to Illustration 92.

8. Install the new water-cooled throttle. Refer to Disassembly and Assembly, "Throttle Control Valve - Install" for more information. use the Steps below to install additional brackets onto the throttle housing.
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   Illustration 93	g02440576
   (13) 364-1913 Bracket As (14) 264-7830 Bracket (15) 360-7990 Gasket

   1. Install gasket (15) onto the throttle housing before the throttle is installed onto the engine.

   2. Insert the bolt that is located in the 12 o'clock position, through bracket (13), and install bolts into the throttle housing. Refer to Illustration 93 and Illustration 95 for the location of the brackets and bolts.

   3. Insert the bolts that are located in the 10 o'clock and 11 o'clock positions through bracket (14). Install the bolts into the air lines group housing.
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   Illustration 94	g02454037
   (16) Jumper harness

   4. Connect the jumper harness (16) connector that is attached to the new throttle to the current engine wiring harness. Refer to Illustration 94.

Installation of Throttle Coolant Supply Lines and Related Components

Illustration 95	g02594182
(13) 363-8651 Bracket As (14) 264-7830 Bracket (17) 6V-8398 O-Ring Seal (18) 3K-0360 O-Ring Seal (19) 6V-9002 Elbow (20) 0S-1594 Bolt (21) 9X-6458 Hard Washer (22) 9S-8752 Full Nut (23) 6V-3265 Clip (24) 6M-9149 Bolt (25) 5P-8247 Hard Washer (26) 363-8643 Tube As (27) 363-8642 Tube As (28) 6V-8625 Elbow (29) 6V-8723 Elbow (30) 363-8644 Tube As (31) 363-8645 Tube As (32) 363-8646 Tube As (33) 6V-8397 O-Ring Seal (52) 4K-0367 Full Nut

Illustration 96	g02467377
(17) 6V-8398 O-Ring Seal (18) 3K-0360 O-Ring Seal (27) 363-8642 Tube As (28) 6V-8625 Elbow (34) 367-5997 Tee As (35) 6V-9746 O-Ring Seal (36) 8C-6920 Elbow (37) 9S-4191 O-Ring Plug (38) 3J-1907 O-Ring Seal

1. Install elbows (19) with O-rings (18) into the throttle housing. Refer to Illustration 95 for proper orientation of the elbows.

2. Install O-rings (17) into the groove of elbow (19) .

3. Install tube (26) between the two elbows, and tighten the fittings.

4. Install elbow (29) with O-ring seal (18) into aftercooler housing.

5. Install O-ring (33) into the grove of elbow (29) .

6. Install tee (33) into the throttle housing. Orient tee (33) with the smaller threads of the adapter directed toward the front of the engine.

7. Install plug (37) with O-ring (38) into the port that is located at the top of tee (33). Alternatively, a connection can be attached to the expansion tank for the SCAC vent.

8. Install clips (23) onto tube (30), and install tube between the two elbows. Refer to Illustration 95 for the proper orientation of tube (30) .

9. Position clip (23) over the hole in bracket (14) that is closest to the throttle housing. Install bolt (20) with washer (22) through the clip and bracket. Install nut (21) with washer (22) onto the bolt, and tighten the bolt.

10. Position clip (23) over the hole in bracket (13). Install bolt (20) with washer (22) through the clip and bracket. Install nut (21) with washer (22) onto the bolt, and tighten the bolt.

11. Tighten the fittings on tube (30) .

12. Install elbow (28) with O-ring seal (18) into the right side of the throttle housing.

13. Install O-ring seal (17) into the groove in the elbow.

14. Install elbow (28) with O-ring seal (18) into the left side of the throttle housing.

15. Install O-ring seal (17) into the groove in the elbow.

16. Install tube (26) between the two elbows. Refer to Illustration 95 and Illustration 96 for proper orientation of tube (26) .

17. Install elbow (36) with O-ring seal (18) into the left side of the throttle housing. Refer to Illustration 96 for proper orientation of elbow (36) .

18. Install tube (32) onto elbow (36) .

19. Install tube (31) onto tee (33) .

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Illustration 97	g02471700
View A-A (39) 1L-2731 Tube Clamp (40) 0S-1591 Bolt (41) 5M-2894 Hard Washer (42) 8M-9124 Washer

20. Install clamps (39) onto tubes (30) and (31) .

21. Install bracket (49) onto the aftercooler housing. Use the current bolts in order to secure the bracket.

22. Install washer (42) between the clamps and the aftercooler housing.

Installation Procedure for the 200-6443 Water Lines Gp

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Illustration 98	g03528239
(45) 200-6441 Tube As

1. Install tube assembly (45) to the engine as shown in Illustration 98.

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Illustration 99	g03528277
(36) 6V-9746 O-Ring Seal (46) 365-0682 Connector

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Illustration 100	g03528279
(36) 6V-9746 O-Ring Seal (47) 6V-8733 Union (48) 437-7371 Hose As (49) 439-4508 Hose As

2. Install connectors (46) with o-ring seals (36) onto the end of hose assemblies (48) and (49) as shown in Illustration 99.

3. Install o-ring seals (36) with unions (47) onto the other ends of hose assemblies (48) and (49.)

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Illustration 101	g03528481
(50) 5M-2894 Hard Washer (51) 2A-2677 Spacer (52) 8M-9124 Washer (53) 0L-2070 Bolt (54) 363-8651 Bracket As (55) 9S-1366 Bolt (56) 353-7953 Grommet (57) 3H-8683 Clip

4. Install grommets (56) on hose assemblies (48) and (49) .

5. Attach clips (57) to grommets (56) and attach to bracket assembly (54). Attach the clips to the bracket assembly using bolt (53) with hard washer (50), (52), and spacer (51) .

6. Attach bracket assembly (54) to the engine using bolt (55) .

7. Fill the aftercooler circuit with coolant. Also, fill the jacket water coolant to the proper level. Loosen the plug that is located on the tee when the SCAC is filled in order to allow air to vent from the SCAC system.

Installation of Throttle and Related Components for G3520C Generator Set Engines (Coal Mine Methane) Group 10

1. Disconnect battery connections, or turn the master disconnect switch to the OFF position.

2. Drain the coolant from the second stage aftercooler circuit. Also, drain jacket water coolant to a level that is below the first stage aftercooler.

3. Remove the tube that is connected to the fuel control valve and the air inlet. Retain the bolts that were removed for reuse.

4. Remove the current fuel valve support brackets. Retain bolts and washers for reuse.

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Illustration 102	g02476652
(1) Fuel Valve (2) 235-3972 Support As (3) 235-3958 Support As

5. Install new support assemblies (3) into position on each side of the aftercooler housing. Install support bracket (2) into position. Install bolts with washers that were previously removed, through the support bracket and tighten the bolts. Refer to Illustration 102.

6. Remove the current throttle control valve. Refer to Disassembly and Assembly, "Throttle Control Valve - Remove" for more information.

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Illustration 103	g02435958
(4) 9S-9334 O-Ring Plug (5) 7M-8485 O-Ring Seal

7. Install plugs (4) with O-rings (5) into the aftercooler ports. Refer to Illustration 103.

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Illustration 104	g02436058
(6) 306-9208 Bracket (7) 0S-1587 Bolt (8) 5P-8245 Hard Washer (9) 363-7478 Bracket As (10) 6H-1717 Bolt (11) 363-7479 Bracket As (12) 1A-5822 Bolt (13) 1F-7958 Full Nut (14) 7N-2597 Spacer

8. Remove the current bracket and install new bracket (6). Install bolts (7) with washers (8) into the two holes in the plate that are located near the turbochargers. Refer to Illustration 104.

   Note: Do not tighten the bolts until all bolts are installed into the plate.

9. Position bracket (9) over to four holes that are located on the plate near the throttle body. Install bolts (7) with washers (8) through bracket (9) and thread the bolts into the bracket. Install bolts (10) with washer (8) through bracket (9) and bracket (6) .

10. Install the new water-cooled throttle. Refer to Disassembly and Assembly, "Throttle Control Valve - Install" for more information. use the Steps below to install additional brackets onto the throttle housing.
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    Illustration 105	g02435876
    (15) 364-1913 Bracket As (16) 264-7830 Bracket (17) 360-7990 Gasket

    1. Install gasket (17) onto the throttle housing before the throttle is installed onto the engine. Refer to Illustration 105.

    2. Insert the bolt that is located in the 12 o'clock position, through bracket (15), and install bolts into the throttle housing. Refer to Illustration 105 and Illustration 108 for the location of the brackets and bolts.

    3. Insert the bolts that are located in the 10 o'clock and 11 o'clock positions through bracket (16). Install the bolts into the air lines group housing.
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    Illustration 106	g02455096
    (18) Jumper harness

    4. Connect the connector of the jumper harness (18) to the current engine wiring harness.

11. Place aftercooler bracket (11) into position. Install the bolts that were removed in Step 6 onto the front end of the aftercooler bracket. Install bolt (12) through aftercooler bracket (11), spacer (14), and the aftercooler housing. Install nut (13) with washer (8) onto the end of the bolt. Tighten the nuts and bolts.

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Illustration 107	g02392717
(19) 306-6581 Bracket As (20) 186-3467 Gasket (21) 235-5537 Gasket (22) 276-2341 Tube As

12. Remove the current bracket that supports air inlet tube.

13. Install bracket (19). Use the current bolts in order to secure the bracket.

14. Install gasket (21) onto the fuel control valve.

15. Install end of tube (22) onto the end of the fuel control valve. Install the bolts that were previously removed through the flange of tube, and the flange of the fuel control valve. Install the nuts with washers onto the end of the bolts, and tighten the bolts.

16. Install gasket (20) onto the bellows.

17. Install opposite end of the tube (22) onto the bellows. Install the bolts through the flange of the tube and the flange of the bellows. Install the nuts with the washers onto the end of the bolts.

18. Install the current u-bolt over the tube. Install the current nuts with washer onto the u-bolt. Tighten the nuts.

Installation of Throttle Coolant Supply Lines and Related Components

Illustration 108	g02594214
Right side view of the throttle housing (15) 364-1913 Bracket As (16) 264-7830 Bracket (23) 6V-8398 O-Ring Seal (24) 3K-0360 O-Ring Seal (25) 6V-9002 Elbow (26) 0S-1594 Bolt (27) 9X-6458 Hard Washer (28) 9S-8752 Full Nut (29) 6V-3265 Clip (30) 6M-9149 Bolt (31) 5P-8247 Hard Washer (32) 363-8643 Tube As (33) 363-8642 Tube As (34) 6V-8625 Elbow (35) 6V-8723 Elbow (36) 363-8644 Tube As (37) 364-1905 Tube As (38) 364-1906 Tube As (39) 6V-8397 O-Ring Seal (58) 4K-0367 Full Nut

Illustration 109	g02436809
Left side view of the throttle housing (23) 6V-8398 O-Ring Seal (24) 3K-0360 O-Ring Seal (34) 6V-8625 Elbow (40) 367-5997 Tee As (41) 6V-9746 O-Ring Seal (42) 8C-6920 Elbow (43) 9S-4191 O-Ring Plug (44) 3J-1907 O-Ring Seal

1. Install elbows (25) with O-rings (24) into the throttle housing. Refer to Illustration 108 for the proper orientation of the elbows.

2. Install O-rings (23) into the groove of elbows (25) .

3. Install tube (32) between the two elbows, and tighten the fittings.

4. Install elbow (35) with O-ring seal (24) into aftercooler housing.

5. Install O-ring seal (39) into the groove of elbow (35) .

6. Install tee (40) into the throttle housing. Orient tee (40) with the smaller threads of the adapter directed toward the front of the engine.

7. Install plug (43) with O-ring seal (44) into the top of the tee assembly, and tighten the plug. Alternatively, a connection can be attached to the expansion tank for the SCAC vent.

8. Install clips (29) onto tube (36), and install tube between the two elbows.

9. Position clip (29) over the hole in bracket (15) that is closest to the throttle housing. Install bolt (26) with washer (27) through the clip and bracket. Install nut (28) with washer (27) onto the bolt, and tighten the bolt.

10. Position clip (29) over the hole in bracket (16). Install bolt (26) with washer (27) through the clip and bracket. Install nut (28) with washer (27) onto the bolt, and tighten the bolt.

11. Tighten the fittings on tube (36) .

12. Install elbow (34) with O-ring seal (24) into the right side of the throttle housing.

13. Install O-ring seal (23) into the groove in the elbow.

14. Install elbow (34) with O-ring seal (24) into the left side of the throttle housing.

15. Install O-ring seal (23) into the groove in the elbow.

16. Install tube (33) between the two elbows. Refer to Illustration 108 and Illustration 109 for proper orientation of tube (33) .

17. Install elbow (42) with O-ring (24) into the left side of the throttle housing. Refer to Illustration 109 for proper orientation of the elbow.

18. Install O-ring (23) into the groove of elbow (42) .

19. Install tube (37) onto elbow (42) .

20. Install tube (38) onto tee (40) .

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Illustration 110	g02437016
View A-A (45) 1L-2731 Tube Clamp (46) 0S-1571 Bolt (47) 5M-2894 Hard Washer (48) 8M-9124 Washer

21. Install clamps (45) onto tubes (37) and (38) .

22. Install hard washer (48) between the clamps and the aftercooler housing.

23. Install bolt (46) with washer (47) through the clamps and hard washer, and install bolt into the aftercooler housing.

    Note: Do not tighten the line connectors or brackets until the assembly is complete.

Installation Procedure for the 200-6443 Water Lines Gp

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Illustration 111	g03528239
(45) 200-6441 Tube As

1. Install tube assembly (45) onto the engine as shown in Illustration 123.

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Illustration 112	g03528277
(36) 6V-9746 O-Ring Seal (46) 365-0682 Connector

2. Install connector (46) with o-ring seal (36) as shown in Illustration 112.

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Illustration 113	g03528279
(36) 6V-9746 O-Ring Seal (47) 6V-8733 Union (48) 437-7371 Hose As (49) 439-4508 Hose As

3. Install union (47) with o-ring seal (36) on the end of hose assemblies (48) and (49) .

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Illustration 114	g03528481
(50) 5M-2894 Hard Washer (51) 2A-2677 Spacer (52) 8M-9124 Washer (53) 0L-2070 Bolt (54) 363-8651 Bracket As (55) 9S-1366 Bolt (56) 353-7953 Grommet (57) 3H-8683 Clip

4. Install grommets (56) onto hose assemblies (48) and (49) .

5. Install clips (57) onto grommets (56) .

6. Attach clips (57) to bracket assembly (54) using bolt (53) with hard washers (50), (52), and spacer (51) .

7. Attach bracket assembly (54) to the engine using bolt (55) .

8. Fill the aftercooler circuit with coolant. Also, fill the jacket water coolant to the proper level. Loosen the plug that is located on the tee when the SCAC is filled in order to allow air to vent from the SCAC system.

Installation of Throttle and Related Components for G3520C Landfill Engines (S/N: HAT) Group 11

1. Disconnect battery connections or turn the master disconnect switch to the OFF position.

2. Drain the coolant from the second stage aftercooler circuit. Also, drain jacket water coolant to a level that is below the first stage aftercooler.

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Illustration 115	g02371778
(1) Fuel Valve (2) 235-3972 Support As (3) 235-3958 Support As

3. Remove the current throttle control valve. Refer to Disassembly and Assembly, "Throttle Control Valve - Remove" for more information.

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Illustration 116	g02425896
(4) 9S-9334 O-Ring Plug (5) 7M-8485 O-Ring Seal

4. Install plugs (4) with O-rings (5) into the aftercooler ports.

5. Remove the current fuel valve support bracket. Retain bolts and washers for reuse.

6. Install supports (3) into position on each side of the aftercooler housing. Install support bracket (2) into position. Install bolts with washers that were previously removed, through the support bracket, and tighten the bolts.

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Illustration 117	g02373557
Right side view of the engine (6) 363-7479 Bracket As (7) 1F-7958 Full Nut (8) 5P-8245 Hard Washer (9) 1A-5822 Bolt (10) 7N-2597 Spacer (11) 235-5648 Plate (12) 0S-1587 Bolt (13) 363-7478 Bracket As (14) 6H-1717 Bolt

7. Remove the current plate and install new plate (11). Install bolts (12) with washers (8) into the two holes in the plate that are located near the turbochargers.

   Note: Do not tighten the bolts until all bolts are installed into the plate.

8. Position bracket (13) over the four holes that are located on plate (11) near the throttle body. Install bolts (12) with washers (8) through bracket (13) and plate (11). Thread the bolt into brackets that are located on the engine.

9. Install the new water-cooled throttle. Refer to Disassembly and Assembly, "Throttle Control Valve - Install" for more information. Use the Steps below in order to install additional brackets onto the throttle housing.
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   Illustration 118	g02425019
   (15) 364-1913 Bracket As (16) 264-7830 Bracket (17) 360-7990 Gasket

   1. Install gasket (17) onto the throttle housing before the throttle is installed onto the engine.

   2. Insert the bolt that is located in the 12 o'clock position, through bracket (15), and install bolts into the throttle housing. Refer to Illustration 130 for the location of the brackets.

   3. Insert the two bolts that are located in the 10 o'clock and 11 o'clock positions, through bracket (16). Install bolts into the air lines group housing.
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   Illustration 119	g02453134
   (18) Jumper harness

   4. Connect the jumper harness (18) connector that is attached to the new throttle to the current engine wiring harness.

10. Place aftercooler bracket (6) into position. Install the bolts that were removed in Step 3 onto the front end of the aftercooler bracket. Also, install bolts through aftercooler bracket (6), spacer (10), and aftercooler housing. Install nut (7) with washer (8) onto the end of bolt (9). Tighten the nuts and bolts.

Installation of Throttle Coolant Supply Lines and Related Components

Illustration 120	g02593599
Right side view of the throttle housing (15) 364-1913 Bracket As (16) 264-7830 Bracket (19) 6V-8398 O-Ring Seal (20) 3K-0360 O-Ring Seal (21) 6V-9002 Elbow (22) 0S-1594 Bolt (23) 9X-6458 Hard Washer (24) 9S-8752 Full Nut (25) 6V-3265 Clip (26) 6M-9149 Bolt (27) 5P-8247 Hard Washer (28) 363-8643 Tube As (29) 363-8642 Tube As (30) 6V-8625 Elbow (31) 6V-8723 Elbow (32) 363-8644 Tube As (33) 364-1905 Tube As (34) 364-1906 Tube As (35) 6V-8397 O-Ring Seal (53) 4K-0367 Full Nut

Illustration 121	g02373957
Left side view of the throttle housing (19) 6V-8398 O-Ring Seal (20) 3K-0360 O-Ring Seal (29) 363-8642 Tube As (30) 6V-8625 Elbow (36) 367-5997 Tee As (37) 6V-9746 O-Ring Seal (38) 8C-6920 Elbow (39) 9S-4191 O-Ring Plug (40) 3J-1907 O-Ring Seal

1. Install elbows (21) with O-rings (20) into the throttle housing.

2. Install O-rings (19) into the groove of elbow (21) .

3. Install tube (28) between the two elbows, and tighten the fittings.

4. Install elbow (31) with O-ring seal (20) into aftercooler housing.

5. Install O-ring seal (35) into the groove of elbow (31) .

6. Install tee (36) into the throttle housing. Orient tee (36) with the smaller threads of the adapter directed toward the front of the engine.

7. Install plug (39) with O-ring seal (40) into the top of the tee assembly, and tighten the plug. Alternatively, a connection can be attached to the expansion tank for the SCAC vent.

8. Install clips (25) onto tube (32), and install tube between the two elbows. Refer to Illustration 120 for the proper orientation of tube (32) .

9. Position clip (25) over the hole in bracket (16) that is closest to the throttle housing. Install bolt (22) with washer (23) through the clip and bracket. Install nut with washer onto the bolt, and tighten the bolt.

10. Position clip (25) over the hole in bracket (15). Install bolt (22) with washer (23) through the clip and bracket. Install nut (24) with washer (23) onto the bolt, and tighten the bolt.

11. Tighten the fittings on tube (32) .

12. Install elbow (30) with O-ring seal (20) into the right side of the throttle housing.

13. Install O-ring seal (19) into the groove in the elbow.

14. Install elbow (30) with O-ring seal (19) into the left side of the throttle housing.

15. Install O-ring seal (19) into the groove in the elbow.

16. Install tube (29) between the two elbows. Refer to Illustration 120 and Illustration 121 for proper orientation of tube (29) .

17. Install elbow (38) with O-ring seal (37) into the left side of the throttle housing. Refer to Illustration 121 for proper orientation of elbow (38) .

18. Install tube (33) onto elbow (38) .

19. Install tube (34) onto adapter (36) .

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Illustration 122	g02438557
View A-A (41) 1L-2731 Tube Clamp (42) 0S-1571 Bolt (43) 5M-2894 Hard Washer (44) 8M-9124 Washer

20. Install clamps (41) onto tubes.

21. Install hard washer (43) between the clamps and aftercooler housing.

22. Install bolt (42) with washer (43) through the clamps and the hard washer. Tighten the bolt.

Installation Procedure for the 200-6443 Water Lines Gp

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Illustration 123	g03528239
(45) 200-6441 Tube As

1. Install tube assembly (45) onto the engine as shown in Illustration 123.

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Illustration 124	g03528277
(36) 6V-9746 O-Ring Seal (46) 365-0682 Connector

2. Install connector (46) with o-ring seal (36) as shown in Illustration 124.

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Illustration 125	g03528279
(36) 6V-9746 O-Ring Seal (47) 6V-8733 Union (48) 437-7371 Hose As (49) 439-4508 Hose As

3. Install union (47) with o-ring seal (36) on the end of hose assemblies (48) and (49) .

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Illustration 126	g03528481
(50) 5M-2894 Hard Washer (51) 2A-2677 Spacer (52) 8M-9124 Washer (53) 0L-2070 Bolt (54) 363-8651 Bracket As (55) 9S-1366 Bolt (56) 353-7953 Grommet (57) 3H-8683 Clip

4. Install grommets (56) onto hose assemblies (48) and (49) .

5. Install clips (57) onto grommets (56) .

6. Attach clips (57) to bracket assembly (54) using bolt (53) with hard washers (50), (52), and spacer (51) .

7. Attach bracket assembly (54) to the engine using bolt (55) .

8. Fill the aftercooler circuit with coolant. Also, fill the jacket water coolant to the proper level. Loosen the plug that is located on the tee when the SCAC is filled in order to allow air to vent from the SCAC system.

Installation of Throttle and Related Components for G3520C Generator Set Engines (Twin Turbo Landfill) Group 12

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Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure.

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NOTICE
When refilling the aftercooling system, open the vent plug on the aftercooler, to allow the aftercooler to fill. Failure to do this will cause an air lock and engine damage.

1. Disconnect battery connections or turn the master disconnect switch to the OFF position.

2. Drain the coolant from the second stage aftercooler circuit. Also, drain jacket water coolant to a level that is below the first stage aftercooler.

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Illustration 127	g02371778
(1) Fuel Valve (2) 235-3972 Support As (3) 235-3958 Support As

3. Remove the current throttle control valve. Refer to Disassembly and Assembly, "Throttle Control Valve - Remove" for more information.

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Illustration 128	g02425896
(4) 9S-9334 O-Ring Plug (5) 7M-8485 O-Ring Seal

4. Install plugs (4) with O-rings (5) into the aftercooler ports. Refer to Illustration 128.

5. Remove the current fuel valve support bracket. Retain bolts and washers for reuse.

6. Install supports (3) into position on each side of the aftercooler housing. Install support bracket (2) into position. Install bolts with washers that were previously removed, through the support bracket, and tighten the bolts. Refer to Illustration 127.

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Illustration 129	g02373557
Right side view of the engine (6) 363-7479 Bracket As (7) 1F-7958 Full Nut (8) 5P-8245 Hard Washer (9) 1A-5822 Bolt (10) 7N-2597 Spacer (11) 235-5648 Plate (12) 0S-1587 Bolt (13) 363-7478 Bracket As (14) 6H-1717 Bolt

7. Remove the current plate and install new plate (11). Install bolts (12) with washers (8) into the two holes in the plate that are located near the turbochargers. Refer to Illustration 129.

   Note: Do not tighten the bolts until all bolts are installed into the plate.

8. Position bracket (13) over the four holes that are located on plate (11) near the throttle body. Install bolts (12) with washers (8) through bracket (13) and plate (11). Thread the bolt into brackets that are located on the engine. Refer to Illustration 129.

9. Install the new water-cooled throttle. Refer to Disassembly and Assembly, "Throttle Control Valve - Install" for more information. Use the Steps below in order to install additional brackets onto the throttle housing.
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   Illustration 130	g02425019
   (15) 364-1913 Bracket As (16) 264-7830 Bracket (17) 360-7990 Gasket

   1. Install gasket (17) onto the throttle housing before the throttle is installed onto the engine. Refer to Illustration 130.

   2. Insert the bolt that is located in the 12 o'clock position, through bracket (15), and install bolts into the throttle housing. Refer to Illustration 130 for the location of the brackets.

   3. Insert the two bolts that are located in the 10 o'clock and 11 o'clock positions, through bracket (16). Install bolts into the air lines group housing.
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   Illustration 131	g02453134
   (18) Jumper harness

   4. Connect the jumper harness (18) connector that is attached to the new throttle to the current engine wiring harness. Refer to Illustration 131.

10. Place aftercooler bracket (6) into position. Install the bolts that were removed in Step 3 onto the front end of the aftercooler bracket. Also, install bolts through aftercooler bracket (6), spacer (10), and aftercooler housing. Install nut (7) with washer (8) onto the end of bolt (9). Tighten the nuts and bolts.

Installation of Throttle Coolant Supply Lines and Related Components

Illustration 132	g02593599
Right side view of the throttle housing (15) 364-1913 Bracket As (16) 264-7830 Bracket (19) 6V-8398 O-Ring Seal (20) 3K-0360 O-Ring Seal (21) 6V-9002 Elbow (22) 0S-1594 Bolt (23) 9X-6458 Hard Washer (24) 9S-8752 Full Nut (25) 6V-3265 Clip (26) 6M-9149 Bolt (27) 5P-8247 Hard Washer (28) 363-8643 Tube As (29) 363-8642 Tube As (30) 6V-8625 Elbow (31) 6V-8723 Elbow (32) 363-8644 Tube As (33) 364-1905 Tube As (34) 364-1906 Tube As (35) 6V-8397 O-Ring Seal (53) 4K-0367 Full Nut

Illustration 133	g02373957
Left side view of the throttle housing (19) 6V-8398 O-Ring Seal (20) 3K-0360 O-Ring Seal (29) 363-8642 Tube As (30) 6V-8625 Elbow (36) 367-5997 Tee As (37) 6V-9746 O-Ring Seal (38) 8C-6920 Elbow (39) 9S-4191 O-Ring Plug (40) 3J-1907 O-Ring Seal

1. Install elbows (21) with O-rings (20) into the throttle housing.

2. Install O-rings (19) into the groove of elbow (21) .

3. Install tube (28) between the two elbows, and tighten the fittings.

4. Install elbow (31) with O-ring seal (20) into aftercooler housing.

5. Install O-ring seal (35) into the groove of elbow (31) .

6. Install tee (36) into the throttle housing. Orient tee (36) with the smaller threads of the adapter directed toward the front of the engine.

7. Install plug (39) with O-ring seal (40) into the top of the tee assembly, and tighten the plug. Alternatively, a connection can be attached to the expansion tank for the SCAC vent.

8. Install clips (25) onto tube (32), and install tube between the two elbows. Refer to Illustration 132 for the proper orientation of tube (32) .

9. Position clip (25) over the hole in bracket (16) that is closest to the throttle housing. Install bolt (22) with washer (23) through the clip and bracket. Install nut with washer onto the bolt, and tighten the bolt.

10. Position clip (25) over the hole in bracket (15). Install bolt (22) with washer (23) through the clip and bracket. Install nut (24) with washer (23) onto the bolt, and tighten the bolt.

11. Tighten the fittings on tube (32) .

12. Install elbow (30) with O-ring seal (20) into the right side of the throttle housing.

13. Install O-ring seal (19) into the groove in the elbow.

14. Install elbow (30) with O-ring seal (19) into the left side of the throttle housing.

15. Install O-ring seal (19) into the groove in the elbow.

16. Install tube (29) between the two elbows. Refer to Illustration 132 and Illustration 133 for proper orientation of tube (29) .

17. Install elbow (38) with O-ring seal (37) into the left side of the throttle housing. Refer to Illustration 133 for proper orientation of elbow (38) .

18. Install tube (33) onto elbow (38) .

19. Install tube (34) onto adapter (36) .

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Illustration 134	g02438557
View A-A (41) 1L-2731 Tube Clamp (42) 0S-1571 Bolt (43) 5M-2894 Hard Washer (44) 8M-9124 Washer

20. Install clamps (41) onto tubes.

21. Install hard washer (43) between the clamps and aftercooler housing.

22. Install bolt (42) with washer (43) through the clamps and the hard washer. Tighten the bolt.

Installation Procedure for the 200-6443 Water Lines Gp

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Illustration 135	g03528239
(45) 200-6441 Tube As

1. Install tube assembly (45) onto the engine as shown in Illustration 123.

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Illustration 136	g03528277
(36) 6V-9746 O-Ring Seal (46) 365-0682 Connector

2. Install connector (46) with o-ring seal (36) as shown in Illustration 136.

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Illustration 137	g03528279
(36) 6V-9746 O-Ring Seal (47) 6V-8733 Union (48) 437-7371 Hose As (49) 439-4508 Hose As

3. Install union (47) with o-ring seal (36) on the end of hose assemblies (48) and (49) .

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Illustration 138	g03528481
(50) 5M-2894 Hard Washer (51) 2A-2677 Spacer (52) 8M-9124 Washer (53) 0L-2070 Bolt (54) 363-8651 Bracket As (55) 9S-1366 Bolt (56) 353-7953 Grommet (57) 3H-8683 Clip

4. Install grommets (56) onto hose assemblies (48) and (49) .

5. Install clips (57) onto grommets (56) .

6. Attach clips (57) to bracket assembly (54) using bolt (53) with hard washers (50), (52), and spacer (51) .

7. Attach bracket assembly (54) to the engine using bolt (55) .

8. Fill the aftercooler circuit with coolant. Also, fill the jacket water coolant to the proper level. Loosen the plug that is located on the tee when the SCAC is filled in order to allow air to vent from the SCAC system.

Installation of Throttle and Related Components for G3520C and G3520E Generator Set Engines (Single Turbo With Engine Driven SCAC Pump) Group 13

1. Drain the coolant from the second stage aftercooler circuit. Also, drain jacket water coolant to a level that is below the first stage aftercooler.

2. Remove the current throttle control valve. Refer to Disassembly and Assembly, "Throttle Control Valve - Remove" for more information.

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Illustration 139	g02381130
(1) 9S-9334 O-Ring Plug (2) 7M-8485 O-Ring Seal

3. Install plugs (1) with O-rings (2) into the aftercooler ports. Refer to Illustration 139.

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Illustration 140	g02456983
View of 201-1483 Control Mounting Gp (3) 0S-1587 Bolt (4) 5P-8245 Hard Washer (5) 6H-1717 Bolt (6) 1A-5822 Bolt (7) 1F-7958 Full Nut (8) 7N-2597 Spacer (9) 363-7479 Bracket As (10) 363-7478 Bracket As (11) 201-1484 Bracket As

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Illustration 141	g02456839
View of 206-4180 Control Mounting Gp (3) 0S-1587 Bolt (4) 5P-8245 Hard Washer (5) 6H-1717 Bolt (6) 1A-5822 Bolt (7) 1F-7958 Full Nut (8) 7N-2597 Spacer (9) 363-7479 Bracket As (10) 363-7478 Bracket As (12) 207-5097 Plate (13) 206-4181 Bracket As

4. Install the 201-1483 Control Mounting Gp . Use the following Steps. Refer to Illustration 140.

   Note: Do not tighten the bolts until all bolts are installed into the plate.

   1. Remove the current plate and install bracket (11). Install bolts (3) with washers (4) into the two holes in the plate that are located near the turbochargers.

   2. Position bracket (10) over the four holes that are located on plate near the throttle body. Install bolts (3) with washers (4) through bracket (10) and thread the bolt into the bracket. Install bolts (5) with washers (4) through the bracket.

5. Install the 206-4180 Control Mounting Gp . Use the following Steps. Refer to Illustration 141.

   Note: Do not tighten the bolts until all bolts are installed into the plate.

   1. Remove the current plate and install bracket (13). Install bolts (3) with washers (4) into the two holes in the plate that are located near the turbochargers.

   2. Install plate (12) onto bracket (13) .

   3. Position bracket (10) over the four holes that are located on plate near the throttle body. Install bolts (3) with washers (4) through bracket (10) and thread the bolt into the bracket. Install bolts (5) with washers (4) through the bracket.

6. Install the new water-cooled throttle. Refer to Disassembly and Assembly, "Throttle Control Valve - Install" for more information. use the Steps below to install additional brackets onto the throttle housing.
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   Illustration 142	g02431407
   (14) 364-1913 Bracket As (15) 264-7830 Bracket (16) 360-7990 Gasket

   1. Install gasket (16) onto the throttle housing before the throttle is installed onto the engine. Refer to Illustration

   2. Insert the bolt that is located in the 12 o'clock position, through bracket (14), and install bolts into the throttle housing. Refer to Illustration 142 and Illustration 144 for the location of the brackets and bolts.

   3. Insert the bolts that are located in the 10 o'clock and 11 o'clock positions through bracket (15). Install the bolts into the air lines group housing.
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   Illustration 143	g02453916
   (17) Jumper harness

   4. Connect the jumper harness (17) that is attached to the new throttle, to the current engine wiring harness. Refer to Illustration 143.

7. Position aftercooler bracket (9) into the proper position. Install the bolts that were removed in Step 2 onto the front end of the aftercooler bracket. Also install bolts through aftercooler bracket (9), spacer (8) and aftercooler housing. Install nut (7) with washer (4) onto the end of bolt (6). Tighten the nuts and bolts. Refer to Illustration 140 and Illustration 141.

Installation of Throttle Coolant Supply Lines and Related Components

Illustration 144	g02594156
(14) 364-1913 Bracket As (15) 264-7830 Bracket (18) 6V-8398 O-Ring Seal (19) 3K-0360 O-Ring Seal (20) 6V-9002 Elbow (21) 0S-1594 Bolt (22) 9X-6458 Hard Washer (23) 9S-8752 Full Nut (24) 6V-3265 Clip (25) 6M-9149 Bolt (26) 5P-8247 Hard Washer (27) 363-8643 Tube As (28) 363-8642 Tube As (29) 6V-8625 Elbow (30) 6V-8723 Elbow (31) 363-8644 Tube As (32) 363-8645 Tube As (33) 363-8646 Tube As (34) 6V-8397 O-Ring Seal (53) 4K-0367 Full Nut

Illustration 145	g02457518
(18) 6V-8398 O-Ring Seal (19) 3K-0360 O-Ring Seal (28) 363-8642 Tube As (29) 6V-8625 Elbow (35) 367-5997 Tee As (36) 6V-9746 O-Ring Seal (37) 8C-6920 Elbow (38) 9S-4191 O-Ring Plug (39) 3J-1907 O-Ring Seal

1. Install elbows (20) with O-rings (19) into the throttle housing.

2. Install O-rings (18) into the groove of elbow (20) .

3. Install tube (27) between the two elbows, and tighten the fittings.

4. Install elbow (30) with O-ring seal (19) into aftercooler housing.

5. Install O-ring into the groove of elbow (30) .

6. Install tee (35) into the throttle housing. Orient tee (35) with the smaller threads of the adapter directed toward the front of the engine.

7. Install plug (38) with O-ring seal (39) into the top of the tee assemble, and tighten the plug. Alternatively, a connection can be attached to the expansion tank for the SCAC vent.

8. Install clips (24) onto tube (31), and install tube between the two elbows. Refer to Illustration 144 for the proper orientation of tube (31) .

9. Position clip (24) over the hole in bracket (15) that is closest to the throttle housing. Install bolt (21) with washer (22) through the clip and bracket. Install nut (23) with washer (22) onto the bolt, and tighten the bolt.

10. Position clip (24) over the hole in bracket (14). Install bolt (21) with washer (22) through the clip and bracket. Install nut (23) with washer (22) onto the bolt, and tighten the bolt.

11. Tighten the fittings on tube (31) .

12. Install elbow (29) with O-ring seal (19) into the right side of the throttle housing.

13. Install O-ring seal (18) into the groove in the elbow.

14. Install elbow (29) with O-ring seal (19) into the left side of the throttle housing.

15. Install O-ring seal (18) into the groove in the elbow.

16. Install tube (28) between the two elbows. Refer to Illustration 144 and Illustration 145 for proper orientation of tube (28) .

17. Install elbow (37) with O-ring seal (36) into the left side of the throttle housing. Refer to Illustration 145 for proper orientation of elbow (37) .

18. Install tube (33) onto elbow (37) .

19. Install tube (32) onto tee (35) .

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Illustration 146	g02458682
View A-A (40) 1L-2731 Tube Clamp (41) 0S-1591 Bolt (42) 5M-2894 Hard Washer (43) 8M-9124 Washer (52) 363-8651 Bracket As

20. Install clamps (40) onto tubes (32) and (33) .

21. Install bracket (52) onto the aftercooler housing. Use the current bolts in order to secure the bracket.

22. Install hard washer (43) between the clamps and the aftercooler housing.

Installation Procedure for the 287-8181 Water Lines Gp

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Illustration 147	g03528239
(45) 200-6441 Tube As

1. Install tube assembly (45) onto the engine as shown in Illustration 123.

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Illustration 148	g03528277
(36) 6V-9746 O-Ring Seal (46) 365-0682 Connector

2. Install connector (46) with o-ring seal (36) as shown in Illustration 148.

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Illustration 149	g03528279
(36) 6V-9746 O-Ring Seal (47) 6V-8733 Union (48) 437-7371 Hose As (49) 439-4508 Hose As

3. Install union (47) with o-ring seal (36) on the end of hose assemblies (48) and (49) .

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Illustration 150	g03528481
(50) 5M-2894 Hard Washer (51) 2A-2677 Spacer (52) 8M-9124 Washer (53) 0L-2070 Bolt (54) 363-8651 Bracket As (55) 9S-1366 Bolt (56) 353-7953 Grommet (57) 3H-8683 Clip

4. Install grommets (56) onto hose assemblies (48) and (49) .

5. Install clips (57) onto grommets (56) .

6. Attach clips (57) to bracket assembly (54) using bolt (53) with hard washers (50), (52), and spacer (51) .

7. Attach bracket assembly (54) to the engine using bolt (55) .

8. Fill the aftercooler circuit with coolant. Also, fill the jacket water coolant to the proper level. Loosen the plug that is located on the tee when the SCAC is filled in order to allow air to vent from the SCAC system.

Installation of Throttle and Related Components for G3520C and G3520E Generator Set Engines (Twin Turbo With Engine Driven SCAC Pump) Group 14

1. Disconnect battery connections, or turn the master disconnect switch to the OFF position.

2. Drain the coolant from the second stage aftercooler circuit. Also, drain jacket water coolant to a level that is below the first stage aftercooler.

3. Remove the current throttle control valve. Refer to Disassembly and Assembly, "Throttle Control Valve - Remove" for more information.

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Illustration 151	g02381130
(1) 9S-9334 O-Ring Plug (2) 7M-8485 O-Ring Seal

4. Install plugs (1) with O-rings (2) into the aftercooler ports. Refer to Illustration 151.

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Illustration 152	g02404003
(3) 207-5097 Plate (4) 206-4181 Bracket As (5) 0S-1587 Bolt (6) 5P-8245 Hard Washer (7) 363-7478 Bracket As (8) 6H-1717 Bolt (9) 363-7479 Bracket As (10) 1A-5822 Bolt (11) 1F-7958 Full Nut (12) 7N-2597 Spacer

5. Remove the current bracket and install new bracket (4). Install bolts (5) with washers (6) into the two holes in the plate that are located near the turbochargers. Refer to Illustration 152.

   Note: Do not tighten the bolts until all bolts are installed into the plate.

6. Install bracket (3) onto plate (4) .

7. Position bracket (7) over the four holes that are located on plate near the throttle body. Install bolts (5) with washers (6) through bracket. Install bolts (6) with washers (8) through bracket. Refer to Illustration 152.

8. Install the new water-cooled throttle. Refer to Disassembly and Assembly, "Throttle Control Valve - Install" for more information. use the Steps below to install additional brackets onto the throttle housing.
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   Illustration 153	g02440576
   (13) 364-1913 Bracket As (14) 264-7830 Bracket (15) 360-7990 Gasket

   1. Install gasket (15) onto the throttle housing before the throttle is installed onto the engine.

   2. Insert the bolt that is located in the 12 o'clock position, through bracket (13), and install bolts into the throttle housing. Refer to Illustration 153 and Illustration 155 for the location of the brackets and bolts.

   3. Insert the bolts that are located in the 10 o'clock and 11 o'clock positions through bracket (14). Install the bolts into the air lines group housing.
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   Illustration 154	g02454037
   (16) Jumper harness

   4. Connect the jumper harness (16) connector that is attached to the new throttle to the current engine wiring harness. Refer to Illustration 154.

Installation of Throttle Coolant Supply Lines and Related Components

Illustration 155	g02594182
(13) 363-8651 Bracket As (14) 264-7830 Bracket (17) 6V-8398 O-Ring Seal (18) 3K-0360 O-Ring Seal (19) 6V-9002 Elbow (20) 0S-1594 Bolt (21) 9X-6458 Hard Washer (22) 9S-8752 Full Nut (23) 6V-3265 Clip (24) 6M-9149 Bolt (25) 5P-8247 Hard Washer (26) 363-8643 Tube As (27) 363-8642 Tube As (28) 6V-8625 Elbow (29) 6V-8723 Elbow (30) 363-8644 Tube As (31) 363-8645 Tube As (32) 363-8646 Tube As (33) 6V-8397 O-Ring Seal (52) 4K-0367 Full Nut

Illustration 156	g02467377
(17) 6V-8398 O-Ring Seal (18) 3K-0360 O-Ring Seal (27) 363-8642 Tube As (28) 6V-8625 Elbow (34) 367-5997 Tee As (35) 6V-9746 O-Ring Seal (36) 8C-6920 Elbow (37) 9S-4191 O-Ring Plug (38) 3J-1907 O-Ring Seal

1. Install elbows (19) with O-rings (18) into the throttle housing. Refer to Illustration 155 for proper orientation of the elbows.

2. Install O-rings (17) into the groove of elbow (19) .

3. Install tube (26) between the two elbows, and tighten the fittings.

4. Install elbow (29) with O-ring seal (18) into aftercooler housing.

5. Install O-ring (33) into the grove of elbow (29) .

6. Install tee (33) into the throttle housing. Orient tee (33) with the smaller threads of the adapter directed toward the front of the engine.

7. Install plug (37) with O-ring (38) into the port that is located at the top of tee (33). Alternatively, a connection can be attached to the expansion tank for the SCAC vent.

8. Install clips (23) onto tube (30), and install tube between the two elbows. Refer to Illustration 155 for the proper orientation of tube (30) .

9. Position clip (23) over the hole in bracket (14) that is closest to the throttle housing. Install bolt (20) with washer (22) through the clip and bracket. Install nut (21) with washer (22) onto the bolt, and tighten the bolt.

10. Position clip (23) over the hole in bracket (13). Install bolt (20) with washer (22) through the clip and bracket. Install nut (21) with washer (22) onto the bolt, and tighten the bolt.

11. Tighten the fittings on tube (30) .

12. Install elbow (28) with O-ring seal (18) into the right side of the throttle housing.

13. Install O-ring seal (17) into the groove in the elbow.

14. Install elbow (28) with O-ring seal (18) into the left side of the throttle housing.

15. Install O-ring seal (17) into the groove in the elbow.

16. Install tube (26) between the two elbows. Refer to Illustration 155 and Illustration 156 for proper orientation of tube (26) .

17. Install elbow (36) with O-ring seal (18) into the left side of the throttle housing. Refer to Illustration 156 for proper orientation of elbow (36) .

18. Install tube (32) onto elbow (36) .

19. Install tube (31) onto tee (33) .

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Illustration 157	g02471700
View A-A (39) 1L-2731 Tube Clamp (40) 0S-1591 Bolt (41) 5M-2894 Hard Washer (42) 8M-9124 Washer

20. Install clamps (39) onto tubes (30) and (31). Refer to Illustration 157.

21. Install bracket (49) onto the aftercooler housing. Use the current bolts in order to secure the bracket.

22. Install washer (42) between the clamps and the aftercooler housing.

23. Install bolt (40) with washer (41) through the clamps and washer. Tighten the bolts.

Installation Procedure for the 287-8181 Water Lines Gp

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Illustration 158	g03528239
(45) 200-6441 Tube As

1. Install tube assembly (45) onto the engine as shown in Illustration 158.

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Illustration 159	g03528277
(36) 6V-9746 O-Ring Seal (46) 365-0682 Connector

2. Install connector (46) with o-ring seal (36) as shown in Illustration 159.

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Illustration 160	g03528279
(36) 6V-9746 O-Ring Seal (47) 6V-8733 Union (48) 437-7371 Hose As (49) 439-4508 Hose As

3. Install union (47) with o-ring seal (36) on the end of hose assemblies (48) and (49) .

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Illustration 161	g03528481
(50) 5M-2894 Hard Washer (51) 2A-2677 Spacer (52) 8M-9124 Washer (53) 0L-2070 Bolt (54) 363-8651 Bracket As (55) 9S-1366 Bolt (56) 353-7953 Grommet (57) 3H-8683 Clip

4. Install grommets (56) onto hose assemblies (48) and (49) .

5. Install clips (57) onto grommets (56) .

6. Attach clips (57) to bracket assembly (54) using bolt (53) with hard washers (50), (52), and spacer (51) .

7. Attach bracket assembly (54) to the engine using bolt (55) .

8. Fill the aftercooler circuit with coolant. Also, fill the jacket water coolant to the proper level. Loosen the plug that is located on the tee when the SCAC is filled in order to allow air to vent from the SCAC system.

Installation of Throttle and Related Components for G3520C Generator Set Engines (Coal Mine Methane) Group 15

1. Disconnect battery connections, or turn the master disconnect switch to the OFF position.

2. Drain the coolant from the second stage aftercooler circuit. Also, drain jacket water coolant to a level that is below the first stage aftercooler.

3. Remove the tube that is connected to the fuel control valve and the air inlet. Retain the bolts that were removed for reuse.

4. Remove the current fuel valve support brackets. Retain bolts and washers for reuse.

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Illustration 162	g02476652
(1) Fuel Valve (2) 235-3972 Support As (3) 235-3958 Support As

5. Install new support assemblies (3) into position on each side of the aftercooler housing. Install support bracket (2) into position. Install bolts with washers that were previously removed, through the support bracket and tighten the bolts. Refer to Illustration 162.

6. Remove the current throttle control valve. Refer to Disassembly and Assembly, "Throttle Control Valve - Remove" for more information.

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Illustration 163	g02435958
(4) 9S-9334 O-Ring Plug (5) 7M-8485 O-Ring Seal

7. Install plugs (4) with O-rings (5) into the aftercooler ports. Refer to Illustration 163.

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Illustration 164	g02436058
(6) 306-9208 Bracket (7) 0S-1587 Bolt (8) 5P-8245 Hard Washer (9) 363-7478 Bracket As (10) 6H-1717 Bolt (11) 363-7479 Bracket As (12) 1A-5822 Bolt (13) 1F-7958 Full Nut (14) 7N-2597 Spacer

8. Remove the current bracket and install new bracket (6). Install bolts (7) with washers (8) into the two holes in the plate that are located near the turbochargers. Refer to Illustration 164.

   Note: Do not tighten the bolts until all bolts are installed into the plate.

9. Position bracket (9) over to four holes that are located on the plate near the throttle body. Install bolts (7) with washers (8) through bracket (9) and thread the bolts into the bracket. Install bolts (10) with washer (8) through bracket (9) and bracket (6) .

10. Install the new water-cooled throttle. Refer to Disassembly and Assembly, "Throttle Control Valve - Install" for more information. use the Steps below to install additional brackets onto the throttle housing.
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    Illustration 165	g02435876
    (15) 364-1913 Bracket As (16) 264-7830 Bracket (17) 360-7990 Gasket

    1. Install gasket (17) onto the throttle housing before the throttle is installed onto the engine. Refer to Illustration 165.

    2. Insert the bolt that is located in the 12 o'clock position, through bracket (15), and install bolts into the throttle housing. Refer to Illustration 165 and Illustration 168 for the location of the brackets and bolts.

    3. Insert the bolts that are located in the 10 o'clock and 11 o'clock positions through bracket (16). Install the bolts into the air lines group housing.
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    Illustration 166	g02455096
    (18) Jumper harness

    4. Connect the connector of the jumper harness (18) to the current engine wiring harness.

11. Place aftercooler bracket (11) into position. Install the bolts that were removed in Step 6 onto the front end of the aftercooler bracket. Install bolt (12) through aftercooler bracket (11), spacer (14), and the aftercooler housing. Install nut (13) with washer (8) onto the end of the bolt. Tighten the nuts and bolts.

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Illustration 167	g02392717
(19) 306-6581 Bracket As (20) 186-3467 Gasket (21) 235-5537 Gasket (22) 276-2341 Tube As

12. Remove the current bracket that supports air inlet tube.

13. Install bracket (19). Use the current bolts in order to secure the bracket.

14. Install gasket (21) onto the fuel control valve.

15. Install end of tube (22) onto the end of the fuel control valve. Install the bolts that were previously removed through the flange of tube, and the flange of the fuel control valve. Install the nuts with washers onto the end of the bolts, and tighten the bolts.

16. Install gasket (20) onto the bellows.

17. Install opposite end of the tube (22) onto the bellows. Install the bolts through the flange of the tube and the flange of the bellows. Install the nuts with the washers onto the end of the bolts.

18. Install the current u-bolt over the tube. Install the current nuts with washer onto the u-bolt. Tighten the nuts.

Installation of Throttle Coolant Supply Lines and Related Components

Illustration 168	g02594214
Right side view of the throttle housing (15) 364-1913 Bracket As (16) 264-7830 Bracket (23) 6V-8398 O-Ring Seal (24) 3K-0360 O-Ring Seal (25) 6V-9002 Elbow (26) 0S-1594 Bolt (27) 9X-6458 Hard Washer (28) 9S-8752 Full Nut (29) 6V-3265 Clip (30) 6M-9149 Bolt (31) 5P-8247 Hard Washer (32) 363-8643 Tube As (33) 363-8642 Tube As (34) 6V-8625 Elbow (35) 6V-8723 Elbow (36) 363-8644 Tube As (37) 364-1905 Tube As (38) 364-1906 Tube As (39) 6V-8397 O-Ring Seal (58) 4K-0367 Full Nut

Illustration 169	g02436809
Left side view of the throttle housing (23) 6V-8398 O-Ring Seal (24) 3K-0360 O-Ring Seal (34) 6V-8625 Elbow (40) 367-5997 Tee As (41) 6V-9746 O-Ring Seal (42) 8C-6920 Elbow (43) 9S-4191 O-Ring Plug (44) 3J-1907 O-Ring Seal

1. Install elbows (25) with O-rings (24) into the throttle housing. Refer to Illustration 168 for the proper orientation of the elbows.

2. Install O-rings (23) into the groove of elbows (25) .

3. Install tube (32) between the two elbows, and tighten the fittings.

4. Install elbow (35) with O-ring seal (24) into aftercooler housing.

5. Install O-ring seal (39) into the groove of elbow (35) .

6. Install tee (40) into the throttle housing. Orient tee (40) with the smaller threads of the adapter directed toward the front of the engine.

7. Install plug (43) with O-ring seal (44) into the top of the tee assembly, and tighten the plug. Alternatively, a connection can be attached to the expansion tank for the SCAC vent.

8. Install clips (29) onto tube (36), and install tube between the two elbows. Refer to Illustration 169 for the proper orientation of tube (36) .

9. Position clip (29) over the hole in bracket (15) that is closest to the throttle housing. Install bolt (26) with washer (27) through the clip and bracket. Install nut (28) with washer (27) onto the bolt, and tighten the bolt.

10. Position clip (29) over the hole in bracket (16). Install bolt (26) with washer (27) through the clip and bracket. Install nut (28) with washer (27) onto the bolt, and tighten the bolt.

11. Tighten the fittings on tube (36) .

12. Install elbow (34) with O-ring seal (24) into the right side of the throttle housing.

13. Install O-ring seal (23) into the groove in the elbow.

14. Install elbow (34) with O-ring seal (24) into the left side of the throttle housing.

15. Install O-ring seal (23) into the groove in the elbow.

16. Install tube (33) between the two elbows. Refer to Illustration 168 and Illustration 169 for proper orientation of tube (33) .

17. Install elbow (42) with O-ring (24) into the left side of the throttle housing. Refer to Illustration 169 for proper orientation of the elbow.

18. Install O-ring (23) into the groove of elbow (42) .

19. Install tube (37) onto elbow (42) .

20. Install tube (38) onto tee (40) .

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Illustration 170	g02437016
View A-A (45) 1L-2731 Tube Clamp (46) 0S-1571 Bolt (47) 5M-2894 Hard Washer (48) 8M-9124 Washer

21. Install clamps (45) onto tubes (37) and (38) .

22. Install hard washer (48) between the clamps and the aftercooler housing.

23. Install bolt (46) with washer (47) through the clamps and hard washer, and install bolt into the aftercooler housing.

Installation Procedure for the 287-8181 Water Lines Gp

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Illustration 171	g03528239
(45) 200-6441 Tube As

1. Install tube assembly (45) onto the engine as shown in Illustration 171.

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Illustration 172	g03528277
(36) 6V-9746 O-Ring Seal (46) 365-0682 Connector

2. Install connector (46) with o-ring seal (36) as shown in Illustration 172.

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Illustration 173	g03528279
(36) 6V-9746 O-Ring Seal (47) 6V-8733 Union (48) 437-7371 Hose As (49) 439-4508 Hose As

3. Install union (47) with o-ring seal (36) on the end of hose assemblies (48) and (49) .

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Illustration 174	g03528481
(50) 5M-2894 Hard Washer (51) 2A-2677 Spacer (52) 8M-9124 Washer (53) 0L-2070 Bolt (54) 363-8651 Bracket As (55) 9S-1366 Bolt (56) 353-7953 Grommet (57) 3H-8683 Clip

4. Install grommets (56) onto hose assemblies (48) and (49) .

5. Install clips (57) onto grommets (56) .

6. Attach clips (57) to bracket assembly (54) using bolt (53) with hard washers (50), (52), and spacer (51) .

7. Attach bracket assembly (54) to the engine using bolt (55) .

8. Fill the aftercooler circuit with coolant. Also, fill the jacket water coolant to the proper level. Loosen the plug that is located on the tee when the SCAC is filled in order to allow air to vent from the SCAC system.

Installation of Throttle and Related Components for G3520C and G3520E Generator Set Engines (Twin Turbo With Engine Driven SCAC Pump) Group 16

1. Disconnect battery connections, or turn the master disconnect switch to the OFF position.

2. Drain the coolant from the second stage aftercooler circuit. Also, drain jacket water coolant to a level that is below the first stage aftercooler.

3. Remove the current throttle control valve. Refer to Disassembly and Assembly, "Throttle Control Valve - Remove" for more information.

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Illustration 175	g02381130
(1) 9S-9334 O-Ring Plug (2) 7M-8485 O-Ring Seal

4. Install plugs (1) with O-rings (2) into the aftercooler ports. Refer to Illustration 175.

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Illustration 176	g02404003
(3) 207-5097 Plate (4) 206-4181 Bracket As (5) 0S-1587 Bolt (6) 5P-8245 Hard Washer (7) 363-7478 Bracket As (8) 6H-1717 Bolt (9) 363-7479 Bracket As (10) 1A-5822 Bolt (11) 1F-7958 Full Nut (12) 7N-2597 Spacer

5. Remove the current bracket and install new bracket (4). Install bolts (5) with washers (6) into the two holes in the plate that are located near the turbochargers. Refer to Illustration 176.

   Note: Do not tighten the bolts until all bolts are installed into the plate.

6. Install bracket (3) onto plate (4) .

7. Position bracket (7) over the four holes that are located on plate near the throttle body. Install bolts (5) with washers (6) through bracket. Install bolts (6) with washers (8) through bracket. Refer to Illustration 176.

8. Install the new water-cooled throttle. Refer to Disassembly and Assembly, "Throttle Control Valve - Install" for more information. use the Steps below to install additional brackets onto the throttle housing.
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   Illustration 177	g02440576
   (13) 364-1913 Bracket As (14) 264-7830 Bracket (15) 360-7990 Gasket

   1. Install gasket (15) onto the throttle housing before the throttle is installed onto the engine.

   2. Insert the bolt that is located in the 12 o'clock position, through bracket (13), and install bolts into the throttle housing. Refer to Illustration 177 and Illustration 179 for the location of the brackets and bolts.

   3. Insert the bolts that are located in the 10 o'clock and 11 o'clock positions through bracket (14). Install the bolts into the air lines group housing.
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   Illustration 178	g02454037
   (16) Jumper harness

   4. Connect the jumper harness (16) connector that is attached to the new throttle to the current engine wiring harness. Refer to Illustration 178.

Installation of Throttle Coolant Supply Lines and Related Components

Illustration 179	g02594182
(13) 363-8651 Bracket As (14) 264-7830 Bracket (17) 6V-8398 O-Ring Seal (18) 3K-0360 O-Ring Seal (19) 6V-9002 Elbow (20) 0S-1594 Bolt (21) 9X-6458 Hard Washer (22) 9S-8752 Full Nut (23) 6V-3265 Clip (24) 6M-9149 Bolt (25) 5P-8247 Hard Washer (26) 363-8643 Tube As (27) 363-8642 Tube As (28) 6V-8625 Elbow (29) 6V-8723 Elbow (30) 363-8644 Tube As (31) 363-8645 Tube As (32) 363-8646 Tube As (33) 6V-8397 O-Ring Seal (52) 4K-0367 Full Nut

Illustration 180	g02467377
(17) 6V-8398 O-Ring Seal (18) 3K-0360 O-Ring Seal (27) 363-8642 Tube As (28) 6V-8625 Elbow (34) 367-5997 Tee As (35) 6V-9746 O-Ring Seal (36) 8C-6920 Elbow (37) 9S-4191 O-Ring Plug (38) 3J-1907 O-Ring Seal

1. Install elbows (19) with O-rings (18) into the throttle housing. Refer to Illustration 179 for proper orientation of the elbows.

2. Install O-rings (17) into the groove of elbow (19) .

3. Install tube (26) between the two elbows, and tighten the fittings.

4. Install elbow (29) with O-ring seal (18) into aftercooler housing.

5. Install O-ring (33) into the grove of elbow (29) .

6. Install tee (33) into the throttle housing. Orient tee (33) with the smaller threads of the adapter directed toward the front of the engine.

7. Install plug (37) with O-ring (38) into the port that is located at the top of tee (33). Alternatively, a connection can be attached to the expansion tank for the SCAC vent.

8. Install clips (23) onto tube (30), and install tube between the two elbows. Refer to Illustration 179 for the proper orientation of tube (30) .

9. Position clip (23) over the hole in bracket (14) that is closest to the throttle housing. Install bolt (20) with washer (22) through the clip and bracket. Install nut (21) with washer (22) onto the bolt, and tighten the bolt.

10. Position clip (23) over the hole in bracket (13). Install bolt (20) with washer (22) through the clip and bracket. Install nut (21) with washer (22) onto the bolt, and tighten the bolt.

11. Tighten the fittings on tube (30) .

12. Install elbow (28) with O-ring seal (18) into the right side of the throttle housing.

13. Install O-ring seal (17) into the groove in the elbow.

14. Install elbow (28) with O-ring seal (18) into the left side of the throttle housing.

15. Install O-ring seal (17) into the groove in the elbow.

16. Install tube (26) between the two elbows. Refer to Illustration 179 and Illustration 180 for proper orientation of tube (26) .

17. Install elbow (36) with O-ring seal (18) into the left side of the throttle housing. Refer to Illustration 180 for proper orientation of elbow (36) .

18. Install tube (32) onto elbow (36) .

19. Install tube (31) onto tee (33) .

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Illustration 181	g02471700
View A-A (39) 1L-2731 Tube Clamp (40) 0S-1591 Bolt (41) 5M-2894 Hard Washer (42) 8M-9124 Washer

20. Install clamps (39) onto tubes (30) and (31). Refer to Illustration 181.

21. Install bracket (49) onto the aftercooler housing. Use the current bolts in order to secure the bracket.

22. Install washer (42) between the clamps and the aftercooler housing.

23. Install bolt (40) with washer (41) through the clamps and washer. Tighten the bolts.

Installation Procedure for the 200-6438 Water Aftercooler Gp

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Illustration 182	g03529696
(35) 6V-9746 O-Ring Seal (43) 6V-8733 Union (44) 418-1233 Hose As (45) 418-1234 Hose As (46) 7X-7902 Elbow

1. Install elbows (47) with o-ring seals (35) .

2. Install union (43) with o-ring seal (35) .

3. Install hose assemblies (44) and (45) .

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Illustration 183	g03529717
(47) 0L-2070 Bolt (48) 5M-2894 Hard Washer (49) 2A-2677 Spacer (50) 353-7953 Grommet (51) 3H-8683 Clip (52) 363-8651 Bracket As (53) 9S-1366 Bolt (54) 8M-9124 Washer

4. Install grommets (50) onto hose assemblies (44) and (45) .

5. Install clips (51) onto grommets (50) .

6. Attach clips (51) to bracket assembly (52) using bolt (47) with hard washer (48), (54), and spacer (49) .

7. Attach bracket assembly (52) to the engine using bolt (53) .

8. Fill the aftercooler circuit with coolant. Also, fill the jacket water coolant to the proper level. Loosen the plug that is located on the tee when the SCAC is filled in order to allow air to vent from the SCAC system.

Installation of Throttle and Related Components for G3520C and G3520E Generator Set Engines (Twin Turbo Without Engine Driven SCAC Pump) Group 17

1. Drain the coolant from the second stage aftercooler circuit. Also, drain jacket water coolant to a level that is below the first stage aftercooler.

2. Remove the current throttle control valve. Refer to Disassembly and Assembly, "Throttle Control Valve - Remove" for more information.

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Illustration 184	g02381130
(1) 9S-9334 O-Ring Plug (2) 7M-8485 O-Ring Seal

3. Install plugs (1) with O-rings (2) into the aftercooler ports. Refer to Illustration 184.

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Illustration 185	g02404003
(3) 207-5097 Plate (4) 206-4181 Bracket As (5) 0S-1587 Bolt (6) 5P-8245 Hard Washer (7) 363-7478 Bracket As (8) 6H-1717 Bolt (9) 363-7479 Bracket As (10) 1A-5822 Bolt (11) 1F-7958 Full Nut (12) 7N-2597 Spacer

4. Remove the current bracket and install new bracket (4). Install bolts (5) with washers (6) into the two holes in the plate that are located near the turbochargers. Refer to Illustration 185.

   Note: Do not tighten the bolts until all bolts are installed into the plate.

5. Install plate (3) onto bracket (4). Use the four bolts that were previously removed in order to secure bracket (4) .

6. Position bracket (7) over the four holes that are located on plate near the throttle body. Install bolts (5) with washers (6) through bracket. Install bolts (8) with washers (6) through bracket. Refer to Illustration 185.

7. Place the aftercooler bracket into the proper position. Install the bots that were removed in Step 2 onto the front end of the aftercooler bracket. Also, install bolt (10) through aftercooler bracket (9), spacer (12), and aftercooler housing. Install nut (11), with washer (6) onto the end of bolt (10). Tighten the nuts and bolts.

8. Install the new water-cooled throttle. Refer to Disassembly and Assembly, "Throttle Control Valve - Install" for more information. use the Steps below to install additional brackets onto the throttle housing.
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   Illustration 186	g02440576
   (13) 364-1913 Bracket As (14) 264-7830 Bracket (15) 360-7990 Gasket

   1. Install gasket (15) onto the throttle housing before the throttle is installed onto the engine.

   2. Insert the bolt that is located in the 12 o'clock position, through bracket (13), and install bolts into the throttle housing. Refer to Illustration 186 and Illustration 186 for the location of the brackets and bolts.

   3. Insert the bolts that are located in the 10 o'clock and 11 o'clock positions through bracket (14). Install the bolts into the air lines group housing.
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   Illustration 187	g02453918
   (16) Jumper harness

   4. Connect the jumper harness (16) that is attached to the new throttle, to the current engine wiring harness. Refer to Illustration 187.

Installation of Throttle Coolant Supply Lines and Related Components

Illustration 188	g02594182
(17) 6V-8398 O-Ring Seal (18) 3K-0360 O-Ring Seal (19) 6V-9002 Elbow (20) 0S-1594 Bolt (21) 9X-6458 Hard Washer (22) 9S-8752 Full Nut (23) 6V-3265 Clip (24) 6M-9149 Bolt (25) 5P-8247 Hard Washer (26) 363-8643 Tube As (27) 363-8642 Tube As (28) 6V-8625 Elbow (29) 6V-8723 Elbow (30) 363-8644 Tube As (31) 363-8645 Tube As (32) 363-8646 Tube As (33) 6V-8397 O-Ring Seal

Illustration 189	g02467363
(17) 6V-8398 O-Ring Seal (18) 3K-0360 O-Ring Seal (27) 363-8642 Tube As (28) 6V-8625 Elbow (34) 367-5997 Tee As (35) 6V-9746 O-Ring Seal (36) 8C-6920 Elbow (37) 9S-4191 O-Ring Plug (38) 3J-1907 O-Ring Seal

1. Install elbows (19) with O-rings (18) into the throttle housing. Refer to Illustration 188 for the proper orientation of the elbows (19) .

2. Install O-rings (17) into the groove of elbow (19) .

3. Install tube (26) between the two elbows, and tighten the fittings.

4. Install elbow (29) with O-ring seal (18) into aftercooler housing.

5. Install O-ring seal (33) into the groove of elbow (29) .

6. Install tee (34) into the throttle housing. Orient tee (34) with the smaller threads of the adapter directed toward the front of the engine.

7. Install plug (37) with seal (38) into the port that is located on the top of the tee assembly. Alternatively, a connection can be attached to the expansion tank.

8. Install clips (23) onto tube (30), and install tube between the two elbows. Refer to Illustration 188 for the proper orientation of tube (30) .

9. Position clip (23) over the hole in bracket (14) that is closest to the throttle housing. Install bolt (20) with washer (21) through the clip and bracket. Install nut (22) with washer (21) onto the bolt, and tighten the bolt.

10. Position clip (23) over the hole in bracket (13). Install bolt (20) with washer (21) through the clip and bracket. Install nut (22) with washer (21) onto the bolt, and tighten the bolt.

11. Tighten the fittings on tube (30) .

12. Install elbow (28) with O-ring seal (18) into the right side of the throttle housing.

13. Install O-ring seal (17) into the groove in the elbow.

14. Install elbow (28) with O-ring seal (18) into the left side of the throttle housing.

15. Install O-ring seal (17) into the groove in the elbow.

16. Install tube (27) between the two elbows. Refer to Illustration 188 and Illustration 189 for proper orientation of tube (27) .

17. Install elbow (36) with O-ring seal (15) into the left side of the throttle housing. Refer to Illustration 189 for proper orientation of elbow (36) .

18. Install O-ring seal (35) into the groove of the elbow.

19. Install tube (32) onto elbow (36) .

20. Install tube (31) onto adapter (34) .

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Illustration 190	g02471700
View A-A (39) 1L-2731 Tube Clamp (40) 0S-1591 Bolt (41) 5M-2894 Hard Washer (42) 8M-9124 Washer

21. Install clamps (39) onto the tubes.

22. Install bracket (49) onto the aftercooler housing. Use the current bolts in order to secure the bracket.

23. Install hard washer (42) between the clamps and the aftercooler housing.

24. Install bolt (40) with washer (41) through the clamps and hard washer. Tighten the bolts.

Installation Procedure for the 200-6443 Water Lines Gp

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Illustration 191	g03528239
(45) 200-6441 Tube As

1. Install tube assembly (45) onto the engine as shown in Illustration 191.

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Illustration 192	g03528277
(36) 6V-9746 O-Ring Seal (46) 365-0682 Connector

2. Install connector (46) with o-ring seal (36) as shown in Illustration 192.

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Illustration 193	g03528279
(36) 6V-9746 O-Ring Seal (47) 6V-8733 Union (48) 437-7371 Hose As (49) 439-4508 Hose As

3. Install union (47) with o-ring seal (36) on the end of hose assemblies (48) and (49) .

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Illustration 194	g03528481
(50) 5M-2894 Hard Washer (51) 2A-2677 Spacer (52) 8M-9124 Washer (53) 0L-2070 Bolt (54) 363-8651 Bracket As (55) 9S-1366 Bolt (56) 353-7953 Grommet (57) 3H-8683 Clip

4. Install grommets (56) onto hose assemblies (48) and (49) .

5. Install clips (57) onto grommets (56) .

6. Attach clips (57) to bracket assembly (54) using bolt (53) with hard washers (50), (52), and spacer (51) .

7. Attach bracket assembly (54) to the engine using bolt (55) .

8. Fill the aftercooler circuit with coolant. Also, fill the jacket water coolant to the proper level. Loosen the plug that is located on the tee when the SCAC is filled in order to allow air to vent from the SCAC system.

Installation of Throttle and Related Components for G3520C Landfill Engines (S/N: HAT) Group 18

1. Disconnect battery connections or turn the master disconnect switch to the OFF position.

2. Drain the coolant from the second stage aftercooler circuit. Also, drain jacket water coolant to a level that is below the first stage aftercooler.

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Illustration 195	g02371778
(1) Fuel Valve (2) 235-3972 Support As (3) 235-3958 Support As

3. Remove the current throttle control valve. Refer to Disassembly and Assembly, "Throttle Control Valve - Remove" for more information.

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Illustration 196	g02425896
(4) 9S-9334 O-Ring Plug (5) 7M-8485 O-Ring Seal

4. Install plugs (4) with O-rings (5) into the aftercooler ports. Refer to Illustration 196.

5. Remove the current fuel valve support bracket. Retain bolts and washers for reuse.

6. Install supports (3) into position on each side of the aftercooler housing. Install support bracket (2) into position. Install bolts with washers that were previously removed, through the support bracket, and tighten the bolts. Refer to Illustration 196.

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Illustration 197	g02373557
Right side view of the engine (6) 363-7479 Bracket As (7) 1F-7958 Full Nut (8) 5P-8245 Hard Washer (9) 1A-5822 Bolt (10) 7N-2597 Spacer (11) 235-5648 Plate (12) 0S-1587 Bolt (13) 363-7478 Bracket As (14) 6H-1717 Bolt

7. Remove the current plate and install new plate (11). Install bolts (12) with washers (8) into the two holes in the plate that are located near the turbochargers. Refer to Illustration 197.

   Note: Do not tighten the bolts until all bolts are installed into the plate.

8. Position bracket (13) over the four holes that are located on plate (11) near the throttle body. Install bolts (12) with washers (8) through bracket (13) and plate (11). Thread the bolt into brackets that are located on the engine. Refer to Illustration 197.

9. Install the new water-cooled throttle. Refer to Disassembly and Assembly, "Throttle Control Valve - Install" for more information. Use the Steps below in order to install additional brackets onto the throttle housing.
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   Illustration 198	g02425019
   (15) 364-1913 Bracket As (16) 264-7830 Bracket (17) 360-7990 Gasket

   1. Install gasket (17) onto the throttle housing before the throttle is installed onto the engine. Refer to Illustration 198.

   2. Insert the bolt that is located in the 12 o'clock position, through bracket (15), and install bolts into the throttle housing. Refer to Illustration 198 for the location of the brackets.

   3. Insert the two bolts that are located in the 10 o'clock and 11 o'clock positions, through bracket (16). Install bolts into the air lines group housing.
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   Illustration 199	g02453134
   (18) Jumper harness

   4. Connect the jumper harness (18) connector that is attached to the new throttle to the current engine wiring harness.

10. Place aftercooler bracket (6) into position. Install the bolts that were removed in Step 7 onto the front end of the aftercooler bracket. Also, install bolts through aftercooler bracket (6), spacer (10), and aftercooler housing. Install nut (7) with washer (8) onto the end of bolt (9). Tighten the nuts and bolts.

Installation of Throttle Coolant Supply Lines and Related Components

Illustration 200	g02593599
Right side view of the throttle housing (15) 364-1913 Bracket As (16) 264-7830 Bracket (19) 6V-8398 O-Ring Seal (20) 3K-0360 O-Ring Seal (21) 6V-9002 Elbow (22) 0S-1594 Bolt (23) 9X-6458 Hard Washer (24) 9S-8752 Full Nut (25) 6V-3265 Clip (26) 6M-9149 Bolt (27) 5P-8247 Hard Washer (28) 363-8643 Tube As (29) 363-8642 Tube As (30) 6V-8625 Elbow (31) 6V-8723 Elbow (32) 363-8644 Tube As (33) 364-1905 Tube As (34) 364-1906 Tube As (35) 6V-8397 O-Ring Seal (53) 4K-0367 Full Nut

Illustration 201	g02373957
Left side view of the throttle housing (19) 6V-8398 O-Ring Seal (20) 3K-0360 O-Ring Seal (29) 363-8642 Tube As (30) 6V-8625 Elbow (36) 367-5997 Tee As (37) 6V-9746 O-Ring Seal (38) 8C-6920 Elbow (39) 9S-4191 O-Ring Plug (40) 3J-1907 O-Ring Seal

1. Install elbows (21) with O-rings (20) into the throttle housing.

2. Install O-rings (19) into the groove of elbow (21) .

3. Install tube (28) between the two elbows, and tighten the fittings.

4. Install elbow (31) with O-ring seal (20) into aftercooler housing.

5. Install O-ring seal (35) into the groove of elbow (31) .

6. Install tee (36) into the throttle housing. Orient tee (36) with the smaller threads of the adapter directed toward the front of the engine.

7. Install plug (39) with O-ring seal (40) into the top of the tee assembly, and tighten the plug. Alternatively, a connection can be attached to the expansion tank for the SCAC vent.

8. Install clips (25) onto tube (32), and install tube between the two elbows. Refer to Illustration 200 for the proper orientation of tube (32) .

9. Position clip (25) over the hole in bracket (16) that is closest to the throttle housing. Install bolt (22) with washer (23) through the clip and bracket. Install nut with washer onto the bolt, and tighten the bolt.

10. Position clip (25) over the hole in bracket (15). Install bolt (22) with washer (23) through the clip and bracket. Install nut (24) with washer (23) onto the bolt, and tighten the bolt.

11. Tighten the fittings on tube (32) .

12. Install elbow (30) with O-ring seal (20) into the right side of the throttle housing.

13. Install O-ring seal (19) into the groove in the elbow.

14. Install elbow (30) with O-ring seal (19) into the left side of the throttle housing.

15. Install O-ring seal (19) into the groove in the elbow.

16. Install tube (29) between the two elbows. Refer to Illustration 200 and Illustration 201 for proper orientation of tube (29) .

17. Install elbow (38) with O-ring seal (37) into the left side of the throttle housing. Refer to Illustration 201 for proper orientation of elbow (38) .

18. Install tube (33) onto elbow (38) .

19. Install tube (34) onto adapter (36) .

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Illustration 202	g02438557
View A-A (41) 1L-2731 Tube Clamp (42) 0S-1571 Bolt (43) 5M-2894 Hard Washer (44) 8M-9124 Washer

20. Install clamps (41) onto tubes.

21. Install hard washer (43) between the clamps and aftercooler housing.

22. Install bolt (42) with washer (43) through the clamps and the hard washer. Tighten the bolt.

Installation Procedure for the 236-5181 Water Lines Gp

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Illustration 203	g03529777
(37) 6V-9746 O-Ring Seal (45) 6V-8733 Union (46) 439-0805 Hose As (47) 437-7369 Hose As (48) 236-5182 Tube As

1. Install tube assembly (48) onto the engine as shown in Illustration 203.

2. Install union (45) with o-ring seal (37) .

3. Install hose assemblies (46) and (47) .

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Illustration 204	g03529780
(37) 6V-9746 O-Ring Seal (49) 365-0682 Connector (50) 0L-2070 Bolt (51) 5M-2894 Hard Washer (52) 2A-2677 Spacer (53) 9S-8752 Full Nut (54) 353-7953 Grommet (55) 3H-8683 Clip

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Illustration 205	g03529783
(56) 0L-2070 Bolt (57) 5M-2894 Hard Washer (58) 2A-2677 Spacer (59) 353-7953 Grommet (60) 3H-8683 Clip (61) 363-8651 Bracket As (62) 9S-1366 Bolt (63) 8M-9124 Washer

4. Install connector (49) with o-ring seal (37) as shown in Illustration 204.

5. Install grommets (59) onto hose assemblies (46) and (47) .

6. Install clips (60) onto grommets (59) .

7. Attach clips (60) to bracket assembly (61) using bolt (56) with hard washer (57), (63), and spacer (58) .

8. Attach bracket assembly (61) to the engine using bolt (62) .

9. Fill the aftercooler circuit with coolant. Also, fill the jacket water coolant to the proper level. Loosen the plug that is located on the tee when the SCAC is filled in order to allow air to vent from the SCAC system.