Retrofitting for the Dynamic Gas Blending Capability on Certain 3512B Engines{1250, 1280} Caterpillar

Engine:

3512B (S/N: PTM1-UP; YAM1-UP; 1GZ1-UP)

Introduction

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

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

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

Refer to Systems Operation / Testing and Adjusting, KENR9743.

Refer to Troubleshooting, KENR9744.

Parts Needed

Table 1

241-0242 Power Harness As
Qty	Part
1	241-0242 Power Harness As

Table 2

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

Table 3

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

Table 4

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

Table 5

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

Table 6

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

Table 7

393-5641 Air Lines Gp
Qty	Part
2	5P-3860 Hose Clamp
6	5P-4869 Hose Clamp
2	8N-5254 Reducer Hose
2	8N-8741 Hose
2	113-1328 Tube

Table 8

393-5642 Precleaner Gp
Qty	Part
8	0S-1591 Bolt
2	1A-1460 Bolt
2	1F-7958 Full Nut
4	2H-3743 Bolt
4	7D-1649 Hard Washer
4	8T-5361 Hard Washer
8	9X-6458 Hard Washer
1	382-5499 Support Bracket As
1	382-5500 Support Bracket As
2	386-3397 Bracket

Table 9

393-5643 Temperature Regulator Gp
Qty	Part
2	0L-2070 Bolt
1	0S-1585 Bolt
5	0S-1590 Bolt
4	0S-1594 Bolt
2	1F-7958 Full Nut
1	2V-4387 Spacer
2	4W-0530 Retaining Ring
4	4W-0531 Retainer
5	5M-2894 Hard Washer
3	6J-2680 O-Ring Seal
2	7C-9597 Flange
5	7D-1649 Hard Washer
4	8T-1919 O-Ring Seal
3	9S-8752 Full Nut
1	9S-9635 Tube Joint
10	9X-6458 Hard Washer
2	9X-8873 Bolt
4	196-5052 Clip
4	196-5053 Clip
1	379-5142 Bracket
1	386-3398 Bracket
1	393-5644 Tube
1	393-5645 Tube

Table 10

393-5646 Air Cleaner Mounting
Qty	Part
2	0S-1571 Bolt
4	0S-1591 Bolt
4	0T-0055 Bolt
14	1A-2029 Bolt
4	2A-4639 Bolt
4	2B-2695 Bolt
8	2K-4973 Locknut
8	5G-4313 Spacer
12	5M-2894 Hard Washer
8	5P-3860 Hose Clamp
4	5S-0003 Nut
11	6H-1717 Bolt
11	7D-1649 Hard Washer
4	7M-1599 Taperlock Stud
2	7N-6986 Support
4	9M-1974 Hard Washer
10	9S-8752 Full Nut
22	9X-6458 Hard Washer
4	162-2177 Hose
4	197-9733 U-Bolt
2	386-3396 Bracket
1	388-2132 Bracket
1	388-2133 Bracket
1	393-5647 Tube As
1	393-5648 Tube As

Table 11

394-5243 Turbocharger Air Lines Gp
Qty	Part
48	1T-0720 Bolt
24	2A-4639 Bolt
12	4S-5898 O-Ring Seal
72	5M-2894 Hard Washer
12	6V-5101 O-Ring Seal
12	7C-8199 Flange
24	153-8455 Manifold Gasket
10	370-7335 Air Inlet Elbow
2	370-7336 Air Inlet Elbow
12	371-5211 Flame Arrestor As

Table 12

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

Table 13

398-0110 Cylinder Block Cover Gp
Qty	Part
36	1A-2029 Bolt
6	1C-2251 Bolt
4	2W-0752 Gasket
6	5L-5840 Washer
36	5M-2894 Hard Washer
6	277-5833 Seal
2	349-6052 Camshaft Cover
4	374-1513 Camshaft Cover

Table 14

398-3729 Water Lines Gp
Qty	Part
1	0S-1571 Bolt
3	0S-1588 Bolt
1	0S-1594 Bolt
1	1L-4031 Service Tee
1	3B-6555 Elbow
1	4B-9030 Elbow
2	4F-7391 O-Ring Seal
4	4J-5477 O-Ring Seal
4	4L-6454 Bolt
3	5M-2894 Hard Washer
5	5P-9297 Clip
1	6B-1628 Reducing Bushing
3	6V-0267 Clip
3	6V-0268 Clip
1	6V-3265 Clip
3	8C-6866 Connector
1	8C-6867 Connector
4	8T-4896 Hard Washer
1	8T-6761 Pipe Plug
4	9S-8752 Full Nut
6	9X-6458 Hard Washer
1	005-8615 Pipe Nipple
1	196-9420 Ball Valve
2	265-5254 Plate
1	318-2484 Orifice
1	318-2485 Gasket
1	384-7876 Bracket
1	398-3728 Hose As
1	419-1798 Hose As

Table 15

415-7978 Engine Wiring Gp
Qty	Part
1	0L-1352 Bolt
1	0S-0509 Bolt
16	0S-1571 Bolt
1	0S-1585 Bolt
1	0S-1588 Bolt
5	0S-1591 Bolt
11	0S-1594 Bolt
2	0S-1608 Bolt
7	1A-2029 Bolt
25	1A-9579 Bolt
2	3A-3692 Clip
6	3B-1915 Bolt
1	4P-7068 Bracket
4	4P-7429 Clip
23	4P-7581 Clip
43	4P-8134 Clip
4	4S-5719 Spacer
15	5M-2894 Hard Washer
12	5N-2126 Connector
4	6L-4428 Taperlock Stud
1	6V-1581 Clip
1	6V-1582 Clip
2	6V-9028 O-Ring Seal
2	6V-9330 Elbow
85	7K-1181 Cable Strap
5	8M-9024 Hard Washer
25	9M-1974 Hard Washer
16	9S-8752 Full Nut
1	9X-0262 Adapter
8	9X-6458 Hard Washer
3	034-3557 Locking Bolt
7	132-5789 Clip
6	195-2431 Detonation Sensor Gp
7	214-7566 O-Ring Seal
2	214-7568 O-Ring Seal
8	228-7100 O-Ring Seal
1	228-7101 O-Ring Seal
4	238-5080 O-Ring Seal
4	256-6453 Temperature Sensor
2	261-6847 Adapter
1	294-3313 Clip
13	302-3908 Spacer
1	305-6873 Pressure Sensor Gp
1	318-1181 Speed Sensor Gp
4	320-3060 Pressure Sensor
1	320-3061 Pressure Sensor
4	320-3063 Pressure Sensor
1	330-9739 Adapter
2	335-3999 Adapter
1	352-3968 Clip
1	353-5439 Connector
2	353-5440 Adapter
5	353-5441 Elbow Adapter
1	377-2872 Engine Wiring Gp
12	383-2990 Temperature Sensor Gp
2	415-2432 Temperature Sensor Gp
1	415-7979 Sensor Harness As

Table 16

415-7979 Sensor Harness As (1800 RPM)
Qty	Part
1	415-7979 Sensor Harness As

Table 17

416-2191 Fuel Lines Gp (Fuel Mixer Gp) (1800 RPM)
Qty	Part
2	6V-4368 O-Ring Seal
2	416-2189 Tube As

Table 18

416-2193 Fuel Mixer Gp (1500 RPM)
Qty	Part
2	6V-4368 O-Ring Seal
2	393-5651 Tube As

Table 19

416-4348 Fuel System Parts Kit
Qty	Part
2	5P-3860 Hose Clamp
6	5P-4869 Hose Clamp
2	8N-5254 Reducer Hose
2	8N-8741 Hose
2	113-1328 Tube

Table 20

416-4349 Fuel System Parts Kit
Qty	Part
8	3B-1915 Bolt
8	5M-2894 Hard Washer
2	5P-0600 Hose Clamp
2	113-1587 Reducer Hose
4	388-2134 Bracket

Table 21

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

Table 22

439-7061 Fuel System Parts Kit (if applicable)
Qty	Part
3	0S-1588 Bolt
1	2T-2305 Elbow
1	3B-7738 Fitting
1	3B-7764 Bushing
1	4J-5477 O-Ring Seal
2	5M-2894 Hard Washer
1	6V-0267 Clip
1	6V-0268 Clip
1	6V-8397 O-Ring Seal
1	8C-6866 Connector
1	8T-6758 Pipe Plug
1	9L-1480 Gasket
1	9S-8752 Full Nut
2	9X-6458 Hard Washer
1	004-5933 Pipe Tee
1	174-5907 Clip
1	301-7944 Hose As

Table 23

439-7062 Fuel System Parts Kit (if applicable)
Qty	Part
2	0S-1587 Bolt
1	0S-1590 Bolt
2	1F-7958 Full Nut
1	1N-8559 Service Tee
1	1P-5274 Valve Spring Pin
1	2B-0941 Spacer
2	3B-7745 Pipe Nipple
1	3H-3433 Spring Pin
2	4L-6454 Bolt
2	5M-2894 Hard Washer
1	5N-6237 Engine Oil Pump Gp
8	5P-0537 Hard Washer
1	5P-5846 O-Ring Seal
1	6V-1889 Clip
3	6V-9746 O-Ring Seal
4	7B-2742 Bolt
4	7D-1649 Hard Washer
1	7J-9108 O-Ring Seal
1	7N-6569 Adapter
1	7X-7731 Pipe Plug
2	8C-1358 Ball Valve
2	8C-6874 Connector
1	9H-2367 Spring
1	9L-0672 Check Valve
1	9S-8752 Full Nut
1	9X-2398 Elbow
1	003-9163 Elbow
1	117-3033 Elbow
1	200-8272 Bracket As
1	201-0578 Fitting
1	211-8759 Elbow
1	246-7844 Hose As
1	391-6014 Hose As

Table 24

439-7063 Fuel System Parts Kit (if applicable)
Qty	Part
2	0S-1585 Bolt
2	1B-2790 Bolt
2	1F-7958 Full Nut
1	1L-4031 Service Tee
1	4B-9030 Elbow
4	5K-9090 O-Ring Seal
2	5S-0003 Nut
4	7D-1649 Hard Washer
2	7G-1239 Spacer
4	8C-6875 Connector
1	8T-6762 Pipe Plug
4	9M-1974 Hard Washer
1	006-5707 Pipe Elbow
1	118-1656 Reducer Bushing
1	122-3201 Pipe Nipple
2	184-7211 Clip
2	196-9420 Ball Valve
1	307-9372 Hose As
1	397-9421 Hose As

Table 25

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

Table 26

442-6986 Fuel Lines Gp (HVL) (1500 RPM and 1800 RPM)
Qty	Part
2	0S-1571 Bolt
6	0S-1591 Bolt
4	2A-4639 Bolt
2	3B-1915 Bolt
12	5M-2894 Hard Washer
2	6V-1581 Clip
2	6V-1582 Clip
2	6V-4368 O-Ring Seal
2	7K-1401 Clip
2	7K-1402 Bracket
14	9S-8752 Full Nut
16	9X-6458 Hard Washer
1	105-8180 Gasket
1	216-2285 Tube Joint
2	255-6464 Joint
1	391-2202 Bracket
1	393-5652 Bracket
2	416-2188 Tube As
1	442-5389 Tube As
1	442-5391 Tube As
1	442-6223 Bracket
1	442-6224 Bracket

Table 27

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

Table 28

461-7758 Transformer Isolation Kit (1500 RPM at 600V)
Qty	Part
3	122-6588 Current Transformer As
3	154-3488 Transformer

Table 29

461-7759 Transformer Isolation Kit (1500 RPM at 400V)
Qty	Part
3	128-0115 Current Transformer As
3	361-7027 Transformer

Table 30

462-1088 Transformer Isolation Kit (1800 RPM at 480V)
Qty	Part
3	122-6589 Current Transformer As
3	154-3488 Transformer

Table 31

Package Components
Qty	Part
1	267-9689 Filter Housing Cover
1	382-1791 Instrument Panel Box Gp

Table 32

Software
Qty	Part
1	423-7627 Engine Ratings Electronic Software Gp (ECM)
1	433-6418 Engine Ratings Electronic Software Gp (ISM)

Table 33

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

Table 34

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

Copying the Product Status Report and the Injector Trim Codes

Copying the Product Status Report

1. Connect Cat Electronic Technician (ET) 2012C or newer to the Electronic Control Module (ECM).

   Note: The Product Status Report is for reference only.

Show/hide table



Illustration 1	g03285257

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

Show/hide table



Illustration 2	g03285338

3. Click on the "Create Report" button.

Show/hide table



Illustration 3	g03285341

4. Click on the "Continue" button.

Show/hide table



Illustration 4	g03285343

5. Wait for the Product Status Report to download.

Show/hide table



Illustration 5	g03285345

6. Click on the "Save As" button.

7. Save the file in a convenient location.

8. Click on the "Close Report" button.

Copying the Injector Trims Codes

Illustration 6	g03285599

1. Click on the "Service" tab.

2. Select "Calibrations".

Show/hide table



Illustration 7	g03285600

3. Click on "Injector Codes Calibration".

Show/hide table



Illustration 8	g03285601

4. Click on the "File" tab.

5. Select "Print To File".

Show/hide table



Illustration 9	g03285603

6. Change the file type to HTML.

7. Save the file in a convenient location.

8. Disconnect Cat ET from the ECM.

Installing the 394-5243 Turbocharger Air Lines Gp

Illustration 10	g03266536

Illustration 11	g03551679
Control panel

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

   • Air inlet covers

   • Aftercooler assembly

   • Clamps

   • Compressor pipes

   • Exhaust crossover manifold

   • Inlet air pipe supports

   • Rubber hoses

   • Shields

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

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

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

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

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

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

8. Using suitable lifting device, remove the awkward shaped air inlet pipes. The air inlet pipes weigh approximately 16 kg (34 lb) apiece.

Show/hide table



Illustration 12	g03276958

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

Show/hide table



Illustration 13	g03276959

10. Remove the water lines from each end of the aftercooler core.

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

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

13. Remove the exhaust crossover manifold from the exhaust manifolds.

Show/hide table



Illustration 14	g03276976

14. Using a suitable lifting device, remove the aftercooler assembly. The aftercooler assembly weighs approximately 151 kg (333 lb).

Show/hide table



Illustration 15	g03266538
(1) 4S-5898 O-Ring Seal (2) 7C-8199 Flange (3) 6V-5101 O-Ring Seal (4) 370-7336 Air Inlet Elbow (5) 2A-4639 Bolt (6) 5M-2894 Hard Washer (7) 370-7335 Air Inlet Elbow (8) 1T-0720 Bolt (9) 153-8455 Manifold Gasket (10) 371-5211 Flame Arrestor As

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

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

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

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

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

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

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

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

21. Remove the pipe plug from the exhaust outlet port per cylinder head.

Show/hide table



Illustration 16	g03266758
The following callouts are from the 415-7978 Engine Wiring Gp . (11) 5N-2126 Connector (12) 383-2990 Temperature Sensor Gp

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

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

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

Show/hide table



Illustration 17	g03271957
The following callouts are from the 393-5646 Air Cleaner Mounting and the 415-7978 Engine Wiring Gp . (13) 238-5080 O-Ring Seal (14) 256-6453 Temperature Sensor (15) 7C-9597 Flange (16) 5B-4399 O-Ring Seal (17) 6J-2680 O-Ring Seal

24. Remove the jacket water temperature sensor from the 111-9375 Housing .

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

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

26. Remove the original flange and O-ring from the 129-3083 Elbow .

27. Install one O-ring (16) onto 129-3083 Elbow .

    Note: Lubricate the bore of flange (15) and O-ring (16) lightly with glycerin.

28. Install flange (15) onto the 129-3083 Elbow .

Note: Lubricate the O-ring groove of flange (15) lightly with glycerin to hold O-ring in place.

29. Install one O-ring (17) into the O-ring groove of flange (15) .

Show/hide table



Illustration 18	g03271976
The following callouts are from the 415-7978 Engine Wiring Gp . (13) 238-5080 O-Ring Seal (14) 256-6453 Temperature Sensor (18) 353-5440 Adapter

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

31. Install adapter (18) into the 283-9599 Manifold .

    Note: Use Loctite 567 on all pipe thread joints.

32. Install temperature sensor (14) and one O-ring (13) into adapter (18) .

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

33. Using a suitable lifting device, install the aftercooler assembly. The aftercooler assembly weighs approximately 151 kg (333 lb).

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

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

36. Attach the air inlet elbows to the aftercooler and the turbochargers.

Installing the 398-0110 Cylinder Block Cover Gp

Illustration 19	g03266756
(1) 2W-0752 Gasket (2) 1C-2251 Bolt (3) 5M-2894 Hard Washer (4) 374-1513 Camshaft Cover (5) 5L-5840 Washer (6) 1A-2029 Bolt (7) 277-5833 Seal (8) 349-6052 Camshaft Cover

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

Installing the Left-Hand Oil Service

Illustration 20	g03288224
(4) 374-1513 Camshaft Cover (8) 349-6052 Camshaft Cover

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

2. Remove the 7N-5094 Drain Elbows from the 8N-9993 Camshaft Covers on cylinders 6 and 10.

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

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

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

6. Attach the 7N-5094 Drain Elbows to camshaft covers (4) use one gasket (1) and the original hardware per elbow.

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

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

9. Install the original 8N-9993 Camshaft Cover with the crankcase pressure onto cylinder 1 or 5 use the original hardware.

10. Install the original 8N-9992 Camshaft Cover onto cylinder 4 use the original hardware.

Show/hide table



Illustration 21	g03288227
(4) 374-1513 Camshaft Cover (8) 349-6052 Camshaft Cover

11. Remove the 7N-5094 Drain Elbows from the 8N-9993 Camshaft Covers on cylinders 3 and 7.

12. Remove the 8N-9992 Camshaft Covers and the 8N-9993 Camshaft Cover from cylinders 3, 7, and 11.

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

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

15. Attach the 7N-5094 Drain Elbows to camshaft covers (8) use one gasket (1) and the original hardware per elbow.

Installing the Right-Hand Oil Service

Illustration 22	g03288236
(4) 374-1513 Camshaft Cover (8) 349-6052 Camshaft Cover

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

2. Remove the 7N-5094 Drain Elbows from the 8N-9993 Camshaft Covers on cylinders 3 and 7.

3. Remove the 8N-9992 Camshaft Cover from cylinder 11.

4. Remove the 8N-9993 Camshaft Covers from cylinders 3 and 7.

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

6. Attach the 7N-5094 Drain Elbows to camshaft covers (4) with one gasket (1) and the original hardware per elbow.

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

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

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

10. Install the original 8N-9993 Camshaft Cover with the crankcase pressure onto cylinder 1 use the original hardware.

11. Remove the 8N-9993 Camshaft Cover with the 7N-1875 Engine Oil Filler Gp from cylinder 9.

12. Install the original 8N-9993 Camshaft Cover with the 7N-1875 Engine Oil Filler Gp onto cylinder 5 use the original hardware.

13. Install the original 8N-9992 Camshaft Covers onto cylinder 4 and 9 use the original hardware.

Show/hide table



Illustration 23	g03288239
(4) 374-1513 Camshaft Cover (8) 349-6052 Camshaft Cover

14. Remove the 7N-5094 Drain Elbows from the 8N-9993 Camshaft Covers on cylinders 6 and 10.

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

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

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

18. Attach the 7N-5094 Drain Elbows to camshaft covers (4) use one gasket (1) and the original hardware per elbow.

Installing 267-9689 Filter Housing Cover (if applicable)

Illustration 24	g03266737
(1) 267-9689 Filter Housing Cover

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

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

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

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

Installing 415-7978 Engine Wiring Gp

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

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

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

Show/hide table



Illustration 25	g03065381
(1) 377-2872 Engine Wiring Gp (2) 7K-1181 Cable Strap (3) 302-3908 Spacer (4) 4P-8134 Clip (5) 0S-1571 Bolt (6) 5M-2894 Hard Washer

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

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

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

Show/hide table



Illustration 26	g03411855
(1) 377-2872 Engine Wiring Gp (2) 7K-1181 Cable Strap (4) 4P-8134 Clip (6) 5M-2894 Hard Washer (7) 4P-7581 Clip (8) 0S-1594 Bolt (9) 6L-4428 Taperlock Stud (10) 9S-8752 Full Nut (11) 4S-5719 Spacer (12) 034-3557 Locking Bolt (13) 352-3968 Clip

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

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

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

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

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

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

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

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

12. Secure engine wiring harness (1) to clips (4), (7), and (13) use one cable strap (2) per clip.

Show/hide table



Illustration 27	g03266960
(1) 377-2872 Engine Wiring Gp (2) 7K-1181 Cable Straps (4) 4P-8134 Clip (6) 5M-2894 Hard Washer (14) 1A-2029 Bolt (15) 4P-7429 Clip

13. Remove the center two bolts and washers from the 101-0836 Flywheel Housing Gp . Refer to Illustration 27 for the correct location.

14. Attach two clips (15) to the 101-0836 Flywheel Housing Gp use the original hardware.

15. Remove the original bolts and washers from the round side of the 7N-4319 Cover . Refer to Illustration 27 for the correct location.

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

17. Remove the original bolts and washers from the flat side of the 7N-4319 Cover . Refer to Illustration 27 for the correct location.

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

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

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

Show/hide table



Illustration 28	g03411860
(1) 377-2872 Engine Wiring Gp (2) 7K-1181 Cable Strap (3) 302-3908 Spacer (4) 4P-8134 Clip (5) 0S-1571 Bolt (6) 5M-2894 Hard Washer (16) 3B-1915 Bolt

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

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

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

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

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

Show/hide table



Illustration 29	g03411868
(1) 377-2872 Engine Wiring Gp (2) 7K-1181 Cable Strap (6) 5M-2894 Hard Washer (7) 4P-7581 Clip (14) 1A-2029 Bolt (17) 273-5041 Speed Sensor Gp

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

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

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

28. Secure engine wiring harness (1) to clip (7) use one cable strap (2) .

Show/hide table



Illustration 30	g03105365
(18) 318-1181 Speed Sensor Gp

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

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

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

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

31. Install speed sensor gp (6) into flywheel housing.

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

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

Show/hide table



Illustration 31	g03476337
(1) 377-2872 Engine Wiring Gp (19) 415-7979 Sensor Harness As (20) 320-3060 Pressure Sensor (21) 228-7100 O-Ring Seal (22) 353-5439 Connector (23) 214-7566 O-Ring Seal (24) 320-3063 Pressure Sensor (25) 353-5441 Elbow Adapter (261) 256-6453 Temperature Sensor (27) 238-5080 O-Ring Seal (28) 330-9739 Adapter (29) 320-3061 Pressure Sensor (30) 228-7101 O-Ring Seal

Note: Use sensor harness (19) with left-hand side fuel service engines to connect engine harness (1) to the fuel and the oil sensors.

32. Attach sensor harness (19) to connect engine harness (1) to the fuel and the oil sensors.

33. Remove the adapter and the pressure sensor from the unfiltered port of the 112-4921 Engine Oil Filter Gp .

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Show/hide table



Illustration 32	g03476342
(19) 415-7979 Sensor Harness As (20) 320-3060 Pressure Sensor (21) 228-7100 O-Ring Seal (23) 214-7566 O-Ring Seal (25) 353-5441 Elbow Adapter

Note: Use sensor harness (19) with left-hand side fuel service engines to connect engine harness (1) to the fuel and the oil sensors.

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

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

46. Install elbow adapters (25) and one O-ring (23) per elbow adapter into the 267-9689 Filter Housing Cover .

47. Install pressure sensors (20) and one O-ring (21) per pressure sensor into each elbow adapter (25) .

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

48. Remove the adapter and the oil pressure sensor from the filtered port of the 112-4921 Engine Oil Filter Gp .

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

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

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

Show/hide table



Illustration 33	g03412196
(1) 377-2872 Engine Wiring Gp (2) 7K-1181 Cable Strap (16) 3B-1915 Bolt (19) 415-7979 Sensor Harness As (31) 132-5789 Clip (32) 8M-9024 Hard Washer

51. Remove the original bolts and washers from the front bolt holes of the 112-4922 Fuel Filter Gp .

52. Attach clips (31) to the front bolt holes of the 112-4922 Fuel Filter Gp with one bolt (16) and one washer (32) per clip.

53. Secure engine wiring harness (1) and sensor harness (19) to clips (31) with one cable strap (2) per clip.

Show/hide table



Illustration 34	g03412199
(1) 377-2872 Engine Wiring Gp (2) 7K-1181 Cable Strap (4) 4P-8134 Clip (6) 5M-2894 Hard Washer (7) 4P-7581 Clip (8) 0S-1594 Bolt (33) 0S-1585 Bolt (34) 0L-1352 Bolt

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

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

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

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

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

59. Attach clip (7) to the middle bolt hole of the 4W-4313 Adapter with one bolt (34) and one washer (6) .

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

61. Secure engine wiring harness (1) to clips (4) and (7) use one cable strap (2) per clip.

Show/hide table



Illustration 35	g03412219
(1) 377-2872 Engine Wiring Gp (2) 7K-1181 Cable Strap (4) 4P-8134 Clip (6) 5M-2894 Hard Washer (10) 9S-8752 Full Nut (35) 0S-1588 Bolt (36) 6V-1581 Clip (37) 6V-1582 Clip

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

63. Attach one clip (4) to clips (36) and (37) with one bolt (35), two washers (6), and one nut (10) .

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

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

Show/hide table



Illustration 36	g03065380
(1) 377-2872 Engine Wiring Gp (2) 7K-1181 Cable Strap (4) 4P-8134 Clip (6) 5M-2894 Hard Washer (8) 0S-1594 Bolt (10) 9S-8752 Full Nut (38) 4P-7068 Bracket

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

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

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

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

Show/hide table



Illustration 37	g03062402
(1) 377-2872 Engine Wiring Gp (2) 7K-1181 Cable Strap (4) 4P-8134 Clip (7) 4P-7581 Clip (39) 1A-9579 Bolt (40) 9M-1974 Hard Washer (41) 383-2990 Temperature Sensor Gp

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

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

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

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

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

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

Show/hide table



Illustration 38	g03062047
Typical left-hand side engine view (1) 377-2872 Engine Wiring Gp (2) 7K-1181 Cable Strap (4) 4P-8134 Clip (6) 5M-2894 Hard Washer (7) 4P-7581 Clip (8) 0S-1594 Bolt (42) 195-2431 Detonation Sensor Gp

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

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

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

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

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

80. Secure engine wiring harness (1) and detonation sensors (42) to clips (4) and (7) with one cable strap (2) per clip.

Show/hide table



Illustration 39	g03062049
Typical right-hand side engine view (1) 377-2872 Engine Wiring Gp (2) 7K-1181 Cable Strap (6) 5M-2894 Hard Washer (7) 4P-7581 Clip (8) 0S-1594 Bolt (42) 195-2431 Detonation Sensor Gp

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

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

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

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

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

84. Secure engine wiring harness (1) and detonation sensors (42) to clips (7) with one cable strap (2) per clip.

Show/hide table



Illustration 40	g03464042
Typical left-hand side engine view. (1) 377-2872 Engine Wiring Gp (2) 7K-1181 Cable Strap (4) 4P-8134 Clip (6) 5M-2894 Hard Washer (8) 0S-1594 Bolt (39) 1A-9579 Bolt (40) 9M-1974 Hard Washer (43) 261-6847 Adapter (44) 415-2432 Temperature Sensor Gp (45) 3A-3692 Clip

85. Remove the adapter and the temperature sensor from the 108-5578 Exhaust Manifold .

86. Install adapter (43) into the 108-5578 Exhaust Manifold .

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

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

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

88. Install one clip (45) around exhaust temperature sensor gp (44). Refer to Illustration 40 for the correct orientation of the clip.

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

90. Remove the original bolts and washers from the right-hand side of the valve cover base on cylinder 12.

91. Attach two clips (4) to the right-hand side of the valve cover base on cylinder 12 with one bolt (39) and one washer (40) per clip.

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

93. Secure exhaust temperature sensor (44) to clips (4) with one cable strap (2) per clip. Refer to Illustration 40 for the correct location.

94. Secure exhaust temperature sensor (44) to engine wiring harness (1) with cable straps (2) as needed.

Show/hide table



Illustration 41	g03438318
Typical right-hand side engine view. (1) 377-2872 Engine Wiring Gp (2) 7K-1181 Cable Strap (4) 4P-8134 Clip (6) 5M-2894 Hard Washer (8) 0S-1594 Bolt (43) 261-6847 Adapter (44) 415-2432 Temperature Sensor Gp (45) 3A-3692 Clip

95. Remove the adapter and the temperature sensor from the 108-5578 Exhaust Manifold .

96. Install adapter (43) into the 108-5578 Exhaust Manifold .

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

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

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

98. Install one clip (45) around exhaust temperature sensor gp (44). Refer to Illustration 41 for the correct orientation of the clip.

99. Attach clip (45) to the cam cover on cylinder 9 with one bolt (8) and one washer (6) .

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

101. Secure exhaust temperature sensor (44) to clip (4) with one cable strap (2). Refer to Illustration 41 for the correct location.

102. Secure exhaust temperature sensor (44) to engine wiring harness (1) with cable straps (2) as needed.

Show/hide table



Illustration 42	g03411938
(26) 256-6453 Temperature Sensor (27) 238-5080 O-Ring Seal (46) 353-5440 Adapter

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

Note: Use Loctite 567 on all pipe thread joints.

104. Install adapter (46) into the 359-4123 Adapter .

105. Install temperature sensor (26) and one O-ring (27) into adapter (46) .

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

Show/hide table



Illustration 43	g03464043
(2) 7K-1181 Cable Strap (4) 4P-8134 Clip (6) 5M-2894 Hard Washer (14) 1A-2029 Bolt (21) 228-7100 O-Ring Seal (23) 214-7566 O-Ring Seal (24) 320-3063 Pressure Sensor (25) 353-5441 Elbow Adapter (47) 0S-0509 Bolt

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

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

107. Install elbow adapter (25) and one O-ring (23) into the 117-0066 Mounting Bracket .

108. Install pressure sensor (24) and one O-ring (21) into elbow adapter (25) .

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

Show/hide table



Illustration 44	g03601317
(1) 377-2872 Engine Wiring Gp (2) 7K-1181 Cable Strap (31) 132-5789 Clip (48) 9X-0262 Adapter (49) 6V-9028 O-Ring Seal (50) 305-6873 Pressure Sensor Gp

Show/hide table



Illustration 45	g03601298
(2) 7K-1181 Cable Strap (4) 4P-8134 Clip

109. Attach one clip (4) to the 397-8631 Tube As with the original 2A-4639 Bolt , 5M-2894 Hard Washers , and the 9S-8752 Full Nut . Refer to Illustration 45 for the correct location.

110. Attach one clip (31) to the 398-7716 Tube As with the original 2A-4639 Bolt , the 5M-2894 Hard Washers , and 9S-8752 Full Nut . Refer to Illustration 44 for the correct location.

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

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

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

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

114. Secure engine wiring harness (1) to clips (4) and (31) with one cable strap (2) per clip.

Show/hide table



Illustration 46	g03284978
Typical left-hand side engine view (1) 377-2872 Engine Wiring Gp (2) 7K-1181 Cable Strap (5) 0S-1571 Bolt (7) 4P-7581 Clip (10) 9S-8752 Full Nut (21) 228-7100 O-Ring Seal (24) 320-3063 Pressure Sensor (51) 6V-9330 Elbow (52) 9X-6458 Hard Washer (53) 335-3999 Adapter (54) 214-7568 O-Ring Seal

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

116. Install adapter (36) and one O-ring (20) into the 6V-9330 Elbow .

117. Install pressure sensor (34) and one O-ring (21) into adapter (36) .

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

Show/hide table



Illustration 47	g03284982
Typical right-hand side engine view (1) 377-2872 Engine Wiring Gp (2) 7K-1181 Cable Strap (5) 0S-1571 Bolt (7) 4P-7581 Clip (10) 9S-8752 Full Nut (21) 228-7100 O-Ring Seal (24) 320-3063 Pressure Sensor (51) 6V-9330 Elbow (52) 9X-6458 Hard Washer (53) 335-3999 Adapter (54) 214-7568 O-Ring Seal

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

119. Install adapter (36) and one O-ring (20) into the 6V-9330 Elbow .

120. Install pressure sensor (34) and one O-ring (21) into adapter (36) .

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

Show/hide table



Illustration 48	g03476407
Callout (52) is from the 373-1527 Electronic Control and Mounting Gp . (1) 377-2872 Engine Wiring Gp (2) 7K-1181 Cable Strap (7) 4P-7581 Clip (52) 9X-6458 Hard Washer (55) 294-3313 Clip (56) 0S-1608 Bolt

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

121. Attach clip (55) to the 231-7070 Bracket with one bolt (56) and one washer (52) .

122. Attach clip (7) to the 231-7070 Bracket with one bolt (56) and one washer (52) .

123. Secure engine wiring harness (1) to clips (7) and (55) use one cable strap (2) per clip.

Show/hide table



Illustration 49	g03273077
(C) 7N-9738 Receptacle Housing (D) 238-8245 Connector Plug As

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

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

125. Strip back the insulation on the two wires.

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

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

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

Installing the 373-1527 Electronic Control and Mounting Gp

Illustration 50	g02979126
(1) 417-6011 Electronic Control Module

Illustration 51	g03023698
(2) 9M-1974 Hard Washer (3) 9N-0869 Hard Washer (4) 8T-9655 Isolation Mount (5) 6I-1418 Spacer (6) 2V-4387 Spacer (7) 1D-4540 Bolt

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

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

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

   Note: Steps 3 through 11 use parts from the 398-3729 Water Lines Gp .

Show/hide table



Illustration 52	g03264263
(8) 005-8615 Pipe Nipple (9) 1L-4031 Service Tee (10) 4B-9030 Elbow (11) 196-9420 Ball Valve (12) 3B-6555 Elbow (13) 8T-6761 Pipe Plug (14) 6B-1628 Reducing Bushing (15) 8C-6867 Connector

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

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

5. Install elbow (12) onto pipe nipple (8) .

6. Install service tee (9) into elbow (12) .

7. Install pipe plug (13) into center port of service tee (9) .

8. Install elbow (10) into service tee (9) .

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

10. Install reducing bushing (14) into ball valve (11) .

11. Install connector (15) into reducing bushing (14) .

Show/hide table



Illustration 53	g03351794
(2) 9M-1974 Hard Washer (3) 9N-0869 Hard Washer (5) 6I-1418 Spacer (16) 353-8089 Electronic Control Module (17) 0T-0065 Bolt (18) 9X-6458 Hard Washer (19) 190-4885 Spacer (20) 231-7070 Bracket (21) 0S-1608 Bolt (22) 1B-9575 Bolt (23) 155-0576 Isolation Mount

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

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

Note: The 4P-7581 Clip and the 294-3313 Clip will be installed on this step. Refer to Steps 121 and 122 of the 415-7978 Engine Wiring Gp .

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

14. Attach electronic control module (16) to bracket (18) with four bolts (21), four washers (3), four spacers (5), and eight isolation mounts (22) .

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

Installing the 393-5646 Air Cleaner Mounting

Illustration 54	g03269236
(1) 393-5648 Tube As (2) 393-5647 Tube As (3) 7M-1599 Taperlock Stud (4) 9M-1974 Hard Washer (5) 5S-0003 Nut

1. Install four studs (3) into tube assemblies (1) and (2)

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

2. Install one washer (4) and one nut (5) per stud loosely onto studs (3). The nuts and washers will be used with the 416-2188 Tube As from the 393-5650 Fuel Lines Gp .

Show/hide table



Illustration 55	g03377228
(1) 393-5648 Tube As (2) 393-5647 Tube As (6) 162-2177 Hose (7) 5P-3860 Hose Clamp

3. Install two hoses (6) per tube assembly onto tube assemblies (1) and (2) use one hose clamp (7) per reducer hose.

4. Attach tube assemblies (1) and (2) to the turbochargers with one hose (6) and one hose clamp (7) per turbocharger.

5. Install the original heat shields.

Show/hide table



Illustration 56	g03377220
(1) 393-5648 Tube As (2) 393-5647 Tube As (8) 2K-4973 Locknut (9) 9X-6458 Hard Washer (10) 5G-4313 Spacer (11) 197-9733 U-Bolt

6. Install two U-bolts (11) per tube assembly around tube assemblies (1) and (2) .

7. Attach U-bolts (11) to the 191-6015 Bracket with two spacers (10), two washers (9), and two nuts (8) per U-bolt.

Show/hide table



Illustration 57	g03269239
Typical right-hand side view. (9) 9X-6458 Hard Washer (12) 1A-2029 Bolt (13) 386-3396 Bracket (14) 6H-1717 Bolt (15) 7D-1649 Hard Washer

8. Attach bracket (13) on top of the right side flywheel housing with six bolts (14) and six washers (15) .

   Note: Bolts (12) and washers (9) are used to install the air cleaner.

Show/hide table



Illustration 58	g03269241
Typical right-hand side view. (9) 9X-6458 Hard Washer (16) 2A-4639 Bolt (17) 9S-8752 Full Nut (18) 388-2133 Bracket (19) 0T-0055 Bolt (20) 0S-1591 Bolt (21) 5M-2894 Hard Washer (22) 0S-1571 Bolt (23) 7N-6986 Support

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

10. Install bracket (23) onto the valve cover base with two bolts (19) .

11. Attach bracket (18) to bracket (23) with one bolt (20), two bolts (22), six washers (21), and three nuts (17) .

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

12. Attach bracket (18) to bracket (13) with two bolts (16), four washers (9), and two nuts (17) .

Show/hide table



Illustration 59	g03269243
Typical left-hand side view. (9) 9X-6458 Hard Washer (12) 1A-2029 Bolt (13) 386-3396 Bracket (14) 6H-1717 Bolt (15) 7D-1649 Hard Washer

13. Attach bracket (13) on top of the left side flywheel housing use five bolts (14) and five washers (15). The rear center hole 94 is used with the 393-5643 Temperature Regulator Gp .

    Note: Bolts (12) and washers (9) are used to install the air cleaner.

Show/hide table



Illustration 60	g03269245
Typical left-hand side view. (9) 9X-6458 Hard Washer (13) 386-3396 Bracket (16) 2A-4639 Bolt (17) 9S-8752 Full Nut (19) 0T-0055 Bolt (20) 0S-1591 Bolt (21) 5M-2894 Hard Washer (23) 7N-6986 Support (24) 388-2132 Bracket

14. Remove the bottom two bolts of the valve cover base of cylinder 12.

15. Install support (23) onto the valve cover base with two bolts (19) .

16. Attach bracket (24) to bracket (23) use three bolts (20), six washers (21), and three nuts (17) .

17. Attach bracket (24) to bracket (13) use two bolts (16), four washers (9), and two nuts (17) .

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

Illustration 61	g03021239
(1) 3B-7296 Fitting (2) 3B-7286 Pipe Nipple (3) 7X-7951 Union Elbow (4) 265-5255 Plate (5) 2M-4108 Gasket (6) 293-8396 Core (7) 0S-1591 Bolt (8) 5M-2894 Hard Washer

Note: Use Loctite 567 on all pipe thread joints.

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

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

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

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

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

5. Install elbow union (3) onto fitting (2) .

Show/hide table



Illustration 62	g03021241
(8) 5M-2894 Hard Washer (9) 0S-1585 Bolt (10) 7D-1649 Hard Washer (11) 397-8632 Bracket (12) 8S-9191 Bolt (13) 2A-4639 Bolt (14) 9X-6458 Hard Washer

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

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

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

Show/hide table



Illustration 63	g02994736
(9) 0S-1585 Bolt (14) 9X-6458 Hard Washer (15) 397-8629 Bracket (16) 3B-1915 Bolt (17) 9S-8752 Full Nut (18) 5P-8245 Hard Washer (19) 417-5543 Bracket As

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

9. Attach brackets (15) to bracket (19) loosely. Use two bolts (16), four washers (14), and two nuts (17) per bracket.

Show/hide table



Illustration 64	g02970964
(1) 3B-7296 Fitting (3) 7X-7951 Union Elbow (20) 6N-4543 Fitting (21) 6L-7322 Pipe Tee (22) 2L-6055 Pipe Cap (23) 210-2007 Gas Pressure Regulator Gp

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

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

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

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

14. Disconnect the front union elbow (3). Refer to Illustration 61.

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

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

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

Show/hide table



Illustration 65	g03021479
(24) 5B-5620 Bolt (25) 9M-1974 Hard Washer (26) 5S-0003 Nut (27) 9X-6138 Pipe Plug (28) 122-0089 Solenoid Valve Gp

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

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

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

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

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

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

Show/hide table



Illustration 66	g03021520
(14) 9X-6458 Hard Washer (16) 3B-1915 Bolt (17) 9S-8752 Full Nut (29) 122-8905 Elbow (30) 6V-8398 O-Ring Seal (31) 397-8628 Tube As (32) 397-8631 Tube As

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

    Note: Union elbow (3) comes apart.

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

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

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

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

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

Show/hide table



Illustration 67	g03022936
(8) 5M-2894 Hard Washer (13) 2A-4639 Bolt (17) 9S-8752 Full Nut (33) 105-8180 Gasket

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

27. Refer to Illustration 78.

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

Illustration 68	g03685234
(1) 440-4791 Tube As (2) 293-8396 Core (3) 425-3549 Gasket (4) 440-4788 Tube As (5) 0S-1591 Bolt (6) 5M-2894 Hard Washer

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

2. Attach long elbow (4) to core (2) with one gasket (3), four bolts (5), and four washers (6) .

Show/hide table



Illustration 69	g03685235
(6) 5M-2894 Hard Washer (7) 0S-1585 Bolt (8) 7D-1649 Hard Washer (9) 397-8632 Bracket (10) 8S-9191 Bolt (11) 2A-4639 Bolt (12) 9X-6458 Hard Washer

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

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

5. Using a suitable lifting device, attach the bracket (9) to the engine below the side cover of cylinder 7 and to the oil pan with two bolts (7), two washers (8), four bolts (10), and four washers (6). The assembled parts weigh approximately 91 kg (202 lb).

Show/hide table



Illustration 70	g03685236
(7) 0S-1585 Bolt (9) 397-8632 Bracket (13) 440-4786 Bracket As (14) 5P-8245 Hard Washer

6. Attach bracket (13) to bracket (9) with eight bolts (7) and eight washers (14) .

Show/hide table



Illustration 71	g03685237
(13) 440-4786 Bracket As (15) 440-4792 Bracket (16) 0S-1591 Bolt (17) 9X-6458 Hard Washer (18) 9S-8752 Full Nut (19) 0S-1571 Bolt (20) 450-3143 Bracket As

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

8. Attach bracket (15) to bracket (13) loosely with four bolts (16), eight washers (17), and four nuts (18) .

Show/hide table



Illustration 72	g03685337
(21) 435-0888 Gas Pressure Regulator Gp (22) 122-8905 Elbow (23) 6V-8398 O-Ring Seal

Note: Use Loctite 567 on all pipe thread joints.

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

10. Install one O-ring (23) into elbow (22) .

Show/hide table



Illustration 73	g03685339
(8) 7D-1649 Hard Washer (13) 440-4786 Bracket As (21) 435-0888 Gas Pressure Regulator Gp (24) 5B-5620 Bolt (25) 9M-1974 Hard Washer (26) 5S-0003 Nut (27) 293-4056 Gasket (28) 9X-8873 Bolt (29) 1F-7958 Full Nut

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

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

12. Attach gas pressure regulator (21) to the 440-4788 Tube As with one gasket (27), four bolts (28), eight washers (8), and four nuts (29).

Show/hide table



Illustration 74	g03685407
(8) 7D-1649 Hard Washer (15) 440-4792 Bracket (17) 9X-6458 Hard Washer (18) 9S-8752 Full Nut (21) 435-0888 Gas Pressure Regulator Gp (27) 293-4056 Gasket (28) 9X-8873 Bolt (29) 1F-7958 Full Nut (30) 450-2989 Tube As (31) 3B-1915 Bolt

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

14. Attach tube assembly (30) to bracket (15) with one two bolts (31), four washers (17), and two nuts (18) .

Show/hide table



Illustration 75	g03685458
(22) 122-8905 Elbow (23) 6V-8398 O-Ring Seal (30) 450-2989 Tube As (32) 211-5237 Connector (33) 440-4794 Tube As

Note: Use Loctite 567 on all pipe thread joints.

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

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

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

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

Show/hide table



Illustration 76	g03685523
(34) 419-0893 Solenoid Valve Gp (35) 1A-8537 Bolt (36) 5P-8247 Hard Washer (37) 4K-0367 Full Nut (38) 420-8789 Gasket (39) 8S-9092 Bolt

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

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

19. Attach solenoid valve gp (34) to the 450-3143 Bracket As and customer fuel supply loosely. Use one gasket (38), two bolts (35), two bolts (39), eight washers (36), and four nuts (37). Refer to Illustration 76 for the correct location of the bolts.

Show/hide table



Illustration 77	g03685525
(6) 5M-2894 Hard Washer (11) 2A-4639 Bolt (18) 9S-8752 Full Nut (40) 105-8180 Gasket

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

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

21. Refer to Illustration 79.

Installing the 424-7719 Electronic Actuator Gp

Illustration 78	g03264078
(1) 424-7719 Electronic Actuator Gp

Illustration 79	g03684974
New design (1) 424-7719 Electronic Actuator Gp

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

Installing the 398-3729 Water Lines Gp

Illustration 80	g02987617
(1) 4J-5477 O-Ring Seal (2) 8C-6866 Connector (3) 4L-6454 Bolt (4) 8T-4896 Hard Washer (5) 265-5254 Plate (6) 318-2484 Orifice (7) 4F-7391 O-Ring Seal (8) 318-2485 Gasket

Note: Use Loctite 567 on all pipe thread joints.

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

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

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

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

5. Install one O-ring (1) into each connector (2) .

Show/hide table



Illustration 81	g03105438
(1) 4J-5477 O-Ring Seal (2) 8C-6866 Connector (9) 419-1798 Hose As (10) 5P-9297 Clip

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

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

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

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

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

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

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

12. Attach clip (10) to the 7E-6017 Cover use the original hardware.

Show/hide table



Illustration 82	g02987619
(1) 419-1798 Hose As (10) 5P-9297 Clip (11) 0S-1588 Bolt (12) 9X-6458 Hard Washer (13) 9S-8752 Full Nut (14) 6V-0267 Clip (15) 6V-0268 Clip (16) 6V-3265 Clip (17) 0S-1594 Bolt (18) 5M-2894 Hard Washer (19) 0S-1571 Bolt (20) 384-7876 Bracket

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

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

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

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

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

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

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

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

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

22. Attach each clip (10) to each clip (14) and (15). Use one bolt (11), two washers (12), and one nut (13) per clip assembly.

23. Attach hose (27) and one O-ring (1) to connector (28) .

Show/hide table



Illustration 83	g03264265
(1) 4J-5477 O-Ring Seal (2) 8C-6866 Connector (21) 8C-6867 Connector (22) 398-3728 Hose As

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

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

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

Installing the 442-6986 Fuel Lines Gp (1500 and 1800 RPM)

Illustration 84	g03274137
(1) 393-5651 Tube As (2) 6V-4368 O-Ring Seal

Note: The three sets of mixing tubes provided are intended for use with specific ranges of gas quality. Installation is the same for all the tube assemblies. The proper mixing tube to be used for optimal substitution performance should be determined by the Lower Heating Value (LHV) of the supply gas as calculated from a gas analysis. The LHV of a gas analysis can be calculated using Caterpillar Gas Engine Rating Pro (GERP). Once a LHV is determined, install the correct mixing tubes listed in reference to Table 35.

Table 35

LHV Range British Thermal Unit (BTU) / Standard Cubic Foot (SCF)	Part	Rpm
450-1400 BTU / SCF	393-5651 Tube As (LHV)	1500
450-1400 BTU / SCF	416-2189 Tube As (LHV)	1800
1300-2300 BTU / SCF	416-2188 Tube As (HHV)	1500 1800

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

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

Show/hide table



Illustration 85	g03274139
(1) 393-5651 Tube As (3) 442-5391 Tube As (4) 255-6464 Joint (5) 216-2285 Tube Joint (6) 442-5389 Tube As (7) 105-8180 Gasket (8) 2A-4639 Bolt (9) 5M-2894 Hard Washer (10) 9S-8752 Full Nut (11) 3B-1915 Bolt

2. Attach tube assembly (3) to tube assemblies (1) with one joint (4) per tube assembly (1) .

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

3. Attach tube assembly (6) to tube assembly (3) with tube joint (5) .

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

5. Attach tube assembly (6) to the 397-8629 Bracket use two bolts (11), four washers (9), and two nuts (10) .

Show/hide table



Illustration 86	g03274141
(3) 442-5391 Tube As (10) 9S-8752 Full Nut (12) 0S-1591 Bolt (13) 9X-6458 Hard Washer (14) 7K-1401 Clip (15) 7K-1402 Bracket (16) 442-6224 Bracket

6. Attach bracket (16) to the 386-3396 Bracket use two bolts (12), four washers (13), and two nuts (10) .

7. Install one clip (14) and one clip (15) around tube assembly (3) .

8. Attach clips (14) and (15) to bracket (16) use one bolt (12), two washers (13), and one nut (10) .

Show/hide table



Illustration 87	g03274142
(3) 442-5391 Tube As (6) 442-5389 Tube As (10) 9S-8752 Full Nut (12) 0S-1591 Bolt (13) 9X-6458 Hard Washer (14) 7K-1401 Clip (15) 7K-1402 Bracket (16) 442-6224 Bracket (17) 6V-1581 Clip (18) 6V-1582 Clip (19) 0S-1571 Bolt (20) 393-5652 Bracket

9. Attach brackets (16) and (20) to the 386-3396 Bracket use two bolts (19), four washers (13), and two nuts (10).

10. Install one clip (14) and one clip (15) around tube assembly (3) .

11. Attach clips (14) and (15) to bracket (16) use one bolt (12), two washers (13), and one nut (10) .

12. Install one clip (17) and one clip (18) around tube assembly (6) .

13. Attach clips (17) and (18) to bracket (20) use one bolt (12), two washers (13), and one nut (10) .

Show/hide table



Illustration 88	g03274143
(10) 9S-8752 Full Nut (12) 0S-1591 Bolt (13) 9X-6458 Hard Washer (17) 6V-1581 Clip (18) 6V-1582 Clip (21) 391-2202 Bracket

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

15. Attach bracket (21) to the 388-2133 Bracket and the 7N-6986 Support with the original hardware.

16. Install clips (17) and (18) around tube assembly (6) .

17. Attach clips (17) and (18) to bracket (21) use one bolt (12), two washers (13), and one nut (10) .

Installing the 393-5643 Temperature Regulator Gp

Illustration 89	g03274902
(1) 393-5644 Tube (2) 4W-0531 Retainer (3) 0S-1594 Bolt (4) 5M-2894 Hard Washer (5) 4W-0530 Retaining Ring (6) 8T-1919 O-Ring Seal

1. Remove the original separate circuit aftercooler tubes.

2. Install one retaining ring (5) and one O-ring (6) around tube (1).

3. Lubricate the O-ring (6) with 1U-6395 O-Ring Assembly Compound .

4. Install tube (1) into the 214-0729 Adapter use two retainers (2), two bolts (3), and two washers (4) .

Show/hide table



Illustration 90	g03471047
(2) 4W-0531 Retainer (4) 5M-2894 Hard Washer (5) 4W-0530 Retaining Ring (6) 8T-1919 O-Ring Seal (7) 7C-9597 Flange (8) 0L-2070 Bolt (9) 393-5645 Tube (10) 6J-2680 O-Ring Seal

5. Install one retaining ring (5) and one O-ring (6) around tube (9) .

6. Lubricate the O-ring (6) with 1U-6395 O-Ring Assembly Compound .

7. Install flange (7) onto tube (9) .

8. Lubricate the O-ring (10) with 1U-6395 O-Ring Assembly Compound .

9. Install one O-ring (10) into flange (7) .

Show/hide table



Illustration 91	g03275080
(1) 393-5644 Tube (2) 4W-0531 Retainer (4) 5M-2894 Hard Washer (7) 7C-9597 Flange (8) 0L-2070 Bolt (9) 393-5645 Tube (11) 9S-9635 Tube Joint

10. Attach tube (1) to tube (9) with one tube joint (11) .

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

11. Attach flange (7) and tube (9) to the aftercooler with two retainers (2), two bolts (8), and two washers (4) .

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

Show/hide table



Illustration 92	g03275283
(1) 393-5644 Tube (12) 2V-4387 Spacer (13) 0S-1590 Bolt (14) 9X-6458 Hard Washer (15) 196-5052 Clip (16) 196-5053 Clip

12. Install one clip (15) and one clip (16) around tube (1). Refer to Illustration 92 for the correct orientation of the clips.

13. Attach clips (15) and (16) to the camshaft cover of cylinder 6 with one spacer (12), one bolt (13), and one washer (14) .

Show/hide table



Illustration 93	g03274904
(1) 393-5644 Tube (13) 0S-1590 Bolt (14) 9X-6458 Hard Washer (15) 196-5052 Clip (16) 196-5053 Clip (17) 386-3398 Bracket (18) 9X-8873 Bolt (19) 7D-1649 Hard Washer (20) 1F-7958 Full Nut (21) 9S-8752 Full Nut

14. Attach bracket (17) to the 386-3396 Bracket with two bolts (18), four washers (19), and two nuts (20) .

15. Install one clip (15) and one clip (16) around tube (1). Refer to Illustration 93 for the correct orientation of the clips.

16. Attach clips (15) and (16) to bracket (17) with one bolt (13), two washers (14), and one nut (21) .

Show/hide table



Illustration 94	g03274905
(1) 393-5644 Tube (9) 393-5645 Tube (13) 0S-1590 Bolt (14) 9X-6458 Hard Washer (15) 196-5052 Clip (16) 196-5053 Clip (19) 7D-1649 Hard Washer (21) 9S-8752 Full Nut (22) 0S-1585 Bolt (23) 379-5142 Bracket

17. Install bracket (23) onto the top of the flywheel housing use one bolt (22) and one washer (19) .

18. Install one clip (15) and one clip (16) around tube (9) .

19. Attach bracket (23) to clips (15) and (16) with one bolt (13), two washers (14), and one nut (21) .

Installing the 439-7061 Fuel System Parts Kit (if applicable)

Note: Refer to 392-5541 Particle Sensor Gp for more information.

Show/hide table



Illustration 95	g03093498
(1) 6V-0267 Clip (2) 6V-0268 Clip (3) 301-7944 Hose As (4) 174-5907 Clip (5) 0S-1588 Bolt (6) 9X-6458 Hard Washer (7) 9S-8752 Full Nut (8) 2T-2305 Elbow (9) 6V-8397 O-Ring Seal (10) 3B-7764 Bushing (11) 5M-2894 Hard Washer (12) 9L-1480 Gasket

Note: Use Loctite 567 on all pipe thread joints.

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

   • Flange

   • Nipple reducer

   • Particle detector

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

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

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

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

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

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

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

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

Show/hide table



Illustration 96	g03108058
(3) 301-7944 Hose As (3) 4J-5477 O-Ring Seal (13) 8T-6758 Pipe Plug (14) 004-5933 Pipe Tee (15) 3B-7738 Fitting (16) 8C-6866 Connector (17) 4J-5477 O-Ring Seal

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

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

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

12. Install the original ball valve onto fitting (15). Refer to Illustration 96 for correct orientation.

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

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

Installing the 439-7062 Fuel System Parts Kit (if applicable)

Note: Refer to 392-7073 Prelubrication Oil Pump and Lines Gp for more information.

Illustration 97	g03266440
(1) 7N-6569 Adapter (2) 3H-3433 Spring Pin (3) 9L-0672 Check Valve (4) 9H-2367 Spring (5) 1P-5274 Valve Spring Pin

Note: Use Loctite 567 on all pipe thread joints.

1. Install spring (4) onto valve spring pin (5) .

2. Install check valve (3) onto valve spring pin (5) .

   Note: Orient the cup side of the check valve toward the spring.

3. Install valve spring pin (5) into adapter (1) use one spring pin (2) .

Show/hide table



Illustration 98	g03266444
(1) 7N-6569 Adapter (6) 003-9163 Elbow (7) 5P-5846 O-Ring Seal (8) 3B-7745 Pipe Nipple

4. Install pipe nipple (8) into adapter (1) .

5. Install elbow (6) onto pipe nipple (8) .

6. Install one O-ring (7) onto adapter (1) .

Show/hide table



Illustration 99	g03266446
(7) 5P-5846 O-Ring Seal (9) 4L-6454 Bolt (10) 8C-1358 Ball Valve (11) 117-3033 Elbow (12) 7J-9108 O-Ring Seal

7. Remove the 4B-3140 Cover from the 7C-9217 Elbow .

8. Install preassembled adapter (1) onto the 7C-9217 Elbow use one O-ring (7) and two bolts (9) .

9. Install ball valve (10) onto elbow (6) .

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

11. Install one O-ring (12) into elbow (11) .

Show/hide table



Illustration 100	g03266453
(13) 5N-6237 Engine Oil Pump Gp (14) 9X-2398 Elbow (15) 6V-9746 O-Ring Seal

12. Install elbow (14) into engine oil pump (13) .

13. Install one O-ring (15) into elbow (14) .

Show/hide table



Illustration 101	g03266459
(8) 3B-7745 Pipe Nipple (10) 8C-1358 Ball Valve (15) 6V-9746 O-Ring Seal (16) 8C-6874 Connector (17) 7X-7731 Pipe Plug (18) 1N-8559 Service Tee (19) 7B-2742 Bolt (20) 5P-0537 Hard Washer (21) 200-8272 Bracket As

14. Attach engine oil pump (13) to bracket (21) use four bolts (19) and eight washers (20).

    Note: The washers go on both sides of the bracket .

15. Install pipe tee (18) into the top of engine oil pump (13) .

16. Install pipe nipple (8) into the front port of pipe tee (18) .

17. Install ball valve (10) onto pipe nipple (8). The ball valve is open when the handle faces the front of the engine.

18. Install pipe plug (17) into the end of ball valve (10) .

19. Install connector (16) into the top port of pipe tee (18) .

20. Install one O-ring (15) into connector (16) .

Show/hide table



Illustration 102	g03266466
(11) 117-3033 Elbow (16) 8C-6874 Connector (22) 391-6014 Hose As (23) 0S-1587 Bolt (24) 7D-1649 Hard Washer (25) 1F-7958 Full Nut

21. Attach hose (22) to connector (16) and elbow (28) .

    Note: Make sure that the O-rings are in the connector and the elbow.

22. Mark the holes from bracket (21) onto the genset base.

23. Move bracket (21) to the side for drilling.

24. Drill holes in the genset base to accommodate bolts (23) .

25. Attach bracket (21) to the genset base use two bolts (23), four washers (24), and two nuts (25) .

Show/hide table



Illustration 103	g03266469
(15) 6V-9746 O-Ring Seal (16) 8C-6874 Connector (26) 201-0578 Fitting (27) 211-8759 Elbow

26. Install fitting (26) into the 8C-1358 Ball Valve coming off the oil pan.

27. Install elbow (27) onto fitting (26) .

28. Install connector (16) into elbow (27) .

29. Install one O-ring (15) into connector (16) .

Show/hide table



Illustration 104	g03266471
(28) 246-7844 Hose As (29) 0S-1590 Bolt (30) 5M-2894 Hard Washer (31) 9S-8752 Full Nut (32) 2B-0941 Spacer (14) 6V-1889 Clip

30. Install hose (28) onto elbow (14) and connector (16) .

    Note: Make sure that O-rings are in the connector and elbow.

31. Install one clip (33) around hose (28) .

32. Mark hole from clip (33) onto the genset base.

33. Move hose (28) to the side for drilling.

34. Drill holes in the genset base to accommodate bolts (29) .

35. Attach clip (33) to the genset base use one bolt (29) two washers (30), one spacer (32), and one nut (31) .

Installing the 439-7063 Fuel System Parts Kit (if applicable)

Note: Refer to 397-9535 Jacket Water Heater Mounting Gp for more information.

Illustration 105	g03264259
Typical right-side engine view. (1) 006-5707 Pipe Elbow (2) 196-9420 Ball Valve (3) 122-3201 Pipe Nipple (4) 4B-9030 Elbow (5) 8C-6875 Connector (6) 5K-9090 O-Ring Seal (7) 307-9372 Hose As (8) 7G-1239 Spacer (9) 184-7211 Clip (10) 1B-2790 Bolt (11) 9M-1974 Hard Washer (12) 5S-0003 Nut

1. Remove the pipe plug from the 1L-4031 Service Tee of the 398-3729 Water Lines Gp .

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

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

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

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

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

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

8. Install one clip (9) around hose (7) .

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

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

Show/hide table



Illustration 106	g03267716
Typical left-side engine view. (5) 8C-6875 Connector (6) 5K-9090 O-Ring Seal (7) 307-9372 Hose As (8) 7G-1239 Spacer (9) 184-7211 Clip (10) 1B-2790 Bolt (11) 9M-1974 Hard Washer (12) 5S-0003 Nut (13) 0S-1585 Bolt (14) 7D-1649 Hard Washer (15) 1F-7958 Full Nut

10. Install the 375-2566 Jacket Water Heater Gp or the 375-4745 Jacket Water Heater Gp onto the genset base. Use two bolts (13), eight washers (14), and two nuts (15) .

11. Install connector (5) into the rear port of the jacket water heater.

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

13. Install one clip (9) around hose (7) .

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

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

Show/hide table



Illustration 107	g03267577
Typical left-side engine view. (5) 8C-6875 Connector (6) 5K-9090 O-Ring Seal (16) 397-9421 Hose As (17) 196-9420 Ball Valve (18) 1L-4031 Service Tee (19) 8T-6762 Pipe Plug (20) 118-1656 Reducer Bushing

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

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

17. Install ball valve (17) into the center hole of pipe tee (18) .

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

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

20. Install connector (5) into ball valve (17) .

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

22. Attach hose (16) and one O-ring (6) per connector to connectors (5) .

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

Note: Refer to 393-5641 Air Lines Gp for more information.

Illustration 108	g03275496
(1) 5P-3860 Hose Clamp (2) 5P-4869 Hose Clamp (3) 8N-5254 Reducer Hose (4) 8N-8741 Hose (5) 113-1328 Tube

1. Fasten reducer hose (3) and hose (4) onto tube (5) with one hose clamp (2) per hose.

Show/hide table



Illustration 109	g03275497
(1) 5P-3860 Hose Clamp (3) 8N-5254 Reducer Hose

2. Install the assembled parts with reducer hose (3) onto the 393-5647 Tube As and the 393-5648 Tube As with one clamp (1) per tube assembly.

Show/hide table



Illustration 110	g03275498
Typical left-side engine view. (2) 5P-4869 Hose Clamp (4) 8N-8741 Hose (6) 1A-2029 Bolt (7) 9X-6458 Hard Washer

3. Attach the air cleaner to the 386-3396 Bracket with seven bolts (6) and seven washers (7) .

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

Show/hide table



Illustration 111	g03275499
Typical right-side engine view. (2) 5P-4869 Hose Clamp (4) 8N-8741 Hose (6) 1A-2029 Bolt (7) 9X-6458 Hard Washer

5. Attach the air cleaner to the 386-3396 Bracket with seven bolts (6) and seven washers (7) .

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

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

Note: Refer to 393-5640 Air Shutoff Gp for more information.

Illustration 112	g03277918
(1) 113-1587 Reducer Hose (2) 5P-0600 Hose Clamp (3) 388-2134 Bracket

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

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

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

3. Fasten one reducer hose (1) to each 359-4912 Air Shutoff Gp with one hose clamp (2) .

Show/hide table



Illustration 113	g03278136
Typical left-side engine view. (3) 388-2134 Bracket (4) 3B-1915 Bolt (5) 5M-2894 Hard Washer

4. Attach brackets (3) to the air cleaner and the 386-3396 Bracket with two bolts (4) and two washers (5) per bracket.

5. Fasten reducer hose (1) to the tube assembly with one 5P-4869 Hose Clamp .

Show/hide table



Illustration 114	g03278137
Typical right-side engine view. (3) 388-2134 Bracket (4) 3B-1915 Bolt (5) 5M-2894 Hard Washer

6. Attach brackets (3) to the air cleaner and the 386-3396 Bracket with two bolts (4) two washers (5) per bracket.

7. Fasten reducer hoses (1) to the tube assembly with one 5P-4869 Hose Clamp .

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

Installing the 393-5642 Precleaner Gp (if applicable)

Illustration 115	g03274777
Typical left-side engine view. (1) 386-3397 Bracket (2) 382-5499 Support Bracket As (3) 2H-3743 Bolt (4) 8T-5361 Hard Washer (5) 0S-1591 Bolt (6) 9X-6458 Hard Washer

1. Attach bracket (1) and bracket (2) to the upper flywheel housing use four bolts (5) and four washers (6) .

   Note: Bracket (1) goes on top of bracket (2) .

2. Attach the bracket (2) to the lower flywheel housing with two bolts (3) and two washers (4) .

Show/hide table



Illustration 116	g03298498
Typical right-side engine view. (1) 386-3397 Bracket (2) 382-5499 Support Bracket As (3) 2H-3743 Bolt (4) 8T-5361 Hard Washer (5) 0S-1591 Bolt (6) 9X-6458 Hard Washer (7) 1A-1460 Bolt (8) 7D-1649 Hard Washer (9) 1F-7958 Full Nut (10) 382-5500 Support Bracket As

3. Attach the bracket (1) and bracket (10) to the upper flywheel housing with four bolts (5) and four washers (6) .

   Note: Bracket (1) is installed on top of bracket (10) .

4. Attach bracket (10) to the 386-3396 Bracket with two bolts (7), four washers (8), and two nuts (9) .

5. Attach bracket (10) to the lower flywheel housing with two bolts (3) and two washers (4) .

   Note: Steps 6 through 10 use parts from the 386-4896 Engine Wiring Gp .

Show/hide table



Illustration 117	g03292108
(11) 386-4897 Wiring Harness (12) 132-5789 Clip (13) 7K-1181 Cable Strap

6. Attach wiring harness (11) to the 376-4787 Engine Wiring Gp .

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

8. Attach ladder clip (12) to the left 7N-4319 Cover use the original hardware.

9. Attach wiring harness (11) to ladder clip (12) use cable strap (13) .

10. Attach wiring harness (11) to the 376-4787 Engine Wiring Gp use cable straps (13) .

11. Attach precleaners to engine with the original hardware.

Installing the 382-1791 Instrument Panel Box Gp

Illustration 118	g03292056
(1) 382-1791 Instrument Panel Box Gp

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

Note: The stand holding the 382-1791 Instrument Panel Box Gp in Illustration 119 is not included in the kit.

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

Installing the 386-4896 Engine Wiring Gp

Illustration 119	g03292136
(1) 7K-1181 Cable Strap (2) 386-4897 Wiring Harness

Note: The stand holding the 382-1791 Instrument Panel Box Gp in Illustration 119 is not included in the kit.

1. Attach wiring harness (2) to the bottom front port of the 382-1791 Instrument Panel Box Gp .

2. Attach wiring harness (2) to the 339-2947 Electrical Conduit Gp use 14 cable straps (1) .

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

4. Attach the precleaners to the 382-5499 Support Bracket As and the 382-5500 Support Bracket As with the original hardware.

5. Attach the precleaners to the air cleaners.

Installing the 386-4901 Generator Wiring Gp

Illustration 120	g03292146
(1) 386-4904 Engine Harness As

Note: The stand holding the 382-1791 Instrument Panel Box Gp in Illustration 120 is not included in the kit.

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

Software Flash Instructions

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

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

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

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

3. Download the 423-7627 Engine Ratings Electronic Software Gp free from the Service Information System (SIS).

4. Install the 423-7627 Engine Ratings Electronic Software Gp on a blank ECM (A4).

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

Installing the Injector Trim Codes and Setting the FLS/FTS

Illustration 121	g03285604

1. Connect Cat ET to the ECM

2. Click on the "Service" tab.

3. Select "Calibrations".

Show/hide table



Illustration 122	g03286182

4. Click on "Injector Codes Calibration".

Show/hide table



Illustration 123	g03286196

5. Select the "Injector".

Show/hide table



Illustration 124	g03286198

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

7. Click the "Change" button.

8. Click the "OK" button.

Show/hide table



Illustration 125	g03286199

9. Click the "Yes" button.

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

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

Setting the Air Shutoffs Configuration and Calibration of the Engine Timing

Setting the Air Shutoffs Configuration

Illustration 126	g03357967
Default air shutoff not installed

Illustration 127	g03357984
Air shutoffs installed

1. Enable the air shutoffs.

Calibration of the Engine Timing

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

Illustration 128	g03286158

1. Click on the "Service" tab.

2. Select "Calibrations".

Show/hide table



Illustration 129	g03286176

3. Click on "Timing Calibration".

Show/hide table



Illustration 130	g03286178

4. Follow the Prompts.

5. Click the "Continue" button.

Software Enabled Attachments (SEA)

Illustration 131	g03342855
SEA not installed

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

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

Illustration 132	g03342857
SEA installed

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

2. Disconnect CAT ET from the ECM

Installing the 444-0554 Film

Show/hide table



Illustration 133	g03814974
Typical 443-5866 Film (Non-Emission Certified Engines)

1. Clean off the valve cover next to the valve cover with the engine certification film.

Note: Do not obstruct the view of any other film.

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

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

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

Startup Checklist

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

Table 36

Step	Description	Complete/Measured Values	Dealer sign-off	Customer sign-off
1	Confirm the air filter covers are removed.
2	Power on engine, check for any fault codes.
3	Check customer Input / Output connections, proper operation (direct rack, secondary gas shutoff valve).
4	Diesel-only startup, ensure proper engine/generator function.
5	Check voltage / current for each phase.
6	Check for leaks (cooling, lube, manifold area, exhaust).
7	Operate engine through as much load range as possible.
8	Confirm no excessive exhaust restriction (including catalyst).
9	Pull a Product Status Report.
10	Measure exhaust Diesel Oxidation Catalyst inlet temperature.
11	Check all temperatures.
12	Check all pressures.
13	Confirm E-stop works.
14	Supply gas system checks.
-	Clean, dry gas per Application and Installation Guide, LEBW4977, "Gaseous Fuels".
-	<10 ppm H2S present in gas (<50 ppm with a stainless steel aftercooler).
-	Gas pressure is (12 to 35 psig).
-	Meets required gas flow (per web calculator tool).
15	Regulator pressure is set properly (engine loaded and running) per procedure. Refer to Testing and Adjusting, "Fuel Pressure (Gas System)".
16	Check gas system for leaks.
17	Confirm Software Enabled Attachment works, blending enabled.
18	Enable Dynamic Gas Blending mode.
19	Set desired substitution percentage and check for fault codes (pressure within range, gas valves performance, etc.).
20	Inspect supply gas equipment for proper operation while gas is flowing.

Register the Retrofit

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

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

1. When performing a retrofit installation, record the vital information in Table 37.

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

   Show/hide table

   Table 37

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

   Show/hide table

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

2. Update the product configuration by entering the information from Table 37 into SIMSi and AIMS.

   Note: For retrofits that have a Caterpillar serial number, the AIMS application is "JIZ111-08". For retrofits that do not have a Caterpillar serial number, the AIMS application is "JIZ111-07".

3. For detailed instructions on updating the product configuration, refer to Special Instruction, REHS5097, "Instructions to Register the Retrofit".