EPC Parts Catalogs

Procedure for the Installing the <NOBR>479-2095</NOBR> Migration Kit on 316E and 318E Excavators {1000, 7000} Caterpillar


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Procedure for the Installing the <NOBR>479-2095</NOBR> Migration Kit on 316E and 318E Excavators {1000, 7000} [M0066102]
ENGINE ARRANGEMENT
ENGINE AR
Procedure for the Installing the <NOBR>479-2095</NOBR> Migration Kit on 316E and 318E Excavators {1000, 7000}
1.1. Introduction
2.1. Safety Section
3.1. Instructions for Ordering 316E and 318E Migration/Decertification Emissions Labels
4.1. Fuel System Conversion
5.2. Required Parts
6.2. Torque Tables for Bolts, Adapters, Plugs, and Couplings
7.2. Conversion Procedure
8.1. Harness Conversion
9.2. Required Parts
10.2. Fuel System Harness Conversion Procedure
11.2. Exhaust System Harness Conversion Procedure
12.1. Exhaust System Conversion
13.2. Required Parts
14.2. Conversion Procedure
15.1. Engine Software
16.1. Machine Labels
17.2. Label Locations
18.2. Removing Adhesive Labels
19.2. Applying Adhesive Labels
20.1. Disabling the Product Link Lockout
21.1. Instruction to Customers
Excavator
316E (S/N: DZW1-UP; WZY1-UP; YZZ1-UP)
318E (S/N: DZF1-UP; WZS1-UP)

Introduction

Note: Order the emissions labels first. The ordering process can take some time.

This Special Instruction is used for the installation of the 479-2095 Migration Kit on 316E and 318E Excavators. All components listed in this Special Instruction are included in the 479-2095 Migration Kit.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

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------ WARNING! ------

Wear goggles, gloves, protective clothing, and a National Institute for Occupational Safety and Health (NIOSH) approved P95 or N95 half-face respirator when handling a used Diesel Particulate Filter or Catalytic Converter Muffler. Failure to do so could result in personal injury.

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NOTICE

Do NOT use electrical components (ECM or sensors) or electronic component grounding points for grounding the welder.

Instructions for Ordering 316E and 318E Migration/Decertification Emissions Labels

  1. Log on to the "Emissions Regulation and Conformance" website at the following web address:

    https://ercrequestspilotprogram.atlassian.net/servicedesk/customer/portal/2
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    Illustration 1g06174531

  2. Click Option 3. Tier 4 Migration/Decertification.
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    Illustration 2g06174530

  3. Click "Migration / Decertification Request – C7.1 and below".

  4. The Migration / Decertification Request form will appear. All fields marked with an "*" must be completed.

    Note: Requests that do not have the decertification serial number included in "Section 5" and do not have the box checked which confirms that applicable local and national regulations permit the engine to be decertified will be rejected.

  5. Proceed to TMI to determine the current "Engine Arrangement Number".
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      Illustration 3g03749286
      (1) "Reference Number" field
      (2) Drop down box
      (3) "Retrieve Data"
      (4) Current "Engine Arrangement Number"

    1. Enter the machine serial number in the "Reference Number" field.

    2. Select "Serial Number" in the drop-down box.

    3. Click "Retrieve Data".

  6. To determine the new "Migrated Arrangement Number", compare the current "Engine Arrangement Number" to Table 1.

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    Table 1
    Current Engine Arrangement Number  Migrated Arrangement Number 
    345-2885  489-6326(1) 
    465-0359 
    454-4407 
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    (1) Order the emissions labels first. The ordering process can take some time.

Fuel System Conversion

Required Parts

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Table 2
New Part Number  Description  Qty 
478-9518  Hose AS  1 
478-9519  Hose AS  1 
478-9520  Hose AS  1 
478-9693  Plate AS  1 
485-1053  Plate AS  1 
341-3504  Collar  1 
7X-2544  Bolt  1 
481-5225  Support As  1 
381-9061  Fuel Filter Base As  1 
382-0664  Water Separator and Fuel Filter As  1 
296-6980  Spacer  1 
347-4734  Clip  1 
274-7395  Temperature Sensor Gp  1 
264-4297  Temperature Sensor  1 
238-5080  O-Ring Seal  5 
319-6217  Connector As  1 
353-5112  Adapter As  1 
9X-0262  Adapter  1 
214-7566  O-Ring Seal  2 
305-6873  Pressure Sensor Gp  1 
307-2670  Plug As  2 
9S-4185  Plug  2 
319-6213  Connector As  1 
6V-8634  Connector  1 
228-7089  O-Ring Seal  3 
141-5138  Fuel Filter Base As  1 
364-5287  Fuel Filter  1 
6N-4414  Filter Base Cover  1 
1P-0436  Gasket  1 
8T-4224  Hard Washer  1 
7X-2537  Bolt  1 
9X-8256  Washer  1 
7X-2533  Bolt  1 
309-5130  Plug As  1 
9S-4182  Plug  1 
214-7566  O-Ring Seal  1 
332-0296  Pressure Sensor Gp  2 
320-3061  Pressure Sensor Gp  2 
228-7101  O-Ring Seal  1 
331-1136  Adapter As  2 
331-1137  Adapter  2 
214-7568  O-Ring Seal  5 
357-4605  Adapter As  1 
8T-0151  Adapter  1 
384-9223  Tee As  1 
6V-1625  O-Ring Tee  1 
448-9021  Adapter As  1 
366-4683  Adapter  1 
343-3918  Connection  1 
228-7100  O-Ring Seal  3 
329-5474  Tee As  1 
7X-2459  O-Ring Tee  1 
459-7560  Bracket As  1 
8T-4137  Bolt  3 
8T-4136  Bolt  2 
8T-4196  Bolt  1 
8T-4121  Hard Washer  8 
135-8575  Bolt As  2 
5P-1076  Hard Washer  2 
8T-4139  Bolt  2 
360-8960  Fuel Filter Element  1 
198-4777  Hard Washer  2 
8T-4182  Bolt  1 
228-7102  O-Ring Seal  1 
482-1865  Hose AS  1 
351-4320  Clip  9 
440-6233  Clip  4 
437-2150  Clip  2 
(450-9357)  Fuel Cap  2 

Torque Tables for Bolts, Adapters, Plugs, and Couplings

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Table 3
Bolt Size  Standard Torque  Half Torque 
M6 x 1  12 ± 3 N·m (9 ± 2 lb ft)  6 ± 1.5 N·m (4.5 ± 1 lb ft) 
M8 x 1.25  28 ± 7 N·m (21 ± 5 lb ft)  14 ± 3.5 N·m (10 ± 2.5 lb ft) 
M10 x 1.5  55 ± 10 N·m (41 ± 7 lb ft)  27.5 ± 5 N·m (20 ± 3.5 lb ft) 
M12 x 1.75  100 ± 20 N·m (74 ± 15 lb ft)  50 ± 10 N·m (37 ± 7 lb ft) 

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Table 4
Adapter Size  Standard Heavy Duty Torque  Half Heavy Duty Torque  Standard Light Duty Torque  Half Light Duty Torque 
7/16–20  30 ± 5 N·m (22 ± 3.5 lb ft)  15 ± 2.5 N·m (11 ± 2 lb ft)  30 ± 5 N·m (22 ± 3.5 lb ft)  15 ± 2.5 N·m (11 ± 2 lb ft) 
9/16–18  55 ± 8 N·m (41 ± 6 lb ft)  27.5 ± 5 N·m (20 ± 3.5 lb ft)  40 ± 6 N·m (30 ± 4.5 lb ft)  20 ± 3 N·m (15 ± 2 lb ft) 
3/4–16  100 ± 15 N·m (74 ± 11 lb ft)  50 ± 7.5 N·m (37 ± 5.5 lb ft)  80 ± 12 N·m (59 ± 9 lb ft)  40 ± 6 N·m (30 ± 4.5 lb ft) 
7/8–14  140 ± 21 N·m (103 ± 15 lb ft)  70 ± 10.5 N·m (52 ± 8 lb ft)  110 ± 17 N·m (81 ± 12.5 lb ft)  55 ± 8.5 N·m (41 ± 6 lb ft) 
M12x1.5  40 ± 6 N·m (29.5 ± 4.4 lb ft)  20 ± 3 N·m (14.8 ± 2.2 lb ft)  30 ± 5 N·m (22.1 ± 3.7 lb ft)  15 ± 2.5 N·m (11.1 ± 1.8 lb ft) 
M16X1.5  60 ± 9 N·m (44.3 ± 6.6 lb ft)  30 ± 4.5 N·m (22.1 ± 3.3 lb ft)  45 ± 7 N·m (33.2 ± 5.2 lb ft)  22.5 ± 4.5 N·m (16.6 ± 3.3 lb ft) 

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Table 5
Plug Size  Standard Torque  Half Torque 
7/16–20  40 ± 6 N·m (29.5 ± 4.4 lb ft)  20 ± 3 N·m (14.8 ± 2.2 lb ft) 
3/4–16  100 ± 15 N·m (73.8 ± 11.1 lb ft)  50 ± 7.5 N·m (36.9 ± 5.5 lb ft) 
M12x1.5  25 ± 4 N·m (18.4 ± 3.0 lb ft)  12.5 ± 2 N·m (9.2 ± 1.8 lb ft) 

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Table 6
Coupling Size  Torque 
11/16–16  45 ± 5 N·m (33.2 ± 3.7 lb ft) 
13/16–16  65 ± 10 N·m (47.9 ± 7.4 lb ft) 

Conversion Procedure

Save all removed parts that are installed on the original machine for reinstallation.

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    Illustration 4g06019168
    (1) 446-5409 Fuel Transfer Pump Asand mounting components
    (2) 434--2671 Hose
    (3) 434-2678 Hose
    (4) 384-8512 Fuel Filter and 5P-4325
    (5) 347-8646 Hose
    (6) 434-2672 Hose As
    (7) 360-5510 Water Separator and Fuel Filter Gp and mounting components
    (8) 434-2673 Hose As

  1. Remove the components and mounting hardware shown in Illustration 4. Retain bolts, washers, and clips for reuse with the installation of the new hose assemblies.
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    Illustration 5g06021628
    Radiator Compartment
    (8) 434-2673 Hose As
    (9) Two 351-4318 Clips
    (10) 361-1233 Primary Fuel Filter Gp

  2. Remove clips (9) shown in Illustration 5.

  3. Disconnect hose assembly (8) from fuel filter group (10).
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    Illustration 6g06019248
    (10) 361-1233 Primary Fuel Filter Gp

  4. Remove the mounting hardware around fuel filter group (10) shown in Illustration 6.

    Note: Retain all the other hose connections to the fuel filter group.

    Note: Save the fuel filter group for reinstallation.

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    Illustration 7g06024194
    Radiator Compartment
    (11) Air cleaner, bracket, and mounting hardware
    (12) Top cover
    (13) Two bolts
    (14) 481-5225 Support As
    (15) Door
    (16) Support

  5. Remove components (11) through (16) as shown in Illustration 7.

  6. Replace support assembly (14).

  7. Reusing the removed parts, reinstall components (11), (12), (13), (15), and (16). Refer to Illustration 7.
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    Illustration 8g06020780
    Radiator compartment
    (1) 446-5409 Fuel Transfer Pump As

  8. Install electric fuel transfer pump (1) using the following mounting hardware: three 8T-4224 Hard Washers and three 7X-0818 Bolts.
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    Illustration 9g06020789
    (17) 478-9693 Plate As
    (18) Two 135-8575 Bolt As (standard duty torque)
    (19) Two 8T-4121 Hard Washers
    (20) Two 8T-4196 Bolts (half duty torque)
    (21) 381-9061 Fuel Filter Base As
    (22) 305-6873 Pressure Sensor Gp
    (23) 353-5112 Adapter As (half light-duty torque)
    (24) 274-7395 Temperature Sensor Gp
    (25) Two 307-2670 Plug As (half duty torque)

  9. Mount plate assembly (17) using bolt assemblies (18).

  10. Mount filter base (21) to plate assembly (17) using washers (19) and bolts (20). Refer to Illustration 9.

  11. Install plug assemblies (25) into filter base (21).

  12. Install pressure sensor (22) on filter base (21) using adapter assembly (23). Tighten to a torque of 10 ± 2 N·m (7.4 ± 1.5 lb ft). Refer to Illustration 9.

  13. Install pressure sensor (24) on filter base (21). Tighten to a torque of 20 ± 3 N·m (14.8 ± 2.2 lb ft). Refer to Illustration 9.
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    Illustration 10g06020801
    (1) 446-5409 Fuel Transfer Pump Asand mounting components
    (21) 381-9061 Fuel Filter Base As
    (26) 319-6213 Connector As (half heavy-duty torque)
    (27) 478-9518 Hose As and 6S-8620 Hose Clamp (11/16 — 16 hose)
    (28) 351-4318 Clip (upside down)
    (29) 8T-4121 Hard Washer
    (30) 8T-4137 Bolt
    (31) 319-6217 Connector As (half heavy-duty torque)
    (32) 482-1865 Hose As (13/16 — 16 hose)
    (33) 440-6233 Clip
    (34) 8T-4121 Hard Washer
    (35) 8T-4137 Bolt

  14. Connect hose assembly (27) to filter base (21) using connector (26).

  15. Route hose assembly (27) from filter base (21) back to electronic fuel transfer pump (1).

  16. Secure hose assembly (27) using clip (28), washer (29), and bolt (30).

  17. Connect hose assembly (32) to filter base (21) using connector (31). Refer to Illustration 10.
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    Illustration 11g06020943
    (32) 482-1865 Hose As
    (A) 60 degrees

  18. Orient hose assembly (32) as shown in Illustration 11.

  19. Secure hose assemblies (27) and (32) using clip (33), washer (34), and bolt (35). Refer to Illustration 10.
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    Illustration 12g06020839
    (21) 381-9061 Fuel Filter Base As
    (36) 382-0664 Water Separator and Fuel Filter As
    (37) 296-6980 Spacer
    (38) 8T-4121 Hard Washer
    (39) 8T-4182 Bolt
    (40) 347-4734 Clip
    (41) Existing level sensor group
    (42) Two 8T-4121 Hard Washers
    (43) Two 8T-4136 Bolts
    (44) 485-1053 Plate As

  20. Install water separator and fuel filter assembly (36) to filter base (21).

  21. Install existing level sensor group (41) on fuel filter (36). Tighten to a torque of 2.5 ± 0.5 N·m (22.1 ± 4.4 lb in). Refer to Illustration 12.

  22. Secure sensor group (41) using spacer (37), washer (38), bolt (39), and clip (40). Refer to Illustration 12.

  23. Install plate assembly (44), attach using washers (42) and bolts (43).

    Note: The plate assembly is for use with the primary filter when servicing the AC condenser.

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    Illustration 13g06020538
    (10) 361-1233 Primary Fuel Filter Gp
    (45) Existing hose
    (46) 351-4318 Clip
    (47) 8T-4121 Hard Washer
    (48) 8T-4137 Bolt
    (49) Two 228-7100 O-Ring Seals
    (50) 367-7564 Hose Connector (half light-duty torque)
    (51) 367-7563 Port Plug (half duty torque)

  24. Reuse fuel filter (10) and install in radiator compartment using the following mounting hardware: 358-2144 Lines Support Gp, two 8T-4121 Hard Washers, and two 8T-4195 Bolts. Replace the 360-8960 Fuel Filter Element.

  25. Move connector (50) from the right port to the left port. Replace O-ring (49).

  26. Move plug (51) from the left port to the right port. Replace O-ring (49).
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    Illustration 14g06021680
    (45) Existing hose
    (46) 351-4318 Clip
    (47) 8T-4121 Hard Washer
    (48) 8T-4137 Bolt
    (B) 30 degrees

  27. Secure hose (45) using clip (46), washer (47), and bolt (48). Orient clip (46) as shown in Illustration 14.
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    Illustration 15g06021685
    Radiator Compartment
    (32) 482-1865 Hose As
    (52) 440-6233 Clip (upside down)
    (53) Two 8T-4121 Hard Washers
    (54) 8T-4136 Bolt
    (55) 8T-4137 Bolt
    (56) 351-4320 Clip
    (57) 351-4320 Clip (upside down)
    (58) Existing hose to fuel filter group

  28. Secure and route hose assembly (32) through the radiator compartment using the following mounting hardware: clips (52), (56), and (57), washers (53), and bolts (54) and (55).

    Note: Clip (52) secures both hose assembly (32) and hose (58) from the fuel filter group.

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    Illustration 16g06020932
    Engine Compartment
    (32) 482-1865 Hose As
    (59) 351-4320 Clip
    (60) Two 437-2150 Clips
    (61) Four 8T-4121 Hard Washers
    (62) Three 8T-4137 Bolts
    (63) 434-2675 Hose As
    (64) 351-4318 Clip
    (65) 440-6233 Clip
    (66) 8T-4136 Bolt
    (C) View detailed area
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    Illustration 17g06020938
    Detailed View of Area C
    (32) 482-1865 Hose As
    (61) 8T-4121 Hard Washer
    (62) 8T-4137 Bolt
    (63) 434-2675 Hose As
    (65) 440-6233 Clip
    (D) 60 degrees

  29. Secure and route hose assembly (32) through the engine compartment using the following mounting hardware: clips (59), (60), (64), and (65), washers (61), and bolts (62) and (66). Refer to Illustrations 16 and 17.
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    Illustration 18g06021810
    Pump Compartment
    (32) 482-1865 Hose As
    (67) Three 8T-4121 Hard Washers
    (68) Two 8T-4136 Bolts
    (69) 459-7560 Bracket As
    (70) 351-4320 Clip
    (71) 341-3504 Collar
    (72) 7X-2544 Bolt
    (73) 351-4320 Clip (upside down)
    (E) View detailed area
    (F) View detailed area
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    Illustration 19g06020973
    Detailed View of Area E
    (67) 8T-4121 Hard Washers
    (68) 8T-4136 Bolts
    (69) 459-7560 Bracket As
    (G) 45 degrees
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    Illustration 20g06021214
    Detailed View of Area F
    (32) 482-1865 Hose As
    (67) 8T-4121 Hard Washers
    (68) 8T-4136 Bolts
    (69) 459-7560 Bracket As
    (73) 351-4320 Clip (upside down)
    (H) 45 degrees

  30. Secure and route hose assembly (32) through the pump compartment using the following mounting hardware: bracket assembly (69), clips (70) and (73), collar (71), washers (67), and bolts (68) and (72). Refer to Illustrations 18,19, and 20.
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    Illustration 21g06021252
    (3) 434-2678 Hose
    (32) 482-1865 Hose As
    (74) Three 351-4320 Clips (upside down)
    (75) 440-6233 Clip (upside down)
    (76) Five 8T-4121 Hard Washers
    (77) Five 8T-4136 Bolts
    (78) Two 351-4318 Clips (upside down)
    (79) 351-4318 Clip
    (J) View detailed area
    (K) View detailed area
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    Illustration 22g06021270
    Detailed View of Area J
    (3) 434-2678 Hose
    (32) 482-1865 Hose As
    (74) 351-4320 Clip (upside down)
    (76) 8T-4121 Hard Washer
    (77) 8T-4136 Bolt
    (78) 351-4318 Clip (upside down)
    (L) 60 degrees
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    Illustration 23g06021259
    Detailed View of Area K
    (3) 434-2678 Hose
    (32) 482-1865 Hose As
    (74) 351-4320 Clip (upside down)
    (76) 8T-4121 Hard Washer
    (77) 8T-4136 Bolt
    (79) 351-4318 Clip

  31. Secure and route hose assembly (32) along the side of the machine using the following mounting hardware: clips (74), (75), (78), and (79), washers (76), and bolts (77). Refer to Illustrations 21,22, and 23.
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    Illustration 24g06019490
    Fuel Tank Bottom View
    (3) 434-2678 Hose
    (32) 482-1865 Hose As
    (80) 8T-4121 Hard Washer
    (81) 8T-4137 Bolt
    (82) 351-4320 Clip
    (83) 6S-8620 Hose Clamp
    (M) 30 degrees

  32. Connect hose assembly (32) to the fuel tank shut off valve and secure with hose clamp (83).

  33. Secure hose assembly (32) with clip (82), washer (80), and bolt (81).

    Note: Orient the clip and hose assembly at angle (M).

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    Illustration 25g06021431
    Radiator Compartment
    (1) 446-5409 Fuel Transfer Pump As
    (84) 332-8576 Elbow As (standard heavy-duty torque)

  34. Reuse elbow assembly (84) and install on electric fuel transfer pump (1) as shown in Illustration 8. Use new 228-7089 O-Ring Seal and 228-7102 O-Ring Seal when installing elbow (84).
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    Illustration 26g06021437
    (84) 332-8576 Elbow As (standard heavy-duty torque)
    (85) 478-9519 Hose As (11/16 — 16 hose)
    (N) 15 degrees

  35. Install hose (85) and connect to elbow (84), orient as shown in Illustration 26.
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    Illustration 27g06023240
    (86) 141-5138 Fuel Filter Base As
    (87) Two 198-4777 Hard Washers
    (88) Two 8T-4121 Hard Washer
    (89) Two 8T-4196 Bolts

  36. Mount fuel filter base (86) using washers (87) and (88) and bolts (89). Refer to Illustration 27. Complete the sub assembly of the fuel filter in this location.
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    Illustration 28g06021575
    Fuel Filter Assembly
    (86) 141-5138 Fuel Filter Base As
    (90) 448-9021 Adapter As (standard light-duty torque)
    (91) 228-7100 O-Ring Seal
    (92) 343-3918 Connection (standard light-duty torque)
    (93) 357-4605 Adapter As (half light-duty torque)
    (94) 9X-8256 Washer
    (95) 7X-2533 Bolt (half duty torque)
    (96) 8T-4224 Hard Washer
    (97) 7X-2537 Bolt (half duty torque)
    (98) 309-5130 Plug As (half light-duty torque)
    (99) Two 332-0296 Pressure Sensor Gp
    (100) Two 331-1136 Adapter As (standard light-duty torque)
    (101) 329-5474 Tee As (half light-duty torque)
    (102) 6N-4414 Filter Base Cover
    (103) 1P-0436 Gasket
    (104) 364-5287 Fuel Filter
    (105) 384-9223 Tee As (half light-duty torque)

  37. Install components (90) through (105) as shown in Illustration 28.

    Torque for pressure sensors (99) ... 10 ± 2 N·m (7.4 ± 1.5 lb ft).

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    Illustration 29g06021527
    (86) 141-5138 Fuel Filter Base As
    (87) Two 198-4777 Hard Washers
    (88) Two 8T-4121 Hard Washer
    (89) Two 8T-4196 Bolts

  38. Remove washers (87) and (88) and bolts (89) from fuel filter base (86). Relocate fuel filter base (86) as shown in Illustration 29 and reuse the mounting hardware.
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    Illustration 30g06020341
    (1) 446-5409 Fuel Transfer Pump As
    (10) 361-1233 Primary Fuel Filter Gp
    (85) 478-9519 Hose As
    (104) 364-5287 Fuel Filter
    (106) 478-9520 Hose As

  39. Connect the other end of hose (85), from fuel transfer pump (1), to fuel filter (104).

  40. Connect hose (106) to the other side of fuel filter (104). Refer to Illustration 30.

  41. Connect the other end of hose (106) to primary fuel filter (10). Refer to Illustration 30.
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    Illustration 31g06022152
    Radiator Compartment
    (10) 361-1233 Primary Fuel Filter Gp
    (107) Three 344-5360 Clips
    (108) 8T-4121 Hard Washer
    (109) 8T-4195 Bolt
    (110) 434-2674 Hose As

  42. Remove components (107) through (109).

  43. Disconnect hose assembly (110) from fuel filter group (10). Refer to Illustration 31.
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    Illustration 32g06022171
    (10) 361-1233 Primary Fuel Filter Gp
    (111) 450-9357 Fuel Cap

  44. Install fuel cap (111) onto fuel filter (10).
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    Illustration 33g06022188
    Radiator Compartment (Back View)
    (10) 361-1233 Primary Fuel Filter Gp
    (110) 434-2674 Hose As
    (112) Two 8T-1889 Clips
    (113) Two 8T-1890 Clips
    (114) Two 351-4089 Grommets
    (115) Two 344-5360 Clips
    (P) View detailed area

  45. Remove components (112) through (115).

  46. Disconnect hose assembly (110) at location (P) and remove.
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    Illustration 34g06022226
    Detailed View of Area P
    (116) 450-9357 Fuel Cap

  47. Install fuel cap (116).

Harness Conversion

Required Parts

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Table 7
New Part Number  Description  Qty 
471-3632  Chassis Harness AS  1 
3S-2093  Cable Strap  16 
7K-1181  Cable Strap  17 
7I-2673  Cable Strap  1 
4P-7428  Clip  1 
132-5789  Clip  1 
342-2974  Connector Cap  1 

Fuel System Harness Conversion Procedure

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    Illustration 35g06018956
    Engine Compartment
    (1) Connection for the wiring harness to the engine ECM J! connector
    (2) Four 7K-1181 Cable Straps
    (3) 471-3632 Wiring Harness

  1. Connect the pins of harness (3) to the engine ECM J1 connector (1) in the following order:

    • Connect "A751-YL" to pin location 24

    • Connect "X999-GN" to pin location 25

    • Connect "C991-PK" to pin location 35

    • Connect "P792-BU" to pin location 47

    Note: Position and secure the new harness assembly by aligning the green tape on the new harness with the green tape on the existing harness.

  2. Secure harness (3) with cable straps (2) at the location shown in Illustration 35.
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    Illustration 36g06018972
    Engine Compartment
    (3) 471-3632 Wiring Harness
    (4) Four 7K-1181 Cable Straps

  3. Secure harness (3) with cable straps (4) at the locations shown in Illustration 36.
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    Illustration 37g06019010
    Pump Compartment
    (3) 471-3632 Wiring Harness
    (5) Connection to the standard chassis harness
    (6) Three 3S-2093 Cable Straps
    (7) Four 7K-1181 Cable Straps
    (8) Connection to the standard chassis harness
    (9) Connection to the standard chassis harness

    Note: Position and secure the new harness assembly by aligning the green tape on the new harness with the green tape on the existing harness.

  4. Secure harness (3) with cable straps (6) and (7) at the locations shown in Illustration 37.

  5. Connect the pins of harness (3) at location (5) that consist of the following wires : "997-OR" and "993-BR".

  6. Connect the pins of harness (3) at location (8) that consist of the following wires: "X976-GN" and "200-BK".

  7. Connect the pins of harness (3) at location (9) that consist of the following wires: "G976-BU", "235-BK", and "147-PU"
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    Illustration 38g06019034
    Radiator Compartment
    (3) 471-3632 Wiring Harness
    (10) Three 7K-1181 Cable Straps
    (11) Three 3S-2093 Cable Straps

    Note: Position and secure the new harness assembly by aligning the green tape on the new harness with the green tape on the existing harness.

  8. Secure harness (3) with cable straps (10) and (11) at the locations shown in Illustration 38.
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    Illustration 39g06019046
    Radiator Compartment
    (3) 471-3632 Wiring Harness
    (12) Connection for pressure before the main fuel filter
    (13) Secondary filter
    (14) Four 3S-2093 Cable Straps
    (15) Primary filter
    (16) 7I-2673 Cable Strap
    (17) Main filter

    Note: Position and secure the new harness assembly by aligning the green tape on the new harness with the green tape on the existing harness.

  9. Secure harness (3) with cable straps (14) and (16) at the locations shown in Illustration 39.

  10. Connect the pressure sensor connector at location (12) that consist of the following wires: "997-OR", "993-BR", and "C991-PK".
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    Illustration 40g06019070
    Radiator Compartment
    (3) 471-3632 Wiring Harness
    (13) Secondary filter
    (15) Primary filter
    (18) Six 3S-2093 Cable Straps
    (19) Connection for the electric lifting pump
    (20) Electric lifting pump
    (21) Location to secure the wiring harness
    (22) Location to secure the wiring harness
    (23) Connection for the primary fuel filter pressure sensor
    (24) Connection for the primary fuel filter temperature sensor
    (25) Connection for pressure after the main fuel filter
    (26) Connection for the water separator level sensor

    Note: Position and secure the new harness assembly by aligning the green tape on the new harness with the green tape on the existing harness.

  11. Secure harness (3) with cable straps (18) at the locations shown in Illustration 40.

  12. Secure harness (3) at location (21) using the following components: one 132-5789 Clip and one 7K-1181 Cable Strap.

  13. Secure harness (3) at location (22) using the following components: one 4P-7428 Clip and one 7K-1181 Cable Strap.

  14. Connect the electric lift pump connector at location (19) that consists of the following wires: "X976-GN" and "200-BK".

  15. Connect the pressure sensor connector at location (23) that consists of the following wires: "997-OR", "993-BR", and "X999-GN".

  16. Connect the temperature sensor connector at location (24) that consists of the following wires: "A751-YL" and "993-BR".

  17. Connect the pressure sensor connector at location (25) that consists of the following wires: "997-OR", "993-BR", and "P792-BU".

  18. Connect the water separator level sensor connector at location (26) that consists of the following wires: "G976-BU", "235-BK", and "147-PU".

Exhaust System Harness Conversion Procedure

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    Illustration 41g06019106
    Pump Compartment
    (27) Exhaust harness
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    Illustration 42g06019110
    DPF Filter
    (27) Exhaust harness
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    Illustration 43g06019116
    Fuel Tank Side
    (27) Exhaust harness

  1. Remove the exhaust harness (27) shown in Illustrations 4142, and 43.

  2. Install cap connector (28).

Exhaust System Conversion

Required Parts

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Table 8
New Part Number  Description  Qty 
478-4187  Muffler As  1 
359-5885  Clamp As  1 

Conversion Procedure

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    Illustration 44g03709741
    (1) DPF inlet clamp
    (2) DPF straps
    (3) Exhaust pipe clamp
    (4) Slip joint clamp

  1. Remove clamp (3) on the outlet side of the diesel particulate filter group, and remove the exhaust piping.

  2. Remove clamp (1) on the inlet side of the diesel particulate filter group, and disconnect the 362-6401 Bellows As.

  3. Remove the DPF inlet temperature sensor.

  4. Disconnect the wiring harness from the soot antennas.

  5. Disconnect straps (2) to remove the diesel particulate filter group.

  6. Attach a suitable lifting device to the DPF. The weight of the DPF is approximately 21.8 kg (48 lb).

  7. Remove the 380-9161 Diesel Particulate Filter Gp.

  8. Loosen slip joint clamp (4) so the flexible piping can be manipulated during the installation process.

  9. Install the new 478-4187 Muffler As onto the DPF support bracket.

  10. Position the muffler assembly and tighten strap groups (2) to a torque of 15 +3/-0 N·m (11 +2/-0 lb ft).

  11. Orient the flexible pipe and torque clamp (1) to a torque of 35 ± 2 N·m (26 ± 1.5 lb ft) using a wrench with a maximum speed of 75 rpm.

  12. Torque clamp (4) to a toque of 55 ± 8 N·m (41 ± 6 lb ft) using a wrench with a maximum speed of 75 rpm.

  13. Reinstall the exhaust piping removed in Step 1 and torque clamp (3) to a toque of 68 ± 4 N·m (50 ± 3 lb ft).

    Note: Ensure that the exhaust pipe orientation is the same as when the pipe was removed.

Engine Software

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Table 9
New Part Number  Description  Qty 
489-6441  Engine Software  1 

Note: When migration kit rework has been completed, the technician must confirm that the latest machine and monitor software are installed. If not, the latest machine and monitor software must be installed at the same time as the new engine software.

  1. Download the decertification flash file. Refer to Table 9.

  2. Factory passwords will be issued utilizing the Dealer Solution Network (DSN).
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    Illustration 45g03672156

  3. When the decertification flash file is downloaded, this screen will appear in the electronic service tool. Refer to Illustration 45.

  4. Click "Save to File". This will create an HTML file.

  5. Attach the HTML file to the DSN factory password request. Do not change the file to a PDF format.

  6. The following text must be included in the DSN factory password request:

    This password request is for the decertification procedure outline in Special Instruction, M0066102. I acknowledge that the applicable local and national regulations permit engine serial number <enter engine serial number> to be decertified, and I will ensure export from the country if the decertified machine no longer complies with local or national regulations governing the sale and/or use of the machine. The labels to confirm that this decertification have been ordered and will be applied as per Special Instruction, M0066102.

    Note: Any service requests for passwords that do not contain the above verbiage will be rejected.

  7. Once the factory passwords have been entered, install the flash file. Refer to Troubleshooting, "Flash Programming".

Machine Labels

The lubrication chart and exterior sound films are located in the machine cab and on the cab door. These labels must be removed. The new lubrication chart film must then be installed in the machine cab. Refer to the information below for label removal and installation instructions.

Label Locations

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Illustration 46g03693967
Lubrication Chart Film Location

Removing Adhesive Labels

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NOTICE

Do not install the new film over the old film. Layered labels compromise label adhesion and durability. Adhesive films must be applied to a clean, dry, smooth painted surface. Surface temperature should be between 15° C (59° F) and 27° C (80.6° F).

  1. Remove old 370-7636 Film. Refer to Illustration 46 for the location of the film. Discard the pieces.

  2. Remove old 205-3229 Film. Refer to Illustration 46 for the location of the film. Discard the pieces.

  3. Clean the surfaces with a 1:1 mixture of isopropyl (IPA) and water. Use a clean, lint-free paper towel to remove all dirt and adhesive from the surfaces. Allow the surfaces to dry before installing the replacement film.

    Note: Never use acetone (propanone) to clean the engine or label surface.

Applying Adhesive Labels

  1. Carefully remove the new 464-2496 Film from the backing. Immediately apply the label in place of the old film. Refer to Illustration 46 for the correct position.

    Note: Avoid trapping air bubbles under the label material.

  2. Apply pressure to entire label to ensure adhesion.

  3. Wait at least 60 minutes before disturbing the label.

Disabling the Product Link Lockout

If Product Link Japan is installed on migrated machine, the machine lockout system must be disabled. This disable configuration setting is needed to prevent the engine start limitation.

  1. Access to machine ECM configuration in AVSpare Electronic Technician (Cat® ET).

  2. Change the "Machine Lockout System Installation Status" to the setting of "Not Installed".

Instruction to Customers

Inform the customer of the following:

  1. Drain water in fuel system water separator every 10 hours, or daily, as indicated in the maintenance interval chart located inside the cab.

  2. When replacing the fuel system primary filter (water separator) element, torque the water level sensor to 2.5 ± 0.5 N·m (22.13 ± 4.43 lb in). This equates to 1 to 1.5 turns after you start feeling the resistance when tightening by hand.

    Note: Be sure to not over torque the sensor more than torque specifications. Damage may occur to sensor.

Information System:

312F and 313F Excavator Machine Systems Machine System
Software Updates for Certain Tier 4 Final Machines {1920, 7620}
924K, 926M, 930K, 930M, 938K and 938M Wheel Loaders Information Display Event Codes
924K, 926M, 930K, 930M, 938K and 938M Wheel Loaders Information Display Diagnostic Trouble Codes
924K, 926M, 930K, 930M, 938K and 938M Wheel Loaders Information Display Determining Diagnostic Trouble Codes
924K, 926M, 930K, 930M, 938K and 938M Wheel Loaders Information Display Diagnostic Capabilities
924K, 926M, 930K, 930M, 938K and 938M Wheel Loaders Information Display Service Menu
C2.4 Tier 4 Final Engines for Caterpillar Built Machines Inlet and Exhaust Valves - Remove and Install
314F and 315F Excavators Safety Messages
Cat<SUP>&reg;</SUP> Electronic Technician (ET) Version 2015C or Higher is Required When Installing Engine Software on a Blank Engine ECM for a C3.4B Machine Engine {7610, 7620}
Improved Expansion Tank Lines Are Now Used on Certain 568 Forest Machines {1354, 1377}
308E2 CR and 308E2 SR Mini Hydraulic Excavators Boom and Stick Linkage - Lubricate
PM620, PM622, PM820, PM822 and PM825 Cold Planers Electronic System Sensor Signal (PWM) - Test
312F and 313F Excavator Machine Systems Pilot System
300.9D VPS Mini Hydraulic Excavator Machine Systems Blade Hydraulic System
312F and 313F Excavator Machine Systems Pump Control (Output Flow) - Test - One Pump Calibration (Optional Test)
312F and 313F Excavator Machine Systems Pump Control (Output Flow) - Test - Two Pump Calibration
A New Diesel Exhaust Fluid Filter is Now Available for C7.1 Engines {108J}
Exhaust Gas Valve (NRS) for C4.4 Engines {5137}
C2.4 Tier 4 Final Engines for Caterpillar Built Machines Crankshaft Front Seal - Remove and Install
A New Filter is Available for the DEF Tank Adaptor for C7.1 Engines {108H}
324D and 325D Forest Machines Machine Systems Track - Separate - PPR2
324D and 325D Forest Machines Machine Systems Track - Connect - PPR2
349D2 MHPU Mobile Hydraulic Power Unit Hydraulic System Swing Speed and Swing Drift on a Slope - Check