78638 2 Mercury STUD, (.437-14/.437-20 x 3.120)

Introduction
Do not perform any procedure in this Special Instruction until you read this information and you understand this information.This Special Instruction provides the following information for C-10 and C-12 Engines:
Required service tools
Requirements for the flash files and new interlock codes
Removal procedure for existing inlet air piping
Installation procedures for the air inlet shutoff
Wiring connections and the corresponding functions that are available to the customer
Initial start-up proceduresReferenceInformation from the following sources will be needed for this Special Instruction:
Troubleshooting Guide, SENR9683
Troubleshooting Guide, SENR2238Required Service Tools
Caterpillar Electronic Technician (ET)
The following components are required to use Cat ET to service the engine.
Table 1
Required Electronic Service Tools for the Use of Cat ET    
Part Number    Description    
    Caterpillar Electronic Technician    
JERD2124     "Electronic Technician Program" (Cat ET)    
JERD2125     "Electronic Technician Truck Engine Data Subscription"    
or        
JERD2129     "Electronic Technician Engine/Machine Data Subscription"    
171-4400 (1)     Communication Adapter II Gp    
237-7547 (2)     Adapter Cable As    
( 1 ) The 7X-1700 Communication Adapter Gp may also be used.
( 2 ) The 237-7547 Adapter Cable As is required to connect to the USB port on computers that are not equipped with a RS232 serial port.Two short jumper wires are needed to check the continuity of some wiring harness circuits. A long extension wire may also be needed to check the continuity of some wiring harness circuits.Refer to Troubleshooting, "Electronic Service Tools" for more information on electronic service tools.Check for the Proper Flash Files
Before proceeding with the installation of the new air inlet shutoff, connect the engine to the Caterpillar Electronic Technician (ET) in order to verify that the engine has the correct flash file. Refer to Tables 2 and 3 for the flash file (personality module) and the proper interlock code. If you do not find the personality module part number currently in the engine you must flash the correct file to the engine. Refer to Troubleshooting, "Flash Programming" for more information on flash programming.
Table 2
Flash Files for Air Inlet Shutoff for the C-10    
H/P     LB/FT Torque     Flash File     New Interlock Code    
335     1250     224-4616     17    
335     1250     224-4619     26    
Table 3
Flash Files for Air Inlet Shutoff for the C-12    
H/P     LB/FT Torque     Flash File     New Interlock Code    
410     1450/1550     224-4617     37    
410     1450/1550     215-7371     63    
430     1650     224-4618     36    Remove the Existing Inlet Air Piping
Illustration 1 g01306372
Typical example of the air inlet elbow (1) 109-4203 Elbow (2) 6V-5218 Bolt (3) 9M-1974 Hard Washer
Remove the four bolts (2) and remove the four hard washers (3) .
Remove the elbow (1) and the 101-3125 Gasket . Ensure that all of the gasket material has been removed.
Disconnect the line clamps for the air conditioner from the manifold. It is not necessary to remove the front bracket from the manifold on C-12 engines.Note: Do not loosen the fluid connections..
Remove both the brackets on C-10 engines. The brackets and the retaining bolts will be reused later in this procedure.Installation of the Air Inlet Shutoff
Note: When you receive the air inlet shutoff the shutoff will be in the Closed position. Open the air inlet shutoff by using a wrench and rotate the hex head of the operating shaft in a counterclockwise direction for 1/4 turn. You may want to write open or closed on the air inlet shutoff.
Illustration 2 g01306467
(4) 211-7861 Elbow (5) 1W-2431 Band Clamp (6) 215-6860 Air Shutoff Gp (7) Air intake manifold (8) 9X-2842 Bolt (9) 211-7855 Adapter (10) 6V-2317 Bolts
Mount the adapter (9) to air intake manifold (7). Use bolts (8) and bolt (10) with washer (3). Tighten the bolts to 47 9 N m (35 7 lb ft). Install 068-9526 Tube Cap over bolt (10) .Note: Upon installation of the 141-8649 Bracket for the air conditioning, washer (3) is required between the bracket and the adapter for the manifold. Standard lubrication for O-ring assembly may be used to hold the O-ring seals for the flange in place during assembly.
Mount air inlet shutoff (6) to adapter (9) by using band clamp (5) and a 6V-6353 O-Ring