9101F4-5625 Tohatsu BOLT

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 C15 Engines:
Required service tools
Requirements for the flash files and new interlock codes
Removal procedure for existing inlet air piping
Installation for the air inlet shutoff
Wiring connections and the corresponding functions that are available to the customerReferenceInformation from the following sources will be needed for this Special Instruction:
Troubleshooting Guide, RENR2238
Troubleshooting Guide, SENR9698
Troubleshooting Guide, RENR9343Required 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 Table 2 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
H/P     LB/FT Torque     Flash File     New Interlock Code    
435/500     1550/1650     277-3086     23    
475     1650     277-3088     47    
475     1850     277-3089     48    Remove the existing Inlet Air Piping
Illustration 1 g01306522
(1) 109-4203 Elbow (2) 101-3125 Gasket (3) 0S-1588 Bolts (4) 5M-2894 Hard Washers (5) 129-3172 Stud
Remove the three bolts (3), stud (5), and washer (4) .
Remove elbow (1) and gasket (2). Ensure that all of the gasket material has been removed.
Disconnect the line clamps for the air conditioner from the manifold.Note: Do not loosen the fluid connections.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 g01306622
(2) 101-3125 Gasket (6) 243-2316 Adapter (7) Cylinder head (8) 248-4841 Band Clamp (9) 226-4752 Air Shutoff Gp
Illustration 3 g01310466
(10) 8T-4136 Bolts (11) 0S-1588 Bolts
Mount gasket (2) and adapter (6) to cylinder head (7) by using bolts (11) and washers (4) to secure the adapter to the cylinder head. Refer to Illustrations 1 and 2. Tighten the bolts to 47 9 N m (35 7 lb ft).
Mount air inlet shutoff (9) by using band clamp (8) and a 6V-6353 O-Ring Seal . Torque the clamp to 8 4 N m (70 35 lb in).
Illustration 4 g01310652
(8) 248-4841 Band Clamp (12) 203-0351 Air Elbow
Mount air elbow (12) to the air inlet shutoff by using band clamp (8) and a 6V-6353 O-Ring Seal . Torque the clamp to 8 4 N m (70 35 lb in).
Mount the 241-8371 Magnetic Switch Gp to the adapter by using bolts (10) and use new washers (4). Tighten the bolts to 47 9 N m (35 7 lb ft). Refer to Illustration 3. The relay can be installed with the battery wire conne