SIS

Installing Optional Migration Kits on C9.3 through C15 ACERT Tier 4 Interim Machine Engines
{1000, 1261, 1380, 775E}
-REHS9720-09 -24/09/2015 -19/09/2017

i07181315

Installing Optional Migration Kits on C9.3 through C15 ACERT Tier

4 Interim Machine Engines {1000, 1261, 1380, 775E}
SMCS - 1000; 1261; 1380; 775E

Articulated Truck
735B (S/N: T4P1-UP)
740B (S/N: T4R1-UP)
740B EJECTOR (S/N: T4S1-UP)
Excavator
336E (S/N: JEA1-UP; RZA1-UP; KED1-UP; YCE1-UP; TEG1-UP; BMH1-UP; FJH1-UP; GTJ1-
UP; JRJ1-UP; SSL1-UP; YEP1-UP; CMR1-UP; HDW1-UP; DPX1-UP; BZY1-UP; GNY1-UP;
TMZ1-UP)
349E (S/N: FJB1-UP; ETC1-UP; DGE1-UP; SPG1-UP; TFG1-UP; RGH1-UP; FEJ1-UP; KCN1-UP;
MZW1-UP; KFX1-UP; MPZ1-UP; WHZ1-UP)
Mobile Hydraulic Power Unit
336E MHPU (S/N: PCE1-UP; RBS1-UP; T3Z1-UP)
Motor Grader
12M Series 2 (S/N: F9B1-UP; F9M1-UP; R9P1-UP; R9S1-UP)
140M Series 2 (S/N: M9D1-UP; R9G1-UP; M9J1-UP; R9M1-UP)
160M Series 2 (S/N: M9E1-UP; M9K1-UP; R9L1-UP; R9T1-UP)
Track-Type Tractor
D6R (S/N: T3J1-UP)
D6T (S/N: KSB1-UP; ZJB1-UP; JZC1-UP; DTD1-UP; EJJ1-UP; SLJ1-UP; GMK1-UP; RRK1-UP;
TSM1-UP; WLM1-UP; PLR1-UP; JRW1-UP; RCW1-UP)
D7E (S/N: TJA1-UP; TAN1-UP)
D8T (S/N: MLN1-UP; FCT1-UP)
Wheel Loader
966K (S/N: PBG1-UP; TFS1-UP)
966K Series XE (S/N: NGX1-UP)
972K (S/N: PEM1-UP; Z4W1-UP)
980K (S/N: W7K1-UP; NEP1-UP; GTZ1-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 optional migration kits on C9.3 through C15 ACERT
Tier 4 Interim Machine Engines.

Read the entire Special Instruction and understand the information before you perform any procedures.

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Migration Kit Part Numbers
Table 1
Sales Model Migration Kit Part Number
12M2 481-6747(1)
140M2
481-6748(1)
160M2
D6T 481-6751(1)
D7E 481-6752(1)
D8T 481-6753(1)
336E
481-8175(1)
336E H
349E 509-9290(1)
735 481-8176(1)
740 481-8177(1)
966K
966K XE 481-8178(1)
972K
980K 481-8181(1)
(1)
Order the emissions labels first. The ordering process can take some time.

Note: All required parts listed in the Special Instruction are included in Table 1 kits.

Instructions for Ordering 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 1 g06174531

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

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 Illustration 2 g06174530

3. Click Migration / Decertification Request – C9.3 - C15.

4. The Migration / Decertification Request form will appear. All fields marked with an "*" must be
completed. Refer to Table 1 for the Migration Kit Part Number.

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 3 g03890905
(1) "Reference Number" field
(2) Drop down box
(3) "Retrieve Data"
(4) Current "Engine Arrangement Number"

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

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

c. Click "Retrieve Data".

Fuel System Conversion

Required Parts

Table 2
Sales Cap for ARD Fuel Plug and O-ring for Diverter Cap for ARD Fuel
Model Pump Valve Manifold
12M2
360-3693 Plug
140M2 6V-9828 6V-9829
033-6028 O-Ring Seal
160M2
D6T 6V-9829 360-3693 Plug 6V-9829
D7E 033-6028 O-Ring Seal
D8T
336E

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 336E H
349E
735
740
966K
966K XE
972K
980K

Conversion Procedure

Illustration 4 g03887760
(1) Fuel diverter valve
(2) Fuel outlet port fitting

1. Remove fuel diverter valve (1) from the ARD fuel pump.

2. Plug the diverter valve port with a 360-3693 Plug and 033-6028 O-Ring Seal.

3. Disconnect the existing fuel line from fitting (2) and cap the fitting with the cap assembly specified in
Table 4.

Note: The fuel pump will remain operational to prime the engine fuel system.

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 Illustration 5 g03888062
(3) ARD fuel manifold inlet fitting
(4) 6V-9829 Cap As

4. Disconnect the fuel line attached to fitting (3) and discard the hose.

5. Cap fitting (3) using cap assembly (4).

Exhaust System Conversion

Required Parts

Table 3
Sales Model Muffler Kit Part Number
12M2 469-7576
140M2
469-7582
160M2
D6T 469-7582
D7E 469-7576
D8T 469-7583
336E
469-7582
336E H
349E 469-7584
735
469-7584
740

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 966K
966K XE 474-4453
972K
980K 469-7584

Conversion Procedure

Illustration 6 g03890235
(1) Diesel Particulate Filter (DPF) straps
(2) DPF center section

Illustration 7 g06074938
Incorrect alignment

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 Illustration 8 g06074942
Correct alignment

1. Put identification marks on both sides of clamp assemblies (1) for installation purposes

2. Disconnect exhaust stack with outlet assembly.

3. Disconnect straps (1) to remove the diesel particulate filter group.

4. Attach a suitable lifting device to the DPF.

5. Remove the DPF center section.

6. Install new muffler kit specified in Table 3 in place of the DPF center section. Be sure to fully engage the
pin and slot on both sides of the muffler.

7. Position the muffler assembly and tighten the new strap groups (1) to a torque of 15 +3/-0 N·m
(11 +2/-0 lb ft) after aligning the new straps with the identification marks on the inlet and outlet sections.

Rework Procedure for 349E

Machines have a possibility of exhaust leaking from the hole.

1. Plug the hole at the bottom of the exhaust pipe.

2. Use high temperature paste with a tolerance (above 600° C (1112° F)).

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 Illustration 9 g06120718

3. Plug and spread the paste around the hole approximately 2 cm in diameter. As shown in Illustration 9.

Cooling System Conversion

Required Parts

Table 4
Sales Plug Assemblies or Cap Assemblies for Coolant Plugs and O-rings for Coolant
Model Fittings (Engine Side) Fittings (CEM Side)
12M2
398-5598 Plug As
140M2
396-0404 Plug As
160M2
307-2671 Plug As
D6T
398-5612 Plug As
307-2671 Plug As
D7E
307-2673 Plug As
D8T (Std) 353-5126 Plug As
D8T (EU) 353-5124 Plug As

336E
Two 9S-8002 Plugs
336E H Two 6V-9828 Cap As Two 6V-9027 O-Ring Seals

349E
735B 398-5612 Plug As
740B 353-5124 Plug As

966K
396-0405 Plug As
966K XE
396-0404 Plug As
972K
353-5140 Plug As
980K
6V-9828 Cap As

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Conversion Procedure

12M2, 140M2, and 160M2 Motor Graders

Illustration 10 g03888492
(1) 398-5598 Plug As
(2) 396-0404 Plug As

1. Disconnect the coolant lines and remove the fittings from the locations shown in Illustration 10. Replace
the existing fittings with plugs (1) and (2).

2. Remove and discard coolant lines from the machine.

D6T Track-Type Tractors

Illustration 11 g03888675

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 (3) 307-2671 Plug As
(4) 398-5612 Plug As

1. Disconnect the coolant lines and remove the fittings from the locations shown in Illustration 11. Replace
the existing fittings with plugs (3) and (4).

2. Remove and discard coolant lines from the machine.

D7E Track-Type Tractors

Illustration 12 g03888697
(5) 307-2671 Plug As
(6) 307-2673 Plug As

1. Disconnect the coolant lines and remove the fittings from the locations shown in Illustration 12. Replace
the existing fittings with plugs (5) and (6).

2. Remove and discard coolant lines from the machine.

D8T Track-Type Tractors

Illustration 13 g03888710
(7) 353-5126 Plug As
(8) 353-5124 Plug As

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 1. Disconnect the coolant lines and remove the fittings from the locations shown in Illustration 13. Replace
the existing fittings with plugs (7) and (8).

2. Remove and discard coolant lines from the machine.

336E and 349E Excavators

Illustration 14 g03888727
(9) 6V-9828 Cap As

1. Disconnect the coolant lines and cap the lines shown in Illustration 14 with cap assemblies (9).

2. Remove and discard coolant lines from the machine.

735B and 740B Articulated Trucks

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 Illustration 15 g03888743
(10) 398-5612 Plug As
(11) 353-5124 Plug As

1. Disconnect the coolant lines and remove the fittings from the locations shown in Illustration 15. Replace
the existing fittings with plugs (10) and (11).

2. Remove and discard coolant lines from the machine.

966K and 972K Wheel Loaders

Illustration 16 g03888760
(12) 396-0405 Plug As
(13) 396-0404 Plug As

1. Disconnect the coolant lines and remove the fittings from the locations shown in Illustration 16. Replace
the existing fittings with plugs (12) and (13).

2. Remove and discard coolant lines from the machine.

980K Wheel Loaders

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 Illustration 17 g03888770
(14) 6V-9828 Cap As
(15) 353-5140 Plug As

1. Disconnect the coolant lines and remove the fittings from the locations shown in Illustration 17. Replace
the existing fittings with cap (14) and plug (15).

2. Remove and discard coolant lines from the machine.

All Applications

Illustration 18 g03891808
Typical example
(16) ARD coolant manifold
(17) Coolant lines

1. Disconnect coolant lines (17) from manifold (16). Remove and discard coolant lines (17) from the
machine.

2. Replace the coolant fittings on manifold (16) with two 9S-8002 Plugs and two 6V-9027 O-Ring Seals.

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

Table 5
Sales Model Software Part Number
12M2 483-3705
140M2 483-3704
160M2 483-3703
D6T 486-2751
D7E 487-6050
D8T 482-9922

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 336E 481-8234
336E H 481-8235
349E 507-8936
735 483-3650
740 483-4183
966K 483-7468
966K XE 483-7470
972K 483-7467
980K 483-7465

Note: Factory passwords are required to install the decertification flash file.

1. Download the decertification flash file from Service Information System (SIS). Refer to Table 5.

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

Illustration 19 g03672156

3. When the decertification flash file is downloaded, this screen will appear in the electronic service tool.
Refer to Illustration 19.

4. Click "Save to File". This action 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 outlined in Special Instruction,
REHS9720. 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 has been ordered and will
be applied as per Special Instruction, REHS9720.

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

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 7. Once the factory passwords have been entered, install the flash file. Refer to Troubleshooting, "ECM
Software - Install"

Machine Labels
The certified emissions labels are located in the machine cab and on the engine block. These labels must be
removed. The new decertified emissions labels must then be installed in the machine cab and on the engine block.
Refer to the information below for label removal and installation instructions.

Removing Adhesive Labels

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 films and discard the pieces.

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

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

Applying Adhesive Labels

1. Carefully remove the new film from the backing. Immediately apply the label in place of removed film.

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 labels.

Removing Spark Plug Maintenance Interval Information on 336E and

349E Excavators

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 Illustration 20 g03894160

1. Use the following steps to set the "Spark Plug" interval to "0".

a. Press "Service" in the main menu.

b. Press "Configuration".

c. Press "Recommended Interval".

d. Press "Spark Plug"

e. Set the interval to "0".

1. Use the following steps to set the "Fuel Priming Pump" interval to "Off".

a. Press "Service" in the main menu.

b. Press "Configuration".

c. Press "Recommended Interval".

d. Press "Fuel Priming Pump"

e. Set the interval to "Off".

Note: Once the "Recommended Interval" is set as "0", the spark plug information is no longer shown on the
"Maintenance Intervals" menu.

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Illustration 21 g03894045

Disabling the Product Link Lockout on 336E and 349E Excavators

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 Caterpillar Electronic Technician (Cat ® ET).

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

1993 — 2018 FriM ay 4 03:32:15 U TC+ 0800 2018

SIS

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