- Cold Planer
- PM-200 (S/N: P1C1-UP; P1M1-UP)
Introduction
This Special Instruction will describe the steps needed to install the fuel cooler system on the above listed cold planers.
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information. Understand the information before you order any parts or perform any work.
Safety Section
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.
Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.
Ensure that all personnel are safe when using a tool, procedure, work method, or operating technique not recommended by Caterpillar. Ensure that the product will not be damaged or the product made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.
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Do not attempt to assemble this machine until you read and you understand the assembly instructions. Improper assembly procedures could result in injury or death. |
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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on. |
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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates. |
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Do not allow any dirt or foreign material to get into the hydraulic system during assembly, connection of lines, when components are filled with fluid, or during any maintenance operation. |
Reference
Reference: Special Instruction, SEHS7332
Reference: Operation & Maintenance Manual, KEBU8005
Required Parts
| Required Parts List | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 2 | 6V-8995 | Union |
| 2 | 1 | 489-3055 | Support As |
| 3 | 1 | 489-3255 | Bracket |
| 4 | 1 | 489-3257 | Bracket |
| 5 | 1 | 334-3325 | Fuel Cooler Core |
| 6 | 4 | 8T-4136 | Bolt |
| 7 | 16 | 7X-7729 | Washer |
| 8 | 8 | 8T-4133 | Nut |
| 9 | 2 | 489-4514 | Bracket |
| 10 | 4 | 8T-7547 | Bolt |
| 11 | 6 | 5P-4116 | Hard Washer |
| 12 | 2 | 5P-7970 | Nut |
| 13 | 4 | 8T-4195 | Bolt |
| 14 | 1 | 492-3406 | Hose As |
| 15 | 1 | 492-3407 | Hose As |
| 16 | 1 | 492-3384 | Hose As |
| 17 | 1 | 492-3385 | Hose As |
| 18 | 2 | 154-6583 | Half Clamp |
| 19 | 1 | 102-8705 | Plate |
| 20 | 1 | 7X-0818 | Bolt |
| 21 | 2 | 6V-9169 | Nut |
| 22 | 4 | 8T-4123 | Washer |
| 23 | 4 | 6V-8398 | O-Ring Seal |
| 24 | 2 | 6V-8638 | Connector |
| 25 | 2 | 228-7090 | O-Ring Seal |
| 26 | 2 | 238-5081 | O-Ring Seal |
Installation Procedure
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| Illustration 1 | g00104545 |
Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch before you service the equipment. These warning tags (Special Instruction, SEHS7332) are available from your Caterpillar dealer.
Machine Preparation
- Prevent the machine from movement. Park the machine on a level surface.
- Follow instructions in the Operation & Maintenance Manual, KEBU8005 to open the engine hood and rear hood.
- Turn the engine start switch OFF position.
- Turn the battery disconnect switch to the OFF position. Place lockout/tag out in the battery disconnect switch.
Frame Rework
- Open engine compartment hood (A).
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Illustration 3 g06065840 Show/hide table
Illustration 4 g06065844 - Remove bolts (C) and lift the rear hood (B).
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Illustration 5 g06067482 (D) is 280.0 mm (11.02 inch)
(E) is75.0 mm (2.95 inch) - Remove the indicated section (F) from the rear door.
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Illustration 6 g06067486 (H) is 95.0 mm (3.74 inch)
(J) is100.0 mm (3.94 inch)
(K) is40.0 mm (1.57 inch) - Remove the indicated section (G) from the rear door.
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| Illustration 2 | g06065833 |
Installation Procedure of Fuel Cooler
- Open access door (L) on the left rear side of the machine.
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Illustration 8 g06067528 (N) is 45.0 mm (1.77 inch)
(P) Diameter is22.0 mm (0.87 inch) at two places
(R) is225.0 mm (8.86 inch)
(S) is50.0 mm (1.97 inch) - Drill two holes (M) as per dimensions shown in Illustration 8.
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Illustration 9 g06075670 (1) 6V-8995 Union
(21)6V-9169 Nut
(22)8T-4123 Washer
(23)6V-8398 O-Ring Seal - Install new union (1a) using nut (21), two washers (22), and two O-Ring seals (23) to the drilled holes on Step 2.
- Similarly install union (1b) using nut (21), two washers (22), and two O-Ring seals (23) to the other drilled hole on Step 2.
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Illustration 10 g06067540 - Remove and discard support (T).
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Illustration 11 g06067545 (2) 489-3055 Support As - Install new support assembly (2).
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Illustration 12 g06067549 - Remove two bolts (U) and two bolts (V). Save two bolts (V) and discard bolts (U).
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Illustration 13 g06067555 (3) 489-3255 Bracket
(4)489-3257 Bracket - Install new bracket (3) and secure using bolt (V) that was saved in Step 7.
- Install new bracket (4) and secure using bolt (V) that was saved in Step 7.
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Illustration 14 g06067583 (5) 334-3325 Fuel Cooler Core
(6)8T-4136 Bolt
(7)7X-7729 Washer
(8)8T-4133 Nut - Install new fuel cooler core (5) to the brackets. Secure using four bolts (6), eight washers (7), and four nuts (8).
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Illustration 15 g06075676 (5) 334-3325 Fuel Cooler Core
(24)6V-8638 Connector
(25)228-7090 O-Ring Seal
(26)238-5081 O-Ring Seal - Install two connectors (24) using two O-Ring seals (25), and two O-Ring seals (26) to fuel cooler core (5).
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Illustration 16 g06067662 (3) 489-3255 Bracket
(4)489-3257 Bracket
(9)489-4514 BracketShow/hide table
Illustration 17 g06067672 (3) 489-3255 Bracket
(7)7X-7729 Washer
(8)8T-4133 Nut
(9)489-4514 Bracket
(10)8T-7547 Bolt
(11)5P-4116 Hard Washer
(12)5P-7970 Nut
(13)8T-4195 Bolt - Attach bracket (9) to bracket (3) using two bolts (13), four washers (7), and two nuts (8). Refer to Illustration16 and Illustration 17.
- Secure bracket (9) with support (X) using bolt (10), two hard washers (11), and nut (12). Refer to Illustration 17.
- Repeat Step 12 and Step 13 to attach bracket (4) with bracket (9) on other side of support (X).
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Illustration 18 g06067702 (1) 6V-8995 Union
(14)492-3406 Hose As
(15)492-3407 Hose As - Install new hose assembly (14) and route from fitting (Y) of cooler to union (1a).
- Install new hose assembly (15) and route from fitting (Z) of cooler to union (1b).
Note: Use zip ties (AA) to secure hose assemblies at location shown in Illustration 18.
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Illustration 19 g06067717 - Open rotor drive belt covers (AB).
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Illustration 20 g06067720 - Remove cover (AC).
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Illustration 21 g06067727 Show/hide table
Illustration 22 g06067729 - Remove fuel return to tank hose assembly (AD) connected to advance high efficiency fuel filter fitting (AE) to the top left side of fuel tank (AF).
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Illustration 23 g06067742 Show/hide table
Illustration 24 g06067746 - Keep hoses (AG) away from moving components.
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Illustration 25 g06067782 (1) 6V-8995 Union
(16)492-3384 Hose As
(17)492-3385 Hose As
(18)154-6583 Half Clamp
(19)102-8705 Plate
(20)7X-0818 Bolt - Install and route hose assembly (16) from union (1a) to fitting (AE) of the advance high efficiency fuel filter.
- Install and route hose assembly (17) from union (1b) to fitting (AF) of fuel tank.
- Secure hose assemblies to support assembly (2) with two half clamps (17), plate (18), and bolt (19).
- Start engine and inspect connections for leaks.
- Stop engine, replace cover (AC), close doors (AB), and close rear hood (B) and secure with bolts (C). Close engine hood (A).
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| Illustration 7 | g06067491 |
