PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE NRS VENTURI, THERMOSTAT, ENGINE SOFTWARE, AND MACHINE SOFTWARE ON CERTAIN D6T AND D7E TRACK-TYPE TRACTORS

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE NRS VENTURI, THERMOSTAT, ENGINE SOFTWARE, AND MACHINE SOFTWARE ON CERTAIN D6T AND D7E TRACK-TYPE TRACTORS - MULTIPLE REPAIRS

Usage:

REBE7560-03

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24Oct2011

(Revised 15Mar2012)

U-458

O-406

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE NRS VENTURI, THERMOSTAT, ENGINE SOFTWARE, AND MACHINE SOFTWARE ON CERTAIN D6T AND D7E TRACK-TYPE TRACTORS - MULTIPLE REPAIRS
1071 1355 1901 7620 108F		PI31938

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31938" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. Exception: If the repair is done after failure, use "PI31938" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:

The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.

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NOTE:	This Revised Service Letter replaces the 24Oct2011 (Revised 17Feb2012) Service Letter. Changes have been made to the Affected Product.

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COMPLETION DATE	TERMINATION DATE
30Apr2012	31Oct2012

PROBLEM

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Multiple updates are needed on the D6T and D7E Track-Type Tractors. The NRS venturi needs updated to avoid potential soot plugging that can occur with the current design. The thermostat needs updated to provide better engine coolant temperature regulation primarily in cold weather and the engine software needs updated to provide a number of engine operation and DPF regeneration improvements also in cold weather. Various machine software is being updated to provide the latest enhancements to the machine systems.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
D7E	TAN00408-00416, 420-423, 425-429, 432-441, 443-451, 455-456, 460-461, 467, 469-471
D7E LGP	TJA00425-00427, 431, 433, 436-443, 445, 451-452, 456

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*****Group 2*****
D6T LGP	KSB00226-00346, 348-352 ZJB00154-00216, 218-315, 318-354, 356
D6T LGP OEM	PLR00100-00103
D6T XL	DTD00175-00212 GMK00101-00161, 163-170, 172-174, 176-178, 180, 182, 184-218, 220, 226, 228-239, 241-242, 245-252, 254, 263-277, 282-363, 366-396, 399-425, 428-475
D6T XW	RCW00200-00289 SLJ00126-00213, 215-229, 246, 258

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	3J7354	SEAL-O-RING
1	4B4276	WASHER
2	4J5477	SEAL-O-RING-ORFS
1	4P8134	CLIP-LADDER
4	5P8245	WASHER-HARD
2	6V5684	BOLT-HEX HEAD
1	6V8628	ADAPTER-ELBOW
2	6V8675	BOLT
1	6V8780	ADAPTER-TEE
1	6V8836	BOLT-HEX HEAD
1	7K1181	STRAP-CABLE
1	7X7729	WASHER-HARD
2	8T0100	BOLT-HEX HEAD
2	8T4121	WASHER-HARD
2	8T4137	BOLT-HEX HEAD
1	8T4182	BOLT-HEX HEAD
2	9M1974	WASHER-HARD
1	9N5085	CLAMP-V-BAND
1	1195152	EXTENDER
1	1214345	SEAL-O-RING-ORFS
1	1243019	BRACKET AS.
1	1333260	SPACER
2	2022762	CLIP-LOOP
1	2263492	BRACKET AS.
1	2287101	SEAL-O-RING-STOR
1	2905664	MOUNT-FIR TREE
4	3147599	CLAMP-BAND
1	3203061	SENSOR GP-PRESS (if needed)
1	3329517	TUBE AS
1	3353438	HOSE AS
1	3537160	BRACKET AS-AIR
1	3561949	SFWR GP-A3011
1	3690805	ADDITIVE-COOLANT
1	3692072	SFWR GP-A2000
1	3754337	SFWR GP-A3018
1	3759548	SFWR GP-A3019
1	3773016	REGULATOR-TEMP
1	3791576	SFWR GP-A4014
1	3808541	TUBE-VENTURI
1	3808557	ELBOW-AIR
2	3808558	HOSE
1	3819172	EYE-LIFTING
1	3820838	SFWR GP-A3000
1	3824384	SENSOR GP-PRESS
1	3849571	SFWR GP-A2038
1	3858165	SOFTWARE GP-ELEK
1	3879543	SFWR GP-A5011
1	3879544	SFWR GP-A5012
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 2*****
2	1P4278	CLAMP-HOSE
1	3J7354	SEAL-O-RING
1	4B4276	WASHER
2	4J5477	SEAL-O-RING-ORFS
1	4P8134	CLIP-LADDER
70	5P1465	HOSE
4	5P8245	WASHER-HARD
1	6V1355	ADAPTER-ELBOW
2	6V5684	BOLT-HEX HEAD
2	6V8202	BOLT-HEX SOCKET
2	6V8675	BOLT
1	6V8780	ADAPTER-TEE
1	6V8836	BOLT-HEX HEAD
2	6V9027	SEAL-O-RING
1	7K1181	STRAP-CABLE
1	8M2770	CLIP-LOOP
1	8M2772	CLIP-LOOP
2	8T0100	BOLT-HEX HEAD
2	8T4121	WASHER-HARD
1	8T4136	BOLT-HEX HEAD
1	8T4137	BOLT-HEX HEAD
4	9M1974	WASHER-HARD
1	9N5085	CLAMP-V-BAND
1	9Y7595	SPACER
1	1195152	EXTENDER
1	1214345	SEAL-O-RING-ORFS
1	2287101	SEAL-O-RING-STOR
1	2905664	MOUNT-FIR TREE
4	3147599	CLAMP-BAND
1	3203061	SENSOR GP-PRESS (if needed)
1	3217938	TUBE AS
1	3329517	TUBE AS
2	3410643	SEAL-RECTANGULAR
1	3537160	BRACKET AS-AIR
1	3659858	SENSOR GP-PRESS (if needed)
1	3690805	ADDITIVE-COOLANT
1	3773016	REGULATOR-TEMP
1	3808541	TUBE-VENTURI
1	3808557	ELBOW-AIR
2	3808558	HOSE
1	3817139	SFWR GP-A2000
1	3817141	SFWR GP-A5000
1	3819172	EYE-LIFTING
1	3858110	SOFTWARE GP-ELEK
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 35% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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Refer to the Rework Procedure.

An owner notification letter will not be sent out with this program.

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SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 8.0-hour job for Group 1

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 10.0-hour job for Group 2

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Rework Procedure

Group Number 1

D7E NRS Venturi Replacement

1. Tilt the cab on the machine. Refer to "Cab - Tilt - Full Tilt" in the Disassembly and Assembly manual for the D7E Track-type tractor machine systems.

2. Remove the cover on the rear of the engine enclosure. Refer to Image1.3.1.

Image1.3.1

4. Disconnect the harness and remove the NRS intake pressure sensor from the venturi. Disconnect and remove the NRS delta pressure sensor from the venturi. The zip tie will need to be cut to remove NRS delta pressure sensor.

NOTE: The sensors will be re-used. Do not discard the sensors.

Refer to Image1.4.1.

Image1.4.1

5. Remove the two bolts that connect the NRS venturi to the elbow.

Remove the bolt that connects the NRS venturi to the engine. Refer to Image1.5.1.

Image1.5.1

6. Loosen the hose clamps from hose the connects the NRS cooler to the NRS venturi.

Separate the venturi from the exhaust tube. Remove the venturi and hose. The hose that connects the NRS cooler to the NRS venturi may be cut to aid in the removal.

8. Loosen the clamp that connects the exhaust tube to the NRS valve. Remove the exhaust tube. Refer to Image1.7.1.

Image1.7.1

9. Remove the two bolts holding the bracket to engine. Remove the bracket. Refer to Image1.8.1.

Image1.8.1

10. Remove the three bolts the hold the lifting eye to the engine. Remove the engine lifting eye.

11. This concludes the removal portion of the NRS venturi replacement.

12. Install the 381-9172 Engine Lifting Eye using two 6V-8675 Bolts, and two 5P-8245 Washers. Tighten the bolts to 100 Nm.

NOTE: There will be a fifth bolt hole in the lifting eye in location number two of Image1.11.1. Do not install a bolt in this location.

Image1.11.1

13. Install 380-8558 Hose on to the NRS cooler outlet. Also install two 314-7599 Hose Clamps on to the hose. Keep the clamps loose until all the remaining hardware is installed. Make sure that the fasteners for the clamps are pointed outward to make tightening them easier.

14. Install 380-8541 Venturi on to 353-7160 Bracket using two 8T-0100 Bolts and two 9M-1974 Washers. Do not tighten the bolts. Refer to Image1.13.1.

Image1.13.1

15. Install the venturi/bracket assembly on the engine by slipping the venturi inlet end into the hose that is connected to the NRS cooler. Install two 6V-5684 Bolts and two 5P-8245 washers to connect the bracket to engine. Tighten the bolts to 100 Nm.

16. Install 380-8558 Hose and 314-7599 Hose Clamps to the outlet of the venturi. Keep the clamps loose until all remaining hardware is installed. Make sure that the fasteners for the clamps are pointed outward to make tightening them easier.

17. Install 9N-5085 Clamp to the flange on the NRS valve inlet.

Install 380-8557 Elbow between the NRS valve and the NRS venturi. Secure the clamp on the NRS valve inlet to mating flange on 380-8557 Elbow. Do not tighten clamp. Refer to Image1.16.1.

Image1.16.1

18. Ensure all the hardware is loosely in place. Tighten the two bolts the connect the venturi to the engine. The torque for the bolt is 28 Nm. Refer to (1) in Image1.17.1.

Tighten the 9N-5085 Clamp the connects the exhaust elbow to the NRS valve. Tighten the clamp to 8.5 Nm. Once tightened, lightly tap the clamp with a small hammer. Tighten the clamp to 8.5 Nm again. Refer to (2) in Image1.17.1.

Tighten the four 314-7599 Hose Clamps. Refer to (3) in Image1.17.1.

Image1.17.1

19. Install the 382-4384 NRS Delta Pressure Sensor onto venturi using two 6V-8202 Bolts and two 9M-1974 Washers. Tighten the mounting bolts to 20 Nm. Install 290-5664 Fir Tree Mount to the delta P sensor and secure the harness.

Image1.18.1

20. Inspect the 320-3061 NRS Intake Pressure Sensor for soot buildup. Some soot accumulation on inner diameter of sensor is acceptable.

If the sensor is plugged, it should be replaced. Install NRS intake pressure sensor to the venturi. Use a new 228-7101 O-ring Seal.

21. Install 4P-8134 Ladder Clip to the exhaust tube using a 6V-8836 Bolt and a 4B-4276 Washer. Use a 7K-1181 Zip Tie to secure the NRS delta pressure sensor connector to the ladder clip. Refer to Image1.21.1.

Image1.20.1

22. This concludes the installation of the new NRS venturi.

23. Re-install the rear panel on the engine enclosure. Lower the cab but do not bolt it down and secure it. This will be completed after testing the tractor to make sure no leaks are present.

Thermostat Replacement

1. Access the coolant drain hose and valve underneath the radiator. Drain approximately seven gallons of coolant from system.

Image1.24.1

2. Remove upper radiator hose elbow from thermostat housing. Bend tube out of way. Remove the 318-0004 Thermostat. Install a new 377-3016 Thermostat. Re-connect upper radiator hose thermostat housing.

3. Remove the 370-6041 ARD Coolant Tube and 148-8316 Adapter. Refer to (1) in Image1.26.1. Install new 6V-8780 Adapter with 3J-7354 and 4J-5477 O-rings into the thermostat housing. Refer to (2) in Image1.26.1. Install a new 332-9517 ARD Coolant Tube. Use a new 121-4345 O-ring on male end of the tube fitting. Refer to (3) in Image1.26.1. Install a new 335-3438 Vent Line for the thermostat housing. Refer to (4) in Image1.26.1.

Image1.26.1

4. Secure the 335-3438 Vent Line to the filter mounting bracket using the 124-3019 Bracket, 202-2762 Clip, 8T-4137 Bolt, and 8T-4121 Washer. Refer to 1.27.1.

Image1.27.1

5. Secure the 335-3438 Vent Line to the support bracket using a 226-3492 Bracket, 133-3260 Spacer, 8T-4182 Bolt, 7X-7729 Washer, 202-2762 Clip, 8T-4137 Bolt and 8T-4121 Washer. Refer to Image1.28.1.

Image1.28.1

6. Remove the panel on top of engine enclosure. Refer to Image1.29.1.

Remove the 318-2946 Plug from the shunt tank. Refer to Image1.29.2.

Install 6V-8628 Elbow using 4J-5477 O-ring and 3J-7354 O-ring. Refer to Image1.29.3.

Connect 335-3438 Vent Line to the fitting.

Image1.29.1

Image1.29.2

Image1.29.3

7. Take the seven gallons of the drained coolant and re-fill cooling system.

8. After cooling system has been refilled, inspect the coolant level through the site glass on the shunt tank. If the coolant is red in color, add one bottle of 369-0805 Coolant Additive through the coolant fill cap. Top off cooling system with ELC if coolant level does not completely fill the site glass. If coolant is not red, proceed to Step 9.

9.If the coolant color is clear or light pink, add one bottle of 369-0805 Coolant Additive and one container of 119-5152 ELC Extender. The loss of coolant color means that the nitrites in the coolant have depleted. ELC extender will add back in the nitrites and the coolant additive will ensure the nitrites do not become depleted again. If coolant level does not completely fill the site glass, top off system with ELC.

10. This concludes the thermostat replacement.

Image1.33.1

Software Update

1. Connect Cat ET to the machine.

Use winflash to flash all ECM's on the machine with the part numbers below.

Flash Powertrain Propulsion Module ECM with 387-9543 software

Flash the Powertrain Generator ECM with 387-9544 Software.

Flash Machine ECM with 382-0838 software.
NOTE: Some machines may already have this installed from factory. No need to flash if Machine ECM already contains this software.

Flash Machine EWPC ECM with 375-4337 Software.
NOTE: Some machines may already have this installed from factory. No need to flash if Machine EWPC ECM already contains this software.

Flash Machine-APC software with 375-9548 Software.
NOTE: Some machines may already have this installed from factory. No need to flash if Machine-APC ECM already contains this software.

Flash Implement ECM with 369-2072 Software.
NOTE: Some machines may already have this installed from factory. No need to flash if Implement ECM already contains this software.

Flash Implement HVAC ECM with 384-9571 Software.
NOTE: some machines may already have this installed from factory. No need to flash if Implement HVAC ECM already contains this software.

Flash Monitor with 379-1576 Software.
NOTE: Some machines may already have this installed from factory. No need to flash if Monitor already contains this software.

Flash Machine-Product Link with 356-1949 Software.
NOTE: Some machines may already have this installed from factory. No need to flash if Machine-Product Link already contains this software.

Flash Product Link GSM with 361-0607 Software.
NOTE: Some machines may already have this installed from factory. No need to flash if Product Link GSM already contains this software.

Flash Engine ECM with 385-8165 Software.

NOTE: Once Cat ET re-connects after engine ECM flash, a message will appear stating that ET was unable to find an exact match for the (XXX engine model and XXX machine model) software found in the ECM. Select ok to bypass message. This message is present due to incompatibility between Cat ET2011C and earlier version and the new engine software just flashed. This message will not appear when using Cat ET 2012A and newer. NOTE: ALL FUNCTIONS AND FEATURES OF CAT ET AND THE ENGINE SOFTWARE WILL STILL WORK PROPERLY

2. Start Machine. Get machine up to operating temperature.

Inspect thermostat housing and lines for any coolant leaks. Connect Cat ET to the engine ECM. Enter the diagnostic service tests menu and select "EGR System Test". Allow the test to complete. This test will detect if there are any issues related to the NRS venturi update. Once test is complete, inspect NRS venturi and components for exhaust leaks.

3. If the EGR system test passes successfully and no leaks are found, the hardware update portion of this program is complete. The cab may be secured and all paneling removed can be re-installed. If the EGR system test does not pass successfully, refer to the "NRS System - Test" in the engine's Troubleshooting manual for the product being serviced to determine what action to take. Repair any leaks that may be found.

Group Number 2

D6T NRS Venturi Replacement

1. Remove the floor mat from the cab. Remove both floor plates from the cab. Refer to Image2.2.1.

Remove all the engine side covers from the left side of machine. Refer to Image2.2.2.

Disconnect the wiring harness. Remove clip holding wiring harness. Refer to Image2.2.3. Move harness to the side.

Remove bracket holding the harness connector and move it to the side. Refer to Image2.2.4.

Image2.2.1

Image2.2.2

Image2.2.3

Image2.2.4

2. Disconnect the harness and remove the NRS intake pressure sensor from the venturi. Disconnect and remove the NRS delta pressure sensor from the venturi. The zip tie will need to be cut to remove NRS delta pressure sensor.

NOTE: The sensors will be re-used. Do not discard the sensors.

Refer to Image2.3.1.

Image2.3.1

3. Remove the two bolts that connect the NRS venturi to the elbow.

Remove the bolt that connects the NRS venturi to the engine. Refer to Image2.4.1.

Image2.4.1

4. Loosen the hose clamps from hose the connects the NRS cooler to the NRS venturi.

Separate the venturi from the exhaust tube. Remove the venturi and the hose. The hose that connects the NRS cooler to the NRS venturi may be cut to aid in the removal.

Loosen clamp connecting exhaust tube to NRS valve. Remove the exhaust tube.

Image2.5.1

Image2.5.2

5. Remove two bolts that hold the bracket to engine. Remove bracket. Refer to Image 2.6.1.

Remove the three bolts holding lifting eye to engine. Remove the engine lifting eye.

This concludes the removal portion of the NRS venturi replacement.

Image2.6.1

6. Install the 381-9172 Engine Lifting Eye using two 6V-8675 Bolts, and two 5P-8245 Washers. Tighten the bolts to 100 Nm. A four inch extension and deep well socket provides the right length to allow a torque wrench to get into available space.
NOTE: There will be a fifth bolt hole in the lifting eye in location number two of Image2.7.1. Do not install a bolt in this location.

Image2.7.1

7. Install 380-8558 Hose on to the NRS cooler outlet. Also install two 314-7599 Hose Clamps on to the hose. Keep the clamps loose until all the remaining hardware is installed. Make sure that the fasteners for the clamps are pointed outward to make tightening them easier.

8. Install 380-8541 Venturi on to 353-7160 Bracket using two 8T-0100 Bolts and two 9M-1974 Washers. Do not tighten the bolts. Refer to Image2.9.1

Image2.9.1

9. Install the venturi/bracket assembly on the engine by slipping the venturi inlet end into the hose that is connected to the NRS cooler. Install two 6V-5684 Bolts and two 5P-8245 washers to connect the bracket to engine. Tighten the bolts to 100 Nm. A four inch extension and deep well socket provides the right length to allow a torque wrench to get into available space. Refer to 2.10.1.

Image2.10.1

10. Install 380-8558 Hose and 314-7599 Hose Clamps to the outlet of the venturi. Keep the clamps loose until all remaining hardware is installed. Make sure that the fasteners for the clamps are pointed outward to make tightening them easier.

11. Install 9N-5085 Clamp to the flange on the NRS valve inlet.

Install 380-8557 Elbow between the NRS valve and the NRS venturi. Secure the clamp on the NRS valve inlet to mating flange on 380-8557 Elbow. Do not tighten clamp. Refer to Image2.12.1.

Image2.12.1

12. Ensure all the hardware is loosely in place. Tighten the two bolts the connect to the venturi to the engine. The torque for the bolt torque is 28 Nm. Due to location of bolts, torquing may not be possible. Refer to (1) in Image2.13.1.

Tighten the 9N-5085 Clamp connecting the exhaust tube to the NRS valve. Torque clamp to 8.5 Nm. Once torqued, lightly tap the clamp with a small hammer. Re torque clamp to 8.5 Nm. Refer to (2) in Image2.13.1.

Tighten the four 314-7599 Hose Clamps. Refer to (3) in Image2.13.1.

Image2.13.1

13. Inspect the 365-9858 NRS Delta Pressure Sensor ports. If ports are plugged with soot, the sensor should be replaced. Refer to Image2.14.2 for example of soot plugging.

Use a Q-tip or small brush with 308-1504 Nozzle Cleaner or spitfire cleaning fluid and clean O-ring grooves on sensor. Refer to Image 2.14.1.

Once clean, install two new 341-0643 O-rings. Use a small amount of 369-9451 Retaining Compound to keep the O-rings in place during sensor installation.

Install NRS delta pressure sensor onto venturi using two 6V-8202 Bolts and two 9M-1974 Washers. Tighten the mounting bolts to 20 Nm, if possible. Also, install 290-5664 Fir Tree Mount to the delta pressure sensor and secure the harness.

NOTE: On D6T tractors only with engine serial number between MME00500-MME01217, the NRS delta pressure sensor installed is part number 358-7306. This sensor must be replaced with a 365-9858 NRS Delta Pressure Sensor so it will connect properly to the engine wiring harness.

Image2.14.1

Image2.14.2

14. Inspect the 320-3061 NRS Intake Pressure Sensor for soot buildup. Some soot accumulation on inner diameter of sensor is acceptable.

If sensor is plugged, it should be replaced. Install NRS intake pressure sensor to venturi. Use new 228-7101 O-ring seal.

15. Install 4P-8134 Ladder Clip to the exhaust tube using a 6V-8836 Bolt and 4B-4276 Washer. Use a 7K-1181 Zip Tie to secure NRS delta pressure sensor connector to the ladder clip.

Image2.16.1

24. This concludes the installation of the new NRS venturi. The system should be checked for leaks prior to re-installing floor panels and engine side covers. This will be addressed at the end of this procedure.

Thermostat Replacement

1. Access coolant drain hose and valve underneath radiator. Drain approximately 6 to 7 gallons of coolant from system.

3. Remove the 370-6041 ARD Coolant Tube and the 148-8316 Adapter. Refer to (1) in Image2.21.1. Install a new 6V-8780 Adapter with 3J-7354 and 4J-5477 O-rings into the thermostat housing. Refer to (3) in Image2.21.1. Install new 332-9517 ARD Coolant Tube. Install a new 121-4345 O-ring on the male end of the tube fitting. Refer to (2) in Image 2.21.1. Install the new 321-7938 Vent Line for the thermostat housing. Refer to (4) in Image2.21.1.

Image2.21.1

4. Secure the 321-7938 Vent Line to the CEM mounting plate using a 8M-2772 Clip, 8T-4137 Bolt and 8T-4121 Washer. Refer to (1) in Image2.22.1.

Install the 5P-1465 Hose to the 321-7938 Vent Line using a 1P-4278 Hose Clamp. Secure the 5P-1465 Hose to the upper radiator tube boss using a 8M-2770 Clip, 8T-4136 Bolt and 8T-4121 Washer.

NOTE: The clip orientation may need to be 180 degrees out from what is shown. Refer to (2) in Image2.22.1.

Image2.22.1

6. Remove inner most plug on shunt tank. Install a 6V-1355 Adapter using a 6V-9027 O-ring. Install the 5P-1465 Hose to the adapter using a 1P-4278 Clamp. Refer to Image2.23.1.

Image2.23.1

7. Remove the 154-2302 Spacer that is used between the engine oil filter base and the clip holding the coolant hose to the water pump. Replace the 154-2302 Spacer with a 9Y-7595 Spacer. Install the hose clip outboard instead of inboard. Refer to Image2.24.1. This new spacer will reduce interference with coolant line and alternator. The bolt holding the clip to the oil filter base can be re-used.

Image2.24.1

8. Re-fill cooling system with coolant that was drained at beginning of the procedure. After cooling system has been refilled, inspect the coolant level through the site glass on the shunt tank. If the coolant is red in color, add one bottle of 369-0805 Coolant Additive through the coolant fill cap. Top off cooling system with ELC if coolant level does not completely fill the site glass. If coolant is not red, proceed to Step 9.

9. If the coolant color is clear or light pink, add one bottle of 369-0805 Coolant Additive and one container of 119-5152 ELC Extender. The loss of coolant color means that the nitrites in the coolant have depleted. ELC extender will add back in the nitrites and the coolant additive will ensure the nitrites do not become depleted again. If coolant level does not completely fill the site glass, top off system with ELC.

Image2.26.1

10. This concludes the thermostat replacement.

Software Update

1. Connect Cat ET to the machine.

Flash Powertrain ECM with 381-7141 Software.

Flash Implement ECM with 381-7139 Software.

Flash engine ECM with 385-8110 Software.

NOTE: Once Cat ET re-connects after engine ECM flash, a message will appear stating that ET was unable to find an exact match for the (XXX engine model and XXX machine model) software found in the ECM. Select ok to bypass message. This message is present due to incompatibility between Cat ET2011C and earlier version and the new engine software just flashed. This message will not appear when using Cat ET 2012A and newer. NOTE: ALL FUNCTIONS AND FEATURES OF CAT ET AND THE ENGINE SOFTWARE WILL STILL WORK PROPERLY

Warm up machine so hydraulics are warm and perform a solenoid calibration for blade raise, blade lower, blade tilt right and blade tilt left solenoids. Perform a ripper raise and ripper lower solenoid calibration if machine is equipped with ripper.

Image2.29.1

2. Inspect thermostat housing and lines for any coolant leaks. With engine up to operating temp, connect Cat ET to the engine. Enter the diagnostic service tests menu and select "EGR System Test". Allow the test to complete. This test will detect if there are any issues related to the NRS venturi update. Once test is complete, inspect the NRS venturi and components for exhaust leaks.

If the EGR system test passes successfully and no leaks are found, the hardware update portion of this program is complete. If the EGR system test does not pass successfully, refer to the "NRS System - Test" in the engine troubleshooting guide for the product being serviced to determine what action to take. Repair any leaks that may be found.

Air Filter Inspection

1. Remove the cover off of the air filter housing.

Remove the primary air filter and inspect for any tears or seal damage where it mates to the air filter housing.

If the primary air filter is torn or has any seal damage that will compromise the performance of it, replace the 349-6258 Air Cleaner Group and 335-1699 Bracket per Service Letter, REBE7852. If the primary air filter requires excessive effort to install, refer to Service Magazine,"Installation Update for Primary Air Filter Element on Certain Cat Products", for the use of 5P-3975 Rubber Lubricant for improved installation of the primary air filter. Obtain an engine oil SOS sample and have it analyzed to determine if there was any dust that may have past the secondary air filter and into the engine.

This concludes the D6T rework. All the side covers and the floor panels can be re-installed. Machine is ready to return to service.