Installation of 0R3950 and 0R3960 3508 (MUI) Remanufactured Engines in D11N Tractors{1200} Caterpillar

Installation of 0R3950 and 0R3960 3508 (MUI) Remanufactured Engines in D11N Tractors{1200}

Usage:

D11N74Z1-Up

Introduction

This instruction contains adaptability and installation information for the Remanufactured Engines listed in the chart that follows.

NOTE: If the engine is to be used for core credit, refer to:

* SELD0164 Core Acceptance Criteria

Reference Literature

NOTE: Refer to the Parts Manual for parts information for a specific Engine Arrangement.

Each Remanufactured Engine arrangement has a Literature Group attached, which includes:

* Parts Manual

* Operation & Maintenance Manual

* Lubrication Instructions

* Torque Specifications (for fasteners) ... and

Specific Special Instructions that will provide, as close as possible, the most current engine/machine configuration.

Refer to Special Instructions in this instruction.

An attached envelope will contain:

* Core Credit Request/Packing List ... and

* Engine Delivery Service Record.

Special Instructions

NOTE: For maximum life and optimum performance, it is factory RECOMMENDED that the following specific Special Instructions be performed at installation.

Each Special Instruction will be referenced by:

* Form Number

* Title

* Model Designation and

* Effective Product Identification Number (PIN) ... and/or

* Effective engine serial number or engine serial number range

A brief review of the instruction is also included.

SEHS8880 ... Governor and Decelerator Control Linkage Modification

D11N ... 74Z1 - 372

This instruction provides the procedure for modification of the 3T1049 Governor & Decelerator Control Group.

The modification simplifies the linkage between the governor and the operators platform.

The improved linkage eliminates the needle bearings at the control rod connections.

The needle bearings were susceptible to dirt contamination, which caused the linkage to become difficult to operate.

The improved linkage is not as susceptible to contamination and will improve service life.

SEHS8895 ... Installation of Fumes Disposal Tube

D11N ... 74Z1 - 372

A new fumes disposal tube plus additional parts are available from the Parts Department as replacement for the existing fumes disposal tube.

Installation of the new group will allow the fumes to exit in front of the radiator core and help eliminate radiator core plugging resulting in HOT spots and possible overheating.

SEHS8951 ... Installation of Engine Enclosure Group

D11N ... 74Z1 - Up

In some applications engine enclosures are needed to help keep debris (non-metallic material, rocks/dirt) out of the engine compartment.

This debris can fill the engine compartment and shorten the engine vibration damper life and damage the engine oil pan.

This instruction gives the procedure for field installation of the 6Y2396 Engine Enclosure Group.

SEHS9173 ... Installation of Automatic Ether Injection System (AEIS)

D11N ... 74Z1 - 729

The automatic ether injection system controls the amount of ether to be injected into the engine intake manifold during cold weather starting.

Correct operation of this electrically controlled system is required to prevent possible damage to the engine during cold-start conditions.

SEHS9186 ... Installing the 1W0723 Fan Guard Group

D11N ... 74Z1 - 846

It is RECOMMENDED that Machines with Product Identification Number (PIN) 74Z1 - 846 be updated with the new 7E4931 and 7E4934 Guard Assemblies.

SEHS9241 ... Operator Instruction Card for Automatic Ether Injection (AEIS) Card

All Machine Models

This provides a new card to be installed in the machine cab.

SEHS9397 ... Installation of Multipoint Pressure Sensing System (MPPS) Version of Automatic Ether Injection System (AEIS)

D11N ... 74Z1 - 961

The Multipoint Pressure Sensing System Version of the Automatic Ether Injection System (AEIS) provides a low oil pressure warning whose switch point varies with engine speed.

The current low oil pressure warning on EMIS has only a single switch point which may not signal a loss of pressure at higher engine rpm until the oil level is very low.

The MPPS measures engine rpm and oil pressure and compares it to a switch point curve of oil pressure vs rpm.

It uses this to determine when a low oil pressure condition exists for any given rpm and signals it through the EMS Panel.

This feature provides better protection of the engine in the event of a loss of oil pressure when running at or near rated speed.

SEHS9257 ... Installation of Overspeed Monitoring System

D11N ... 74Z1 - 828

An engine overspeed warning system is now available for all D11N 74Z1 - 828 Tractors.

The system will require the installation of an:

* Engine speed pick up at the flywheel housing.

* Electronic control mounted in the manhole (wiring harness from manhole to dash) ... and

* A new cover at the top of the dash.

SEHS9340 ... Jacket Water Heater Installation Procedures

All Machine Models

The jacket water heater keeps the engine water temperature warm when ALL the ambient air temperature is below 13°C (55.4°F).

The warm jacket aids in preventing rough combustion after cold start-ups.

SEHS9227 ... Installation of Switches/Sensors with Sure-Seal Connectors

All Machine Models

This instruction provides the necessary procedure for field installation of upgraded electrical components where the original parts used screws, studs, blade, bullet or MS connectors instead of Sure-Seal connectors.

Sure-Seal connectors offer improved reliability over the mentioned terminals.

Installation of an upgraded component in place of the former component requires installation of a mating Sure-Seal connector on the machine harness.

Exchange of Parts

Each Remanufactured Engine is built to a reference engine arrangement, as shown in the Reference Literature Chart in this instruction.

All 3500 series MUI Remanufactured Engines are remanufactured to the most critical engineering changes for the arrangement ordered:

* Alternator belt guard

* Connecting rods

* Crankshaft

* Exhaust manifold

* Exhaust thermocouples

* Fuel lines and clamps

* Gear train

* Governor

* Improved camshaft

* Lubrication tubes and clamps

* New exhaust valves

* Oil pan

* Oil cooler cores

* Turbocharger

* Valve lifters

NOTE: All non-metallic parts (gaskets, seals) and fasteners (bolts) are replaced and the improved parts are Remanufactured where applicable.

This minimizes or eliminates the need for the user to make modifications and reduces downtime provided the CORRECT arrangement was ordered.

However, some of the engine related engineering changes incorporated in the Remanufactured engine received may require machine changes at installation time to achieve optimum performance available from this updated Remanufactured Engine.

The Special Instructions, as shown in the Reference Literature Chart, provides the effective Product Information Number of all the changes which may apply to the machine.

If the machine's Product Information Number appears in the Reference Literature Chart it is RECOMMENDED that the update/changes be made to maximize the performance of this new Remanufactured Engine.

Each Remanufactured Engine is built to the advertised Rated Power @ at specified RPM, that agrees with the original engine's power rating and rpm.

This is recorded on each Remanufactured Engine Information Plate.

NOTE: Do NOT change/adjust any fuel setting(s) before referring to the specific Fuel Setting and Related Information Library.

Inspect (Replace as REQUIRED), (OPTIONAL Parts Replacement), (RECOMMENDED Parts Replacement)

For maximum life of the Caterpillar Remanufactured Engine, the following machine components MUST be inspected for reusability before engine installation and REPLACED as REQUIRED.

8N8114 Support Group

Inspect 4W0077 Mount Assembly rubber for:

* Loss of bond, oil damage (sticky, soft or spongy) ... and

* Heat or ozone damage (cracked, crumbles or hard spots).

Replace if damage is evident.

If inspection indicates no apparent damage, rotate position from:

* Left to right ... or

* Right to left and REUSE

8N8114 Support Group (Optional Parts Replacement)

1W0716 Fumes Disposal Group (REQUIRED Parts Replacement)

3T9677 Torque Convertor Group (REQUIRED Parts Replacement)

Show/hide table

NOTICE

The 7T4083 Ring is a critical part. Failure to install the 7T4083 Ring will cause power train impact loading to the engine's crankshaft.

3T0923 Lines Group ... Power Train (REQUIRED Parts Replacement)

3T2327 Lines Group ... Hydraulic (REQUIRED Part Replacement)

1W4548 Cooler Group ... Transmission (RECOMMENDED Parts Replacement)

The following parts are RECOMMENDED to be replaced with Remanufactured Transmission Oil Cooler Cores.

1W0725 Lines Group ... Air/Exhaust (Replace Parts as REQUIRED)

1W0725 Lines Group ... Air/Exhaust (REQUIRED Parts Replacement)

1W0726 Muffler Group ... Exhaust (RECOMMENDED Parts Replacement)

1W3508 Dust Ejector Group (Replace as REQUIRED)

1W3508 Dust Ejector Group (REQUIRED Parts Replacement)

1W0724 Air Cleaner Group (Replace as REQUIRED)

1W1024 Air Cleaner Group (REQUIRED Parts Replacement)

3T2012 Lines Group ... Fuel (Replace as REQUIRED)

3T1049 Control Group ... Governor and Decelerator (RECOMMENDED Update)

There are four versions of the 3T1049 Control Group. Select the version that matches the machine's Effective Product Identification Number (PIN).

Inspect each part and replace as REQUIRED.

Refer to:

SEHS8880 ... Governor and Decelerator Control Linkage Modification

D11N ... 74Z1 - 372

1W0723 Fan Group ... Suction

Inspect the 8N9005 Spider Assembly ... Fan for:

* Loose and/or missing rivets ... and

* Damaged blades

Replace if REQUIRED.

7E4931 and 7E4934 Guard Assemblies (RECOMMENDED Update)

D11N ... 74Z1 - 846

It is RECOMMENDED that Machines with Product Identification Number (PIN) 74Z1 - 846 be updated with the new 7E4931 and 7E4934 Guard Assemblies.

Refer to:

SEHS9186 ... Installing the 1W0723 Fan Guard Group

D11N ... 74Z847 - Up

These machines are equipped with the new 7E4931 and 7E4934 Guard Assemblies.

It is RECOMMENDED that on machines with Product Identification Number (PIN) 74Z847 - Up the 7E4931 and 7E4934 Guard Assemblies be inspected for:

* Broken and/or separated weldments ... and

* Broken wires.

Replace if REQUIRED.

(OPTIONAL Parts Replacement)

8N8676 Radiator Group

Inspect the 8N8702 Radiator for:

* Coolant leaks

* Plugged Cores ... and

* Cracked side channels

Replace as REQUIRED

(REQUIRED Parts Replacement)

1W0547 Lines Group ... Transmission Oil Cooler and Coolant Drain

(REQUIRED Parts Replacement)

3T2327 Lines Group - Hydraulic (Fan Drive) 9J7015 Pump Group - Piston (Fan Drive) and 4N9611 Motor Group (Fan Draive)

Replace as REQUIRED

Inspect the 3T2327 Lines Group - Hydraulic (Fan Drive), 9J7015 Pump Group - Piston (Fan Drive) and 4N9611 Motor Group (Fan Draive) for serviceability and replace as REQUIRED.

NOTE: Two 6V8260 O-ring Seals are required in install the Fan Drive and Implement Pumps to engine.