Replacement of Direct Drive Fan with Rockford Demand Fan{1356, 1359} Caterpillar

Replacement of Direct Drive Fan with Rockford Demand Fan{1356, 1359}

Usage:

D10R 3KR

Track-Type Tractor:: D10R (S/N: 3KR1-UP; AKT1-507)

Introduction

The Rockford demand control fan system is now available. This special instruction provides the procedures to replace the current direct drive fan with a Rockford demand control fan system.

Two service letters also addressed different configurations of the fan drive system. Refer to Service Letter, PS4451 and Service Letter, PS40071.

Do not attempt any procedure in this Special Instruction or order any parts until you read the information and you understand the information.

Safety

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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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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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At operating temperature, the hydraulic tank is hot and under pressure.
Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly in order to relieve pressure.

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Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine.

To prevent possible injury, perform the procedure that follows before testing and adjusting the brake system.

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide"for tools and supplies to collect and contain fluids in Caterpillar machines. Dispose of all fluids according to local regulations.

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NOTICE

Keep all parts clean from contaminants. Contamination of the hydraulic system with foreign material will reduce the service life of the hydraulic system components. To prevent contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected. Cover any disassembled components and clean them properly before assembly. Clean the hydraulic system properly after any major component exchange or especially after a component failure, to remove any contamination.

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NOTICE

Maintain the oil in the hydraulic system at the correct level to prevent pump cavitation.

References

Reference: Contamination Control Guideline, SEBF8456, "(D7-D11) Track-Type Tractor"

Reference: Operation and Maintenance Manual, SEBU6969, "D10R (3KR) Track-Type Tractor"

Reference: Disassembly and Assembly, SENR8418, "D10R (3KR) Track-Type Tractor"

Reference: Disassembly and Assembly, RENR3923, "D10R (AKT) Track-Type Tractor"

Reference: Operation and Maintenance Manual, SEBU7244, "D10R (AKT) Track-Type Tractor"

Reference: Service Letter, PS4451

Reference: Service Letter, PS40071

Required Tools for Machine Serial Numbers (S/N: 3KR1-UP)

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Table 1
Required Tools
Part Number	Part Description	Qty
5P-9736	Link Bracket	4
6V-2156	Link Bracket	2
6V-3160	Double Acting Cylinder	1
9S-5564	Pin Puller Sleeve As	1
9U-6600	Hand Hydraulic Pump	1
138-7575	Link Bracket	1
138-7576	Link Bracket	2
171-4400	Communication Adapter Gp	1
	3/4 - 10 X 20 inch Threaded Rod.	1
	3/4 - 10 inch Nut	1

Required Tools for Machine Serial Numbers (S/N: AKT1-507)

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Table 2
Required Tools
Part Number	Part Description	Qty
2S-4680	Stud	1
3S-6224	Electric Hydraulic Pump Gp	1
5P-5247	Hydraulic Puller	1
8M-4856	Sleeve	1
FT-0861	Sleeve End	1
138-7575	Link Bracket	1
139-3328	Link	1
171-4400	Communication Adapter Gp	1

Necessary Parts

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Table 3
Required Parts
Item	Part Number	Part Description	Qty
5	189-3094	Tube As	1
6	1P-3708	Rectangular Seal	1
7	6V-8633	Connector	1
8	6V-5049	O-Ring Seal	6
9	6V-5050	O-Ring Seal	1
10	6V-3965	Fitting As	1
11	6V-0852	Dust Cap	1
12	7X-0871	Tee	1
13	033-6033	O-Ring Seal	6
14	214-3531	Adapter As	1
15	116-5256	Crankshaft Pulley	1
16	3D-9348	Bolt	4
17	192-6148	Bracket As	1
18	1K-4649	Spacer	1
19	7X-0332	Bolt	1
20	8T-4223	Hard Washer	4
21	7X-0328	Bolt	1
22	4S-7523	Taperlock Stud	2
23	6V-8188	Nut	6
24	192-0729	Control Valve Gp	1
25	153-3699	Bracket As	1
26	8T-9377	Bolt	6
27	8T-4896	Hard Washer	20
28	6V-8636	Connector	2
29	8L-2779	O-Ring Seal	5
30	6V-9873	Connector	1
31	6V-9837	Swivel Tee	1
32	227-7512	Fan Clutch Gp	1
33	5M-1932	Taperlock Stud	4
34	8T-0788	Elbow	1
35	8T-0130	Elbow	1
36	6V-8632	Connector	1
37	8L-2746	O-Ring Seal	2
38	8L-2786	O-Ring Seal	1
39	6V-9872	Connector	1
40	6V-5048	O-Ring Seal	1
41	8C-8988	Elbow	1
42	180-7891	Hose As	1
43	123-5898	Hose As	1
44	8E-3430	Strip	1
45	4L-6454	Bolt	5
46	5P-1075	Hard Washer	3
47	8M-2773	Clip	3
48	5M-3062	Bolt	4
49	8T-4896	Hard Washer	20
50	216-4541	Hose As	1
51	1S-0994	Clip	2
52	6V-8801	Nut	4
53	8V-0442	Angle	1
54	0S-1591	Bolt	1
55	8S-0948	Clip	1
56	6V-8556	Nut	1
57	6V-8942	O-Ring Reducer	1
58	6V-8791	Face Seal Tee	1
59	5P-9757	O-Ring Seal	5
60	180-7884	Hose As	1
61	8C-6874	Connector	1
62	180-7913	Bracket As	1
63	9B-7237	Bolt	15
64	6V-5185	Clip	3
65	6V-5186	Clip	3
66	180-7886	Hose As	1
67	7W-2131	Bracket As	1
68	8T-2502	Bolt	1
69	4D-7735	Clip	1
70	180-7883	Hose As	1
71	180-7912	Bracket As	1
72	0S-1594	Bolt	1
73	192-2843	Bracket As	1
74	6V-8739	Union	1
75	180-7887	Tube As	1
76 ⁽¹⁾	207-2837	Harness	1
77	150-1960	Pulley	1

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^( 1 )

This Harness is only required for the following serial numbers.(S/N: AKT1-507)

Machine Preparation

Permit only one operator on the machine. Keep all other personnel away from the machine or keep personnel in the view of the operator.

Move the machine to a smooth horizontal location. Move away from machines that are working. Move away from personnel. Lower implements to the ground.

Engage the parking brake.

Stop the engine.

Use the air purge valve that is on the top of the hydraulic tank to release the pressure in the tank.

Move the hydraulic control levers to all positions in order to release the pressure in the hydraulic system. Move the control lever to the FLOAT position.
Note: Make sure that all of the hydraulic pressure is released before any fitting, any hose, or any component is loosened, tightened, removed or adjusted.

Removal Procedure

Remove the hood.
Disassembly and Assembly, SENR8418-01, "D10R Track-Type Tractor - 3KR", "Hood - Remove and Install"
Disassembly and Assembly, RENR3923, "D10R Track-Type Tractor - AKT", "Hood - Remove"

Tilt the radiator guard forward.
Disassembly and Assembly, SENR8418-01, "D10R Track-Type Tractor - 3KR", "Radiator Guard - Tilt"
Disassembly and Assembly, RENR3923, "D10R Track-Type Tractor - AKT", "Radiator Guard - Tilt"

Remove the fan.
Disassembly and Assembly, SENR8418-01, "D10R Track-Type Tractor - 3KR", "Fan - Remove and Install"
Disassembly and Assembly, RENR3923, "D10R Track-Type Tractor - AKT", "Fan - Remove and Install"

Remove the fan drive belt tightener.
Disassembly and Assembly, SENR8418-01, "D10R Track-Type Tractor - 3KR", "Fan Belt Tightener - Remove"
Disassembly and Assembly, RENR3923, "D10R Track-Type Tractor - AKT", "Fan Belt Tightener - Remove"

If air conditioning is present remove the following components:

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Illustration 1	g01092092
(1) Air conditioner belt (2) Guards (3) Compressor (4) Support Bracket

Note: Do not unhook the lines.

Remove the fan drive.
Disassembly and Assembly, SENR8418-01, "D10R Track-Type Tractor - 3KR", "Fan Drive - Remove and Install"
Disassembly and Assembly, RENR3923, "D10R Track-Type Tractor - AKT", "Fan Drive - Remove and Install"

Remove the belt tensioner gp from the fan drive bracket. Save the belt tensioner gp and hardware for later use.

Remove the crankshaft pulley gp.

Remove the power train oil fill tube at location (A). Save the hardware for later use.

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Illustration 2	g01092746

Remove the following components from the power train manifold at location (B) :
- 3J-1907 O-Ring Seal
- 6V-0852 Dust Cap
- 6V-3965 Fitting As
- 148-8309 Adapter As

Installation Procedure

Install 189-3094 Tube As (5) at location (A). Use 1P-3708 Rectangular Seal (6) and existing hardware.

Install the following components into the power train manifold at location (B) :

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Illustration 3	g01093052
(7) 6V-8633 Connector (8) 6V-5049 O-Ring Seal (9) 6V-5050 O-Ring Seal (10) 6V-3965 Fitting As (11) 6V-0852 Dust Cap (12) 7X-0871 Tee (13) 033-6033 O-Ring Seal (14) 214-3531 Adapter As

Install 116-5256 Crankshaft Pulley (15). Use four 3D-9348 Bolts (16) .

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Illustration 4	g01093507

Install the belt tensioner gp onto the new 192-6148 Bracket As (17). Use existing hardware.

Install 192-6148 Bracket As (17). Use the following hardware.

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Illustration 5	g01097830
(17) 192-6148 Bracket As (18) 1K-4649 Spacer (19) 7X-0332 Bolt (20) 8T-4223 Hard Washer (21) 7X-0328 Bolt (22) 4S-7523 Taperlock Stud (23) 6V-8188 Nut

Install 192-0729 Control Valve Gp (24) onto 153-3699 Bracket As (25). Use two 8T-9377 Bolts (26) and two 8T-4896 Hard Washers (27) .

Install 153-3699 Bracket As (25) onto the engine. Use four 9B-7237 Bolts (63) and four 8T-4896 Hard Washers (27) .

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Illustration 6	g01111840
(24) 192-0729 Control Valve Gp (25) 153-3699 Bracket As (26) 8T-9377 Bolt (27) 8T-4896 Hard Washer (63) 9B-7237 Bolt

Install the following components into the 192-0729 Control Valve Gp (24) :

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Illustration 7	g01093191
(8) 6V-5049 O-Ring Seal (13) 033-6033 O-Ring Seal (24) 192-0729 Control Valve Gp (25) 153-3699 Bracket As (28) 6V-8636 Connector (29) 8L-2779 O-Ring Seal (30) 6V-9873 Connector (31) 6V-9837 Swivel Tee

Install 227-7512 Fan Clutch Gp (32). Use four 5M-1932 Taperlock Studs (33) and 6V-8188 Nuts (23) .

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Illustration 8	g01093998

Install the following components into the 227-7512 Fan Clutch Gp (32) :

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Illustration 9	g01094279
(8) 6V-5049 O-Ring Seal (13) 033-6033 O-Ring Seal (29) 8L-2779 O-Ring Seal (34) 8T-0788 Elbow (35) 8T-0130 Elbow (36) 6V-8632 Connector (37) 8L-2746 O-Ring Seal (38) 8L-2786 O-Ring Seal (39) 6V-9872 Connector (40) 6V-5048 O-Ring Seal (41) 8C-8988 Elbow

Assemble the 90° coupling of 180-7891 Hose As (42) to the fittings that were assembled in step 8. Assemble the straight coupling to the fittings in the 227-7512 Fan Clutch Gp (32) that were assembled in step 10.

Assemble the straight coupling of 123-5898 Hose As (43) to the fittings that were assembled in step 8. Assemble the 45° coupling to the fittings in the 227-7512 Fan Clutch Gp (32) that were assembled in step 10. Use the following hardware to secure the hoses:

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Illustration 10	g01094762
(42) 180-7891 Hose As (43) 123-5898 Hose As (44) 8E-3430 Strip (45) 4L-6454 Bolt (46) 5P-1075 Hard Washer (47) 8M-2773 Clip (48) 5M-3062 Bolt (49) 8T-4896 Hard Washer

Assemble the 45° coupling of 216-4541 Hose As (50) to the fittings that were assembled in step 2. Assemble the straight coupling to the fittings in the 227-7512 Fan Clutch Gp (32). The fittings were assembled in step 10. Use the following hardware to secure the hose:

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Illustration 11	g01095073
(45) 4L-6454 Bolt (48) 5M-3062 Bolt (49) 8T-4896 Hard Washer (50) 216-4541 Hose As (51) 1S-0994 Clip (52) 6V-8801 Nut (53) 8V-0442 Angle (54) 0S-1591 Bolt (55) 8S-0948 Clip

Preassemble the following components:

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Illustration 12	g01095237
(13) 033-6033 O-Ring Seal (56) 6V-8556 Nut (57) 6V-8942 O-Ring Reducer (58) 6V-8791 Face Seal Tee (59) 5P-9757 O-Ring Seal

Assemble the 45° coupling of 180-7884 Hose As (60) to the power train oil fill tube that was assembled in step 3. Assemble the straight coupling to the tee fitting. The tee fitting was preassembled in step 14. Use the following hardware to secure the hose:

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Illustration 13	g01095473
(45) 4L-6454 Bolt (46) 5P-1075 Hard Washer (49) 8T-4896 Hard Washer (52) 6V-8801 Nut (59) 5P-9757 O-Ring Seal (60) 180-7884 Hose As (61) 8C-6874 Connector (62) 180-7913 Bracket As (63) 9B-7237 Bolt (64) 6V-5185 Clip (65) 6V-5186 Clip

Note: The 180-7913 Bracket As (62) bolts to the fumes disposal gp.

Assemble the 45° coupling of 180-7886 Hose As (66) to the fittings that were assembled in step 8. Assemble the straight coupling to the tee fitting. The tee fitting was preassembled in step 14. Use the following hardware to secure the hose:

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Illustration 14	g01095650
(46) 5P-1075 Hard Washer (49) 8T-4896 Hard Washer (63) 9B-7237 Bolt (66) 180-7886 Hose As (67) 7W-2131 Bracket As (68) 8T-2502 Bolt (69) 4D-7735 Clip

Note: The 7W-2131 Bracket As (67) bolts to the engine oil filter gp.

Assemble the straight coupling of 180-7883 Hose As (70) to the tee fitting. The tee fitting was preassembled in step 14. Use the following hardware to secure the hose:

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Illustration 15	g01095835
(37) 8L-2746 O-Ring Seal (45) 4L-6454 Bolt (49) 8T-4896 Hard Washer (59) 5P-9757 O-Ring Seal (63) 9B-7237 Bolt (64) 6V-5185 Clip (65) 6V-5186 Clip (70) 180-7883 Hose As (71) 180-7912 Bracket As (72) 0S-1594 Bolt (73) 192-2843 Bracket As (74) 6V-8739 Union

Assemble 180-7887 Tube As (75) to the fittings that were assembled in step 10. Assemble the other end of the tube assembly to the 6V-8739 Union (74). The union was assembled in step 17.

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Illustration 16	g01095859

Perform this step for the following serial numbers: (S/N: 3KR1-UP). The engine wiring harness has two receptacles that connect to the demand fan. Locate the 2-pin connector for the Fan control valve. Connect the 2-pin connector to the 192-0729 Control Valve Gp (24). The control valve was assembled in step 6. Locate the 3-pin connector for the Fan speed sensor. Connect the 3-pin connector to the 227-7512 Fan Clutch Gp (32). The clutch group was assembled in step 10.

Perform this step for the following serial numbers: (S/N: AKT1-507). The engine wiring harness has a 6-pin connector that connects to the demand fan. Connect 207-2837 Harness (76) to the 6-pin connector. Locate the 2-pin connector for the Fan control valve. Connect the 2-pin connector to the 192-0729 Control Valve Gp (24). The control valve was assembled in step 6. Locate the 3-pin connector for the Fan speed sensor. Connect the 3-pin connector to the 227-7512 Fan Clutch Gp (32). The clutch group was assembled in step 10.

Assemble 150-1960 Pulley (77). Use six 9B-7237 Bolts (63) .

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Illustration 17	g01098135

If air conditioning is present reinstall the following components:

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Illustration 18	g01092092
(1) Air conditioner belt (2) Guards (3) Compressor (4) Support Bracket

Reinstall the fan drive belt tightener.
Disassembly and Assembly, SENR8418-01, "D10R Track-Type Tractor - 3KR", "Fan Belt Tightener - Install"
Disassembly and Assembly, RENR3923, "D10R Track-Type Tractor - AKT", "Fan Belt Tightener - Install"

Reinstall the fan.
Disassembly and Assembly, SENR8418-01, "D10R Track-Type Tractor - 3KR", "Fan - Remove and Install"
Disassembly and Assembly, RENR3923, "D10R Track-Type Tractor - AKT", "Fan - Remove and Install"

Tilt the radiator guard back to the original position.
Disassembly and Assembly, SENR8418-01, "D10R Track-Type Tractor - 3KR", "Radiator Guard - Tilt"
Disassembly and Assembly, RENR3923, "D10R Track-Type Tractor - AKT", "Radiator Guard - Tilt Back"

Reinstall the hood.
Disassembly and Assembly, SENR8418-01, "D10R Track-Type Tractor - 3KR", "Hood - Remove and Install"
Disassembly and Assembly, RENR3923, "D10R Track-Type Tractor - AKT", "Hood - Install"

Connect a computer with electronic technician software (ET) to the data communication port socket.

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Illustration 19	g01098355

Follow the steps below in order to turn the engine fan control ON:
- Turn the tractor's ignition key to the ON position.
- Launch ET
- Select the engine ECM from the list.
- Select the "Configuration" option from the "Service" drop-down menu.
- Select "Configuration Group 1".
- Set "Engine Fan Control" to "ON".