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Relocation of Primary Fuel/Water Separator with Winch Arrangement{1260, 1263} Caterpillar


Relocation of Primary Fuel/Water Separator with Winch Arrangement{1260, 1263}

Usage:

D6N AKM
Track-Type Tractor:
D6N (S/N: CCK1-UP; AKM1-UP; CCS1-UP; ALY1-UP; CBL1-UP; CBF1-UP; CCG1-UP; ALH1-UP; CBJ1-UP; ALR1-UP)

Introduction

This Special Instruction provides the procedures for the relocation of the primary fuel filter. This relocation is for the D6N that have a winch arrangement.

Note: An electric fuel priming pump is required due to space limitations which do not permit the use of a hand pump.

Required Parts

The following parts are required to relocate the primary fuel filter. These parts are used with only the following electric fuel priming pumps:

  • 212-3657 Water Separator and Fuel Priming Pump Gp

  • 225-7654 Fuel Priming Pump Gp

The parts that are identified in Table 1are generally available through the Caterpillar parts department with the exception of the mounting bracket and the wiring harness which must be fabricated by the dealer.

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Table 1
Qty     Pt. No.     Description     Item    
1     150-3024     Elbow Gp     1    
650 mm (25.6 inch)     5P-1442     Hose     2    

1520 mm (59.8 inch)    		 5P-1442     Hose     3    

1930 mm (76.0 inch)    		 5P-1442     Hose     4    
2     5P-4961     Hose Clamp     5    
7     7K-1181     Cable Strap     6    
1     5K-2748     Coupling     7    
1     4P-7581     Clip     8    
1     See Illustration 1.     Bracket (1)     9    
1     See Illustration 2.     Wiring Harness (2)     10    
3     8T-3490     Weld Nut     11    
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( 1 ) This is a new bracket that must be fabricated.
( 2 ) This is a new wiring harness that must be constructed.
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Illustration 1g01272881

(11) 8T-3490 Weld Nut

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Table 2
Item     Reference Point     Dimension    
F     C    
41 mm (1.6 inch)    
G     C    
45 mm (1.77 inch)    
H     B    
127 mm (5.00 inch)    
J     B    
140 mm (5.5 inch)    
K     A    
20 mm (0.79 inch)    
L     A    
22 mm (0.9 inch)    
M     A    
48 mm (1.9 inch)    
N     A    
75 mm (2.95 inch)    
P     A    
36.5 mm (1.44 inch)    
R     A    
90.5 mm (3.56 inch)    
S     A    
130 mm (5.12 inch)    
T     A    
113 mm (4.45 inch)    
U     A    
126 mm (5.0 inch)    
V     C    
30 mm (1.18 inch)    
W     B    
31 mm (1.22 inch)    
X     B    
139 mm (5.47 inch)    
Y     B    
156 mm (6.1 inch)    
Z     E    
148 mm (5.8 inch)    
AA     E    
106 mm (4.2 inch)    
BB     E    
93 mm (3.66 inch)    
CC     E    
54 mm (2.1 inch)    
DD     E    
15.5 mm (0.61 inch)    
EE     B    
10 mm (0.4 inch)    
FF     D    
15 mm (0.59 inch)    
GG     C    
55 mm (2.2 inch)    
HH     C    
15 mm (0.6 inch)    
JJ     C    
10 mm (0.4 inch)    
KK     D    
118 mm (4.65 inch)    
LL     D    
13 mm (0.5 inch)    
MM     B    
15 mm (0.6 inch)    
NN     B    
105 mm (4.1 inch)    
PP     D    
152 mm (6.0 inch)    
RR     D    
157 mm (6.18 inch)    
SS     D    
165 mm (6.5 inch)    
TT     D    
174 mm (6.85 inch)    
UU     D    
180.5 mm (7.11 inch)    
VV     D    
187 mm (7.4 inch)    
WW     D    
201 mm (7.9 inch)    
XX     E    
153 mm (6.0 inch)    
YY     E    
131.5 mm (5.18 inch)    
ZZ     E    
82 mm (3.2 inch)    
AAA     E    
79.5 mm (3.13 inch)    
BBB     E    
22.5 mm (0.89 inch)    
CCC     E    
5 mm (0.2 inch)    
DDD         20° radius    
EEE         10° radius    
FFF         10° radius    
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Illustration 2g01273174

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Table 3
Qty     Pt. No.     Description     Item    

100 cm (39.4 inch)    		 6A-3361     Electrical Wire     12    

800 mm (31.5 inch)    		 142-3389     Braid (Yellow)     13    
1     155-2269     Connector Plug As     14    
1     8T-8730     Connector Socket     15    

150 cm (59.1 inch)    		 5P-0658     Electrical Wire     16    
1     128-4187     Terminal As     17    

Procedures for Relocation

Note: All torques that are not specified are standard torques.

Fabrication of Bracket

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Illustration 3g01276358

(18) 5 mm (0.2 inch) steel plate

(19) 5 mm (0.2 inch) steel gusset

  1. Refer to Illustration 1 in order to cut steel plate (18) for bracket (9) .

  1. Drill 13.8 + 0.4 − 0.15 mm (0.543 + 0.016 − 0.006 inch) holes in location (K), location (N),and location (S) .

  1. Drill 11 + 0.3 − 0.1 mm (0.433 + 0.012 − 0.004 inch) holes in location (P), location (R), and location (T) .

  1. Bend steel plate (18) at location (LL) and location (PP) .

  1. Attach three nuts (11) to plate (18) by using a projection weld.

  1. Attach gusset (19) to plate (18) by arc welding.

Location of Bracket on Hood

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    Illustration 4g01276609

    (GGG) 209.8 mm (8.26 inch)

    (HHH) 11.0 mm (0.43 inch)

    (JJJ) 21.8 mm (0.86 inch)

    (KKK) 13.8 mm (0.54 inch)

    (LLL) 56.5 mm (2.22 inch)

    (MMM) 52.7 mm (2.08 inch)

    (NNN) 249.7 mm (9.83 inch)

  1. Drill three holes (HHH). See illustration 4 for the location of the drilled holes.

  1. Attach bracket (9) to the hood by using three bolts and three washers.

  1. Attach the fuel filter to bracket (9) by using the existing three bolts, three washers, and one clip (ladder).

Changes to Rear of Machine (Fuel Tank)

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    Illustration 5g01276407

    New hose on left and old hose on right

  1. Remove hose (21) from the old hose arrangement.

  1. Rotate elbow (20) .

  1. Replace existing hose with 650 mm (25.6 inch) of hose (2) .

Changes to Front of Machine (Engine Compartment)

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    Illustration 6g01276432

  1. Disconnect supply hose (22) from pipe.
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    Illustration 7g01276443

  1. Connect 1520 mm (59.8 inch) of hose (3) by using two clamps (5) and coupling (7) .
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    Illustration 8g01276603

    New fitting on left old fitting on right

  1. Remove 164-5562 Connector Gp (23) .

  1. Install fitting (1) .

  1. Add 1930 mm (76.0 inch) of hose (4) to fitting (1). Then connect to pipe that is shown in Illustration 6.

Routing the Hoses

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    Illustration 9g01276800

  1. Use strap (6) to hold the three hoses to the other two hoses on the engine.
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    Illustration 10g01276804

    (24) Connection with old hose

  1. Use strap (6) to hold the two hoses together.

  1. Use strap (6) in order to hold the fuel tank line with 207-2524 Hose As from 236-3975 Power Train Oil Lines Gp .

Installing the New Wiring Harness

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Illustration 11g01276827
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    Illustration 12g01276817

    Connection with fuel pump

  1. Connect plug (14) to the fuel pump. Secure harness (10) to clip (ladder) with a strap.
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    Illustration 13g01276825

    (25) 223-7577 Magnetic Switch Gp

  1. Connect ground wire (17) to the existing bolt for the intake manifold.
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    Illustration 14g01276848

  1. Use two straps (6) to hold the harness.

  1. Remove wire from pin A of the 3-pin connector.

  1. Connect wire connection (15) to pin A of the 3-pin connector.

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