Tier III Level Emissions Engine Repower for a D10N Track-Type Tractor {1000, 7000} Caterpillar

Track-Type Tractor

D10N (S/N: 2YD1-UP; 3SK1-UP)

Introduction

This Special Instruction provides the procedure in order to repower a D10N Track-Type Tractor. The replacement engine will be a Tier III level C27 ACERT engine. See table 1 for the engine arrangement numbers. The D10N Track-Type Tractor was originally equipped with a 3412 engine. The original 3412 engine is not regulated for emissions. This Special Instruction will provide the information in order to install the Tier III level replacement engine.

This Special Instruction does not include procedures that can be found in your existing manuals. Refer to the original Service Manual, Parts Manual, and Operation and Maintenance Manual for more information.

When you have completed this procedure, prepare the machine for service. Refer to the Operation and Maintenance Manual.

Note: Do not perform any procedure in this Special Instruction until the information has been read and understood.

Reference: Service Manual, Parts Manual, Operation and Maintenance Manual.

Note: This instruction contains some procedures that come from dealer feedback. If errors have been found, submit feedback in SIS Web or contact the Emissions Retrofit Group.

Safety

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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine.

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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 or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

Welding on Electronically Controlled Engines

Proper welding procedures are necessary in order to avoid damage to electronic controls. Perform welding on the engine according to the following procedure.

1. Set the engine control to the "STOP" mode.

2. Turn OFF the fuel supply to the engine.

3. Disconnect the negative terminal from the battery.

4. Disconnect the electronic components from the wiring harnesses for the engine: ECM, throttle actuator, actuator for the bypass on the turbocharger compressor, fuel metering valve and sensors.

5. Protect the wiring harnesses from welding debris and/or from welding spatter.
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   NOTICE
   Do NOT use electrical components (ECM or sensors) or electronic component grounding points for grounding the welder.

6. Connect the ground cable of the welder directly to the engine component that will be welded. Place the clamp as close as possible to the weld in order to reduce the 5 mm (0.20 inch) possibility of welding current damage to the engine bearings, to the electrical components, and to other engine components.

7. Use standard welding procedures to weld the materials together.

Original Machine Cycle Times

1. Refer to the Service Manual for your particular machine in order to record cycle times.

2. Record the cycle times for the original machine.

Original Machine Stall Speeds

Refer to SIS for Techniques for Loading Engines, SEHS7050-00.

1. Refer to the Service Manual for your particular machine in order to record stall speed.

2. Record the stall speed for the original machine.

Required Parts

Refer to Parts Manual, SEBP5302.

Note: The required parts are subject to some change. Refer to TMI for the most recent required parts list.

Note: If part fabrication is necessary, ensure that all fabricated parts are deburred. Use caution when deburring parts. Avoid excessive grinding and notches.

Note: A breakdown of the kit provides a parts list for the repower. The kit part number is not serviceable. Order the engine arrangement plus the list of parts provided in this kit.

Procedure to Install the C27 Repower Engine in the Machine

Preparation of the Machine

1. Wash the machine.

2. Remove the hood and the guards.

3. Reclaim the used engine coolant.

4. Disconnect all water lines.

5. Remove the cooling system.

6. Drain the engine oil.

7. Remove the oil and fuel filters.

8. Disconnect the remaining lines and electrical wires that are connected to the engine.

Removal of the Engine

Note: Before you remove the engine, measure the position of the crankshaft from centerline to the right and left frame rails. Also, measure the height from the centerline of the crankshaft to the top of the main frame. Record all measurements.

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Illustration 1	g01576641

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Illustration 2	g01847607

1. Remove the original engine. Refer to Disassembly and Assembly, SENR3408.

2. Remove dirt and grease from the machine.

Preparation of the Engine

Note: Temporarily install the engine. Locate and install the front trunnion supports on the frame before you install the installation iron. Hardware, such as pumps, air cleaners, and exhaust may be best installed after the engine is in the chassis for easier installation of the engine.

Note: Ensure that the fuel hoses do not contact nearby parts. Pressure pulsations in these hoses will cause the lines to flex. Inadvertent contact with nearby surfaces will produce chafing/abrasion damage that could eventually lead to a leak.

1. Disconnect, remove, and discard of the fuel supply and return lines and the clips from the right side of the engine. These parts will not be used in the repower.
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   Illustration 3	g06028220

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   Illustration 4	g02201233

2. Disconnect the fuel lines and the sensor harness. Remove the 279-5730 Secondary Fuel Filter from the right side of the engine. Discard the 312-5587 Bracket As and the 275-6274 Plate. The removed parts will not be used in the repower.
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   Illustration 5	g02202213

3. Install the 324-9718 Bracket As on the left front housing. Use the four 5M-2894 Hard Washers and four 3B-1915 Bolts
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   Illustration 6	g02203396

4. Install the secondary fuel filter on the 324-9718 Bracket As on the left side of the engine. Use two 8T-4121 Hard Washers and two 8T-4182 Bolts
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   Illustration 7	g06028246
   (1) 235-3172 Bracket As (2) 356-3099 Bracket As (3) 9X-6458 Hard Washers (4) 8T-8915 Bolts

5. Install the bracket assembly (2). Remove the original bolts and replace with new bolts (4). This bracket will serve as the fixture point for the new fuel lines routing clip support.

   Note: Install the intake air lines bracket assembly (1) under the bracket assembly (2).

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   Illustration 8	g06028258
   (5) 053-2141 Coupling (6) 9X-3826 Coupling (7) 8C-8775 Hose (60 cm) (8) 9X-3826 Couplings (9) 8C-8775 Hose (60 cm) (10) 6V-9012 Connector (11) 8T-1898 Clips (12) 8T-1897 Clips (13) 353-7952 Grommets (14) 5T-6374 Spacer (15) 8T-9101 Bolt (16) 246-8809 Plate As. (17) 5M-3062 Bolt (18) 8T-4896 Washers

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   Illustration 9	g06028443
   (11) 8T-1898 Clips (12) 8T-1897 Clips (13) 353-7952 Grommets (19) 0S-1595 Bolts (20) 5P-8245 Washers (21) 307-2928 Bracket As. (22) 1A-5183 Bolts

6. Install bracket assembly (21) to front of right side air inlet manifold using bolts (22) with original washers.

7. Fabricate a filter hose using 60 cm (24 inches) of hose (7) with couplings (5) and (6).

8. Fabricate center hose using 166 cm (66 inches) of hose (9) with couplings (8).

9. Route center hose down the engine vee through four sets of clips (11) and (12) with grommets (13).

10. Attach swivel nuts to the fuel transfer pump and the outboard connector on the filter base finger tight.

11. Attach the filter hose from the connector at the center of the vee to the inboard connector on the filter base finger tight.

12. Attach plate assembly (16) to existing 356-3099 Bracket As with bolt (17) and washer (18).

13. Installs clips (11) and (12) and grommets (13) on the filter hose and center hose.

14. Attach clips to plate assembly using bolt (15), washer (18), and spacer (14) at a 30 degree angle to the engine centerline finger tight.

15. Adjust routing of center hose and filter hose to provide adequate bend radius and clearance to surrounding components.

16. Tighten bolt (15).

17. Tighten center hose and filter he swivel nuts at the fuel filter.

18. Tighten the center hose at the fuel transfer pump.

19. Tighten the filter hose to the connector at the center of the vee.

    Note: Ensure that the fuel hoses do not contact nearby parts. Pressure pulsations in these hoses cause the hose to flex. Inadvertent contact with nearby surfaces will produce chafing/abrasion damage that could eventually lead to a leak.

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    Illustration 10	g06028624
    (23) 324-9718 Bracket As (24) 5M-2894 Hard Washers (25) 3B-1915 Bolts (26) 8T-4121 Hard Washers (27) 8T-4182 Bolts (28) 133-1281 Oil Filter Gp (29) 8T-6466 Bolt

20. Install the oil filter group (28) on the right side of the front engine housing. Use the bracket assembly (23). The filter will filter the hydraulic fan circuit oil before returning to the tank. Use the hardware that is listed. Remove the 9S-8008 O-Ring Plug and install the 164-7577 Bypass Switch Gp to allow for proper bypass valve functionality.
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    Illustration 11	g06028639

21. Modify the fuel line guard by elongating the lower slot by 12.7 mm (0.5 inch).
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    Illustration 12	g06028760
    (17) 5M-3062 Bolt (18) 8T-4896 Washer (30) 344-5675 Nut (31) 7X-7729 Washer

22. Attach guard to the hydraulic oil filter base. Use bolt (17) with washer (18) to attach the top of the guard. Use nut (30) with hard washer (31) to attach the bottom of the guard.
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    Illustration 13	g06028810
    (32) 105-4729 Electric Starting Motor Gp

23. Install the electric starting motor (32) onto the engine.
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    Illustration 14	g06028818
    (33) 212-7688 Heat Shield Gp

24. Install the heat shield group (33).
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    Illustration 15	g06028831
    (34) 212-9648 Crankshaft Pulley Gp (35) 219-0312 Refrigerant Compressor Gp

25. Install the crankshaft pulley (34) and the refrigerant compressor (35).
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    Illustration 16	g06028891
    (36) 218-4962 Charging Alternator Gp

26. Install the charging alternator (36).
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    Illustration 17	g01587403

27. Install 6N-3897 Engine Supports on the flywheel housing. Refer to 4P-5544 Engine Support Gp.
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    Illustration 18	g06028896
    (37) 3D-8241 O-Ring Seal (38) 5P-2566 Bolt (39) 8T-4223 Hard Washer (40) 165-4854 O-Ring Seal (41) 8T-8919 Bolt

28. Install the original torque converter on the engine. Replace the following parts during the installation:
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    Illustration 19	g06028906
    (41) 324-7780 Power Train Oil Lines Gp

29. Install the power train oil lines group (41).
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    Illustration 20	g06028986
    (43) 134-2252 Temperature Sensor Gp

30. Install a temperature sensor (43) in the TC relief valve body.
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    Illustration 21	g06028996
    (44) 291-4724 Fumes Disposal Gp

31. Install the fumes disposal group (44).
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    Illustration 22	g06029021
    (45) 267-2905 Air Lines Gp

32. Install the air lines group (45).

    Note: Install the 274-6717 Pressure Sensor Gp with the 155-2078 Connector in the 213-6907 Cover Support.

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    Illustration 23	g06029197
    (46) 235-4177 Air Cleaner Gp

33. Install the air cleaner group (46) from the 268-6368 Air Cleaner Gp.
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    Illustration 24	g06029213
    (47) 212-9645 Air Lines Gp

34. Install the air lines group (47).
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    Illustration 25	g06029220
    (48) 323-9943 Air Lines Gp

35. Install the air lines group (48).
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    Illustration 26	g06029274
    (49) 304-1122 Piston Pump Gp (50) 7X-0346 Bolts (51) 8T-4122 Washers

36. Install a 5F-3106 O-Ring Seal onto the piston pump group (49). Use two bolts (50) and two washers (51) to install the piston pump group (49) onto the left rear drive of the engine. Orient the pump so that the valve body faces downward.

37. Install a new 5F-3106 O-Ring Seal on the 9T-1080 Vane Pump Gp.
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    Illustration 27	g06029298
    (52) 9T-1080 Vane Pump Gp

38. Use two 7X-0345 Bolts and two 8T-4122 Hard Washers to install vane pump group (52) to the engine.

    Note: The vane pump group (52) is installed after the third pump section has been removed. Refer to the hydraulic section of this manual for additional information. The additional information will provide more details on the removal of third section of the implement pump.

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    Illustration 28	g01603555
    101-3120 Spacer Qty 1 7B-1598 Clip Qty 1 8T-4121 Hard Washer Qty 1 8T-4182 Bolt Qty 1

39. Remove the 165-6170 Plug from the front left port in the block and install the 216-0821 Oil Level Gauge Gp (Dipstick). Modify the tube to provide clearance of the oil filters.
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    Illustration 29	g06029345
    (18) 8T-4896 Hard Washers (53) 209-4590 Band Clamp Assemblies (54) 7S-8780 Hose (55) 230-0079 Elbow (56) 4L-9337 Bolts (57) 209-4588 Clamps (58) 5P-0764 Hose Qty 1 (59) 322-7302 Tube As Qty 1 (60) 4L-6459 Bolt Qty 1

40. Use the preceding parts from the 212-7682 Water Lines Gp and the 321-6558 Radiator Gp to install the water lines.
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    Illustration 30	g02312818

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    Illustration 31	g02312864

    Note: During the installation of the 230-0079 Elbow, which connects the water pump and the elbow from the bottom of the tank. There could be a misalignment between the two elbows. Refer to the Illustration 30 and 31 for reference.

    Note: Perform the following step if misalignment has occurred.

41. Resolve this issue by drilling and tapping a (3/8 - 16 thread) hole in the engine support plate. Adjust the elbow.

Installation of the Engine

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Illustration 32	g01604593
The illustration shows the engine supports that are already installed. Remove the material to provide clearance for the rear support of the radiator guard. The large hole that is closest to the frame rail will be needed for the bottom guard bolt.

1. Remove the front engine mounts from the machine. The removed mounts will need to be moved forward with respect to the original mounts. The move is done to accommodate the additional length of the C27 engine.

   Note: The original rear engine mounts will be used. Do not modify the rear engine mounts.

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   Illustration 33	g01607753

2. Fabricate two top plates that are used for the front motor mounts.
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   Illustration 34	g01608993

3. Fabricate two front gussets that are used for the front motor mounts.
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   Illustration 35	g01608828

4. Fabricate two rear gussets that are used on the front motor mounts.
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   Illustration 36	g01606873
   Right front engine support assembly (A).

5. Fabricate the front supports. Use the reference pieces that are shown above.

   (1) Top Plate

   (2) Front Gusset

   (3) Rear Gusset

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   Illustration 37	g01607501
   Left front engine support assembly (B).

6. Fabricate the front supports. Use the reference pieces that are shown above.

   (1) Top Plate

   (2) Front Gusset

   (3) Rear Gusset

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   Illustration 38	g01611703
   (A) Right front engine support assembly (B) Left front engine support assembly

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   Illustration 39	g01618139
   The illustration shows the nominal dimensions of the frame with new front engine supports that are already installed.

7. Weld the new front supports in the frame.

   Note: The following print shows nominal locations for welding the front supports. The following procedure is recommended for the installation of the front mount. The engine being installed correctly is critical for the alignment of the power train oil pump drive.

   1. Fabricate front supports.

   2. Bolt the front frame supports onto the engine trunnion.

   3. Install new rear supports on the engine.

   4. Position the engine in the chassis. Be sure that the tractor frame is level. Use the bottom plane of the frame as a reference. The centerline of the crankshaft should be parallel to the reference.

   5. Adjust the engine to level and center. Torque the rear cup mounts to the proper specification.

   6. Recheck the engine level. If necessary, adjust the engine level.

   7. Tack weld the front supports to the frame.

   8. If necessary, remove the engine to finish welding the supports to the frame.
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   Illustration 40	g01611638

8. The preceding illustration is an optional reference to level the engine during the installation.

   Note: The 300-5905 Aftercooler Support Gp may be used to level the engine. This surface is also parallel to the centerline of the crankshaft. Use the top of the machined surface as a reference.

Note: The previous illustration shows the assembled supports. The clearance hole that is nearest to the frame rail is used for the bolt which attaches the belly guard.

Power train

1. Remove the power train oil pump from the case on the tractor. Refer to Disassembly and Assembly, SENR3516-01 for the removal of the power train oil pump. Remove the compressor for the air conditioning if the machine is equipped.

   Note: The compressor for the air conditioning will be installed on the new engine.

2. Remove the 7G-4993 Power Train Oil Pump Suction Tube. Discard the tube. A new suction tube will be used with the power train oil pump modification.

3. After the pump is removed, remove three 2M-1588 Studs from the case.

   Note: The studs will not be reused.

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   Illustration 41	g02312913

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   Illustration 42	g01621067

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   Illustration 43	g01621070

4. Apply 9S-3263 Thread Lock Compound onto one 191-3026 Stud (1) and onto one 312-6143 Stud (2). Install the studs into the case.

5. Refer to the following steps for the modification of the power train oil pump and the power train oil pump cover assembly. Refer to Power train Oil Pump Disassembly and Assembly, SENR3516-01 for the removal of the cover assembly.
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   Illustration 44	g01621211

   1. Remove the original cover assembly from the power train oil pump.
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      Illustration 45	g01621236
      D10N Power train Oil Pump with the 322-7298 Cover As

   2. Install the 322-7298 Cover As on the power train oil pump for the D10N (S/N: 2YD1-UP; 3SK1-847). This cover will shift the centerline of the power train oil pump to align with the C27 left pump drive. Refer to the 324-2801 Pump Cover Gp for the list of parts and the assembly.

   3. Install the 322-7300 Cover As on the power train oil pump for the D10N (S/N: 3SK848-UP). The cover will shift the centerline of the power train oil pump. The shift will align the C27 pump drive on the left side of the engine. Refer to the 324-2802 Pump Cover Gp for the list of parts and assembly.
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      Illustration 46	g01623432
      The illustration shows the power train oil pump that is mounted on the D10N machine. The illustration shows the 322-7298 Oil Pump Cover.

   4. Lubricate the seals and install the seals on the 322-7297 Tube (3). Install the 322-7297 Tube (3) onto the power train oil pump (4). Refer to 324-2653 Power Train Oil Lines Gp for detailed information. Install new seals on the face of the cover. Install the power train oil pump to the case. Replace the 2H-6184 O-Ring Seal (5) on the flange. For a complete parts list, refer to 324-2801 Pump Cover Gp or the 324-2802 Pump Cover Gp. The parts list depends on the machine serial number.
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   Illustration 47	g01623749

6. Cut a hole (6) in the bulkhead above the firewall to route the wire harness.

   Note: See the dimension of the 9X-1343 Connector Receptacle As below.

Illustration 48	g01623781

The cut hole in the bulkhead is needed to install the 9X-1343 Connector Receptacle As (40 pin).

Installation of the Cooling System

Note: If you use the waste handler application, then some alternate components from the standard cooling conversion group will be needed. Refer to 338-5047 Waste Handling Ar for additional details.

1. Remove radiator assembly from the original guard.
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   Illustration 49	g01624342

2. Remove material from each side of the guard to provide clearance for the new radiator group. Refer to the illustration above for the dimensions.
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   Illustration 50	g01624364

3. Remove the six front tabs for the door for the radiator guard. Relocate the tabs to the positions that are shown. Tab relocation is done to provide clearance for the new radiator core group.

   Note: The following recommendations are suggested for the installation of components.

   • Install the fan shroud plate in the location that is shown. Installation of the shroud plate is critical in order for the correct fit of the radiator group.

   • Install the radiator mounting hardware. Tack weld the components to verify the locations before you finish welding.

   • Build up the air to air aftercooler core mounting hardware with new fabricated brackets. Fit in the radiator guard according to the prints. Tack weld the radiator guard. Fitting is done to ensure that the cores for the air to air aftercooler are parallel to the radiator cores.

   • There is little clearance between the engine and the cooling package. Install the radiator and the components for the air to air aftercooler according to the following instructions.

   Fabricate the following parts that will be installed into the modified radiator guard. The fabricated parts will support the Tier III cooling package.

   Note: The mounting brackets that are shown below in some prints have Caterpillar part numbers. The brackets are not serviceable. Fabricate all parts that are shown below for the cooling system by using 1E0357 steel or the equivalent.

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   Illustration 51	g01624732

   1. 228-5147 Bar (1) Qty 2.
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      Illustration 52	g01624768

   2. 232-7818 Plate (2) Qty 2.

      Install a weld nut 139-9599 Weld Nut onto the bottom of the bar.

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      Illustration 53	g01624872

   3. 281-8655 Stabilizer Mount (3) Qty 2.
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      Illustration 54	g01625303

   4. 281-8656 Radiator Baffle Support (4) Qty 2.
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      Illustration 55	g01625366

   5. 228-5131 Fan Support Boss (5) Qty 4.

Fan Shroud Fabrication

Fabricate the following pieces:

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Illustration 56	g01626440
Item 1

1. Fabricate one plate for the fan shroud.
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   Illustration 57	g01626523
   Item 2

2. Fabricate the fan shroud plate assembly by using the installed bosses and weld nuts.
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   Illustration 58	g01626535
   Item 3

3. Fabricate one patch for the upper radiator guard.
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   Illustration 59	g01626639
   Item 4

4. Fabricate two support plates.
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   Illustration 60	g01626893
   Item 5

5. Fabricate one bracket for the top support of the radiator core. Install 20 8T-3490 Weld Nuts onto the side of the bracket that faces forward.
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   Illustration 61	g01627210
   Item 7

6. Fabricate two top brackets for short radiator end cores. Install two 8T-3490 Weld Nuts onto the side of the bracket that faces forward.
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   Illustration 62	g01627233
   Item 9

7. The illustration shows the unbent frame for the radiator guard.

   Note: Two different parts will be made from the piece above. Fabrication is done by bending at the angles that are shown in the following two illustrations.

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   Illustration 63	g01627284
   Item 9

8. One left side bent radiator guard frame. Refer to the original fabricated piece in step 7.
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   Illustration 64	g01627366
   Item 9

9. One right side radiator guard frame. Refer to the original fabricated piece in step 7.
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   Illustration 65	g01629893
   Item 10

10. Fabricate the two bottom support brackets for the air to air aftercooler.
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    Illustration 66	g01629994
    Item 11

11. Fabricate two gussets for Item 10. Refer to step 10.
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    Illustration 67	g01631295
    Item 13

12. Fabricate one top left air to air aftercooler mount assembly with weld nuts.
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    Illustration 68	g01633493
    Item 14

13. Fabricate one top right air to air aftercooler mount assembly with weld nuts.
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    Illustration 69	g01633573
    (15A) Bottom right side support for shroud plate (15B) The bottom left side support for shroud plate.

14. Fabricate the bottom right side support for the shroud plate (Item 15A). Fabricate the bottom left side support plate (Item 15B). Use the dimensions from the previous illustration.

    Note: The center section is left open for the installation and removal of the bracket for the fan support. An additional removable cover should be added to cover the opening once the installation is complete.

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    Illustration 70	g01634253
    Item 16

15. Fabricate two top spacers for the hinge on the front radiator guard door.
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    Illustration 71	g01635316
    Item 17

16. Fabricate two bottom spacers for the hinge on the front radiator guard door.
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    Illustration 72	g01636313

17. The illustration above shows the assembled fabricated items.
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    Illustration 73	g01636748
    Item 20

18. Fabricate a guard for the fan motor. Refer to the illustration above for dimensions. Modify the guard into the shape that is shown.
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    Illustration 74	g01636844
    Item 21

19. Fabricate one brace for the door of the left radiator guard.
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    Illustration 75	g01637331

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    Illustration 76	g01637444
    Item 23

20. Modify the left radiator guard door assembly. Remove material that is shown in the previous illustrations.
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    Illustration 77	g01637450
    Item 22

21. Fabricate one support for the right radiator guard door.
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    Illustration 78	g01637460

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    Illustration 79	g01637462
    Item 24

22. Modify the right radiator guard door assembly. Remove material that is shown in the previous illustrations.
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    Illustration 80	g01637465

23. Fabricate two gussets for the hood mount.

24. Complete the assembly of all the fabricated components in the radiator guard.

25. Install the 321-6558 Radiator Gp.

    Note: If you use the waste handler application, then use the cores from the 338-5047 Waste Handling Ar.

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    Illustration 81	g01639073

26. Remove enough material on the 213-6739 Radiator Tank As to provide clearance for the rear mounts for the radiator guard on the frame.
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    Illustration 82	g01639995

27. Assemble additional hardware to the tank assembly by using one. 8T-4186 Bolt (3), two 8T-4121 Hard Washers (4) and one 8T-4133 Nut (5).
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    Illustration 83	g01642273

28. Modify the 267-2884 Bracket As (6) before installation, to provide clearance for the thermostat housing (7).
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    Illustration 84	g01640427

29. Install the 267-2880 Air Aftercooler Gp.

    Note: The following parts are not used in the machine. 267-2882 Bracket As, 267-2883 Bracket As, 267-2885 Bracket and 267-2886 Bracket

30. Install the 212-7682 Water Lines Gp. Refer to Parts Manual, SEBP3655.
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    Illustration 85	g01642794

31. Remove the material from the 234-1977 Manifold that is shown above.
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    Illustration 86	g01644013

32. Modify the 230-2521 Bracket to provide clearance for the 234-1977 Manifold.
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    Illustration 87	g01644153

33. Install the 214-6665 Hydraulic Oil Cooler Gp (8) and the 234-1977 Manifold (9).
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    Illustration 88	g01644354

34. Install the inlet line (10) and the outlet line (11) onto the 234-1977 Manifold (9).
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    Illustration 89	g01646200

35. Install the 213-8358 Suction Fan Gp. Refer to Parts Manual, SEBP3655.
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    Illustration 90	g01646354

36. Remove material on both sides of the 248-6259 Support. Material removal is done in order to fit into the radiator guard.
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    Illustration 91	g01840074

37. Install the 267-2904 Coolant Tank As (12) into the 270-0519 Hood As (13).
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    Illustration 92	g01841123

38. After you install the 267-2904 Coolant Tank As, install the remaining 267-2875 Coolant Tank Gp components.
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    Illustration 93	g01696355

39. Install the optional 255-1302 Brush Guard Gp to utilize the reversing fan.
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    Illustration 94	g01646713

40. Refer to the previous cooling schematic to complete the cooling circuit.

41. Install the 338-5048 Air Conditioner Ar (Optional).

    Note: In order to ensure the proper fit, some hose lengths may need modified.

Installation of the Hydraulic System

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Illustration 95	g01648334

1. Modify the hydraulic tank. Remove the existing cooler suction block. Remove the block from the tank (1).
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   Illustration 96	g01648553

2. Cut a hole on the left side of the hydraulic tank (2). Cutting is done in order to install the return for the hydraulic fan circuit.

   Note: The size of the hole has a tolerance of ±1.5mm. Tolerance is based on the size of the punch.

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   Illustration 97	g01648615

3. Trim the 3G-2689 Baffle Tube 356 mm (14 inch) from the crimped end. Crimping is done in order for the cut tube to be welded onto the 8J-9208 Boss.
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   Illustration 98	g01649113

4. Weld one 8J-9208 Boss (3) to the tank. Weld the modified 3G-2689 Baffle Tube (4) onto the boss.

   Note: The drain holes should be facing toward the bottom of the tank. Ensure that there is sufficient clearance between the baffles and the bottom of the tank.

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   Illustration 99	g01649296

5. Install one 322-7309 Block (5) and weld to the tank.
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   Illustration 100	g01652542

6. Use the following hardware to install the 322-7308 Tube As onto the 322-7309 Block.

   (6) 8T-4648 Bolt Qty 2

   (7) 8T-4223 Hard Washer Qty 4

   (8) 8T-4183 Bolt Qty 2

   (9) 322-7308 Tube As Qty 1

   (10) 4J-0527 O-Ring Seal Qty 1

   (11) 322-7309 Block Qty 1

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   Illustration 101	g01652999

7. The tank is shown with the suction tube for the implement (13), fan return (14), case drain return (15), and new fan circuit suction (16). The fan circuit suction tube is already installed.
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   Illustration 102	g01653053

8. Install the following parts. 4J-0527 O-Ring Seal (17) Qty 1, 5P-2566 Bolts (18) Qty 4, 8T-4223 Hard Washers (19) Qty 4, 1P-4582 Half Flange (20) Qty 2 and 124-2108 Permanent Coupling (21) Qty 1.
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   Illustration 103	g01653974

9. Install the 237-0957 Pressure Sensor Gp (22) into the 304-1122 Piston Pump Gp (23).

   • Outlet Port SAE 1 inch Code 62

   • Suction Port: SAE 2 inch Code 61

   • Case Drain: 2 X M22

   Note: Install the case drain line on the highest vertical port to keep the case full of oil during operation of the machine.

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   Illustration 104	g01654294

10. Use the 164-3651 Adapter and the 3J-1907 O-Ring Seal to install the 145-7028 Temperature Sensor Gp in the six STOR Port (24).
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    Illustration 105	g01655595

11. Install the 212-0272 Piston Motor Gp.

    Note: If you use a waste handler application, then install the 212-4977 Piston Motor Gp and the 220-0550 Hydraulic Fan Valve and Mounting Gp. Refer to the 338-5047 Waste Handling Ar.

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    Illustration 106	g01656195

12. Install the 168-6355 Bracket (25) on the left fender on the fuel tank. Install the 166-4647 Oil Filter Gp (26) onto the 168-6355 Bracket.

    Note: The oil in the case drain returns through the 166-4647 Oil Filter Gp. Draining happens before returning to the tank.

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    Illustration 107	g01656696

13. Install the hydraulic fan lines group. Refer to illustration 107 for routing of the lines. Replace the existing 229-5681 Tube As per Special Instruction, REHS7617.
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    Table 3

    Group 1 from Tank to the Pump Inlet
    QTY	Part	Description
    2	1P-4582	Half Flange
    4	5P-2566	Bolt
    4	8T-4223	Hard Washer
    1	124-2108	Permanent Coupling
    1	4J-0527	O-Ring Seal
    TBD	122-6908	Hydraulic Hose
    1	124-2059	Permanent Coupling
    1	4J-0527	O-Ring Seal
    2	1P-4582	Half Flange
    4	8T-4183	Bolt
    4	8T-7971	Hard Washer

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    Table 4

    Group 2 From Pump to Hard line
    QTY	Part	Description
    2	124-4288	Split Flange
    4	8T-4183	Bolt
    4	8T-4223	Hard Washer
    1	155-2847	45 deg Elbow
    1	4J-0520	O-Ring Seal
    TBD	165-0021	Hose
    1	6V-9975	Permanent Coupling As
    1	5K-9090	O-Ring Seal

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    Table 5

    Group 3 Hard line at the Bulkhead to the Fan Motor.
    QTY	Part	Description
    1	6V-9973	Permanent Coupling As
    1	5K-9090	O-Ring Seal
    TBD	165-0021	Hose
    1	9X-7667	Coupling As
    1	4J-0520	O-Ring Seal
    2	1P-4577	Half Flange
    4	5S-7382	Bolt
    4	8T-4896	Hard Washer

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    Table 6

    Group 4 from the Fan Motor to Radiator Guard Bulkhead
    QTY	Part	Description
    2	1P-4577	Half Flange
    4	5S-7382	Bolt
    4	8T-4896	Hard Washer
    1	124-2087	Permanent Coupling
    1	4J-0520	O-Ring Seal
    TBD	122-6892	Hydraulic Hose
    1	124-2134	Permanent Coupling
    1	6V-8400	O-Ring Seal
    1	6V-8985	Elbow

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    Table 7

    Group 5 from the Bulkhead to Oil Cooler
    QTY	Part	Description
    1	124-2124	Permanent Coupling
    1	6V-8400	O-Ring Seal
    	122-6892	Hydraulic Hose
    1	124-2103	Permanent Coupling
    1	4J-0520	O-Ring Seal
    2	1P-4577	Half Flange
    4	5S-7382	Bolt
    4	8T-4896	Hard Washer

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    Table 8

    Group 6 From Cooler Outlet to Filter
    QTY	Part	Description
    1	124-2107	Permanent Coupling
    1	4J-0520	O-Ring Seal
    2	1P-4577	Half Flange
    4	5S-7382	Bolt
    4	8T-4896	Hard Washer
    TBD	122-6892	Hydraulic Hose
    1	124-2055	Permanent Coupling
    1	4J-0522	O-Ring Seal
    2	1P-4578	Half Flange
    4	8T-4196	Bolt
    4	8T-4121	Hard Washer

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    Table 9

    Group 7 From Filter Outlet to Tank
    QTY	Part	Description
    1	124-2055	Permanent Coupling
    1	4J-0522	O-Ring Seal
    2	1P-4578	Half Flange
    4	8T-4196	Bolt
    4	8T-4121	Hard Washer
    TBD	122-6892	Hydraulic Hose
    1	124-2156	Permanent Coupling
    1	6V-8400	O-Ring Seal
    1	8T-3611	Connector
    1	5P-7815	O-Ring Seal

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    Table 10

    Group 8 Case Drain from the Fan Motor to the Fan Pump
    QTY	Part	Description
    1	6V-5050	O-Ring Seal
    1	8T-0120	Elbow
    1	124-2148	Permanent Coupling
    1	7J-9108	O-Ring Seal
    TBD	122-6870	Hydraulic Hose
    1	124-2149	Permanent Coupling
    1	6V-9746	O-Ring Seal
    1	6V-9846	Swivel Tee
    1	171-8676	Metric Adapter

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    Table 11

    Group 9 Case Drain from Pump to Hard line
    QTY	Part	Description
    1	124-2149	Permanent Coupling
    1	6V-9746	O-Ring Seal
    TBD	122-6870	Hydraulic Hose
    1	147-1716	Permanent Coupling
    1	6V-9746	O-Ring Seal
    1	162-3122	Elbow
    1	5P-7701	O-Ring Seal

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    Table 12

    Group 10 The Case Drain from the Filter to the Tank
    QTY	Part	Description
    1	5P-7701	O-Ring Seal
    1	162-3122	Elbow
    1	147-1716	Permanent Coupling
    1	6V-9746	O-Ring Seal
    TBD	122-6870	Hydraulic Hose
    1	147-1716	Permanent Coupling
    1	6V-9746	O-Ring Seal
    1	6V-9007	Elbow
    1	6V-5050	O-Ring Seal

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    Illustration 108	g01695735
    (A) Fan Motor Supply/Return/Case Drain with Clipping Bracket (B) Fan Pump Supply/Outlet/Case Drain (C) Fan Pump Outlet (D) Fan Pump Outlet at Radiator Guard

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    Illustration 109	g01661153

14. Remove two bolts (28).
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    Illustration 110	g01663133

15. Remove the third stage (29) from the 9T-1080 Vane Pump Gp. The original function of the pump circulated the oil through the cooler. The hydraulic fan pump will now provide this functionality. Refer to Disassembly and Assembly, SENR3520 for information on the implement pump.
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    Illustration 111	g01663195

16. Remove one 3D-8317 Retaining Ring (30) and one 4T-9369 Coupling (31).

    Note: Retain the seal (32). If necessary, replace the seal.

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    Illustration 112	g01663975

17. Remove 3 mm (0.12 inch) from the face of the 203-5618 Cover. The removal will allow clearance for the installation of the o-ring. The gasket will seal after the installation.
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    Illustration 113	g01664574

18. Use one 6D-1004 Gasket (33) while you install the modified 203-5618 Cover (34) on the pump.

    Note: Make sure that you retain the O-ring seal.

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    Illustration 114	g01664853

19. Relocate the lube reservoir for the pivot shaft to provide clearance for the exhaust lines. If necessary, modify the oil tube for the power train oil.
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    Illustration 115	g01665134

20. Relocate the 6Y-1161 Manifold. Relocating the manifold will allow clearance of the lift cylinder lines at the turbocharger.
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    Illustration 116	g01666375

21. Remove the 5S-3777 Stem (36) at the manifold end of the 6Y-1173 Hose As which is found on the 9W-5229 Lift Cylinder Lines Gp. Replace the 5S-3777 Stem with the 7S-4105 Collet Stem. Removal will provide clearance around the air to air aftercooler core. The new collet stem will also provide sufficient clearance when you route the lines down the right side of the radiator guard.

Power Train Modification

1. Replace the original main drive shaft with the 317-5413 Universal Joint Gp. Refer to Disassembly and Assembly, SENR3516 for information on the drive shaft.

2. Use the following procedure in order to build the 317-5413 Universal Joint Gp.

   1. By using eight 9V-3811 Bolts, assemble two 173-0889 Spider and Bearing Assemblies to the 2Q-3023 Coupling Yoke.

      Note: Clean the cap and the faces of the yoke before assembly.

      Use an alternating X pattern while you tighten the 9V-3811 Bolts to a torque of 160 ± 15 N·m (120± 11 lb ft).

3. Install the assembled 317-5413 Universal Joint Gp in the tractor. Replace the 0S-1604 Bolts on the torque converter output and transmission input yokes when you install the new drive shaft. Tighten the new 0S-1604 Bolts to a torque of 135 ± 15 N·m (100 ± 11 lb ft).
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   Illustration 117	g01668035

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   Illustration 118	g01668356

4. Install the 209-3420 Pump Coupling Gp (1) in order to connect the power train oil pump to the fan pump drive.

5. Reinstall the drive shaft guard for the power train oil pump.

   Note: The distance from the hub face of the fan pump to the hub face of the power train oil pump should be 225 mm (8.86 inch) or less.

   Add a 3T-5284 Spacer if the distance is greater than 225 mm (8.86 inch). As required, use longer bolts with a spacer.

   Use three 4L-6459 Bolts in order to connect to the drive hub of the power train oil pump.

Fuel System

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Illustration 119	g01669193

1. Remove the original primary fuel system. Remove the mounts for the fuel system.

2. Add a 133-0661 Boss at location (1). The boss will be the new fuel return port.
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   Illustration 120	g01670393

3. Use welded bosses in order to install the 213-0047 Fuel Filter and Lines Gp (2) to the tank.

   Note: Ensure that the fuel hoses do not contact nearby parts. Pressure pulsations in these hoses cause the hoses to flex. Inadvertent contact with nearby surfaces will produce chafing/abrasion damage that could eventually lead to a leak.

   Note: Before the final installation of the filter base onto the tank, ensure that there is sufficient clearance for the hydraulic oil filter.

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   Illustration 121	g01670755

   Note: Ensure that the fuel hoses do not contact nearby parts. Pressure pulsations in these hoses cause flexing. Inadvertent contact with nearby surfaces will produce chafing/abrasion damage that could eventually lead to a leak

4. Install the lines from the 213-0047 Fuel Filter and Lines Gp (3). Use clips (4) in order to fasten the routed lines to the machine. Clips will prevent the rubbing of the hoses on the machine.

Hood Modifications

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Illustration 122	g01843217

1. Cut off the original D10N mounting blocks for the hood. The removed blocks will be welded onto the new 270-0519 Hood As.
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   Illustration 123	g01843641

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   Illustration 124	g01844496

2. Tack weld the removed mounts (1) to the 270-0519 Hood As (2). Ensure that the mounts fit on the hood before you weld.
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   Illustration 125	g01844593

3. The illustration above shows the front mounts that are installed on the 270-0519 Hood As.
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   Illustration 126	g01844854

4. Install fabricated supports (3) in order to mount the coolant tank (4).
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   Illustration 127	g01845074

5. Cut a clearance hole (5) in the 272-9665 Access Cover As. A clearance hole will ensure access to the coolant tank (4).
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   Illustration 128	g01845354

6. Cut a clearance hole in the hood (6) in order to be able to view the sight gauge for the coolant tank.

Enclosure Modifications

Modify the original hood in the following steps.

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Illustration 129	g01682694

1. The right side engine enclosure and the left side engine enclosure will be modified. Modifying the enclosure will provide clearance for lines at the turbocharger and the exhaust.
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   Illustration 130	g01682874

2. Install the precleaner and the lines from the 268-6368 Air Cleaner Gp.

   Note: If the waste handler application is used, then install the precleaners that are specified in the 338-5047 Waste Handling Ar.

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   Illustration 131	g01684300

3. Install the 269-7113 Muffler Gp onto the machine.
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   Illustration 132	g01684433

4. Install the 269-0889 Dust Ejector Gp onto the machine.

Electrical System

1. Remove the original 7T-6928 Governor Control Gp.
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   Illustration 133	g01690614

2. Install the new 172-7938 Decelerator Control (1).

3. Install the wiring harness on the machine. Use harness clips in order to secure the harness. Clips will prevent chafing of the harness. Refer to the following schematics:

   • 328-5313 Cab Harness

   • 328-5314 Engine Harness

4. Connect the harness to the following inputs on the EMS system on the machine. The wiring harness supports the usage of all the EMS inputs on the engine. Use the original machine harness in order to connect to the transmission temperature switch and the temperature sender. Refer to the "Preparation of the Engine" section of this Special Instruction for the location of the sensor and the sender. Refer to the electrical schematic for further information regarding the following:

   Note: The EMS system may be different on certain machines with a S/N:3SK prefix. Additional wiring may be needed to support the EMS sensors.

   • 329-5704 Temperature Sender As

   • 3E-6451 Temperature Switch Gp

   • 130-7459 Pressure Switch

   • 258-0883 Pressure Switch Gp Tee into the existing switch on the C27 engine

   • 8N-3844 Temperature Sender

   • 203-3221 Temperature Switch
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   Illustration 134	g01692755

5. Install the 180-4523 Rocker Switch on the right-hand side console in a suitable location. The 121-2843 Switch Harness As is used in order to connect the switch to the wire harness.
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   Illustration 135	g01693934

6. Install the 223-8173 Fuse Holder As (3) and install the 239-8107 Alternator Fuse (4) in the battery box.
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   Illustration 136	g01694094

7. Install the 197-8832 Service Meter Gp (5). The 197-8832 Service Meter Gp connects to the alternator R terminal. Refer to the electrical schematic for additional information.

8. If necessary, replace the remaining gauges in the cluster.

9. Install the optional 243-3820 Display Module Gp.

10. Install the 6T-3644 Circuit Breaker As so that the manual reset is accessible on the dash.

Machine Cycle Times

1. Refer to the "Service Manual" for your particular machine in order to record cycle times.

2. Record the cycle times. Compare the cycle times from the original machine to the repowered machine.

Machine Stall Speed

Refer to Service Information System SIS for Techniques for Loading Engines, SEHS7050-00.

1. Refer to the Service Manual for your particular machine in order to record stall speed.

2. Record the stall speed and compare the stall speed between the original machine and the Repower machine.

Test and Adjust

Hydraulic Fan Speed-Procedure

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Hydraulic oil pressure can remain in the hydraulic system on this machine after the engine and pump have been stopped. Serious injury can result if this pressure is not released before any service is done on the hydraulic systems. In order to prevent possible injury, release the hydraulic system pressure before working on any fitting, hose, or hydraulic component. Lower all attachments to the ground before service is started. If the hydraulic system must be serviced, tested, or adjusted with the attachment in the raised position, the attachments and lift cylinders must be supported properly. Always move the machine to a location away from the travel of other machines. Be sure that other personnel are not near the machine when the engine is running and tests or adjustments are being made.

Tools Needed:

• 1U-5796 Pressure Differential Tool Gp

• 8T-0860 5800 psi Pressure Gauge

• 13mm wrench

• 6mm wrench

• 9U-7400 Multitach Tool Gp

• 9U-5140 Photo Pickup

• 6V-6560 O-Ring Seal Qty 2

• 8C-6864 Adapter Qty 2

• 164-5567 Quick Disconnect Coupler As Qty 2

• 8C-3451 Dust Cap Qty 2

1. Move the machine onto a smooth horizontal surface.

2. Lower all the implements on the machine.

3. Remove the floorplate in order to access the pump.

4. Connect the delta P gauge in order to measure the margin pressure. The margin pressure is the difference between the pump outlet pressure and the load sensing pressure. Ensure that the high side is connected to the pump outlet pressure. Ensure that the low side is connected to the load sensing. Refer to illustration 137 and illustration 138.

5. Connect the 5800psi pressure gauge to the pump outlet pressure of the differential pressure gauge.

6. Connect Electronic Technician (ET) to the diagnostic port. Display the engine configuration screen in ET. Make sure that the fan control is turned on in the configuration screen before you proceed with this procedure.

7. Engage the parking brake.

8. Start the engine and run the engine. Warm the hydraulic oil to a minimum operating temperature of 65° C (149° F).

9. Select the engine ECM. Select the diagnostic tab that is located in ET. Choose override parameters. Select the fan bypass override in order to change the fan pump pressure.

   Note: Do not leave the screen for the pressure override during the setting of the pressure compensator. Decreasing the override will increase the fan speed, and increasing the override will decrease the fan speed.

10. Set the engine to high idle. Use the override for the fan pump in ET in order to achieve a pump outlet pressure of approximately 10200 kPa (1500 psi).

11. Verify that the measurement for the mechanical pump outlet pressure and the measurement for the fan pressure in ET are relatively close. If the measurement is not close, then resolve before you continue. If the measurement is close, then use the measurement from ET. Use the measurement to monitor the pressure of the fan in the following steps.

12. Use the load sensing adjusting stud in order to set the margin pressure. Use the delta P gauge, in order to adjust to 2050 ± 72 kPa (300 ± 10 psi). To increase the margin pressure, turn the stud clockwise. To decrease the margin pressure, turn the stud counterclockwise. Refer to illustration 139.

13. After the margin pressure is set, with the engine at high idle, take the override for the fan bypass to 0% in ET. Adjust the stud for the pressure compensator in order to achieve a pump outlet pressure of 1500 ± 850 kPa (2175 ± 125 psi). Refer to illustration 139.

14. After the setting for the pressure compensator is achieved, set the override for the fan bypass to 20%. Monitor the fan speed.

15. The maximum controlled fan speed is also known as the clip speed. The clip speed should be 1150±25rpm.

16. Adjust the override for the fan bypass in order to bring the clip speed within the specified limit. Use ET to check the fan pump pressure. Record the exact fan pump pressure when the clip speed is within the specified limit. The pump pressure at the clip speed should be 11400 ± 1250 kPa (1665 ± 185 psi).

17. Display the engine configuration screen in ET. Enter the pump pressure that was recorded in step 16 on the line that is marked “Engine Cooling Fan Maximum Clip Pump Pressure”.

18. Shut down the machine. Remove the testing hardware for the fan from the machine. Verify that there are no active diagnostic codes in ET.

Note: The “Engine Cooling Fan Maximum Clip Pump Pressure” is read by the engine electronic control module (ECM). The engine ECM regulates the current to the solenoid on the control for the fan pump. The current is regulated to control the flow of the fan and the resulting fan speed. The strategy for the pump control in the engine software ensures that the pump pressure will never exceed the clip speed pressure.

Note: Verify that the hydraulic oil temperature sensor is connected to the engine ECM. The sensor serves a critical function in the control of the strategy of the demand fan.

Illustration 137	g01689638

Illustration 138	g01689673

Illustration 139	g01689715

Schematic

Illustration 140	g02502817

Illustration 141	g02512918

Illustration 142	g02512997

Illustration 143	g02513017