Installation Procedure For The New Duct Assembly{1405} Caterpillar

Track-Type Tractor:

D6R Series III (S/N: GJB194-195,216-217,231,278-279,298,303,314-315,323,338,363,369-370,372,377,394,404-405,414,424-426,450,468-469,476,511,546,551-553,568,579,591-593,602,610,617,625-628,631,653,674,713-714,724-725,733,735,758,777,814,828,844-845,865,911,916-917,955,964,1001-1003,1009,1017,1064-1065; WCB114-115,117,120,128-129,133-134,136-137,139-144,147,151-154,159-161,167,175-179,183-191,193,195-203,209-215,218-234,236-241,243,247-251,253-257,261-263,268-273,275; HDC145-146,149-150,152-154,158-161,163,170-175,177-182,194-199,201-203,209,213-215,218,221,223-230,237-241,250-254,262-266,276-279,292,301-303,305-306; TBC189-191,380; HCD123-132,134-141,149-154,156-158,160,162-164,169,178-195,197-216; HKE151,164-166,173,200,223,233,235,237,247-248,258-259,262; WRG156,163,168,177,182-183,206,213,294,322,325,340,353,355-356,358-360,365,392-392,411-412,417-421,432,471-475,478,491,496,500-501,503-504,530,546,555-556,568-569,591,604-606,615-618,622,630,640,642,644,650,652,664,671-672,674-675,678,682,689,697-707,726,735-737,740,743,751,756-757,764,766,768,770,773-779,793,800,802,821,823-826,850-851,857-860; DMK273; JEK109,112-115,118-119; EXL126,129,132,142,165-167,195-196,200-202; JDL155,246; LFM377-377; LGP195-196; GMT160,246; MRT166-168,170-174,188,190,195,197-199,203,219-221,234,241-244,252-254,265-266,278,280-281,299,302-303,311,323,332,354,373-377,385-392,412-414,423-424,426-429,432,435-444,458,462-469,488-500,502-504,512,527,535)

D6T (S/N: JHB141-144,147,179,262; LAE141; DJG296-297,326-333,340-355,363-367,370,372,389; WCG342,361,363-370,375-383,385-387,389,392-394,401-404,423-425,430,435-438,452-454; WFH279,305,312,314,319,324,331,344,352-353,355,360,377; KJL400,405,407,417,444-445,466,483,489,507-511,529-530,534-541,558-563,567-572,575,596-600,611-612,616,636,651-656,669,688-688,692-692,695,712,726-736,740; SKL248-290,303,340-341,361-366,370-373,376-380,383,385,423-425,494-495; GCT243,247,287,294; LAY510,527,534,558,608,622,645,650,661,683-684,712,738-739,794,819,825,875)

Introduction

This Special Instruction contains the procedure for installing the new 281-7377 Duct onto the D6R Series III and D6T Track-Type Tractors that have an alternator that is equipped with an air duct.

Safety

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

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Personal injury or death can result from not engaging the parking brake. Transmission engagement alone will not prevent machine from rolling when the engine is stopped.

Required Parts

Procedure

1. Move the machine to a smooth, horizontal location that is away from operating machines and away from personnel.

   Note: Permit only one operator on the machine. Keep all other personnel away from the machine or in the operator's sight.

2. Place the steering control lever in the NEUTRAL position.

3. Engage the parking brake.

4. Lower the attachments to the ground.

5. Stop the engine.

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Illustration 1	g01624763

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Illustration 2	g01624794

6. Open the right hand side engine access panel.

7. Remove the following components:
   • Band clamps (9)

   • Cable straps (10)

   • Existing duct (11)

   • Existing hose (12)

   • Ladder Clip (13)

   Retain all band clamps and ladder clip for later use.

8. Inspect hose (12) for damage. This hose may have been worn from the previous duct assembly. If the hose is damaged replace the damaged hose with hose (5) .

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Illustration 3	g01624780

9. Install plate assembly (8) onto existing bracket (14) that is also seen in Illustration 2. Use two washers (15) and two bolts (16) in order to mount the new plate.

10. Install ladder clip (13) onto new bracket (8) with washer (3) and bolt (4) .

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Illustration 4	g01624880

11. Use bolt (1) and washer (3) in order to install ladder clip (6) onto bracket (17) .

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Illustration 5	g01624917

12. Connect duct (7) to the alternator with band clamp (11) .

13. Route duct (7) up to ladder clip (6), and attach with cable strap (2) .

14. Ensure that there is no contact with duct (7) and battery cable (18) .

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Illustration 6	g01624914

15. Route duct (7) to both ladder clips (13) and connect with cable strap (2) .

16. Ensure that there is no contact between duct (7) and the frame of the access pannel.

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Illustration 7	g01624916

17. Route duct (7) up to previous ladder clip (19) and attach with cable strap (2) .

18. Attach band clamp (9) onto the end of duct (7) .

19. Ensure that there is no contact between duct (7) and hose (5) .

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Illustration 8	g01624918

20. Complete view of the duct routing.

    Note: Ensure that duct (7) does not make contact with any components that may cause wear from rubbing.