- Track-Type Tractor:
- D9T (S/N: RJS1-UP)
Introduction
This Special Instruction provides the procedure for installing new alternator and starter cables on D9T (S/N: RJS1-UP).
Note: The work outlined in this special instruction can be performed in the most efficient manner by two people. One person should focus on the work in the engine compartment and the other person should focus on the work inside the cab.
Safety
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Do not attempt to disassemble or assemble this machine until you read and understand the disassembly and assembly instructions. Improper disassembly and assembly procedures could result in injury or death. |
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Required Parts
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Table 1
| Required Parts |
| Item |
Part Number |
Description |
Quantity |
| 1 |
053-0558 |
Clip |
1 |
| 2 |
1S-0994 |
Clip |
2 |
| 3 |
209-7807 |
Cable As |
1 |
| 4 |
217-4590 |
Bracket As |
1 |
| 5 |
275-1442 |
Clip |
1 |
| 6 |
275-1443 |
Clip |
1 |
| 7 |
275-1444 |
Grommet |
1 |
| 8 |
377-8591 |
Bracket As |
1 |
| 9 |
378-5628 |
Cable As |
1 |
| 10 |
378-5629 |
Receptacle As |
1 |
| 11 |
4P-8134 |
Clip |
1 |
| 12 |
5G-3676 |
Grommet |
2 |
| 13 |
5P-1075 |
Hard Washer |
3 |
| 14 |
6V-8801 |
Nut |
1 |
| 15 |
7K-1181 |
Cable Strap |
28 |
| 16 |
7N-1637 |
Stud |
1 |
| 17 |
8T-1895 |
Clip |
2 |
| 18 |
8T-1896 |
Clip |
2 |
| 19 |
8T-4121 |
Hard Washer |
3 |
| 20 |
8T-4136 |
Bolt |
1 |
| 21 |
8T-4196 |
Bolt |
2 |
| 22 |
127-1570 |
Stud |
2 |
Installing the New Alternator and Starter Cables
Note: Attention to detail is required when rerouting the cables to prevent chaffing, wire cuts, or the potential for wires to pull out of clipping hardware.
- Move the machine to a smooth horizontal location.
- Lower all implements. Engage the parking brake. Turn the engine OFF. Disconnect all electrical power. For more information refer to Operation and Maintenance Manual. Turn the battery disconnect switch to the OFF position.
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| Illustration 1 | g03080377 |
- Remove left-hand engine enclosures (A) .
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| Illustration 2 | g03080397 |
- Remove seat (B), seat suspension (D), electrical covers under left arm rest (C), and manhole covers (E) to gain access to starter and alternator cables.
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| Illustration 3 | g03080401 |
Close up view of fuse panel. |
- Disconnect alternator cable (F) from fuse panel.
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| Illustration 4 | g03080403 |
- In the engine compartment remove the following tie straps:
- Five tie straps (G) restraining 209-7807 Cable As (H)
- Four tie straps (J) restraining 213-6672 jump-start receptacle assembly (K)
- One tie strap (L) restraining 209-7808 Cable As (M) in engine compartment.
Note: The pivot shaft oil bottle may need to be temporarily repositioned to cut tie straps (J) restraining jump-start receptacle assembly (K)
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| Illustration 5 | g03080410 |
- In the man hole, remove the following tie straps:
- Three tie straps (L) restraining 209-7808 Cable As (M)
- Six tie straps (G) restraining 209-7807 Cable As (H)
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| Illustration 6 | g03080413 |
- Remove 213-6672 jump-start receptacle assembly (K). Hardware will be reused.
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| Illustration 7 | g03080436 |
- Disconnect Alternator Cable (H) from Alternator (N). The 208-1569 Hose As (P) may need to be temporarily rotated to access the bolts used to restrain the P-clips and alternator cable.
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| Illustration 8 | g03080459 |
- Remove old alternator cable (K) and install new alternator cable (3) .
Note: The removal and installation will work best if the new alternator cable (3) is attached to alternator end of cable (K) and two people work together. One person should pull the old cable from inside the cab and one person should push and guide the new cable from the engine compartment. Be careful not to damage the new cable or surrounding parts when pulling the new alternator cable (3) into position.
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| Illustration 9 | g02777358 |
- Install new jump-start receptacle assembly (10). Reuse hardware removed in step 8. Do not add tie straps until step 14.
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| Illustration 10 | g03080460 |
- Install new cable assembly (9) into place.
Note: The end of cable assembly with the cover boot connects to the battery pass through block (R) .
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| Illustration 11 | g03080476 |
- Connect alternator cable (3) to alternator. Attach alternator cable (3) to compressor using new P-Clips (2). If 208-1569 Hose As (P) was slightly rotated in step 10, return the 208-1569 Hose As (P) to the original position.
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| Illustration 12 | g03081098 |
- Attach alternator cable (3) using four tie straps (15)
Note: Use appropriate tool (1U-5227) in order to tighten straps.
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| Illustration 13 | g03080478 |
- Carefully remove existing stud bolt (S) and install bracket (8) using stud bolts (22). The existing washer should be in between the isolation mount and the bracket (8) .
- Attach Cable Assembly (9) and jump-start receptacle assembly (10) to the starter.
Note: Cable Assembly (9) should be closest to the starter.
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| Illustration 14 | g03081121 |
- Install grommet (7), clips (5) and (6), and ladder clip (11) using bolt (21) and washer (19) .
Note: The clips should contact the bracket (8) first, followed by the ladder clip (11), and then the washer (19) .
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| Illustration 15 | g03080481 |
(P) Existing 208-1569 Hose As
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| Illustration 16 | g03080600 |
(P) Existing 208-1569 Hose As
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- Remove existing hardware and attach clip (1) with stud bolt (16) and washer (13). Then install grommet (12), clips (17) and (18), on cable assembly (9) and attach to stud bolt (16) using washers (13) and nut (14) .
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| Illustration 17 | g03080605 |
(P) Existing 208-1569 Hose As
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- Remove existing bolt and washer connecting front ground strap to the case and frame. Rotate the ground strap connector 180 degrees so the flat side (T) of the connector is closest to the center of the tractor as shown in Illustration 17.
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| Illustration 18 | g03080658 |
- Remove paint (U) from both sides of bracket (4) near the bottom bolt hole.
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| Illustration 19 | g03080637 |
- Install grommet (12), clips (17) and (18), to cable assembly (10). Then attach clips (17) and (18) to bracket (4) with bolt (21) and washer (19) .
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| Illustration 20 | g03080718 |
- Attach bracket (4) using bolt (20) and washer (19) as shown in Illustration 19. Make sure the front ground strap (W) is removed and rotated in order to contact the boss welded to the case and frame as shown in Illustration 20.
Note: Paint should be removed from bracket (4) per Step 22 and installed on top of the ground strap (W) .
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| Illustration 21 | g03775477 |
- Route receptacle cable assembly (10) to final location and install four tie straps (15) .
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| Illustration 22 | g03081198 |
- Route cable assembly (9) and cable assembly (3) to final position at location (AD) and install one tie strap (15) on each cable. Route cable assembly (9) and cable assembly (3) to final position at location (AC) and install two tie straps (15) on each cable. Route cable assembly (9) and cable assembly (3) to final position at location (AA) and install one tie strap (15) on each cable.
Note: Installing two straps is important at location (AC) and positioning cable (3) and cable (9) so the cables do not contact the edge of the frame rail at location (AB) .
Note: Use appropriate tool (1U-5227) in order to tighten straps.
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| Illustration 23 | g02780637 |
- Connect cable assembly (9) to battery pass through block using existing hardware.
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| Illustration 24 | g03081201 |
- Route cable assembly (3) to final position and install three tie straps (15). Then attach cable assembly (3) to fuse panel using hardware removed in step 5.
Note: Use appropriate tool (1U-5227) in order to tighten straps.
- Reinstall fuse panel covers, seat suspension, seat, and man hole cover.
- Reinstall engine enclosures.
