Updating a D6T with the Engine Cooling Fan Bypass Attachment{1356, 1386, 1387, 1408, 1902, 5057, 5264, 7620} Caterpillar

Track-Type Tractor:

D6T (S/N: KSB1-1328; ZJB1-1145; JZC1-174; DTD1-1144; EJJ1-239; SLJ1-1079; GMK1-1140; RRK1-204; TSM1-217; WLM1-127; PLR1-551; JRW1-251; RCW1-1242)

Introduction

This Special Instruction contains the needed information for installing of the engine cooling fan bypass valve attachment on certain D6T Track-Type Tractors.

Note: Each section contains the related parts list.

After assembly is complete, prepare the machine for service.

Read the information and understand the information in this publication before you perform any procedures.

Safety

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Do not attempt to assemble this machine until you have read and understand the assembly instructions. Improper procedures could result in injury or death.

Compatibility Table

Required Parts

Software

Machines Equipped with Standard Hydraulic Fan (Group 1)

Machines Equipped with Reversing Hydraulic Fan (Group 2)

Installation of Electrical Harnesses

This section applies to all machines

Parts Reference

Installation Procedure

1. Place the blade on the ground.

2. Relieve any pressure in the hydraulic system

   ReferenceDisassembly and Assembly, KENR8915, "System Pressure"

3. Turn the battery disconnect to the OFF position.

   Note: The battery disconnect is located on the left fender in the ground level service center box.

4. Put vacuum on the hydraulic tank.

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Illustration 1	g03177416

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Illustration 2	g03177417

5. Remove the eight bolts attaching the grill doors to the radiator guard. Open the grill doors.

   Note: Use the hold open rods to hold the grill doors open during this procedure or the grill doors can be removed from the radiator guards.

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Illustration 3	g03177418

6. Open the engine enclosure doors on the left side of the engine compartment until the door is open about 90 degrees. Lift the door off the hinges and place the door out of the way.

7. Remove the four bolts from the rear vertical panel next to the cab. Remove the panel and store it out of the way.

8. Remove the lower engine enclosure panel and frame. The frame is attached to the machine with one bolt in the front and two bolts in the rear. Store the panel and frame out of the way.

9. Access the 70-pin connector on the engine ECM. The engine ECM is on the rear left corner of the engine.

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Illustration 4	g03177419

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Illustration 5	g03188477

10. Remove the white plug from position 20 of the 70-pin connector on the engine ECM. Insert the socket of harness (1) into position 20. Make sure that the socket is fully secured in the connector. Refer to Illustrations 4 and 5 for the correct pin location.

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Illustration 6	g03177420

11. Route harness (1) along the existing engine harness up to the 12-pin connector above the left side of the engine.

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Illustration 7	g03177421

12. Disconnect the 12-pin connector between the engine and the hood harness. Remove the white plug from position 9 of the 12-pin connector on the engine harness. Plug harness (1) wire into position 9 of the connector. Check to make sure that socket is secure in the connector.

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Illustration 8	g03177422

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Illustration 9	g03177423

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Illustration 10	g03177427

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Illustration 11	g03177425
Tie up extra harness length at the strap on the right.

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Illustration 12	g03177428

13. Secure harness (1) to the engine harness using nine straps (2) .

    Note: Ensure that the harness is not contacting any other hoses, panels, or brackets.

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Illustration 13	g03177747

14. Remove the existing hood harness from the machine and discard. This harness will not be reused.

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Illustration 14	g03177748

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Illustration 15	g03177750

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Illustration 16	g03177751

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Illustration 17	g03177752

15. Route harness (3) to all of the connection points of the hood harness. Then secure harness (3) at the existing strapping points using nine straps (2) .

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Illustration 18	g03177863
(A) Brown (B) Black (C) Yellow

16. Remove the three wires and pins from the Deutsch connector on harness (4). Doing this allows the harness to fit through the hole in the radiator guard.

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Illustration 19	g03177864

17. Remove the grommet in the radiator guard. Insert harness (4) through the hole in the upper left corner of the radiator guard. Reinstall the grommet around harness (4) .

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Illustration 20	g03177863
(A) Brown (B) Black (C) Yellow

18. Reinstall the 3-pin Deutsch connector onto the end of harness (4) .

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Illustration 21	g03177753

19. Install clip (5). Attach harness (4) to clip (5) using strap (2) .

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Illustration 22	g03177865

20. Install bracket (6) to the engine enclosure door hinge if there is not an under hood work light installed. Assemble clip (7) to bracket (6) with bolt (8) and washer (9). Secure 3-pin Deutsch connector to clip (7) with strap (2) .

21. If there is an under hood work light and bracket installed, install clip (7) to the under hood work light bracket with bolt (8) and washer (9). Secure 3-pin Deutsch connector to clip (7) with strap (2) .

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Illustration 23	g03177866

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Illustration 24	g03177867

22. Secure harness (4) to the radiator guard using five straps (2) .

Installation of the Engine Cooling Fan Bypass Attachment on Machines Equipped with Standard Hydraulic Fan

Parts Reference

Installation Procedure

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Illustration 25	g03177879

1. Remove two bolts and eight washers from the guard.

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Illustration 26	g03177882

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Illustration 27	g03222899

2. Remove the existing bulkhead connector from the front, lower left corner of the radiator guard. Disconnect the tube line from the bottom side of the bulkhead first. Then, remove the existing hose assembly from the bulkhead connector and the fan motor. Plug the hose, tube line, and fan motor while the engine cooling fan bypass valve is being installed.

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Illustration 28	g03295580

3. Inspect Control Manifold Gp (1). Ensure that the solenoid valve is installed in the port closest to port "1". Ensure that the Flow Control Valve is installed in the port closest to port "2". If the valves are not assembled correctly, they will need to be reversed. Tighten the Flow Control Valve to a torque of 47.5 ± 2 N·m (35 ± 1.5 lb ft). Tighten the Solenoid Valve to a torque of 31 ± 3 N·m (23 ± 2 lb ft).

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Illustration 29	g03177887

4. Remove the plug from the port labeled "1" on manifold (1). This plug is located on the opposite end of the solenoid. Install adapter (2) and O-rings (3) and (4) into the port. Torque adapter (2) to 140 ± 21 N·m (103 ± 15 lb ft).

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Illustration 30	g03177888

5. On the solenoid end of manifold (1), remove the plug from the port labeled "2". Install connector (5) and O-rings (3) and (4) into the port. Torque connector (5) to 140 ± 21 N·m (103 ± 15 lb ft).

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Illustration 31	g03177889

6. Attach manifold (1) to bracket (6) using two bolts (7) and two washers (8). Torque bolts (7) to 28 ± 7 N·m (248 ± 62 lb in).

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Illustration 32	g03177893

7. Remove the existing two bolts and washers from the radiator guard.

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Illustration 33	g03177894

8. Install bracket (6) to the radiator guard using two bolts (9) and two washers (10). Toque bolts (9) to 55 ± 10 N·m (40 ± 7 lb ft).

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Illustration 34	g03177897

9. Reconnect the tube line to the bottom of connector (5). Torque the nut to 140 ± 21 N·m (103 ± 15 lb ft).

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Illustration 35	g03177898

10. Install hose (11) use a new O-ring (12) at the motor connection. Torque the nut onto adapter (2) to 140 ± 21 N·m (103 ± 15 lb ft). Torque the bolts for the half flanges to the motor to 55 ± 10 N·m (40 ± 7 lb ft). Torque the bolts for the hose clamp to 28 ± 7 N·m (248 ± 62 lb in).

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Illustration 36	g03177899

11. Remove existing bolt and washer, install clip (15) as shown. Plug the 2-pin connector for the engine cooling fan bypass attachment on harness (13) into the solenoid on manifold (1). Pull the excess harness and secure using strap (14) to clip (15) .

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Illustration 37	g03177416

12. Close the grill doors on the radiator guard. Torque eight bolts to 100 ± 20 N·m (74 ± 15 lb ft).

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Illustration 38	g03177418

13. Install all of the engine enclosure panels on the left side of the machine. Torque seven bolts to 55 ± 10 N·m (40 ± 7 lb ft).

14. Remove the vacuum suction on the hydraulic tank and check the fluid level. Add hydraulic fluid as needed.

15. Proceed to ""Installing the New Software" ".

Installation of the Engine Cooling Fan Bypass Attachment on Machines Equipped with Reversing Hydraulic Fan

Parts Reference

Installation Procedure

1. Remove the front bottom guard from underneath the machine.

   ReferenceDisassembly and Assembly, KENR8915, "Bottom Guard"

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Illustration 39	g03177879

2. Remove two bolts and eight washers from the guard.

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Illustration 40	g03177897

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Illustration 41	g03177885

3. Disconnect the tube line from the bottom side of the reversing valve and the hydraulic oil cooler. Cap the open hydraulic ports. Remove the bolt and clip from the bottom of the radiator support and discard.

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Illustration 42	g03198077

4. Disconnect the hose assembly from the reversing valve.

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Illustration 43	g03188619

5. Remove two bolts and washers from the bracket that is restraining the reversing valve. Move the bracket and valve out of the way.

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Illustration 44	g03188620
(A) 34 mm (1.339 inch) (B) 31 mm (1.220 inch)

6. Drill a 25.4 mm (1 inch) hole. Refer to Illustration 44 for the location of the hole.

7. Route harness (2) through the hole. Install grommet (1) around harness (2) into the hole.

8. Reinstall the reversing valve and bracket back on the radiator guard using the two bolts and washers. Torque the bolts to 55 ± 10 N·m (40 ± 7 lb ft).

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Illustration 45	g03188621

9. Plug the reversing fan connector of harness (2) into the solenoid on the reversing valve. Restrain harness (2) using four straps (3). Refer to Illustration 45 for the location of the straps.

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Illustration 46	g03295588

10. Inspect Control Manifold Gp (4). Ensure that the solenoid valve is installed in the port closest to port "1". Ensure that the Flow Control Valve is installed in the port closest to port "2". If the valves are not assembled correctly, they will need to be reversed. Tighten the Flow Control Valve to a torque of 47.5 ± 2 N·m (35 ± 1.5 lb ft). Tighten the Solenoid Valve to a torque of 31 ± 3 N·m (23 ± 2 lb ft).

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Illustration 47	g03219716

11. Remove the plug from the port labeled "1" on manifold (4). This plug is located on the opposite end of the solenoid. Install connector (5) and O-rings (6) and (7) into the port. Torque connector (5) to 140 ± 21 N·m (103 ± 15 lb ft).

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Illustration 48	g03225556

12. On the solenoid end of manifold (4), remove the plug from the port labeled "2". Install connector (5) and O-rings (6) and (7) into the port. Torque connector (5) to 140 ± 21 N·m (103 ± 15 lb ft).

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Illustration 49	g03188622

13. Attach manifold (4) to plate (8) using two bolts (9) and two washers (10). Torque bolts (9) to 28 ± 7 N·m (248 ± 62 lb in).

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Illustration 50	g03188660

14. Install plate (8) to the lower radiator support with bolt (11), washer (12), and clip (13). Align the edge of plate (8) with the radiator guard support on the right side. Mark the center of the hole. Refer to Illustration 50 for the correct hole.

15. Remove plate (8) .

16. Drill a 11.5 mm (0.453 inch) hole into the radiator guard support.

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Illustration 51	g03188678

17. Attach plate (8) to the lower radiator support with bolt (11), bolt (14), nut (15), clip (13), and three washers (12) .

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Illustration 52	g03188696

18. Install hose (16) between the reversing valve and the engine cooling fan bypass manifold. Rotate the engine cooling fan bypass valve end of the hose downward approximately 30 degrees. Tight the nut on each coupling to 140 ± 21 N·m (103 ± 15 lb ft).

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Illustration 53	g03188700

19. Install hose (17) between the engine cooling fan bypass valve and the hydraulic oil cooler. Use a new O-ring (7) for the hose connection to the hydraulic oil cooler. Check the hose routing and adjust so there is more than 25.4 mm (1 inch) of clearance to the damper on the front of the engine. Tighten the nut on each coupling to 140 ± 21 N·m (103 ± 15 lb ft).

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Illustration 54	g03241157

20. Connect the hose assembly to the reversing valve. Use a new O-ring (7), if needed.

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Illustration 55	g03190663

21. Connect harness (2) to the solenoid on manifold (4). Use strap (3) to tie extra harness length to clip (13) .

22. Install the front bottom guard from underneath the machine. Tighten the nuts to 370 ± 50 N·m (273 ± 37 lb ft)

    ReferenceDisassembly and Assembly, KENR8915, "Bottom Guard"

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Illustration 56	g03177416

23. Close the grill doors on the radiator guard. Torque eight bolts to 100 ± 20 N·m (74 ± 15 lb ft).

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Illustration 57	g03177418

24. Install all of the engine enclosure panels on the left side of the machine. Torque seven bolts to 55 ± 10 N·m (40 ± 7 lb ft).

25. Remove the vacuum suction on the hydraulic tank and check the fluid level. Add hydraulic fluid as needed.

26. Proceed to ""Installing the New Software" ".

Installing the New Software

Note: Cat Electronic Technician (Cat ^® ET) version "2012B" or later is required in order to configure the Engine Cooling Fan Bypass.

1. Before installing the software, make sure that the tractor is in proper operating condition.

2. Turn the battery disconnect switch to the ON position.

3. Connect a computer with Cat ET to the communication port in the cab.

4. Turn the ignition key to the ON position.

5. Download the Product Status Report.

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Illustration 58	g03204842

6. Flash the 422-8380 Engine Ratings Electronic Software Gp or the most current software onto the tractor. The above error message may display when you attempt to flash the software.

7. Use Cat ET to navigate to the Configuration page for the engine ECM.

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Illustration 59	g03204976

8. Change the "Fan Bypass" parameter to "Installed".

9. After the software is installed and the parameter is modified, disconnect Cat ET.

10. Cycle the ignition key and the battery disconnect.

11. Reconnect Cat ET and check to make sure that all software changes and configurations are saved.

12. Start the tractor and check for leaks and proper functionality of the Engine Cooling Fan Bypass attachment.

Proper Functionality of the Engine Cooling Fan Bypass Attachment

In order for the fan bypass feature to become enabled, the hydraulic oil temperature must be greater than the temperatures listed in table 8.

In order for the fan bypass to become active, the following "Work Mode"conditions must exist for 10 minutes after the hydraulic oil temperature has exceeded the temperature listed in table 8.

• Park Brake ON

• Engine Speed less than 1675 rpm

• Engine Regen "Not Active"

If the engine coolant temperature is below 75° C (167° F), the fan bypass feature will be turned ON.

When the fan bypass feature is ON, the cooling fan speed will drop below normal minimum fan speed. The typical fan speed with fan bypass active should be 100-150 rpm.

The fan bypass will remain ON until the engine coolant temperature reaches 80° C (176° F) or one of the "Work Mode" conditions are no longer met.

The fan bypass valve will turn back ON when the temperature falls back below 75° C (167° F).

Anytime the fan bypass feature is disabled due to a "Work Mode" condition change, the "Work Mode" conditions must then be met again for 10 minutes before the fan bypass value will be turned ON again.

If the fan bypass is ON, Auto Purge from the Reversing Fan feature is disabled. (if equipped)