Rework Procedure to Update Water Lines Group on Certain D6T Track-Type Tractor Equipped with a Water Cooled Turbocharger{1052, 1380} Caterpillar

Track-Type Tractor:

D6T (S/N: KSB1-UP; ZJB1-UP; JZC1-UP; SLJ1-UP; GMK1-UP; TSM1-UP; JRW1-UP; RCW1-UP)

Introduction

This Special Instruction provides the rework procedure to update water lines group on the machines listed above.

Do not perform any procedure in this Special Instruction until you read the information and you understand the information.

Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person must also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance of a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Avoid using a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar. If used, ensure the safety of the operating personnel and others.

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Personal injury or death can result from improper troubleshooting and repair procedures. The following troubleshooting and repair procedures should only be performed by qualified personnel familiar with this equipment.

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Cat dealer for replacement manuals. Proper care is your responsibility.

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

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Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak.

Note: Cleanliness is an important factor. Before beginning the removal procedure, clean the exterior of the components thoroughly. Cleaning the components will help to prevent dirt from entering the internal mechanism.

Note: Put identification marks on all hoses, on all hose assemblies, on all harness assemblies, and on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies in order to prevent fluid loss, and contaminants from entering the system.

Machine Preparation

1. Park machine on a level surface.

2. Remove key and lock out master switch.

3. Drain the coolant into a suitable, clean container and save for reuse. Refer Operation and Maintenance Manual, SEBU8548.

4. Open right-hand engine enclosure door and locate the turbo return water line, alternator belt guard, air conditioning compressor, and water pump inlet elbow.

Required Parts List

Rework Procedure-Disassembly

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Illustration 1	g03744484
Right side view of engine

1. Remove 396-0405 Plug As (B) from water pump elbow. Discard the part.

2. Remove 255-1281 Bolt (A) from Air Conditioner (AC) compressor. Discard the part.

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Illustration 2	g03744487

3. Remove 112-8293 Bolt (D) and 6V-9189 Locknut (E) from alternator guard (C). Discard all parts.

4. Remove 8T-2947 Bolt (F), 198-4775 Hard Washer (G), and 6V-7743 Locknut (H) from alternator guard (C). Discard all parts.

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Illustration 3	g03744491

5. Remove 5C-2890 Nut (J), 198-4775 Hard Washer (K), 210-3322 Stud (L), and 7X-2503 Clip (M). Discard all parts.

6. Disconnect hose (N) of turbo return water lines from turbo tube. Save hose (N) .

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Illustration 4	g03744492

7. Remove 6V-7357 Bolt (T) and 9X-8256 Washer (U). Save the parts.

8. Remove 8T-4136 Bolts (P) and 198-4777 Hard Washers (R). Save the parts.

9. Remove 349-4311 Bracket As (S) and discard the part.

Rework Procedure - Assemble

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Illustration 5	g03744493

1. Install new O-ring seal (7) onto elbow (6) and assemble into the bottom of manifold (1) .

2. Install new O-ring seal (3) onto adapter (2) and assemble into the rear of manifold (1) .

3. Install new O-ring seal (5) onto adapter (4) and assemble into the front of manifold (1) .

4. Install new O-ring seal (3) onto adapter (2) and assemble into adapter (4) .

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Illustration 6	g03744497

5. Attach manifold (1) to bracket assembly (8) using two bolts (9) and two hard washers (10) .

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Illustration 7	g03744501

6. Attach manifold (1) and bracket assembly (8) to the CEM support casting using two 8T-4136 Bolts (P) and two 198-4777 Hard Washers (R) that were saved in Step 7.

7. Reinstall the CEM coolant tubes using bolt (11), washer (12), and 6V-7357 Bolt (T), 9X-8256 Washer (U) that were saved in Step 7.

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Illustration 8	g03744504

8. Connect the turbo coolant return tube to manifold (1) using 350 mm (13.8 inch) of hose (13) and hose clamp (14). Refer to Illustration 8.

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Illustration 9	g03744506

9. Cut the original turbo return hose (N) that was saved in Step 6 to a length to allow hose to attach to the adapter on front of manifold (1). secure hose (N) using hose clamp (14) .

   Note: Cut hose (N) approximately to a length of 460 mm (18.1 inch) from the original hose length.

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Illustration 10	g03744512

10. Connect 800 mm (31.5 inch) of hose (13) to the adapter on bottom manifold (1) using hose clamp (14) .

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Illustration 11	g03744514

11. Secure water line hose (13) to top of alternator guard (C) using clip (15), bolt (16), and spacer (17) .

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Illustration 12	g03744515

12. Secure water line hose (13) to side of alternator guard (C) using clip (15), bolt (18), hard washer (12), spacer (19), hard washer (20), and locknut (21) .

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Illustration 13	g03744518

13. Secure water line hose (13) to AC compressor using clip (15), bolt (22), hard washer (23), and spacer (24) .

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Illustration 14	g03744519

14. Install elbow (6) with O-ring seal (7) into water pump inlet elbow.

15. Install water line hose (13) on elbow (6) using hose clamp (14) .

16. Fill the cooling system

17. Run the machine and check for any leaks.