Procedure to Install 490-5632 Kit Variable Pitch Fan on 950M and 962M Medium Wheel Loaders {1353, 1386, 1387, 138R, 1408, 5057, 7960} Caterpillar

Wheel Loader

950M (S/N: KSA1-UP; EMB2101-UP; XCJ1-UP; NHL1-UP; FTR901-UP; J1S1-UP)

950M Z (S/N: HE81-UP)

962M (S/N: K881-UP; EJB501-UP; JYD1-UP; RKH1-UP; J2S1-UP; F2T501-UP)

962M Z (S/N: SA81-UP)

Introduction

This Special Instruction includes parts and procedure to install 490-5632 Kit Variable Pitch Fan. Do not perform any procedure in this publication or order parts until you understand the information that is contained in this publication.

Safety Section

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

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Shut off engine and remove key before performing maintenance or repair work. Failure to do so may result in personal injury due to inadvertant machine operation. Do not start the engine or move any of the controls if there is a “Do Not Operate” or similar warning tag attached to the start switch or controls.

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Personal injury or death can result from the work tool falling. Fully lower the loader arms before you release the hydraulic system pressure.

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

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Use an appropriate lifting device that is rated for the specific load. Failure to do so can result in serious injury or death.

Reference

Operation and Maintenance Manual, SEBU9052, "Steering Frame Lock".

Operation and Maintenance Manual, SEBU9052, "System Pressure Release".

Disassembly and Assembly, UENR3108, "Fan Group (Includes Fan, Fan Guard, Fan Shroud, and Hydraulic Fan Motor) - Remove and Install".

Special Instruction, REHS1841, "General Welding Procedures".

Required Parts

Procedure to Install Variable Pitch Fan Kit

Preparing Machine for Service

1. Move the machine to a hard level surface.

2. Engage the parking brake and chock the wheels.

3. Turn the engine start switch to the OFF position.
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   Illustration 1	g03023936

4. Lock out and tag out the main power supply.

5. Engage the steering frame lock.

   Note: Refer to Operation and Maintenance Manual, SEBU9052, "Steering Frame Lock".

6. Lower work tools to the ground and release system pressure. Refer to Operation and Maintenance Manual, SEBU9052, "System Pressure Release"

Removal of Suction Fan and Engine Compartment Shield Group

7. Remove fan, fan guard, fan shroud, and hydraulic fan motor as per Disassembly and Assembly, UENR3108, "Fan group (Includes fan, fan guard, fan shroud, and hydraulic fan motor) - Remove and Install".

Installing Mounting Hardware Group

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Illustration 2	g06019375
Top View (1) 430-5327 Weld Boss (2) 125-9738 Block (A) 128.6 ± 3 mm (5.1 ± 0.2 inch) (B) 124 ± 3 mm (4.9 ± 0.2 inch) (C) 45.6 ± 3 mm (1.8 ± 0.2 inch) (D) 150.6 ± 3 mm (5.9 ± 0.2 inch) (W1) 3 mm Square Weld All Around (W2) 3 mm Fillet Weld

8. All grease, paint, and foreign objects must be removed before welding. Any of these materials will discharge gas which will cause porosity in the weld deposit. Water and rust will cause hydrogen embrittlement. Hydrogen embrittlement causes cracks in the weld deposit. Remove foreign objects with a wire brush, a buffer, or a grinder. Refer to Special Instruction, REHS1841, "General Welding Procedures".

9. Weld one weld boss (1) to the machine. Use a 3 mm (0.12 inch) square weld all around completely to the outer edge of the weld boss. Refer to Illustration 2 for dimensions.

10. Weld one block (2) to the machine. Use a 3 mm (0.12 inch) fillet weld completely at the contact area of the link. Refer to Illustration 2 for dimensions.

11. After welding, allow all areas to cool to room temperature. After the areas have cooled, paint the area with primer. After the primer has dried, coat the area with 4C-4200 paint (YELLOW).

Disassembly Procedure

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Illustration 3	g06016076
(F) Suction Fan (G) Support Assembly (H) Fan Motor (J) Nut (K) Washer

12. Lay the suction fan (F) on a smooth, level surface.

13. Remove fan motor (H) and support assembly (G). Remove and retain eight nuts (J) and eight washers (K). Refer to Illustration 3.

Assembling the Air Lines

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Illustration 4	g06016078
(3) 364-9872 Tube As (4) 346-4791 Band Clamp (L) 365-0133 Molded Hose (M) 358-8831 Hose

14. Assemble molded hose (L) and hose (M) to tube assembly (3), using two band clamps (4). Refer to Illustration 4.
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    Illustration 5	g06016080
    View of Air Lines Assembly (3) 364-9872 Tube As (4) 346-4791 Band Clamp (5) 211-8073 Protection Cap

15. Tighten band clamps (4) with tube assembly (3) to torque 7.5 ± 1 N·m (66 ± 9 lb in). Assemble four protection caps (5) to the ends of band clamps (4). Refer to Illustration 5.
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    Illustration 6	g06016083
    View of Air lines Assembly (3) 364-9872 Tube As (6) 2D-0032 U-bolt (7) 3K-6060 Locknut (8) 7X-7729 Washer (N) 365-0113 Bracket As

16. Secure tube assembly (3) to bracket assembly (N) using U-bolt (6), two locknuts (7), and two washers (8). Torque locknuts (7) to 6 ± 1 N·m (53 ± 9 lb in). Refer to Illustration 6.

Assemble the Engine Compartment Shield Group

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Illustration 7	g06016085
(9) 457-2247 Engine Compartment Shield Gp (10) 8T-4908 Bolt (11) 8T-7547 Bolt (12) 156-0283 Hard washer (P) 436-2321 Engine Compartment Shield Gp (R) 375-0895 Support As

17. Assemble engine compartment shield group (P) to engine compartment shield group (9). Use three hard washers (12) and three bolts (10). Torque bolts to 15 ± 3 N·m (133 ± 26 lb in). Refer to Illustration 7.

18. Assemble two support assembly (R) to assembled engine compartment shield group (9) and (P). Use four hard washers (12) and four bolts (11). Torque bolts to 15 ± 3 N·m (133 ± 26 lb in). Refer to Illustration 7.
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    Illustration 8	g06016087
    (9) 457-2247 Engine Compartment Shield Gp (11) 8T-7547 Bolt (12) 156-0283 Hard Washer (13) 214-5514 Grommet (14) 1V-6688 Grommet (15) 1M-4543 Grommet (16) 7Y-5497 Grommet (17) 5F-9757 Grommet (18) 6P-0699 Grommet (19) 267-8828 Grommet (20) 7Y-8171 Grommet (21) 6P-6641 Grommet (S) 376-9074 Bracket As (T) 370-9075 Bracket As

19. Assemble bracket assembly (S) and bracket assembly (T) to engine compartment shield group (9). Use two hard washers (12) and two bolts (11). Torque bolts to 15 ± 3 N·m (133 ± 26 lb in). Refer to Illustration 8.

20. Assemble the grommet (13) to grommet (21) to engine compartment shield group (9). Refer to Illustration 8.

Assembling to Suction Fan Group

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Illustration 9	g06016089
(22) 432-4174 Motor Support As (23) 8T-4223 Hard Washer (24) 8T-4956 Bolt (U) 246-6152 Gear motor Gp

21. Assemble gear motor group (U) to motor support assembly (22). Use two hard washers (23) and two bolts (24). Torque bolts to 50 ± 10 N·m (37 ± 8 lb ft). Refer to Illustration 9.

    Note: Ensure that the drain port (# 6 port) is oriented facing upward.

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    Illustration 10	g06016090
    (8) 7X-7729 Washer (22) 432-4174 Motor Support As (26) 8T-6466 Bolt (27) 375-3750 Fan Guard (V) 235-9822 Cone

22. Assemble cone (V) to motor support assembly (22). Refer to Illustration 10.

23. Assemble fan guard (27) to motor support assembly (22). Use nine washers (8) and nine bolts (26). Torque bolts to 30 ± 7 N·m (264 ± 60 lb in). Refer to Illustration 10.
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    Illustration 11	g06016091
    (22) 432-4174 Motor Support As (24) 8T-4956 Bolt (28) 7X-0515 Hard Washer (29) 8T-4132 Nut (30) 8T-7971 Hard Washer (U) 246-6152 Gear motor Gp (W) 243-3416 Adapter (X) 364-9823 Shroud

24. Assemble adapter (W) to the shaft of gear motor group (U). Use hard washer (28) and nut (29). Torque nut to 200 ± 30 N·m (148 ± 22 lb ft). Refer to Illustration 11.

25. Assemble shroud (X) to motor support assembly (22). Use eight hard washers (30) and four bolts (24). Refer to Illustration 11.
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    Illustration 12	g06016092
    (31) 447-1484 Flange (32) 8T-1160 Bolt (U) 246-6152 Gear motor Gp (W) 243-3416 Adapter (Y) 380-1619 Deflector

26. Assemble deflector (Y) to the shaft of gear motor group (U). Assemble flange (31) to deflector (Y). Six thread bolts (32) through flange (31) and deflector (Y) and into the adapter (W) that was assembled in Step 24. Refer to Illustration 12.
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    Illustration 13	g06016093
    (33) 307-7313 Fan (34) 312-6458 Reflective Tape

27. Apply 120 ± 10 mm (4.75 ± 0.4 inch) of reflective tape (34) to one of the wings of fan (33). Refer to Illustration 13.
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    Illustration 14	g06016094
    View of bolts positioned through flange. (31) 447-1484 Flange (35) 8T-4224 Hard Washer (36) 8T-5093 Bolt

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    Illustration 15	g06016097
    Location of hole in the shroud (33) 307-7313 Fan

28. Assemble fan (33) to flange (31) using six hard washers (35) and six bolts (36). Torque the bolts to 15 ± 3 N·m (132 ± 24 lb in). Refer to Illustration 14 and Illustration 15.

    Note: Orient fan with the harness pointing toward the hole in the lower right-hand corner of the shroud.

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    Illustration 16	g06016098
    (Z) 7X-7729 Washer (AA) 8T-4196 Bolt

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    Illustration 17	g06016101
    (22) 432-4174 Motor Support As (24) 8T-4956 Bolt (30) 8T-7971 Hard Washer

    Note: Install fan, fan guard, fan shroud, and hydraulic fan motor as per Disassembly and Assembly, UENR3108, "Fan group (Includes fan, fan guard, fan shroud, and hydraulic fan motor) - Remove and Install".

29. Secure the shroud using four washers (Z) and two bolts (AA). Secure motor support assembly (22) using eight hard washers (30) and four bolts (24). Refer to Illustration 16 and Illustration 17.
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    Illustration 18	g06016194
    (8) 7X-7729 Washer (25) 8T-4195 Bolt (37) 8T-4196 Bolt (38) 432-0095 Cover As (39) 344-5675 Nut (X) 364-9823 Shroud

30. Assemble cover assembly (38) to the right-hand side of the machine. Use two washers (8) and two bolts (25). Refer to Illustration 18.

31. Secure the shroud (X) by using two bolts (37), four washers (8) and two nuts (39).

32. Repeat this step on the left-hand side of the machine.

33. Secure the shroud (X) by using bolt (37).

Assemble the Hydraulic Oil Cooler Lines Group

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Illustration 19	g06016104
(40) 148-8324 Connector As (41) 148-8327 Connector As (42) 268-1621 Fitting As (AB) 148-8378 Elbow As (AC) 341-0108 Elbow As

34. Assemble elbow assembly (AB) to fan motor.

35. Assemble connector assembly (40) to fitting assembly (42). Refer to Illustration 19.

36. Assemble elbow assembly (AC) to fan motor.

37. Assemble connector assembly (41) to elbow assembly (AC). Refer to Illustration 19.
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    Illustration 20	g06016117
    Side View (45) 399-3349 Bracket As (AD) 169-7409 Union As (AE) 190-9821 Elbow As (AF) 6C-9170 Bulk Head Nut

38. Assemble union assembly (AD) and elbow assembly (AE) to bracket assembly (45), using bulk head nut (AF). Refer to Illustration 20.
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    Illustration 21	g06016186
    Top View (45) 399-3349 Bracket As

39. Assemble union assembly (AD) and elbow assembly (AE) to bracket assembly (45), using bulk head nut (AF). Refer to Illustration 20 and Illustration 21
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    Illustration 22	g06016118
    (9) 457-2247 Engine compartment shield Gp (43) 8T-4121 Hard Washer (44) 8T-4136 Bolt (45) 399-3349 Bracket As (46) 7Y-5074 Hose Guard

40. Assemble bracket assembly (45) to the frame using two hard washers (43) and two bolts (44). Refer to Illustration 22.

41. Assemble the hose guard (46) to the engine compartment shield group (9).
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    Illustration 23	g06016122
    Shown without Engine Compartment Shield Group (37) 8T-4196 Bolt (43) 8T-4121 Hard Washer (47) 9X-8250 Clip (AG) 360-0334 Hose As (AH) 450-5457 Hose As

42. Assemble the clip (47), using two bolts (37) and three hard washers (43).

43. Assemble the straight end of hose assembly (AG) to union assembly (AD). Assemble the straight end of hose assembly (AH) to elbow assembly (AE). Refer to Illustration 20 and Illustration 23
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    Illustration 24	g06016124
    (AJ) Oil cooler lines on the engine (AK) 355-3951 Hose As (AL) 148-8378 Elbow As

44. Assemble the straight end of hose assembly (AK) to elbow assembly (AL) on the fan motor. Assemble the 45 degree end of hose assembly to the oil cooler lines on the engine (AJ). Refer to Illustration 24.

Installation of the Chassis Wiring Group

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Illustration 25	g06016126
(48) Wring Harness (49) 7K-1181 Cable Strap

44. Assemble the wiring harness (48) to weld links using two cable straps (49). Refer to Illustration 25.
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    Illustration 26	g06016125
    (AN) Valve Group Solenoid Connector

45. Secure valve group solenoid connector (AM) of wiring harness. Refer to Illustration 26.

Installation of the Air Lines Group

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Illustration 27	g06016119
Solenoid Valve Group Top View (50) 188-2461 Solenoid Valve Gp (51) 396-4307 Bracket As (52) 170-5632 Bolt (53) 8T-3016 Washer

46. Assemble solenoid valve group (50) to bracket assembly (51) using two washers (53) and two bolts (52). Refer to Illustration 27.
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    Illustration 28	g06016123
    Solenoid Valve Group Side View (50) 188-2461 Solenoid Valve Gp (51) 396-4307 Bracket As (54) 377-9564 Elbow As (55) 7J-8611 Elbow Adapter (56) 4H-6112 Breather

47. Assemble two elbow assembly (54) to solenoid valve group (50). Orient elbows as per Illustration 28.

    Note: Apply loctite 536 to threads prior to installation.

48. Assemble elbow adapter (55) to the bottom of solenoid valve group (51). Assemble breather (56) to elbow adapter (55). Refer to Illustration 28.

    Note: Apply loctite 536 to threads prior to installation.

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    Illustration 29	g06016132
    (25) 8T-4195 Bolt (43) 8T-4121 Hard Washer (51) 396-4307 Bracket As

49. Assemble bracket assembly (51) to the machine using two hard washers (43) and two bolts (25). Refer to Illustration 29 for bracket orientation.
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    Illustration 30	g06016133
    (16) 5F-9757 Grommet (54) 377-9564 Elbow As (57) 396-4306 Hose As (X) 364-9823 Shroud

50. Assemble grommet (16) to the hole in the shroud (X). Assemble the threaded end of hose assemble (57) to elbow assembly (54). Route the non-threaded end of the hose through grommet (16). Refer to Illustration 30.
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    Illustration 31	g06016134
    (57) 396-4306 Hose As (58) 1P-4278 Hose Clamp

51. Assemble hose clamp (58) to hose assembly (57). Do not tighten the clamp at this time. Assemble hose assembly (57) to the tube from the fan. Refer to Illustration 31.
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    Illustration 32	g06017556
    (AN) and (AM) dimensions are measured from the center line of the fan. (57) 396-4306 Hose As (58) 1P-4278 Hose Clamp (AN) 117.5 ± 5 mm (4.63 ± 0.20 inch) (AP) 187 ± 5 mm (7.36 ± 0.20 inch) (AR) 30 ± 0.8 mm (1.18 ± 0.03 inch)

52. Position hose clamp (58) on hose assembly (57) according to the dimensions in Illustration 32.

    Note: Tighten the clamp onto the fan tube. Ensure a proper fit and no tension from the hose to the fan tube.

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    Illustration 33	g06016145
    (54) 377-9564 Elbow As (59) 377-9581 Elbow As (60) 389-6081 Hydraulic Fan Pump and Mounting Gp

53. Assemble elbow assembly (54) and elbow assembly (59) to hydraulic fan pump and mounting groups (60). Refer to Illustration 33.

    Note: Apply loctite 536 to threads prior to installation.

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    Illustration 34	g06017605
    (2) 125-9738 Block (25) 8T-4195 Bolt (43) 8T-4121 Hard Washer (48) 464-1470 Wiring Harness Gp (60) 389-6081 Hydraulic Fan Pump and Mounting Gp (61) 7X-0579 Hard Washer (62) 8T-6912 Bolt (63) 130-5300 Clip (64) 8T-4137 Bolt (65) 464-4881 Plate As. (66) 8T-4222 Hard washer

54. Assemble hydraulic fan pump and mounting group (60) to the machine using plate assembly (65). Use three hard washers (61) and three bolts (62). Refer to Illustration 34.

55. Connect the pump harness to chassis harness interface (48), Using clip (63) and two bolts (64), two hard washers (43). Refer to Illustration 34

56. Install two bolts (64), three hard washers (66) and block (2) with hydraulic pump and mounting group (60). Refer to Illustration 34
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    Illustration 35	g06017609
    (1) 430-5327 Weld Boss (25) 8T-4195 Bolt (39) 344-5675 Nut (43) 8T-4121 Hard Washer (48) 464-1470 Harness As. (49) 7K-1181 Cable Strap (50) 188-2461 Solenoid Valve Gp (51) 396-4307 Bracket As (67) 463-1126 Hose As (68) 463-1127 Hose As (69) 142-3953 Stud Bolt (70) 124-0174 Clip (71) 206-2423 Saddle (72) 132-5789 Clip

57. Install two bolts (25), two hard washers (43) with bracket assembly (51) to mount solenoid valve group (50).

58. Assemble hose assembly (67) to elbow assembly (54). Assemble hose assemble (68) to elbow assemble (59). Refer to Illustration 35.

59. Secure hose assembly (67) and hose assembly (68) using, two hard washers (43), stud bolt (69) and clip (70) on the weld boss (1) with cable strap (49). Refer to Illustration 35.

60. Connect hose assembly (67) to elbow assembly (54) on solenoid valve group (50). Refer to Illustration 35.

61. Place the saddle (71) over the hose assembly (68).

62. Secure the harness assembly (48) using clip (72).

    Note: For location of elbow assembly (54) and (59). Refer to Illustration 33

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    Illustration 36	g06016158
    (8) 7X-7729 Hard washer (9) 457-2247 Engine Compartment shield (25) 8T-4195 Bolt (67) 463-1126 Hose As (73) 2Y-5429 Grommet (74) 4D-9517 Clip

63. Route hose assembly (67) through the grommet (73) on the engine compartment shield (9). Refer to Illustration 36.

64. Secure the hose assembly (67) using clip (74), bolt (25) and washer (8).
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    Illustration 37	g06016159
    (3) 364-9872 Tube As (67) 463-1126 Hose As (75) 148-8368 Elbow As

65. Assemble elbow assembly (75) to the tube assembly (3). Route hose assembly (67) across the engine compartment. Connect hose assembly (67) to elbow assembly (75). Refer to Illustration 37.
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    Illustration 38	g06016161
    Shown with parts removed for clarity (8) 7X-7729 Washer (28) 8T-7547 Bolt (30) 8T-7971 Washer (64) 8T-4137 Bolt (67) 463-1126 Hose As (74) 4D-9517 Clip (76) 364-9876 Bracket As (77) 8T-4194 Bolt (78) 5P-4116 Hard Washer (79) 198-4766 Hard Washer

66. Assemble bracket assembly (76) to the machine using bolt (77) and washer (30). Refer to Illustration 38.

67. Secure hose assembly (67) to bracket assembly (76) using clip (74), washer (8), and bolt (64). Refer to Illustration 38.

68. Secure hose assembly (67) using clip (74), hard washer (78), hard washer (79) and bolt (28) to engine compartment shield. Refer to Illustration 38.

Applying Film

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Illustration 39	g06006851
(80) 442-6378 Film (81) 442-6377 Film

69. Apply film (80) and film (81) to the hood of the machine. Refer to Illustration 39.

Installing the Relay

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Illustration 40	g06006843
Location of Relay As (82) 248-2841 Relay As

70. Assemble relay assembly (82) in fuse compartment 6. Refer to Illustration 40.

Software Configuration and Calibration of the 387-1357 Fan Control Arrangement (Variable Pitch Fan)

Note: This feature can be configured and must be activated with Product Software Programming System (PSPS) or a service tool.

1. Use a Caterpillar Electronic Technician (Cat ET) and select the proper Electronic Control Module (ECM). Select "SERVICE" from the menu.

2. Select "CONFIGURATION" from the menu.

3. Double-click on the desired feature on the configuration screen.

4. Select the desired status of the feature and click "OK". The feature will be activated on the next power cycle.