- Track-Type Tractor:
- D6T (S/N: KSB1329-UP; ZJB1146-UP; DTD1145-UP; SLJ1080-UP; GMK1141-UP; PLR552-UP; RCW1243-UP)
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. |
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| NOTICE |
|---|
Do not let any dirt or foreign material get into the hydraulic system during assembly or maintenance operation. Keep the oil in the hydraulic system at the correct level to prevent pump cavitation. |
| NOTICE |
|---|
When a hoist is used to lift any part or assembly, stand clear of the area. Always make sure the hoist has the correct capacity. Approximate weights of the components are shown in the chart. |
Compatibility Table
| Compatibility Table | |
| Current Tractor Fan Ar | Group Description and Part Number |
| 378-3893 Hydraulic Fan Ar | (Group 1) 399-7739 |
| 420-8620 Blower Fan Ar | |
| 378-3896 Reversible Fan Ar | (Group 2) 420-5918 |
| 420-8621 Blower Fan Gp | |
Required Parts
Software
| Software Required for both Group 1 and Group 2 Tractors | |
| 422-8380 | Engine Ratings Electronic Software Gp |
Machines Equipped with Standard Hydraulic Fan (Group 1)
| Required Parts for Machines Equipped with Standard Hydraulic Fan Group 1 |
||
|---|---|---|
| Qty | Part Number | Description |
| 2 | 8T-4186 | Bolt |
| 2 | 8T-4224 | Hard Washer |
| 2 | 8T-6869 | Bolt |
| 2 | 2M-9780 | O-Ring Seal |
| 2 | 6V-8640 | Connector |
| 4 | 6V-9746 | O-Ring Seal |
| 1 | 388-5493 | Control Manifold Gp |
| 1 | 419-8897 | Wiring Harness |
| 16 | 7K-1181 | Cable Strap |
| 1 | 130-5300 | Clip |
| 1 | 8T-4121 | Hard Washer |
| 1 | 8T-4137 | Bolt |
| 1 | 4P-8134 | Clip |
| 1 | 7X-4780 | Grommet |
| 1 | 420-8601 | Bracket As |
| 2 | 198-4777 | Hard Washer |
| 1 | 391-7101 | Hose As |
| 1 | 391-7108 | Hose As |
Machines Equipped with Reversing Hydraulic Fan (Group 2)
| Required Parts for Machines Equipped with Reversing Hydraulic Fan Group 2 |
||
|---|---|---|
| Qty | Part Number | Description |
| 1 | 7X-4780 | Grommet |
| 2 | 8T-4133 | Nut |
| 2 | 8T-4224 | Hard Washer |
| 2 | 8T-6869 | Bolt |
| 2 | 2M-9780 | O-Ring Seal |
| 2 | 6V-8640 | Connector |
| 4 | 6V-9746 | O-Ring Seal |
| 1 | 388-5493 | Control Manifold Gp |
| 1 | 7K-1181 | Cable Strap |
| 2 | 8T-4186 | Bolt |
| 2 | 198-4777 | Hard Washer |
| 1 | 391-7107 | Hose As |
| 1 | 391-7108 | Hose As |
| 1 | 420-8601 | Bracket As |
Installation of Electrical Harnesses on Machines Equipped with Standard Hydraulic Fan
Parts Reference
| Parts Reference for Installation of Electrical Harnesses on Machines Equipped with Standard Hydraulic Fan | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 15 | 7K-1181 | Cable Strap |
| 2 | 1 | 4P-8134 | Clip |
| 3 | 1 | 130-5300 | Clip |
| 4 | 1 | 8T-4137 | Bolt |
| 5 | 1 | 8T-4121 | Hard Washer |
| 6 | 1 | 7X-4780 | Grommet |
| 7 | 1 | 419-8897 | Wiring Harness |
Installation Procedure
- Place the blade on the ground.
- Relieve any pressure in the hydraulic system
ReferenceDisassembly and Assembly, KENR8915, "System Pressure"
- 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.
- Put vacuum on the hydraulic tank.
- 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 1 | g03177416 |
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| Illustration 2 | g03177417 |
- 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.
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| Illustration 3 | g03349363 |
- Remove the front bottom guard from underneath the machine.
ReferenceDisassembly and Assembly, KENR8915, "Bottom Guard"
- Remove the three wires and pins from the Deutsch connector on harness. Removing wires allows the harness to fit through the hole in the radiator guard.
 | |
| Illustration 4 | g03177863 |
(A) Brown (B) Black (C) Yellow | |
- Remove the grommet in the radiator guard. Insert harness through the hole in the upper left corner of the radiator guard. Reinstall the grommet around harness.
 | |
| Illustration 5 | g03177864 |
- Reinstall the 3-pin Deutsch connector onto the end of harness.
| | |
| Illustration 6 | g03177863 |
(A) Brown (B) Black (C) Yellow | |
- Install clip (2). Attach wiring harness (7) to clip (2) using cable strap (1) .
 | |
| Illustration 7 | g03350998 |
- Install clip (3) to the under hood bracket assembly with bolt (4) and hard washer (5). Secure 3-pin Deutsch connector to clip (3). Secure other connections here with cable strap (1) .
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| Illustration 8 | g03350999 |
- Secure the harness to the radiator guard using five cable straps (1) .
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| Illustration 9 | g03177866 |
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| Illustration 10 | g03177867 |
- Install wiring harness (7) through the hole in the lower left front corner of the radiator guard. Install grommet (6) around the harness in the hole.
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| Illustration 11 | g03352158 |
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| Illustration 12 | g03348202 |
- Tie up the unused connector and excess harness length for the reversing fan valve. Secure to existing harness using four cable straps (1) .
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| Illustration 13 | g03348205 |
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| Illustration 14 | g03348206 |
- Secure harness under the cooling package with the routing shown. Attach harness to the radiator guard with four cable straps (1) .
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| Illustration 15 | g03348207 |
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| Illustration 16 | g03348208 |
Installation of Electrical Harness on Machines Equipped with Reversing Hydraulic Fan
Parts Reference
| Parts Reference for Installation of the Electrical Harnesses with Reversing Hydraulic Fan | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 1 | 7X-4780 | Grommet |
Installation Procedure
- Place the blade on the ground.
- Relieve any pressure in the hydraulic system
ReferenceDisassembly and Assembly, KENR8915, "System Pressure"
- 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.
- Put vacuum on the hydraulic tank.
- 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.
| | |
| Illustration 17 | g03177416 |
| | |
| Illustration 18 | g03177417 |
- 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.
 | |
| Illustration 19 | g03349345 |
- Remove the front bottom guard from underneath the machine.
ReferenceDisassembly and Assembly, KENR8915, "Bottom Guard"
- Locate the two pin electrical harness connector on the radiator guard for the engine cooling fan bypass valve. Connector will be labeled "Low Speed Fan".
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| Illustration 20 | g03348176 |
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| Illustration 21 | g03348177 |
- Install grommet (1) around the harness in the hole in the radiator guard.
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| Illustration 22 | g03348180 |
Installation of the Engine Cooling Fan Bypass Attachment
Parts Reference
| Required Parts for Machines Equipped with Reversing Hydraulic Fan Group 2 |
|||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 1 | 7K-1181 | Cable Strap |
| 2 | 1 | 388-5493 | Control Manifold Gp |
| 3 | 2 | 6V-8640 | Connector |
| 4 | 2 | 2M-9780 | O-Ring Seal |
| 5 | 4 | 6V-9746 | O-Ring Seal |
| 6 | 1 | 420-8601 | Bracket As |
| 7 | 2 | 8T-6869 | Bolt |
| 8 | 2 | 8T-4224 | Hard Washer |
| 9 | 2 | 8T-4186 | Bolt |
| 10 | 2 | 198-4777 | Hard Washer |
| 11 | 2 | 8T-4133 | Nut |
| 12 | 1 | 391-7107 | Hose As |
| 13 | 1 | 391-7108 | Hose As |
Installation Procedure
- Remove two bolts and eight washers from the guard. Remove the guard from the machine.
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| Illustration 23 | g03177879 |
- 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 24 | g03177897 |
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| Illustration 25 | g03177885 |
- Inspect Control Manifold Gp (2). 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, the valves should 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 26 | g03349390 |
- Remove the plug from the port labeled "1" on manifold (2). This plug is located on the opposite end of the solenoid. Install connector (3) and O-ring seal (4) and O-ring seal (5) into the port. Torque connector (3) to 140 ± 21 N·m (103 ± 15 lb ft).
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| Illustration 27 | g03349402 |
- On the solenoid end of manifold (2), remove the plug from the port labeled "2". Install connector (3) and O-ring seal (4) and O-ring seal (5) into the port. Torque connector (3) to 140 ± 21 N·m (103 ± 15 lb ft).
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| Illustration 28 | g03349404 |
- Attach the manifold (2) to the bracket assembly (6) using two bolts (7) and two hard washers (8) .
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| Illustration 29 | g03348183 |
- Attach the manifold and plate to the lower radiator support using two bolts (9) and two hard washers (10) .
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| Illustration 30 | g03348185 |
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| Illustration 31 | g03348186 |
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| Illustration 32 | g03349333 |
- Install hose (12) between the reversing valve and the engine cooling fan bypass manifold. A new O-ring seal (5) is provided as needed. Rotate the engine cooling fan bypass valve end of the hose downward approximately 30 degrees. Tighten the nut on each coupling to 140 ± 21 N·m (103 ± 15 lb ft).
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| Illustration 33 | g03348187 |
- Install hose (13) between the engine cooling fan bypass valve and the hydraulic oil cooler. Use a new O-ring (5) 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 34 | g03349415 |
- Connect harness to the solenoid on manifold (2). Use cable strap (1) to tie extra harness length to the bracket assembly.
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| Illustration 35 | g03349416 |
- 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"
- Install two bolts and eight washers from the guard. Install the guard from the machine.
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| Illustration 36 | g03352157 |
- Close the grill doors on the radiator guard. Torque eight bolts to 100 ± 20 N·m (74 ± 15 lb ft).
| | |
| Illustration 37 | g03177416 |
- Install the engine enclosure door on the left side of the machine.
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| Illustration 38 | g03349348 |
- Remove the vacuum suction on the hydraulic tank and check the fluid level. Add hydraulic fluid as needed.
- Proceed to ""Installing the New Software" ".
Installing the New Software
- Before installing the software, make sure that the tractor is in proper operating condition.
Note: Cat Electronic Technician (Cat ® ET) version "2012B" or later is required in order to configure the Engine Cooling Fan Bypass.
- Turn the battery disconnect switch to the ON position.
- Connect a computer with Cat ET to the communication port in the cab.
- Turn the ignition key to the ON position.
- Download the Product Status Report.
- 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.
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| Illustration 39 | g03204842 |
- Use Cat ET to navigate to the Configuration page for the engine ECM.
- Change the "Fan Bypass" parameter to "Installed".
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| Illustration 40 | g03204976 |
- After the software is installed and the parameter is modified, disconnect Cat ET.
- Cycle the ignition key and the battery disconnect.
- Reconnect Cat ET and check to make sure that all software changes and configurations are saved.
- 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.
| Tractor Model | Temp |
|---|---|
| D6T | 0° C (32° F) |
| D7E | 0° C (32° F) |
| D8T | −30° C (−22° F) |
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)