Application, Installation, and Assembly Guide for On-Highway Cooling Systems for the CX28, CX31, CX31 HT, and the CX35 On-Highway Transmissions{1374, 1375, 1378, 1408, 3030, 7610} Caterpillar

Engine:

C13 (S/N: LEE1-UP)

C15 (S/N: SDP1-UP)

C7 (S/N: C7S1-UP)

C9 (S/N: C9S1-UP)

On-Highway Transmission:

CX28 (S/N: TBB1-UP; T3X1-UP)

CX31 (S/N: EBW1-UP; B3X1-UP)

CX35 (S/N: W3X1-UP)

Introduction

This document is a reference and guide for the application and installation of Caterpillar cooling modules. The purpose of this document is to assist OEMs, engineers, and manufacturers who provide cooling systems for recreational vehicles. This document is divided into eleven sections. Section one is an Introduction that explains a cooling module, technical review, and nomenclature for the cooling modules. Section one also lists engines, transmissions, and fluid references. Section two is General Information about all of the cooling modules discussed in this manual. Sections three, four, and five contain information on the Hydraulic System, Electrical System, and the Assembly and Disassembly of the cooling modules. Sections six through ten are the technical Specifications for each of the cooling systems contained in this manual. Section eleven is an Appendix of acronyms, standard torques, ambient temperatures of various geographical areas and a generic installation check list.

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NOTICE
The Cooling and Application Guide is stored and printed from an electronic file. The files are revised periodically. To ensure that your hard copy of this Special Instruction is the current version of the Cooling Module Application and Installation Guide, consult your local Caterpillar representative. All paper copies are uncontrolled. Caterpillar reserves the right to update, improve, and change the design of the cooling modules. Due to continuous design and product development updates, the information contained herein is subject to change without notification.

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COOLING MODULE TECHNICAL REVIEW

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Caterpillar cooling modules are designed and built to provide superior value. However, achieving the end user expectations depends upon the proper selection of the appropriate cooling module for the engine and transmission being used as well as the application and ambient conditions where the vehicle will operate. During the initial stages of the OEM's application request, the engine, transmission, and cooling requirements must be considered. The engine, transmission, and the cooling module have specifications and ratings that must be evaluated before selecting the cooling system.

The dimensions for each cooling module are provided on the specification sheet of this Application and Installation Guide. Specifications and ratings for the engines and the transmissions can be found in other engine and transmission-related publications. The OEM will need to determine the specific heat rejection and absorption of each cooling system's components with a Caterpillar Application Engineer. The cooling modules can cool to the "C" level that is shown in the ambient temperature chart that is provided in the Appendix. The engine power ratings for each module are printed at the top of each specification sheet.

In order to validate the overall vehicle performance when a Caterpillar engine, transmission, and a cooling system are installed, Caterpillar requires a mandatory technical review of each OEM's initial production model. This production review of the OEM's production units is a prerequisite for the sale of the cooling modules on an ongoing basis. In addition, another review is necessary whenever an installation change is made that can affect system performance. It is the OEM's responsibility to inform Caterpillar when these production changes are to occur. The cooling guide Check List in the Appendix of this manual provides a generic set of requirements for the five cooling systems.

This review is performed by OEM personnel at the OEM facility with the assistance of qualified Caterpillar technicians. Particular attention is given to the following: line routing, electrical systems, mounts, hydraulic tank size and location, serviceability, operator safety, and operating environment. A copy of Caterpillar's Installation Review Report with recommended improvements to the installation will be provided to the OEM. The review documents the important features and details of the system installation and designates those characteristics in the following categories:

• Satisfactory

• Marginally satisfactory

• Likely to lead to user dissatisfaction

• Unsatisfactory

Although Caterpillar exercises all reasonable efforts to ensure proper system performance, the OEMs have the overall responsibility for the installation of the cooling system in the OEM vehicle. Caterpillar assumes no responsibility for installation deficiencies within the OEM's vehicle.

Note: It is the responsibility of the installer to consider and avoid possible hazardous conditions, which could develop from the systems involved in any specific installation. The suggestions that are provided in this guide regarding avoidance of hazardous conditions apply to all applications and are necessarily of a general nature since only the installer is familiar with the details of the installation. The suggestions that are provided in this guide should be considered general examples only and are in no way intended to cover every possible hazard in every installation.

Note: During a system failure of internal components, the power train generates abrasive debris that circulates throughout the system. The debris can cause the valves, the power train, pumps, and actuators to suffer repeat failures. Thoroughly clean debris from the system after a component failure and replace the transmission oil cooler core in order to prevent repeat failures. Refer to Operation and Maintenance Manual, SEBU6250, "Caterpillar Machine Fluids Recommendations" for information on improving the durability of machine components and for additional fluid information.

Nomenclature

The Caterpillar Cooling Systems described in this Application and Installation Guide do not have model nomenclature designations due to the variability within the bill of materials for each of the cooling modules. Therefore, each cooling module has an engine displacement in liters and a fan configuration as its nomenclature. Fans are designated as Single or Dual units. As a result, the CM-9S is a Cooling Module with a 9 liter engine and a single fan. The remaining four cooling modules are the following: CM-9D, CM-13D, CM-15S and CM-15D. Each cooling module can cool the engine horsepower that is listed on the specification sheet to the "C" level of ambient temperature provided in the Appendix of this publication.

References

• Operation and Maintenance Manual, SEBU6250, "Caterpillar Machine Fluids Recommendations "

• Operation and Maintenance Manual, SEBU6385, "Caterpillar On-Highway Diesel Engine Fluids Recommendations"

• Parts Manual, SEBP4354, "C9 On-Highway Engine With Cooling Module"

• Parts Manual, SEBP4356, "C13 On-Highway Engine With Cooling Module"

• Parts Manual, SEBP4419, "C15 On-Highway Engine With Cooling Module"

• Special Instruction, REHS2883, "Application and Installation Guide (Mechanical) for the CX28 On-Highway Transmission"

• Special Instruction, REHS2790, "Application and Installation Guide (Mechanical) for the CX31 On-Highway Transmission"

• Special Instruction, REHS2885, "Application and Installation Guide (Mechanical) for the CX35 On-Highway Transmission"

• Special Instruction, REHS2884, "Application and Installation Guide (Electrical) for the CX28, CX31, and CX35 On-Highway Transmissions"

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GENERAL INFORMATION

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This section contains information that applies to all of the cooling modules. The recommended parts and design suggestions in this section are not repeated with each module's technical Specification.

Each of the cooling modules has a different top-level arrangement number which defines a unique cooling system bill of material. The cooling systems have similar features. However, each module has the following unique components: radiator group, hydraulic oil cooler, air-to-air aftercooler, fan assembly, fan shroud and fan motor. Each module has a unique bill of material (parts list group) provided within this General Information section in the Summary of Cooling Module Groups.

Hydraulics

There are two basic hydraulic schematics. One depicts a single hydraulic fan and the second depicts dual hydraulic fans. While the basics are similar, each module has a unique hydraulic system because the pumps, fan motors, hoses, and part numbers are different. A generic hydraulic schematic for the single fan system is provided in Illustration 6 and the generic dual fan system is shown in Illustration 7. Each cooling module has specific pump and motor components listed within a section that is dedicated to that particular cooling system.

Hydraulic Oil

Caterpillar hydraulic oil is the recommended fluid for most hydraulic systems. The oil is formulated with a balanced additive package. Engine oils may also be used to reduce the number of fluids required. Fluids meeting Caterpillar DEO (diesel engine oil) requirements for SAE 5W-20 are an alternative fluid. Caterpillar DEO ULS (ultra low sulfur) 319-2260 Oil is the recommended engine oil for 2007 on-highway diesels. Synthetic diesel engine oils are required for extended service intervals. Operation and Maintenance Manual, SEBU6385, "Caterpillar On-Highway Diesel Engine Fluids Recommendations" is a reference for 2007 diesel engine synthetic oils.

Hydraulic Lines and Hoses (High Pressure)

Caterpillar recommends Cat XT-5 hydraulic high-pressure hoses and lines from the pump to the motors. Supplier hoses that meet SAE specification 100R13 can also be used. However, hoses that cannot withstand working requirements of 276000 kPa (4000 psi) at 110 °C (230 °F) are not recommended. Caterpillar's bulk hoses that meet these high pressure and temperature requirements are 165-0021 Hose (25.4 mm (1.00 inch) ID) and 165-0020 Hose (19.0 mm (0.75 inch) ID).

Hydraulic Lines and Hoses (Intermediate Pressure)

The hoses and lines from the fan motors to the coolers need a working pressure rating of 700 kPa (100 psi) at 80 °C (180 °F). These hydraulic hoses need to meet SAE specifications 100R1 or Caterpillar specification 716. Caterpillar hoses that meet this specification are the 122-6873 Hydraulic Hose that has a 25.4 mm (1.00 inch) ID. The 122-6872 Hydraulic Hose that has a 19.0 mm (0.75 inch) ID. The 122-6871 Hydraulic Hose that has a 15.9 mm (0.625 inch) ID. And the 122-6869 Hydraulic Hose that has a 9.5 mm (0.375 inch) ID.

Hydraulic Drain Lines (Low Pressure)

The low-pressure drain and return lines need to have a working pressure rating of 275 kPa (40 psi) at 80 °C (180 °F). Hoses meeting the SAE specification 100R or Caterpillar 716 are the 122-6909 Hydraulic Hose that has a 50.8 mm (2.0 inch) ID. And the 122-6908 Hydraulic Hose that has a 38.1 mm (1.5 inch) ID.

Hydraulic Suction Lines (Low Pressure)

Suction line hoses need to meet SAE specification 100R4 or Caterpillar specification 844. Caterpillar hoses meeting these specifications are 122-6909 Hydraulic Hose (50.8 mm (2.0 inch) ID) and 122-6907 Hydraulic Hose (38.1 mm (1.5 inch) ID).

Hydraulic Filter

The Caterpillar hydraulic filter base requires a 295 mm x 117 mm (11.6 inch x 4.6) spin-on filter element. Caterpillar recommends a 5 micron 126-1817 Oil Filter Element . There is a differential pressure switch in the filter base that must be hooked to a warning light in the operator compartment.

Service Intervals (Hydraulic Oil and Filter)

Distance (odometer), service hours or calendar time, whichever occurs first, can be used to determine maintenance and service intervals.

Table 1

RV COOLING MODULE SERVICE INTERVALS
NON-SYNTHETIC SAE 5W-20 ENGINE OILS
Mileage	Time	Service
12, 500	1 year	Filter
25, 000	2 years	Hydraulic oil
SYNTHETIC SAE 5W-20 ENGINE OILS
Mileage	Time	Service
25, 000 (1)	2 years	Filter
100, 000 (1)	3 years	Hydraulic oil

( 1 )

Requires acceptable SOS oil analysis results every 12, 500 miles or every year which ever occurs first.

Hydraulic Reservoir (Tank)

To reduce the potential for pump cavitation, the location of the hydraulic oil sump/reservoir must be above the pump suction port. The oil reservoir also needs to have a volume large enough and deep enough to allow entrapped air to escape prior to entering the pump suction port. Due to differences of pump flow rates and OEM tank installation locations, each cooling system may need a unique hydraulic oil tank. The oil reservoir needs an oil volume that will allow the pumps to circulate the oil three to four times per minute with a non-air entrapped fluid. The return lines need to discharge the oil below the tank oil level to reduce the amount of air in the oil.

The hydraulic tank also needs to have dimensions that will facilitate expelling the entrapped air and allow easy inspections of oil volume. The suction port must be submerged in the liquid (solid non-aerated oil) three inches on slopes the vehicle is anticipated to negotiate. Expansion, contraction, and aeration of the oil necessitates a tank volume that is 30 percent larger than required to meet the previously mentioned flows. The recommended sight gauge has a visual depth measuring range of 140 mm (5.5 inch). Therefore, a tank design limiting the expansion and aeration of the hot oil to less than 70 mm (2.75 inch) is ideal.

Note: A rule of thumb for hydraulic tank design is to allow for a 15 percent fluctuation in oil volume due to temperature and aeration.

Fabricated hydraulic reservoirs and hose assemblies must meet cleanliness and flushing standards for new components as described in SAE J1227 and ISO/WD 18409.

Hydraulic Tank Breather

The reservoir needs an atmosphere vent with an air filter that will allow for thermal expansion and contraction without allowing dust and dirt to enter the hydraulic oil system. A filter that excels at removing fine dust particles and is frequently used by Caterpillar is the 9T-1119 Breather .

Oil Level Sight Gauge for the Hydraulic Oil Tank

The Caterpillar parts system has tank mounted six inch tall sight gauge. This 280-2566 Liquid Level Gauge is frequently used by Caterpillar customers. This sight gauge allows for a quick, clean and easy oil level check.

Engine Cooling Components

The cooling modules (heat exchangers) that are discussed in this Application and Installation Guide provide cooling for the engine radiator and the turbocharged inlet air. All of the drawings that are provided in this publication have enlarged print dimensions showing the connecting tube sizes. Additional drawing details will require enlarged prints of the complete heat exchangers. The air-to-air cooling lines and the engine liquid cooling lines must be routed and sized to minimize restrictions to flow.

Engine Coolant

Caterpillar recommends an ethylene glycol to water ratio of 1:1 for most applications. If the vehicle operates where ambient temperatures are below minus 37 °C (minus 35 °F) a 60:40 ratio of ethylene glycol to water is recommended.

Note: Caterpillar also recommends coolant corrosive inhibitors. See Operation and Maintenance Manual, SEBU6385, "Caterpillar On-Highway Diesel Engine Fluids Recommendations" for specific engine recommendations.

Radiator Surge Tank and Shunt Line

In addition to the engine radiator and lines group, the engine coolant system will need an expansion tank. The expansion tank must be located above the engine and the radiator. Coolant in the expansion tank ensures that the radiator remains full. The expansion tank will be at radiator cap pressure. See the included engine cooling lines in Illustration 1. Also see the cooling shunt information in the Engine Application and Installation Guide for the cooling shunt line, vent line, pressure cap, and the surge tank requirements.

Illustration 1	g01441685
Shunt Cooling System (1) Engine block (2) Cylinder head (3) Temperature regulator (partially open) (4) Engine vent (5) Baffle vent (6) Upper chamber (7) Baffle (8) Lower chamber (9) Radiator (10) Water pump (11) Shunt line (12) Bypass (13) Engine oil cooler (14) Transmission oil cooler

Cooling Module Mounts

Differences in the location and design of cooling systems require various OEM support groups. Therefore, the cooling module mounts become an OEM responsibility. Each cooling module in this Application and Installation Guide has a heavy metal frame that surrounds the three heat exchangers. Each side frame support has a mounting bracket above the center of gravity, capable of supporting the operating weight of the three heat exchangers. The lower mounts on each end of the cooler frame keep the cooling module vertical and restrain side-to-side motion. All of the isolation mounts for the cooling module need flexibility to insure that structural vehicular loads are not applied to the cooler frame. Caterpillar recommends isolation mounts capable of two g's that have adequate performance and endurance capabilities. The cooler mounts are sized to be compatible with supplier isolation mounts available to OEMs. The three heat exchanger dry weights for each of the cooling systems are provided on the specification sheets for each cooling module.

Note: Totally isolating the heat exchangers from the structural loads of the vehicle may necessitate an electrical ground to the vehicle frame to reduce static charges.

Steering Pumps

Vehicle steering pumps are the responsibility of the OEM. The steering pump's capacity must be considered with the cooling system's pump capacity when both pumps use the same hydraulic reservoir. The steering pump and the cooling system pump capacity are additive for pump flow rate when sizing the reservoir for circulation volumes. See the hydraulic reservoir section of this Guide for acceptable oil flow rates per minute as it relates to the size and design of the reservoir tank.

Cooling Hydraulic Fan Pump PTO Drives

The transmission PTOs are supplied by the OEMs. PTOs for Caterpillar CX transmissions are provided by PTO manufacturers. Several suppliers build PTOs that mate to the Caterpillar PTO ports. The PTO suppliers provide various gear ratios that operate at a percentage of engine speed. The rotation of the PTOs are dependent upon supplier designs. PTO specifications are available and can be obtained from the PTO manufacturers.

Caterpillar CX transmissions are available with two side PTOs and an optional rear PTO port. The PTOs used in this Application and Installation Guide are side mounted. The PTOs must provide the pump/engine speed ratios shown in Table 2. Overspeeding the pumps may damage the pumps while reducing the pump speeds will lower the performance of the cooling module.

Note: The Caterpillar engine ECM is programmed to limit overspeeding the pumps for the five modules discussed in this manual.

Table 2

PTO to Hydraulic Pump Gear Ratios
Module	Transmission	Engine Speeds to PTO Speed
CM-9S	CX28	1.0:1.33
CM-9D	CX28	1.0:1.33
CM-13D	CX31	1.0:1.24
CM-15S	CX35	1.0:1.26
CM-15D	CX31	1.0:1.24

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Common Hydraulic Components

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Illustration 2	g01427892
178-0094 Oil Filter Gp

The 178-0094 Oil Filter Gp is a remote mounted filter. The group includes the 173-7194 Filter Base and the 134-3014 Filter Element . Caterpillar recommends that the filter element be mounted in a vertical plane to facilitate function and ease of service. As noted in the Illustration, the filter element requires 70 mm (2.75 inch) of clearance for removal.

Illustration 3	g01427898
280-2566 Liquid Level Gauge

Aluminum body liquid level gauge with silicate glass vision tube. Can be used with hot or cold liquids. Two Buna N seals attach the gauge to the external surface of the hydraulic tank.

Illustration 4	g01427982
9T-1119 Breather

The Caterpillar 9T-1119 Breather has minimum restrictions to air flow while also providing a fine mesh screen that prevents some of the atmospheric dust from gaining access to the hydraulic system.

Illustration 5	g01427985
253-2673 Pressure Switch (differential switch)

Installation port is 9/16 STO.

3E-3364 Receptacle (Deutch)

Installation torque for the pressure switch is 6.78 ± 1.4 N·m (60 ± 12 lb in).

Activation voltage is 5 VDC (minimum) to 28 VDC (maximum).

The temperature range is -40 to 120 °C (-40 to 250 °F).

The Major Components Summary for the Cooling Module Systems Part Number Groups

Table 3

Summary of Cooling Module Groups
Part Name	9S	9D	13D	15S	15D
Cooling Arrangement	306-7119	299-5828	299-5827	299-5826	299-5830
Warning Film (Universal)	228-3581	228-3581	228-3581	228-3581	228-3581
Hydraulic Schematic	308-9149	308-9148	308-9150	308-9152	308-9151
Radiator Group	306-7205	302-3769	299-3302	299-3312	302-3754
Radiator (RAD)	306-7147	302-3770	299-3303	299-3313	302-3755
Hydraulic Oil Cooler (HOC)	306-7148	302-3771	299-3304	299-3314	302-3756
ATAAC (CAC)	306-7149	302-3772	299-3305	299-3315	302-3757
Fan Assembly	306-7150	302-3773	299-3306	299-3316	302-3758
Fan Shroud	306-7151	302-3774	299-3307	299-3317	302-3759
Bracket	302-3775	302-3775	299-3308	299-3308	299-3308
Sensor GP	266-8576	266-8576	266-8576	266-8576	266-8576
Plate (Target)	310-3455	310-3455	310-3455	310-3455	310-3455
Motor Mount	299-5267	302-3777	299-5267	299-3319	302-3777
Fan Motor	308-1556	299-9134	299-9132	299-9133	303-8750
A/C Condenser	299-3309	299-3309	299-3309	299-3309	302-2396
Condenser Core	304-8886	304-8886	304-8886	304-8886	304-8887
Fan Shroud					304-8891
Fan A/C	304-8888	304-8888	304-8888	304-8888	304-8888
Installation Group	302-3768	302-3768	299-3301	299-3311	299-3311
Transmission Oil Cooler (TOC)	299-5772	299-5772	299-5772	238-7997	238-7997
Fan Pump	299-9129	299-9129	299-9130	299-9131	299-9131
Pressure Switch Filter GP (1)	253-2673	253-2673	253-2673	253-2673	253-2673
Filter GP (Fan Filter GP)	178-0094	178-0094	178-0094	178-0094	178-0094

( 1 )

Optional

HYDRAULIC SYSTEM

Illustration 6	g01440014
(1) Anti Cavity Check Valve (2) Motor (3) Hydraulic Pump (4) Hydraulic Oil Cooler (5) Steering Gear (6) Hydraulic Tank (7) Filter Bypass Valve (8) Hydraulic Oil Filter (9) Filter Bypass Switch (10) Steering Pump (11) Steering Priority Flow Control

Illustration 7	g01440683
(1) Anti Cavity Check Valve (2) Motor (3) Hydraulic Pump (4) Hydraulic Oil Cooler (5) Steering Gear (6) Hydraulic Tank (7) Filter Bypass Valve (8) Hydraulic Oil Filter (9) Filter Bypass Switch (10) Steering Pump (11) Steering Priority Flow Control

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ELECTRICAL SYSTEM

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All five cooling modules have similar but not identical electrical systems. One system has two motors and fans and the second system has one motor driven fan. Both systems require programming and electrical connections to the engine ECM.

Caterpillar Hydraulic Fan (Electrical Information)

The Caterpillar Hydraulic Fan system requires programming of Customer Parameters and electrical connections to the engine ECM.

Customer Parameter Programming

Three Customer Programmable Parameters must be programmed in order to enable the Caterpillar Hydraulic Fan.

Fan Control Type

The Fan Control Type parameter must be programmed to the Variable Speed Option C. This will enable the Caterpillar Hydraulic Fan control strategy. This parameter is programmed according to the Information in Table 5.

Fan Speed Control Output

The Fan control output at J1/P1: 21 will provide a PWM signal to the hydraulic pump. This signal is required for fan speed control. If this signal is not connected, the fan will turn at the maximum speed.

Minimum Fan Speed

The Minimum Fan Speed parameter must be programmed for the control strategy to function properly. This parameter is programmed according to the Information in Table 5.

Maximum Fan Speed

The Maximum Fan Speed parameter must be programmed for the control strategy to function properly. This parameter is programmed according to the Information in Table 5.

Maximum Fan Speed Ratio Multiplier

The Maximum Ratio Fan Speed Multiplier parameter must be programmed for the control strategy to function properly. This parameter is programmed according to the information in Table 5.

Table 4

Customer Parameter	Required Fan Programming	Default
Fan Control Type	Variable Speed Option C	None

Table 5

Cooling System Part Number	Required Program for Minimum Fan Speed (RPM)	Required Program for Maximum Fan Speed Ratio Multiplier	Required Program for Maximum Fan Speed (RPM)
309-7119 CM - 9S	800	1.54	2800
299-5828 CM - 9D	800	1.60	2900
299-5827 CM - 13D	700	1.56	2600
299-5826 CM - 15S	600	1.28	2200
299-5830 CM - 15D	800	1.77	3000

General Wiring Guidelines

The wiring must be routed and secured in order to prevent rubbing of wires against abrasive surfaces and sharp edges. The wiring should be routed to allow for movement between soft mounted chassis components. Wiring must be routed to prevent exposure to sources of intense heat that can degrade or melt insulation.

Engine ECM

Illustration 8	g01424393

Fan Speed Sensor Function Verification

The fan Speed Sensor must be installed with a 3 mm gap (+/1 mm). The voltage supply must be 5 to 14 VDC. When positioned over a sensor wheel target, the sensor output will be low (1 VDC or less). When positioned over a gap in the sensor wheel, the sensor output will be approximately the supplied voltage.

A simple circuit can be assembled (as shown) to validate sensor function when not connected to the engine ECM.

Illustration 9	g01438668
Test box for speed sensor (1) Suggested wire size is 16 Gauge (2) Plastic container (LED, resistor, and battery) (3) 9 Volts (4) Diffused LED HLMP-3401 (5) 330 Ohms (6) 155-2267 Connector Plug As (requires three 126-1768 Connector Sockets ) (7) Sensor

Connectors

All OEM points of connection to the engine are on the 70-terminal J1 connector.

Note: Caterpillar does not recommend the use of non-conductive grease with this connector.

ECU 70 Terminal Connector Part Numbers

The ECU uses an integral rectangular 70 Terminal AMP connector to interface to the OEM vehicle wiring harness (AMP part number 776241-1, Caterpillar part number 160-7689).

Table 6

REQUIRED TERMINAL CONNECTOR PARTS
Description	Usage	Vendor - Part Number	Cat - Part Number
70 Terminal Plug	ECU Vehicle Harness	AMP - 776241 - 1	160-7689 Connector Plug As
3 Pin Terminal Plug	Speed Sensor Connector	Deutsch connector DT06-3S-EP06	155-2267 Connector Plug As
2 Pin Terminal Plug	Pump Control Connection	Deutsch connector DT06-2S-EP06	155-2269 Connector Plug As
AMP Gold Socket Contact (stamped & formed)	# 16 & #18 AWG SXL and #14, #16, and #18 AWG GXL wire	AMP - 638090-1	126-1766 Connector Socket
Deutsch connector Gold Socket Contact (machined for field service)	# 14 AWG SXL and #14 AWG GXL wire	Deutsch connector – 0462-209-1631	126-1768 Connector Socket
Deutsch connector Gold Socket Contact (machined for field service)	#16 & #18 AWG SXL and #16 & #18 AWG GXL wire	Deutsch connector – 0462-201-1631	9X-3402 Connector Socket
Sealing Plug # 14 - 18 AWG	Sealing Unused Connector Cavities	PEI Genesis – 225-0093-000	9G-3695 Plug
Sealing Plug # 14 - 18 AWG	Sealing Unused Connector Cavities	Deutsch connector - 114017	8T-8737 Seal Plug

Terminal Connector Allen Screw Torque

The 70-Terminal ECU Connector Screw torque should be 6 Nm ±1 Nm (4.4 lb.- ft. ± 0.7 lb.- ft., 53 lb. - in. ± 8.9 lb. - in.). The screw requires a 4MM (or 5/32) Hex wrench.

Wire Gauge Size

The maximum wire size is #14 AWG SAE J1128 type GXL. Recommended wire size is #16 or #18 AWG SAE J1128 type SXL or #16 or #18 AWG SAE J1128 type GXL (or equivalent gauge and diameter).

Wire Insulation and Size Range

The wire insulation diameter must be within the ranges that are shown in Table 7 in order to assure proper sealing.

Table 7

WIRE SPECIFICATIONS
Wire Type	Wire Gauge	Insulation Diameter
GXL	14	0.114 - 0.125
	16	0.096 - 0.112
	18	0.089 - 0.098
SXL	16	0.116 - 0.131
	18	0.103 - 0.118

ECU 70-Terminal Connector Socket Installation Guidelines

It is critical that the harness supplier uses the correct crimp tools and tool calibration/setup procedures, when installing AMP and Deutsch connector terminals. The following tables indicate proper crimp tooling, go-no-go criteria, and crimp dimensions for each contact wire combination.

Table 8

WIRE CRIMP SPECIFICATIONS
Wire Type	Wire Gauge	Crimp Height (+/- 0.002)	Crimp Width (in)
GXL	14	0.064	0.10
	16	0.059	0.10
	18	0.054	0.10
SXL	16	0.054	0.10
	14	0.059	0.10

Note: Insulation barrel crimp height for AMP 776093-1 stamped and formed sockets must be set according to the insulation diameter. Crimp width for all insulations is 0.145 inches maximum.

Table 9

Deutsch connector 0462-209-1631 Solid Socket with #14 AWG Wire (Caterpillar P/N 126-1768)
Crimp Tool Options	DIE	Locator	Go (in)	No - Go (in)
Deutsch connector Hand Tool HDT – 48 - 00	N/A	N/A	0.052	0.057
Pico Model 400	414DA - 16N	4301 - 16	0.043	0.050

Table 10

Deutsch connector 0462-201-1631 Solid Socket with #16 and #18 AWG Wire (Caterpillar P/N 9X3402)
Crimp Tool Options	DIE	Locator	Go (in)	No - Go (in)
Deutsch connector Hand Tool HDT – 48 - 00	N/A	N/A	0.045	0.050
Pico Model 400	414DA - 16N	4301 - 16	0.043	0.050

Sealing Plugs

Caterpillar requires sealing plugs for all unused connector cavities. Two options are available. Either the deutsch connector 114017 (Caterpillar part number 8T-8737) or PEI Genesis 225-0093-000 (Caterpillar part number 9G-3695) sealing plugs can be used. Correct installation of either of these cavity plugs is critical to maintain connector-sealing integrity. The figure shown below indicates correct insertion of the plug. The plug cap is designed to rest against the seal, not inserted into the hole in the seal.

Illustration 10	g01424395

ECU 70-Terminal Connector Interface Seal

Illustration 11	g01424396

The ECU Connector Interface seal is serviceable using Caterpillar part number 159-9322.

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ASSEMBLY AND DISASSEMBLY INFORMATION

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The general information section of this article illustrates the assembly and disassembly procedures for the five cooling modules. The methods and illustrations are of generic nature due to the design similarity of the cooling modules.

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Fan Assembly (Remove and Install)

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Removal Procedure

Show/hide table

NOTICE
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Show/hide table



Illustration 12	g01407738

1. Remove bolts (2). Remove fan assembly (1) .

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Illustration 13	g01407740

2. Remove bolts (4). Install bolts (4) into holes (3) .

3. Hand tighten bolts (4). Tighten bolts (4) in an alternating sequence to remove fan assembly (5) from bushing (6) .

4. Remove fan assembly (5) .

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Illustration 14	g01407746

5. Loosen setscrew (7) and remove bushing (6) .

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Illustration 15	g01407747

6. Turn over bushing (6) and remove bolts (8). Remove target disk (9) .

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Illustration 16	g01407748

7. Remove bolts (10) and motor (11) .

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Illustration 17	g01438850

8. Loosen nut (12) and remove sensor (13) .

Note: The other fan assembly does not have a target disk or a sensor.

9. Repeat Steps 1 through 5 and Step 7 for the other fan assembly.

Installation Procedure

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NOTICE
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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Illustration 18	g01407748

1. Install motor (11) and bolts (10) .

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Illustration 19	g01407747

2. Orient the key slot in bushing (6) with target disk (9). Place target disk (9) in position. Install bolts (8) in bushing (6). Do not tighten bolts (8) at this time.

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Illustration 20	g01407746

Note: For CM-9D, CM-13D, and CM-15D, ensure that the face of the bushing is flush with the end of the shaft.

Note: For CM-9S and CM-15S, ensure that the end of the shaft is −3.0 mm (−0.12 inch) from the face of the bushing.

3. Place bushing (6) in position and tighten setscrew (7) .

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Illustration 21	g01438877

Note: Do not overtighten the bolts. Damage to the bushing can occur.

4. Install fan assembly (5) on bushing (6). Install bolts (4). Tighten the bolts to a torque of 12.2 N·m (108 lb in).

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Illustration 22	g01439041

5. Tighten bolts (8) from Step 2.

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Illustration 23	g01439055

6. Install sensor (13) into weld nut (14). Set the distance between sensor (13) and target disk (9) to Dimension (X). Dimension (X) is 3.0 ± 1.0 mm (0.12 ± 0.04 inch).

7. Tighten nut (12) .

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Illustration 24	g01407738

8. Install fan assembly (1). Center the fan assembly and install bolts (2) .

Note: The other fan assembly does not have a target disk or a sensor.

9. Repeat Step 1, Step 3 and Step 4, and Step 8 for the other fan assembly.

____________________

Radiator (Disassembly and Assembly)

____________________

Disassembly Procedure

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NOTICE
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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Illustration 25	g01407738

1. Remove bolts (2). Remove fan assembly (1) .

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Illustration 26	g01407791

2. Remove bolts (3). Remove fan assembly (4) .

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Illustration 27	g01407795

3. Remove bolts (5). Remove bolts (5) for the opposite side.

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Illustration 28	g01407797

4. Remove bolts (6). Remove bolts (6) for the opposite side.

5. Remove shroud (7) .

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Illustration 29	g01407804

6. Remove bolts (8) and (10) .

7. Remove aftercooler (9), radiator (11), and hydraulic oil cooler (12) .

Assembly Procedure

____________________

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NOTICE
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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Illustration 30	g01407804

1. Place hydraulic oil cooler (12), radiator (11), and aftercooler (9) in position.

2. Install bolts (10) and (8) .

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Illustration 31	g01407797

3. Install shroud (7) .

4. Install bolts (6). Install bolts (6) for the opposite side.

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Illustration 32	g01407795

5. Install bolts (5). Install bolts (5) for the opposite side.

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Illustration 33	g01407791

6. Install fan assembly (4). Install bolts (3) .

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Illustration 34	g01407738

7. Install fan assembly (1). Install bolts (2) .

Motor (Disassembly and Assembly)

____________________

Disassembly Procedure

Table 11

Required Tools
Tool	Part Number	Part Description	Qty
A	1P-1857	Retaining Ring Pliers	1

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NOTICE
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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Illustration 35	g01408059

1. Remove plugs (2) and (3) .

2. Remove bolts (1) and cover (4) .

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Illustration 36	g01408065

3. Remove O-ring seal (6) from housing (5) .

4. Remove seal (8) and bearing (7) .

5. Remove housing (5) from adapter (9) .

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Illustration 37	g01408069

6. Remove O-ring seal (10) from housing (5) .

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Illustration 38	g01408070

7. Remove gear (11) and gear (12) from adapter (9) .

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Illustration 39	g01408071

8. Remove bearing (13) from adapter (9) .

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Illustration 40	g01408072

9. Remove seal (14) from bearing (13) .

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Illustration 41	g01408075

10. Remove seal (15) .

11. Use Tooling (A) to remove retaining ring (16) .

12. Remove seal (17) .

Assembly Procedure

Table 12

Required Tools
Tool	Part Number	Part Description	Qty
A	1P-1857	Retaining Ring Pliers	1

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NOTICE
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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Illustration 42	g01408075

1. Install seal (17) .

2. Use Tooling (A) to install retaining ring (16) .

3. Install seal (15) .

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Illustration 43	g01408072

4. Install seal (14) in bearing (13) .

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Illustration 44	g01408071

5. Install bearing (13) on adapter (9) .

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Illustration 45	g01408070

6. Install gear (12) and gear (11) on adapter (9) .

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Illustration 46	g01408069

7. Install O-ring seal (10) on housing (5) .

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Illustration 47	g01408065

8. Install housing (5) on adapter (9) .

9. Install bearing (7) and seal (8) .

10. Install O-ring seal (6) on housing (5) .

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Illustration 48	g01408059

11. Install cover (4) and bolts (1) .

12. Install plugs (3) and (2) .

CM-9S SPECIFICATIONS

Table 13

CM-9S (425 HP/1350 ft-lb System)
Units	Item (1)	Weight kg (lb)	Size Metric (English)
1	Hydraulic Pump (PTO Driven)	18 kg (39.6 lb)	45 cc (2.7 in3)
1	Heat Exchanger Components	237 kg (522 lb) (2)	1578 x 776 x 557 mm (62.1 x 30.5 x 21.9 inch) (Length x Height x Thickness)
1	Fan Motor	8.5 kg (18.7 lb) Each	29 cc (1.8 in3)
1	Fan		737 mm (29 inch) Diameter
1	Air Conditioner (A/C) Condenser with Fan	10.7 kg (23.6 lb) Total Weight	500 x 450 x 132 mm (19.7 x 17.7 x 5.2 inch) (Length x Height x Thickness)
1	Fan A/C - 12 Volt		406 mm (16 inch) Diameter
1	Cooling System Hydraulic Filter	3.7 kg (8.1 lb)	368 x 117 mm (14.5 x 4.6 inch) (Length x Diameter)
1	Filter Base with Bypass Switch	2 kg (4.4 lb)	127 x 117 x 78 mm (5 x 4.6 x 3.2 inch)
1	Filter Element Spin - on	1.7 kg (3.7 lb)	295 x 117 mm (11.6 x 4.6 inch) Diameter
1	Transmission Cooler (Oil to water)	6.8 kg (15 lb) (Aluminum Single Pass)	474 x 136 mm (18.7 x 5.4 inch) (Length x Diameter)
4	Isolator Mounts	OEM Purchased and Installed	See the General Information Section of this Guide as per these OEM components
1	Hydraulic Tank	OEM Purchased and Installed
1	Surge Tank	OEM Purchased and Installed
1	Lines and Hose Groups	OEM Purchased and Installed
1	Steering Pump	OEM Purchased and Installed

( 1 )	All of the specifications listed are close approximations for the components without fluids (that is, dry weights). The isolation mounts, steering pump, and lines and hose groups are OEM-dependent based on the design and location of the system components.
( 2 )	Weight includes fan, fan motor, radiator, ATAAC, and HOC.

CM - 9S Hydraulic Schematic

Illustration 49	g01429332
(1) Anti Cavity Check Valve (2) Motor (3) Hydraulic Pump (4) Hydraulic Oil Cooler (5) Steering Gear (6) Hydraulic Tank (7) Filter Bypass Valve (8) Hydraulic Oil Filter (9) Filter Bypass Switch (10) Steering Pump (11) Steering Priority Flow Control

Illustration 50	g01432756

Illustration 51	g01430435
299-3309 Refrigerant Condenser and Mounting Gp

Illustration 52	g01430437
299-5772 Oil Cooler Core Gp

This oil cooler (single pass aluminum shell) is also available in a two-pass version. The two-pass version with both inlet and outlet water bonnets on the same end may be a better installation for some OEM applications. The group level part number for the two-pass oil to water cooler is the 287-6593 Oil Cooler .

CM-9D SPECIFICATIONS

Table 14

CM-9D (425 HP - 1350 ft-lb System)
Units	Item (1)	Weight kg (lb)	Size Metric (English)
1	Hydraulic Pump (PTO Driven)	18 kg (39.6 lb)	45 cc (2.7 in3)
1	Heat Exchanger Components	237 kg (522 lb) (2)	1878 x 696 x 493 mm (73.9 x 27.4 x 19.4 inch) (Length x Height x Thickness)
2	Fan Motors	4 kg (8.8 lb) Each	14 cc (0.85 in3)
2	Fans		660 mm (26 inch) Diameter
1	Air Conditioner (A/C) Condenser with Fan	10.7 kg (23.6 lb) Total Weight	500 x 450 x 132 mm (19.7 x 17.7 x 5.2 inch) (Length x Height x Thickness)
1	Fan A/C - 12 Volt		406 mm (16 inch) Diameter
1	Cooling System Hydraulic Filter	3.7 kg (8.1 lb)	368 x 117 mm (14.5 x 4.6 inch) (Length x Diameter)
1	Filter Base with Bypass Switch	2 kg (4.4 lb)	127 x 117 x 78 mm (5 x 4.6 x 3.2 inch)
1	Filter Element Spin - on	1.7 kg (3.7 lb)	295 x 117 mm (11.6 x 4.6 inch) Diameter
1	Transmission Cooler (Oil to water)	6.8 kg (15 lb) (Aluminum Single Pass)	474 x 136 mm (18.7 x 5.4 inch) (Length x Diameter)
4	Isolator Mounts	OEM Purchased and Installed	See the General Information Section of this Guide as per these OEM components
1	Hydraulic Tank	OEM Purchased and Installed
1	Surge Tank	OEM Purchased and Installed
1	Lines and Hose Groups	OEM Purchased and Installed
1	Steering Pump	OEM Purchased and Installed

( 1 )	All of the specifications listed are close approximations for the components without fluids (that is, dry weights). The isolation mounts, steering pump, and lines and hose groups are OEM-dependent based on the design and location of the system components.
( 2 )	Weight includes fan, fan motor, radiator, ATAAC, and HOC

CM-9D Hydraulic Schematic

Illustration 53	g01429775
(1) Anti Cavity Check Valve (2) Motor (3) Hydraulic Pump (4) Motor (5) Hydraulic Oil Cooler (6) Steering Gear (7) Hydraulic Tank (8) Filter Bypass Valve (9) Hydraulic Oil Filter (10) Filter Bypass Switch (11) Steering Pump (12) Steering Priority Flow Control

Illustration 54	g01430441
302-3769 Radiator Gp

Illustration 55	g01430435
299-3309 Refrigerant Condenser and Mounting Gp

Illustration 56	g01430437
299-5772 Oil Cooler Core Gp

This oil cooler (single pass aluminum shell) is also available in a two-pass version. The two-pass version with both inlet and outlet water bonnets on the same end may be a better installation for some OEM applications. The group level part number for the two-pass oil to water cooler is the 287-6593 Oil Cooler .

CM-13D SPECIFICATIONS

Table 15

CM-13D (525 HP/1750 ft-lb System)
Units	Item (1)	Weight kg (lb)	Size Metric (English)
1	Hydraulic Pump (PTO Driven)	22 kg (48.5 lb)	60 cc (3.7 in3)
1	Heat Exchanger Components	246 kg (541 lb) (2)	1778 x 855 x 523 mm (70.5 x 33.6 x 20.6 inch) (Length x Height x Thickness)
2	Fan Motors	4.2 kg (9.3 lb) Each	19 cc (1.2 in3)
2	Fans		737 mm (29 inch) Diameter
1	Air Conditioner (A/C) Condenser with Fan	10.7 kg (23.6 lb) Total Weight	500 x 450 x 132 mm (19.7 x 17.7 x 5.2 inch) (Length x Height x Thickness)
1	Fan A/C - 12 Volt		406 mm (16 inch) Diameter
1	Cooling System Hydraulic Filter	3.7 kg (8.1 lb)	368 x 117 mm (14.5 x 4.6 inch) (Length x Diameter)
1	Filter Base with Bypass Switch	2 kg (4.4 lb)	127 x 117 x 78 mm (5 x 4.6 x 3.2 inch)
1	Filter Element Spin - on	1.7 kg (3.7 lb)	295 x 117 mm (11.6 x 4.6 inch)
1	Transmission Cooler (Oil to water)	6.8 kg (15 lb) (Aluminum Single Pass)	474 x 136 mm (18.7 x 5.4 inch) (Length x Diameter)
4	Isolator Mounts	OEM Purchased and Installed	See the General Information Section of this Guide as per these OEM components
1	Hydraulic Tank	OEM Purchased and Installed
1	Surge Tank	OEM Purchased and Installed
1	Lines and Hose Groups	OEM Purchased and Installed
1	Steering Pump	OEM Purchased and Installed

( 1 )	All of the specifications listed are close approximations for the components without fluids (that is, dry weights). The isolation mounts, steering pump, and lines and hose groups are OEM-dependent based on the design and location of the system components.
( 2 )	Weight includes fan, fan motor, radiator, ATAAC, and HOC

CM-13D Hydraulic Schematic

Illustration 57	g01429789
(1) Anti Cavity Check Valve (2) Motor (3) Hydraulic Pump (4) Motor (5) Hydraulic Oil Cooler (6) Steering Gear (7) Hydraulic Tank (8) Filter Bypass Valve (9) Hydraulic Oil Filter (10) Filter Bypass Switch (11) Steering Pump (12) Steering Priority Flow Control

Illustration 58	g01430432
299-3302 Radiator Gp

Illustration 59	g01430435
299-3309 Refrigerant Condenser and Mounting Gp

Illustration 60	g01430437
299-5772 Oil Cooler Core Gp

This illustrated single pass aluminum shell oil cooler is also available in a two-pass version. The two-pass version with both inlet and outlet water bonnets on the same end may be a better installation for some OEM applications. The group level part number for the two-pass oil to water cooler is 287-6593

CM-15S SPECIFICATIONS

Table 16

CM-15S (625 HP - 1900 ft-lb System)
Units	Item (1)	Weight kg (lb)	Size Metric (English)
1	Hydraulic Pump (PTO Driven)	22 kg (48.5 lb)	63 cc (3.7 in3)
1	Heat Exchanger Components	285 kg (628 lb) (2)	1678 x 1128 x 626 mm (66.1 x 44.5 x 24.6 inch) (Length x Height x Thickness)
1	Fan Motor	23.8 kg (52.4 lb) Each	50 cc (3.1 in3)
1	Fan		1067 mm (42 inch) Diameter
1	Air Conditioner (A/C) Condenser with Fan	10.7 kg (23.6 lb) Total Weight	500 x 450 x 132 mm (19.7 x 17.7 x 5.2 inch) (Length x Height x Thickness)
1	Fan A/C - 12 Volt		406 mm (16 inch) Diameter
1	Cooling System Hydraulic Filter	4 kg (8.8 lb)	368 x 117 mm (14.5 x 4.6 inch) (Length x Diameter)
1	Filter Base with Bypass Switch	2 kg (4.4 lb)	127 x 117 x 78 mm (5 x 4.6 x 3.2 inch)
1	Filter Element Spin - on	1.7 kg (3.7 lb)	295 x 117 mm (11.6 x 4.6 inch)Diameter
1	Transmission Cooler (Oil to water)	17.3 kg (38 lb) (Aluminum Single Pass)	508 x 220 mm (20 x 8.7 inch) (Length x Diameter)
4	Isolator Mounts	OEM Purchased and Installed	See the General Information Section of this Guide as per these OEM components
1	Hydraulic Tank	OEM Purchased and Installed
1	Surge Tank	OEM Purchased and Installed
1	Lines and Hose Groups	OEM Purchased and Installed
1	Steering Pump	OEM Purchased and Installed

( 1 )	All of the specifications listed are close approximations for the components without fluids (that is, dry weights). The isolation mounts, steering pump, and lines and hose groups are OEM-dependent based on the design and location of the system components.
( 2 )	Weight includes fan, fan motor, radiator, ATAAC, and HOC.

CM-15S Hydraulic Schematic

Illustration 61	g01429798
(1) Anti Cavity Check Valve (2) Motor (3) Hydraulic Pump (4) Hydraulic Oil Cooler (5) Steering Gear (6) Hydraulic Tank (7) Filter Bypass Valve (8) Hydraulic Oil Filter (9) Filter Bypass Switch (10) Steering Pump (11) Steering Priority Flow Control

Illustration 62	g01430436
299-3312 Radiator Gp

Illustration 63	g01430435
299-3309 Refrigerant Condenser and Mounting Gp

Illustration 64	g01432582

CM-15D SPECIFICATIONS

Table 17

CM-15D (625 HP - 1900 ft-lb System)
Units	Item (1)	Weight kg (lb)	Size Metric (English)
1	Hydraulic Pump (PTO Driven)	22 kg (48.5 lb)	63 cc (3.8 in3)
1	Heat Exchanger Components	246 kg (541 lb) (2)	1678 x 979 x 527 mm (66.1 x 38.5 x 20.7 inch) (Length x Height x Thickness)
2	Fan Motors	4.2 kg (9.3 lb) Each	18 cc (3.1 in3)
2	Fans		737 mm (26 inch) Diameter
1	Air Conditioner (A/C) Condenser with Fan	19.5 kg (43 lb) Total Weight	950 x 462 x 171 mm (37.4 x 18.2 x 6.7 inch) (Length x Height x Thickness)
2	Fans A/C - 12 Volt		406 mm (16 inch) Diameter
1	Cooling System Hydraulic Filter	3.7 kg (8.1 lb)	368 x 117 mm (14.5 x 4.6 inch) (Length x Diameter)
1	Filter Base with Bypass Switch	2 kg (4.4 lb)	127 x 117 x 78 mm (5 x 4.6 x 3.2 inch)
1	Filter Element Spin - on	1.7 kg (3.7 lb)	295 x 117 mm (11.6 x 4.6 inch) Diameter
1	Transmission Cooler (Oil to water)	17.3 kg (38 lb) (Aluminum Single Pass)	508 x 220 mm (20 x 8.7 inch) (Length x Diameter)
4	Isolator Mounts	OEM Purchased and Installed	See the General Information Section of this Guide as per these OEM components
1	Hydraulic Tank	OEM Purchased and Installed
1	Surge Tank	OEM Purchased and Installed
1	Lines and Hose Groups	OEM Purchased and Installed
1	Steering Pump	OEM Purchased and Installed

( 1 )	All of the specifications listed are close approximations for the components without fluids (i.e. dry weights). The isolation mounts, steering pump and lines and hose groups are OEM-dependent based on the design and location of the system components.
( 2 )	Weight includes fan, fan motor, radiator, ATAAC, and HOC.

CM-15D Hydraulic Schematic

Illustration 65	g01429794
(1) Anti Cavity Check Valve (2) Motor (3) Hydraulic Pump (4) Motor (5) Hydraulic Oil Cooler (6) Steering Gear (7) Hydraulic Tank (8) Filter Bypass Valve (9) Hydraulic Oil Filter (10) Filter Bypass Switch (11) Steering Pump (12) Steering Priority Flow Control

Illustration 66	g01430440
302-3754 Radiator Gp

Illustration 67	g01430439
302-2396 Refrigerant Condenser and Mounting Gp

Illustration 68	g01432582

APPENDIX

Acronyms

Table 18

Acronyms	Description
A and I	Application and Installation
A/C	Air Conditioner
ABS	Anti-lock Braking System
ADEM	Advanced Diesel Engine Management - control
ATAAC	Air To Air After cooler
ATF	Automatic Transmission Fluid
CC	Cubic Centimeters - Pump and Motor Displacement
CID	Component Identifier Diagnostic - code that informs the service personnel of specific component or system failure
ECM	Engine Control Module - controls all aspects of an engine's emissions compliance, performance, operator/chassis interaction and diagnostics.
ECU	Electronic Control Unit - electronic device used to control transmission functions
EMS	Electronic Monitoring System
FEA	Finite Element Analysis
FWH	Flywheel Housing
HOC	Hydraulic Oil Cooler
LUC	Lockup Clutch
OEM	Original Equipment Manufacturer
PT	Power Train - transmission and auxiliary components
PS	Power System - engine, transmission, and cooling system
PTO	Power Take-Off - referred to in this manual is engine rpm controlled
SAE	Society of Automotive Engineers - standards
STO	Straight Thread O-Ring
STR	Stall Torque Ratio - torque converter stall torque ratio
TBU	Transmission Business Unit
TSG	Technical Standards and Guidelines
ISO	International Standards Organization
OMM	Operation and Maintenance Manual
kPa	x 0.145 = pressure (PSI)
bar	x 14.5 = pressure (PSI)
CC	x 0.061 = cubic inch
kg	x 2.2 = pound
kW	x 1.34 = horsepower
L/min	x 0.26 = gallons/min
N·m	x 0.74 = ft × lb
SOS	Scheduled Oil Sampling

Standard Bolt Torque

____________________

Note: The torques in the following tables are based on metric Grade 10.9 or higher fasteners (SAE Grade 8 or higher fasteners). Use hardened washers. Split lock washers are not permitted.

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NOTICE
If bolts are removed from the CX31 transmission to add mounting brackets, etc. they must be replaced with longer bolts so that thread engagement is maintained. The replacement bolts must be of the same grade and torqued to the required specifications. Thread engagement length and bolt torques are critical on the Aluminum Case and Cover of the CX Transmissions. The bolts selected for aluminum threaded bores must have a thread engagement length of twice the bolt diameter. Standard torques on short bolts will strip the threads. The bolts must not be too long because the bolts will bottom out and damage the case.

Table 19

Inch Nuts and Bolts
Thread Size Inch	Standard Torque
1/4	12 ± 3 N·m (9 ± 2 lb ft)
5/16	25 ± 6 N·m (18 ± 4 lb ft)
3/8	47 ± 9 N·m (35 ± 7 lb ft)
7/16	70 ± 15 N·m (50 ± 11 lb ft)
1/2	105 ± 20 N·m (75 ± 15 lb ft)
9/16	160 ± 30 N·m (120 ± 22 lb ft)
5/8	215 ± 40 N·m (160 ± 30 lb ft)
3/4	370 ± 50 N·m (275 ± 37 lb ft)
7/8	620 ± 80 N·m (460 ± 60 lb ft)
1	900 ± 100 N·m (660 ± 75 lb ft)
1 1/8	1300 ± 150 N·m (960 ± 110 lb ft)
1 1/4	1800 ± 200 N·m (1320 ± 150 lb ft)
1 3/8	2400 ± 300 N·m (1780 ± 220 lb ft)
1 1/2	3100 ± 350 N·m (2280 ± 260 lb ft)

Table 20

Metric Nuts and Bolts
Thread Size Metric	Standard Torque
M6	12 ± 3 N·m (9 ± 2 lb ft)
M8	28 ± 7 N·m (21 ± 5 lb ft)
M10	55 ± 10 N·m (41 ± 7 lb ft)
M12	100 ± 20 N·m (75 ± 15 lb ft)
M14	160 ± 30 N·m (120 ± 22 lb ft)
M16	240 ± 40 N·m (175 ± 30 lb ft)
M20	460 ± 60 N·m (340 ± 44 lb ft)
M24	800 ± 100 N·m (590 ± 75 lb ft)
M30	1600 ± 200 N·m (1180 ± 150 lb ft)
M36	2700 ± 300 N·m (2000 ± 220 lb ft)

Ambient Temperatures

Illustration 69	g01283117

Installation Checklists

The attached Checklist is a basic OEM review form. It does not cover all possible design and installation errors that may occur. The objective is to highlight common installation problems that frequently occur. The review form is a convenient Checklist that the OEM and application engineers can use as a basic installation auditing guide.

Illustration 70	g01444941

Illustration 71	g01444866

Illustration 72	g01444870

Illustration 73	g01444874