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Installation of the Water Lines Group and Oil Cooler For Certain MT4400D Off-Highway Trucks{1378, 1380} Caterpillar


Installation of the Water Lines Group and Oil Cooler For Certain MT4400D Off-Highway Trucks{1378, 1380}

Usage:

MT4400D AC MH4
Off-Highway Truck/Tractor:
CAT MT4400D AC (S/N: MH41-UP; MT41-UP)

Introduction

Before performing any of the following procedure be sure to read and understand all of the information first. The procedure that follows is for the installation of the water lines group and oil cooler for the MT4400D Off-Highway Truck.

Required Parts

Table 1 contains the new parts required for installation. Table 2 contains the parts that will be reused from the removal procedure.

Show/hide table
Table 1
Item     Qty     Part Number     Part Description    
1     1     100-8075     Clamp As    
2     1     1W-2447     Outlet Adapter    
3     1     111-9373     Clamp As    
4     1     7N-4945     Gasket    
5     2     9M-4594     Spacer    
6     2     105-8901     Gasket    
7     4     108-6170     Clamp As    
8     2     111-3820     Retaining Ring    
9     1     124-4273     Bypass Valve    
10     1     136-3296     Plate As    
11     1     146-7359     Tube    
12     1     150-6612     Outlet Elbow    
13     1     150-6613     Elbow    
14     1     150-6614     Elbow    
15     1     152-0993     Tube    
16     1     187-4560     Tube As    
17     1     191-6695     Plate    
18     1     225-3227     Film    
19     4     237-7623     O-Ring Seal    
20     1     253-8284     Bonnet    
21     2     264-0450     Clamp As    
22     1     285-9361     Bonnet    
23     1     286-9966     Bracket    
24     1     373-6537     Oil Cooler Core As    
25     4     388-3917     Flange    
26     4     388-6443     Ring    
27     1     440-8355     Flange    
28     2     440-8356     Flange    
29     1     440-8357     Tube As    
30     1     440-8363     Bracket    
31     1     440-8366     Tube    
32     1     440-8367     Elbow    
33     1     462-0504     Bracket As    
34     1     462-0505     Bracket As    
35     1     7N-4932     Gasket    
36     2     0L-1143     Bolt    
37     4     0L-1352     Bolt    
38     17     165-3931     Bolt    
39     2     0S-1585     Bolt    
40     12     0S-1588     Bolt    
41     2     0S-1590     Bolt    
42     2     165-3929     Bolt    
43     18     0S-1594     Bolt    
44     2     109-2332     O-Ring Seal    
45     2     110-0096     Ring    
46     1     193-2120     Grommet    
47     4     1A-1460     Bolt    
48     2     1F-7958     Full Nut    
49     2     2K-4973     Locknut    
50     2     3B-1915     Bolt    
51     1     3M-7045     Plug    
52     1     3P-0653     O-Ring Seal    
53     1     3P-0655     O-Ring Seal    
54     12     3V-3308     Hard Washer    
55     2     5B-9603     Bolt    
56     40     5M-2894     Hard Washer    
57     1     5P-4892     O-Ring Seal    
58     1     5P-5846     O-Ring Seal    
59     8     5P-8245     Hard Washer    
60     4     6B-0933     Spacer    
61     1     6J-2244     O-Ring Seal    
62     1     6V-1867     Clip    
63     1     6V-1868     Clip    
64     1     6V-3908     O-Ring Seal    
65     2     2A-4639     Bolt    
66     2     6V-6609     O-Ring Seal    
67     12     7B-3235     Bolt    
68     14     7D-1649     Hard Washer    
69     1     7N-3674     Block    
70     2     7W-7071     Gasket    
71     6     8B-9725     Boss    
72     1     8C-3107     O-Ring Seal    
73     2     8M-9024     Hard Washer    
74     4     8T-1919     O-Ring Seal    
75     4     8T-6765     Pipe Plug    
76     18     9S-1366     Bolt    
77     2     9S-4185     Plug    
78     5     9S-8752     Full Nut    
79     2     9X-8873     Bolt    
80     4     6V-5066     O-Ring Seal    
81     1     4N-1320     Gasket    
82     1     6V-1574     Grommet    

Show/hide table
Table 2
Item     Qty     Part Number     Part Description    
23     2     286-9966     Brackets    
83     1     8N-7641     Tube    
84     1     8N-0386     Flange    
85     1     1W-1475     Lines Adapter    
86     1     2W-1635     Spring    
87     1     4B-3140     Cover    
88     1     7N-9045     Tube    
89     1     7W-1713     Oil Cooler Core Gp    
90     1     6V-1572     Clip    
91     1     6V-1573     Clip    
92     1     8F-8151     Shutoff Valve    

Removal Procedure

    Show/hide table

    Illustration 1g03785327

    (1) 7N-4944 Elbow

    (2) 392-4069 Water Lines Gp

    (3) 1W-1475 Lines Adapter

  1. Remove water lines group (2) from the engine.

    1. Remove all components between elbow (1) and lines adapter (3). The elbow and the lines adapter can be reused in the installation procedure.

Installation Procedure

Note: Use standard torque for all fasteners unless noted otherwise.

    Show/hide table

    Illustration 2g03790340

    (27) 440-8355 Flange

    (35) 7N-4932 Gasket

    (40) 0S-1588 Bolts

    (56) 5M-2894 Hard Washers

  1. Place gasket (35) between flange (27) and the end of the oil cooler.

    1. Secure the flange to the cooler using four bolts (40) with four hard washers (56) .
    Show/hide table

    Illustration 3g03790350

    (22) 228-9361 Engine Installation Ar

    (41) 0S-1590 Bolts

    (56) 5M-2894 Hard Washers

    (65) 2A-4639 Bolts

    (80) 6V-5066 O-Ring Seals

    (81) 4N-1320 Gasket

    (83) 8N-7641 Tube

    (84) 8N-0386 Flange

    (85) 1W-1475 Lines Adapter

  1. Install o-ring seals (80) onto each end of tube (82) .

  1. Place gasket (81) between flange (84) and lines adapter (85) .

    1. Secure the flange to the lines adapter using bolts (41), bolts (65), and hard washers (56) .

      Note: Be sure to install the bolts in the locations shown in Illustration 3.

  1. Press tube (83) into flange (84) .

  1. Press engine installation arrangement (22) onto tube (83.)
    Show/hide table

    Illustration 4g03790451

    (11) 146-7359 Tube

    (12) 150-6612 Outlet Elbow

    (13) 150-6613 Elbow

    (19) 237-7623 O-Ring Seals

    (40) 0S-1588 Bolts

    (60) 6B-0933 Spacers

    (64) 6V-3908 O-Ring Seal

  1. Install o-ring seals (19) on each end of tube (11) .

  1. Install o-ring seal (64) between outlet elbow (12) and the housing as shown in Illustration 4.

  1. Secure the outlet elbow using four bolts (40) with four spacers (60) .

  1. Install tube (11) into the outlet elbow.

  1. Install elbow (13) onto tube (11) .
    Show/hide table

    Illustration 5g03790458

    (6) 105-8901 Gasket

    (17) 191-6695 Plate

    (22) 285-9361 Bonnet

    (24) 373-6537 Oil Cooler Core As

    (40) 0S-1588 Bolts

    (51) 3M-7045 Plug

    (52) 3P-0653 O-Ring Seal

    (56) 5M-2894 Hard Washers

    (67) 7B-3235 Bolts

    (75) 8T-6765 Pipe Plug

  1. Install o-ring seal (52) between oil cooler core assembly (24) and plate (17) .

    1. Secure the plate to the oil cooler core assembly using four bolts (40) with four hard washers (56) .

  1. Install plug (51) into plate (17) .

  1. Place gasket (6) between oil cooler core assembly (24) and bonnet (22) .

    1. Secure the bonnet to the oil cooler core assembly using six bolts (67) .

    1. Install pipe plug (75) into the bonnet in the location shown in Illustration 5.
    Show/hide table

    Illustration 6g03790485

    (6) 105-8901 Gasket

    (20) 253-8284 Bonnet

    (24) 373-6537 Oil Cooler Core As

    (66) 6V-6609 O-Ring Seal

    (67) 7B-3235 Bolts

    (75) 8T-6765 Pipe Plug

    (77) 9S-4185 Plug

  1. Install gasket (6) between bonnet (20) and oil cooler core assembly (24) .

    1. Secure the bonnet to the oil cooler core assembly using six bolts (67) .

  1. Install pipe plug (75) into the top of the bonnet. Install plug (77) with o-ring seal (66) into the side of the bonnet.
    Show/hide table

    Illustration 7g03790491

    (2) 1W-2447 Outlet Adapter

    (9) 124-4273 Bypass Valve

    (10) 136-3296 Plate As

    (13) 150-6613 Elbow

    (15) 150-0993 Tube

    (19) 237-7623 O-Ring Seal

    (24) 373-6537 Oil Cooler Core As

    (42) 165-3929 Bolts

    (43) 0S-1594 Bolts

    (53) 3P-0655 O-Ring Seal

    (56) 5M-2894 Hard Washers

    (57) 5P-4892 O-Ring Seal

    (66) 6V-6609 O-Ring Seal

    (72) 8C-3107 O-Ring Seal

    (77) 9S-4185 Plug

    (86) 2W-1635 Spring

  1. Install o-ring seal (19) on the engine of tube (15) .

  1. Press elbow (13) onto tube (15) .

  1. Place o-ring seal (72) between elbow (13) and oil cooler core assembly (24) .

    1. Fasten the elbow to the oil cooler core assembly using four bolts (43) .

  1. Install bypass valve (9) into the bottom of elbow (13) .

    1. Install spring (86) into the bypass valve.

    1. Install o-ring seal (57) onto plate assembly (10) .

    1. Install the plate assembly to the elbow using two bolts (42) with two hard washers (56) .

    1. Install plug (77) with o-ring seal (66) into plate assembly (10) .

  1. Place o-ring seal (53) between oil cooler core assembly (24) and outlet adapter (2) .

    1. Secure the outlet adapter to the oil cooler core assembly using four bolts (43) .
    Show/hide table

    Illustration 8g03790494

    (14) 150-6614 Elbow

    (15) 150-0993 Tube

    (19) 237-7623 O-Ring Seal

    (24) 373-6537 Oil Cooler Core As

    (37) 0L-1352 Bolts

    (43) 0S-1594 Bolts

    (56) 5M-2894 Hard Washers

    (58) 5P-5846 O-Ring Seal

    (61) 6J-2244 O-Ring Seal

    (83) 4B-3140 Cover

  1. Install o-ring seal (19) onto the end of tube (15) .

  1. Press elbow (14) onto the tube.

  1. Place o-ring seal (61) between the elbow and oil cooler core assembly (24) .

  1. Secure the elbow to the oil cooler core assembly using four bolts (37) .

  1. Place o-ring seal (58) between the elbow and cover (83) .

    1. Secure the cover to the elbow using two bolts (43) with two hard washers (56) .
    Show/hide table

    Illustration 9g03790519

    (23) 286-9966 Bracket

    (39) 0S-1585 Bolts

    (71) 9B-9725 Bosses

    (76) 9S-1366 Bolts

    (79) 9X-8873 Bolts

  1. Install bracket (23) to the cylinder block using two bolts (76) with two bosses (71) .

  1. Install the end of the oil cooler to the cylinder block using two bolts (39) with two bosses (71) .

  1. Attach the oil cooler to the bracket using two bolts (79) with two bosses (72) .
    Show/hide table

    Illustration 10g03790596

    (7) 108-6170 Clamp As

    (38) 165-3931 Bolts

    (43) 0S-1594 Bolts

    (45) 110-0096 Ring

    (54) 3V-3308 Hard Washers

    (78) 9S-8752 Full Nut

    (80) 6V-5066 O-Ring Seal

    (88) 7N-9045 Tube

  1. Install o-ring seal (80) into the flange of the oil cooler.

  1. Press tube (88) into the end of the oil cooler.

  1. Install clamp assemblies (7) around the tube.

  1. Fasten the clamp assemblies together using two bolts (43), four hard washers (54), and two full nuts (78) .

  1. Fasten the clamp assembly to the oil cooler flange using two bolts (38) with two hard washers (54) .
    Show/hide table

    Illustration 11g03790607

    (7) 108-6170 Clamp As

    (32) 440-8367 Elbow

    (38) 165-3931 Bolts

    (43) 0S-1594 Bolts

    (45) 110-0096 Ring

    (54) 3V-3308 Hard Washers

    (78) 9S-8752 Full Nuts

    (80) 6V-5066 O-Ring Seal

    (88) 7N-9045 Tube

  1. Install o-ring seal into the flange of elbow (32) .

  1. Install ring (45) onto the end of tube (88) .

  1. Install clamp assemblies (7) around the tube.

  1. Fasten the clamp assemblies together using two bolts (43), four hard washers (54), and two full nuts (78) .

  1. Fasten the clamp assembly to the elbow flange using two bolts (38) with two hard washers (54) .
    Show/hide table

    Illustration 12g03790615

    (4) 7N-4945 Gasket

    (32) 440-8367 Elbow

    (50) 3B-1915 Bolts

    (55) 5B-9603 Bolts

    (56) 5M-2894 Hard Washers

  1. Place gasket (4) between elbow (32) and the oil cooler.

  1. Secure the elbow using two bolts (50) with two hard washers (56) on the one side.

  1. Secure the other side of the elbow using two bolts (55) with two hard washers (56) .
    Show/hide table

    Illustration 13g03790626

    (33) 462-0504 Bracket As

    (34) 462-0505 Bracket As

    (68) 7D-1649 Hard Washers

    (76) 9S-1366 Bolts

  1. Install bracket assembly (33) using four bolts (76) with four hard washers (68) .

  1. Install bracket assembly (34) using four bolts (76) with four hard washers (68) .
    Show/hide table

    Illustration 14g03790638

    (71) 8B-9725 Bosses

    (76) 9S-8752 Bolts

    (23) 286-9966 Bracket

  1. Install bracket (23) using two bolts (76) with two bosses (71) .
    Show/hide table

    Illustration 15g03790642

    (28) 440-8356 Flanges

    (47) 1A-1460 Bolts

    (59) 5P-8245 Hard Washers

    (68) 7D-1649 Hard Washers

    (70) 7W-7071 Gaskets

    (76) 9S-1366 Bolts

    (89) 7W-1713 Oil Cooler Core Gp

  1. Install flanges (28) to each end of oil cooler core group (89) using two bolts (47) with two hard washers (59) on each end.

    1. Place gaskets (70) between the flange and oil cooler core group before installing the flanges.

  1. Attach each end of the oil cooler core group to the brackets using two bolts (76) with two hard washers (68) on each end.
    Show/hide table

    Illustration 16g03790657

    (25) 388-3917 Flanges

    (26) 388-6443 Rings

    (28) 440-8356 Flange

    (31) 440-8366 Tube

    (32) 440-8367 Elbow

    (38) 165-3931 Bolts

    (56) 5M-2894 Hard Washers

    (74) 8T-1919 O-Ring Seals

  1. Install o-ring seals (74), rings (26), and flanges (25) on both end of tube (31) .

  1. Install one end of the tube into flange (28) .

    1. Secure the flanges using two bolts (38) with two hard washers (56) .

  1. Install the other end of the tube into flange (32) .

    1. Secure the flanges using two bolts (38) with two hard washers (56) .
    Show/hide table

    Illustration 17g03790662

    (25) 388-3917 Flanges

    (26) 388-6443 Rings

    (29) 440-8357 Tube As

    (38) 165-3931 Bolts

    (56) 5M-2894 Hard Washers

    (74) 8T-1919 O-Ring Seals

    (75) 8T-6765 Pipe Plugs

  1. Install flanges (25), rings (26), and o-ring seals (74) on each end of tube assembly (29) .

  1. Install each end of the tube assembly into each end of the oil cooler core assembly. Secure the flanges on each end using two bolts (38) with two hard washers (56) on each end.
    Show/hide table

    Illustration 18g03790702

    (23) 286-9966 Bracket

    (29) 440-8357 Tube As

    (30) 440-8363 Bracket

    (38) 165-3931 Bolts

    (46) 193-2120 Grommet

    (48) 1F-7958 Full Nut

    (59) 5P-8245 Hard Washers

    (62) 6V-1867 Clip

    (63) 6V-1868 Clip

    (68) 7D-1649 Hard Washers

    (73) 8M-9024 Hard Washers

    (76) 9S-1366 Bolts

    (78) 9S-8752 Full Nut

  1. Install bracket (30) to bracket (23) .

    1. Place two hard washers (59) on to bolts (76) .

    1. Place two hard washers (59) between the two brackets.

    1. Install the bolts through the brackets and fasten using two hard washers (68) with two full nuts (48) .

  1. Attach tube assembly (29) to bracket (30) .

    1. Place grommet (46) around the tube assembly.

    1. Install clip (62) and clip (63) around the grommet.

    1. Place hard washer (73) onto bolt (38) .

    1. Install the bolt through the clips into the bracket and fasten using hard washer (73) with full nut (78) .
    Show/hide table

    Illustration 19g03790679

    (1) 100-8075 Clamp As

    (2) 1W-2447 Outlet Adapter

    (8) 111-3820 Retaining Ring

    (16) 187-4560 Tube As

    (21) 264-0450 Clamp As

    (38) 165-3931 Bolts

    (43) 0S-1594 Bolts

    (44) 109-2332 O-Ring Seal

    (56) 5M-2894 Hard Washers

  1. Install retaining ring (8) and o-ring seal (44) on the end of tube assembly (16) .

  1. Install clamp assembly (1) and (21) around the tube assembly. Fasten the clamp assemblies together using two bolts (43) with two hard washers (56) .

  1. Press the tube assembly into outlet adapter (2) .

  1. Fasten the clamp assemblies to the outlet adapter using two bolts (38) with two hard washers (56) .
    Show/hide table

    Illustration 20g03790681

    (3) 111-9373 Clamp As

    (8) 111-3820 Retaining Ring

    (21) 264-0450 Clamp As

    (38) 165-3931 Bolts

    (43) 0S-1594 Bolts

    (44) 109-2332 O-Ring Seal

    (56) 5M-2894 Hard Washers

  1. Install retaining ring (8) and o-ring seal (44) onto the tube.

  1. Install clamp assembly (3) and (21) around the tube. Fasten the clamp assemblies together using two bolts (38) with two hard washers (56) .

  1. Fasten the clamp assemblies to the flange using two bolts (38) with two hard washers (56) .
    Show/hide table

    Illustration 21g03790683

    (5) 9M-4594 Spacers

    (36) 0L-1143 Bolts

    (49) 2K-4973 Locknuts

    (56) 5M-2894 Hard Washers

    (75) 8T-6765 Pipe Plug

    (82) 6V-1574 Grommets

    (90) 6V-1572 Clips

    (91) 6V-1573 Clips

  1. Install grommets (82) around the tube assembly.

  1. Install clips (90) and (91) around the grommets.

  1. Fasten the clips to the brackets using two bolts (36), four hard washers (4), and two locknuts (49) .

  1. Install pipe plug (75) into the tube assembly in the location shown in Illustration 21.
    Show/hide table

    Illustration 22g03790698

    (69) 7N-3674 Block

  1. Install block (69) on the tube assembly.

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