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Remove Install & Repair OB Hauler
RIR Water Pump HD 785-7 & OHT 777E
1|RIR Water Pump OBH
Disusun oleh: Diki P.
Cooling System
Sistem pendingin pada engine yang biasa disebut dengan Cooling System Engine sangat penting perannya dalam menjaga performa kerja dan kelangsungan umur / lifetime engine. Jika coolng system suatu engine baik maka bisa dipastikan engine tersebut lifetime nya bisa mencapai 100 % bahkan lebih. Untuk alur system nya hampir semua branch alat berat memiliki alur yang sama baik Komatsu, Caterpillar maupun Volvo. Sistem pendingin pada engine memiliki beberapa component penting untuk mendukung tujuan dari adanya sistem ini. Disini akan kami bahas mengenai general component dari cooling system yang terdiri dari beberapa komponen penting yaitu: 2|RIR Water Pump OBH
Disusun oleh: Diki P.
1. Radiator Komponen ini memiliki bagian yang bernama core yang dialiri oleh coolant dan fins atau sirip – sirip yang berfungsi untuk melepas panas yang dihasilkan oleh engine. Pada radiator itu sendiri umumnya memiliki spesifikasi yaitu perbedaan antara upper tank dan bottom tank yang disebut juga dengan ΔT. Nilai ΔT bervariasi setiap branch / product tapi umumnya adalah sekitar 5° Celcius. 2. Water Pump Sesuai urutan alirannya sistem pendingin memiliki komponen kedua yang bernama water pump dengan tipe sentrifugal dan digolongkan ke dalam tipe non positive displacement pump. Komponen ini berfungsi untuk mengalirkan coolant ke system pendingin. Memiliki komponen penting di dalamnya yaitu impeller, housing dan seal.
3|RIR Water Pump OBH
Disusun oleh: Diki P.
Pada impeller water pump memiliki sudu – sudu dan arah putar seperti gambar di bawah ini. Dengan cara kerja melemparkan aliran coolant ke arah housing sehingga coolant dapat mengalir ke bagian output dan ke system.
Komponen bagian dalam water pump sebagai berikut.
4|RIR Water Pump OBH
Disusun oleh: Diki P.
Water pump pada unit Caterpillar khususnya OHT 777D terdapat 2 buah water pump yaitu 1 buah water pump system terletak di sebelah Kenan engine dan 1 buah lainnya auxillary water pump terletak di sebelah kiri engine yang berfungsi khusus untuk pendinginan jacket water aftercooler dan brake cooling oil cooler.
Auxillary water pump juga mendinginkan brake cooling oil cooler (1) akan tetapi porsi pendinginannya diatur oleh brake oil cooler diverter valve (2). Cara kerjanya ketika service brake diaktifkan maka oli pendingin brake dialirkan seluruhnya ke oil cooler sedangkan saat brake tidak aktif oli brake dialirkan tidak melalui cooler tapi bypass langsung ke brake tujuannya saat tanjakan dan memerlukan power tambahan unit tidak mengaktifkan brake sehingga coolant hanya terfokus untuk mendinginkan aftercooler.
5|RIR Water Pump OBH
Disusun oleh: Diki P.
3. Oil Cooler Bagian ini coolant mengalir dengan tujuan untuk mendinginkan oli. Pada beberapa engine memiliki beberapa cooler seperti engine oil cooler, hydrolic cooler, tranmisi oil cooler dan brake cooling oil cooler. 4. Jacket Water Selanjutnya coolant masuk ke dalam cylinder block untuk mendinginkan bagian terpenting dari komponen engine yaitu cylinder liner dan piston. Jacket water terdiri dari 2 yaitu jacket water pada cylinder block dan jacket water pada cylinder head. Pada cylinder head coolant dialirkan berfungsi untuk mendinginkan area valve mechanism. 5. Thermostat Nama lain dari thermostat adalah water temperature regulator. Fungsinya adalah untuk mempercepat naiknya temperature operasi engine yang diinginkan dan menjaga agar tetap pada temperature operasi yang dizinkan. Komponen thermostat terdapat di bagian atas engine pada 3 jalur yaitu jalur dari jacket water, jalur ke radiator dan jalur bypass coolant.
6|RIR Water Pump OBH
Disusun oleh: Diki P.
Cara kerjanya mengatur aliran coolant dari jacket water berdasarkan temperature coolant yang melewatinya. Jika temperaturnya masuk category panas thermostat mebuka untuk mengalirkan coolant ke radiator untuk didinginkan. Jika coolant masih masuk kategori dingin maka thermostat tetap menutup sehingga coolant mengalir kembali ke water pump melalui bypass line untuk dialirkan kembali ke sistem.
6. Radiator Cap Komponen ini terdapat pada bagian atas radiator. Fungsi radiator cap adalah untuk menjaga tekanan dalam sistem pendingin yang tujuannya adalah untuk menaikkan titik didih. Jika titik didih coolant tinggi maka akan mengurangi bubble / gelembung pada coolant system. Gelembung / bubble terjadi akibat air mendidih, jika titik didih air normal 100° C maka titik didih air bertekanan naik menjadi 120° C sehingga coolant pada sistem yang nilainya bisa mencapai 100° C tetap tidak mendidih dan gelembung dapat dikurangi.
7|RIR Water Pump OBH
Disusun oleh: Diki P.
Pengukuran Cooling System System HD785-7 Spesifikasi performa engine SAA12V140E-3:
8|RIR Water Pump OBH
Disusun oleh: Diki P.
Untuk melakukan pengukuran pada cooling system bisa menggunakan thermogun. Tembak bagian atas dan bagian bawah radiator kemudian berapa nilai selisihnya. Umumnya engine memiliki spesifikasi sekitar ΔT 5° C.
9|RIR Water Pump OBH
Disusun oleh: Diki P.
Basic Remove Intall Untuk melakukan proses remove install pada unit harus berdasarkan service manual. Berikut ini adalah simbol – simbol yang biasa ditemukan pada service manual.
Untuk proses pemasangan baut harus dikencangkan berdasarkan tabel standard tightening torque di bawah ini. Berikut ini adalah standard torque general berdasarkan diameter thread.
10 | R I R W a t e r P u m p O B H
Disusun oleh: Diki P.
50 Disassembly and assembly
SEN00321-00
18. Supply pump assembly 1) Remove oil tube (1) 2) Remove supply pump assembly mounting bolt (2). 3) Remove supply pump assembly (3).
3)
Remove water pump assembly (3).
4)
Remove housing (5) from water pump (4).
19. Corrosion resister and filter head assembly Remove corrosion resister and filter head assembly (1).
21. Oil cooler (rear side) 1) Remove oil manifold (1). 2) Remove oil cooler (2) Ir Remove the oil cooler (front side) after removing the supply pump drive case. 20. Water pump assembly 1) Remove block ( I ) 2) Remove water connector (2).
12V140E-3 Series
i
50 Disassembly and assembly
42. Head cover lnstall head cover (I). Head cover mounting bolt: 14.7 - 34.3 Nm {I.5
- 3.5 kgm)
43. Fuel tube lnstall fuel tube (1). Fuel tube joint bolt: 9.8 12.7 Nm { I .O - 1.3 kgm)
45. Oil cooler (rear side) 1) lnstall oil cooler (2). 2) lnstall oil manifold (1).
46. Water pump assembly 1) lnstall housing (5) to water pump (4).
-
I
1
2)
44. Plate and block lnstall block (3) and plates (2) and (I).
12V140E-3 Series
lnstall water pump assembly (3).
50 Disassembly and assembly
3) 4)
Tighten the mounting bolts in the following order. Tighten it once and then tighten again with the same torque. AIL Exhaust manifold assembly mounting bolt: Molybdenum disulfide lubricant (LM-P) Exhaust manifold assembly mounting bolt: 44.1 - 53.9 Nm (4.5 - 5.5 kgm)
Sr
lnstall water connector (2). lnstall block (I).
*
47. Corrosion resister and filter head assembly lnstall corrosion resister and filter head assembly (1).
3)
lnstall bracket (4), water pipe (3), muffler bracket (2) and insulating plate (1).
48. Exhaust manifold assembly 1) lnstall the gasket. $r Install the gasket directing its "OUT" marking to the exhaust manifold side. 2) Lift and install exhaust manifold assembly (5). Exhaust manifold assembly: 25 kg
12Vl40E-3 Series
SAA12V140E-3B-02 S/N 500001-UP
00052851
26
27 23 22
28
25
24
28
31 29 36 30
35
21
33 32
34
39
40
37
19 1 38
17 16
13 5
12 2
6
11 17 16
3
8
9
4
10
15 14
18
Ref.
7
20
A5010-A7E7
Page
031110
SAA12V140E-3B-02 S/N 500001-UP
WATER PUMP (HARD WATER AREA ARRANGEMENT SPEC.)(#500013-) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Part No. 6219-61-1100 6215-61-1506
Part Name WATER PUMP ASS'Y WATER PUMP ASS'Y BODY BODY 6219-61-1470 IMPELLER 6215-61-1451 IMPELLER 6219-61-1230 SHAFT 6215-61-1221 SHAFT 6215-61-1160 GEAR 6166-61-1511 SEAL, WATER 6162-63-1515 SEAL, WATER (K6) 6150-61-1510 SEAL,OIL (K6) 6215-61-1180 SEAL,OIL (K6) 06330-06206 BEARING,BALL 06030-06206 BEARING,BALL 06340-06306 BEARING,BALL 06330-06306 BEARING,BALL 06030-06306 BEARING,BALL 6162-63-1440 RING,SNAP 6215-81-9520 PLUG 6215-81-9720 O-RING (K6) 6219-61-1120 HOUSING 6216-61-1120 HOUSING 07000-G2140 O-RING 07000-02140 O-RING (K6) 07000-A2060 O-RING 07000-02060 O-RING (K6) 07000-A2016 O-RING 07000-72016 O-RING (K6) 6215-81-9520 PLUG
Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2
Serial No. 500449500013-500448 500449500013-500448 500449500013-500448 500449500013-500448 500013500449500013-500448 500014500013-500013 500043500013-500042 500449500043-500448 500013-500042 500013500013500013500449500013-500448 500440500013-500439 500440500013-500439 500440500013-500439 500013-
Reference:A5010-A7E7
Printed By : Dwi Iswanto (airafather6107170) 2nd edition
Page:031110
SAA12V140E-3B-02 S/N 500001-UP
WATER PUMP (HARD WATER AREA ARRANGEMENT SPEC.)(#500013-) Item 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Part No. 6215-81-9720 01010-81230 07000-72100 01011-81265 01011-81210 6215-61-7510 01011-81010 6215-61-6531 6215-61-6530 6215-61-7521 6215-61-6520 01010-81020 07000-G3045 6219-61-7110 07000-G2080 07000-G2090 07043-70617 07043-70108 07730-50004 01010-81040 01010-81030 6934-71-5860 6143-11-4290 01010-81080 01643-31032
Part Name O-RING (K6) BOLT O-RING (K6) BOLT BOLT CONNECTOR BOLT GASKET GASKET (K6) TUBE PLATE BOLT O-RING (K6) CONNECTOR O-RING (K6) O-RING (K6) PLUG PLUG VALVE,DRAIN BOLT BOLT BRACKET SPACER BOLT WASHER
Qty 2 2 1 2 2 1 3 1 1 1 1 1 2 1 1 1 1 1 1 3 2 1 1 1 1
Serial No. 500013500013500013500013500013500013500013500801500013-500800 500013500013500013500013500013500013500013500013500013500013500013500013500013500013500013500013-
Reference:A5010-A7E7
Printed By : Dwi Iswanto (airafather6107170) 2nd edition
Page:031110
SAA12V140E-3B-02 S/N 500001-UP
00062167
31
34
35
33
30
24
32
22 26 23
25
21
28 27
29
19
7
1 17 16
13 5
12 2
11 17 16
9
4
10
15 14
18
Ref.
6
3
8
20
A5010-A7E8
Page
031120
SAA12V140E-3B-02 S/N 500001-UP
WATER PUMP(#500013-) Item
Part No. 6219-61-1100 6215-61-1506
Part Name WATER PUMP ASS'Y WATER PUMP ASS'Y BODY BODY IMPELLER IMPELLER SHAFT SHAFT GEAR SEAL, WATER SEAL, WATER (K6) SEAL,OIL (K6) BEARING,BALL BEARING,BALL BEARING,BALL RING PLUG O-RING (K6) HOUSING HOUSING O-RING O-RING (K6) O-RING O-RING (K6) O-RING O-RING (K6) PLUG O-RING (K6) BOLT O-RING (K6)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
6219-61-1470 6215-61-1451 6219-61-1230 6215-61-1221 6215-61-1160 6166-61-1511 6162-63-1515 6150-61-1510 06330-06206 06340-06306 06330-06306 6162-63-1440 6215-81-9520 6215-81-9720 6219-61-1120 6216-61-1120 07000-G2140 07000-02140 07000-A2060 07000-02060 07000-A2016 07000-72016 6215-81-9520 6215-81-9720 01010-81230 07000-72100
Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1
Serial No. 500449500013-500448 500449500013-500448 500449500013-500448 500449500013-500448 500013500449500013-500448 500013500013500449500013-500448 500013500013500013500449500013-500448 500440500013-500439 500440500013-500439 500440500013-500439 500013500013500013500013-
Reference:A5010-A7E8
Printed By : Dwi Iswanto (airafather6107170) 2nd edition
Page:031120
SAA12V140E-3B-02 S/N 500001-UP
WATER PUMP(#500013-) Item 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
Part No. 01011-81265 01011-81210 6219-61-7110 07000-G2080 07000-G2090 01010-81030 01010-81040 07043-70617 07043-70108 07730-50004 6215-61-6510 6215-61-6520 6215-61-6531 6215-61-6530 07000-G3045 01010-81020 01010-81025
Part Name BOLT BOLT CONNECTOR O-RING (K6) O-RING (K6) BOLT BOLT PLUG PLUG VALVE,DRAIN TUBE PLATE GASKET GASKET O-RING (K6) BOLT BOLT
Qty 2 2 1 1 1 3 3 1 1 1 1 1 1 1 1 1 3
Serial No. 500013500013500013500013500013500013500013500013500013500013500013500013500801500013-500800 500013500013500013-
Reference:A5010-A7E8
Printed By : Dwi Iswanto (airafather6107170) 2nd edition
Page:031120
SAA12V140E-3B-02 S/N 500001-UP
00055614
24 26 37
38
35
25
36
34
23
28 27 33
22
29 30
19
32 31
21
7
1 17 16
13 5
12 2
11 17 16
9
4
10
15 14
18
Ref.
6
3
8
20
A5010-A7E9
Page
031130
SAA12V140E-3B-02 S/N 500001-UP
WATER PUMP (EXTREMELY BAD FUEL AND POOR FUEL ARRANGEMENT SPEC.) (WATER+DUST)(#500013-) Item
Part No. 6219-61-1100 6215-61-1506
Part Name WATER PUMP ASS'Y WATER PUMP ASS'Y 1 BODY BODY 2 6219-61-1470 IMPELLER 6215-61-1451 IMPELLER 3 6219-61-1230 SHAFT 6215-61-1221 SHAFT 4 6215-61-1160 GEAR 5 6166-61-1511 SEAL, WATER 6162-63-1515 SEAL, WATER (K6) 6 6150-61-1510 SEAL,OIL (K6) 6215-61-1180 SEAL,OIL (K6) 7 06330-06206 BEARING,BALL 8 06340-06306 BEARING,BALL 06330-06306 BEARING,BALL 9 6162-63-1440 RING,SNAP 10 6215-81-9520 PLUG 11 6215-81-9720 O-RING (K6) 12 6219-61-1120 HOUSING 6216-61-1120 HOUSING 13 07000-G2140 O-RING 07000-02140 O-RING (K6) 14 07000-A2060 O-RING 07000-02060 O-RING (K6) 15 07000-A2016 O-RING 07000-72016 O-RING (K6) 16 6215-81-9520 PLUG 17 6215-81-9720 O-RING (K6) Reference:A5010-A7E9
Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Serial No. 500449500013-500448 500449500013-500448 500449500013-500448 500449500013-500448 500013500449500013-500448 500014500013-500013 500013500449500013-500448 500013500013500013500449500013-500448 500440500013-500439 500440500013-500439 500440500013-500439 500013500013-
Printed By : Dwi Iswanto (airafather6107170) 2nd edition
Page:031130
SAA12V140E-3B-02 S/N 500001-UP
WATER PUMP (EXTREMELY BAD FUEL AND POOR FUEL ARRANGEMENT SPEC.) (WATER+DUST)(#500013-) Item 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
Part No. 01010-81230 07000-72100 01011-81265 01011-81210 6215-61-6531 6215-61-6530 6215-61-6510 6215-61-6520 01010-81020 07000-G3045 6219-61-7110 07000-G2080 07000-G2090 07043-70617 07043-70108 07730-50004 01010-81040 01010-81030 6934-71-5860 6143-11-4290 01010-81080 01643-31032
Part Name BOLT O-RING (K6) BOLT BOLT GASKET GASKET (K6) TUBE PLATE BOLT O-RING (K6) CONNECTOR O-RING (K6) O-RING (K6) PLUG PLUG VALVE BOLT BOLT BRACKET SPACER BOLT WASHER
Qty 2 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 3 2 1 1 1 1
Serial No. 500013500013500013500013500801500013-500800 500013500013500013500013500013500013500013500013500013500013500013500013500013500013500013500013-
Reference:A5010-A7E9
Printed By : Dwi Iswanto (airafather6107170) 2nd edition
Page:031130
SAA12V140E-3B-02 S/N 500001-UP
00075037
14 15
16 28 3 13
2 29 4
25
1
26
31 30
27
6
5
21
26
22 18 11
18
17
22
20
Ref.
19
24 23
12
7 8 10 9
24 23
A5010-B7E7
Page
031140
SAA12V140E-3B-02 S/N 500001-UP
WATER PUMP BYPASS PIPING(#500013-) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
Part No. 6219-61-7130 07042-A0415 6215-61-7361 01010-81230 6219-61-7120 6162-63-7390 01010-81030 6934-71-5860 01010-81040 01643-31032 6219-61-7140 01010-81025 6219-61-7420 6215-61-7490 01010-81250 01010-81245 01643-31232 6219-61-7410 07332-02000 6219-61-7151 6219-61-7150 01010-81025 07283-26163 07283-56170 01597-01009 01643-31032 6219-61-7471 01010-81025 01010-81035 01643-31032
Part Name TUBE,WATER INLET PLUG GASKET (K6) BOLT TUBE,BYPASS GASKET (K6) BOLT BRACKET BOLT WASHER BRACKET BOLT TUBE,BYPASS GASKET (K6) BOLT BOLT WASHER TUBE,BYPASS COUPLING BRACKET BRACKET BOLT CLIP SEAT NUT WASHER BRACKET BOLT BOLT WASHER
Qty 1 1 1 4 1 1 3 1 1 1 1 2 1 1 4 4 4 1 2 1 1 2 2 2 4 4 1 2 2 2
Serial No. 500013500013500013500013500013500013500013500013500013500013500013500013500013500013500046500013-500045 500013500013500013501169500013-501168 500013500013500013500013500013500013500496500013-500495 500496-
Reference:A5010-B7E7
Printed By : Dwi Iswanto (airafather6107170) 2nd edition
Page:031140
SAA12V140E-3B-02 S/N 500001-UP
WATER PUMP BYPASS PIPING(#500013-) Item 28 29 30 31
Part No. 07283-36163 07283-56170 01597-01009 01643-31032
Part Name CLIP SEAT NUT WASHER
Qty 1 1 2 2
Serial No. 500013500013500013500013-
Reference:A5010-B7E7
Printed By : Dwi Iswanto (airafather6107170) 2nd edition
Page:031140
SAA12V140E-3B-02 S/N 500001-UP
00075037
14 15
16 28 3 13
2 29 4
25
1
26
31 30
27
6
5
21
26
22 18 11
18
17
22
20
Ref.
19
24 23
12
7 8 10 9
24 23
A5010-B7E8
Page
031150
SAA12V140E-3B-02 S/N 500001-UP
WATER PUMP BYPASS PIPING(#500013-) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
Part No. 6219-61-7130 07042-A0415 6215-61-7361 01010-81230 6219-61-7120 6162-63-7390 01010-81030 6934-71-5860 01010-81040 01643-31032 6219-61-7140 01010-81025 6219-61-7420 6215-61-7490 01010-81250 01643-31232 6219-61-7410 07332-02000 6219-61-7151 6219-61-7150 01010-81025 07283-36163 07283-56170 01597-01009 01643-31032 6219-61-7471 01010-81025 01643-31032 07283-36163 07283-56170
Part Name TUBE,WATER INLET PLUG GASKET (K6) BOLT TUBE,BYPASS GASKET (K6) BOLT BRACKET BOLT WASHER BRACKET BOLT TUBE,BYPASS GASKET (K6) BOLT WASHER TUBE,BYPASS COUPLING BRACKET BRACKET BOLT CLIP SEAT NUT WASHER BRACKET BOLT WASHER CLIP SEAT
Qty 1 1 1 4 1 1 3 1 1 1 1 2 1 1 4 4 1 2 1 1 2 2 2 4 4 1 2 2 1 1
Serial No. 500013500013500013500013500013500013500013500013500013500013500013500013500013500013500013500013500013500013501169500013-501168 500013500013500013500013500013500013500496500496500013500013-
Reference:A5010-B7E8
Printed By : Dwi Iswanto (airafather6107170) 2nd edition
Page:031150
SAA12V140E-3B-02 S/N 500001-UP
WATER PUMP BYPASS PIPING(#500013-) Part No. Item 30 01597-01009 31 01643-31032
Part Name NUT WASHER
Qty Serial No. 2 5000132 500013-
Reference:A5010-B7E8
Printed By : Dwi Iswanto (airafather6107170) 2nd edition
Page:031150
SAA12V140E-3B-02 S/N 500001-UP
00075042
15 16
17 28 3 14
2 29 27
32 33
5
23
31 30 19 19
18
24
22
Ref.
21
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6
26 25
24 13 12
4 1
7 8 10 9
11 26 25
A5010-B7E9
Page
031160
SAA12V140E-3B-02 S/N 500001-UP
WATER PUMP BYPASS PIPING (EXTREMELY BAD FUEL AND POOR FUEL ARRANGEMENT SPEC.) (WATER+DUST)(#500013-) Item Part No. Part Name 1 6219-61-7130 TUBE,WATER INLET 2 07042-A0415 PLUG 3 6215-61-7361 GASKET (K6) 4 01010-81230 BOLT 5 6219-61-7120 TUBE,BYPASS 6 6162-63-7390 GASKET (K6) 7 01010-81030 BOLT 8 6934-71-5860 BRACKET 9 01010-81040 BOLT 10 01643-31032 WASHER 11 6219-61-7140 BRACKET 12 01010-81025 BOLT 13 01643-31032 WASHER 14 6219-61-7420 TUBE,BYPASS 15 6215-61-7490 GASKET (K6) 16 01010-81250 BOLT 17 01643-31232 WASHER 18 6219-61-7410 TUBE,BYPASS 19 07332-02000 COUPLING 20 6219-61-7151 BRACKET 21 01010-81025 BOLT 22 01643-31032 WASHER 23 07283-36163 CLIP 24 07283-56170 SEAT 25 01597-01009 NUT 26 01643-31032 WASHER 27 6219-61-7471 BRACKET 28 07283-36163 CLIP 29 07283-56170 SEAT Reference:A5010-B7E9
Qty 1 1 1 4 1 1 3 1 1 1 1 2 2 1 1 4 4 1 2 1 2 2 2 2 4 4 1 1 1
Serial No. 500013500013500013500013500013500013500013500013500013500013500013500013500013500013500013500013500013500013500013500013500013500013500013500013500013500013500013500013500013-
Printed By : Dwi Iswanto (airafather6107170) 2nd edition
Page:031160
SAA12V140E-3B-02 S/N 500001-UP
WATER PUMP BYPASS PIPING (EXTREMELY BAD FUEL AND POOR FUEL ARRANGEMENT SPEC.) (WATER+DUST)(#500013-) Item 30 31 32 33
Part No. 01597-01009 01643-31032 01010-81025 01643-31032
Part Name NUT WASHER BOLT WASHER
Qty 2 2 2 2
Serial No. 500013500013500477500477-
Reference:A5010-B7E9
Printed By : Dwi Iswanto (airafather6107170) 2nd edition
Page:031160
SAA12V140E-3B-02 S/N 500001-UP
00057215
Ref.
A8160-A7A2
Page
031450
SAA12V140E-3B-02 S/N 500001-UP
WATER PUMP GASKET KIT (FOR HD785-7)(#500013-) Part No. Part Name Item 6 6219-K6-1200 GASKET KIT,WATER PUMP 07000-02060 O-RING,(SEE FIG.A5010) 07000-02140 O-RING,(SEE FIG.A5010) 07000-72016 O-RING,(SEE FIG.A5010) 07000-72100 O-RING,(SEE FIG.A5010) 07000-G2080 O-RING,(SEE FIG.A5010) 07000-G2090 O-RING,(SEE FIG.A5010) 07000-G3045 O-RING,(SEE FIG.A5010) 6162-63-1515 SEAL, WATER,(SEE FIG.A5010) 6150-61-1510 SEAL,(SEE FIG.A5010) 6215-61-6530 GASKET,(SEE FIG.A5010) 6215-81-9720 O-RING,(SEE FIG.A5010) 6162-63-7390 GASKET,(SEE FIG.A5010) 6215-61-7361 GASKET,(SEE FIG.A5010) 6215-61-7490 GASKET,(SEE FIG.A5010)
Qty 1 1 1 1 1 1 1 2 1 1 1 3 1 1 1
Serial No. 500013500013500013500013500013500013500013500013500013500013500013500013500013500013500013-
Reference:A8160-A7A2
Printed By : Dwi Iswanto (airafather6107170) 2nd edition
Page:031450
5/8/2020
777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine(SEBP4975 - 114) - Systems & Components
Previous Screen
Welcome: jva6ij Product: TRUCK Model: 777D TRUCK FKR Configuration: 777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine
Disassembly and Assembly 3500 and 3500B High Displacement Engines for Caterpillar Built Machines Media Number -SENR1126-33
Publication Date -01/07/2015
Date Updated -14/09/2018 i05056215
Water Pump - Remove SMCS - 1361-011
Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates.
1. Drain the coolant from the cooling system into a suitable container for storage or disposal.
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777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine(SEBP4975 - 114) - Systems & Components
Illustration 1
g01053075
2. Remove bolts (1). Remove tube assembly (2).
Illustration 2
g01053077
3. Attach a suitable lifting device to water pump (4). Remove bolts (3).
Illustration 3
g01053079
4. Remove bolts (5).
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777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine(SEBP4975 - 114) - Systems & Components
Illustration 4
g01053081
5. Remove water pump (4). The weight of the water pump is approximately 45 kg (100 lb).
Removal Procedure (Type 2) Table 1 Required Tools Tool ZZ
Part Number
Part Description
Qty
9U-7089
Tapered Cap/Plug
1
9U-7095
Tapered Cap/Plug
1
Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL OR THE INSTALLATION. THIS TOOLING IS SHOWN IN ORDER TO ASSIST THE EXPERIENCED SERVICEMAN.
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates. https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/productsearch/productheaderinfoframeset.jsp&calledpage… 3/5
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777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine(SEBP4975 - 114) - Systems & Components
1. Drain the cooling system coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant (DEAC) - Change".
Illustration 5
g01127935
2. Disconnect hose assembly (1). 3. Disconnect adapter (2) and the gasket from water pump (3). 4. Disconnect tube assembly (6) from adapter (5). 5. Remove bolts (4) in order to remove adapter (5) and the O-ring seal from water pump (3). 6. Remove bolts (7) in order to remove guard assembly (8) from the engine.
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777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine(SEBP4975 - 114) - Systems & Components
Illustration 6
g01127942
7. Remove bolts (9) in order to remove water pump (3) from the engine. Use two people in order to remove water pump (3) from the engine. The weight of water pump (3) is approximately 34 kg (75 lb). Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.
Fri May 08 2020 15:25:27 GMT+0800 (Singapore Standard Time) jva6ij
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777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine(SEBP4975 - 114) - Systems & Components
Previous Screen
Welcome: jva6ij Product: TRUCK Model: 777D TRUCK FKR Configuration: 777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine
Disassembly and Assembly 3500 and 3500B High Displacement Engines for Caterpillar Built Machines Media Number -SENR1126-33
Publication Date -01/07/2015
Date Updated -14/09/2018 i05831622
Water Pump - Install SMCS - 1361-012
Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
NOTICE Water pumps may leak as a result of damaged face seals. Relative movement between the shaft and the housing may allow the drive shaft to contact the face seal in the water pump. If contact occurs, the face seal will be damaged, and very early hour failures can result.
1. Refer to Special Instruction , REHS9244 for proper water pump handling procedures prior to installation.
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5/8/2020
777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine(SEBP4975 - 114) - Systems & Components
Illustration 1
g01053081
2. Attach a suitable lifting device to water pump (4). Place water pump (4) in position. The weight of the water pump is approximately 45 kg (100 lb).
Illustration 2
g01053079
3. Install bolts (5).
Illustration 3
g01053077
4. Install bolts (3). Remove the suitable lifting device from water pump (4).
Illustration 4
g01053075
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777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine(SEBP4975 - 114) - Systems & Components
5. Position tube assembly (2). Install bolts (1). 6. Fill the cooling system. For the proper procedure and coolant to use, see the Operation and Maintenance Manual.
Installation Procedure (Type 2) NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
NOTICE Water pumps may leak as a result of damaged face seals. Relative movement between the shaft and the housing may allow the drive shaft to contact the face seal in the water pump. If contact occurs, the face seal will be damaged, and very early hour failures can result.
1. Refer to Special Instruction , REHS9244 for proper water pump handling procedures prior to installation.
Illustration 5
g01127942
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777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine(SEBP4975 - 114) - Systems & Components
2. Use a suitable lifting device to position water pump (3) onto the engine. The weight of water pump (3) is approximately 34 kg (75 lb). 3. Install bolts (9) in order to secure water pump (3) to the engine. Remove the suitable lifting device.
Illustration 6
g01127935
4. Install bolts (7) in order to attach guard assembly (8) to the engine. 5. Install bolts (4) in order to attach adapter (5) and the O-ring seal to water pump (3). 6. Connect tube assembly (6) to adapter (5). 7. Connect adapter (2) and the gasket to water pump (3). 8. Connect hose assembly (1). 9. Fill the cooling system. Refer to Operation and Maintenance Manual, "Cooling System Coolant (DEAC) Change". Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.
Fri May 08 2020 15:26:25 GMT+0800 (Singapore Standard Time) jva6ij
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777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine(SEBP4975 - 114) - Systems & Components
Previous Screen
Welcome: jva6ij Product: TRUCK Model: 777D TRUCK FKR Configuration: 777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine
Specifications 3500B, 776D, 777D, 784C, 785C, 789C, 793C and and 793D Off-Highway Truck/Tractors Media Number -SENR1122-27
Publication Date -01/11/2010
Date Updated -23/08/2019 i04395597
Water Pump SMCS - 1361 Part Number - 2W-9726 S/N - AFS1-UP Part Number - 2W-9726 S/N - 5ER1-UP Part Number - 2W-9726 S/N - FKR1-UP Part Number - 2W-9726 S/N - 3PR1-UP Part Number - 2W-9726 S/N - AGC1-UP
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777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine(SEBP4975 - 114) - Systems & Components
Illustration 1
g02847239
(2) Ring assembly (3) Water pump seal group
Table 1 Specification for 2W-9726 Water Pump Gp Item
Qty
Part
Specification Description
1
1
8C-5236 Lip Type Seal
Do not lubricate the sealing lip of the lip type seal.
4
1
149-5462 O-Ring Seal
Lubricate the bore of the O-ring seals with glycerin or an approved equivalent.
5
1
5H-6734 OLubricate the bore of the O-ring seals with glycerin or an approved equivalent. Ring Seal
6
1
Lubricate the shaft with a thin film of clean engine oil before pressing the 212-8180 impeller onto the shaft. The end of the shaft must be flush with the face of the Pump Drive impeller within 0.15 mm (0.006 inch). Shaft As Diameter of the shaft to the impeller seating is 25.400 to 25.413 mm (1.0000 to 1.0005 inch).
7
3
9M-2151 Taperlock Stud
Torque to 35 ± 5 N·m (26 ± 4 lb ft).
8
3
9S-8752
Torque to 27 ± 4 N·m (239 ± 35 lb in).
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777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine(SEBP4975 - 114) - Systems & Components
Full Nut 9
1
10 1 B 11
1
12
1
7N-4758 Thrust Washer
Thickness of new thrust washer is 8.5 mm (0.33 inch). Width of the groove for thrust washer is 8.75 ± 0.05 mm (0.344 ± 0.002 inch).
212-8187 Impeller
Bore of the impeller for new shaft is 25.342 ± 0.013 mm (0.9977 ± 0.0005 inch). Clearance between the impeller and the cover is 0.5000 ± 0.4925 mm (0.01968 ± 0.01939 inch).
3D-2824 OLubricate the bore of the O-ring seals with glycerin or an approved equivalent. Ring Seal 7G-8478 Adapter
Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.
Torque to 100 ± 10 N·m (74 ± 7 lb ft).
Fri May 08 2020 15:30:38 GMT+0800 (Singapore Standard Time) jva6ij
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5/8/2020
777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine(SEBP4975 - 114) - Systems & Components
Previous Screen
Welcome: jva6ij Product: TRUCK Model: 777D TRUCK FKR Configuration: 777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine
Testing and Adjusting C27 and C32 Engines for Caterpillar Built Machines Media Number -SENR9937-30
Publication Date -01/08/2015
Date Updated -14/08/2019 i02169116
Water Pump - Test SMCS - 1361-081
Table 1 Tools Needed Part Number
Part Name
Quantity
6V-7775
Air Pressure Gauge
1
Illustration 1
g01105967
(1) Water manifold assembly
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777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine(SEBP4975 - 114) - Systems & Components
Making contact with a running engine can cause burns from hot parts and can cause injury from rotating parts. When working on an engine that is running, avoid contact with hot parts and rotating parts.
Perform the following procedure in order to determine if the water pump is operating correctly: 1. Remove a plug from water manifold assembly (1). 2. Install the 6V-7775 Air Pressure Gauge in the port. 3. Start the engine. Run the engine until the coolant is at operating temperature. 4. Note the water pump pressure. The water pump pressure should be at least 100 kPa (15 psi) at rated speed. Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.
Fri May 08 2020 15:31:32 GMT+0800 (Singapore Standard Time) jva6ij
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777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine(SEBP4975 - 114) - Systems & Components
Welcome: jva6ij
Previous Screen Product: TRUCK Model: 777D TRUCK FKR Configuration: 777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine
6 11
7
1 2
4-3 5
9
GRAPHIC #1 g00905564
777D Off-Highway Truck, Powered By 3508B Engine Media Number - SEBP4975-114 | Publication Date - 01/04/2020 Updated - 01/04/2020
|
Date i05645562
212-8176 PUMP GP-WATER S/N JDM100-363; C8T1-2363 PART OF 2W-9726 PUMP GP-WATER ALSO AN ATTACHMENT ENTIRE GROUP Ref. Qty.
Note
Grp
Part No.
Part Name
212-8176
PUMP GP-WATER
INDIVIDUAL PARTS https://sis.cat.com/sisweb/servlet/cat.cis.sis.PController.CSSISConsistList?calledpage=/sisweb/sisweb/productsearch/productheaderinfoframeset.jsp&…
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777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine(SEBP4975 - 114) - Systems & Components
Ref. Qty.
Part No.
Req. Part Name Qty.
7N-4756
1
HOUSING AS-PUMP
J
3D-2824
1
SEAL-O-RING
J
4N-5834
2
FILTER-FOAM (WATER PUMP HOUSING)
7G-8478
1
ADAPTER
8T-6765
1
PLUG-PIPE (1/4-18-THD)
212-8180
1
4B-9782
1
Note
1
2
J
SHAFT AS-PUMP DRIVE BALL
3
J
0S-1618
2
BOLT (5/16-18X1-IN)
4
J
9M-1974
2
WASHER-HARD (8.8X16X2-MM THK)
5
J
7N-4758
1
WASHER-THRUST
6
J
8C-5236
1
SEAL-LIP TYPE
7
J
166-4376
1
SEAL GP (WATER PUMP)
9
J
212-8187
1
IMPELLER
11
J
166-4374
1
RING AS
1L-5316
1
PIN-SPRING
AVAILABLE REPAIR KIT(S): YJ
222-5153
KIT-WATER PUMP
Key: J - KIT MARKED J INCLUDES PART(S) MARKED J
SMCS Codes 1361
Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.
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777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine(SEBP4975 - 114) - Systems & Components
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Previous Screen Product: TRUCK Model: 777D TRUCK FKR Configuration: 777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine
GRAPHIC #1 g03163878
777D Off-Highway Truck, Powered By 3508B Engine Media Number - SEBP4975-114 | Publication Date - 01/04/2020 Updated - 01/04/2020
|
Date i05814726
379-3978 PUMP GP-WATER S/N C8T2446-UP PART OF 331-1423 ENGINE AR ALSO AN ATTACHMENT ENTIRE GROUP Ref. Qty.
Note
Grp
Part No.
Part Name
379-3978
PUMP GP-WATER
INDIVIDUAL PARTS Ref. Qty.
Note
1 2
RY
Part No.
Req. Part Name Qty.
8N-6423
1
COVER (WATER INLET) PUMP GP-WATER
416-0609
1
R
10R-1670
1
3
149-5462
1
SEAL-O-RING
4
3B-1915
4
BOLT (3/8-16X1.375-IN)
PUMP GP-WATER -B
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777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine(SEBP4975 - 114) - Systems & Components
5
5H-6734
1
SEAL-O-RING
6
9M-2151
3
STUD-TAPERLOCK (3/8-16X1.378IN)
7
9S-8752
3
NUT-FULL (3/8-16-THD)
Key: R - REMANUFACTURED PART MAY BE AVAILABLE Y - SEPARATE ILLUSTRATION
SMCS Codes 1361
Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.
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