Rework Procedure To Update the Radiator Group{1353, 7251} Caterpillar


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Rework Procedure To Update the Radiator Group{1353, 7251} [REHS4241]
COOLING SYSTEM
RADIATOR GP
1.1. Introduction
2.1. Safety
3.1. Weights
4.1. Parts List
5.1. References
6.1. Specifications for Cables, Chains, and Lifting Devices
7.1. Procedure for Installation of the New Baffle, New Bracket, and New Seals
Wheel Tractor-Scraper:
631G (S/N: DFA1-UP)
637G (S/N: DFJ1-UP)

Introduction

This Special Instruction provides the rework procedure to update the radiator group. The new baffle, a new bracket, and new seals will prevent rocks from being directed or entering the area of the fan on the machine. This change will prevent leaks that are caused by small rocks that are deflected off the fan into the radiator core.

Refer to the necessary parts list.

Prepare the machine for service after installation of the new baffle, the new bracket, and the new seals. Follow the procedure in the Operation and Maintenance Manual for your machine.

Safety

------ WARNING! ------

Do not attempt to assemble this machine until you read and you understand the assembly instructions.

Improper assembly procedures could result in injury or death.

----------------------

------ WARNING! ------

When a hoist is used to lift any part or assembly, stand clear of the area under the part being raised. Always make sure that the hoist has adequate lifting capacity and the wire cable is not damaged.

Failure to follow this instruction could lead to injury or death.

Approximate weights of the components are shown in the table which follows.

----------------------

Weights

The weights that are listed are approximate.

Table 1
Approximate Weights    
Description     Weight    
240-9476 Access Door As     78 kg (172 lb)    
302-1540 Hood As    
114 kg (250 lb)    

Parts List

Table 2
Required Parts for Group 1    
Qty     New Part     Description    
3     223-8985     Radiator Core As (1)    
6     272-5438     Radiator Seal (1)    

80 cm (31.496 inch)    
333-9632     Seal    
1     5P-6126     Seal    
8     8T-4195     Bolt    
1     332-3618     Bracket    
( 1 ) This is an optional part.

Table 3
Required Parts for Group 2    
Qty     New Part     Description    
1     332-7600     Baffle    
10     139-3785     Pop Rivet    
3     223-8985     Radiator Core As (1)    
6     272-5438     Radiator Seal (1)    

80 cm (31.496 inch)    
333-9632     Seal    
1     5P-6126     Seal    
8     8T-4195     Bolt    
1     332-3618     Bracket    
( 1 ) This is an optional part.

References

ReferenceRefer to Disassembly and Assembly, "Crankcase Guard - Remove and Install" for additional information on removing and installing the crankcase guard.

ReferenceRefer to Disassembly and Assembly, "Hood - Remove and Install" for additional information on removing and installing the hood.

ReferenceRefer to Disassembly and Assembly, "Radiator Module - Remove" for additional information on removing the radiator module.

ReferenceRefer to Disassembly and Assembly, "Radiator Module - Install" for additional information on installing the radiator module.

ReferenceRefer to Disassembly and Assembly, "Radiator Core - Remove and Install" for additional information on removing and installing the radiator core.

ReferenceRefer to Disassembly and Assembly, SENR5664, "Refrigerant System - Evacuate" in the Testing and Adjusting section for additional information on evacuating the air conditioning system.

ReferenceRefer to Special Instruction, "Procedure to Install High Durometer Radiator Seals".

Specifications for Cables, Chains, and Lifting Devices

Use approved cables, chains, and lifting devices in order to lift components. Refer to the manufacturer's weight's in order to determine the application when you select the following items: cable, chain and lifting devices. When you lift a component, the lift angle is critical. Refer to the Illustration that follows in order to see the effect of the lift angle on the working load limit.

Note: The lifting devices that are shown in this publication are not AVSpare parts.




Illustration 1g00629745

Lift angles for lifting slings.

(A) The load capacity is 100% of the working load limit for the sling.

(B) The load capacity is 86% of the working load limit for the sling.

(C) The load capacity is 70% of the working load limit for the sling.

(D) The load capacity is 50% of the working load limit for the sling.

Procedure for Installation of the New Baffle, New Bracket, and New Seals

Note: For machines in Group 1, do not perform Steps 10 through 12.

Table 4
Required Parts    
Callout     Part Number     Description     Qty    
1     332-7600     Baffle     (1)    
2     139-3785     Pop Rivet     10 (1)    
3     223-8985     Radiator Core As     (2)    
4     272-5438     Radiator Seal     (2)    
5     333-9632     Seal    
80 cm (31.496 inch)    
6     5P-6126     Seal     1    
7     8T-4195     Bolt     8    
8     332-3618     Bracket     1    
( 1 ) Required part for machines in Group 2 only
( 2 ) This is an optional part.



    Illustration 2g01936656

    View of guard assembly (A) before removal

  1. Remove guard assembly (A) for the crankcase. Retain hardware for later use.



    Illustration 3g01930873

    View of connections (B) that are disconnected

  1. Disconnect two connections (B) for the lighting harness. This will disconnect the lighting harness from the chassis harness.



    Illustration 4g01936773

    View of lift link on top door assembly (C)

  1. Attach a lifting crane and attach a lift link to top door assembly (C) .



    Illustration 5g01933715

    View of struts (D) before removal

  1. Open the access door assembly (C) and secure access door assembly (C) .

    Note: Use a suitable lifting device in order to lift and secure the access door assembly (C). The approximate weight of the access door assembly (C) is 78 kg (172 lb).

  1. Disconnect two struts (D) .



    Illustration 6g01933717

    View of nine bolts (E) and hinge (F) .

  1. Remove nine bolts (E) and hinge (F) on access door assembly (C). Retain hardware for later use.

  1. Remove access door assembly (C) .

    Note: Use a suitable lifting device in order to lift the access door assembly (C). The approximate weight of the access door assembly (C) is 78 kg (172 lb).




    Illustration 7g01930875

    View of two connections (G) and (H)

  1. Disconnect the two connections (H) for the window washer. Disconnect connections (G) for the ether aid, if equipped.



    Illustration 8g01934016

    View of front hood assembly (J)




    Illustration 9g01937093

    View of bolts (K) before removal

  1. Remove front hood assembly (J) and bolts (K) that hold the hood assembly to the chassis on both sides.

    Note: Use a suitable lifting device in order to lift front hood assembly (J). The approximate weight of the front hood assembly (J) is 114 kg (250 lb).




    Illustration 10g01930877

    View of retaining strips (L), baffle (M), and pop rivets (N) before removal

  1. Position front hood assembly (J) so that the face side is in the down position. Protect the face of the front hood in order to prevent scratches. Drill out old pop rivets (N). Remove retaining strips (L). Retain strips (L) for later use.

  1. Remove old baffle (M) .

    Note: For machines in Group 1, do not perform Steps 10 through 12.




    Illustration 11g01930879

    View of new baffle (1) that is installed

  1. Install new baffle (1) with retaining strips (L) and ten new pop rivets (2) .

    Note: For machines in Group 1, do not perform Step 10 through Step 12.




    Illustration 12g01930881

    View of the path of small rocks




    Illustration 13g01930882

    View of accumulated gravel and stones

  1. The accumulation of gravel and stones may cause a radiator core to leak. Drain the coolant, and remove the damaged core and seals. If no leaks are found, skip this step.

  1. Inspect the radiator and the aftercooler for gravel and stones.

  1. Remove gravel and stones that have built up.

    Note: In most cases, removal of the radiator core is not necessary to complete this step.

  1. If a leaking core was removed in Step 13, install new radiator core assembly (3) and new radiator seals (4) and refill with coolant.

    ReferenceRefer to Special Instruction, "Procedure to Install High Durometer Radiator Seals".

    Note: This step is optional.




    Illustration 14g01930883

    View of new seal (5), seal (6), and new bracket (8) that is installed with eight bolts (7) .

  1. To prevent the entry of gravel and stones in the future, install new seal (5) and seal (6). Install new bracket (8) with eight new bolts (7) in order to retain the seals in place.



    Illustration 15g01930884

    View of front hood assembly (J) that is installed

  1. Install the front hood assembly (J) and bolts (K) that hold the hood assembly to the chassis on both sides.

    Note: Use a suitable lifting device in order to lift front hood assembly (J). The approximate weight of the front hood assembly (J) is 114 kg (250 lb).




    Illustration 16g01930885

    View of connectors (G) and (H) that are installed

  1. Reattach the two connections (H) for the window washer. If equipped, reattach ether aid (G) .



    Illustration 17g01934294

    View of access door assembly (C) that is installed with nine bolts (E) and hinge (F) .

  1. Install access door assembly (C) .

  1. Install nine bolts (E) and hinge (F) on access door assembly (C) .

    Note: Use a suitable lifting device in order to lift access door assembly (C). The approximate weight of access door assembly (C) is 78 kg (172 lb).




    Illustration 18g01937153

    View of struts (D) that are reconnected

  1. Reconnect two struts (D) .



    Illustration 19g01937193

    View of connections (B that are reconnected.)

  1. Connect two pin connections (B) from the lighting harness to the chassis harness.

  1. Close access door assembly (C) .



    Illustration 20g01937281

    View of guard assembly (A) that is reinstalled

  1. Install guard assembly (A) for the crankcase.

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