Procedure for Converting the 815F Radiator Mounting Brackets to the Upgraded 815F Tier II Design{1353, 1374} Caterpillar

Introduction

Illustration 1	g00983767

This special instruction is intended to provide the service technician with the proper instructions in order to convert the Group-C radiator mounting brackets to the new Tier II radiator mounting brackets.

This special instruction is intended for machines that have a radiator mounting bracket with three bolt holes to be updated to the new radiator mounting brackets with four bolt holes. The new radiator mounting brackets are a much stronger support bracket system for the entire cooling package. The new brackets are redesigned with more surface area in order to strengthen the entire cooling package. This will also prevent cracking under high stress.

Note: This Special Instruction is intended for the repair of the 815F Soil Compactor. This Special Instruction may also be used for the repair of an 814F Wheel Tractor or an 816F Landfill Compactor.

Do not perform any procedure that is outlined in this publication until you understand the information that is contained in the document.

Parts that are Required for Updating the Radiator Mounting Brackets

Preparation of the Machine

Show/hide table

To prevent personal injury due to accidental starting of the engine, disconnect the batteries during maintenance or repair work.

Show/hide table

Batteries give off combustible gases which can explode. A spark can cause the combustible gases to ignite. This can result in severe personal injury or death. Ensure proper ventilation for batteries that are in an enclosure. Follow the proper procedures in order to help prevent electrical arcs and/or sparks near batteries. Do not smoke when batteries are serviced.

Park the machine on a smooth hard surface. Ensure that there is nothing under the machine that is a flammable material when the machine is parked prior to starting the repair process.

The following repair will require partial disassembly of the radiator system. Follow the steps below in order to properly disassemble the radiator system.

Note: This procedure does not require the complete removal of the radiator. Draining the engine coolant or the hydraulic oil is not necessary.

Reference: For more information on disassembling the radiator system, refer to Disassembly and Assembly Manual, SENR1318, "814F Wheel Tractor, 815F Soil Compactor and 816F Landfill Compactor Machine Systems", "Radiator and Hydraulic Oil Cooler".

Note: Begin the following procedure by first removing the hood and the air conditioner condenser.

Reference: For more information on removing the hood, refer to Disassembly and Assembly Manual, SENR1306, "3306 Engine Supplement For 814F Wheel Tractor, 815F Soil Compactor and 816F Landfill Compactor", "Hood".

Reference: For more information on removing the air conditioning condenser, refer to Disassembly and Assembly Manual, SENR1306, "3306 Engine Supplement For 814F Wheel Tractor, 815F Soil Compactor and 816F Landfill Compactor", "Air Conditioning Condenser".

Show/hide table



Illustration 2	g00984693

1. Fasten a strap and a suitable lifting device to grill (2), as shown.

2. Remove bolt (1) and the washer. Carefully open grill (2). Do not remove the lifting equipment from grill (2) at this time.

Show/hide table



Illustration 3	g00984680

3. Disengage rod assembly (4) through hole (3) that is located in the lower channel of the radiator guard. Remove grill (2) from the machine. The weight of the grill is 34 kg (75 lb).

Show/hide table



Illustration 4	g00984707

4. Remove six bolts (5) and washers that hold frame (6) in position. Remove the frame. The frame weighs approximately 23 kg (50 lb).

Show/hide table



Illustration 5	g00984710

5. Remove eight bolts (7) and the washers that hold cover assembly (8) in position. By using two people, remove the cover assembly. The weight of cover assembly is approximately 23 kg (50 lb).

   Note: Two of the eight bolts (7) and washers are located on the back of the cover. Six of the bolts (7) are located on the top of cover (8) .

Show/hide table



Illustration 6	g00984714

6. Remove cover (10) from each tail light (9) .

Show/hide table



Illustration 7	g00984719

7. Disconnect wires (11) and wiring harness (12) from each tail light. Do not remove the tail lights from the machine. The tail lights will remain on the covers when the covers are removed from the machine.

Show/hide table



Illustration 8	g00984762

8. Remove bolts (14) and the washers that hold the upper fan guards and the lower fan guards (13) in position. Remove the fan guards.

9. Remove four bolts (not shown) that hold brackets (15) for the air conditioning condenser in place. Remove brackets (15) for the air conditioning condenser from the machine.

Show/hide table



Illustration 9	g00984776

10. Remove four bolts (16) and the washers (two on each side of the radiator guard) that hold the right and left panel assemblies of the radiator guard to the fan shroud.

Show/hide table



Illustration 10	g00984777

11. Fasten a suitable lifting device to the right hand panel assembly (18). Remove four bolts (17) (four on each panel) that hold the panel assembly in position. Remove the right hand panel assembly. Remove the left side panel assembly in the same manner. The weight of each panel assembly is 50 kg (110 lb).

Note: The existing side channels ( 7E-3548 Channel and 7E-3549 Channel ) that are now visible will not be removed. The side channels will be modified in order to complete the conversion.

Procedure In Order To Convert the Radiator Mounting Brackets

Show/hide table

Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas.

Show/hide table

Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts.

Note: It is very important to only remove one bracket at a time. This will help in order to maintain the integrity of the entire conversion. This will also ensure that the new brackets are correctly mounted.

Replacement of the Radiator Bracket (Engine Side)

Show/hide table



Illustration 11	g00985234
Typical Example

1. Weld nuts (19) will be removed and replaced in order to mount the new radiator mounting brackets. Begin the conversion procedure from the engine side of the cooling package.

Show/hide table



Illustration 12	g00984991
Left Side Radiator Mounting Bracket (Engine Side)

2. Remove bolts (20) and the washers from radiator mounting bracket (21). It may be necessary to apply slight pressure to the radiator group toward the rear of the machine in order to easily remove the bolts.

3. Remove bolts (22) and the washers that secure the radiator group to the frame of the machine. Radiator mounting bracket (21) can now be removed from the machine.

   Note: Retain bolts (22) after removal, as the bolts will be used again.

Show/hide table



Illustration 13	g00985005
Side View of the Mounting Bracket (Engine Side)

4. Weld nuts (19) must now be removed from the channel assembly.

Show/hide table



Illustration 14	g00985029

5. Place the new 206-4311 Support Bracket (23) in position. Ensure that bolts (22) are tightened to the proper specification in order to ensure that the bracket is level with the chassis of the machine.

   Note: You should bolt the new 206-4311 Support Bracket into position by utilizing the upper and lower mounting holes. These holes will remain at the same point. When you torque the bolts into the radiator support temporarily, you will ensure that the holes are concentric with the bracket.

6. Ensure that you mark the holes that will be drilled into the channel assembly. Remove bolts (22) from the chassis. Remove 206-4311 Support Bracket (23) from the radiator group.

7. Drill out the channel assembly at the marked areas to a diameter of 16.75 mm (.66 inch).

   Note: The upper and lower existing mounting holes will be used again. The mounting holes that will be used again must be drilled out in order to create a 16.75 mm (.66 inch) pilot hole.

Show/hide table



Illustration 15	g00985044
Location for the Weld Nuts

Show/hide table

Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas.

Note: Ensure that the areas that will be welded are cleaned of the following substances: grease, oil, paint and flammable solvents.

8. Weld the new 8T-3597 Weld Nuts on the inside of the channels. Ensure that weld nuts are centered exactly on the new holes prior to welding.

Show/hide table



Illustration 16	g00985040
Completed Conversion is Shown.

9. Allow the welded area to cool prior to attempting to install the new 206-4311 Support Bracket (23) .

10. Fit the new 206-4311 Support Bracket (23) into position.

11. Install bolts (22) into the correct position, and torque to 105 ± 20 N·m (75 ± 15 lb ft).

12. Install three 8T-4910 Bolts (24), three 7X-0550 Hard Washers , and three 146-5067 Spacers into the upper three mounting holes. Torque bolts (24) to a torque of 100 ± 20 N·m (70 ± 15 lb ft).

13. Install one 8T-4648 Bolt , one 7X-0550 Hard Washer , and one 146-5067 Spacer into the lower mounting hole. Torque bolt (25) to a torque of 100 ± 20 N·m (70 ± 15 lb ft).

Show/hide table



Illustration 17	g00985075
Right Side Radiator Mounting Bracket (Engine Side) Completed Installation is Shown.

14. The right side radiator mounting bracket ( 206-4312 Support ) is replaced in the exact same manner as the left side radiator mounting bracket. Repeat steps 1 through 12 for the replacement of the radiator mounting bracket that is located on the right side of the machine.

Replacement of the Radiator Mounting Bracket (Grill Side)

Show/hide table



Illustration 18	g00985234
Typical Example

1. Weld nuts (19) will be removed and replaced in order to mount the new radiator mounting brackets. Begin the conversion procedure from the engine side of the cooling package.

Show/hide table



Illustration 19	g00984992

2. Remove bolts (20) and the washers from radiator mounting bracket (21). It may be necessary to apply slight pressure to the radiator group toward the front of the machine in order to easily remove the bolts.

3. Remove bolts (22) and the washers that secure the radiator group to the frame of the machine. Radiator mounting bracket (21) can now be removed from the machine.

   Note: Retain bolts (22) after removal, as the bolts will be used again.

Show/hide table



Illustration 20	g00985005
Side View of the Mounting Bracket (Engine Side)

4. Weld nuts (19) must now be removed from the channel assembly.

Show/hide table



Illustration 21	g00985217

5. Place the new 206-4466 Support Bracket (23) in position. Ensure that bolts (22) are tightened to the proper specification in order to ensure that the bracket is level with the chassis of the machine.

   Note: You should bolt the new 206-4466 Support Bracket into position by utilizing the upper and lower mounting holes. These holes will remain at the same point. When you torque the bolts into the radiator support temporarily, you will ensure that the holes are concentric with the bracket.

6. Ensure that you mark the areas that will be drilled into the channel assembly. Remove bolts (22) from the chassis. Remove 206-4466 Support Bracket (23) from the radiator group.

7. Drill out the channel assembly at the marked areas to a diameter of 16.75 mm (.66 inch).

   Note: The upper and lower existing mounting holes will be used again. The mounting holes that will be used again must be enlarged to 16.75 mm (.66 inch).

Show/hide table



Illustration 22	g00985209
Location for the Weld Nuts

Show/hide table

Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas.

Note: Ensure that the areas that will be welded are cleaned of the following substances: grease, oil, paint and flammable solvents.

8. Weld the new 8T-3597 Weld Nuts on the inside of the channels. Ensure that weld nuts are centered exactly on the new holes prior to welding.

Show/hide table



Illustration 23	g00985217
Completed Conversion is Shown.

9. Allow the welded area to cool prior to attempting to install the new 206-4466 Support Bracket (23) .

10. Fit the new 206-4466 Support Bracket (23) into position.

11. Install bolts (22) into the correct position, and torque to 105 ± 20 N·m (75 ± 15 lb ft).

12. Install four 8T-4910 Bolts (24), four 7X-0550 Hard Washers , and four 146-5067 Spacers into the four mounting holes. Torque bolts (24) to a torque of 100 ± 20 N·m (70 ± 15 lb ft).

Show/hide table



Illustration 24	g00985214
Right Side Radiator Mounting Bracket (Engine Side) Completed Installation is Shown.

13. The right side radiator mounting bracket ( 206-4464 Support ) is replaced in the exact same manner as the left side radiator mounting bracket. Repeat steps 1 through 12 for the replacement of the radiator mounting bracket that is located on the right side of the machine.

Reassembly Of the Radiator Group

Reference: For more information on assembly of the radiator system, refer to Disassembly and Assembly Manual, SENR1318, "814F Wheel Tractor, 815F Soil Compactor and 816F Landfill Compactor Machine Systems", "Radiator and Hydraulic Oil Cooler".

Show/hide table



Illustration 25	g00984777

1. Fasten a suitable lifting device to the right hand panel assembly (18). Install the right hand panel assembly. Install four bolts (17) (four on each panel) that hold the panel assembly in position. Install the left side panel assembly in the same manner. The weight of each panel assembly is 50 kg (110 lb).

Show/hide table



Illustration 26	g00984776

2. Install four bolts (16) and the washers (two on each side of the radiator guard) that hold the right and left panel assemblies of the radiator guard to the fan shroud.

3. Install four bolts (not shown) that hold brackets (15) for the air conditioning condenser in place. Install brackets (15) for the air conditioning condenser onto the machine.

Show/hide table



Illustration 27	g00984762

4. Install fan guards (13) onto the mounting studs. Install bolts (14) and the washers that hold the upper fan guards and the lower fan guards (13) in position.

Show/hide table



Illustration 28	g00984719

5. Connect wires (11) and wiring harness (12) onto each tail light.

Show/hide table



Illustration 29	g00984714

6. Install cover (10) onto each tail light (9) .

Show/hide table



Illustration 30	g00984710

7. By using two people, install the cover assembly. Install eight bolts (7) and the washers that hold cover assembly (8) in position. The weight of cover assembly is approximately 23 kg (50 lb).

   Note: Two of the eight bolts (7) and washers are located on the back of the cover. Six of the bolts (7) are located on the top of cover (8) .

Show/hide table



Illustration 31	g00984707

8. Install the frame. Install six bolts (5) and washers that hold frame (6) in position. The frame weighs approximately 23 kg (50 lb).

Show/hide table



Illustration 32	g00984693

9. Fasten a strap and a suitable lifting device to grill (2), as shown.

Show/hide table



Illustration 33	g00984680

10. Install grill (2) onto the machine. Engage rod assembly (4) through hole (3) that is located in the lower channel of the radiator guard. The weight of the grill is 34 kg (75 lb).

11. Install bolt (1) and the washer. Close grill (2). Remove the lifting equipment from grill (2) at this time.

12. Install the air conditioning condenser.

    Reference: For more information on installation of the air conditioning condenser, refer to Disassembly and Assembly Manual, SENR1306, "3306 Engine Supplement For 814F Wheel Tractor, 815F Soil Compactor and 816F Landfill Compactor", "Air Conditioning Condenser".

13. Install the hood.

    Reference: For more information on installation of the hood, refer to Disassembly and Assembly Manual, SENR1306, "3306 Engine Supplement For 814F Wheel Tractor, 815F Soil Compactor and 816F Landfill Compactor", "Hood".