Installation of the 156-7013 Radiator Field Upgrade Kit on the 994 Wheel Loader{1353} Caterpillar

Wheel Loader:

994 (S/N: 9YF1-UP)

Introduction

Illustration 1	g00998169

This special instruction is intended to provide the service technician with the proper instructions in order to upgrade the radiator that is on the 994 Wheel Loader. This special instruction is intended for machines that do not use the "High Ambient" radiator system. The new 156-7013 Radiator Field Upgrade Kit will upgrade the cooling system from the "A" series machines to the later cooling system that is used on the "D" series machines.

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

Parts that are Required in Order to Install the 156-7013 Radiator Field Upgrade Kit

The following table will list the parts that are required in order to install the new 156-7013 Radiator Field Upgrade Kit .

Table 1

Parts that are Required
Quantity	Part Number	Description
1	156-7013	Radiator Field Upgrade Kit (1)

( 1 )

This kit will contain all of the parts in order to perform the conversion to the radiator system.

Note: Check the part number of the water regulator housing before you order any parts. If you have 157-2838 Regulator Housing , you will need only the 156-7013 Radiator Field Upgrade Kit . If you have 9Y-4090 Regulator Housing , you will also need to order the parts that are listed in Table 2.

Table 2

Parts that are Used with 9Y-4090 Regulator Housing
Quantity	Part Number	Description
1	9Y-4090	Regulator Housing
4	8T-6762	Pipe Plug
1	9S-4182	Plug
1	6V-9027	O-Ring Seal
1	7E-9584	Elbow
1	4W-3100	Gasket
1	2N-0931	Gasket
1	9X-6458	Hard Washer
4	1D-4706	Bolt
1	7L-7524	Bolt
1	5B-2638	Bolt
2	8N-4524	Gasket

Preparation of the Machine

Perform the following steps prior to removal of the radiator system.

Install the Wheel Chocks

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Before service work is begun, park the machine on a hard level surface. Block the wheels of the machine so unexpected movement will not occur. Unexpected movement of the machine can cause personal injury or death.

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Illustration 2	g00998051
Wheel chocks are shown in the correct installed position.

1. Install the 155-3597 Wheel Chocks (Front and Rear) on all of the tires in order to prevent the machine from rolling.

Install the Frame Lock Link

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Personal injury or death can result from machine articulation or movement. Machine frames can move and a person can be crushed. Connect the steering frame lock link between the front and rear frames before working on machine. Secure clevis pin with locking pin. Before operating the machine, fasten the steering frame lock link into the stored position and secure the clevis pin with locking pin. Failure to lock into the stored position before operating can result in loss of steering.

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Illustration 3	g00997993
The frame lock link is shown in the installed position.

1. Perform Step 1.a through Step 1.f in order to install the frame lock link.

   1. Move the machine to a hard, level surface. Park the machine in the straight ahead position and engage the parking brake.
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   Illustration 4	g00512380
   The frame lock link is shown in the disconnected position.

   2. Remove two cotters (2) .

   3. Remove two pins (1) .
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   Illustration 5	g00511881
   The frame lock link is shown in the installed position.

   4. Position frame lock link (3), as shown.

   5. Install two pins (1) .

   6. Install two cotters (2) .

Release the Hydraulic System Pressure

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

1. Release the hydraulic system pressure. Follow the Step 1.a through Step 1.h in order to release the hydraulic system pressure.

   1. Ensure that the machine is parked on a hard surface. Ensure that the machine is parked on a level surface.

   2. Engage the parking brake.

   3. Turn the engine start switch to the OFF position in order to stop the engine.

   4. Turn the engine start key to the ON position, but do not start the engine.

   5. Move all of the control levers through the full range of travel in order to release the hydraulic system pressure.

   6. Apply the foot brake several times in order to ensure that there is no hydraulic system pressure in the service brake circuit.

   7. Turn the engine start switch to the OFF position.
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   Illustration 6	g00998056
   Location of the breaker relief valve on (S/N: 9YF1-41) (4) Breaker relief valve. (5) Hydraulic tank.

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   Illustration 7	g00998057
   Location of the breaker relief valve on (S/N: 9YF42-59) (4) Breaker relief valve. (6) Tube.

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   Illustration 8	g00998058
   Location of the breaker relief valve on (S/N: 9YF116-UP) (4) Breaker relief valve. (7) Hydraulic hose to the hydraulic tank.

   8. If equipped, press the breaker relief valve several times in order to remove any remaining pressure that is in the hydraulic system. Refer to the illustrations above in order to locate the breaker relief valve for the machine that is being serviced.

      Note: If your machine is not equipped with a breaker relief valve, ensure that you slowly loosen the hydraulic filler cap that is located on the hydraulic tank. It is not necessary to completely remove the filler cap.

Drain the Hydraulic System

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

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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, "AVSpare Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on AVSpare products. Dispose of all fluids according to local regulations and mandates.

Note: The entire hydraulic system must be drained prior to performing the remainder of the procedure. Ensure that both the main hydraulic system and the steering and brake systems have been drained before continuing with the rest of the procedure.

Drain the Main Hydraulic System

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Illustration 9	g00733078

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Illustration 10	g00998206
Typical Example

1. Press breaker relief valve (9) in order to release the pressure in the hydraulic tank.

2. Remove filler cap (8). Also, remove the filler strainer from the filler tube.

3. Wash the filler strainer and the filler cap in a clean, nonflammable solvent.

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Illustration 11	g00998208

4. Remove drain plug (10) from the bottom of the hydraulic tank.

5. Attach a hose to a 1-NPT pipe nipple that is 100 mm (4 inch) long.

6. Install the 1-NPT pipe nipple into the drain valve in order to open the internal drain valve. Allow the oil to drain into a suitable container. Dispose of the used oil properly.

7. Remove the 1-NPT pipe nipple in order to close the internal drain valve.

8. Clean the drain plug and install the drain plug.

Drain the Brake System and the Steering System

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Illustration 12	g00998249
Location of the brake and steering hydraulic oil tank

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Illustration 13	g00998209
Brake and steering hydraulic oil tank

1. Open the access door that is located on the platform behind the cab. Slowly loosen filler cap (11) in order to relieve any tank pressure from the axle oil cooler tank.

2. Remove filler cap (11) and the filler strainer. Wash filler cap (11) and the filler strainer in a clean, nonflammable solvent.

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Illustration 14	g00998216
The location of the brake oil tank drain and the steering hydraulic oil tank drain.

3. Remove drain plug (12) from the bottom of the hydraulic tank for the axle oil cooler.

4. Attach a hose to a 1-NPT pipe nipple that is 100 mm (4 inch) long.

5. Install the pipe nipple into the drain plug opening in order to open the internal drain valve. Allow the oil to drain into a suitable container. Dispose of the used oil properly.

6. Remove the pipe nipple in order to close the internal drain valve.

7. Clean drain plug (12) and install drain plug (12) .

8. Install brake oil filler cap (11) onto the oil tank that is for the brake and steering hydraulic oil.

Drain the Axle Oil Cooler

The hydraulic tank for the axle oil cooler is connected to the steering and brake hydraulic oil tank. In order to completely drain the hydraulic system, perform the following procedure. In order to avoid excessive hydraulic fluid loss, ensure that you drain the hydraulic tank for the axle oil cooler.

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Illustration 15	g00732997
Location of the hydraulic tank for the axle oil cooler

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Illustration 16	g00998245
Hydraulic tank for the axle oil cooler

1. Open the access door that is located on the platform behind the cab. Slowly loosen filler cap (13) in order to relieve any tank pressure from the axle oil cooler tank.

2. Remove filler cap (13) and the filler strainer. Wash filler cap (13) and the filler strainer in a clean, nonflammable solvent.

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Illustration 17	g00998247
Location of the drain for the hydraulic tank for the axle oil cooler

3. Remove drain plug (14) from the bottom of the hydraulic tank for the axle oil cooler.

4. Attach a hose to a 1-NPT pipe nipple that is 100 mm (4 inch) long.

5. Install the pipe nipple into the drain plug opening in order to open the internal drain valve. Allow the oil to drain into a suitable container. Dispose of the used oil properly.

6. Remove the pipe nipple in order to close the internal drain valve.

7. Clean drain plug (14) and install drain plug (14) .

8. Install the oil filler cap that is for the steering and brake oil tank (13) onto the hydraulic tank for the axle oil cooler.

Drain the Cooling System

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Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand. Cooling System Conditioner contains alkali. Avoid contact with skin and eyes.

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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, "AVSpare Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on AVSpare products. Dispose of all fluids according to local regulations and mandates.

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Illustration 18	g00998317
Typical Example

1. Slowly remove the two radiator caps that are located on top of the radiator tank in order to relieve any coolant system pressure.

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Illustration 19	g00998289
Location of cooling system drain valve (16) Located under the machine on the inside of the right side frame rail

2. Position a suitable container under drain tube (15) in order to contain the drained coolant. Ensure that you have a container that is large enough to hold the coolant. For more information about the capacity of the cooling system for the machine that is being serviced, refer to Operation and Maintenance Manual, SEBU6715, "994 Wheel Loader Operation and Maintenance Manual".

3. Open cooling system drain valve (16) that is located on the inside of the right frame rail.

4. Allow the coolant to drain into a suitable container.

5. Close cooling system drain valve (16) .

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Illustration 20	g00998291

6. Position a suitable container under drain tube (18) in order to contain the drained coolant. Ensure that you have a container that is large enough to hold the coolant. For more information about the capacity of the cooling system for the machine that is being serviced, refer to Operation and Maintenance Manual, SEBU6715, "994 Wheel Loader Operation and Maintenance Manual".

7. Open radiator drain valve (17) that is located on the inside of the right frame rail.

8. Allow the coolant to drain into a suitable container.

9. Close radiator drain valve (17) .

Removal of Existing Radiator System

Note: Install caps and plugs on all openings in order to prevent dirt or debris from entering the system. Cleanliness is an important factor. Before the removal procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.

Note: For easier assembly, mark all hose assemblies, tube assemblies, wire harnesses and cables for identification purposes.

Removal of the Existing Hydraulic Hoses

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Illustration 21	g00997946
The hydraulic coolant hoses are located on the right side of the machine above the bumper.

1. Remove the bolts, washers, and two half flanges that retain hydraulic hose (1) to the hydraulic tube that runs under the machine.

2. Remove the bolts, washers, and two half flanges that retain hydraulic hose (2) to the hydraulic tube that runs under the machine.

3. Remove the bolts, washers, and two half flanges that retain hydraulic hose (3) to the hydraulic tube that runs under the machine.

4. Remove the bolts, washers, and two half flanges that retain hydraulic hose (4) to the hydraulic tube that runs under the machine.

5. Ensure that you install caps and plugs on all open hydraulic lines in order to avoid excessive fluid loss.

6. The hydraulic system is now separated from the radiator.

Removal of the Existing Water Lines

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Illustration 22	g00998100
Location of existing water lines This view is from the right side of the machine.

1. Loosen two hose clamps (9a). This will enable water tube (11) to be separated from hump hose (9) .

2. Remove hose clamps (12) that connect hump hose (13) to water tube (8) and water tube (11) .

3. Remove the bolts and washers that hold metal clamps (10) to the frame. Remove metal clamps (10) that retain water tube (11) to the frame.

4. Lower water tube (11) from the machine, and remove water tube (11) from the machine.

5. Disconnect hose clamp (6a) from hump hose (6b). It is not necessary to remove hose clamp (6c). Hose clamp (6c) will be replaced.

6. Remove the bolt and the washer that retains metal clamp (7) in place. Metal clamp (7) retains water tube (8) to another water tube.

7. Remove the bolt and the washer that retains metal clamp (7a) in place. Metal clamp (7a) holds water tube (8) to the side of the radiator guard. At this time, water tube (8) may be removed from the underside of the machine.

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Illustration 23	g00998694
View from right side of machine

8. Loosen hose clamp (14) which connects the lower radiator tank to water pump inlet tube (18) .

9. Loosen hose clamp (17) which connects water tube (16) to water pump inlet tube (18) .

10. Loosen hose clamp (20) which connects hump hose (19) to the aftercooler water pump.

11. You can now remove water pump inlet tube (18) from the machine. Water tube (16) is not removed at this time. Water tube (16) will be removed with the radiator group.

    Note: Water pump inlet tube (18) and the related hoses will be replaced with a new assembly.

12. Remove four bolts (21) and the washers that retain water elbow (22) to the lower radiator tank.

    Note: Retain water elbow (22), as water elbow (22) will be reused on the new radiator assembly.

    Note: Ensure that you clean any old gasket material from the surface of water elbow (22) .

    Note: Water elbow (22) can remain attached to the machine until reassembly.

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Illustration 24	g00998814
Removal of the coolant bypass tube

13. Remove bolt (28) and the washer. Remove metal clamp (26) from coolant bypass tube (24) .

14. Remove bolts (23) from the flanges that retain coolant bypass tube (24) to regulator housing inlet elbow (25) .

15. Remove bolts (29) and the flanges that retain bypass tube (24) to the water pump outlet.

16. Remove coolant bypass tube (24) from the machine.

    Note: Coolant bypass tube (24) will be replaced with a new water tube.

17. Remove bolts (27) that retain regulator housing inlet elbow (25) to the regulator housing. Remove regulator housing inlet elbow (25) .

    Note: Retain regulator housing inlet elbow (25) .

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Illustration 25	g00998847
Removal of the water return tube

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Illustration 26	g00999972
Typical Example

Note: Illustration 26 is used only to illustrate the path of hose (31) and the connection point of fitting (30) .

18. Loosen hose clamp (36) from hose (35). This will free water return tube (34) from the water temperature regulator housing.

19. Disconnect turbocharger water return hose (31) from the engine by disconnecting fitting (30) .

    Note: Fitting (30) connects to an adapter that is on the end of the turbocharger water return line.

20. Remove four bolts (32) that retain elbow (33) to the radiator top tank.

21. At this point, you can remove the following parts from the machine as an assembly: elbow (33), water return tube (34), turbocharger coolant return tube (31) and hose (35) .

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Illustration 27	g00999024

22. Disconnect fitting (37) that is located on the end of hose (38) .

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Illustration 28	g00999036
View of the left side of the machine

23. Remove four bolts (39) that retain elbow (40) onto the lower radiator tank. Ensure that you also separate the rubber hose from the water pump. The 4W-7729 Hose that connects the lower radiator tank to the water pump will be replaced. The hose clamps will also be replaced upon reassembly.

    Note: It is not necessary to disassemble the radiator hose assembly at this time. The hose assembly may remain in place on the machine until reassembly.

Removal of A/C Hoses

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Personal injury can result from contact with refrigerant. Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury. Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant. Always use precaution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated area. Personal injury or death can result from inhaling refrigerant through a lit cigarette. Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death. Do not smoke when servicing air conditioners or wherever refrigerant gas may be present. Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system.

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NOTICE
Effective July 1, 1992 regulations prohibit the venting of any refrigerant into the atmosphere. Refer to AVSpare publications Service Manuals, SENR3334, SENR5664, and NEDG5065 for the proper procedure, the proper equipment, and the proper tools needed in order to reclaim refrigerant from any AVSpare equipment.

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Illustration 29	g00998790
Removal of A/C hose from compressor

1. Remove A/C hose (42) from compressor (41) .

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Illustration 30	g00998795
Removal of the A/C hose from the radiator group

2. Remove the bolt, the washers, and the nut that secures clamp (43) to the mounting bracket on the radiator.

3. Remove clamp (43) from hose assembly (44) .

4. Disconnect hose assembly (45) from hose assembly (44) .

Removal of the Rear Lights and the Backup Alarms

1. Disconnect the two electrical harnesses that connect the frame to the radiator group. The wiring harnesses can be located on the left side frame rail. One wiring harness has six electrical contacts. A smaller wiring harness has four electrical contacts.

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Illustration 31	g00999170
Location of the rear lights and the backup alarms

2. Remove eight bolts (49) and the washers in order to access bracket bolts (48). There are four bolts on each light guard. Disconnect the wiring that is located inside lamp assembly (47). Ensure that the wiring for work light (46) has also been disconnected.

3. Remove two bolts (48) that retain the entire lamp assembly (47) to the side of the radiator guard. Remove lamp assembly (47) from the machine and set lamp assembly (47) aside.

4. Repeat Step 1 through Step 3 for the lamp assembly that is on the opposite side of the machine.

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Illustration 32	g00999239
Detail of the backup alarms

Note: The backup alarms must be removed in order to install the backup alarms onto the new radiator group.

5. While the back cover is removed from the lamp assembly, disconnect electrical connector (52) from the wiring harness.

6. Remove four bolts (50) that are located on housing (51) .

7. Remove two bolts (53) and the washers that retain backup alarm (54) to the side of the radiator guard. Backup alarm (54) may now be removed from the side of the radiator guard.

8. Repeat Step 5 through Step 7 for the backup alarm that is on the opposite side of the machine.

Removal of the Water Temperature Regulator Housing

Follow the steps that are found below in order to remove the existing water temperature regulator housing. A new water temperature regulator housing will be installed at a later time.

Table 3

Required Tools
Tool	Quantity	Part Number	Description
A	2	6V-2156	Link Bracket

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Illustration 33	g00999605
Rear view of the water temperature regulator housing This illustration shows that the water bypass hose is not installed.

1. Loosen two fittings (55) in order to disconnect the turbocharger water tubes from water temperature regulator housing (56) .

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Illustration 34	g00999614
Bracket assembly (58) is shown.

2. Remove two bolts (57) that retain bracket assembly (58) to the top of water temperature regulator housing (56). Remove two bolts (57) that retain bracket assembly (58) to the side of water temperature regulator housing (56) .

   Note: Bracket (58) is bolted to the side cover of the water temperature regulator housing. Bracket assembly (58) only uses the top two side cover bolts.

3. Remove bracket (58) from water temperature regulator housing (56) .

4. Attach tool (A) to water temperature regulator housing (56) in order to lift water temperature regulator housing (56) from the engine.

Note: A bracket (not shown) rests on the center to the housing. This bracket is bolted in place. The bolts that retain this bracket must be removed in order to remove water temperature regulator housing (56).

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Illustration 35	g00999959

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Illustration 36	g01000594
Removal of bolts that hold the bracket in position

5. Fasten a hoist and a suitable lifting device to water temperature regulator housing (56). Remove the remaining bolts (59) and cover (60) from the top of water temperature regulator housing (56) .

   Note: Cover (60) can remain on the housing. However, cover (60) is not secured to the housing at this time.

6. Lift water temperature regulator housing (56) from the engine. Water temperature regulator housing (56) weighs 18 kg (40 lb).

   Note: Water temperature regulator housing (56) will be replaced with a new housing. Water temperature regulator housing (56) will not be reused.

Removal of the Fan and the Fan Guards

Note: Remove only one section of the fan guard assembly at a time. There are four sections that make up the entire fan guard.

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Illustration 37	g00999792
Location of the bolts for the fan guards

1. Begin by removing the bolts (62) that attach fan guards (64) to each other. All 20 bolts (62) may be removed at the same time. Guards (64) will be retained to the radiator shield until you remove bolts (63) .

2. Remove four bolts (63) that retain the section of fan guard (64) to the radiator group. Remove the section of fan guard (64) from the radiator group.

3. Repeat Step 2 for each of the remaining three sections of fan guard (64) .

4. Attach a hoist and a suitable lifting device to fan spider assembly (65) .

5. Remove eight bolts (61) that retain fan spider assembly (65) to the fan drive.

6. Carefully remove fan spider assembly (65) from the fan drive, and place fan spider assembly (65) inside the radiator group. Carefully rest the fan spider assembly against the radiator. Fan spider assembly weighs approximately 88 kg (194 lb).

Removal of the Radiator Group

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Do not approach the package while the package is being lifted. The package is extremely heavy. If the package is dropped or collided with, serious injury or death may occur.

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Personal injury or death can result from lifting a heavy assembly. The heavy assembly can fall if using an incorrect hoist to lift the load. Be sure the hoist has the correct capacity to lift a heavy assembly. Approximate weight of the assembly is given below.

Note: All of the connections between the engine and the radiator must be removed. All connections between the machine and the radiator must be removed.

Note: Illustration 38 shows the bracket that must be removed on each side of the handhold assembly. This bracket is used on both sides of the machine. Your machine may not be equipped with this bracket.

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Illustration 38	g01000188
Removal of the bracket for the handhold (If equipped) S/N:9YF29-UP

1. Remove the mounting hardware from the bracket.

2. Separate the bracket from the handhold assembly.

3. Repeat Step 1 through Step 2 for the opposite side of the machine.

   Note: The handhold assembly that is located on top of the radiator assembly can remain in place when the radiator assembly is removed.

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Illustration 39	g01000156
Location of the lifting straps

4. Install an appropriate lifting device and a hoist to the mounting points that are on each radiator guard. The mounting points consist of a strap that is welded to the upper portion of each of the radiator guards.

   Note: Prior to removing the cooling package, ensure that you have a lifting device that is capable of lifting 4100 kg (9000 lb).

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Illustration 40	g00999801
Left side of the machine Typical example

5. Remove three bolts (66) that retain radiator guard (67) to the frame of the machine.

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Illustration 41	g00999815
Right side of the machine Typical example

6. Remove three bolts (68) that retain radiator guard (69) to the frame of the machine.

7. Lift the radiator group away from the machine. The entire radiator assembly weighs approximately 3660 kg (8060 lb).

Installation of the new 156-7013 Radiator Field Upgrade Kit

Installation of the Fan and the Fan Guards

Table 4

Required Tools
Tool	Part Number	Part Description	Qty
A	138-7575	Link Bracket	1

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Illustration 42	g01000316

1. Attach Tool (A) to fan spider assembly (1). Position a suitable lifting sling to Tool (A). Secure the suitable lifting sling to a hoist.

2. Position fan spider assembly (1) to the radiator. The weight of fan spider assembly (1) is 104 kg (230 lb).

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Illustration 43	g01000324

3. Position two lower fan guard assemblies (3) and (4) to the radiator as one unit. Install eight bolts (2) and the washers that secure two lower fan guard assemblies (3) and (4) to the shield assemblies.

4. Install the bolt, the washers, and the nut that secures fan guard assemblies (3) and (4) to the bracket assembly at the bottom of the radiator.

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Illustration 44	g01000326

5. Position fan guard assembly (6) to the radiator.

6. Install four bolts (5) and the washers that secure fan guard assembly (6) to the shield assembly.

7. Install bolt (8), the washers, and the nut that secures fan guard assembly (6) to the bracket and the lower fan guard assembly.

8. Install three bolts (7) that secure fan guard assembly (6) to the lower fan guard assembly.

Installation of the New Radiator Assembly

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Do not approach the package while the package is being lifted. The package is extremely heavy. If the package is dropped or collided with, serious injury or death may occur.

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Personal injury or death can result from lifting a heavy assembly. The heavy assembly can fall if using an incorrect hoist to lift the load. Be sure the hoist has the correct capacity to lift a heavy assembly. Approximate weight of the assembly is given below.

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Illustration 45	g01000156
Location of the lifting straps

1. Install an appropriate lifting device and a hoist to the mounting points that are on each radiator guard. The mounting points consist of a strap that is welded to the upper portion of each of the radiator guards.

   Note: Prior to installing the cooling package, ensure that you have a lifting device that is capable of lifting 4100 kg (9000 lb).

2. Lower the new radiator group onto the machine. The entire radiator assembly weighs approximately 4100 kg (9000 lb).

Note: You must use the old bolts that secured the original cooling package. Check the bolts for excessive wear prior to installation. If the bolts appear excessively worn, replace any worn bolts or any damaged bolts with new bolts.

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Illustration 46	g01000469
Right side of the machine Typical example

3. Install three bolts (9) that retain radiator guard (10) to the frame of the machine.

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Illustration 47	g01000470
Left side of the machine Typical example

4. Install three bolts (11) that retain radiator guard (12) to the frame of the machine.

Install the New Handrails

Note: The separation of the handrails is covered in the ""Removal of the Radiator Group" ". However, the old handrails will not work on the new radiator assembly. The new handrails must be installed onto the top of the radiator assembly. You must first bolt the radiator assembly to the frame.

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Illustration 48	g01000527
Top view of the handrail assembly

1. You must install the new 133-1507 Handhold Assembly (18) and the 133-1508 Handhold Assembly (13) onto the top of the cooling package. These parts are included in the 156-7013 Radiator Field Upgrade Kit . Do not attempt to reuse the handrails from the old radiator assembly, as the old handrails will not fit the new radiator assembly.

2. By using six 8T-4136 Bolts and six 8T-4121 Washers , attach handhold (13) to the left side of the top of the radiator assembly.

3. Handhold (13) will attach to the radiator assembly at mounts (14), (15), and (16) .

4. By using six 8T-4136 Bolts and six 8T-4121 Washers , attach handhold (18) to the right side of the top of the radiator assembly.

5. Handhold (18) will attach to the radiator assembly at mounts (17), (19), and (20) .

Assemble and Install the New Water Temperature Regulator Housing

Note: The water temperature regulator system must be replaced due to new water tube lines. Part of the regulator system must be assembled prior to installation onto the engine. Follow the procedure that is outlined below in order to assemble the water temperature regulator housing.

Note: In order to install the new water temperature regulator housing, you must reuse the original mounting bolts which bolt to the engine. You must reinstall the original water bypass elbow that is located on the top of the regulator housing. You must also reinstall the water inlet elbow that is located on the front of the regulator housing.

Illustration 49	g00999786
Front view of water temperature regulator housing Typical example

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Illustration 50	g01000627

1. Install a 6V-4589 O-Ring Seal onto a 6K-3607 Connector (22) .

2. Install assembled connector (22) into the back of water temperature regulator housing (21). Repeat Step 1 and Step 2 for the other side of water temperature regulator housing (21) .

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Illustration 51	g01000630
The installed regulator housing is shown.

3. Install a 7E-6016 Gasket onto a 7E-6017 Cover (25). Install cover (25) and the gasket assembly onto the side of water temperature regulator housing (21) .

4. Secure cover (25) with four 0S-1594 Bolts (26) and four 5M-2894 Hard Washers .

5. Repeat Step 3 and Step 4 for the other side of water temperature regulator housing (21) .

6. Place a new 7N-4927 Housing Cover Gasket on the lower regulator housing. The new gasket is located between the engine and water temperature regulator housing (21) .

7. Attach a suitable hoist and a lifting device to water temperature regulator housing (21). Set water temperature regulator housing (21) onto the engine. Water temperature regulator housing (21) weighs approximately 18 kg (40 lb).

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Illustration 52	g01000645
Installation of the bolts that hold the bracket in position

8. Install the bracket in the center of water temperature regulator housing (21). Install two bolts (29) .

9. Place a new 2N-0931 Gasket in place on top of water temperature regulator housing (21) .

10. Position bypass elbow (27) onto water temperature regulator housing (21) .

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Illustration 53	g01000879

11. Install four bolts (28) and four washers through bypass elbow (27) and into the engine. Torque the bolts to 55 ± 10 N·m (41 ± 7.5 lb ft). Use Illustration 53 as a reference for the correct torque sequence. Tighten bolts (28) in the following order: (A), (B), (C) and (D) .

12. Place a new 4W-3100 Gasket in front of water inlet elbow (23) prior to installation.

13. Place water inlet elbow (23) onto water temperature regulator housing (21) .

14. Install four bolts (24) and four washers through water inlet elbow (23) and into the engine.

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Illustration 54	g01000658

15. Place a 2N-0931 Gasket on top of water temperature regulator housing (21) before you install cover (31) .

16. Place 7N-4928 Cover (31) onto water temperature regulator housing (30) .

17. Install cover (31) with four bolts (30) and four washers.

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Illustration 55	g01002749

18. Connect the two fittings that come from the turbochargers into the back of water temperature regulator housing (21) .

Install the Rear Lights and the Backup Alarms

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Illustration 56	g01001122
Location of the rear lights and the backup alarms

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Illustration 57	g01001121
Detail of backup alarms

1. The backup alarms from the old radiator guards must be installed onto the new radiator group.

2. Place backup alarm (40) in position on the side of the radiator guard. Install two bolts (39) and the washers that retain backup alarm (40) to the side of the radiator guard.

3. Place housing (37) in position over backup alarm (40). Install four bolts (36) and the washers that retain housing (37) .

4. Place lamp assembly (33) in position on the side of the radiator guard. Install two bolts (34) that retain the entire lamp assembly (33) to the side of the radiator guard.

   Note: Bolts (34) are installed on the inside of lamp assembly (33) .

   Note: Work light (32) is installed with lamp assembly (33) as a complete unit.

5. Connect wiring (38) that is located inside lamp assembly (33). Install the back cover, the eight bolts (35), and the washers into the back of lamp assembly (33). There are four bolts on each lamp assembly (33). Ensure that the wiring for work light (32) has been connected prior to installing the lamp cover.

6. Repeat Step 1 through Step 7 for the backup alarm and the lamp assembly that is located on the opposite side of the machine.

7. Connect the two electrical harnesses that connect the frame to the radiator group. The wiring harnesses can be located on the left side frame rail. One wiring harness has six electrical contacts. A smaller wiring harness has four electrical contacts.

   Note: The new wiring harness that is factory installed in the radiator assembly uses the same type of connectors that were used on the previous radiator.

Install the A/C Hoses

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Personal injury can result from contact with refrigerant. Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury. Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant. Always use precaution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated area. Personal injury or death can result from inhaling refrigerant through a lit cigarette. Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death. Do not smoke when servicing air conditioners or wherever refrigerant gas may be present. Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system.

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NOTICE
Effective July 1, 1992 regulations prohibit the venting of any refrigerant into the atmosphere. Refer to AVSpare publications Service Manuals, SENR3334, SENR5664, and NEDG5065 for the proper procedure, the proper equipment, and the proper tools needed in order to reclaim refrigerant from any AVSpare equipment.

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Illustration 58	g01001182
Installation of A/C hose onto compressor

1. Install A/C hose (42) onto compressor (41) .

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Illustration 59	g01001183
Installation of the A/C hose from the radiator group

2. Connect hose assembly (45) onto hose assembly (44) .

3. Install clamp (43) onto hose assembly (44) .

4. Install the bolt, the washers, and the nut that secures clamp (43) to the mounting bracket on the radiator.

Install the New Water Lines

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Illustration 60	g01001074
Left side of machine

1. Place a new 8H-8754 Gasket onto water elbow (47) .

2. Secure water elbow (47) to the lower radiator with four bolts (46) .

3. Install two 9X-6654 Hose Clamps (48) onto 5P-1269 Hose (49) .

4. Install hose (49) and two clamps (48) onto water elbow (47). Connect the opposite end of hose (49) onto water pump inlet (50) .

5. Tighten two hose clamps (48) to the proper specification.

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Illustration 61	g01001263
Right side of machine

6. Install an 8H-8754 Gasket onto the lower radiator tank.

7. Place 2W-3150 Radiator Elbow (55) onto the lower radiator tank. Secure radiator elbow (55) with four bolts (56) and four washers.

8. Place two 8T-4986 Hose Clamps (52) onto 7S-8780 Hose (51). Install hose (51) and hose clamps (52) onto radiator elbow (55) .

   Note: Do not tighten hose clamps (52) at this time.

9. Connect tee (53) and bolts (54) if the parts were disconnected during the removal process.

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Illustration 62	g01001254
View from the right side of the machine

10. Slip two 5P-1717 Hose Clamps (58) onto a 7S-8780 Hose (59). Attach hose (59) and two hose clamps (58) onto 132-3500 Tube Assembly (57) .

    Note: Do not tighten hose clamps (58) at this time.

11. Attach tube assembly (57) with hose (59) and two hose clamps (58) that are installed onto hose (51). Attach the opposite end of hose (59) to the water pump inlet (not shown).

12. Tighten two hose clamps (52) and two hose clamps (58) to the proper specification.

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Illustration 63	g01001376

13. Place a 2S-3440 Hose Clamp (61) onto the end of 8I-1362 Hose (60) .

14. Connect the end of hose (60) with clamp (61) onto fitting (62). Tighten hose clamp (61) to specifications.

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Illustration 64	g01001370
Typical Example Right side water return tube installation

15. Attach a 209-4679 Hose Clamp (75a) to 9X-3990 Hose (76). Attach hose (76) to the aftercooler water return tube. Tighten hose clamp (75a) to the proper specification.

16. Place 4P-8158 Tube (72) into position under the machine. Slip tube (72) in place inside hose (76). Tighten hose clamp (75b) to the proper specification.

    Note: When hose clamp (75b) is tightened, tube (76) will remain in place. At this time, you can install the mounting brackets.

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Illustration 65	g01001508
Location of the aftercooler water return tube brackets

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Illustration 66	g01001535
Detail of 4P-8223 Bracket (77)

17. Attach 4P-8223 Bracket (77) to the machine by using a 8T-4779 Bolt (78) and a washer.

18. Install 6V-5039 Clip (70a) and 6V-5040 Clip (70b) onto tube (72). Secure the clip assembly with a 8T-4184 Bolt (71) and a 8T-4244 Nut .

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Illustration 67	g01001373
Detail of 4P-8222 Bracket (80) Mounting point of new water tubes

19. Attach 4P-8222 Bracket (80) to the machine by using a 8T-4779 Bolt (79) and a washer.

20. Install 6V-5039 Clip (74a) and 6V-5040 Clip (74b) onto tube (72). Secure the clip assembly with a 8T-4184 Bolt (73) and a 8T-4244 Nut .

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Illustration 68	g01001556
Inside right hand frame rail

21. Install a 9X-3990 Hose (83) on the end of tube (72) with a 209-4579 Hose Clamp (82) .

22. Install a 132-3501 Tube (81) into position. Use Illustration 65 as a guide, if necessary.

23. Connect tube (81) to hose (83) with a 209-4579 Hose Clamp (82) .

    Note: Do not tighten hose clamps (82) at this time.

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Illustration 69	g01001404
Mounting point to the lower radiator tank

24. Install a 9X-3990 Hose (85) onto the end of tube (81) with a 209-4579 Hose Clamp (84) .

25. Connect the open end of hose (85) to the lower radiator tank by using a 209-4579 Hose Clamp (84) .

    Note: Do not tighten hose clamps (84) at this time.

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Illustration 70	g01001558
Detail of bracket mounting

26. Position tube (81) in order to attach tube (81) to the frame.

27. Install a 6V-5039 Clip (86a) and a 6V-5040 Clip (86b) around tube (81) .

28. Secure clip (86a) and clip (86b) with the following hardware: an 8T-4184 Bolt (87), an 8T-4244 Nut and a 5P-1076 Hard Washer . Use Illustration 70 as a guide, if necessary.

29. Tighten hose clamps (82) and hose clamps (84) to the proper specification.

30. Reinstall any remaining brackets and hoses that were previously removed.

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Illustration 71	g01001401
View from inside right side frame rail

31. Connect water drain line (88) (if equipped) to water tube (72) .

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Illustration 72	g01001610
Full view of coolant bypass tube

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Illustration 73	g01001607
Detail of the lower bypass tube

32. Place a new 6V-5066 O-Ring Seal (not shown) and a new 8N-3640 Retaining Ring (not shown) onto 137-8226 Bypass Tube (91) .

33. Press bypass tube (91) into the water pump outlet.

34. Install two 8N-3639 Retainers (96), two 0S-1594 Bolts (95), and two 5M-2894 Hard Washers in order to retain bypass tube (91) to the water pump.

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Illustration 74	g01001631
Detail of the top of the bypass hose

35. Place a new 6V-5066 O-Ring Seal (not shown) and a new 8N-3640 Retaining Ring (not shown) onto 137-8226 Bypass Tube (91) .

36. Press bypass tube (91) into the elbow that is located on top of the water temperature regulator.

37. Attach bypass tube (91) by using two 8N-3639 Retainers (98), two 0S-1594 Bolts (97), and two 5M-2894 Hard Washers .

38. Secure bypass tube (91) to the engine bracket by using 6V-6782 Clip (100a) and 6V-6783 Clip (100b). Secure clip (100a) and clip (100b) with the following items: one 1A-2029 Bolt (99), one 9L-9132 Washer and one 9S-8752 Full Nut .

    Note: Ensure that you install a 103-0892 Grommet between bypass tube (91) and the clips (100a) and (100b) .

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Illustration 75	g01001666

39. Install two 110-2445 Hose Clamps (101) onto 8I-1362 Hose (102) .

    Note: Ensure that you install hose clamps (101) in the correct position. Refer to Illustration 75 as a guide.

40. Connect hose (102) onto bypass tube (91) .

41. Securely tighten hose clamps (101) .

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Illustration 76	g01002401
Location of the components for the radiator inlet tube

42. Install 132-3515 Tube (108) in place on the machine.

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Illustration 77	g01002617
Detail of the connection from the water tube to the radiator

43. Slide 5P-0764 Hose (110) onto the end of tube (108) .

44. Place two 209-4588 Clamps (109) onto hose (110) .

45. Push the open end of hose (110) onto the lower radiator tank.

46. Position clamps (109), as shown. Do not tighten clamps (109) at this time.

47. Place 138-1770 Bracket (112) onto the frame. Secure bracket (112) with one bolt 8T-4136 Bolt (113) and one 8T-4121 Hard Washer .

48. Assemble a 6V-4356 Clip (104) and a 6V-4357 Clip (105) over tube (108). Secure tube (108) with one 8T-4196 Bolt (111), one 8T-4121 Hard Washer , and one 8T-4133 Nut .

    Note: Do not tighten the metal clamp assembly completely at this time, as adjustment to tube (108) may be necessary.

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Illustration 78	g01002572
Detail of the mounting system for the radiator inlet tube that is located on the left side inner radiator guard

49. From the top of tube (108), install a 6V-4356 Clip (104) and a 6V-4357 Clip (105) around tube (108). Secure tube (108) with one 8T-4196 Bolt and one 8T-4121 Hard Washer .

50. Place 5P-0764 Hose (107) onto the top of tube (108) .

51. Slide two 209-4588 Clamps (106) onto hose (107) .

52. Position the 132-3503 Tube (103) onto the open end of hose (107) .

53. Assemble a 6V-4356 Clip (104) and a 6V-4357 Clip (105) over tube (103). Secure tube (103) with one 8T-4196 Bolt and one 8T-4121 Hard Washer .

    Note: Repeat Step 53 for the top of tube (103) .

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Illustration 79	g01002721

54. Position 5P-0764 Hose (114) into the inlet of the water temperature regulator.

55. Slide two 209-4588 Clamps (115) over hose (114) .

56. Push water tube (103) onto hose (114) .

57. Ensure that the connection between tube (103) and tube (108) is straight. Check the alignment of all hoses and all tubes. When you have verified that all of the hoses and all of the tubes are correctly installed, tighten two clamps (106), two clamps (109), and two clamps (115) .

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Illustration 80	g01002402
Detail of the components for the turbocharger water outlet hose

58. Position 214-3645 Hose Assembly (117) between tube (103) and the water cooling lines for the turbocharger.

59. Tighten fitting (118) onto tube (103). Tighten fitting (116) onto the water lines for the turbocharger.

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Illustration 81	g01002478
Routing for the aftercooler drain

60. Position 105-0251 Hose Assembly (126) between the radiator and the engine.

61. Connect fitting (127) to the water tube that runs under the muffler assemblies.

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Illustration 82	g01002479
Detail of the hose for the aftercooler drain

62. Connect fitting (125) to the top radiator tank.

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Illustration 83	g01002420
Detail of lower radiator inlet tube

63. Install a 3D-2824 O-Ring Seal (128) (not shown) onto a 127-1647 Elbow (129) .

64. Install assembled elbow (129) into tube (108) .

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Illustration 84	g01002450
Placement of the new radiator drain hose.

65. Place a 6V-8398 O-Ring Seal (130) onto elbow (129) .

66. Position 138-1769 Hose Assembly (131) on the rear crossmember. Ensure that you route hose (131) correctly.

67. Place 8D-9671 Clip (132) around hose (131). Secure clip (132) in place on the rear crossmember.

68. Place 6D-4246 Clip (133) around hose (131). Secure clip (133) to the rear crossmember with one 8T-4137 Bolt and one 8T-4121 Hard Washer .

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Illustration 85	g01002461
Connection for the radiator drain that is located on the rear crossmember

69. Attach the open end of hose (131) to tee (135) that is located on the side of the water drain. The water drain is located at the bottom of the rear crossmember.

Install the Hydraulic Hoses

Note: The new hydraulic hoses will already be assembled into the new radiator assembly. Follow the steps that are given below in order to connect the hydraulic hoses to the machine.

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Illustration 86	g01002782
The hydraulic coolant hoses are located on the right side of the machine above the bumper.

1. Install the bolts, washers, and two half flanges that retain 135-4495 Hydraulic Hose (136) to the hydraulic tube that runs under the machine.

2. Install the bolts, washers, and two half flanges that retain 135-4494 Hydraulic Hose (137) to the hydraulic tube that runs under the machine.

3. Install the bolts, washers, and two half flanges that retain 135-4496 Hydraulic Hose (138) to the hydraulic tube that runs under the machine.

4. Install the bolts, washers, and two half flanges that retain 135-4493 Hydraulic Hose (139) to the hydraulic tube that runs under the machine.

Install the Decals on the Machine

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Illustration 87	g01002968
Painting instructions

1. Paint the areas that are outlined in Illustration 87 prior to placement of the model number decals.

Note: Prior to placing any films on the machine, ensure that the surfaces of the machine are free of oil and free of debris. This will help to ensure good adhesion.

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Illustration 88	g01002973
Guide for the placement of the decals

2. Position 104-4451 Film (140) on the left side of the machine.

3. Position 104-4450 Film (142) on the right side of the machine.

4. Cut two sections of 104-6457 Film (141) that are each approximately 140 cm (55 inch) long.

5. Place a cut section of film (141) onto each side of the radiator guard. Use Illustration 88 as a guide, if necessary.

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Illustration 89	g01002988
Rear of radiator grill

6. Place a 3E-1701 Film (143) onto top of the upper radiator grill. Use Illustration 89 as a guide, if necessary. Ensure that you have centered film (143) on the upper grill prior to the final placement of film (143) .

Install the Treads for the Top Radiator Guard

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Illustration 90	g01002997
Placement of treads

1. Place three 7D-6496 Treads (144) in position. Use Illustration 90 as a guide, if necessary.

   Note: Dimension (A) is 75 ± 3 mm (3 ± .12 inch). Dimension (B) is 127 ± 5 mm (5 ± .2 inch).

2. Trim two outer treads (144) in order to conform to latches (145) .

Install the Rear Guard Grills

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Illustration 91	g01003015

1. Attach a suitable lifting device to 213-2316 Grill Assembly (146). Secure the suitable lifting device to a hoist. Position grill assembly (146) to the radiator guard. The weight of guard assembly (146) is 127 kg (280 lb).

2. Install ten 8T-4137 Bolts (147) and ten 7X-7729 Washers that secure grill assembly (146) to the radiator guard.

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Illustration 92	g01003013

3. Attach a suitable lifting device to 213-1846 Protection Screen (148). Secure the suitable lifting device to a hoist. Position protection screen (148) to the radiator guard. The weight of protection screen (148) is 150 kg (330 lb).

4. Install ten 8T-4137 Bolts (149) and ten 7X-7729 Washers that secure protection screen (148) to the radiator guard.

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Illustration 93	g01003014

5. Install five bolts (150) and the washers that secure upper guard assembly (148) to the radiator guard.

Fill the Fluid Tanks and Perform a Final System Check

Perform the procedure that is outlined below in order to ensure that all systems are filled with fluid and that there are no leaks in the system.

Note: Due to the new hydraulic oil cooler that is installed, you should install new filters for the hydraulic systems that were drained.

1. Fill the cooling system with the required amount of engine coolant. Ensure that you fill the system slowly in order to help minimize that amount of air in the system.

   Note: Ensure that the two drain tubes are closed prior to filling the coolant system.

2. Fill the main hydraulic tank with the required amount of oil. Ensure that the correct weight of oil is used.

3. Fill the tank for the axle oil cooler with the required amount of oil.

   Note: The axle oil cooler is directly connected to the main hydraulic tank. Some fluid may already be present in the axle oil cooler.

4. Fill the tank for the brake and the steering system with the required amount of oil.

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Personal injury can result from contact with refrigerant. Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury. Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant. Always use precaution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated area. Personal injury or death can result from inhaling refrigerant through a lit cigarette. Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death. Do not smoke when servicing air conditioners or wherever refrigerant gas may be present. Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system.

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NOTICE
Effective July 1, 1992 regulations prohibit the venting of any refrigerant into the atmosphere. Refer to AVSpare publications Service Manuals, SENR3334, SENR5664, and NEDG5065 for the proper procedure, the proper equipment, and the proper tools needed in order to reclaim refrigerant from any AVSpare equipment.

5. Follow the proper procedures that are outlined in the following manuals in order to fill the A/C system:
   • SENR3334

   • SENR5664

   • NEDG5065

6. After the machine has been filled to the proper capacities, perform a walk around inspection. Check the system for any leaks. Pay particular attention to the new fluid connections at the radiator.

7. If no leaks are found, start the machine. Run the machine at idle and observe the fluid levels. Fill the hydraulic oil tanks and the radiator tanks, if necessary.

8. Continue to run the machine, and monitor the fluid levels until there is no drop in the fluid levels.

9. Shut off the machine. Perform a second walk around inspection in order to determine if any leaks are present. Repair any leaks that are found.