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AP600D and BG600D Asphalt Pavers C6.6 Engine Supplement Caterpillar


Radiator and Hydraulic Oil Cooler - Remove and Install

Usage:

AP-600D TFM

Removal Procedure

Start By:

  1. Remove the engine enclosure (hood). Refer to Disassembly and Assembly, "Engine Enclosure (Hood) - Remove and Install".
  2. Remove the exhaust (muffler). Refer to Disassembly and Assembly, "Exhaust (Muffler) - Remove and Install".
  3. Remove the air cleaner. Refer to Disassembly and Assembly, "Air Cleaner - Remove and Install".

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

Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact the skin.

Be sure that the engine and components are cool enough to touch with your bare hand prior to performing any service work.

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

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 work tools have been lowered to the ground, and the 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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------ WARNING! ------

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.

Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns.

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, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

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    Illustration 1g01524158

  1. Use two people and remove bolts (2) and door (1). The weight of door (1) is approximately 44 kg (98 lb).
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    Illustration 2g01350614

  1. Disconnect hose assemblies (3) .
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    Illustration 3g01350616

  1. Remove bolts (4) and panel (5) .
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    Illustration 4g01350617

  1. Loosen clamp (6) and remove hose (7) .

  1. Remove bolt (9) and clip (10) from hose (8) .

  1. Remove bolt (11) and clip (12) from hose (7) .

  1. Loosen clamp (14) and remove hose (13) .
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    Illustration 5g01524167

  1. Disconnect harness assemblies (15) .
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    Illustration 6g01524168

  1. Disconnect harness assembly (16) .
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    Illustration 7g01524169

  1. Disconnect harness assembly (17) and harness assembly (18). Remove the bolt and move harness assemblies (19) out of the way.

  1. Remove the hydraulic generator. Refer to Disassembly and Assembly, "Hydraulic Generator - Remove and Install".
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    Illustration 8g01350622

  1. Disconnect harness assembly (20) that is located behind the hose assemblies.
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  1. Disconnect harness assembly (21) and harness assembly (22) .
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    Illustration 10g01350648

  1. Disconnect harness assembly (23) .
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  1. Disconnect harness assemblies (24) .
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  1. Disconnect harness assemblies (25) .
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  1. Disconnect hose assemblies (26) .
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  1. Remove clamp (27) from hose assemblies (26) .
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  1. Open clamp (28) and remove the harness assemblies and hose assemblies (29) from the housing.
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  1. Disconnect hose assemblies (30) .
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  1. Disconnect harness assembly (32) .

  1. Disconnect hose assembly (33) .

  1. Remove bolts (34) and pump (31) .
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    Illustration 18g01524387

  1. Loosen clamp (35) and disconnect hose (36) .

  1. Loosen clamp (37) and disconnect hose (38) .
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    Illustration 19g01524413

  1. Loosen clamp (39) and remove hose (40) .
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  1. Loosen clamp (41) and remove hose (44) .

  1. Remove nut (43) and harness assembly (42) .
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    Illustration 21g01350665

  1. Loosen clamp (45) and remove hose (46) .
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  1. Disconnect hose assembly (47) .
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  1. Loosen clamp (48) and remove hose (49) from the radiator.
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  1. Loosen clamp (50) and remove hose (51) .
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  1. Remove bolts (53) and plate (52) .
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  1. Remove bolts (55) and bracket (54) .
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    Illustration 27g01351175

  1. Disconnect hose assembly (56) .
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    Illustration 28g01351178

  1. Disconnect harness assembly (57) .

  1. Loosen clamp (58) and remove hose (59) .
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    Illustration 29g01351179

  1. Disconnect harness assembly (60) .
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  1. Remove bolts (61) from both sides of the radiator and the hydraulic oil cooler assembly.
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    Illustration 31g01351185

  1. Remove bolts (62) from both sides of the radiator and hydraulic oil cooler assembly.
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    Illustration 32g01351186

  1. Attach a suitable lifting device. Remove radiator and hydraulic oil cooler assembly (63). The weight of radiator and hydraulic oil cooler assembly (63) is approximately 176 kg (388 lb).

Installation Procedure

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    Illustration 33g01351186

  1. Attach a suitable lifting device. Install radiator and hydraulic oil cooler assembly (63). The weight of radiator and hydraulic oil cooler assembly (63) is approximately 176 kg (388 lb).
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    Illustration 34g01351185

  1. Install bolts (62) to both sides of the radiator and hydraulic oil cooler assembly.
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  1. Install bolts (61) to both sides of the radiator and hydraulic oil cooler assembly.
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    Illustration 36g01351179

  1. Connect harness assembly (60) .
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    Illustration 37g01351178

  1. Install hose (59) and tighten clamp (58) .

  1. Connect harness assembly (57) .
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    Illustration 38g01351175

  1. Connect hose assembly (56) .
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    Illustration 39g01351174

  1. Install bracket (54) and bolts (55) .
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    Illustration 40g01351172

  1. Install plate (52) and bolts (53) .
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    Illustration 41g01351171

  1. Install hose (51) and clamp (50) .
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    Illustration 42g01351170

  1. Install hose (49) and tighten clamp (48) to the radiator.
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    Illustration 43g01524419

  1. Connect hose assembly (47) .
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    Illustration 44g01350665

  1. Install hose (46) and tighten clamp (45) .
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    Illustration 45g01524415

  1. Install harness assembly (42) and nut (43) .

  1. Install hose (44) and tighten clamp (41) .
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    Illustration 46g01524413

  1. Install hose (40) and tighten clamp (39) .
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    Illustration 47g01524387

  1. Connect hose (38) and tighten clamp (37) .

  1. Connect hose (36) and tighten clamp (35) .
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    Illustration 48g01524381

  1. Install pump (31) and bolts (34) .

  1. Connect hose assembly (33) .

  1. Connect hose assembly (32) .
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    Illustration 49g01524195

  1. Connect hose assemblies (30) .
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    Illustration 50g01524194

  1. Install the harness assemblies and hose assemblies (29) into the housing and close clamp (28) .
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    Illustration 51g01524192

  1. Install clamp (27) and hose assemblies (26) .
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    Illustration 52g01524191

  1. Connect hose assemblies (26) .
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    Illustration 53g01524189

  1. Connect harness assemblies (25) .
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    Illustration 54g01524188

  1. Connect harness assemblies (24) .

  1. Install the hydraulic generator. Refer to Disassembly and Assembly, "Hydraulic Generator - Remove and Install".
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    Illustration 55g01350648

  1. Connect harness assembly (23) .
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    Illustration 56g01350647

  1. Connect harness assembly (22) and (21) .
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    Illustration 57g01350622

  1. Connect harness assembly (20) that is located behind the hose assemblies.
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    Illustration 58g01524169

  1. Reposition harness assemblies (19) and install the bolt. Connect harness assembly (18) and harness assembly (17) .
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    Illustration 59g01524168

  1. Connect harness assembly (16) .
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    Illustration 60g01524167

  1. Connect harness assemblies (15) .
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    Illustration 61g01350617

  1. Install hose (13) and tighten clamp (14) .

  1. Install clip (12) to hose (7). Install bolt (11) .

  1. Install clip (10) to hose (8). Install bolt (9) .

  1. Install hose (7) and tighten clamp (6) .
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    Illustration 62g01350616

  1. Install panel (5) and bolts (4) .
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    Illustration 63g01350614

  1. Connect hose assemblies (3) .
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    Illustration 64g01524158

  1. Use two people and install door (2) and bolts (1). The weight of door (1) is approximately 44 kg (98 lb).

End By:

  1. Install the air cleaner. Refer to Disassembly and Assembly, "Air Cleaner - Remove and Install".
  2. Install the exhaust (muffler). Refer to Disassembly and Assembly, "Exhaust (Muffler) - Remove and Install".
  3. Install the engine enclosure (hood). Refer to Disassembly and Assembly, "Engine Enclosure (Hood) - Remove and Install".

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