- Off-Highway Truck/Tractor
- 797F (S/N: LAJ1-599; WSP1-129)
Introduction
The following special instruction provides the procedure and required parts to improve the water lines routing on the 797F Off-Highway Truck. The improved water lines routing includes: reworking the 272-3418 Oil Cooler Core Gp, reworking the 272-3431 Water Lines Gp, reworking the 451-3312 Oil Cooler Lines Gp, and reworking the 272-3257 Water Lines Gp.
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.
Reference: Most recent version of Special Instruction, REHS1841 , "General Welding Procedures"
Reference: Most recent version of Torque Specifications, SENR3130
Reference: Most recent version of Operation and Maintenance Manual, SEBU8417, "797F and 797F XQ Off-Highway Truck"
Reference: Most recent version of Special Instruction, M0083019 , "Procedure to Improve the Water Lines Group on Certain 797F Off-Highway Trucks"
Safety
Reference: Most recent version of Operation and Maintenance Manual, SEBU8417, "797F and 797F XQ Off-Highway Truck", "Prepare the Machine for Maintenance"
Do not perform any procedure in this special instruction until you have read this special instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.
A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.
Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If the tools, the procedure, the work method, or your actions are not recommended by Caterpillar, ensure that the tools and your actions are safe for you and for others.
Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures.
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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Cat dealer for replacement manuals. Proper care is your responsibility. |
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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on. |
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Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed. |
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The space between the body and the frame becomes a zero clearance area when the body is lowered. Failure to install the retaining cable can result in injury or death to personnel working in this area. |
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At operating temperature, the hydraulic tank is hot and under pressure. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly in order to relieve 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 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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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 by reading and understanding 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 instructions of the manufacturer and the safety practices of your employer. Do not touch live electrical parts. See “American National Standard Z49.1, Safety in Welding and Cutting” which is published by the American Welding Society. American Welding Society8669 NW 36 Street #130 Miami, Florida 33166-6672 1-800-443-9353 See “OSHA Safety and Health Standards, 29 CFR 1910” which is available from the U.S. Department of Labor. U.S. Department of LaborWashington, D.C. 20210 See applicable requirements for your local area. |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
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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, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates. |
Coolant System Drain/Fill
Prior to performing the following rework drain the coolant system. Refer to Operation and Maintenance Manual, SEBU8417, "797F and 797F XQ Off-Highway Truck", "Coolant System Coolant (ELC) - Change".
After completing the rework, refer to Operation and Maintenance Manual, SEBU8417, "797F and 797F XQ Off-Highway Truck", "Coolant System Coolant Extender (ELC) - Add" to fill the coolant system.
Rework Procedure
| Required Parts to Remove the 272-3420 Water Lines Gp, the 291-8388 Water Connection Gp, and the 250-6720 Auxiliary Water Pump Gp | |
|---|---|
| Qty | Part |
| 1 | 295-4202 Cover |
| 1 | 2V-7343 Cover |
| 1 | 292-0734 Cover |
| 1 | 155-5428 Gasket |
| 1 | 129-1609 O-Ring Seal |
| 1 | 4J-0523 O-Ring Seal |
| 1 | 293-4410 Cover |
| 1 | 5H-6734 O-Ring Seal |
| 4 | 6V-5230 Bolt |
| 4 | 6V-5839 Washer |
| Required Parts to Rework the 272-3418 Oil Cooler Core Gp | |
|---|---|
| Qty | Part |
| 1 | 524-4130 Bonnet |
| 4 | 8N-8570 Retaining Ring |
| 4 | 8T-2903 O-Ring Seal |
| 1 | 5F-8000 O-Ring Seal |
| 1 | 129-0987 Drain Assembly |
| 2 | 8T-4195 Bolt |
| 48 | 8T-4121 Hard Washer |
| 6 | 287-6096 Gasket |
| 3 | 278-6389 Taperlock Stud |
| 1 | 451-3097 Plate As |
| 2 | 470-1561 Bonnet |
| 2 | 340-5657 Bonnet |
| 1 | 8T-5005 Bolt |
| 4 | 214-7568 O-Ring Seal |
| 4 | 9S-4191 Plug |
| 4 | 8T-6466 Bolt |
| 44 | 8T-4133 Nuts |
| 4 | 288-5221 Retainer |
| 1 | 340-5658 Bonnet |
| 37 | 355-7217 Stud |
| 14 | 8T-4198 Bolt |
| 1 | 342-5924 Bracket As |
| 8 | 8T-4193 Bolt |
| 8 | 198-4780 Hard Washer |
| 1 | 342-5925 Bracket As |
| Required Parts to Rework the 451-3312 Oil Cooler Lines Gp | |
|---|---|
| Qty | Part |
| 15 | 8T-4223 Hard Washer |
| 1 | 355-5225 Hose As(1) |
| 1 | 4S-7492 Collet Stem |
| 1 | 4S-7498 Stem |
| 2 | 4S-7507 Sleeve |
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5P-0184 Hose |
| 2 | 6V-4590 O-Ring Seal |
| 1 | 8T-4194 Bolt |
| 1 | 329-3356 Nut |
| 1 | 6V-1867 Clip |
| 1 | 6V-1868 Clip |
| 1 | 6V-1869 Grommet |
| 1 | 6V-4356 Clip |
| 1 | 6V-4357 Clip |
| 5 | 8T-4183 Bolt |
| 4 | 8T-4139 Bolt |
| 1 | 524-4166 Bracket |
| 1 | 192-5805 Bracket As |
| 1 | 524-4129 Tube |
| 8 | 226-0087 T Bolt Clamp |
| 1 | 288-4415 Hose |
| 1 | 7W-2033 Clip |
| 1 | 7W-2034 Clip |
| 1 | 217-4193 Hose |
| (1) | Part not serviceable. Individual components must be ordered separately. |
| Required Parts to Rework the 272-3431 Water Lines Gp, and 272-3257 Water Lines Gp | |
|---|---|
| Qty | Part |
| 1 | 465-8104 Tube |
| 1 | 489-1240 Plate |
| 1 | 6V-9829 Cap As |
| 1 | 489-1248 Bracket As |
| 1 | 217-4193 Hose |
| 8 | 226-0087 T Bolt Clamp |
| 2 | 154-6340 Block |
| 1 | 217-4192 Hose |
| 1 | 6V-8397 O-Ring Seal |
| 1 | 489-1239 Tube As |
| 1 | 8T-5918 O-Ring Seal |
Remove the
| Parts Needed During Removal Procedure | ||
|---|---|---|
| Item | Qty | Part |
| 1 | 1 | 295-4202 Cover |
| 2 | 1 | 2V-7343 Cover |
| 3 | 1 | 292-0734 Cover |
| 4 | 1 | 155-5428 Gasket |
| 5 | 1 | 129-1609 O-Ring Seal |
| 6 | 1 | 4J-0523 O-Ring Seal |
| 7 | 1 | 293-4410 Cover |
| 8 | 1 | 5H-6734 O-Ring Seal |
| 9 | 4 | 6V-5230 Bolt |
| 10 | 4 | 6V-5839 Washer |
- Remove and discard clamps (A), hose (B), clips (C), and clip mounting hardware, clips (E), clamps (F) and tube (D).
- Remove and discard elbow (AB) and gasket. Retain mounting hardware.
- Remove and discard brace assembly (AC) and discard mounting hardware.
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Illustration 2 g06092067 View of the back side of the radiator
(3)292-0734 Cover
(4)155-5428 Gasket - Install gasket (4) and cover (3) onto the radiator group using the hardware retained in Step 2.
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Illustration 3 g06057835 View underneath the right-hand side of the radiator group
(G) Clamp
(H) Hose
(J) Tube
(K) Tube
(L) Mounting hardware - Disconnect tube (J) and retain mounting hardware.
- Remove and discard four clamps (G), hose (H), and tube (K). Retain mounting hardware (L).
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Illustration 4 g06058853 View underneath the right-hand side of the radiator group
(1)295-4202 Cover
(5)129-1609 O-Ring Seal - Install O-Ring seal (5) and cover (1) secure using the mounting hardware retained in Step 6.
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Illustration 5 g06058803 View of the front of the engine
(2)2V-7343 Cover
(6)4J-0523 O-Ring Seal - Install O-Ring seal (6) and cover (2) onto the tube assembly and secure using the mounting hardware retained in Step 5.
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Illustration 6 g06058660 View of the front of the engine
(M) Elbow - Remove elbow (M), discard elbow and mounting hardware.
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Illustration 7 g06058788 View of the front of the engine
(N) Auxiliary water pump - Remove and discard auxiliary water pump (N).
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Illustration 8 g06092087 View of the front of the engine
(P) Clamp
(R) Hose
(S) Elbow
(7)293-4410 Cover
(8)5H-6734 O-Ring Seal
(9)6V-5230 Bolt
(10)6V-5839 Washer - Install O-Ring seal (8), cover (7), secure cover using four washers (10), and four bolts (9).
- Remove and discard four clamps (P), hose (R), and elbow (S).
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Illustration 9 g06058947 View of the front right-hand side of the engine
(T) Bracket assembly
(U) Tube
(V) Clamp
(W) Hose - Remove and discard bracket assembly (T), tube (U), four clamps (V), hose (W), and mounting hardware.
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Illustration 10 g06058994 View of the right-hand side of the engine
(X) Hose
(Y) Clamp
(Z) Clip
(AA) Tube
(BB) Clip
(CC) Tube
(DD) Clip
(EE) Clamp
(FF) Hose - Remove and discard four clamps (Y), hose (X), clips (Z), clips (BB), clips (DD), eight clamps (EE), two hoses (FF), tube (AA), and tube (CC). Discard all mounting hardware.
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Illustration 11 g06059038 View of the right-hand side of the engine
(GG) Bracket - Remove and discard brackets (GG).
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Illustration 12 g06059055 View of the right-hand side of the engine
(HH) Clip
(JJ) Tube
(KK) Clip
(LL) Clamp
(MM) Hose - Remove and discard clips (HH), clips (KK), four clamps (LL), hose (MM), and tube (JJ). Discard all mounting hardware.
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Illustration 13 g06057603 View behind the oil cooler
(NN) Clamp
(PP) Hose - Remove and discard four clamps (NN), and hose (PP).
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Illustration 14 g06059096 View inside the right-hand side of the frame
(RR) Clip
(SS) Clip
(TT) Tube - Remove and discard clips (RR), clips (SS), and tube (TT). Discard mounting hardware.
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Illustration 15 g06059099 View inside the right-hand side of the frame
(UU) Bracket - Remove and discard brackets (UU).
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Illustration 16 g06057236 View of the right-hand side of the machine
(A) Clamp
(B) Hose
(C) Clip
(D) Bracket assembly
(E) Tube - Remove and discard four clamps (VV), hose (WW), clips (XX). bracket (YY), and tube (ZZ). Discard mounting hardware.
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| Illustration 1 | g06057687 |
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View above the engine behind the radiator (AB) Elbow (AC) Brace assembly (A) Clamp (B) Hose (C) Clip (D) Tube (E) Clip (F) Clamp | |
Remove the
- Remove plate (A), clips (B), retainer (C), retaining ring (D), tube assembly (F), and guard (J). Discard plate (A), clips (B), retainer (C), retaining ring (D), guard (J), and tube assembly (F). Retain mounting hardware (E) (except for bolts), clip (G), clip (H), and mounting hardware.
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Illustration 18 g06042756 View of the right-hand side
(K) Hose
(L) Clip
(M) Clip
(N) Hose
(P) Tube assembly - Remove and discard hose (K), clip (L), Clip (M), hose (N), and tube assembly (P). Discard mounting hardware.
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Illustration 19 g06042775 View of the right-hand side
(R) Bracket
(S) Bracket
(T) Bracket - Remove and discard bracket assembly and plate (R), bracket assembly, and plate (T) remove and retain bracket assembly (S) and discard plate. Discard mounting hardware.
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Illustration 20 g06042784 View of the right-hand side
(U) Hose assembly
(V) Adapter assembly
(W) Clip
(X) Clip
(Y) Hose
(Z) Tube assemblyNote: Steering accumulators are transparent for viewing purposes.
- Remove and discard hose assembly (U), adapter assembly (V), clips (W), clips (X) tube assembly (Z), and hose (Y). Retain on set of mounting hardware (nuts, bolts, washers, and clips) and discard the remaining mounting hardware.
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Illustration 21 g06042799 View of the front right-hand side
(AA) Bracket assembly
(AB) Tube
(AC) Clips
(AD) Hose - Remove and discard bracket assembly (AA), tube (AB), clips (AC), and hose (AD). Retain mounting hardware.
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| Illustration 17 | g06042736 |
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View of the right-hand side (A) Plate (B) Clip (C) Retainer (D) Retaining ring (E) Mounting hardware (F) Tube assembly (G) Clip (H) Clip (J) Guard | |
Removal from the
- Remove panel assembly (A) and panel assembly (B), retain panel assemblies and mounting hardware.
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Illustration 23 g06036579 View of the front right-hand side
(C) Gusset assembly - Remove gusset assemblies (C), retain gusset assemblies and mounting hardware.
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Illustration 24 g06036849 View of the front right-hand side
(D) Tube assembly - Remove tube assembly (D). Discard tube assembly and retain mounting hardware.
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Illustration 25 g06113604 - Remove oil cooler (E). Refer to Disassembly and Assembly , KENR8382 , Oil Cooler (Brake) - Remove and Install.
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Illustration 26 g06331995 Former bracket assembly
(E) Oil cooler
(F) Former bracket assembly286-1933 Bracket As
(G)8T-7338 Bolt
(H)198-4780 Hard Washer - Note the bracket assembly during the removal of oil cooler (E). If bracket assembly (F) is secured to the frame by three bolts (G), and three washers (H), both bracket assemblies, all bolts, and all hard washers must be replaced.
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| Illustration 22 | g06036566 |
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View of the front right-hand side (A) Panel assembly (B) Panel assembly | |
Rework the
Refer to Special Instruction, M0083019, "Procedure to Improve the Water Lines Group on Certain 797F Off-Highway Trucks" for more information to rework the 272-3418 Oil Cooler Core Gp and 451-3312 Oil Cooler Lines Gp.
Removal Procedure
- Remove two bolts (A), two washers (B), two hard washers (C) (backside), and two nuts (D) (backside) to disconnect the tube joint at the cooler. Discard the parts.
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Illustration 28 g06202659 (E) 491-7920 Plate
(F)8T-4184 Bolt
(G)8T-4223 Hard Washer
(H)329-3356 Nut - Remove plate (E) along with bolt (F), hard washer (G), and nut (H). Discard the plate (E).
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Illustration 29 g06202661 (K) 288-5221 Retainers
(L)8N-8570 Retaining Ring - Remove two retainers (K) along with retaining ring (L). Discard the parts.
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Illustration 30 g06202662 (M) 226-0087 T Bolt Clamps
(N)217-4193 Hose
(P)465-8105 Tube - Loosen and remove four T bolt clamps (M) along with hose (N) on the other side of tube (P). Discard the parts.
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Illustration 31 g06202664 (G) 8T-4223 Hard Washer
(P)465-8105 Tube
(R)8T-4183 Bolt
(S)7W-2033 Clip
(T)7W-2034 Clip - Remove clip (S), clip (T), bolt (R), and hard washer (G) that connects tube (P) to the frame. Save the parts.
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Illustration 32 g06202667 (B) 7X-7729 Washers
(P)465-8105 Tube
(S)7W-2033 Clip
(T)7W-2034 Clip
(U)8T-4186 Bolt
(V)344-5675 Nut - Remove clip (S), clip (T), bolt (U), nut (V), and two washers (B) that connects tube (P) to 490-7212 Hose As. Save the parts.
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Illustration 33 g06202668 (P) 465-8105 Tube
(X)8T-2903 O-Ring Seal - Remove tube (P) and O-Ring seal (X). Discard the parts.
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Illustration 34 g06323892 Top of the oil cooler
(C)8T-4121 Hard Washer
(Y)8T-4186 Bolt
(Z)288-5960 Bonnet
(AA)286-4907 Bonnet - Remove bolts (Y), and hard washers (C) that connect the three bonnets to the coolers. Save the bolts, and washers.
Note: Make sure to have the three bonnets attached to a lifting device to prevent the bonnets from dropping.
Approximate weight of 288-5970 Bonnet is
7.7 kg (17 lb) .Approximate weight of 286-4907 Bonnet is
6.7 kg (15 lb) .Show/hide table
Illustration 35 g06324086 Three top bonnets
(C)8T-4121 Hard Washer
(D)8T-4133 Nut
(K)288-5221 Retainer
(Z)288-5960 Bonnet
(AA)286-4907 Bonnet
(AB)8T-6466 Bolt - Remove the three bonnets from the oil cooler. Remove the two nuts (D), four hard washers (C), two bolts (AB), and the two retainers (K). Save the nuts, hard washers, bolts, and retainers. Discard the three bonnets
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Illustration 36 g06324112 Top bonnet gaskets
(AC)287-6096 Gasket - Remove the three gaskets (AC). Discard the gaskets.
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Illustration 37 g06324155 Three bottom bonnets
(C)8T-4121 Hard Washer
(U)8T-4186 Bolt
(Z)288-5960 Bonnet
(AA)286-4907 Bonnet
(AD)286-4908 Bonnet - Remove the bolts (U), and the hard washer (C) that assemble the three bonnets to the bottom of the oil cooler. Save the bolts, and hard washers.
Note: Make sure to have the three bonnets attached to a lifting device to prevent the bonnets from dropping.
Approximate weight of 288-5960 Bonnet is
7.7 kg (17 lb) .Approximate weight of 286-4907 Bonnet is
6.7 kg (15 lb) .Approximate weight of 286-4908 Bonnet is
7.9 kg (17.4 lb) .Show/hide table
Illustration 38 g06324173 Top of the three bottom bonnets
(AC)287-6096 Gasket - Remove the three gaskets (AC). Discard the gaskets.
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Illustration 39 g06324655 Top view of the two back bonnets
(C)8T-4121 Hard Washer
(D)8T-4133 Nut
(K)288-5221 Retainer
(L)8N-8570 Retaining Ring
(X)8T-2903 O-Ring Seal
(AB)8T-6466 Bolt - Remove the two nuts (D), four washers (C), two bolts (AB), and two retainers (K) from the bonnets. Save the parts.
- Discard the three bonnets, retaining ring (L), and O-Ring seal (X).
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| Illustration 27 | g06202658 |
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(A) (B) (C) (D) | |
Assembly Procedure for the
| Required Update Parts | ||
|---|---|---|
| Item | Qty | Part |
| 1 | 1 | 524-4130 Bonnet |
| 2 | 4 | 8N-8570 Retaining Ring |
| 3 | 4 | 8T-2903 O-Ring Seal |
| 4 | 1 | 5F-8000 O-Ring Seal |
| 5 | 1 | 129-0987 Drain Assembly |
| 6 | 2 | 8T-4195 Bolt |
| 7 | 48 | 8T-4121 Hard Washer |
| 8 | 6 | 287-6096 Gasket |
| 9 | 3 | 278-6389 Taperlock Stud |
| 10 | 1 | 451-3097 Plate As |
| 32 | 2 | 470-1561 Bonnet |
| 33 | 2 | 340-5657 Bonnet |
| 34 | 1 | 8T-5005 Bolt |
| 35 | 4 | 214-7568 O-Ring Seal |
| 36 | 4 | 9S-4191 Plug |
| 37 | 4 | 8T-6466 Bolt |
| 38 | 44 | 8T-4133 Nuts |
| 39 | 4 | 288-5221 Retainer |
| 40 | 1 | 340-5658 Bonnet |
| 41 | 37 | 355-7217 Stud |
| 42 | 14 | 8T-4198 Bolt |
| 43 | 1 | 342-5924 Bracket As |
| 44 | 8 | 8T-4193 Bolt |
| 45 | 8 | 198-4780 Hard Washer |
| 46 | 1 | 342-5925 Bracket As |
- Assemble one retaining ring (2), and one O-Ring seal (3) onto one bonnet (32). Assemble bonnet (32) to bonnet (33).
- Use two nuts (D), four washers (C), one bolt (AB), two retainers (K) saved in Step 13, and one bolt (34) to assemble the two bonnets.
- Assemble two O-Ring seals (35) onto two plugs (36). Assemble the plugs onto the bonnets as shown.
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Illustration 41 g06325808 Assemble the front, bottom bonnet
(1)524-4130 Bonnet
(2)8N-8570 Retaining Ring
(3)8T-2903 O-Ring Seal
(7)8T-4121 Hard Washer
(32)470-1561 Bonnet
(37)8T-6466 Bolt
(38)8T-4133 Nut
(39)288-5221 Retainer - Assemble one retaining ring (2), and one O-Ring seal (3) onto one bonnet (1). Assemble bonnet (1) to bonnet (32).
- Use two bolts (37), four washers (7), two nuts (38), and two retainers (39) to secure bonnet (1) to bonnet (32).
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Illustration 42 g06202687 (1) 524-4130 Bonnet
(4)5F-8000 O-Ring Seal
(5)129-0987 Drain Assembly
(6)8T-4195 Bolt
(7)8T-4121 Hard Washer - Install drain assembly (5) to the bottom of bonnet (1) along with O-Ring seal (4), two bolts (6), and two hard washers (7).
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Illustration 43 g06202691 (8) 287-6096 Gasket - Position one gaskets (8) onto each of the bonnets.
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Illustration 44 g06326276 Assemble the bottom bonnets to the oil cooler
(1)524-4130 Bonnet
(7)8T-4121 Hard Washer
(32)470-1561 Bonnet
(33)340-5657 Bonnet
(38)8T-4133 Nut
(41)355-7217 Stud
(C)8T-4121 Hard Washer
(U)8T-4186 Bolt - Use 22 bolts (U), and 22 hard washer (C) that were saved in Step 11 to assemble the three bonnets to the bottom of the oil cooler. Assemble the bolts, and washers in the positions shown.
Note: Make sure to have the three bonnets attached to a lifting device to prevent the bonnets from dropping.
The approximate weight of the 524-4130 Bonnet is
9.9 kg (22 lb) .The approximate weight of the 470-1561 Bonnet is
7.9 kg (18 lb) .The approximate weight of the 340-5657 Bonnet is
6.7 kg (15 lb) . - Assemble 18 studs (41), 18 hard washers (7), and 18 nuts (38) in the positions shown to the bottom bonnets.
Note: Make sure that the three bonnets are correctly positioned to the cooler before hardware is final tightened.
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Illustration 45 g06331415 Bottom bracket
(1)524-4130 Bonnet
(7)8T-4121 Hard Washer
(9)278-6389 Taperlock Stud
(32)470-1561 Bonnet
(38)8T-4133 Nut
(41)355-7217 Stud
(42)8T-4198 Bolt
(43)342-5924 Bracket As - Loosely assemble three studs (41), three hard washers (7), and three nuts (38) in the three positions shown to the bottom bonnet (1).
- Use 14 bolts (42), and 14 hard washers (7) in the positions shown to assemble bracket assembly (43) to the bottom three bonnets.
- Assemble three taperlock studs (9), three hard washers (7), and three nuts (38) in the three positions shown to the bottom bonnet (1), and bonnet (32).
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Illustration 46 g06332006 Bottom bracket assembly to machine
(43)342-5924 Bracket As
(44)8T-4193 Bolt
(45)198-4780 Hard Washer
(46)342-5925 Bracket As - Use four bolts (44), and four hard washers (45) to assemble bracket assembly (46) to bracket assembly (43). Four bolts, and four hard washers will be used to assemble the oil cooler to the machine.
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Illustration 47 g06331418 (1) 524-4130 Bonnet
(7)8T-4121 Hard Washer
(10)451-3097 Plate As
(38)8T-4133 Nut
(41)355-7217 Stud - Use three studs (41), three hard washers (7), and three nuts (38) installed in Step 10 to assembly plate (10) to bonnet (1).
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Illustration 48 g06325850 View of the top of the oil cooler from the front, right corner
(8)287-6096 Gasket - Assemble one gasket (8) to the top of the oil cooler as shown.
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Illustration 49 g06325858 First bonnet assembled to the top of the oil cooler
(C)8T-4121 Hard Washer
(Y)8T-5005 Bolt
(2)8N-8570 Retaining Ring
(3)8T-2903 O-Ring Seal
(38)8T-4133 Nut
(40)340-5658 Bonnet
(41)355-7217 Stud - Use ten bolts (Y), ten hard washers (C) that were saved in Step 8, four studs (41), four hard washers (C), and four nuts (38) to assemble one bonnet (40) to the top of the oil cooler as shown.
- Assemble one retaining ring (2), and one O-Ring seal (3) to bonnet (40).
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Illustration 50 g06325873 Middle oil cooler
(8)287-6096 Gasket - Assemble one gasket (8) to the middle oil cooler as shown.
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Illustration 51 g06325916 Top, middle bonnet installation
(2)8N-8570 Retaining Ring
(3)8T-2903 O-Ring Seal
(32)470-1561 Bonnet
(35)214-7568 O-Ring Seal
(36)9S-4191 Plug
(38)8T-4133 Nut
(40)340-5658 Bonnet
(41)355-7217 Stud
(C)8T-4121 Hard Washer
(D)8T-4133 Nut
(K)288-5221 Retainer
(Y)8T-5005 Bolt
(AB)8T-6466 Bolt - Assemble bonnet (32) to bonnet (40)
- Use six bolts (Y), six hard washers (C) that were saved in Step 9, eight studs (41), eight hard washers (C) that were saved in Step 9, and eight nuts (38) to assemble bonnet (32) to the top of the oil cooler as shown.
- Use the two nuts (D), four hard washers (C), two bolts (AB), and the two retainers (K) that were saved in Step 9 to assemble bonnet (32) to bonnet (40).
- Assemble one retaining ring (2), and one O-Ring seal (3) to bonnet (32).
- Assemble one O-Ring seal (35) onto one plug (36). Assemble the plug to bonnet (32).
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Illustration 52 g06325940 Front oil cooler position
(8)287-6096 Gasket - Assemble one gasket (8) to the front oil cooler as shown.
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Illustration 53 g06325968 Front bonnet
(7)8T-4121 Hard Washer
(32)470-1561 Bonnet
(33)340-5657 Bonnet
(35)214-7568 O-Ring Seal
(36)9S-4191 Plug
(37)8T-6466 Bolt
(38)8T-4133 Nut
(39)288-5221 Retainer
(41)355-7217 Stud
(C)8T-4121 Hard Washer
(Y)8T-5005 Bolt - Assemble bonnet (33) to bonnet (32).
- Use ten bolts (Y), ten hard washers (C) that were saved in Step 8, four studs (41), four hard washers (C), and four nuts (38) to assemble bonnet (33) the front oil cooler.
- Use two bolts (37), four hard washers (7), two nuts (38), and two retainers (39) to secure bonnet (33) to bonnet (32).
- Assemble one O-Ring seal (35) onto one plug (36). Assemble the plug to bonnet (33).
- Install the oil cooler. Refer to Disassembly and Assembly , KENR8382 , Oil Cooler (Brake) - Remove and Install.
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| Illustration 40 | g06324673 |
|
Assembly of the back two bottom bonnets (2) (3) (32) (33) (34) (35) (36) (C) (D) (K) (AB) | |
| Required Update Parts | ||
|---|---|---|
| Item | Qty | Part |
| 11 | 4 | 8T-4184 Bolt |
| 12 | 15 | 8T-4223 Hard Washer |
| 13 | 1 | 355-5225 Hose As(1) |
| 13A | 1 | 4S-7492 Collet Stem |
| 13B | 1 | 4S-7498 Stem |
| 13C | 2 | 4S-7507 Sleeve |
| 13D | |
5P-0184 Hose |
| 14 | 2 | 6V-4590 O-Ring Seal |
| 15 | 1 | 8T-4194 Bolt |
| 16 | 1 | 329-3356 Nut |
| 17 | 1 | 6V-1867 Clip |
| 18 | 1 | 6V-1868 Clip |
| 19 | 1 | 6V-1869 Grommet |
| 20 | 1 | 6V-4356 Clip |
| 21 | 1 | 6V-4357 Clip |
| 22 | 5 | 8T-4183 Bolt |
| 23 | 4 | 8T-4139 Bolt |
| 24 | 1 | 524-4166 Bracket |
| 25 | 1 | 192-5805 Bracket As |
| 26 | 1 | 524-4129 Tube |
| 27 | 8 | 226-0087 T Bolt Clamp |
| 28 | 1 | 288-4415 Hose |
| 29 | 1 | 7W-2033 Clip |
| 30 | 1 | 7W-2034 Clip |
| 31 | 1 | 217-4193 Hose |
| (1) | Part not serviceable. Individual components must be ordered separately. |
Note: Use the below rework instruction along with the rework instructions provided by the engine install group.
- Disconnect hose assembly (AJ) along with O-Ring seal (AK) by removing four bolts (F), four bolts (R), and eight hard washers (G). Discard the parts.
- Remove and save four half flanges (AH).
- Remove and save clip (AL), clip (AM), bolt (F), two hard washers (G), and nut (J).
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Illustration 56 g06202731 Show/hide table
Illustration 57 g06332232 View of area AN
(F)8T-4184 Bolt
(G)8T-4223 Hard Washer
(J)329-3356 Nut
(AH)1P-4582 Half Flange
(AL)6V-4356 Clip
(AM)6V-4357 Clip
(10)451-3097 Plate As
(11)8T-4184 Bolt
(12)8T-4223 Hard Washer
(13)355-5225 Hose As
(14)6V-4590 O-Ring Seal
(15)8T-4194 Bolt
(16)329-3356 Nut
(17)6V-1867 Clip
(18)6V-1868 Clip
(19)6V-1869 Grommet
(20)6V-4356 Clip
(21)6V-4357 Clip
(22)8T-4183 Bolt - Install four half flanges (AH) that were saved in Step 2.
- Connect hose assembly (13) along with O-Ring seal (14) using four bolts (11), four bolts (22), and eight hard washers (12).
- Clip tube to plate assembly (10) using clip (AL), clip (AM), bolt (F), two hard washers (G), and nut (J) that were saved in Step 3.
- Clip hose assembly (13) to tube using clip (17), clip (18), clip (19), clip (20), clip (21), bolt (15), two hard washers (12), and nut (16).
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Illustration 58 g06202733 (12) 8T-4223 Hard Washer
(23)8T-4139 Bolt
(24)524-4166 Bracket - Install bracket (24) to the block on frame using two bolts (23) and two hard washers (12).
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Illustration 59 g06202734 (12) 8T-4223 Hard Washer
(23)8T-4139 Bolt
(24)524-4166 Bracket
(25)192-5805 Bracket As - Install bracket assembly (25) to bracket (24) using two bolts (23), and two hard washers (12).
Note: Do not final tighten bolts (23).
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Illustration 60 g06202736 (1) 524-4130 Bonnet
(26)524-4129 Tube
(27)226-0087 T Bolt Clamps
(28)288-4415 Hose - Connect one end of tube (26) to bonnet (1) using hose (28), and four T bolt clamps (27).
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Illustration 61 g06202737 (12) 8T-4223 Hard Washer
(22)8T-4183 Bolt
(25)192-5805 Bracket As
(26)524-4129 Tube
(29)7W-2033 Clip
(30)7W-2034 Clip - Clip tube (26) to bracket assembly (25) using clip (29), clip (30), bolt (22), and hard washer (12).
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Illustration 62 g06202739 (G) 8T-4223 Hard Washer
(R)8T-4183 Bolt
(S)7W-2033 Clip
(T)7W-2034 Clip
(26)524-4129 Tube - Clip tube (26) to the frame using clip (S), clip (T), bolt (R), and hard washer (G) that were saved in Step5 of"Rework the
272-3418 Oil Cooler Core Gp" section.Note: Do not final tighten bolts (R).
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Illustration 63 g06202740 (AP) 465-8104 Tube
(26)524-4129 Tube
(27)226-0087 T Bolt Clamp
(31)217-4193 Hose - Connect the other side of tube (26) to tube (AP) using hose (31), and four T bolt clamps (27).
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Illustration 64 g06202741 (B) 7X-7729 Washer
(S)7W-2033 Clip
(T)7W-2034 Clip
(U)8T-4186 Bolt
(V)344-5675 Nut
(AR)490-7212 Hose As
(26)524-4129 Tube - Clip hose assembly (AR) to tube (26) using clip (S), clip (T), bolt (U), nut (V), and two washers (B) that were saved in Step 6 of "Rework the
272-3418 Oil Cooler Core Gp" section. - Final tighten bolts (23) to clip the tube to bracket assembly (25), and bolts (R) to attach tube (26) to the cooler on the other side.
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| Illustration 54 | g06202725 |
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| Illustration 55 | g06202727 |
|
View of area AG (F) (G) (J) (R) (AH) (AJ) (AK) (AL) (AM) | |
Update Procedure for the
| Required Parts | ||
|---|---|---|
| Item | Qty | Part |
| 11 | 1 | 465-8104 Tube |
| 12 | 1 | 489-1240 Plate |
| 13 | 1 | 6V-9829 Cap |
| 14 | 1 | 489-1248 Bracket As |
| 15 | 1 | 217-4193 Hose |
| 16 | 8 | 226-0087 T Bolt Clamp |
| 18 | 2 | 154-6340 Block |
| 21 | 1 | 217-4192 Hose |
| 22 | 1 | 6V-8397 O-Ring Seal |
| 26 | 1 | 489-1239 Tube As |
| 27 | 1 | 8T-5918 O-Ring Seal |
- Install O-Ring seal (27), and tube assembly (26) and secure with mounting hardware retained in Step 3 in Section "Removal from the
272-3257 Water Lines Gp".Show/hide table
Illustration 66 g06339546 View inside the right-hand side of the frame
(A)374-8401 Plate
(11)465-8104 Tube
(15)217-4193 Hose
(16)226-0087 T Bolt Clamp
(18)154-6340 Block
(21)217-4192 Hose - Install tube assembly (11), hose (21), and hose (15). Do not secure into position.
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Illustration 67 g06339387 Position of the forward block (18)
( A)374-8401 Plate
(18)154-6340 Block
(21)217-4192 Hose
(A)3.7 mm (0.15 inch)
(B)10.4 mm (0.41 inch)
(C)251.9 mm (9.92 inch) Show/hide table
Illustration 68 g06339392 Position of the rear block (18)
( A)374-8401 Plate
(18)154-6340 Block
(D)631.7 mm (24.87 inch)
(E)75.6 mm (2.98 inch) - Use the information in Illustration 67, and Illustration 68 to locate the positions for blocks (18) for mounting bracket assembly (14) and plate (12).
- Prepare the areas for welding. For the proper procedure, refer to "General Welding Procedures", Preparing the Area for Welding.
- Use the information in 67, and Illustration 68 to weld both blocks (18) onto the frame. Before you weld the mounting block to the machine, read Welding on Machines and Engines with Electronic Controls in the above referenced operation and maintenance manual. The weld material must meet one of the following specifications: AWS E7018. AWS A5.17 F7A2-EM12K. AWS A5.17 F7A2-EM13K. AWS A5.18 ER70S-2. AWS A5.18 ER70S-3. AWS A5.18 ER70S-6. AWS A5.18 ER70C-6M. AWS A5.20 E70T-1. AWS A5.20 E70T-5. AWS A5.20 E70T-9. AWS A5.20 E70T-12. AWS A5.20 E71T-1. AWS A5.20 E71T-5. AWS A5.20 E71T-9. AWS A5.20 E71T-12
- Remove tube assembly (11) and weld blocks (18) onto the frame assembly using a
6 mm (0.24 inch) fillet weld.Show/hide table
Illustration 69 g06042829 View inside the right-hand side of the frame
(11)465-8104 Tube
(12)489-1240 Plate
(14)489-1248 Bracket As
(15)217-4193 Hose
(16)226-0087 T Bolt Clamp
(21)217-4192 Hose - Install tube (11), hose (21), four T-bolt clamps (16), hose (15), and four T-bolt clamps (16) onto tube (26) and tube (17).
- Install bracket assembly (14) and plate (12) secure using mounting hardware retained in Step 4 and Step 5 in Section "Remove the
272-3431 Water Lines Gp".Show/hide table
Illustration 70 g06042842 View of the frame at the right-hand side of the engine
(13)6V-9829 Cap
(22)6V-8397 O-Ring Seal - Install O-Ring seal (22) and cap (13).
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Illustration 71 g06036920 View of the front right-hand side
(C) Gusset assembly - Install gusset assemblies (C) and secure using mounting hardware retained in Step 2 in Section "Removal from the
272-3257 Water Lines Gp".Show/hide table
Illustration 72 g06036923 View of the front right-hand side
(D) Panel assembly
(E) Panel assembly - Install panel assembly (D) and panel assembly (E) and secure using mounting hardware retained in Step 1 in Section "Removal from the
272-3257 Water Lines Gp".
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| Illustration 65 | g06036910 |
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View of the front right-hand side (26) (27) | |
