545 Wheel Skidder Engine Supplement Caterpillar

Radiator - Remove and Install

Usage:

545 2FZ

Removal Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	135-7575	Link Bracket	2

Start By:

Connect the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect" for the machine that is being serviced.
Remove the sweeps. Refer to Disassembly and Assembly, "Sweeps - Remove and Install" for the machine that is being serviced.
Remove the muffler. Refer to Disassembly and Assembly, "Muffler - Remove and Install" for the machine that is being serviced.
Remove the refrigerant condenser. Refer to Disassembly and Assembly, "Referigerant Condenser - Remove and Install" for the machine that is being serviced. Removal of the inlet line and removal of the outlet line are not necessary.

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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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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin.
At operating temperature, the engine coolant is hot and under pressure.
Steam can cause personal injury.
Check the coolant level only after the engine has been stopped and the cooling system pressure cap is cool enough to touch with your bare hand.
Remove the cooling system pressure cap slowly to relieve pressure.

Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.

Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, hoses, and tubes. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.

The radiator assembly is located at the front of the machine.

Drain the cooling system. Refer to the Operation and Maintenance Manual, SEBU7140, "Cooling System Coolant (DEAC) - Change" for the correct procedure. The capacity of the cooling system is 56 L (14.8 US gal).

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Illustration 1	g00583775

Remove two bolts (2) and plate (1). Repeat this step for the remaining plate on the other side of the machine.

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Illustration 2	g00583863

Remove eight bolts (3) and hood (4). Use two persons to remove hood (4). The weight of hood (4) is 39 kg (85 lb).

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Illustration 3	g00583893

Loosen two clamps (5) and disconnect hose assembly (6) .

Remove baffle (8), tube (7), and hose assembly (6) as one unit. Use two persons to remove baffle (8). The weight of baffle (8) is 20 kg (45 lb).

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Illustration 4	g00583896

Remove four bolts (9) and eight bolts (10) .

Remove two-piece guard assembly (11) .

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Illustration 5	g00584137

Remove six nuts (13) and fan spider assembly (12). Use two persons to remove fan spider assembly (12). The weight of fan spider assembly (12) is 27 kg (60 lb).

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Illustration 6	g00584213

Cut cable straps (16) that secure hose (17) .

Remove sixteen bolts (14) and shroud assembly (15). Use two persons to remove shroud assembly (15). The weight of shroud assembly (15) is 20 kg (45 lb).

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Illustration 7	g00584280

Loosen two clamps (18) and remove tube (19) .

Disconnect two transmission oil cooler lines (20) .

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Illustration 8	g00584310

Loosen clamp (21) and remove hose (22) .

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Illustration 9	g00584370

Install Tooling (A) on the radiator top tank assembly. Attach a hoist and suitable lifting slings, as shown.

Remove two bolts (24) and open radiator guard (23) .

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Illustration 10	g00584381

Remove four bolts (26). Use the hoist to remove radiator (25). The weight of radiator (25) is 208 kg (460 lb).

Installation Procedure

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Table 2
Required Tools
Tool	Part Number	Part Description	Qty
A	135-7575	Link Bracket	2

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Illustration 11	g00584381

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Illustration 12	g00584370

Install tooling (A) on the radiator top tank assembly. Attach a hoist and suitable lifting slings, as shown.

Use the hoist to install radiator (25). Install four bolts (26). The weight of radiator (25) is 208 kg (460 lb).

Close radiator guard (23) and install two bolts (24) .

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Illustration 13	g00584310

Install hose (22) and tighten clamp (21) .

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Illustration 14	g00584280

Connect two transmission oil cooler lines (20) .

Install tube (19) and tighten two clamps (18) .

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Illustration 15	g00584213

Install shroud assembly (15) and sixteen bolts (14). Use two persons to install shroud assembly (15). The weight of shroud assembly (15) is 20 kg (45 lb).

Install cable straps (16) that secure hose (17) .

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Illustration 16	g00584137

Install fan spider assembly (12) and six nuts (13). Use two persons to install fan spider assembly (12). The weight of fan spider assembly (12) is 27 kg (60 lb).

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Illustration 17	g00583896

Install two-piece guard assembly (11) .

Install eight bolts (10) and four bolts (9) .

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Illustration 18	g00583893

Install baffle (8), tube (7), and hose assembly (6) as one unit. Use two persons to install baffle (8). The weight of baffle (8) is 20 kg (45 lb).

Connect hose assembly (6) on both ends and tighten clamps (5) .

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Illustration 19	g00584501

Install hood (4). Use two persons to install hood (4). The weight of hood (4) is 39 kg (85 lb).

Install eight bolts (3). Three bolts (27) secure baffle to the hood (4) .

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Illustration 20	g00583775

Install plate (1) and two bolts (2). Repeat this step for the remaining plate on the other side of the machine.

Fill the cooling system. Refer to the Operation and Maintenance Manual, SEBU7140, "Cooling System Coolant (DEAC) - Change" for the correct procedure. The capacity of the cooling system is 56 L (14.8 US gal).

End By:

Install the refrigerant condenser. Refer to Disassembly and Assembly, "Referigerant Condenser - Remove and Install" for the machine that is being serviced.
Install the muffler. Refer to Disassembly and Assembly, "Muffler - Remove and Install" for the machine that is being serviced.
Install the sweeps. Refer to Disassembly and Assembly, "Sweeps - Remove and Install" for the machine that is being serviced.
Separate the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect" for the machine that is being serviced.