Procedure to Relocate the Cooling System on 904B Compact Wheel Loader {1353, 1374, 5057} Caterpillar

Compact Wheel Loader:

904B (S/N: B4L1-UP)

Introduction

This Special Instruction will give the procedure for placing the hydraulic oil cooler onto the front of the machine. It will be easier to clean the hydraulic oil cooler.

Welding Preparation

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Personal injury can result from working with cleaning solvent. Because of the volatile nature of many cleaning solvents, extreme caution must be exercised when using them. If unsure about a particular cleaning fluid, refer to the manufacturer's instructions and directions. Always wear protective clothing and eye protection when working with cleaning solvents.

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

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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; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

Note: Personal breathing protection should be worn by the personnel that are welding. Personal breathing protection will prevent fumes from entering the lungs of the person that is welding. Use a 1U-8088 Type H Respirator Gp for breathing protection.

Note: Refer to Service Magazine, SEPD0025 July, "Welding on Fuel and Hydraulic Tanks".

Clean the area in order to be welded. Clean the area of the substances that follow:

• Oil

• Grease

• Paint

• Dirt

The tank must be at a minimum temperature of 16° C (60° F) before welding and during welding.

Note: Heat distortion of the base metal is possible when you weld. Avoid excessive heating of the base metal.

Attach the welding ground cable directly to the base metal. Protect machined surfaces from the sparks. Protect machined surfaces from the weld splatter.

Proper Welding Procedure on Machines and Engines with Electronic Controls

Proper precautions are necessary in order to prevent damage to electronic controls. When you weld on a machine with electronic controls, use the steps that follow:

1. Turn off the engine. Put the key start switch in the OFF position.

2. If the machine has a battery disconnect switch, open the switch. If the machine does not have a battery disconnect switch, disconnect the negative battery cable at the battery.

3. Connect the ground cable for the welder directly to the actual machine component that will be welded. Attach the clamp for the ground cable as close as possible to the area that is being welded.

   Follow the procedure that is listed above in order to prevent damage from the welding current to the components that follow:

   • Bearings

   • Hydraulic components

   • Electrical components

   Note: Do not use electrical components as a ground point for the welder. Do not use ground points for electronic components as a ground point for the welder.

4. Protect wiring harnesses from the sparks. Protect wiring harnesses from the weld splatter.

Parts

Assemble O-ring Seals to Fittings

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Illustration 1	g02019333
(8) 5K-9090 O-Ring Seal (16) 6V-9008 Elbow (22) 7M-8485 O-Ring Seal

1. Assemble O-ring seals to 6V-9008 Elbow (16). Refer to Illustration 1.

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Illustration 2	g02019376
(8) 5K-9090 O-Ring Seal (19) 6V-9847 Swivel Tee

2. Assemble O-ring seals to 6V-9847 Swivel Tee (19). Refer to Illustration 2.

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Illustration 3	g02019377
(8) 5K-9090 O-Ring Seal (18) 6V-9840 Swivel Tee

3. Assemble O-ring seals to 6V-9840 Swivel Tee (18). Refer to Illustration 3.

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Illustration 4	g02019378
(8) 5K-9090 O-Ring Seal (20) 6V-9854 Elbow

4. Assemble O-ring seals to 6V-9854 Elbow (20). Refer to Illustration 4.

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Illustration 5	g02019379
(8) 5K-9090 O-Ring Seal (15) 6V-8635 Connector (22) 7M-8485 O-Ring Seal

5. Assemble O-ring seals to 6V-8635 Connector (15). Refer to Illustration 5.

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Illustration 6	g02020154
(8) 5K-9090 O-Ring Seal (22) 7M-8485 O-Ring Seal (24) 8C-6798 Swivel Tee

6. Assemble O-ring seals to 8C-6798 Swivel Tee (24). Refer to Illustration 6.

Procedure for Moving the Hydraulic Oil Cooler

1. Raise the lift arms. Make sure that the lift arms are properly supported. Refer to Operation and Maintenance Manual, SEBU7891, "Crushing Prevention and Cutting Prevention".

2. Drain the hydraulic fluid from the tank. Refer to Operation and Maintenance Manual, SEBU7891, "Hydraulic System Oil - Change".

3. Drain the coolant from the radiator. Refer to Operation and Maintenance Manual, SEBU7891, "Cooling System Coolant (ELC) - Change".

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Illustration 7	g01997294

4. Remove hood group (145), air cleaner group (146), and counterweight (147) from the machine.

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Illustration 8	g01997318

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Illustration 9	g01997319
Area A

5. Remove two bolts (159) from fuel tank (148) .

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Illustration 10	g01997393

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Illustration 11	g01997433
Area B

6. Remove two bolts (161) from the machine. Remove water separator (162) from the machine.

   Note: Do not disconnect the fuel lines.

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Illustration 12	g01997975
The radiator is located at the rear of the machine.

7. Remove three washers (163) and three bolts (164) from radiator (74). Remove fan guard (75) from radiator (74) .

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Illustration 13	g01998013

8. Remove washer (76), two washers (77), bolt (78), two clips (79), and bolt (80) in order to remove hose (81) from radiator (74) .

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Illustration 14	g01998140

9. Remove the four clamps (82) that hold hose (83) and hose (84) onto the machine. Remove hose (83) and hose (84) .

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Illustration 15	g01998274

10. Remove hose (85), hose (86), and elbow (160) from radiator (74) .

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Illustration 16	g01998513

11. Remove bolt (87) and washer (88) from the machine. Remove radiator (74) from the machine. Clean the external surfaces of the radiator.

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Illustration 17	g02031203

12. Remove four bolts (89), two wing nuts (90), and four nuts (91) .

13. Remove shroud (92) from radiator (74) .

14. Remove connector (150) and two O-rings (151). Discard connector (150) and two O-rings (151) .

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Illustration 18	g01998734

15. Remove core assembly (93) from radiator (74) .

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Illustration 19	g01999513

16. Place shroud (92) onto radiator (74) with four bolts (89), two wing nuts (90), and four nuts (91). Tighten the four bolts (89) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).

    Note: If your machine is equipped with air conditioning proceed to Step 17. If your machine is not equipped with air conditioning proceed to step 21.

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Illustration 20	g01999774

17. Loosen bracket (94) for the tension on the belt. Move air compressor (95) toward the centerline of the machine.

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Illustration 21	g01999913

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Illustration 22	g01999914
Area C

18. Remove two bolts (96) and two washers (97) from filter (98). Move filter (98) toward the engine.

19. Remove the straps from the engine temperature sensor and the wiring harness for the compressor to the air conditioner.

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Illustration 23	g01999939

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Illustration 24	g01999941
View D-D

20. Remove guard (99), support (100), guard (101), support (102), and condenser (103) from the machine.

    Note: Do not disconnect hoses from condenser (103) .

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Illustration 25	g02000175
Right side view

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Illustration 26	g02004273
View E-E

21. Remove bolt (136), washer (137), clip (138), grommet (139), and clip (141) from the machine. Discard bolt (136), washer (137), clip (138), grommet (139), and clip (141).

22. Remove elbow assembly (149). Retain elbow assembly (149) .

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Illustration 27	g02000049
Top view of machine

23. Unbolt the main control valve. Raise the control valve in order to remove 148-8431 Tee (100), 258-5674 Hose As (101), and 150-3073 Plug As (102) from the machine. Discard 148-8431 Tee (100), 258-5674 Hose As (101), and 150-3073 Plug As (102). Install elbow assembly 6V-9008 Elbow (16) on the main control valve. Reattach the main control valve.

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Illustration 28	g02003534
View F-F

24. Remove bolt (117), washer (141), clip (118), grommet (119), and clip (120) from the machine. Discard bolt (117), washer (141), clip (118), grommet (119), and clip (120) .

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Illustration 29	g02003594
View G-G

25. Remove grommet (121), clip (122), bolt (123), washer (124), and clip (125) from the machine. Retain grommet (121), clip (122), bolt (123), washer (124), and clip (125) .

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Illustration 30	g02003615
View H-H

26. Remove bolt (126), washer (127), clip (128), grommet (129), and clip (130) from the machine. Retain bolt (126), washer (127), clip (128), grommet (129), and clip (130) .

27. Disconnect the hoses that are indicated in Illustration 25 and Illustration 27. Remove the hardware in Step 24 through Step 26. Pull the assembly that consists of the following items through the rear of the machine:
    • Hose (104)

    • Hose (106)

    • Hose (111)

    • Hose (113)

    • Tee (105)

    • Tee (112)

    • Bypass valve (140)

    Remove the bypass valve (140) from the assembly. Retain bypass valve (140) .

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Illustration 31	g02003634
View J-J

28. Remove grommet (131), bolt (132), washer (133), clip (134), and clip (135) from the machine. Discard grommet (131), bolt (132), washer (133), clip (134), and clip (135) .

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Illustration 32	g02017877

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Illustration 33	g02017993
View R-R

29. Remove O-ring (152), reducer (153), nut (154), adapter (155), O-ring (156), tee as (157), and tee as (158) from the machine. Retain adapter (155) .

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Illustration 34	g02004514

30. Remove hose (142) and remove hose (143) from the machine. Discard hose (142) and remove hose (143) .

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Illustration 35	g02004593

31. Remove hose (144) from the machine.

32. Install the straps from the engine temperature sensor and the wiring harness for the compressor to the air conditioner.

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Illustration 36	g01999913

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Illustration 37	g01999914
Area C

33. Install filter (98) with two bolts (96) and two washers (97) .

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Illustration 38	g01999774

34. Install air compressor (95). Tighten bracket (94) for the tension on the belt.

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Illustration 39	g01998513

35. Install radiator (74). Secure the radiator with bolt (87) and washer (88) .

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Illustration 40	g01998140

36. Install hose (84) and hose (83). Install the four clamps (82) that hold hose (84) and hose (83) .

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Illustration 41	g01998013

37. Install hose (81) onto radiator (74). Secure hose (81) with washer (76), two washers (77), bolt (78), two clips (79), and bolt (80) .

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Illustration 42	g01997975
The radiator is located at the rear of the machine.

38. Install the fan guard (75) onto radiator (74). Secure the fan guard with three washers (163) and three bolts (164) .

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Illustration 43	g02005330

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Illustration 44	g02005331

39. Place water separator (162) onto the machine with two bolts (161) .

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Illustration 45	g02005333

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Illustration 46	g02005334

40. Place two bolts (159) onto the fuel tank (148) .

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Illustration 47	g02005355

41. Install hood group (145), air cleaner group (146), and counterweight (147) onto the machine.

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Illustration 48	g02005357

42. Place 346-0711 Hose As (63) and 346-0712 Hose As (64) onto the machine.

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Illustration 49	g02007953

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Illustration 50	g02008056
View N-N

43. Place 5K-9090 O-Ring Seal (8) and 7M-8485 O-Ring Seal (22) onto elbow (160). Install elbow (160) onto the machine.

44. Install 6V-9847 Swivel Tee (19) onto elbow (160) .

45. Place 6V-9746 O-Ring Seal (17) onto adapter (108). Install adapter (108) onto 6V-9847 Swivel Tee (19) .

46. Install 6V-9840 Swivel Tee (18) onto 6V-9847 Swivel Tee (19) .

47. Place 6V-8398 O-Ring Seal (14) onto reducer (153). Place reducer (153) and nut (154) onto 6V-9840 Swivel Tee (18) .

48. Connect 346-0713 Hose As (65) to 6V-9840 Swivel Tee (18) .

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Illustration 51	g02008536
View P-P

49. Connect two 6V-9008 Elbows (16) to the radiator in two places.

50. Connect 8C-6798 Swivel Tee (24), bypass valve group (140), 6V-8635 Connector (15), 334-4949 Tube As (46), and 6V-9840 Swivel Tee (18) together. Connect 8C-6798 Swivel Tee (24) and 6V-9840 Swivel Tee (18) to two 6V-9008 Elbows (16) .

51. Connect 346-0713 Hose As (65) to 8C-6798 Swivel Tee (24) .

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Illustration 52	g02020501

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Illustration 53	g02020522
View S-S (U) 30°

52. Place 346-0714 Hose As (66) onto the machine at the angle that is shown in Illustration 53.

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Illustration 54	g02020973

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Illustration 55	g02020635
View V-V

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Illustration 56	g02020994
View W-W

53. Secure 347-8445 Chassis Harness As (69) to the machine with 14 7K-1181 Cable Straps (21) .

54. Place 4K-5122 Fuse Holder As (6), 8M-8947 Fuse (25), 189-3158 Arc Suppressor (39), 209-0857 Relay As (40), and 225-3364 Relay (41) onto the machine.

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Illustration 57	g02021353
Non-engine end frame

55. Secure 347-8446 Front Harness As (70) to the machine with two 3S-2093 Cable Straps (5), ten 7K-1181 Cable Straps (21), and two 266-7379 Cable Straps (44) .

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Illustration 58	g02021453

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Illustration 59	g02021454
View Y-Y (Z) 37 mm (1.457 inch) (AA) 61.2 mm (2.409 inch)

56. Machine two holes at the locations that are shown in Illustration 59. The diameter of the holes should be machined to 8.5 mm (0.33465 inch) all the way through the plate. Machine the two holes with a M10 X 1.5 tap through the plate.

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Illustration 60	g02021757

57. Secure 327-3347 Blower Fan Gp (45) onto 344-8799 Cover As (61) with four 5C-9553 Bolts (7) and four 9X-8256 Washers (37) .

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Illustration 61	g02046413

58. Place two 6V-5163 Seals (13) onto 344-8799 Cover As (61) .

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Illustration 62	g02022133

59. Secure 327-3347 Blower Fan Gp (45) onto 354-0355 Shroud Assembly (71) with four 5C-9553 Bolts (7) and four 9X-8256 Washers (37) .

60. Place 9X-7345 Grommet (36) onto 354-0355 Shroud Assembly (71) .

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Illustration 63	g02139128
(168) 243-4505 Connector Receptacle As for the Fan (169) Connector on Harness Assembly

61. Secure 335-0671 Front Harness As (55), 347-8446 Front Harness As (70), and harness (163) with two 7K-1181 Cable Straps (21)

    Note: Either change the harness connector (169) to a 230-4011 Connector Plug As , or change both connectors to 2-pin Deutsche industrie norm. Wire black to black and orange to red.

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Illustration 64	g02029037

62. Place two 334-7317 Liner (53), 335-1403 Liner (56) and 6V-5163 Seal (13) onto 354-0355 Shroud Assembly (71) .

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Illustration 65	g02046523

63. Place 334-5519 Hydraulic Oil Cooler Gp (47) on the inside of 354-0355 Shroud Assembly (71). Place 5P-5637 Seal (11) onto 354-0355 Shroud Assembly (71) .

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Illustration 66	g02028871

64. Secure 344-8799 Cover As (61) to 354-0355 Shroud Assembly (71) with two 8T-4136 Bolt (28) and two 132-7551 Spacer (38) .

65. Place 334-7132 Plate (51) onto 344-8799 Cover As (61) with six 8T-4200 Bolt (33) and six 8T-4224 Hard Washer (34) .

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Illustration 67	g02022749

66. Secure two 339-3327 Blocks (60) to 354-0355 Shroud Assembly (71) with two 8T-4121 Hard Washers (26) and two 8T-4136 Bolts (28) .

    Note: Hand tighten the bolts only.

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Illustration 68	g02029058

67. Place 334-7134 Liner (52) onto 334-5519 Hydraulic Oil Cooler Gp (47) .

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Illustration 69	g02139152
334-7130 Plate As

68. Modify 334-7130 Plate As . Cut along the line. Refer to Illustration 69. Paint the plate when you are finished cutting.

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Illustration 70	g02029074

69. Secure 334-7130 Plate (50) to 354-0355 Shroud Assembly (71) with three 5P-4116 Hard Washer (10) and three 8T-4195 Bolt (30) .

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Illustration 71	g02022832
Rear view of machine

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Illustration 72	g02022834
View "AB"

70. If existing blocks are on the machine, remove the blocks before welding the new parts onto the frame.

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Illustration 73	g02028732

71. Secure 354-0355 Shroud Assembly (71) to the machine with two 7X-7729 Washers (23) and two 8T-4137 Bolts (29) .

    Note: Hand tighten the bolts until the bolts are snug.

72. Place two 9M-3835 Rubber Latches (35) onto the machine with two 2M-5795 Clevis Pins (1) and two 3B-4607 Cotter Pins (2) .

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Illustration 74	g02022763
Back of radiator

73. Mark the location of two 339-3327 Blocks (60) onto frame (165). Use the angle of the plate to align the blocks on the frame for marking.

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Illustration 75	g02028735

74. Remove two 8T-4137 Bolts (29) and two 7X-7729 Washers (23) in order to remove 354-0355 Shroud (71) .

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Illustration 76	g02023020
View AC

75. Weld 339-3327 Blocks (60) to frame (165) with a 5 mm (0.197 inch) fillet weld on three sides.

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Illustration 77	g02022199

76. Secure 346-3362 Support As (67) onto the machine with two 7X-7729 Washers (23) and two 8T-4195 Bolts (31). Secure 346-3364 Support As (68) to the machine with two 7X-7729 Washers (23) and two 8T-4195 Bolts (31) .

    Note: Hand tighten the bolts only.

Note: The installation of the support assemblies and mounting hardware for the condenser are required for machines with air conditioning and for machines without air conditioning. Disregard installation of the condenser for machines that are not equipped with air conditioning.

77. Install 346-3362 Support As (67) onto condenser (166) with three 8T-4200 Bolts (33) and three 8T-4224 Hard Washers (34). Install 346-3364 Support As (68) onto condenser (166) with three 8T-4200 Bolts (33) and three 8T-4224 Hard Washers (34) .

    Note: Hand tighten the bolts only.

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Illustration 78	g02022279

78. Place two 3E-3892 Seals (3) onto 334-7544 Cover As (54) .

79. Place 334-7544 Cover As (54) onto the machine with two 8T-4200 Bolts (33) and two 8T-4224 Hard Washers (34) .

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Illustration 79	g02022320

80. Secure 335-1656 Plate As (57) to 334-7544 Cover As (54) with two 8T-4200 Bolt (33) and two 8T-4224 Hard Washer (34) .

    Note: Hand tighten the bolts only.

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Illustration 80	g02022435

81. Make sure that the gap is uniform between 334-7544 Cover As (54) and 346-3362 Support As (67). Make sure that the gap is uniform between 334-7544 Cover As (54) and 346-3364 Support As (68). Refer to Illustration 80.

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Illustration 81	g02022531

82. Make sure that the gap is uniform between 346-3362 Support As (67) and 6V-9008 Elbow (16). Make sure that the gap is uniform between 346-3364 Support As (68) and 6V-9008 Elbow (16). Refer to Illustration 81.

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Illustration 82	g02022455

83. Mark a line along frame (165) onto 346-3362 Support As (67) and onto 346-3364 Support As (68) .

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Illustration 83	g02023183

84. Remove two 8T-4200 Bolts (33) and two 8T-4224 Hard Washers (34) in order to remove 334-7544 Cover As (54) from the machine.

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Illustration 84	g02022568

85. Remove five 8T-4200 Bolts (33) and five 8T-4224 Hard Washers (34) from the machine. Remove two 7X-7729 Washers (23) and two 8T-4195 Bolts (31) from the machine. Remove 346-3362 Support As (67) and 346-3364 Support As (68) from the machine.

86. Remove four bolts (167) and four washers (168) in order to remove condenser (166) .

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Illustration 85	g02022591

87. Hold 346-3362 Support As (67) in the location marked in Step 83. Mark the hole location in 346-3362 Support As (67) onto frame (165). The hole location is shown in Illustration 85.

88. Repeat Step 87 for 346-3364 Support As (68) .

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Illustration 86	g02022814

89. Drill two 11 mm (0.433 inch) holes in frame (165). The locations are marked in Step 87.

90. Connect 346-0710 Hose As (62) to 6V-9840 Swivel Tee (18) and 6V-9008 Elbow (16). The 6V-9008 Elbow (16) was attached to the main control valve in Step 23. Refer to Illustration 51.

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Illustration 87	g02023121

91. Secure 346-3362 Support As (67) and 346-3364 Support As (68) to the machine with four 7X-7729 Washers (23), two 8T-4195 Bolts (31), and two 8T-4200 Bolts (33). Tighten the four bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

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Illustration 88	g02023213

92. Install condenser (166) onto 346-3362 Support As (67) and 346-3364 Support As (68) with five 8T-4200 Bolts (33) and five 8T-4224 Hard Washers (34). Tighten five bolts to a torque of 28 ± 7 N·m (21± 5 lb ft).

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Illustration 89	g02023190

93. Install 334-7544 Cover As (54) with 8T-4200 Bolts (33) and two 8T-4224 Hard Washers (34). Tighten the two bolts to a torque of 28 ± 7 N·m (21± 5 lb ft).

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Illustration 90	g02023225

94. Install 335-1656 Plate As (57) onto 334-7544 Cover As (54) with two 8T-4200 Bolts (33) and two 8T-4224 Hard Washers (34). Tighten the two bolts to a torque of 28 ± 7 N·m (21± 5 lb ft).

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Illustration 91	g02023854

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Illustration 92	g02028734

95. Install two 8T-4121 Hard Washers (26) and two 8T-4136 Bolts (28) onto the machine. Install 354-0355 Shroud (71) onto the machine with two 7X-7729 Washers (23) and two 8T-4137 Bolts (29). Tighten four bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

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Illustration 93	g02023925
(H) Depth of Hole (AM) 8 ± 2 mm (0.3 ± 0.07 inch) (AN) 50 ± 2 mm (1.9 ± 0.07 inch) (59) 338-0171 Bracket As

96. Weld 338-0171 Bracket As (59) onto the machine. Use a plug weld. Refer to Illustration 93.

97. Secure 338-0170 Bracket As (58) to the machine with two 3E-4352 Hard Washer (4), two 6C-7706 Pins (12) and four 5P-0372 Lock Pins (9) .

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Illustration 94	g02024009

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Illustration 95	g02024077
View AH (AJ) 9 ± 5 mm (0.354 ± 0.197 inch) (AK) 20 ± 5 mm (0.787 ± 0.197 inch)

98. Place 239-9429 Film (42) onto the right side of the machine and the left side of the machine at the location that is shown above for machines that are located in the United States. Place 239-9430 Film (43) onto the right side of the machine and the left side of the machine at the location that is shown above for machines that are located outside the United States.

99. Add the coolant for the radiator. Refer to Operation and Maintenance Manual, SEBU7891, "Cooling System Coolant (ELC) - Change".

100. Add the hydraulic fluid to the tank. Refer to Operation and Maintenance Manual, SEBU7891, "Hydraulic System Oil - Change".

101. Raise the lift arms. Remove lift arm supports. Operate the machine in order to check for leaks.