69D and 769D Off-Highway Trucks and 771D Quarry Truck Caterpillar

Radiator - Remove

Usage:

769D 5SS

Removal Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	504-9791	Lift Gp (60Hz)⁽¹⁾	2
	OR
	504-9793	Lift Gp (50Hz)⁽²⁾	2
B	439-3938	Link Bracket	2

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⁽¹⁾	High-Voltage (480V) Low-Voltage (240V)
⁽²⁾	High-Voltage (400V) Low-Voltage (200V)

Start By:

Remove the cowling (radiator).
Remove the crankcase guards.

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NOTICE

Refer to Disassembly and Assembly, "Cowling (Radiator) - Remove and Install" 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.

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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.

Release the pressure in the cooling system by slowly loosening the filler cap on the radiator. Drain the coolant from the radiator into a suitable container for storage or disposal. The capacity of the cooling system is 106 L (28 US gal). Refer to Operation and Maintenance Manual, SEBU7092, "Cooling System Coolant (ELC) - Change".
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Illustration 1 g06345513

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Illustration 2 g00469071
Position Tooling (A) under the frame, as shown. Tooling (A) will ease the installation of tube assembly (1) and shims (3) during the installation procedure. Refer to Tool Operating Manual, NEHS1303, "Lift Group (Stand - 25 Ton)" for more information on Tooling (A).
Attach a suitable lifting device to tube assembly (1). Secure the lifting device to a hoist. Record the number of shims (3) (not shown) for installation purposes. Shims (3) are on each end of tube assembly (1). Remove eight bolts (2) and the washers that hold tube assembly (1) to the frame assembly. The weight of tube assembly (1) is 27 kg (60 lb).
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Illustration 3 g00559409
Disconnect wire harness (5) at the electrical connections of each headlamp (4).
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Illustration 4 g00559418
Remove tie strap (6). Pull wire harness (5) from fender assembly (7).
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Illustration 5 g00559445
Disconnect wire harness (8) at the electrical connection (7).
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Illustration 6 g00469081
Remove bolt (9) and the washer. Disconnect clip (10) to allow drain tube (11) to be repositioned.
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Illustration 7 g00469082
Remove bolt (12) and the washer. Bolt (12) holds hose assembly (14) and air conditioning dryer (13).
Remove bolt (15) and the washer. Bolt (15) holds hose assemblies (14) and (16) to the radiator.
Remove bolt (17) and the washer. Bolt (17) holds air conditioner accumulator and mounting (18) to the radiator. Position air conditioner accumulator and mounting (18) and accumulator (19) out of the way.
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Illustration 8 g00469085

Note: It is not necessary to evacuate the air conditioning system during the removal of air conditioner condenser (21).
Remove four bolts (20), the nuts, and washers from the air conditioner condenser (21). Use two people to fasten air conditioner condenser (21) on the front of the cab.
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Illustration 9 g00469088
Remove three bolts (22) and the washers that hold baffle assembly (23) to the frame assembly. Remove baffle assembly (23).
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Illustration 10 g00469097
Remove bolt (24), the washer, and the nut that holds supplemental steering hoses (25) to the bracket.
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Illustration 11 g00469101
Put identification on four bolts (26) for installation purposes. Remove four bolts (26). Remove bracket (29). Remove clip (27). Remove outlet tube assembly (30) and gasket (28) (not shown).
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Illustration 12 g00469102
Remove two bolts (32) and the washers that hold fan guard (33) to the radiator. Remove three bolts (31) and the washers that hold two heater hoses (34) to the radiator.
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Illustration 13 g00469104
Remove two bolts (35) and the washers from fan guard (33). Remove five bolts (36), the washers, and the spacers. Remove bar (37) and baffle strip (38). Position battery cable (39), and wire harness (40) out of the way.
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Illustration 14 g00469106
Remove two bolts (41), the washers, and clip (42). Remove valve assembly (43). Position valve assembly (43) out of the way.
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Illustration 15 g00469127
Remove three tie straps (44) that hold wire harness (45).
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Illustration 16 g00469128
Loosen hose clamps (46) on two hump hoses (47) and (48). Disconnect each hump hose (47) and (48) from inlet tube assemblies (49).
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Illustration 17 g00469129
Install Tooling (A) on the radiator, as shown. Attach a suitable lifting device to Tooling (B). Attach the lifting device to a hoist.
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Illustration 18 g00469130
Remove four bolts (50), the nuts, and the washers that hold radiator (51) to the frame assembly.
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Illustration 19 g00469131
Remove radiator (51) from the frame assembly. The weight of the radiator (51) is 400 kg (882 lb).