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

Radiator - Install

Usage:

769D 5SS

Installation 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)

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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, 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.

Verify that all the components of the radiator are clean and free of foreign material prior to installation.
Inspect all components for wear and replace the components, if necessary.
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Illustration 1 g00469129

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Illustration 2 g00469131
Fasten Tooling (B) to the radiator. Attach a suitable lifting device to Tooling (B). Attach the lifting device to a hoist. Install radiator (51) onto the frame assembly. The weight of radiator (51) is 400 kg (882 lb).
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Illustration 3 g00469130
Install four bolts (50), the nuts, and the washers that hold radiator (51) to the frame assembly.
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Illustration 4 g00469128
Slide two hump hoses (47) and (48) onto inlet tube assemblies (49). Tighten hose clamps (46).
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Illustration 5 g00469127
Install three tie straps (44) that hold wiring harness (45).
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Illustration 6 g00469106
Position valve assembly (43), as shown. Install clip (42), two bolts (41), and the washers.
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Illustration 7 g00469104
Install baffle strip (38). Install two bolts (35) and the washers that hold the top of fan guard (33). Position plate (37), battery cable (39), and wire harness (40) on radiator guard (32). Install five bolts (36), the spacers, and the washers.
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Illustration 8 g00469102
Install two bolts (32) and the washers that hold fan guard (33) to the radiator. Install three bolts (31) and the washers that hold two heater hoses (34) to the radiator.
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Illustration 9 g00469101
Position gasket (28) (not shown) and tube assembly (30). Position hose clamp (27) and bracket (29). Install four bolts (26).
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Illustration 10 g00469097
Install bolt (24), the washer, and the nut that holds supplemental steering hoses (25) to the bracket.
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Illustration 11 g00469088
Position lower baffle assembly (23) on the frame assembly, as shown. Install three bolts (22) and the washers.
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Illustration 12 g00469085
Use two people to remove the air conditioner condenser from the front of the cab. Position air conditioner condenser (20) on the radiator. Install four nuts (19), bolts, and the washers.
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Illustration 13 g00469082
Position air conditioner accumulator (19), as shown. Position air conditioner accumulator and mounting (18), as shown. Install bolt (17) and the washer.
Position two hose assemblies (14), and (16), as shown. Install bolt (15), and the washer.
Position hose assembly (14), and air conditioning dryer (13), as shown. Install bolt (12) and the washer.
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Illustration 14 g00469081
Position drain tube (11), as shown. Install bolt (9), the washer, and clip (10).
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Illustration 15 g00559445
Connect wire harness (8) at the electrical connection. Position the electrical connection on the clip.
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Illustration 16 g00559418
Pull wire harness (5) through fender assembly (7). Install new tie strap (6).
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Illustration 17 g00559409
Connect wire harness (5) at the electrical connections of headlamps (4).
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Illustration 18 g06345513

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Illustration 19 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. Install tube assembly (1). Install shims (3). Install the same amount of shims (3) that were removed. Install eight bolts (2) and the washers. The weight of tube assembly (1) is 27 kg (60 lb).
Remove Tooling (A).
Refill the radiator. Refer to Operation and Maintenance Manual, SEBU7092, "Cooling System Coolant (ELC) - Change".