Repair Procedure for Repairing a Radiator{1353} Caterpillar

Motor Grader:

14H (PIN: 7WJ)

143H (PIN: 1AL)

163H (PIN: 5AK)

120H (PIN: 4MK; 6TM; 6NM)

135H (PIN: 3YK; 7MM)

140H (PIN: 2ZK; 8KM; 8JM)

160H (PIN: 6WM; 9JM; 9EJ)

Introduction

This Special instruction provides the necessary information for repairing a 7C-1420 Radiator .

The Repairing of a Tube to Header Leak

To repair a leak at a tube to the header on a 7C-1420 Radiator , follow the procedure that is outlined below. In most cases, a leak in a tube to the header can be repaired without removing the tanks. In all cases, these repairs should be made by a reputable repair shop which follows appropriate safety and environmental procedures.

1. The radiator must be removed from the machine and drained.

2. The area of the leak must be thoroughly cleaned.

   1. To remove mud and loose debris, wash the radiator with water pressure.

   2. Remove any paint by the application of heat or chemicals.

   3. The removal of any chemicals that are used in the removal of paint must be removed per the specifications of the manufacturer.

   4. To pinpoint any leak, perform a leak test.

3. Remove any oxidation on the solder joint. With flux, the oxidation can be removed from the tube.

4. Resoldering

5. Perform a leak test.

   1. If the radiator does not leak, proceed to Step 6.

   2. If the radiator leaks repeat Step 3, Step 4 and Step 5.

6. To prevent corrosion, clean the flux off the radiator.

7. Repaint the radiator.

This procedure will repair solder joints that have failed, cracked tubes and cracked headers. The cracked headers will only be a temporary repair.

If the radiator still leaks, the tube needs to be blocked. This can be accomplished by cutting the tube and crimping the two open ends of the tube and soldering each end shut.

Removing the Tanks

Remove the tanks only if blocking the tube does not stop the leak.

Illustration 1	g00482077
(1) Gusset (2) Saddle

1. The welds between the saddle (2) and the side should be ground off.

2. The saddle (2) should be bent away from the sides.

3. The welds on the gussets (1) should then be cut with a saw or a grinder.

4. Now, the sides should be pulled off the radiator.

5. The tanks can be removed by sweating. Repair the radiator by using the same process that is used in order to repair a brass tank radiator.

6. After the tanks are soldered in place, any holes that were put in the tanks from cutting or grinding must be repaired. Repair the tanks with a TIG weld or a MIG weld. The MIG weld is the second best alternative.

7. Perform a leak test.

8. Weld the sides and gussets (1) back to the radiator.

9. Bend back the saddle (2) and weld in place.

10. Retest the radiator for leaks.

11. Thoroughly clean the radiator and repaint the radiator.

    Note: The repair of radiator should only be attempted by qualified personnel. Always use common sense. Never forget safety.