Installation of 290-3540 Axle Oil Cooler Gp Kit{1365} Caterpillar

Wheel Loader:

966H (S/N: A6D1-UP)

972H (S/N: A7D1-UP)

Introduction

This publication contains the information for installation of the axle oil cooler. A complete listing of the parts that are contained in this kit are listed in the Parts Manual, SEBC1496. This supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for this standard machine.

Do not perform any procedure or order parts outlined in this publication until you understand the information that is contained in this document.

Machining of the Axle Center Housings

Note: Cleanliness is an important factor. Before the disassembly procedure, clean the exterior of the component thoroughly. This process will help to prevent dirt from entering the internal mechanism.

1. Remove the front fixed axle. Refer to Disassembly and Assembly, RENR8847, "Fixed Axle (Front) - Remove and Install".

2. Remove the rear oscillating axle. Refer to Disassembly and Assembly, RENR8847, "Oscillating Axle (Rear) - Remove". Also refer to Disassembly and Assembly, RENR8847, "Oscillating Axle (Rear) - Install".

3. Remove the differential and bevel gears from both axles. Refer to Disassembly and Assembly, RENR8847, "Differential and Bevel Gear - Remove". Also refer to Disassembly and Assembly, RENR8847, "Differential and Bevel Gear - Install".

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Illustration 1	g01320905
View of the axle center housing (C) 187 mm (7.36 inch) (D) 117.5 mm (4.62 inch) (E) 48 mm (1.889 inch) (F) 40.5 mm (1.59 inch) (G) 20 mm (0.78 inch) (H) 121 mm (4.76 inch) (J) 250 mm (9.84 inch) (K) 240 mm (9.44 inch) (L) 188 mm (7.40 inch) (M) 178 mm (7.00 inch) (N) 243 mm (9.56 inch) (P) 29 mm (1.14 inch) (R) 164 mm (6.45 inch) (S) 253 mm (9.96 inch) (T) 220 mm (8.66 inch) (U) 194.5 mm (7.65 inch) (V) 176.65 mm (6.95 inch) (W) 196.19 mm (7.72 inch) (X) 77.5 mm (3.05 inch) (Y) 252.37 mm (9.93 inch) (Z) 77.5 mm (3.05 inch) (AA) 252.37 mm (9.93 inch) (BB) 16 mm (0.63 inch) radius in four places (CC) 0.8 ± 0.2 mm (0.03 ± 0.0079 inch) radius on three surfaces (DD) 276 mm (10.86 inch) radius on three surfaces (EE) 1.6 ± 0.4 mm (0.063 ± 0.015 inch) radius

4. Refer to Illustration 1 in order to locate the dimensions for the machining process.

   Note: The same machining is required on both of the axle center housings.

5. Machine the front axle center housing.

6. Machine the rear axle center housing.

Installation of 160-0718 Axle Heat Exchanger Gp

Note: Refer to Disassembly and Assembly, RENR8847, "Heat Exchanger (Axle Oil Cooler) - Remove and Install".

Installation of Axle Oil Cooler Lines Group

Illustration 2	g01296380
Top and right side views of the rear and loader frames

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Illustration 3	g01296407
Section E-E from Illustration 2

1. Use the following hardware and install the 244-3280 Bracket As (8) :
   • Two 8T-4121 Hard Washers (29)

   • Two 8T-4136 Bolts (31)

2. Use the following hardware and install the 237-8180 Control Manifold Gp (Axle Oil Flow Divider) (7) :
   • Two 8T-4121 Hard Washers (29)

   • Two 7X-2545 Bolts (27)

3. Install a 148-8364 Elbow As (17) into both rear ports of the 237-8180 Control Manifold Gp (Axle Oil Flow Divider) (7) .

4. Install a 153-6241 Elbow As (20) onto the top 148-8364 Elbow As (17) .

5. Connect the straight end of the 122-0082 Hose As (3) onto the 153-6241 Elbow As (20) .

6. Refer to Illustration 2. Route the 122-0082 Hose As (3) to the rear axle. Connect the 122-0082 Hose As (3) onto the axle oil cooler.

7. Install a 148-8370 Elbow As (18) onto the bottom 148-8364 Elbow As (17) .

8. Connect the straight end of the 102-1758 Hose As (2) onto the 148-8370 Elbow As (18) .

9. Refer to Illustration 2. Route the 102-1758 Hose As (2) to the rear axle. Connect the 102-1758 Hose As (2) onto the axle oil cooler.

10. Use the following hardware and secure the 122-0082 Hose As (3) and the 102-1758 Hose As (2) :
    • One 285-9235 Bracket As (13)

    • One 7D-7735 Clip (26)

    • One 7X-2553 Bolt (28)

    • One 8T-4121 Hard Washer (29)

    • One 8T-4137 Bolt (32)

    • One 9X-8257 Washer (33)

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Illustration 4	g01296558
Partial top view of rear frame (Z) Tube assembly

11. Remove tube assembly (Z). Seals from tube assembly (Z) will be reused.

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Illustration 5	g01296594
Section E-E from Illustration 2

12. Install a 148-8327 Connector As (15) into the 237-8180 Control Manifold Gp (Axle Oil Flow Divider) (7) .

13. Connect the angled end of the 141-7722 Hose As (4) onto the 148-8327 Connector As (15) .

14. Use the original seal. Connect the other end of the 141-7722 Hose As (4) onto the elbow in place of the tube (Z). Refer to Illustration 4.

15. Install a 148-8347 Elbow As (16) into the manifold.

16. Connect the angled end of the 244-3283 Hose As (10) onto the 148-8347 Elbow As (16) .

17. Use the original seal and connect the other end of the 244-3283 Hose As (10) onto the adapter in place of the tube (Z). Refer to Illustration 4.

18. Install a 164-5572 Union As (21) into the long legs of the 272-0293 Tube As (12) and the 272-0292 Tube As (11) .

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Illustration 6	g01296619
Section A-A and Section D-D from Illustration 2

19. Use two 6V-9169 Bulkhead Nuts (25) and install the two 148-8375 Elbow Assemblies (19) into the bulkhead.

20. Connect the 272-0293 Tube As (12) and the 272-0292 Tube As (11) onto the two 148-8375 Elbow Assemblies (19) .

21. Refer to Section A-A from Illustration 2. Use the following hardware and secure the 272-0293 Tube As (12) and the 272-0292 Tube As (11) :
    • Two 1B-3057 Clips (22)

    • One 8T-4121 Hard Washer (29)

    • One 8T-4133 Nut (30)

22. Refer to Illustration 2. Connect the straight end of the 152-1872 Hose As (6) onto the 272-0293 Tube As (12) .

23. Connect the other end of the 152-1872 Hose As (6) onto the front axle oil cooler.

24. Refer to Illustration 2. Connect the straight end of the 4E-9273 Hose As (1) onto the 272-0292 Tube As (11) .

25. Connect the other end of the 4E-9273 Hose As (1) onto the front axle oil cooler.

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Illustration 7	g03337220
Section B-B, Section D-D, and Section E-E from Illustration 2

26. Install two 148-8364 Elbow Assemblies (17) into the 237-8180 Control Manifold Gp (Axle Oil Flow Divider) (7) .

27. Connect one end of the 244-3282 Hose As (9) onto the bottom 148-8364 Elbow Assembly (17) .

28. Connect the other end of the 244-3282 Hose As (9) onto the bottom 148-8375 Elbow Assembly (19) .

29. Connect one end of the 152-0264 Hose As (5) onto the top 148-8364 Elbow Assembly (17) .

30. Connect the other end of the 152-0264 Hose As (5) onto the top 148-8375 Elbow Assembly (19) .

31. Use the following hardware and secure the 152-0264 Hose As (5) and the 244-3282 Hose As (9) :
    • One 287-2072 Bracket As (14)

    • Six 1S-0994 Clips (23)

    • Four 8T-4121 Hard Washers (29)

    • Two 8T-4133 Nuts (30)

    • Four 8T-4136 Bolt (31)

Removal of Existing Oil Cooler Core

Note: Cleanliness is an important factor. Before the disassembly procedure, clean the exterior of the component thoroughly. This process will help to prevent dirt from entering the internal mechanism.

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Illustration 8	g01296966
Rear view of existing oil cooler core (A) Existing oil cooler core (B) Bolts (C) Washers (D) Bracket assembly

1. Disconnect all plumbing from the existing oil cooler core assembly (A) .

2. Remove the two bolts (B) and two washers (C) that hold the bracket assembly (D). Remove the bracket assembly (D). The two bolts and two washers will be reused.

3. Remove the three bolts (B) and three washers (C) that hold the oil cooler core assembly (A). Remove the oil cooler core assembly (A). The three bolts and three washers will be reused.

Installation of the Oil Cooler Core Assembly

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Illustration 9	g03337203
Rear view of oil cooler core

1. Use the three bolts (B) and three washers (C) and mount the bracket assembly (D) onto the 349-5934 Oil Cooler Core As (1) .

2. Use the three bolts (B) and three washers (C) and install the 349-5934 Oil Cooler Core As (1) .

3. Reconnect all plumbing onto the 349-5934 Oil Cooler Core As (1) .