Installation of 291-1185 Axle Oil Cooler Gp (Kit){1365} Caterpillar


Installation of 291-1185 Axle Oil Cooler Gp (Kit){1365}

Usage:

950H K5K


Wheel Loader:
950H (S/N: K5K1-UP)
962H (S/N: K6K1-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, SEBC1495. 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 and do not order parts that are outlined in this publication until you understand the information that is contained in this document.

Note: Cleanliness is an important factor. Before the removal of any component, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.


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, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.


------ WARNING! ------

At operating temperature, the engine coolant is hot and under pressure.

Steam can cause personal injury.

Check the coolant level only after the engine has been stopped and the filler cap is cool enough to touch with the bare hand.

Remove the filler cap slowly to relieve pressure.

Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent personal injury.

----------------------

------ WARNING! ------

Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact skin.

----------------------

Removal of the Engine Compartment Shield Gp




    Illustration 1g01325063

    Rear view of the engine compartment shield gp

  1. Refer to Disassembly and Assembly, RENR8863, "Engine Compartment Shield - Remove and Install" and remove the engine compartment shield.

Removal of the Power Train Guard for the Transmission




    Illustration 2g01325072

    Bottom view of the power train guard for the transmission

    (A) Bolts

    (B) Washers

    (C) Plate

  1. Remove four bolts (A) and four washers (B) .

  1. Remove plate (C) .

Modifying the Front Frame




    Illustration 3g01585913

  1. Use Illustration 3 for the location and weld the following parts onto the front frame:

Modifying the Rear Frame




    Illustration 4g01327084

    Front view of rear frame

    (D) 103 mm (4.1 inch)

    (E) 434.4 mm (17.1 inch)

  1. Weld one 091-1735 Block (1) onto the rear frame.



    Illustration 5g01327134

    View A-A from 4

    (F) 943 mm (37.1 inch)

    (G) 863 mm (33.9 inch)

    (H) 861 mm (33.9 inch)

    (J) 16 mm (0.6299 inch)

  1. Weld one 282-3456 Bracket Assembly (3) onto the rear frame.

  1. Weld one 7X-0752 Weld Boss (4) onto the rear frame.



    Illustration 6g01327194

    View B-B from 4

    (K) 876 mm (34.5 inch)

    (L) 163.5 mm (6.4 inch)

    (M) 141.3 mm (5.6 inch)

    (N) 1091.9 mm (42.9 inch)

    (P) 1013 mm (39.9 inch)

    (R) 803 mm (31.6 inch)

    (S) 16 mm (0.6 inch)

    (T) 16 Degrees

    (U) 1414 mm (55.7 inch)

    (V) 553 mm (21.9 inch)

    (W) 1225 mm (48.2 inch)

  1. Weld two 282-3454 Angle Assemblies (2) onto the rear frame.

  1. Weld one 7X-7964 Weld Boss (5) onto the rear frame.

  1. Weld one 8T-3851 Weld Boss (6) onto the rear frame.

  1. Weld one 8X-6780 Block (7) onto the rear frame.



    Illustration 7g01327249

    View C-C from Illustration 6

    (X) 110 mm (4.3 inch)

    (Y) 402.4 mm (15.8 inch)

  1. Weld one 7X-0752 Weld Boss (4) onto the rear frame.

Install the Axle Oil Cooler




    Illustration 8g01325123

  1. Use the 6V-9746 O-Ring Seals (7) that are part of the 130-5202 Check Valve Gp (1). Install a 130-5202 Check Valve Gp (1) onto each 260-6465 Tube As (4). Refer to Illustration 8 for correct orientation of the 130-5202 Check Valve Gp (1) .

  1. Use the 7M-8485 O-Ring Seals (7) that are included in the 148-8442 Tee As (5) and install the two 148-8442 Tee As (5) onto the left hand end of the 313-7721 Axle Oil Cooler Core As (2). Tighten finger tight.

  1. Use the 7M-8485 O-Ring Seals (7) that are included in the kit and install the two 250-1441 Tee (3) onto the right hand end of the 313-7721 Axle Oil Cooler Core As (2). Tighten finger tight.

  1. Use the two 3D-2824 O-Ring Seals that are included in the 130-5202 Check Valve Gp (1) and connect each 130-5202 Check Valve Gp (1) onto the 250-1441 Tees (3). Tighten finger tight.

  1. Use the 6V-9746 O-Ring Seals (7) that are included in the 148-8442 Tee As (5) and connect the other end of each the 260-6465 Tube As (4) onto the 148-8442 Tee As (5). Tighten finger tight.

  1. Make sure that the parts are not in a bind and tighten all fittings.

  1. Use the following hardware and install the axle oil cooler:

Installation of the Axle Oil Cooler Pump and Mounting Gp on Machines that do not have Air Conditioning




    Illustration 9g01434029

    Rear view of engine

  1. Remove the 246-6296 Serpentine Belt .

  1. Remove the 220-1858 Serpentine Belt .

  1. Remove the 9X-7381 O-Ring Seal .

  1. Use the following hardware and install the 276-7533 Bracket As (5) onto the engine:

  1. Use the following hardware and install the 215-3013 Gear Pump Gp (Axle Oil Cooler) (2) onto the 276-7533 Bracket As (5) :

  1. Use the following hardware and install the 215-3014 Electric Clutch (Axle Oil Cooler Pump) (3) onto the 215-3013 Gear Pump Gp (Axle Oil Cooler) (2) :

  1. Install the 215-3015 Serpentine Belt (6) .

  1. Install the 301-0359 Hose As (6) .

  1. Use the following hardware and secure the 301-0359 Hose As (6) :

Installation of the Axle Oil Cooler Pump and Mounting Gp on Machines that have Air Conditioning




    Illustration 10g01441799

    Rear view of engine

  1. Remove the 220-1858 Serpentine Belt (A) that is part of the compressor gp.



    Illustration 11g01441800

    Top view of air conditioner lines group

  1. Remove the 301-0356 Hose As (B) .

  1. Remove the 9X-7381 O-Ring Seal (C). Keep the 9X-7381 O-Ring Seal (C) for later use.

  1. Remove the 202-8696 Fitting As (D) .

  1. Remove the following hardware:




    Illustration 12g01442676

    Rear view of engine

  1. Use the following hardware and install the 276-7533 Bracket As (5) onto the engine:

  1. Use the following hardware and install the 215-3013 Gear Pump Gp (Axle Oil Cooler) (2) onto the 276-7533 Bracket As (5) :

  1. Use the following hardware and install the 215-3014 Electric Clutch (Axle Oil Cooler Pump) (3) onto the 215-3013 Gear Pump Gp (Axle Oil Cooler) (2) :

  1. Install the 217-3015 Serpentine Belt (4) .

  1. Install the 118-9517 Air Conditioner Fitting (8) .

  1. Connect one end of the 301-0359 Hose As (6) onto the 118-9517 Air Conditioner Fitting (8) .

  1. Connect the other end of the 301-0359 Hose As (6) onto the radiator.

  1. Use the following hardware and secure the 301-0359 Hose As (6) onto 276-7533 Bracket As (5) :

Installation of the Electric Clutch Wiring for the Axle Oil Cooler Pump




    Illustration 13g01382283

    Front views of the clutch for the axle oil cooler gp.

    (A) View of machine with air conditioning

    (B) View of machine without air conditioning

  1. Install the 147-0385 Clip (5) in order to secure the power lead for the clutch.

  1. On machines without air conditioning, install the following hardware:

  1. On machines with air conditioning, install a 7K-1181 Cable Strap (2) .

  1. Connect the power lead of the clutch to the engine harness.



    Illustration 14g01383853

    Right hand view of cab

  1. Install the 3E-5239 Relay As (Axle Oil Cooler) (1) in the cab.

Installation of the Water Lines Gp for the Axle Oil Cooler




    Illustration 15g01327513

    Front view of engine




    Illustration 16g01448231

    View A-A and View B-B from Illustration 16




    Illustration 17g01327545

  1. Use a 5D-1026 Hose Clamp (1) and connect a 149 ± 1 cm (58.7 ± 0.4 inch) length of 5P-0767 Hose (18A) onto the left hand end of the axle oil cooler.

  1. Route the 5P-0767 Hose (18A) to the elbow group for the water.

  1. Remove the plug assembly from the elbow group.

  1. Install the 161-9916 Adapter Gp (3) into the elbow group.

  1. Install the 170-0965 Connector As (4) into the 161-9916 Adapter Gp (3) .

  1. Use a 5D-1026 Hose Clamp (1) and connect the other end of the 5P-0767 Hose (18A) onto the 170-0965 Connector As (4) .

  1. Use the following hardware and secure the 5P-0767 Hose (18A) :

    Note: The 7X-2552 Bolt (10) should be tightened to 240 ± 40 N·m (177.01 ± 29.50 lb ft).

    Note: The 8T-4136 Bolt (14) and the 8T-4137 Bolt (15) should be tightened to 55 ± 10 N·m (40.57 ± 7.38 lb ft).

  1. Use a 5D-1026 Hose Clamp (1) and connect a 252 ± 1 cm (99.2 ± 0.4 inch) length of 5P-0767 Hose (18B) onto the right hand end of the axle oil cooler.

  1. Route the 5P-0767 Hose (18B) to the rear of the cylinder block.

  1. Remove the plug and seal from the rear of the cylinder block.

  1. Install the 155-7321 Adapter As (6) into the rear of the cylinder block.

  1. Install the 170-0965 Connector As (4) into the 155-7321 Adapter As (6) .

  1. Use a 5D-1026 Hose Clamp (1) and connect the other end of the 5P-0767 Hose (18B) onto the 170-0965 Connector As (4) .

  1. Use the following hardware and secure the 5P-0767 Hose (18B) :

    Note: The 8T-4136 Bolt (14) and the 8T-4195 Bolt (16) should be tightened to 55 ± 10 N·m (40.57 ± 7.38 lb ft).

Installation of the Axle Oil Cooler Lines Group




    Illustration 18g01328758



    Illustration 19g01448242



    Illustration 20g01434211



    Illustration 21g01434221

  1. Refer to View F-F in Illustration 21. Use the following hardware and install the 242-8419 Bracket Assembly (26) onto the bracket for the fuel filter:

  1. Refer to Illustration 18. Install a 153-6244 Elbow As (39) into the right hand rear port of the axle oil cooler pump.

  1. Connect the 242-8417 Tube As (24) onto the 153-6244 Elbow As (39) .

  1. Refer to Illustration 18. Install a 153-6244 Elbow As (39) into the right hand front port of the axle oil cooler pump.

  1. Connect the 242-8416 Tube As (23) onto the 153-6244 Elbow As (39).

  1. Refer to View F-F in Illustration 21. Use the following hardware and secure the two tube assemblies onto the 242-8419 Bracket Assembly (26) :

  1. Refer to Illustration 18. Install a 148-8362 Elbow As (35) into the left hand rear port of the axle oil cooler pump.

  1. Connect the 242-8415 Tube As (22) onto the 148-8362 Elbow As (35).

  1. Refer to Illustration 18. Install a 148-8362 Elbow As (35) into the left hand front port of the axle oil cooler pump.

  1. Connect the 242-8414 Tube As (21) onto the 148-8362 Elbow As (35) .

  1. Refer to view F-F in Illustration 21. Use the following hardware and secure the two tube assemblies onto the 242-8419 Bracket Assembly (26) :

  1. Refer to View H-H in Illustration 21. Use a 6V-9746 O-Ring Seal (49) and connect the straight end of 241-0089 Hose As (18) onto the 242-8417 Tube As (24) .

  1. Use the 6V-9746 O-Ring Seal (7) that was included in the 148-8442 Tee As (5) and connect the other end of 241-0089 Hose As (18) onto the rear 148-8442 Tee As (5). Refer to Illustration 8.

  1. Use a 6V-9746 O-Ring Seal (49) and connect the straight end of 241-0088 Hose As (17) onto the 242-8416 Tube As (23) .

  1. Use the 6V-9746 O-Ring Seal (7) that was included in the 148-8442 Tee As (5) and connect the other end of 241-0088 Hose As (17) onto the front 148-8442 Tee As (5). Refer to Illustration 8.

  1. Refer to Illustration 20. Install a 148-8391 Elbow As (37) into each end of the 251-6351 Magnetic Filter (Axle Oil Cooler) (28).

  1. Use the following hardware and mount a 251-6351 Magnetic Filter (Axle Oil Cooler) (28) onto the 242-8418 Bracket As (25) :

  1. Use the following hardware and install the 251-6351 Magnetic Filter (Axle Oil Cooler) (28) and the 242-8418 Bracket As (25) onto the rear frame.

  1. Use the following hardware and mount the other 251-6351 Magnetic Filter (Axle Oil Cooler) (28) onto the 153-3495 Bracket As (10) :

  1. Refer to Illustration 20. Install a 148-8323 Connector As (33) into each end of the 251-6351 Magnetic Filter (Axle Oil Cooler) (28) .

  1. Use the following hardware and install the 251-6351 Magnetic Filter (Axle Oil Cooler) (28) and the 153-3495 Bracket As (10) onto the front frame:

  1. Refer to view A-A that is shown in Illustration 20. Remove the plugs on each side of the rear axle.

  1. Install a 164-5598 Plug As (40) into each side of the rear axle.

  1. Install a 148-8378 Elbow As (36) into each 164-5598 Plug As (40) .

  1. Loosely connect one end of the 192-4264 Tube As (14) onto the 148-8378 Elbow As (36) .

  1. Loosely connect one end of a 192-4263 Tube As (13) onto the other 148-8378 Elbow As (36) .

  1. Install a 148-8454 Tee As (38) between the two tubes.

  1. Tighten all nuts on the 192-4263 Tube As (13) and the 192-4264 Tube As (14) .

  1. Refer to View A-A that is shown in Illustration 20. Install a 150-3032 Elbow As (7) into the 148-8454 Tee As (38).

  1. Refer to View A-A that is shown in Illustration 20. Remove the original plug and install a 148-8335 Connector As (34) .

  1. Refer to View B-B that is shown in Illustration 20. Remove the plugs on each side of the front axle.

  1. Install a 164-5598 Plug As (40) into each side of the front axle.

  1. Install a 148-8378 Elbow As (36) into each 164-5598 Plug As (40) .

  1. Loosely connect one end of the 151-4506 Tube As (8) onto the 148-8378 Elbow As (36) .

  1. Loosely connect one end of a 151-4507 Tube As (9) onto the other 148-8378 Elbow As (36) .

  1. Install a 148-8454 Tee As (38) between the two tubes.

  1. Tighten all nuts on the 151-4506 Tube As (8) and the 151-4507 Tube As (9) .

  1. Refer to view B-B that is shown in Illustration 20. Install a 150-3032 Elbow As (7) into the 148-8454 Tee As (38).

  1. Refer to view B-B that is shown in Illustration 20. Remove the original plug and install a 148-8335 Connector As (34) .

  1. Refer to view H-H that is shown in Illustration 21. Use a 6V-9746 O-Ring Seal (49) and connect the straight end of the 241-0089 Hose As (18) onto the 242-8417 Tube As (24) .

  1. Connect the angled end of the 241-0089 Hose As (18) onto the rear right hand tee on the axle oil cooler. Use the 6V-9746 O-Ring Seal that came with the rear right hand tee.

  1. Refer to View H-H that is shown in Illustration 21. Use a 6V-9746 O-Ring Seal (49) and connect the straight end of the 241-0088 Hose As (17) onto the 242-8416 Tube As (23) .

  1. Connect the angled end of the 241-0088 Hose As (17) onto the front right hand tee on the axle oil cooler. Use the 6V-9746 O-Ring Seal that came with the front right hand tee.

  1. Refer to Illustration 20. Use a 5K-9090 O-Ring Seal (43) and connect the straight end of the 241-0091 Hose As (19) onto the 242-8415 Tube As (22) .

  1. Connect the other end of the 241-0091 Hose As (19) onto the bottom elbow that is on the rear magnetic filter. Use the seal that came with the elbow.

  1. Refer to Illustration 20. Use a 5K-9090 O-Ring Seal (43) and connect the straight end of the 242-9820 Hose As (27) onto the 242-8414 Tube As (21) .

  1. Refer to Illustration 18. Route the 242-9820 Hose As (27) forward to the front magnetic filter. Connect the other end of the 242-9820 Hose As (27) onto the 148-8323 Connector Gp (33) that is located in the rear of the front magnetic filter.

  1. Connect one end of the 241-0092 Hose As (20) onto the 150-3032 Elbow As (7) that is mounted on the rear axle housing. Use the 6V-9746 O-Ring Seal that came with the 150-3032 Elbow As (7) .

  1. Connect the other end of the 241-0092 Hose As (20) onto the 250-1441 Tee that is located on the left rear of the core assembly for the axle oil cooler. Use the 6V-9746 O-Ring Seal that came with the 250-1441 Tee . Refer to Illustration 8.

  1. Connect the straight end of the 275-9955 Hose As (29) onto the 148-8335 Connector As that is mounted in the rear axle housing. Use the 7M-8485 O-Ring Seal that came with the 148-8335 Connector As .

  1. Connect one end of the 241-0086 Hose As (15) onto the 148-8335 Connector As that is mounted in the front axle housing. Use the 7M-8485 O-Ring Seal that came with the 148-8335 Connector As .

  1. Connect the other end of the 241-0086 Hose As (15) onto the 148-8323 Connector Gp that is located on the front of the front magnetic filter. Use the 5K-9090 O-Ring Seal that came with the 148-8323 Connector Gp .

  1. Connect one end of the 241-0087 Hose As (16) onto the 250-1441 Tee that is located on the left front of the core assembly for the axle oil cooler. Use the 6V-9746 O-Ring Seal that came with the 250-1441 Tee . Refer to Illustration 8.

  1. Refer to Illustration 18. Connect the other end of the 241-0087 Hose As (16) onto the 150-3032 Elbow As (7) that is mounted on the front axle housing. Use the 6V-9746 O-Ring Seal that came with the 150-3032 Elbow As (7) .

  1. Refer to Illustration 18 through Illustration 21. Use the following hardware and secure the hoses:

Installation of the Power Train Guard Gp




    Illustration 22g01326308

    Top and right side view of the power train guard gp

  1. Use the following hardware and install the 153-3715 Plate (1) :

Installation of the Axle Oil Cooler Guard Gp




    Illustration 23g01325607

    View of right side and top of rear axle guard

  1. Remove original bolts. Use three 9X-2075 Bolts (6) and install a 143-0004 Plate As (5) onto the rear left hand side of the machine.

  1. Remove original bolts. Use three 8T-0282 Bolts (1) and install a 143-0003 Plate As (7) onto the rear right hand side of the machine.

  1. Use the following hardware and install a 212-7753 Plate As (2) onto the 143-0004 Plate As (5) and the 143-0003 Plate As (7) :

  1. Use the following hardware and install a 212-7754 Plate (10) onto the 212-7753 Plate As (2) :




    Illustration 24g01325618

    View of right side and top of front axle guard

  1. Remove original bolts. Use three 9X-2075 Bolts (6) and install a 143-0004 Plate As (5) onto the front right hand side of the machine.

  1. Remove original bolts. Use three 8T-0282 Bolts (1) and install a 143-0003 Plate As (7) onto the front left hand side of the machine.

  1. Use the following hardware and install a 212-7753 Plate As (2) onto the 143-0004 Plate As (5) and the 143-0003 Plate As (7) :

  1. Use the following hardware and install a 212-7754 Plate (10) onto the 212-7753 Plate As (2) :

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