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

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.

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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.

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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

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Illustration 1	g01325063
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

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Illustration 2	g01325072
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) .

2. Remove plate (C) .

Modifying the Front Frame

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Illustration 3	g01585913

1. Use Illustration 3 for the location and weld the following parts onto the front frame:
   • One 4I-2201 Bar (1)

   • One 091-1735 Block (2)

Modifying the Rear Frame

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Illustration 4	g01327084
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.

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Illustration 5	g01327134
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.

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

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Illustration 6	g01327194
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.

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

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

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

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Illustration 7	g01327249
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

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Illustration 8	g01325123

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) .

2. 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.

3. 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.

4. 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.

5. 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.

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

7. Use the following hardware and install the axle oil cooler:
   • Four 8T-4121 Hard Washers (9)

   • Four 8T-4136 Bolts (10)

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

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Illustration 9	g01434029
Rear view of engine

1. Remove the 246-6296 Serpentine Belt .

2. Remove the 220-1858 Serpentine Belt .

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

4. Use the following hardware and install the 276-7533 Bracket As (5) onto the engine:
   • Four 8T-4196 Bolts (10)

   • Four 8T-4121 Hard Washers (9)

5. Use the following hardware and install the 215-3013 Gear Pump Gp (Axle Oil Cooler) (2) onto the 276-7533 Bracket As (5) :
   • Two 118-9573 Bolts (8)

   • Two 8T-4121 Hard Washers (9)

6. 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) :
   • One 6V-3960 Bolt (7)

   • One 8T-4205 Hard Washer (1)

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

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

9. Use the following hardware and secure the 301-0359 Hose As (6) :
   • One 091-9035 Spacer (7)

   • One 6D-4246 Clip (10)

   • One 8T-4182 Bolt (13)

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

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Illustration 10	g01441799
Rear view of engine

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

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Illustration 11	g01441800
Top view of air conditioner lines group

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

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

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

5. Remove the following hardware:
   • One 5I-3883 Bracket As (E-)

   • Two 8T-4121 Hard Washers (F)

   • One 8T-4133 Nut (G)

   • One 8T-4196 Bolt (H)

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Illustration 12	g01442676
Rear view of engine

6. Use the following hardware and install the 276-7533 Bracket As (5) onto the engine:
   • Four 8T-4196 Bolts (14)

   • Four 8T-4121 Hard Washers (12)

7. Use the following hardware and install the 215-3013 Gear Pump Gp (Axle Oil Cooler) (2) onto the 276-7533 Bracket As (5) :
   • Two 118-9573 Bolts (9)

   • Two 8T-4121 Hard Washers (12)

8. 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) :
   • One 6V-3960 Bolt (11)

   • One 8T-4205 Hard Washer (15)

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

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

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

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

13. Use the following hardware and secure the 301-0359 Hose As (6) onto 276-7533 Bracket As (5) :
    • One 091-9035 Spacer (7)

    • One 6D-4246 Clip (10)

    • One 8T-4121 Hard Washer (12)

    • One 8T-4182 Bolt (13)

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

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Illustration 13	g01382283
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.

2. On machines without air conditioning, install the following hardware:
   • One 191-7699 Bracket As (3)

   • One 130-5300 Clip (4)

   • One 3E-9854 Bolt (6)

   • One 8T-4121 Hard Washer (7)

   • One 8T-4136 Bolt (8)

   • One 8T-4224 Hard Washer (9)

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

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

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Illustration 14	g01383853
Right hand view of cab

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

Installation of the Water Lines Gp for the Axle Oil Cooler

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Illustration 15	g01327513
Front view of engine

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Illustration 16	g01448231
View A-A and View B-B from Illustration 16

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Illustration 17	g01327545

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.

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

3. Remove the plug assembly from the elbow group.

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

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

6. 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) .

7. Use the following hardware and secure the 5P-0767 Hose (18A) :
   • Two 7K-1181 Cable Straps (2)

   • One 193-1034 Bracket As (5)

   • One 3S-7608 Clip (7)

   • Two 4S-1962 Clips (8)

   • One 7X-2552 Bolt (10)

   • One 8M-2769 Clip (11)

   • Two 8T-4121 Hard Washers (12)

   • One 8T-4133 Nut (13)

   • One 8T-4136 Bolt (14)

   • One 8T-4137 Bolt (15)

   • One 9X-8257 Washer (17)

   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).

8. 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.

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

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

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

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

13. 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) .

14. Use the following hardware and secure the 5P-0767 Hose (18B) :
    • One 7K-1181 Cable Strap (2)

    • Two 4S-1962 Clips (8)

    • One 6V-1889 Clip (9)

    • Three 8T-4121 Hard Washers (12)

    • One 8T-4133 Nut (13)

    • One 8T-4136 Bolt (14)

    • One 8T-4195 Bolt (16)

    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

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Illustration 18	g01328758

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Illustration 19	g01448242

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Illustration 20	g01434211

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Illustration 21	g01434221

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:
   • Two 8T-4195 Bolts (59)

   • Two 8T-4121 Hard Washers (53)

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

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

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

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

6. 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) :
   • One 8T-4186 Bolt (58)

   • One 8T-4121 Hard Washers (53)

   • One 091-0081 Spacer (3)

   • One 4H-7655 Tube Clamp (41)

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

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

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

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

11. 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) :
    • One 8T-4186 Bolt (58)

    • One 8T-4121 Hard Washers (53)

    • One 123-9814 Spacer (6)

    • One 5K-2697 Tube Clamp (42)

12. 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) .

13. 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.

14. 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) .

15. 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.

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

17. Use the following hardware and mount a 251-6351 Magnetic Filter (Axle Oil Cooler) (28) onto the 242-8418 Bracket As (25) :
    • One 162-8352 U-Bolt (12)

    • Two 8T-4121 Hard Washers (53)

    • Two 8T-4133 Nuts (54)

18. 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.
    • Two 8T-4121 Hard Washers (53)

    • Two 8T-4136 Bolts (55)

19. Use the following hardware and mount the other 251-6351 Magnetic Filter (Axle Oil Cooler) (28) onto the 153-3495 Bracket As (10) :
    • One 162-8352 U-Bolt (12)

    • Two 8T-4121 Hard Washers (53)

    • Two 8T-4133 Nuts (54)

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

21. 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:
    • Two 8T-4121 Hard Washers (53)

    • Two 8T-4136 Bolts (55)

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

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

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

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

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

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

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

29. 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).

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

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

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

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

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

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

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

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

38. 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).

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

40. 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) .

41. 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.

42. 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) .

43. 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.

44. 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) .

45. 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.

46. 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) .

47. 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.

48. 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) .

49. 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.

50. 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 .

51. 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 .

52. 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 .

53. 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.

54. 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) .

55. Refer to Illustration 18 through Illustration 21. Use the following hardware and secure the hoses:
    • Two 7K-1181 Cable Strap (1)

    • One 8R-5144 Washer (2)

    • One 114-9224 Spacer (4)

    • One 115-9664 Hose As (5)

    • One 153-3495 Bracket As (11)

    • One 279-6141 Bracket As (30)

    • One 279-6143 Bracket As (31)

    • Two 130-9984 Clip (32)

    • One 1S-0833 Clip (44)

    • Two 5P-7468 Clips (45)

    • Two 5P-7469 Clips (46)

    • Two 5P-8444 Grommets (47)

    • Five 6V-1889 Clips (48)

    • One 7D-1553 Clip (50)

    • One 7D-4092 Clip (51)

    • Six 7D-7233 Clips (52)

    • Seventeen 8T-4121 Hard Washers (53)

    • Four 8T-4133 Nuts (54)

    • Four 8T-4136 Bolts (55)

    • Four 8T-4137 Bolts (56)

    • Two 8T-4179 Bolts (57)

    • Five 8T-4195 Bolts (59)

    • Two 8T-4223 Hard Washers (60)

    • One 8T-5005 Bolt (61)

    • One 9Y-2700 Spacer (62)

Installation of the Power Train Guard Gp

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Illustration 22	g01326308
Top and right side view of the power train guard gp

1. Use the following hardware and install the 153-3715 Plate (1) :
   • Four 7X-2552 Bolts (3)

   • Four 3E-9411 Hard Washers (2)

Installation of the Axle Oil Cooler Guard Gp

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Illustration 23	g01325607
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.

2. 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.

3. 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) :
   • Two 6V-3668 Bolts (3)

   • Two 7X-0618 Hard Washers (4)

4. Use the following hardware and install a 212-7754 Plate (10) onto the 212-7753 Plate As (2) :
   • Two 8T-4186 Bolts (9)

   • Two 8T-4121 Hard Washers (8)

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Illustration 24	g01325618
View of right side and top of front axle guard

5. 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.

6. 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.

7. 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) :
   • Two 6V-3668 Bolts (3)

   • Two 7X-0618 Hard Washers (4)

8. Use the following hardware and install a 212-7754 Plate (10) onto the 212-7753 Plate As (2) :
   • Two 8T-4186 Bolts (9)

   • Two 8T-4121 Hard Washers (8)