Installation Of D5 Radiator Conversion Groups{1353} Caterpillar


Installation Of D5 Radiator Conversion Groups{1353}

Usage:



D5H ( 1DD261, 1YD571, 2SD243, 3MD431, 4KD261, 7NC571, 8RC431, 9HC243)

Introduction

This instruction gives the recommended procedure for replacing the folded core module type radiator with a new conventional multi-row radiator.

The conventional multi-row radiator has more space between the fins than the folded core modules. This will allow debris to flow through and also make it more resistant to plugging. In many applications, this can result in decreased maintenance and improved engine performance.

Do not perform any procedure, outlined in this publication, or order any parts until you read and understand the information contained within.

Order the individual parts for the conversion group for your machine only.

(Not Serviced as a Group)

* D5H with direct drive transmission.* D5H with power shift transmission.* D5H with sound suppression and power shift.

The exact cause of over-heating should be determined before a conversion group is installed.

Reference: Service Manual, Operation and Maintenance Manual, Parts Book and Special Instructions SEHS8864 Assembly of Multiple Row Modules on Folded Core Radiators.

Necessary Parts

Direct Drive Transmission

Power Shift Transmission

Vehicles With Sound Suppression And Power Shift

Removing Folded Cores

1. Drain coolant from radiator. Refer to the Operation and Maintenance Manual.

2. Remove engine side covers (1), exhaust pipe (2) and pre-cleaner (3).

3. Remove the pre-cleaner hose located under the hood.

4. Remove hood assembly (4) and lower side panels (5).

5. Remove fan guard bolts (6) from the radiator guard. Leave the fan guard in position.

6. Remove front grill assembly (7).

7. Disconnect the electrical connector that goes to the horn and lights.

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

Always wear goggles when the air conditioning system is opened. This system is charged with Freon-12 (ccL2F2-Dichlorodifluoromethane) which is not toxic or flammable. But, there is a reason for caution. When Freon-12 makes contact with a flame, lethal phosgene gas is made. INHALING FREON THROUGH A LIGHTED CIGARETTE CAN CAUSE VIOLENT ILLNESS. This system is under pressure at all times, engine running or not. HEAT MUST NEVER BE PUT ON A CHARGED SYSTEM. See AIR CONDITIONING AND HEATING SERVICE MANUAL Form No. SENR3334 for more information on procedures and requirements on removal and installation of lines and refrigerant for the system.

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

8. Disconnect the air conditioning hoses (if equipped).

9. Disconnect the upper and lower radiator hoses.

10. Use a hoist to aid in removal of radiator guard (8). The unit weighs approximately 227 Kg (500 lb).

NOTE: Inspect the fan and fan blades. Repair or replace as necessary.

11. Open radiator fill door (9), so that the radiator does not hit the fill door spring when it is removed.

12. Remove the radiator from the radiator guard.

13. Remove and discard the baffle assembly (Direct Drive Machines only).

14. Remove top tank (10).

15. Remove (cut) block (11) and block (12) from top tank (10) as follows:


Conversion Group (Left Side).

a. Remove left side block (11) for All Vehicles.

b. Remove right block also, (12) for Power Shift Vehicles.

NOTE: A new upper tank is supplied for machines with sound suppression and power shift.


Conversion Group (Right Side).

16. Drill a hole or holes in the radiator guard according to the dimensions shown in the illustrations.

17. Remove and discard folded core assemblies (13).

Installing New Multi-Row Modules

1. Thoroughly clean holes (A) for the lower and upper tank assembly modules. This will ensure a good seal for the new core assemblies.

NOTE: New top and bottom tank assemblies are provided, for vehicles with sound suppression.

2. Install new seals for the lower tank assembly.

NOTE: Refer to SEHS8864 for correct positioning and location of seals and core assemblies. There are two sizes of seals. Make sure the correct size seals are used for each core assembly.

3. Lubricate the sealing area with a light coat of 5P3975 Rubber Lubricant or equivalent.

4. Install a new 9Y4644 Core Assembly (1) at the left end position as shown. (The 9Y4644 Core Assembly is "rounded" at top and bottom).

5. Install the next three 9Y0067 Core Assemblies (2). These will have the square tanks.

6. Install a 9Y4644 Core Assembly (3) at the right end or sixth position as shown. It will be rounded at the top and bottom (it must be installed before the module next to it because it is recessed behind the radiator frame).

7. Install the remaining core assembly.

* The direct drive machine will have only five core assemblies. It will have a baffle assembly in the sixth position.

8. Install the correct seals at each location in the upper tank assembly. Lubricate the sealing area with a light coat of 5P3975 Rubber Lubricant.

9. Position the top tank on the core assemblies and fasten it to the channel assembly. Make sure all core assemblies are correctly seated in the tank holes.

10. Use bolts to fasten the strap assemblies to the center stiffening plates.

11. Install the baffle assembly (direct drive only).

12. Install the fan shields.

13. Use 9B7237 Bolts with 5P1075 Washers to fasten 9Y6702 Bracket to the radiator top tank as follows:

* Left side only for direct drive machines.* Both sides for all other machines.

14. Use bolts to fasten the radiator to the radiator guard. Use a 4L6454 Bolt with a 5P1075 Washer and 6V8801 Nut to install 9Y6702 Bracket, or Brackets, from the radiator to the radiator guard. (Holes were drilled in Step 16, in the preceding topic.)

15. Install radiator guard on the machine.

16. Connect the radiator hoses, electrical wire and air conditioner lines (if equipped).

17. Fasten fan guard to shields.

18. Install the grill on the radiator guard.

19. Install the hood, exhaust pipe, air cleaner, lower side panels and the upper side panels.

20. Fill the radiator with coolant and charge the air conditioner (if equipped). Check for leaks. (Refer to the Operation and Maintenance Manual for specifications and capacity).

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