Operation and maintenance manual

Section 210-0040
Cooling System - Radiator and Mounting
SM 2118 Rev 1 11-04
4
6. Remove bolts and washers securing top baffle (1,
Fig. 1) to radiator assembly. Remove top baffle (1, Fig.
1) from radiator assembly.
7. Remove bolts and washers securing LH baffle (2,
Fig. 1) and RH baffle (3, Fig. 1) to radiator assembly.
Remove baffles (2 & 3, Fig. 1) from radiator assembly.
Note: Take care not to damage radiator core, charge
cooler (18) core, fuel cooler core and hydraulic oil cooler
core during disassembly.
8. Remove mounting hardware securing fuel cooler and
hydraulic oil cooler to radiator assembly. Note which
radiator bolts are used for mounting coolers to aid in
assembly. Remove coolers from radiator assembly.
9. Remove bolts, washers and spacers securing
charge cooler (18) to mounting brackets. Remove
charge cooler (18) from radiator assembly.
10. Identify mounting brackets for ease of assembling
and remove bolts, washers and mounting brackets
from side tanks (3 & 4).
11. Remove bolts, washers, lockwashers and nuts
securing top column (5) to LH tank (3) and RH tank (4).
Remove top column (5).
12. Remove bolts, washers, lockwashers and nuts
securing bottom column (6) to LH tank (3) and RH tank
(4). Remove bottom column (6).
13. Remove bolts, washers and nuts securing LH tank
(3) to radiator core (1). If required, remove drain hose
and fittings (16 - 22, Fig. 1) and elbow (29, Fig. 1) from
LH tank (3). Remove LH tank (3) assembly and discard
joint (2).
14. Remove bolts, washers and nuts securing RH tank
(4) to radiator core (1). Remove RH tank (4) assembly
and discard joint (2).
15. If damaged, remove rubber mountings (6, Fig. 1)
from mounting brackets on side tanks (3 & 4) and
discard.
INSPECTION
Numbers in parentheses refer to Fig. 2.
1. Steam clean all parts thoroughly with a suitable
solvent.
2. Examine radiator core (1), charge cooler (18) core,
fuel cooler core and hydraulic oil cooler core carefully
20. If required, remove bolts (13), washers (14) and
locknuts (15) securing bottom baffle (4) on the vehicle.
Note: If Header Tank (36) requires to be removed,
follow steps 21 through 26.
21. With suitable container in position, remove lower
drain plug from header tank (36) to ensure coolant has
been drained from header tank (36). When all coolant
has been drained, apply Loctite 225 to drain plug and
reinstall in header tank (36).
22. Disconnect overflow line (43) from header tank (36).
23. Ensure deaeration lines (28, 30 & 32) connected to
header tank (36) are identified for ease of installation
and disconnect deaeration lines. Fit blanking caps to
open lines and fittings.
24. Slacken clamp (42) and disconnect make-up line
(41) from header tank (36). Blank off open line end.
25. Following removal instructions in Section
100-0040, HOOD AND MOUNTING, remove goalpost
and header tank (36) as an assembly from the vehicle.
26. Remove bolts (39), nuts (37) and washers (38)
securing header tank (36) to goalpost. Remove header
tank (36) from goalpost.
DISASSEMBLY
Numbers in parentheses refer to Fig. 2, unless
otherwise specified.
1. Remove bolts and washers securing fan guard (10)
to radiator assembly. Remove fan guard (10) from
radiator assembly.
2. Remove bolts (19) and washers (20,21) securing
motor carrier frame (9) to radiator assembly. Remove
motor carrier frame (9) from radiator assembly.
3. Following removal instructions in Section
210-0010, COOLING FAN AND MOTOR, remove fan
drive motor (12) from motor carrier frame (9).
4. Remove bolts and washers securing fan plate
assembly (7) to radiator assembly. Remove fan plate
assembly (7) from radiator assembly.
5. Lay radiator assembly down flat on wooden blocks
with baffle plates (1, 2 & 3, Fig. 1) facing up.