Operation and maintenance manual

Section 210-0040
SM 2118 Rev 1 11-04
5
Cooling System - Radiator and Mounting
11. Install top baffle (1, Fig. 1) to top front of the
radiator assembly and secure with bolts and washers.
12. Position side baffles (2 & 3, Fig. 1) to radiator
assembly and secure with bolts and washers.
13. Fit drain hose and fittings (17 - 22, Fig. 1) to
bushing (16, Fig. 1) in LH tank (3).
14. Position fan plate assembly (7) to radiator
assembly and secure to supports and columns (5 & 6)
using bolts and washers.
15. Fit fan drive motor (12) to motor carrier frame (9).
Refer to Section 210-0010, COOLING FAN AND
MOTOR.
16. Install motor carrier frame (9) to radiator assembly
and secure with bolts (19), lockwashers (20) and
washers (21).
Note: Ensure clearance around cooling fan tips to plate
assembly is of equal dimension all round.
17. Position fan guard (10) to radiator assembly and
secure using bolts and washers.
INSTALLATION
Numbers in parentheses refer to Fig. 1 & 4, unless
otherwise specified.
Note: Tighten all fasteners without special torques
specified to standard torques listed in Section
300-0020, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
WARNING
To prevent personal injury and property
damage, be sure lifting equipment is properly
secured and of adequate capacity to do the job
safely.
1. If removed, secure bottom baffle (4) to the vehicle
with bolts (13), washers (14) and locknuts (15).
2. Using suitable lifting equipment, position radiator
assembly to mounting brackets on the frame and
secure with bolts (7), snubbing washers (8) and locknuts
(9). Tighten bolts (7) to a torque of 165 Nm (122 lbf ft).
3. Install air inlet pipe (4, Fig. 3) between engine
turbocharger and charge cooler assembly (2, Fig. 3)
and secure with hoses (6, Fig. 3) and clamps (5, Fig. 3).
4. Install air outlet pipe (3, Fig. 3) between engine inlet
manifold and charge cooler assembly (2, Fig. 3) and
for possible damage. Repair any damage discovered if
equipped to do so, or, have repairs made at a reputable
radiator repair shop.
3. Clean radiator LH tank (3) and RH tank (4) of all
traces of corrosion, scale and old joint material.
ASSEMBLY
Numbers in parentheses refer to Fig. 2, unless
otherwise specified.
Note: Tighten all fasteners to standard torques listed in
Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATION.
1. If removed, apply Loctite 225 to threads of bushing
(16, Fig. 1) and install in LH tank (3).
2. Fit new joint (2) on radiator LH tank (3) and secure
LH tank (3) to radiator core (1) and supports with bolts,
washers and nuts.
3. Fit new joint (2) on radiator RH tank (4) and secure
RH tank (4) to radiator core (1) and supports with bolts,
washers and nuts.
Note: Tighten LH tank (3) and RH tank (4) to radiator
core (1) from the centre out to ensure an evenly spread
load.
4. If removed, apply Loctite 225 to threads of elbow
(29, Fig. 1) and install in LH tank (3) noting orientation
of elbow as identified at disassembly.
5. If removed, install new rubber mountings (6, Fig. 1)
in mounting brackets on side tanks (3 & 4).
6. Position top column (5) to radiator assembly and
secure to side tanks (3 & 4) with bolts, washers,
lockwashers and nuts.
7. Position bottom column (6) to radiator assembly and
secure to side tanks (3 & 4) with bolts, washers,
lockwashers and nuts.
8. Secure mounting brackets to side tanks (3 & 4), as
identified at disassembly, with bolts and washers.
9. Position charge cooler (18) to mounting brackets and
secure with bolts, washers and spacers.
10. Install fuel cooler and hydraulic oil cooler to radiator
assembly picking up mounting locations and hardware
as identified at disassembly.