Operation and maintenance manual

Section 210-0040
Cooling System - Radiator and Mounting
SM 2118 Rev 1 11-04
6
secure with hoses (6, Fig. 3), elbow (7, Fig. 3) and
clamps (5, Fig. 3).
5. Install coolant outlet pipe (26) between engine water
pump inlet and bottom port on radiator assembly and
secure with hoses (24) and clamps (23).
6. Install coolant inlet pipe (25) between engine
thermostat housing and top port on radiator assembly
and secure with hoses (24) and clamps (23).
7. If removed, apply Loctite 225 to threads of elbow
(27) and install in coolant inlet pipe.
8. Remove blanking caps from deaeration lines
(28 & 30) and connect deaeration line (28) to elbow (27)
in coolant inlet pipe (25) and deaeration line (30) to
elbow (29) in top of radiator assembly. Do not clip lines
at this point.
9. Remove blanking caps from fuel cooler lines and
fittings, hydraulic oil cooler lines and fittings, and fan
drive motor (12, Fig. 2) lines and fittings. Connect all
fuel lines to fuel cooler, hydraulic lines to hydraulic oil
cooler and hydraulic lines to fan drive motor (12, Fig. 2)
as identified at removal.
10. Secure all lines with clips and clamps as removed
during removal. Ensure no lines are chaffing on sharp
edges or resting against areas where heat will be
evident.
11. Fit 1-off nuts (50) and lockwashers (47) to each
rod (51) and run up full length of thread. Locate rod end
through holes on radiator support arms. Take remaining
nuts (50) and lockwashers (47) and thread onto rod
(51), securing brace rods to radiator brackets.
12. Fit 1-off nuts (46), lockwashers (47),washers (48) and
rubber mounts (49) to both rods (51), run up full length of
the thread. Locate rod ends trhough frame support brackets.
Fit remaining nuts (46), lockwashers (47) washers (48)
and rubber mounts (49) to end of rods (51) and tighten in
accordance with standard torques listed in Section
300-0020, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
13. Ensure fittings, lines and pipes are securely
tightened to prevent leaks at initial fill and start up.
Note: If Header Tank (36) was removed and has not
yet been installed, proceed from step 14, however, if
header tank (36) was not removed or has been
reinstalled, proceed from step 20.
14. Fit header tank (36) to goalpost and secure using
bolts (39), nuts (37) and washers (38).
15. Following installation instructions in Section
100-0040, HOOD AND MOUNTING, install header tank
(36) and goalpost assembly on the vehicle.
16. Remove blanking from make-up line (41) and
connect to header tank (36). Secure with clamp (42).
17. Remove blanking caps from deaeration lines
(28, 30 & 32) and connect to appropriate fittings on
header tank (36), as noted on removal.
18. Connect overflow line (43) to header tank (36).
19. Secure all lines with clips and tie clips as removed
during removal. Ensure no lines are chaffing on sharp
edges or resting against areas where heat will be
evident.
Note: If make-up line (41) had been removed
completely, ensure that firemaster hose (40) is
correctly fitted and is properly clamped away from the
engine turbocharger.
20. Refer to Section 210-0000, COOLING SYSTEM for
correct selection of coolant. Fill the cooling system
through filler in header tank (36) with coolant until coolant
level stabilizes at the bottom of filler neck.
21. Check all line and pipe connections for leaks prior
to starting the vehicle. Tighten as required.
22. Switch the battery master switch to the 'On'
position, start up the engine and check for leaks.
Tighten lines and fittings and top up coolant level as
required.
23. Entrapped air must be purged after filling the
cooling system. To do this, allow the engine to warm
up with filler cap (35) still removed. With the
transmission in neutral, increase engine speed above
1000 rev/min and add coolant as required. Vent the
cock on the water return line at the water-jacketed
turbocharger until a steady stream of water (no air) is
seen. Close the cock.
24. Install filler cap (35) on header tank (36) after the
coolant level has stabilized at the bottom of filler neck.
25. Following installation instructions in Section
100-0040, HOOD AND MOUNTING, install hood
assembly on the vehicle.
Note: Check that gap between hood and cowl is correct
12 mm (0.5 in) maximum).