Operation and maintenance manual

Section 210-0100
Cooling System - Hydraulic Oil Cooler
SM 1403 Rev 1 10-03
2
1. Position the vehicle in a level work area, ensure the
body is fully lowered, apply the parking brake and
switch off the engine. Turn steering wheel several
times to relieve any pressure in the steering circuit.
2. Block all road wheels and place the battery master
switch in the 'Off' position.
3. Remove blanking cap from remote drain line at the
bottom of the hydraulic tank. Install a length of hose on
remote drain fitting, open drain cock and drain
hydraulic oil into a suitable container. Close drain
cock, remove hose and reinstall blanking cap.
4. Remove mounting hardware securing the front grille
on the hood assembly and remove grille for access to
hydraulic oil cooler (4).
5. Pull on handle to release hood catch mechanism
and raise hood.
6. Remove oil outlet line (7) from hydraulic oil cooler
(1) and drain oil into a suitable container.
7. Remove oil inlet line (8) from hydraulic oil cooler (1)
and drain any remaining oil into a suitable container.
8. Remove bolts (18), lockwasher (12) and plate (15)
securing oil cooler (4) to brackets (1 & 5).
9. Remove bolts (17) and lockwashers (12) securing
bracket (5) to bracket (1) and remove bracket (5).
10. Remove bolts (29) and lockwasher (30) securing
bracket (1) to fuel cooler bracket (22) and the radiator
assembly and remove bracket (3).
11. Remove bolts (29), lockwasher (30) securing
bracket (3) fuel cooler bracket (21) and the radiator
assembly and remove bracket (3).
12. If required remove bolt (24) washer (26) and
locknut (27) securing fleximount (23) to fuel cooler (20)
and brackets (21) and (22).
13. Disconnect oil inlet & outlet line (7 & 8) and filter
line (28) from diverter tube. Blank off open ends and
plug ports to prevent ingress of dirt.
14. If required remove bolts (32), lockwasher (33) and
split flanges (34) securing diverter tube (31). Remove
diverter tube (31), discard 'O' ring (35) and blank off
open end.
15. Remove bolt (11), lockwasher (12), nuts (14) and
clips (13) securing lines (7 & 8).
16. If oil inlet & outlet lines (7 & 8) require to be
replaced, note location of all clips (13) and remove
lines from the vehicle.
CLEANING AND INSPECTION
1. Inspect fins on hydraulic oil cooler carefully, for
trapped debris and damage. If hydraulic oil cooler fins
show signs of leakage or are excessively damaged, it
must be replaced as an assembly.
2. Check connectors in hydraulic oil cooler ports for
damaged threads. Replace if required.
3. After hydraulic oil cooler is completely drained,
circulate a solution of Agmasol PS40 through the
cooler tubes.
4. If cooler tubes are badly clogged, circulate an oakite
or alkaline solution through the hydraulic oil cooler, in
the reverse direction to normal flow, for approximately
15 minutes. The duration of circulation depends on how
badly clogged the cooler tubes are. Flush thoroughly
with clean hot water.
INSTALLATION
Numbers in parentheses refer to Fig. 1.
Note: Tighten all fasteners to standard torques
specified in Section 300-0080, STANDARD BOLT
AND NUT TORQUE SPECIFICATIONS.
1. Remove blanking cap from body control valve and
diverter tube (31).
2. Install new ‘O‘ ring (35) in split flange end of
diverter tube (31) and connect to body control valve
with split flanges (34), bolts (32) and lockwasher (33).
Do not tighten bolts (32) securely at this point.