793C XQ Off-Highway Truck and 793C Off-Highway Truck Engine Supplement Radiator - Remove Caterpillar

Removal Procedure

Start By:

1. Remove the ladder. Refer to Disassembly and Assembly, "Ladder - Remove and Install" for the correct procedure.

2. Remove the fan. Refer to Disassembly and Assembly, "Fan Drive (Hydraulic) - Remove" for the correct procedure.

Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL OR THE INSTALLATION. THIS TOOLING IS SHOWN TO ASSIST THE EXPERIENCED SERVICEMAN.

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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the cooling system pressure cap is cool enough to touch with your bare hand. Remove the cooling system pressure cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.

Note: If the left radiator is being removed, both radiators must be drained. If the right radiator is being removed, only drain the right radiator.

1. Drain engine coolant from the appropriate radiator into a suitable container. The total cooling system contains approximately 681 L (150 US gal) of coolant.

2. Evacuate the air conditioning system. Refer to Service Manual, "Air Conditioning and Heating R-134a All AVSpare Machines".
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   Illustration 1	g00915228

3. Loosen clamps (4). Disconnect bottom radiator hose (5). Remove clips (1) on drain hose (6).

4. Remove lower radiator mount bolts (2). Remove 1/2 mount (3).

5. Repeat Step 4 for the opposite lower radiator mount.
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   Illustration 2	g00915231

6. Remove bolts (8) that secure handhold (7). Remove the handhold from the truck.
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   Illustration 3	g00915230

7. Disconnect harness assembly (9) for warning light (12).
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   Illustration 4	g00915229

8. Attach a suitable lifting device to lower grill assembly (10). Attach the lifting device to a suitable hoist. The weight of grill assembly is approximately 70 kg (154 lb).
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   Illustration 5	g00916070

9. Remove bolts (14) that secure lower grill assembly (10) to the truck.

10. Repeat Step 9 for opposite side of grill assembly.

11. Remove lower grill assembly (10) from the truck.

    Note: Do not damage harness assembly for warning light (12) when panel (11) is removed.

12. Remove bolts (13) that secure panel (11). Remove the panel from the truck.
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    Illustration 6	g00915232

13. Remove bolts (16) that secure the elbow to radiator (15). Disconnect elbow (17) from the radiator.
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    Illustration 7	g00915309

14. Disconnect hose assemblies (21) from condenser (18). Remove hose clips (19) in order to disconnect hose assemblies from radiator (15). Lay hose assemblies aside.

15. Disconnect harness clips (20) from the radiator.
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    Illustration 8	g00915320

16. Loosen clamp (23) and disconnect hose (24) from elbow (22).
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    Illustration 9	g00915347

17. Install Tooling (A) to both sides of radiator (15).
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    Illustration 10	g00915367

18. Attach a suitable lifting device to Tooling (A). The weight of a radiator assembly is approximately 735 kg (1620 lb).
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    Illustration 11	g00915381

19. Remove bolts (25) that secure radiator (15).

20. Repeat Step 19 for opposite side of radiator.
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    Illustration 12	g00915390

21. Lift radiator (15) slightly and turn in order to remove the radiator from the truck.