Remove/install radiator unit

AR20.20-Y-3871B

Remove/install radiator unit

02.12.2019

Engine

410.950 in model 400.543/571/594/597

Radiator and charge air cooler removal procedure

1

AC high and low pressure pipes mounting bracket

4

AC condenser (LHS) bottom

2

AC condenser (RHS) bottom

5

AC condenser (LHS) top

3

AC condenser (RHS) top

6

AC condenser mesh (RHS) mounting bolt

7

AC condenser mesh (LHS) mounting bolt

11

Electrical connector

8

Engine oil filling hose

12

Coolant heater hose

9

Engine oil filling hose mounting bolts

13

Radiator top hose

10

Coolant tank bracket

14

Over flow hose

17

Coolant hose

15

Heater pipe

18

Heater hose

16

Heater hose worm-drive clamp

19

De-aeration tank bottom pipe

22

Fan belt

20

Radiator worm hose

23

Viscous clutch

21

De-aeration tank

24

Fan blade

25

Radiator shroud

28

Transmission oil outlet pipe

26

Radiator bottom hose

29

Radiator mounting bracket (RHS)

27

Transmission oil inlet pipe

30

Radiator mounting bracket (LHS)

31

Radiator and charge air cooler assembly

34

Radiator

32

Charge air cooler

35

Rubber bush

33

Side bracket

36

Transmission oil hose adaptor

Radiator and charge air cooler refitment procedure

31

Radiator and charge air cooler assembly

34

Radiator

32

Charge air cooler

35

Rubber bush

33

Side bracket

36

Transmission oil hose adaptor

25

Radiator shroud

28

Transmission oil outlet pipe

26

Radiator bottom hose

29

Radiator mounting bracket (RHS)

27

Transmission oil inlet pipe

30

Radiator mounting bracket (LHS)

19

De-aeration tank bottom pipe

22

Fan belt

20

Radiator worm hose

23

Viscous clutch

21

De-aeration tank

24

Fan blade

14

Over flow hose

17

Coolant hose

15

Heater pipe

18

Heater hose

16

Heater hose worm-drive clamp

7

AC condenser mesh (LHS) mounting bolt

11

Electrical connector

8

Engine oil filling hose

12

Coolant heater hose

9

Engine oil filling hose mounting bolts (9)

13

Radiator top hose

10

Coolant tank bracket

1

AC high and low pressure pipes mounting bracket

4

AC condenser (LHS) bottom

2

AC condenser (RHS) bottom

5

AC condenser (LHS) top

3

AC condenser (RHS) top

6

AC condenser mesh (RHS) mounting bolt

 

Remove/install

1

Tilt the cabin

Tilt cab to repair position, tilt back

AR60.80-Y-0010A

2

Drain coolant from radiator

Drain/pour in coolant

AR20.00-Y-1142B

3

Remove charge air cooler inlet and outlet hoses

Testing and repair work - Air intake, charging

AR09.00-Y-0861A

4

Remove AC high and low pressure pipes mounting bracket (1) from radiator bracket

5

Remove AC condenser (RHS) bottom (2) and (RHS) top (3) from charge air cooler


Handle condenser carefully during removal
It may cause damages to condenser fins.

 Condenser need not be removed for removal of radiator.

If condenser is removed,



AC gas needs to be refilled.

6

Remove AC condenser (LHS) bottom (4) and (LHS) top (5) from charge air cooler

7

Remove AC condenser mesh (RHS) mounting bolt (6) and (LHS) mounting bolt (7) from charge air cooler

8

Remove engine oil filling hose (8) mounting bolts (9) from charge air cooler

9

Remove engine oil filling hose from coolant tank bracket (10)

10

Disconnect electrical connector (11) from the de-aeration tank

11

Remove the coolant heater hose (12) worm drive clamps using screwdriver

12

Remove the radiator top hose (13) worm-drive clamp using screwdriver

13

Remove over flow hose (14) worm-drive clamp from de-aeration tank using screwdriver

14

Remove heater pipe (15) from radiator bracket

15

Remove heater hose worm-drive clamp (16) between inlet pipes to heater core pipe using screwdriver

16

Remove coolant hose (17) worm-drive clamp from de-aeration tank to water pump bottom hose using screwdriver

17

Remove heater hose (18) worm-drive clamp from de-aeration tank using screwdriver

18

Remove tag and coolant hose (17) worm-drive clamp from between de-aeration tank to oil cooler using screwdriver

19

Remove de-aeration tank bottom pipe (19) from radiator bracket

20

Remove the radiator worm hose (20) worm-drive clamp using screwdriver

21

Remove de-aeration tank (21)

22

Remove fan belt (22)

 Installation: By using 19 mm ring spanner.

23

Remove viscous clutch (23)


Carefully remove/insert the fan and fan clutch from/to radiator
It may cause damage to the radiator fins.

24

Remove fan blade (24)

25

Remove radiator shroud (25) from radiator bracket

26

Remove radiator bottom hose (26) worm-drive clamp from radiator using screwdriver

27

Remove transmission oil inlet pipe (27) and outlet pipe (28)

 Installation: By using 22 mm open-end torque wrench.

28

Remove radiator mounting bracket (RHS) (29) and (LHS) (30) from cabin mounting bracket

29

Remove radiator and charge air cooler assembly (31) from vehicle using crane and rope


Carefully remove the radiator assembly from the chassis.
It may cause any damages to radiator fins.

 Never remove the side bracket mounting bolts to avoid misalignment of the radiator and the charge air cooler.

30

Remove charge air cooler (32) from radiator

31

Remove radiator (RHS) mounting bracket with side bracket (33)

32

Remove radiator (LHS) mounting bracket from radiator (34)

33

Remove rubber bush (35) from radiator

34

Remove transmission oil hose adaptor (36) from radiator

 Installation:
Do not directly apply pressurized water jet onto the radiator.
It damage's the radiator fins.

 Installation: By using 24 mm open-end torque wrench.
Hoses should not be kinked or stressed while assembly. Check condition of coolant hoses and clamp.
Ensure worm-drive clamps are tightened properly to avoid any leakages.

If found damaged,



Replace hoses/clamp.

35

Install in the reverse order