R
TOOL OPERATING MANUAL 178-3704 Lifting Bracket Assembly European Union Compliant, CE marked SMCS: 1353-010, 1353-011, 1353-012
Used to Remove and Install AMOC Radiator Cores
NEHS0968 July 2009
The message that appears under the warning explains the hazard and can be either written or pictorially presented.
Important Safety Information
Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all-inclusive. If a tool, procedure, work method, or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.
Think Safety Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.
The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.
Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the operation, lubrication, maintenance, and repair information.
WARNING When replacement parts are required for this product, Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.
Failure to heed this warning can lead to premature failures, product damage, personal injury, or death.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING”, or “CAUTION”. The Safety Alert “WARNING” label is shown below.
WARNING The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. 2
Contents
Literature Information
Literature Section Safety Section . . . . . . . . . . . . . . . . . . . . . . . . 3 General Information Section . . . . . . . . . . . . . 3 Operation Section . . . . . . . . . . . . . . . . . . . . . 3 Maintenance Section . . . . . . . . . . . . . . . . . . . 3 Safety Section Safety Icon Nomenclature . . . . . . . . . . . . . . . 4 Personal Protection/Important Information. . . 4 Prohibited Action . . . . . . . . . . . . . . . . . . . . . 4 Hazard Avoidance . . . . . . . . . . . . . . . . . . . . 4 Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . 4 Personal Protection . . . . . . . . . . . . . . . . . . . 4 Hazard Avoidance . . . . . . . . . . . . . . . . . . . . 5 Tool Operation Hazards . . . . . . . . . . . . . . . . 5 General Information Section Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 6 References. . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 7 Additional Contact information . . . . . . . . . . . 7 Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . 7 Operation Section Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Maintenance Section Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Service Parts . . . . . . . . . . . . . . . . . . . . . . . . 14 Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Tool Disposal . . . . . . . . . . . . . . . . . . . . . . . . 15
This manual should be stored with the tool group. It contains safety information, operation instructions, and maintenance information. Some photographs or illustrations in this publication show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes. Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication. Whenever a question arises regarding your service tool or this publication, please consult Dealer Service Tools (DST) for the latest available information.
Safety Section The Safety section lists basic safety precautions. Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.
General Information Section The General Information section describes tooling functions and features. It provides useful information on individual parts, additional tooling, and resources.
Operation Section The Operation section is a reference for the new operator and a refresher for the experienced operator. Photographs and illustrations guide the operator through correct procedures for using the tool group. Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and its capabilities.
Maintenance Section The Maintenance section is a guide to tool inspection, cleaning, storage, service parts, and tool disposal. 3
Safety Section
Slipping hazard
Safety Icon Nomenclature Tripping hazard
Personal Protection/Important Information
Safety Warnings
Read the manual
Personal Protection
Ear protection
WARNING Eye protection
To avoid personal injury or death, carefully read and understand all instructions before attempting to operate any equipment or tools. Do not operate or work on a machine unless you read and understand the instructions and warnings in this and all other applicable manuals. Contact Dealer Service Tools for replacement manuals. Proper care is your responsibility. Always follow all State and Federal health and safety laws and/or local regulations.
Face protection Inspect equipment AR N I
NG
Legible information
Prohibited Action Do not weld
To prevent possible damage to your hearing, always wear ear protection when using this tool and/or working around noise generating tools.
No smoking
Hazard Avoidance Caustic fluids hazard
To avoid eye injury, always wear protective glasses or face shield. Make sure no one can be injured by flying objects or debris when using tools or working on a component.
Crushing hazard Crushing hazard (foot)
Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.
Fall hazard Fire hazard Hot fluid hazard Pinch point Pressurized air Safety alert symbol
4
Hazard Avoidance
Tool Operation Hazards
WARNING
WARNING
Clean up all leaked or spilled fluids immediately. Oil, fuel, or cleaning fluid leaked or spilled onto any hot surfaces or electrical components can cause a fire, resulting in personal injury or death.
To avoid serious injury or death, this tooling should never be used for any application other than its intended use. Improper lifting procedures can create risk for the operator and bystanders. DO NOT use the lifting bracket assembly before making sure no one will be endangered.
Personal injury can result from slips or falls. DO NOT leave tools or components laying around the work area and clean up all spilled fluids immediately.
At operating temperature, engine coolant is hot and under pressure. Personal injuries can occur from contact with hot engine coolant. Do not open or drain the system until coolant is at ambient temperature.
Personal injuries can occur as a result of using pressurized air. Maximum air pressure at the nozzle must be below 205 kPa (30 psi) for cleaning purposes. Wear protective clothing, protective glasses, and a protective face shield when using pressure air.
To avoid personal injury or death, do not exceed working load limit (WLL) of 45.4 kg (100 lbs). Overhead lifting device, shackles, and slings must have adequate weight rating.
To avoid personal injury or death, inspect tools before each use. Do not use any tool that is damaged, altered, or in poor condition. Replace all worn, cracked, or damaged parts immediately.
To avoid personal injury or death, do not stand or place any part of your body under a suspended load. Do not move a suspended load over or near other persons. Do not ride on a load being lifted. Potential pinch point. Use caution when installing or removing the lifting bracket assembly. Keep hands clear when removing or installing radiator cores.
AMOC radiator cores are heavy. Failure to properly secure a radiator core could create a tip over condition that may result in personal injury or even death. AR N I
NG
To avoid personal injury or death, do not weld on lifting bracket assembly. Do not expose to extreme heat, such as from a
Make sure all tools have a working load limit (WLL) identification that is clear and readable.
torch. The lifting bracket assembly weighs 1.3 kg (2.8 lbs). Always store laying flat to prevent falling, which can cause personal injury.
5
References (continued)
General Information Section Introduction
RENR6357 - 834H Wheel Dozer and 836H Landfill Compactor Engine Supplement
The 178-3704 Lifting Bracket Assembly is designed to lift AMOC (Advanced Modular Cooling) style radiator cores for removal, service, and installation. It is used with a suitable overhead lifting device on 950 through 994 Wheel loaders, all wheel tractors, and any vehicle using AMOC radiator cores.
SENR5895 - 854G Wheel Tractor and 992G Wheel Loader Engine Supplement RENR6207 - 988H Wheel Loader Engine Supplement RENR2018 - 994D Wheel Loader Engine Supplement RENR6264 - 990 Series II Wheel Loader and 844 Wheel Tractor Engine Supplement RENR2196 - 834G Wheel Tractor and 836G Landfill Compactor Engine Supplement
References
RENR4070 - 3408E Engine Supplement for 631G and 637G Wheel Tractor
RENR7469 - D9T Track-Type Tractor Engine Supplement
RENR1554 - 3406E Engine Supplement for 621G, 623G, and 627G Wheel Tractor
RENR7544 - D10T Track-Type Tractor Engine Supplement KENR8184 - 777F OEM Off-Highway Truck Engine Supplement KENR8187 - 773F and 775F OEM Off-Highway Truck Engine Supplement
NOTE: The list of references may change. Always locate and refer to the appropriate disassembly and assembly service manual for the most current information on radiator core service.
KENR5813 - 993K Wheel Loader Engine Supplement RENR7479 - D8T Track-Type Tractor Engine Supplement KENR6020 - 24M Motor Grader Engine Supplement RENR8908 - 992K Wheel Loader and 854K Wheel Dozer Engine Supplement RENR6303 - 994F Wheel Loader Engine Supplement
Specifications
RENR8223 - D11T Track-Type Tractor Engine Supplement RENR8255 - 770 and 772 Off-Highway Trucks Engine Supplement
C
RENR8233 - 587T Pipelayer Engine Supplement RENR3091 - 988G Wheel Loader Engine Supplement RENR8300 - 777F Off-Highway Truck Engine Supplement RENR8278 - 773F Off-Highway Truck and 775F Off-Highway Truck Engine Supplement RENR8962 - 814F Series 2 Wheel Dozer, 815F Series 2 Soil Compactor, and 816F Series 2 Landfill Compactor Engine Supplement RENR8334 - 793D Off-Highway Truck Engine Supplement
A
RENR9710 - 657G Wheel Tractor Engine Supplement
B
RENR9711 - 657G Wheel Scraper Engine Supplement RENR8602 - 631G and 637G Wheel Tractor-Scrapers Engine Supplement
0968-01
RENR7477 - 583T Pipelayer Engine Supplement RENR8808 - 844H Wheel Dozer and 990H Wheel Loader Engine Supplement 178-3704 Lifting Bracket Assembly Item A B C — —
6
Description Approximate Height Approximate Length Approximate Width Approximate Weight Working Load Limit
Specification 136 mm (5.3 in) 169 mm (6.6 in) 114 mm (4.5 in) 1.3 kg. (2.8 lbs) 45.4 kg (100 lbs)
Additional Contact Information
Operation Section
For additional product support questions concerning this tool, contact the Caterpillar Dealer Service Tools Hotline at:
WARNING Improper lifting procedures can create risk for the operator and bystanders. DO NOT use the lifting bracket assembly before making sure no one will be endangered.
U.S.A.: 1-800-542-8665 Illinois: 1-800-541-8665 Canada: 1-800-523-8665 World: 1-309-675-6277 Fax: 1-309-494-1355
[email protected]
To avoid personal injury or death, do not exceed working load limit (WLL) of 45.4 kg (100 lbs). Overhead lifting device, shackles, and slings must have adequate weight rating.
Nomenclature
Potential pinch point. Use caution when installing or removing the lifting bracket assembly. Keep hands clear when removing or installing radiator cores.
3a 5 4a
AMOC radiator cores are heavy. Failure to properly secure a radiator core could create a tip-over condition that may result in personal injury or even death.
1 4 2 5a 3
3b
Operation 1. Inspect 178-3704 Lifting Bracket Assembly (1) before each use. Do not use any tool that is damaged, altered, or in poor condition.
0968-02
WARNING At operating temperature, engine coolant is hot and under pressure. Personal injuries can occur from contact with hot engine coolant. Do not open or drain the system until coolant is at ambient temperature.
178-3704 Lifting Bracket Assembly Item 1 2 3 3a 3b 4 4a 5 5a
Description Lifting Bracket Assembly Base Plate Bail (handle) Thumbscrew Spring Pin Locking Plate Spring Hinge Rod Push Nut
Qty 1 1 1 2 2 2 4 2 4
NOTE: For more information on specific AMOC radiator core disassembly and assembly, refer to the appropriate service manual for the vehicle being serviced.
7
2. If necessary, disassemble cooling system components such as cover, top tank, core support brackets, and/or hoses, to expose the top of AMOC (Advanced Modular Cooling) radiator core (7).
NOTE: Make sure the radiator core is stable (positioned in a fixture, blocked on a work surface, or installed in a machine) before attaching the lifting bracket assembly. 4. Attach the lifting bracket assembly to the radiator core.
7
a. Position lifting bracket assembly (1) on top of radiator core (7) with base plate (2) center hole over core protrusion and locking plates (4) extending down the front and rear of the radiator core. 1
3
3a
2 7
0968-03
(7) Radiator Core. 4
NOTICE Care must be taken to ensure fluids are contained during radiator core service. Be prepared to collect coolant in a suitable container. Store and dispose of all fluids according to local, State, and Federal regulations and mandates.
0968-05
(1) Lifting Bracket Assembly. (2) Base Plate. (3) Bail. (3a) Thumbscrew (qty 2). (4) Locking Plate (qty 2). (7) Radiator Core.
3. On lifting bracket assembly (1), loosen (turn counterclockwise) thumbscrews (3a) and push down on bail (3) to allow locking plates (4) to spring outward at the bottom. 3
b. Pull up on bail (3) to push the curved lip on the bottom of each locking plate (4) inward, under edge of radiator core (7) top plate.
3a 4
1
0968-04
(1) Lifting Bracket Assembly. (3) Bail. (3a) Thumbscrews (qty 2). (4) Locking Plates (qty 2). 8
5. Attach a suitable overhead lifting device (8) to bail (3) and raise tooling with radiator core (7) attached.
3
7
NOTE: For more information on removing or installing AMOC radiator cores, refer to the appropriate disassembly and assembly service manual. 8 4
3
0968-06
7
(3) Bail. (4) Locking Plate (qty 2). (7) Radiator Core.
c. Tighten (turn clockwise) thumbscrews (3a) just enough to secure locking plates (4) against radiator core (7).
NOTICE To avoid damage to tooling and/or radiator cores, only tighten thumbscrews enough to secure lock plate to radiator core. 0968-08
(3) Bail. (7) Radiator Core. (8) Overhead Lifting Device. 3a
WARNING
7
AMOC radiator cores are heavy. Failure to properly secure a radiator core could create a tip-over condition that may result in personal injury or even death. 4
6. Remove the AMOC radiator core. Follow all appropriate disassembly and assembly manual procedures for service of the radiator core.
0968-07
(3a) Thumbscrew (qty 2). (4) Locking Plate (qty 2). (7) Radiator Core.
9
7. Remove the lifting bracket assembly from the radiator core.
c. Loosen (turn counterclockwise) thumbscrews (3a) and push down on bail (3) to allow locking plates (4) to spring outward at the bottom.
NOTE: Make sure the radiator core is stable (positioned in a fixture, blocked on a work surface, or installed in a machine) before removing the lifting bracket assembly.
3
3a 4
a. Lower overhead lifting device (8) to remove all load on bail (3).
1
b. Remove overhead lifting device (8).
8 3
0968-10
(3) Bail. (3a) Thumbscrew (qty 2). (4) Locking Plate (qty 2).
d. Carefully raise lifting bracket assembly (1) up and off of AMOC radiator core (7).
1
0968-09
(3) Bail. (8) Overhead Lifting Device.
7
0968-11
(1) Lifting bracket Assembly. (7) Radiator Core. 10
Maintenance Section
3a
WARNING
4a
To avoid personal injury or death, inspect tools before each use. Do not use any tool that is damaged, altered, or in poor condition. Replace all worn, cracked, or damaged parts immediately.
4
5a
To avoid personal injury or death, do not weld on lifting bracket assembly. Do not expose to extreme heat, such as from a
3b
torch. The lifting bracket assembly weighs 1.3 kg (2.8 lbs). Always store laying flat to prevent falling, which can cause personal injury. 0968-12
(3a) Thumbscrew (qty 2). (3b) Spring Pin (qty 2). (4) Locking Plate (qty 2). (4a) Spring (qty 4). (5a) Push Nut (qty 4).
Inspection Inspect prior to each use for nicks, burrs, dents, cracks, bends, or worn parts. If damage is found, discontinue use until inspected and released for use by an approved inspector at the dealership.
7. Do not use unless all load identification markings are legible.
1. Have tools inspected annually by an approved dealership inspector. Maintain a written record of all inspections. 2. Make sure thumbscrews (3a) operate freely. Lightly lubricate threads with Caterpillar 222-3123 Light Penetrating and Lubricating Oil. 3. Make sure bail spring pins (3b) are not broken, bent, or damaged. Replace as required. 4. Make sure locking plates (4) pivot freely. Lightly lubricate pivot points with Caterpillar 222-3123 Light Penetrating and Lubricating Oil.
17 8 W -37 L 0 (D L = 4 a 1 (S te C 00 up o LB plie de S (4 r C) 5.4 od Kg e) )
0968-13
5. Make sure locking plate springs (4a) are not broken, bent, or damaged. Replace as required. 6. Make sure push nuts (5a) are not damaged or missing. Replace as required. 11
Service Parts
Cleaning 3a
Clean tool after each use, using a non-solvent based cleaner.
3b 4a
Storage Store tool indoors in a clean, dry location, laying flat to prevent falling.
Tool Disposal At the end of the tools operational life, destroy the tool and dispose of as scrap, according to all current environmental regulations.
5a
0968-14
178-3704 Lifting Bracket Assembly Service Parts Item Part No. 3a 90200A257 1 3b 4H-3119 4a 9271K23 1 5a 94803A030 1 1 Available from McMaster-Carr
Description Thumbscrew Spring Pin Spring Push Nut
Qty 2 2 4 4
For information on service tools or shop supplies, contact Dealer Service Tools on: Dealer Service Tools 501 S. W. Jefferson Peoria, IL U.S.A. 61630-2125 U.S.A.: 1-800-542-8665 Illinois: 1-800-541-8665 Canada: 1-800-523-8665 World: 1-309-675-6277 Fax: 1-309-494-1355
[email protected]
©2009 Caterpillar All Rights Reserved
NEHS0968 Printed in U.S.A.
