777E, 777F and 777G Off-Highway Truck Caterpillar

Installation Procedure

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Illustration 1	g01320460

1. Install seal (15).

   1. Use a cleaning fluid to clean the entire surface that will be in contact with seal (15). Use a cleaning fluid to clean the inside diameter of the holes in the bottom tank. Dry the surface.

      Note: Cleaning these spots is done to ensure that no lubrication remains between the system tank and seals (15). If any lubrication remains, it may cause seals (15) to be damaged during core assembly

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      Illustration 2	g06191847
      Example of bottom seal installed incorrectly.

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      Illustration 3	g06191851
      Example of bottom seal installed correctly.

   2. Install new seals (15) in the bottom tank without the use of any lubrication. Seat seals (15) in the holes of the tank by using a non-metallic mallet.
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      Illustration 4	g06191873

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      Illustration 5	g06191884

   3. Apply Tooling (C) to the inside seal (15) and the snout on core (14).

   4. Once all the cores have been installed in the bottom tank, install the center plate straps or transverse stiffener leaving all the bolts loose.
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   Illustration 6	g01320457

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   Illustration 7	g06191906
   Typical Example

2. Install the outermost cores first and work towards the center of the radiator assembly in the sequence shown in Illustration 7.

3. Attach Tooling (B) and a suitable lifting device to a radiator core (14). The weight of radiator cores (14) is approximately 33 kg (73 lb). The weight of the outer two radiator cores is approximately 27 kg (60 lb). Install radiator core (14).
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   Illustration 8	g01320456

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   Illustration 9	g01320311

4. Install seals (13). Repeat steps 1.a through step 1.c to install seals (13).

5. Attach Tooling (A) and a suitable lifting device to radiator top tank (10). The weight of radiator top tank (10) is approximately 113 kg (250 lb). Install top tank (10).
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   Illustration 10	g01320306

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   Illustration 11	g01320314

6. Install bolts (11) to each side of the front of the radiator. Repeat for the rear of the radiator. Install bolts (12) to each side of the radiator.
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   Illustration 12	g01320308

7. Install bolts (9). Install upper fan guards (8) and (7).
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   Illustration 13	g01320305

8. Connect hoses (4) and (5). Install tube assemblies (1), (2), (3), and (6).

9. Fill the cooling system. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change".

End By:

1. Install the aftercoolers. Refer to Disassembly and Assembly, "Aftercooler - Install".

2. Install the cowling. Refer to Disassembly and Assembly, "Cowling (Radiator) - Remove and Install".

3. Install the hood. Refer to Disassembly and Assembly, "Hood - Remove and Install".