- Landfill Compactor
- 816K (S/N: WNB1-UP; WCL1-UP)
- 826K (S/N: 2321-UP; SET1-UP)
- 836K (S/N: LWZ1-UP; TWZ1-UP)
- 826K (S/N: 2321-UP; SET1-UP)
- Soil Compactor
- 815K (S/N: MBB1-UP; WCS1-UP)
- 825K (S/N: 2331-UP; SEE1-UP)
- Wheel Dozer
- 814F Series 2 (S/N: BXG1-UP)
- 814K (S/N: DMB1-UP; WCM1-UP)
- 824K (S/N: 2341-UP; RWB1-UP)
- 834K (S/N: LWY1-UP; TWY1-UP)
- 844K (S/N: MBE1-UP; KLS1-UP)
- 854K (S/N: KK31-UP; RM31-UP)
- 814K (S/N: DMB1-UP; WCM1-UP)
- Wheel Loader
- 986H (S/N: 9861-UP)
- 986K (S/N: MH81-UP; NL81-UP)
- 988K (S/N: LWX1-UP; TWX1-UP)
- 988K XE (S/N: EWX1-UP)
- 990K (S/N: DJK1-UP; A9P1-UP)
- 992K (S/N: KK21-UP; RM21-UP)
- 993K (S/N: Z4D1-UP; Z4Z1-UP)
- 994K (S/N: MM91-UP; MRK1-UP; SMX1-UP)
- 986K (S/N: MH81-UP; NL81-UP)
Reference: Special Instruction, SEBD0518, "Know Your Cooling System"
Reference: Special Instruction, REHS7296, "Instructions for Use of Cat Coolant Conditioner for Aluminum Components"
Reference: Special Instruction, REHS9442, "Instructions for Use of Cat Coolant Conditioner for Modular Core Aluminum Radiators"
Introduction
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.
This Special Instruction provides guidelines for proper installation and maintenance of 2-pass Aluminum Modular Radiators (AMR) cores that are 2-pass in nature.
This information is applicable to the all machines listed above that utilize 2-Pass Aluminum Modular Radiators (AMR).
The information helps ensure best possible life and durability from the Aluminum Modular Radiator (AMR) cores.
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| Illustration 1 | g06331083 |
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2–Pass Modular Radiator with inlet and outlet connection at the bottom tank. The ports on the top are for venting air. | |
- Aluminum Modular Radiators (AMR) core material is aluminum which includes the tubes, fins, tanks, and headers. Aluminum Modular Radiators (AMR) were implemented in mid 2014 as a drop-in replacement for the previous vintage modular radiator that had Brass tubes, tanks, headers, and Copper fins. An E-coated Aluminum Modular Radiators (AMR) core is provided as an optional service replacement for locations where the operational environment is corrosive in nature.
- 2–Pass Aluminum Modular Radiators (AMR): 2-pass refers to the coolant passages inside the radiator. If the coolant enters and exits the radiators from the same side, then it is referred to as 2-pass ( in other words, if the coolant enters the bottom of the radiator and goes up through the height of the core, makes a U-turn and exits from the bottom of the radiator). Refer to Illustration 1.
Safety Section
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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility. |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates. |
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Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand. Cooling System Conditioner contains alkali. Avoid contact with skin and eyes. |
Guidelines for Aluminum Modular Radiator (AMR) Core Installation
Pre-Installation
If an Aluminum Modular Radiator (AMR) core is ordered to replace an older vintage core, ensure that the older part number is used for warranty claim.
This will make it easier to accurately identify any emerging issues with the Aluminum Modular Radiator (AMR) cores.
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| Illustration 2 | g06331093 |
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Empty wooden boxes that are used to ship Aluminum Modular Radiator (AMR) cores from Cat logistics facility to Cat dealer | |
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| Illustration 3 | g06331105 |
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Snouts damaged due to mishandling/improper packaging/transportation | |
Details for inspection and evaluation are listed below:
Proper care and observation is required for the installation of an Aluminum Modular Radiators (AMR) cores. Aluminum is lighter than copper/brass and is more susceptible to damage due to improper packaging or handling.
- Aluminum Modular Radiator (AMR) cores are shipped individually and packaged in wooden crates. Refer to Illustration 2.
- Prior to installation, ensure that the cores and snouts are not bent and that there are no obvious signs of packaging or transportation damages. If there is any damage on the core, avoid installation of such cores. Refer to Illustration 3 for examples of visible damage.
- Capture damages through pictures or perform leak test (air under water) and file for a claim. Installing cores suspected of damage could lead to problems like increase in downtime in case the radiator leaks after coolant fill.
During-Installation
Coolant quality is an important aspect of the functionality of Aluminum Modular Radiator (AMR).
If the drained coolant is old (beyond the recommended life of the coolant), replace the coolant after flushing the system. Refer to Special Instruction, SEBD0518, "Know Your Cooling System" for more information on the flushing procedure.
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| Illustration 4 | g06331138 |
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Microscopic view of the flow divider area (inside the Aluminum Modular Radiator (AMR) inlet tank) that indicates the erosion pattern | |
Debris in the system increases the erosion failure rate exponentially. Refer to Illustration 4 for erosion damage on an Aluminum Modular Radiator (AMR) core due to debris in the coolant.
Flushing the system a multiple times has been demonstrated to get rid of most of the debris. The installation of a kidney-loop coolant filter should not be considered as a final solution for fixing the debris issue.
Coolant filters have been tested on machines and based on the debris in the system, the filter can easily become clogged and ineffective.
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| Illustration 5 | g06331162 |
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Lifting boss on top of the 2-pass Aluminum Modular Radiator (AMR) cores | |
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| Illustration 6 | g06331185 |
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Proper way to temporarily rest the Aluminum Modular Radiator (AMR) cores vertically - if installing the cores by hand | |
Use proper tools to lift the Aluminum Modular Radiator (AMR) cores.
Use an M8 lifting eye tool to lift the cores and install them. Refer to Illustration 5 that shows the provision made to include a lifting boss on top of the tank of the Aluminum Modular Radiator (AMR).
Aluminum Modular Radiator (AMR) cores could be installed by hand since, they are lighter than the older cores.
Ensure that the cores do not rest on the snouts. If they are not properly supported, the snouts could be damaged due to the impact with ground.
Use wooden blocks to support the cores on the bottom tank in case vertical resting of cores is required. Do not rest the cores on the snouts. Refer to Illustration 6.
Ensure that the bottom tank area is clean and free from dirt, mud, or debris.
If the cleanliness of the area is not maintained, dirt or mud can pollute the coolant in turn harming the Aluminum Modular Radiator (AMR) core. Replace old rubber seals with new seals.
Post-Installation
After the cooling system has been flushed to minimize the risk with debris, refill the system with the new coolant ( if the drained coolant has exceeded its recommended life ) or drained coolant ( if the drained coolant has significant life remaining ).
Caterpillar recommends the Extended Life Coolant (ELC) and since this is an Organic Acid Technology (OAT) based coolant that includes nitrites, one bottle of Coolant Conditioner for Aluminum Components (CCAC) should be added to each Aluminum Modular Radiator (AMR) core installed.
For more information on Coolant Conditioner for Aluminum Components (CCAC), refer to Special Instruction, REHS7296, "Instructions for Use of Cat Coolant Conditioner for Aluminum Components" or refer to Special Instruction, REHS9442, "Instructions for Use of Cat Coolant Conditioner for Modular Core Aluminum Radiators" that was provided in the wooden box used for the shipment of the cores.
If a Supplemental Coolant Additive (SCA) based coolant is used, Coolant Conditioner for Aluminum Components (CCAC) is not required.
Ensure that proper coolant maintenance recommendations are followed.
Perform a Level 2 Scheduled Oil Sampling (SOS) analysis to assess the coolant quality adequacy.
If a Supplemental Coolant Additive (SCA) based coolant is utilized, ensure not to mix the coolant with tap water. Cat Extended Life Coolant (ELC) is already premixed and will eliminate this potential failure mode.
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| Illustration 7 | g06331704 |
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Example of level 1 Scheduled Oil Sampling (S-O-S) report with a micrograph of the coolant sample showing rust particles | |
A micrograph of a coolant sample which shows the presence of rust particles is shown in Illustration 7. As mentioned earlier, these particles are highly detrimental to the operation of Aluminum Modular Radiators (AMR).
This example shows how a simple coolant sample can help assess the potential risk to the Aluminum Modular Radiator (AMR) core.
Regular sampling and taking proactive steps can minimize downtime due to radiator leaks.
Level 2 Scheduled Oil Sampling (SOS) analysis is recommended every 500 hours. If Scheduled Oil Sampling (SOS) reports suggest no actions, the sampling can stop.
Summary
Aluminum Modular Radiators (AMR) cores are lighter, equal or better than the previous vintage cores in several failure modes. At the same time, proper care and maintenance is required to ensure that Aluminum Modular Radiators (AMR) core’s performance is superior.
In the event of a failure, notify your Dealer Technical Communicator (TC) along with the information mentioned below:
- The total number of modular cores on the machine and the number of Aluminum Modular Radiators (AMR) cores out of the total.
- The date and hours on the machine when the Aluminum Modular Radiators (AMR) cores were installed.
- Specific information on the Aluminum Modular Radiators (AMR) core(s). Use a numbering system for the identification of the leaking core number.
- The date and hours on the machine when the Aluminum Modular Radiators (AMR) core(s) leaked.
- Details of the type of coolant used on the machine (Cat Extended Life Coolant (ELC) or others, to be specified).
- Information on whether the coolant was replaced or re-used during Aluminum Modular Radiators (AMR) installation.
- The last time the cooling system was flushed.
- The date and hours on the machine when the coolant was filled in the machine.
- The number of hours accumulated by the coolant in the machine.
- Results of level 2 Scheduled Oil Sampling (SOS). If unavailable, time details on when the coolant sample can be sent to the lab.