BAR 9Y6313 - Caterpillar

Introduction
This special instruction provides the necessary information for installing improved radiator baffles on Challenger 35 and Challenger 45 Agricultural Tractors.Do not perform any procedure outlined in this publication or order any parts until you read and understand the information contained within.Reference: Service Manual Module; SENR5379-01; Disassembly & Assembly; "3116 Engine Supplement For Challenger 35 and Challenger 45 Agricultural Tractors and 3126 Engine Supplement For Challenger 55 Agricultural Tractors." The foam seals installed in this rework procedure are held in place by adhesive. The areas of the engine compartment where the new seals are placed must be free of dirt and grease. Clean these surfaces with 4C-4079 Solvent or equivalent before the foam parts are installed. Disassembly
1. Remove the bolt from the clamp retaining the Air Conditioner lines on the front of the aftercooler and disconnect the aftercooler according to the instructions in SENR5379-01. DO NOT remove the air conditioner condenser or air conditioner lines.2. When the aftercooler is disconnected, slide it forward with the air conditioner condenser attached until the hump hoses are disconnected from the aftercooler lines to the engine. Remove the bolt from the clip attaching the line to the front of the fuel tank. DO NOT loosen the hose clamps on the front of the orange hump hoses. Loosen the two clamps on the rear of the hump hoses instead.3. Using the instructions in SENR5379-01, remove the mounting fasteners from the radiator. The radiator must be disconnected and raised enough to install foam baffles under the bottom tank. DO NOT drain the radiator, remove the hydraulic cooler, or disconnect any hoses or wires.4. Trim the front frame seals flush to the front of the radiator bottom tank as shown in Illustration 1.5. Using the instructions in SENR5379-01, remove the fan shroud and fan assembly.6. Remove former foam seal from the hood assembly with a razor or utility knife. Because the new seal will be placed over this location, any remaining foam must be carefully removed with a scraper or wire brush. For Challenger 35 (8DN1-384) and Challenger 45 (1DR1-899) Agricultural Tractors only.7. Raise the radiator about 50.8 mm (2 in) so a foam baffle can be installed under the bottom tank. Place a 2 x 4 shim between the frame and the bottom tank to hold the radiator in the raised position.Assembly
Carefully clean all surfaces receiving the adhesive back foam material. Use 4C-4079 Solvent or equivalent to make sure that no grease or oil remains on these surfaces.
Illustration 1. Radiator bottom tank.1. Install the foam seal (4) under the radiator bottom tank. Insert the two hydraulic lines into the foam cutouts (3) on the left side of the frame before gluing the foam to the frame. The seal should be installed as far forward as possible with the two semi-circular cutouts nestled around the two bosses (5) on the radiator bottom tank.2. Remove the supporting shims from under the radiator and install the foam seals (1), making sure that the sharp corner of the seal