Usage:
START BY:
a. remove batteries *
b. remove fan
c. tilt cab (24° position) *
d. remove oil pan **
*These operations are in the Vehicle Systems Disassembly And Assembly section.
**It is only necessary to remove the oil pan on earlier machines.
NOTE: Put plugs or caps on all oil, fuel and water lines when they are disconnected. Put identification marks on all wires before they are disconnected.
1. Drain the cooling system.
2. Turn fuel valve (1) on the fuel tank to the "OFF" position.
3. Remove nuts (2), and remove tool box (3) from the fender.
| NOTICE |
|---|
Be extra careful not to damage the tube on the ether starting aid when it is removed and installed. |
4. Remove clips (4), and disconnect the tube for the ether starting aid from the air inlet elbow. Disconnect the wires from the ether starting aid, and remove ether starting aid and tube (5) from the panel.
5. Remove clips (6) and plate (8) from the fender.
6. Remove grommet (7), and pull the battery cable through the panel.
7. Remove bracket (9) for the air cleaner indicator from the fuse panel. Disconnect hose (10) from the back of the air cleaner indicator.
NOTE: The air cleaner indicator is removed to prevent possible damage from the engine removal.
8. Remove bolts (11) from the panel.
9. Remove the grille from the radiator guard.
NOTE: If the engine has been stopped for a short time, it is not necessary to drain the transmission to disconnect the oil lines from the transmission oil cooler.
10. Disconnect oil lines (12) from the top of the transmission oil cooler and the hydraulic oil cooler. Remove the hydraulic oil cooler. Remove the two clips that hold the oil line for the transmission oil cooler to the radiator frame.
11. Disconnect wires (13) for the back-up alarm.
12. Disconnect wire (14) for the lights.
13. Remove the clamp that holds exhaust pipe (15) to the muffler.
14. Remove the four bolts that hold tube (16) for the air cleaner to the hood.
15. Remove clip (17) that holds the radiator top tube to the hood. Disconnect the radiator top hose from the radiator.
16. Remove the guard below the radiator.
17. Remove clip (20) and the clips that hold the hydraulic oil cooler lines to the frame. Pull oil lines (12) down and clear of the radiator guard. Disconnect oil line (19) from the bottom of the transmission oil cooler.
18. Loosen hose clamp (18), and disconnect the radiator bottom hose from the tube that comes from the engine.
19. Fasten a hoist to the brackets inside muffler shield (21) at three points. Remove four bolts (22), and remove the muffler from the hood. Weight is approximately 43 kg (95 lb.).
20. Remove precleaner (23) from the hood. The precleaner is just pushed on to a tube on the hood.
21. Remove the rubber material from the battery boxes.
22. Remove bolts (24), (25) and (26) from both sides of the radiator guard and engine enclosure.
NOTE: On the 953 it will be necessary to make an opening so bolts (25) and (26) can be removed. Make the opening no larger than 80 x 178 mm (3.15 x 7 in.). Make the opening 43 mm (1.69 in.) to the rear of the 76 x 76 mm (2.99 x 2.99 in.) opening with the long sides in alignment with the front opening as shown. Each corner of the new opening must have approximately a 15 mm (.59 in.) radius to prevent stress cracks.
23. Fasten tooling (B), (C) and a hoist to the radiator guard and engine enclosure as shown.
24. Remove bolts (27) at the rear of the radiator guard.
| NOTICE |
|---|
When the radiator guard and engine enclosure are removed, be extra careful not to damage belt tightener (28) on the compressor for the air conditioner. |
25. Remove bolts (29) from both sides of the engine enclosure, and carefully remove the radiator guard and engine enclosure as a unit. Weight is approximately 495 kg (1100 lb.).
NOTE: Later machines will have a connector at location (30) in the wire harness that goes over the flywheel housing. Do not disconnect the wires from different points on the engine, as shown in the following steps, if your machine has a connector at location (30). Disconnect the connector at location (30).
26. Disconnect wires (32) from the alternator.
27. Disconnect the wires from fuel pressure switch (33) on the fuel filter base.
28. Remove clips (31) that hold the wire harness to the cylinder block, and move the wire harness clear of the engine.
29. Disconnect fuel lines (34) from the engine.
30. Disconnect hose (35) for the heater from the valve.
31. Remove clip (36) that holds the heater hose to the cylinder block, and move the heater hose clear of the engine.
32. Loosen hose clamp (37). Remove bolt (38) that holds the clip and water tube (40) in place, and remove water tube (40).
33. Remove clips (39), and move the oil line for the transmission oil cooler clear of the engine.
34. Disconnect heater hose (41) from the valve in the cylinder block.
35. Disconnect governor linkage (42) from the governor.
36. Disconnect rod (43) from the bellcrank.
37. Disconnect the rod from lever (44) on the underspeed override valve.
38. Remove bolts (45), and move bracket (46), the governor linkage and the heater clear of the engine.
39. Disconnect connectors (47) only if your machine is equipped with a connector in the harness that goes over the flywheel housing as shown in illustration B18384X1.
40. Disconnect wires (48) and (49) from the starter solenoid.
41. Disconnect wires (50) from the starter.
42. Disconnect the wires from coolant temperature switch (51).
43. Disconnect the wire from temperature cutout switch (52) for the ether starting aid.
44. Disconnect the wires from pressure switch (53) for the service meter.
45. Disconnect the wires from pressure switch (54) for engine low oil pressure.
46. Remove three clips (55) that hold the wire harness to the cylinder block.
47. Remove clip (56) that holds the two refrigerant hoses for the air conditioner to the cab support.
48. Remove the belt from the air conditioner compressor.
49. Disconnect the wire from terminal (58) on the compressor, and move the wire clear of the engine.
50. Remove bolts (57), (59) and the bolts at the rear and bottom of the compressor. Move the air conditioner compressor clear of the engine.
51. Remove clips (60), and move the oil line for the transmission oil cooler clear of the engine.
52. Remove the two bolts that hold hydraulic pump (61) to the timing gear plate. Remove the hydraulic pump from the engine, and use a piece of wire to hold the pump to the side as shown.
53. Fasten tooling (A) and a hoist to the engine.
54. Remove the guard below the engine. Weight is 66 kg (146 lb.) on a 943. Weight is 75 kg (166 lb.) on 953.
55. Remove bolts (62) that hold the transmission to the engine. Remove the lower bolts first.
56. Remove bolt (63), mount (64) and the sleeve from the engine mount.
57. Lift the engine a short distance, and remove six bolts (65), plate (66) and the mount under the engine front support.
58. Slide the engine straight back to disengage the flexible coupling from the transmission.
| NOTICE |
|---|
Do not damage fuse panel (67) as the engine is removed. Be sure all wires and hoses are disconnected and clear of the engine. |
59. Remove the engine from the machine. Weight is approximately 653 kg (1450 lb.).
Install Engine
1. Fasten tooling (A) and a hoist to the engine as shown. Carefully put the engine in position in the machine.
2. Be sure O-ring seal (1) is in position on the flexible coupling on the flywheel. The splines on the flexible coupling must engage in the splines of the gear in the pump drive in the transmission.
3. Install several of the top bolts (2) that hold the engine to the transmission.
4. Put mount (3) and the bolts in position in plate (4). Put plate (4) in position below the engine front support, and tighten the bolts that hold the plate to the frame.
5. Lower the engine into position on the front mount, and remove tooling (A) and the hoist. Install the remainder of the bolts in the flywheel housing.
6. Install mount (5), the sleeve and bolt (6) in the engine front mount. Tighten bolt (6) to a torque of 865 ± 110 N·m (640 ± 80 lb.ft.).
7. Put hydraulic pump (7) and the gasket in position on the timing gear plate, and install bolts (8) that hold it in place.
8. Put clips (9) and the transmission oil cooler line in position, and install the bolts that hold them in place.
9. Put the air conditioner compressor in position on bracket (10), and install the bolts in the bracket. Install the bolt in the bracket at the bottom of the compressor. Install the bolt in belt tightener (11). Do not tighten the bolts.
10. Install the drive belt on the compressor. See Fan Belt Removal And Installation for the belt tension chart. Adjust the drive belt. Tighten bolts (12) to a torque of 100 ± 15 N·m (75 ± 11 lb.ft.). Tighten bolt (14) to a torque of 200 ± 25 N·m (150 ± 18 lb.ft.). Tighten the remainder of the bolts that hold the compressor in place.
11. Connect wire (13) to the compressor.
12. Install the bolt that holds clip (15) on the refrigerant hoses to the cap support.
13. Put the wire harness in position, and connect two light green wires (18) for the service meter to the pressure switch in the cylinder block. Connect the grey and black wires (16) for lower oil pressure to the other pressure switch in the cylinder block.
14. Put clips (17) and the harness in position on the side of the cylinder block, and install the bolts that hold them in place.
15. Connect the two wires to coolant temperature switch (19) on the front of the engine. Connect the single wire to temperature cutout switch (20) for the ether starting aid.
16. Connect harness connectors (21) below the air cleaner if they were disconnected.
17. Connect cables and wire (22) to the starter solenoid. Connect cables (23) to the starter.
18. Put bracket (24) for the governor linkage in position on the flywheel housing, and install the bolts that hold it in place. Tighten the bolts to a torque of 200 ± 25 N·m (150 ± 18 lb.ft.).
19. Connect rod (25) to the bellcrank.
20. Connect the rod to lever (26) on the underspeed override valve.
21. Connect governor control rod (28) to the governor.
22. Connect heater hose (27) to the valve in the cylinder block.
23. Put the oil line for the transmission oil cooler in position, and install clips (31) that hold it in place.
24. Put the lower water tube and hose (29) in position on the engine. Tighten the hose clamp on hose (29), and install the bolt that holds clip (30) to the engine front support.
25. Connect heater hose (33) to the valve in the timing gear cover, and install the bolt in the clip that holds the heater hose to the engine.
26. Connect fuel lines (32) to the engine.
27. Put the wire harness in position on the engine, and install clips (35) that hold it in place. Connect wires (34) to the alternator. Connect the two wires to fuel pressure switch (36) on the fuel filter base.
28. Fasten tooling (C), (B) and a hoist to the radiator guard and engine enclosure as shown. Carefully put the radiator guard and engine enclosure in position on the machine so the lip of the baffle at the rear of the frame is behind and above the lip on the bottom of the radiator guard.
29. Install the two bolts at the back of the radiator guard.
30. Install bolts (37) on both sides of the engine enclosure.
31. Install bolts (38), (39) and (40) on both sides of the machine.
32. Install precleaner (42) on the hood.
33. Fasten a hoist to the brackets inside muffler shield (41) at three points. Put the muffler and shield (41) in position on the hood, and install the four bolts that hold it in place.
34. Put exhaust pipe (43) in position on the muffler, and install the clamp that holds it in place.
35. Put tube (44) for the air cleaner in position on the hood, and install the four bolts that hold it in place.
36. Connect the top radiator hose to the radiator, and install clip (45) that holds the top radiator tube to the hood.
37. Connect wire (46) for the lights. Connect wires (47) for the back-up alarm.
38. Put oil cooler lines (48) in position up through the radiator guard. Install clip (51) on the top oil line for the transmission oil cooler and the clips that hold the hydraulic oil cooler lines to the frame.
39. Connect oil line (50) to the bottom of the transmission oil cooler.
40. Connect radiator lower hose (49) to the water tube that comes from the engine.
41. Install the guard below the radiator.
42. Connect oil lines (48) to the top of the transmission oil cooler and to hydraulic oil cooler (52). After the oil lines are connected to hydraulic oil cooler (52), put the oil cooler in position on the radiator guard, and install the bolts that hold it in place. Install the two clips that hold the top oil line to the frame on the radiator.
43. Put the grille in position on the radiator guard, and install the three brackets that hold it in place.
44. Connect hose (54) to the air cleaner indicator. Put bracket (53) and the air cleaner indicator in position on the bottom of the fuse panel, and install the bolts that hold it in place.
45. Push battery cable (55) through the hole in the engine enclosure, and install the grommet in the hole.
46. Put plate (57) and clips (56) in position on the studs on the fender, and install the nuts on the studs.
47. Put ether starting aid (58) in position on the engine enclosure, and install the bolts that hold it in place.
48. Connect the tube for the ether starting aid to fitting (59) on the air inlet elbow, and install the two clips on the tube.
49. Put tool box (60) in position on the fender, and install the eight nuts that hold it in place.
50. Install the oil pan on the engine if it was necessary to remove the oil pan to install the engine. Fill the engine to the correct level with clean oil. See the Maintenance Guide.
51. Install the guard below the engine.
52. Open fuel valve (61) on the fuel tank.
53. Fill the cooling system with coolant to the correct level. See the Maintenance Guide.
END BY:
a. lower cab *
b. install fan
c. install batteries *
These operations are in the Vehicle Systems Disassembly And Assembly section.