Usage:
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At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Drain the coolant only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap from the radiator slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to avoid personal injury. |
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1. Drain the coolant from the engine.
2. Attach a hoist to steps (1).
3. Remove the bolts that hold the steps in place. Remove the steps. The weight of the step assembly is approximately 87 kg (192 lb).
4. If replacement of top cores is required;
a. Attach tooling (A) and a hoist to upper grill (2). Remove the mounting bolts and grill (2). The weight of the grill is 39 kg (86 lb).
5. Attach tooling (A) and a hoist to lower grill (3). Remove the mounting bolts and grill (3). The weight of the grill is 39 kg (86 lb).
6. Remove four bolts (4) that hold the fan guard stiffener angles to the radiator. Move the fan guard away from the radiator.
7. Remove center bolt (5) from each corner of the bottom tank. Obtain four M10-1.50 X 100 mm (4 in) bolts. These bolts must be threaded the full length of the bolts. Replace center bolts (5) with the longer bolts. Screw in four bolts (5) completely to the bolt head.
8. Remove the bolts that connect water lines (6) to the bottom tank. Remove the gaskets.
9. Remove ten bolts (7) that hold the bottom tank to the fan guard.
10. Remove the mounting bolts that hold two brackets (8) to the frame.
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To prevent personal injury, do not remove the four 101 mm (4 in) center bolts (5) that were inserted in Step 7. The four bolts are necessary to keep the bottom tank from falling from the machine. |
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11. Remove four bolts (9) from each corner of the bottom tank.
12. Replace any top cores by;
NOTE: If there are no top cores that require replacement; proceed to Step 13.
a. Remove center support (11) from the radiator.
b. Remove four bolts (10) from each bracket holding the center tank assembly to the radiator side channels.
c. Remove four brackets (12) that hold the lower row of cores to the radiator side channels.
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Always wear goggles when working on air conditioning systems. The system is under pressure at all times, engine running or not. Escaping Freon-12 (C C12 F2 Dichloro Difluoro Methane) can cause freezing of human flesh. Do not smoke while working on air conditioning. Inhaling Freon-12 through any smoking material, although not toxic or flammable, can cause violent illness. Also heat must never be applied to a charged system. See Air Conditioning And Heating Service Manual Form No. SENR3334-01, for more information on removal and installation of lines and refrigerant from the system. |
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d. Remove the bolts that hold two supports (13) to the top and center tank assemblies. Do not disconnect the hoses from the air conditioning condenser. See warning above. Tie the condenser and the supports out of the way.
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To prevent personal injury, do not completely remove four 101 mm (4 in) center bolts (5). They are the only thing holding the bottom tank in place. |
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e. Slowly and evenly unscrew four bolts (5) to lower the bottom tank, the bottom row of cores and the center tank assembly. Do not unscrew four bolts (5) more than 64 mm (2.5 in).
f. Remove two bolts (14), one at the rear not shown, from each core that is to be removed.
g. Remove the radiator core.
h. Remove rubber seals (15) from the tank assemblies.
j. Install the radiator cores in the reverse order of removal. Leave bolts (14) loose.
k. Lubricate all rubber seals (15) at the bottom and top of the cores with liquid soap just prior to assembly.
l. Raise the bottom tank, the bottom row of cores and the center tank assembly into position by slowly and evenly screwing four bolts (5) completely in.
m. Before tightening bolts (14), adjust gap (X), at the front of the radiator, to 6.5 mm (.25 in) and gap (Y) at the rear of the radiator to 2.0 ± 1.5 mm (.08 ± .06 in). The cores must not contact each other after assembly. Tighten bolts (14) on each core removed.
n. Install four bolts (10) to hold the center tank assembly to the radiator side channels.
p. Install four brackets (12) that hold the lower row of cores to the radiator side channels.
q. Install center support (11) to the radiator.
r. Put the air conditioning condenser in position. Install the bolts that hold two supports (13) to the top and center tank assemblies.
13. Change the lower cores by;
NOTE: If there are no bottom cores that require replacement; proceed to Step 14.
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To prevent personal injury, do not completely remove four 101 mm (4 in) center bolts (5). They are the only thing holding the bottom tank in place. |
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a. Slowly and evenly unscrew four bolts (5) to lower the bottom tank, the bottom row of cores and the center tank assembly. Do not unscrew four bolts (5) more than 64 mm (2.5 in).
b. Remove two bolts (14), one at the rear not shown, from each core that is to be removed.
c. Remove the radiator core from the center tank assembly.
d. Remove rubber seals (15) from the tank assemblies.
e. Install the radiator cores in the reverse order of removal. Leave bolts (14) loose.
f. Lubricate all rubber seals (15) at the bottom and top of the cores with liquid soap just prior to assembly.
g. Slowly and evenly screw four bolts (5) completely in to raise the bottom tank into position.
h. Before tightening bolts (14), adjust gap (X), at the front of the radiator, to 6.5 mm (.25 in) and gap (Y) at the rear of the radiator to 2.0 ± 1.5 mm (.08 ± .06 in). The cores must not contact each other after assembly. Tighten bolts (14) on all cores removed.
14. Install four bolts (9) at each corner of the bottom tank.
15. Remove center bolt (5) from each corner of the bottom tank. Replace with the original bolts.
16. Install the mounting bolts that hold two brackets (8) to the frame.
17. Install ten bolts (7) that hold the bottom tank to the fan guard.
18. Install the gaskets. Install the bolts that connect water lines (6) to the bottom tank.
19. Move the fan guard in position against the radiator. Install the bolts that hold fan guard (4) to the radiator.
20. Attach tooling (A) and a hoist to lower grill (3). Install the mounting bolts and grill (3). The weight of the grill is 39 kg (86 lb).
21. If removed, attach tooling (A) and a hoist to upper grill (2). Install the mounting bolts and grill (2). The weight of the grill is 39 kg (86 lb).
22. Attach a hoist to step assembly (1). Install step assembly (1). The weight of the step assembly is approximately 87 kg (192 lb).
23. Fill the cooling system with coolant and check for leaks. See the Operation & Maintenance Manual.