Usage:
a. remove radiator guard
b. remove fan
c. remove crankcase guards
d. remove air conditioning condenser
1. Remove plates (1) from each side of the shroud.
2. Remove air conditioner condenser hoses (2) and (3) and the grommets from the shroud.
3. Fasten a nylon strap and hoist to pipe (4).
4. Place tooling (A) beneath the frame as shown. Apply force to the frame until pipe (4) and the spacers can be removed. Note the location of the spacers so they can be installed in the same position.
5. Disconnect wire connector (5), and remove the bolts from top of the shroud. Move wire (6) out of the way.
6. Install two 3/8 -16 NC guide pins (7) through the shroud and into the top tank as shown.
7. Remove the remainder of the bolts that hold shroud (8). Move shroud (8) out enough so tooling (B) and a hoist can be installed. The weight of shroud (8) is 36 kg (80 lb).
8. Remove the clamp that holds dryer (9) to the radiator, and move dryer (9) out of the way.
9. Remove clamp (10) and clip (11) that hold the steering hoses and heater hoses to the radiator.
10. Remove clips (12) that hold the heater hoses to the radiator.
11. Disconnect the clips that hold battery cables (13) to the fan guard.
12. Disconnect wire connector (14).
13. Disconnect tube (15) from the ether starting aid.
14. Remove bolt (16) that holds the braces together.
15. Remove bolts (17) and (18).
16. Remove the bolts that hold tube (19) to the radiator bottom tank.
17. Fasten tooling (C) and a hoist to radiator (20). The weight of the radiator is 442 kg (975 lb).
18. Remove the clips that hold air conditioner condenser hoses (2) and (3) to each side of the radiator.
19. On each side of the radiator, remove the bolts that hold supports (21) to the frame.
| NOTICE |
|---|
Be careful not to damage the radiator core during removal. |
20. Carefully remove radiator (20) from the machine. Be careful not to damage the radiator core.
21. Inspect mount assemblies (22) on each side of the frame. Replace them if they are worn or damaged.
22. Inspect mount assemblies (23) on each side of the radiator. Replace them if they are worn or damaged.
23. Install mount assemblies (22) on each side of the frame.
24. Install mount assemblies (23) on each side of the radiator.
25. Fasten tooling (C) and a hoist to the radiator.
26. Carefully put the radiator in position on the machine frame.
27. Install the bolts and washers that hold supports (21) (one on each side of the radiator) to the machine frame.
28. Fasten the clips that hold air conditioner condenser hose (2) (one on each side of the radiator) to the radiator.
29. Install bolts (17) and (18) to fasten the radiator to the mount assemblies.
30. Be sure the mating surfaces of pipe (19) and the radiator are clean.
31. Install a new gasket, and install the bolts to hold tube (19) to the radiator.
32. Install the grommet and bolt (16) in the braces.
33. Install the clips to hold battery cables (13).
34. Connect ether starting aid tube (15).
35. Connect wiring connector (14).
36. Connect clips (12) that hold heater hoses to the radiator.
37. Install clamp (10) and clip (11) that hold the steering hoses and heater hoses to the radiator.
38. Put dryer (9) in position on the radiator, and install the clamp to hold it.
39. Fasten tooling (B) and a hoist to shroud (8).
40. Install two 3/8 "-16 NC guide pins (7) in the radiator top tank.
41. Move shroud (8) onto the guide pins, and remove tooling (B).
42. Move shroud (8) into position, and install the bolts to hold it.
43. Connect wire connector (5). Install the bolts and clips that hold wire (6) to the shroud.
44. Place tooling (A) beneath the frame as shown.
45. Fasten a nylon strap and hoist to pipe (4), and put pipe (4) in position.
46. Apply lifting face to the frame with tooling (A) until pipe (4) and spacers can be installed. Install the spacers in their original position.
47. Install plates (1) on each side of the shroud.
48. Install air conditioner condenser hoses (2) and (3) through the grommets on each side of the shroud.
End By:
a. install radiator guard
b. install fan
c. install crankcase guards
d. install air conditioning condenser