Usage:
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
Disassemble Radiator
START BY:
a. remove radiator (earlier)
1. Place the radiator on blocks in a horizontal position as shown.
2. Remove plate (1) with the ether starting aid.
3. Remove fan guard (3).
4. Remove four shields (2).
5. Remove three plates (4).
6. Remove the nuts and washers that hold two channels (5) to the radiator core.
7. Remove damper (6) from channel (5).
| NOTICE |
|---|
Whenever the radiator is disassembled, replace from rubber dampers (7). Use 6V2499 Seal (bulk) to put new seals on channels (6). |
8. Remove channel (9).
9. Remove top tank (8), the plate and gaskets.
10. Remove bottom tank (10), the strips and gaskets.
| NOTICE |
|---|
The top (thin) header is very flexible. Do not lift the radiator core until the top and bottom tanks and side channels have been installed. |
11. Inspect all parts and replace them as necessary.
Assemble Radiator
NOTE: The thickness of the top header plate is less than the bottom header plate. It is possible to install these core assemblies with the thin header plate at the top or the bottom. The core assembly must be installed with the thin header plate next to the radiator top tank.
1. While the core is still in its container, put the core assembly in a horizontal position on blocks.
2. Remove the top and sides of the container.
| NOTICE |
|---|
The thin header is very flexible. Do not lift the core assembly until the top and bottom tanks and side channels have been installed. When lifting the radiator, install link brackets on the end flanges of the top tank. |
3. Put the top tank, plate, gaskets and brackets in position on the thin header of the radiator core. Install the bolts finger tight.
4. Put the bottom tank gasket and brackets in position on the thick header of the radiator core. Install the bolts finger tight.
NOTE: Be sure the inlet and outlet openings in the tanks are in the same direction.
5. Tighten the bolts for the top and bottom tanks. Tighten the bolts in the sequence shown. Tighten the bolts from the center toward the sides and then from the front to the back.
NOTE: Whenever the radiator is disassembled, replace foam rubber dampers (3). Use 6V2499 Seal (bulk) to put new seals on dampers (2).
6. Peel the protective backing from foam rubber dampers (3), and install dampers (2) in channels (1).
7. Put channels (1) in position on the brackets on the radiator core, and install the nuts and washers.
8. Install three plates (4).
9. Install four shields (7).
10. Install fan guard (6).
11. Install plate (5) with the ether starting aid.
END BY:
a. install radiator (earlier)