Radiator Service Kit

1. Close the hood, but do not secure the latches (Figure 1).

   

   Figure 1

   1. Hairpin
   2. Hood-pivot bracket
   3. Hood support
   4. Hood
   5. Latch

2. Remove the hairpin from the pin of the right hood-pivot bracket (Figure 1).

3. Move the hood to the right, from the left hood support, and raise the left hood-pivot bracket (Figure 1).

4. Move the hood to the left, from the right hood support, and raise the right hood-pivot bracket (Figure 1).

5. Remove the hood from the machine (Figure 1).

1. At the back of the operator’s seat, remove the 2 flange-head capscrews that secure the heat shield and seat straps cross tube, and remove the heat shield (Figure 2).

   

   Figure 2

   1. Flange-head capscrews
   2. Seat
   3. Heat shield
   4. Seat straps

2. Remove the 2 flange-head capscrews that secure the seat straps to the support channel (Figure 3).

   

   Figure 3

   1. Flange-head capscrews
   2. Seat strap
   3. Support channel

3. Tip the seat forward to access the bottom of the seat.

4. Remove the 2-socket connector from the terminals for the seat switch (Figure 4).

   

   Figure 4

   1. Seat switch
   2. 2-socket connector (machine-wire harness)

5. Remove the seat from the machine.

Lift the console cover from the console control panel (Figure 5).

Figure 5

Drain pan capacity: 7 quarts or more.

1. Remove the radiator cap from the radiator filler neck (Figure 6).

   You no longer need the radiator cap.

   

   Figure 6

   1. Radiator cap
   2. Radiator filler neck

2. Align a drain pan of the specified capacity below the radiator drain valve and open the valve (Figure 7).

   

   Figure 7

   1. Radiator drain valve

3. Allow the radiator to drain the coolant completely.

4. Close the drain valve (Figure 7).

5. Dispose of used coolant at a certified recycling center, hazardous waste facility, or according to your state and local regulations.

1. Remove the hose clamp that secures the hose to the radiator overflow fitting, and remove the hose from the fitting (Figure 8).

   

   Figure 8

   1. Radiator overflow fitting
   2. Coolant reservoir tank
   3. Reservoir bracket
   4. Hose
   5. Hose clamp

2. Lift the reservoir from the reservoir bracket and remove the reservoir from the machine (Figure 8).

3. Drain the coolant reservoir tank.

4. Remove the hose clamp that secures the hose to the cap fitting of the coolant reservoir tank, and remove the hose.

   Retain the coolant reservoir tank for installation later. Discard the hose and hose clamps.

   

   Figure 9

   1. Cap fitting (coolant reservoir tank)
   2. Hose clamp
   3. Hose

Drain pan capacity: 4 quarts or more.

1. Remove the hose clamp that secures the tank-return hose to the barbed fitting of the hydraulic filter head (Figure 10).

   

   Figure 10

   1. Tank-return hose
   2. Hose clamp
   3. Barbed fitting (filter head—hydraulic)

2. Remove the tank-return hose and allow the hydraulic fluid to fully drain from the filter head and hose (Figure 10).

3. Assemble the tank-return hose and hose clamp to the barbed fitting and tighten the clamp (Figure 10).

1. Remove the 4 flange head screws (1/4 x 1/2 inch) that secure the upper fan shroud to the flange of the radiator, and remove the shroud from the machine (Figure 18).

   

   Figure 18

   1. Flange head screws (1/4 x 1/2 inch)
   2. Flange (radiator)
   3. Upper fan shroud

2. Remove the 4 flange head screws (1/4 x 1/2 inch) that secure the lower fan shroud to the flange of the radiator, and remove the shroud from the machine (Figure 19).

   

   Figure 19

   1. Flange head screws (1/4 x 1/2 inch)
   2. Lower fan shroud
   3. Flange (radiator)

1. At the forward, lower corner of the radiator, remove the 2 flange capscrews (3/8 x 3/4 inch) that secure the radiator bracket to the rear casting of the machine (Figure 20).

   

   Figure 20

   1. Flange capscrews (3/8 x 3/4 inch)
   2. Right radiator bracket
   3. Right side of the machine
   4. Left radiator bracket
   5. Left side of the machine

2. Remove the 2 flange capscrews (3/8 x 3/4 inch) that secure the radiator bracket to the rear casting of the machine at the other side of the machine (Figure 20).

   Retain the flange capscrews for installation later.

3. Lift the radiator out of the machine (Figure 21).

   

   Figure 21

1. Remove the 2 flange head screws that secure the mounting frame to the radiator (Figure 22).

   

   Figure 22

   1. Carriage bolt
   2. Serrated-flange nut
   3. Mounting frame
   4. Flange head screw

2. Remove the 4 carriage bolts and 4 serrated-flange nuts that secure the mounting frame to the radiator (Figure 22).

   Discard the flange head screws, carriage bolts, and serrated-flange nuts.

3. Separate the mounting frame from the radiator (Figure 23).

   

   Figure 23

4. Remove the flange-head screw (#10 x 3/4 inch) and locknut (#10) that secure the glow plug relay to the radiator, and remove the relay (Figure 24).

   Retain the mounting frame, screw, locknut, and relay. Discard the radiator and attached hoses, tubes, and clamps.

   

   Figure 24

   1. Flange-head screw (#10 x 3/4 inch)
   2. Radiator
   3. Glow plug relay
   4. Locknut (#10)

1. Remove the 2 foam seals at the lower, inside corners of the mounting frame (Figure 25).

   

   Figure 25

   1. Foam seals (old)
   2. Mounting frame
   3. Foam seals (new)

2. Clean the surface of the frame where you removed the seals (Figure 25).

3. Remove the backing from the new foam seals (Figure 25).

4. Assemble the foam seals as shown in Figure 25.

1. Align the holes in the mounting frame to the holes in the radiator/oil cooler (Figure 26).

   

   Figure 26

2. Loosely assemble the mounting frame to the radiator/oil cooler (Figure 27) with the 2 flange head screws (1/4 x 3/4 inch).

   

   Figure 27

   1. Carriage bolt (5/16 x 3/4 inch)
   2. Serrated-flange nut (5/16 inch)
   3. Mounting frame
   4. Flange head screw (1/4 x 3/4 inch)

3. Assemble the mounting frame to the radiator/oil cooler (Figure 27) with the 4 carriage bolts (5/16 x 3/4 inch) and 4 serrated-flange nuts (5/16 inch).

   Tighten the serrated-flange nuts and the flange head screws.

1. At the forward, lower corner of the radiator, loosely assemble the radiator bracket to the rear casting of the machine (Figure 28) with the 2 flange capscrews (3/8 x 3/4 inch) that you removed in Removing the Radiator from the Machine.

   

   Figure 28

   1. Flange capscrews (3/8 x 3/4 inch)
   2. Right radiator bracket
   3. Right side of the machine
   4. Left radiator bracket
   5. Left side of the machine

2. At the other side of the machine, loosely assemble the radiator bracket to the rear casting (Figure 28) with the 2 flange capscrews (3/8 x 3/4 inch).

3. Tighten the 4 flange capscrews.

1. At the forward, lower corner of the radiator, assemble the 90° fitting (-8 O-ring face seal / 3/4 inch SAE) into the oil-cooler outlet as shown in Figure 29, and tighten the fitting nut.

   

   Figure 29

   1. Oil-cooler outlet
   2. 90° fitting (-8 O-ring face seal / 3/4 inch SAE)

2. Assemble the straight fitting (-8 O-ring face seal / 3/4 inch SAE) into the oil-cooler outlet of the radiator/oil cooler, and tighten the fitting (Figure 30).

   

   Figure 30

   1. Oil-cooler outlet
   2. Straight fitting (-8 O-ring face seal / 3/4 inch SAE)

3. Remove the fitting from the top port of the filter head (Figure 31).

   Discard the fitting.

   

   Figure 31

   1. Fitting
   2. Filter head
   3. Straight fitting (-8 O-ring face seal / 1-1/16 inch SAE)

4. Install the straight fitting (-8 O-ring face seal / 1-1/16 inch SAE) into the top port of the filter head (Figure 31).

5. Loosely assemble the straight fitting (Figure 32) of the hose—30 cm (11-3/4 inches) onto the straight fitting that you installed in step 4.

   

   Figure 32

   1. Straight fitting (-8 O-ring face seal / 1-1/16 inch SAE)
   2. Hose—30 cm (11-3/4 inches)
   3. Straight fitting (-8 O-ring face seal / 3/4 inch SAE)

6. Install the 90 fitting (Figure 32) of the hose onto the straight fitting (-8 O-ring face seal / 3/4 inch SAE) that you installed in step 2.

7. Tighten the hose fittings.

1. Align the bottom fan shroud to the machine as shown in Figure 33.

   

   Figure 33

   1. Bottom fan shroud

2. Assemble 2 support clamps to the oil-inlet tube (Figure 34).

   

   Figure 34

   1. Self-tapping screw (1/4 x 3/4 inch)
   2. Support clamp
   3. Oil-inlet tube
   4. Bottom fan shroud
   5. 90° fitting (-8 O-ring face seal / 3/4 inch SAE)

3. Thread the swivel nut of the tube onto the 90° fitting (Figure 34).

4. Secure the clamps, tube, and bottom shroud to the radiator/oil cooler (Figure 34) with 3 self-tapping screws (1/4 x 3/4 inch).

5. Tighten the swivel nut of the oil-inlet tube.

6. Align the top fan shroud to the machine as shown in Figure 35.

   

   Figure 35

   1. Top fan shroud

7. Secure the top fan shroud to the radiator/oil cooler (Figure 36) with 3 self-tapping screws (1/4 x 3/4 inch).

   

   Figure 36

   1. Self-tapping screws (1/4 x 3/4 inch)
   2. Top fan shroud
   3. Radiator/oil cooler

8. At the left side of the machine, assemble the top and bottom fan shrouds (Figure 37) with 2 flange-head screws (1/4 x 1/2 inch) and 2 serrated-flange nuts (1/4 inch).

   

   Figure 37

   1. Top fan shroud
   2. Serrated-flange nut (1/4 inch)
   3. Bottom fan shroud
   4. Flange-head screw (1/4 x 1/2 inch)

1. Loosely assemble the lower radiator hose to the outlet of the radiator with a hose clamp as shown in Figure 38.

   

   Figure 38

   1. Outlet (radiator)
   2. Hose clamp
   3. Lower radiator hose
   4. Inlet (engine)

2. Assemble the other end of the lower radiator hose to the inlet of the engine with a hose clamp (Figure 38).

3. Tighten both hose clamps.

Assemble the hose—8 x 254 mm (5/16 x 10 inches) onto the radiator overflow fitting and secure the hose to the fitting with a small hose clamp (Figure 39).

Figure 39

1. Radiator overflow fitting
2. Hose clamp
3. Hose—8 x 254 mm (5/16 x 10 inches)

1. Assemble the free end of the air-intake hose over the outlet at the top of the radiator (Figure 40).

   

   Figure 40

   1. Hose clamp
   2. Air-intake hose
   3. Outlet (radiator)

2. Secure the hose to the outlet with the hose clamp (Figure 40) that you removed in Removing the Radiator Hoses.

1. At the right side of the machine, remove the 2 flange-head screws (5/16 x 1 inch) and 2 serrated-flange nuts (5/16 inch) that secure the engine mount to the engine bracket of the frame (Figure 41).

   

   Figure 41

   1. Flange-head screw (5/16 x 1 inch)
   2. Serrated-flange nut (5/16 inch)
   3. Engine mount

2. Align the holes in the coolant reservoir bracket with the holes in the top and bottom fan shrouds, and the holes in the engine mount (Figure 42).

   

   Figure 42

   1. Top fan shroud
   2. Coolant reservoir bracket
   3. Flange-head screw (5/16 x 1 inch)
   4. Serrated-flange nut (5/16 inch)
   5. Engine mount

3. Loosely assemble the coolant reservoir bracket to the engine mount (Figure 42) with the 2 flange-head screws (5/16 x 1 inch) and 2 serrated-flange nuts (5/16 inch) that you removed in step 1.

4. Assemble the top fan shroud, bottom fan shroud, and coolant reservoir bracket (Figure 43) with 2 flange-head screws (1/4 x 1/2 inch) and 2 serrated-flange nuts (1/4 inch).

   

   Figure 43

   1. Top fan shroud
   2. Serrated-flange nut (1/4 inch)
   3. Bottom fan shroud
   4. Coolant reservoir bracket
   5. Flange-head screw (1/4 x 1/2 inch)

5. Tighten the flange-head screws (1/4 x 1/2 inch) and (5/16 x 1 inch) and serrated-flange nuts (1/4 inch) and (5/16 inch).

1. Loosely assemble the upper radiator hose to the inlet of the radiator (Figure 44) with a hose clamp that you removed in Removing the Radiator Hoses.

   

   Figure 44

   1. Upper radiator hose
   2. Hose clamp
   3. Inlet (radiator)
   4. Thermostat housing (engine)

2. Assemble the other end of the upper radiator hose to the thermostat housing of the engine (Figure 44) with the other hose clamp that you removed in Removing the Radiator Hoses.

3. Tighten the hose clamps.

1. At the reel-drive manifold, remove the straight fitting of the oil cooler return hose from port-T of the manifold (Figure 45).

   

   Figure 45

   1. Port-T (reel-drive manifold)
   2. Straight fitting
   3. Oil cooler return hose

2. Remove the oil cooler return hose from the machine (Figure 46).

   Discard the oil cooler return hose.

   

   Figure 46

Assemble the hose 90 cm (35-1/4 inches) onto the straight barb fitting and secure the hose with a hose clamp (Figure 47).

Figure 47

1. Hose 90 cm (35-1/4 inches)
2. Hose clamp
3. Straight barb fitting

1. At the bottom of the machine, align the oil cooler return hose to the right frame channel as shown in Figure 48.

   

   Figure 48

   1. Oil cooler return hose

2. Route the hose along the frame channel toward the control console (Figure 49).

   Important: Ensure that the hose routes through the hose guard welded to the frame channel.

   

   Figure 49

   1. Oil cooler return hose
   2. Hose guard

3. Install the straight barb fitting of the hose into port-T of the reel drive manifold (Figure 50).

   

   Figure 50

   1. Port-T (reel-drive manifold)
   2. Straight fitting
   3. Oil cooler return hose

4. Assemble the free end of the oil cooler return hose onto the oil-inlet tube and secure the hose with a hose clamp (Figure 51).

   

   Figure 51

   1. Oil Cooler Return Hose
   2. Hose clamp
   3. Oil-inlet tube

1. Align the console cover over the control console and lower the cover (Figure 54).

   

   Figure 55

2. Ensure that the magnetic catches of the console secure the cover.

1. Align the operator's seat over the fuel tank, and tip the seat to access the bottom.

2. Connect the 2-socket connector to the terminals for the seat switch (Figure 56).

   

   Figure 56

   1. Seat switch
   2. 2-socket connector (machine-wire harness)

3. Tilt the seat down and align the front holes in the seat straps with the holes in the support channel (Figure 57).

   

   Figure 57

   1. Flange-head capscrews
   2. Seat strap
   3. Support channel

4. Assemble the seat straps to the support channel (Figure 57) with the 2 flange-head capscrews that you removed in Removing the Operator’s Seat.

5. At the back of the operator’s seat, align the slots of the heat shield and the holes in the seat straps with the standoff on the cross tube (Figure 58).

   

   Figure 58

   1. Flange-head capscrews
   2. Seat
   3. Heat shield
   4. Seat straps

6. Secure the heat shield and seat straps to the cross tube with the 2 flange-head capscrews that you removed in Removing the Operator’s Seat.