Heater Kit

Park the machine on a level surface.

Engage the parking brake.

Shut off the engine and remove the key.

Raise the bed and insert the safety bar.

Remove the battery cover and disconnect the positive battery cable.

Drain the engine coolant; refer to the Operator’s Manual.

Remove the hood; refer to the Operator’s Manual.

Remove the shield covering the hydraulic lines under the front, center of the machine (Figure 1).

Figure 1

1. Hydraulic shield

Loosely attach the elbow hose to the bottom fitting of the heater assembly with a hose clamp (Figure 2).

Figure 2

1. Hose (12 inches)
2. Heater
3. Hose clamp
4. Fill tee cap
5. Gasket
6. White fill tee
7. Short hose
8. Long hose
9. Heater valve
10. Elbow hose

Connect the heater valve to the elbow hose with a hose clamp (Figure 2).

Cut a 31 cm or 12 inches piece of hose (5/8 inch) and attach it to the top fitting of the heater assembly with a hose clamp (Figure 2).

Connect the white fill tee, gasket, and cap to the upper heater hose with a hose clamp (Figure 2).

Attach the heater bracket to the heater using the screws supplied with the heater (Figure 3).

Figure 3

1. Heater bracket

Attach the heater and bracket assembly onto the front frame tube using the U-bolts and flange nuts (Figure 4).

Figure 4

1. U-bolt
2. Flange nut
3. R-clamp

Attach the R-clamp under the top nut closest to the center of the machine (Figure 4).

Attach the heater control to the heater control mount using 4 sheet metal screws (Figure 5).

Figure 5

1. Self-tapping screw (#12 x 1/2 inch)
2. Flange-head bolt (5/16 x 3/4 inch)
3. Flange-head bolt (1/4 x 3/4 inch)

Connect the heater-control cable and black wire-harness connector to the heater control and the white wire-harness connector to the heater (Figure 5).

Align the bracket with the cutout in the dash, mark the area where the holes need to be drilled, and drill the holes.

Secure using 4 flange-head bolts (5/16 x 3/4 inch) in the front of the heater control mount and either 2 bolts (5/16 inch for the HD vehicles) on the side of the mount or 2 bolts (1/4 inch for the MD vehicles) on the inside top of the mount, depending on which model you have (Figure 5).

Route and connect the heater-control cable to the heater valve (Figure 6).

Figure 6

1. Heater-control cable

Remove the temperature switch from the thermostat housing (Figure 7).

Figure 7

1. Temperature switch

Install the adapter and tee fitting (Figure 8).

Figure 8

1. Adapter fitting
2. Tee fitting

Install the temperature switch and the hose (3/8 inch) and adapter fitting (5/8 inch) with hose clamps as shown in Figure 9.

Figure 9

1. Tee fitting
2. Temperature switch
3. Adapter fitting
4. Hose clamp

Cut the lower radiator hose and connect the tee fitting to each newly cut end of the lower radiator hose with the 2 wide hose clamps (Figure 10).

Figure 10

1. Short hose
2. Tee fitting

Cover the hoses (5/8 inch) with split corrugated tubing.

Connect the long hose to the heater valve with a hose clamp, and route it under the machine, over the axel, and to the straight fitting (Figure 11).

Figure 11

1. Long hose
2. Short hose

Connect the shorter hose to the white fill tee with a hose clamp, route it through the R-clamp on the heater bracket, and connect it to the tee fitting in the lower radiator hose with a hose clamp (Figure 11).

Remove the plug or temperature switch depending on the type of engine.

For gasoline engines:

1. Remove the plug in the thermostat housing (Figure 12).

   

   Figure 12

   1. Plug

2. Install the straight fitting (5/8 inch) with a hose clamp (Figure 13).

   

   Figure 13

   1. Hose clamp
   2. Straight fitting (5/8 inch)

For diesel engines:

1. Remove the temperature switch from the thermostat housing (Figure 14).

   

   Figure 14

   1. Temperature switch

2. Install a tee fitting (Figure 15).

3. Install the temperature switch (Figure 15).

   

   Figure 15

   1. Temperature switch
   2. Tee fitting

4. Install the hose (3/8 inch) and adapter fitting (5/8 inch) with hose clamps (Figure 16).

   

   Figure 16

   1. Hose clamp
   2. Straight fitting (5/8 inch)
   3. Temperature switch and tee fitting

Cut the lower radiator hose approximately 89 mm or 3-1/2 inches from the center line of the hose at the 90° bend (Figure 17).

Figure 17

1. Tee fitting
2. Lower radiator hose

Connect the tee fitting to each newly cut end of the lower radiator hose with the 2 wide hose clamps (Figure 17).

Cover the hoses (5/8 inch) with split corrugated tubing.

Connect the long hose to the heater valve with a hose clamp, and route it under the machine, over the axel, and to the straight fitting (Figure 18). Cut any excess hose to fit.

Figure 18

1. Long hose
2. Short hose

Connect the shorter hose to the white fill tee with a hose clamp, route it through the R-clamp on the heater bracket, and connect it to the tee fitting in the lower radiator hose with a hose clamp (Figure 18). Cut any excess hose to fit.

Connect the pink wire from the heater wire harness to an open lead on the fuse block.

If there is not an open fuse slot, install a new fuse block. Install the fuse in the open slot corresponding to the power lead you use.

Connect the black wire from the heater wire harness to the ground block.

Tie all the hoses and wires away from sharp edges and moving parts.

Install the previously removed hydraulic shield over the hoses. Install the battery cable and battery cover.

Remove the radiator cap and fill the radiator with coolant; refer to the Operator’s Manual.

Remove the cap on the white tee near the heater assembly and fill with coolant. Install the cap. Install the hood.

Remove the radiator cap.

Start the engine and open the bleed screw on the thermostat cover until a steady stream of coolant comes out.

Close the bleed screw.

Shut off the engine.

Top off the radiator and install the cap.

After running the engine up to full temperature and letting it cool down, check the coolant level again and fill it, if needed.

Park the machine on a level surface.

Engage the parking brake.

Shut off the engine and remove the key.

Raise the bed and engage the prop rod.

Remove the battery cover and the positive battery cable.

Drain the coolant; refer to the Operator’s Manual.

Open the hood.

Attach the elbow hose to the bottom fitting of the heater assembly with a hose clamp (Figure 19).

Figure 19

1. Hose (14 inches)
2. Heater
3. Hose clamp
4. Fill tee cap
5. Gasket
6. White fill tee
7. Short hose
8. Long hose
9. Heater valve
10. Elbow hose

Connect the heater valve to the elbow hose with a hose clamp (Figure 19).

Cut a 36 cm or 14 inch piece of hose (5/8 inch) and attach it to the top fitting of the heater assembly with a hose clamp (Figure 19).

Connect the white fill tee, gasket, and cap to the upper heater hose with a hose clamp (Figure 19).

Drill a hole (5/16 inch) in the glove box 216 mm or 8-1/2 inches from the left and 38 mm or 1-1/2 inches from the bottom (Figure 20).

Figure 20

Attach the heater bracket to the heater using the screws supplied with the heater (Figure 21).

Figure 21

1. Heater bracket

Attach the heater and bracket assembly onto the front frame tube, snug against the U-frame, using the U-bolts and flange nuts provided (Figure 22).

Figure 22

1. R-clamp
2. Flange nut
3. U-frame
4. U-bolt

Attach the R-clamp to the glove box with a flange-head bolt and nut (Figure 22).

Attach the heater-control mount to the dash under the cup holders with 2 flange-head bolts and nuts (Figure 23).

Figure 23

1. Heater-control cable
2. White wire-harness connector
3. Heater-control mount
4. Black wire-harness connector
5. Heater control
6. Flange-head bolt
7. Sheet metal screw

Connect the heater-control cable and black wire-harness connector to the heater control and the white wire-harness connector to the heater (Figure 23).

Attach the heater control to the heater-control mount using 4 sheet metal screws (Figure 23).

Route and connect the heater-control cable to the heater valve (Figure 24).

Figure 24

1. Heater-control cable

Mark and drill 2 holes in the seatbase using a hole saw (1 inch) as shown in Figure 25.

Ensure that you drill through both layers of plastic.

Figure 25

Put down a drip pan. Remove the plug under and to the front of the thermostat housing, apply pipe sealant to the threads on the straight fitting (5/8 inch), and install it on the machine (Figure 26).

Figure 26

1. Straight fitting (5/8 inch)

Cut the lower radiator hose about 54 mm or 2-1/8 inches from the end of the hose going into the radiator (Figure 27).

Figure 27

1. Tee fitting in the lower radiator hose

Connect the tee fitting to each newly cut end of the lower radiator hose with the 2 wide hose clamps (Figure 27).

Connect the long hose to the heater valve with a hose clamp, and route it through the hole in the seat base, the hole in the bed frame, and to the straight fitting with a hose clamp (Figure 28). Cut any excess hose to fit.

Figure 28

1. Short hose
2. Long hose

Connect the shorter hose to the white fill tee with a hose clamp, route it through the R-clamp on the glove box, through the hole in the seat base, and connect it to the tee fitting in the lower radiator hose with a hose clamp (Figure 28). Cut any excess hose to fit.

Connect the pink wire from the heater wire harness to an open lead on the fuse block.

If there is not an open fuse slot, install a new fuse block. Install the fuse in the open slot corresponding to the power lead you use.

Connect the black wire from the heater wire harness to the ground block.

Cover the exposed hoses (5/8 inch) with split corrugated tubing.

Tie all the hoses and wires away from sharp edges and moving parts.

Place the hose channel over the hoses on the floorboard and line up the forward edge with the front edge of the floorboard. Mark and drill holes in the floorboard and install the self-tapping screws (Figure 29).

Figure 29

1. Hose channel

Install the previously removed battery cable and battery cover.

Remove the radiator cap and fill the radiator with coolant; refer to the Operator’s Manual.

Important: When filling the coolant system, do not leave the pressurized recovery tank open when filling at another point in the system. This can result in overfilling the tank. It is important to have an air gap at the top of the tank. Do not have more than 1 system cap off at a time.

Remove the cap on the white tee near the heater assembly and fill with coolant. Install the cap.

Remove the cap from the pressurized recovery tank and fill it up to the bottom of the down-tube.

After running the engine up to full temperature and letting it cool down, check the coolant level again at the pressurized recovery tank, and fill it up to the bottom of the down-tube if needed.