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 cooling system.
2. Loosen the hose clamps and remove tubes (1).
3. Remove fan guard bracket (2).
4. Remove tube (3).
5. Loosen the clamps. Move two hoses (4) down to clear the elbows on the engine.
6. Disconnect four hoses (5). Two to each water line (4).
7. Disconnect ground strap (6) from the engine front support.
8. Remove the bolts that hold electrical box (7) to the engine front support. Tie the electrical box in place while the support is removed.
9. Loosen the clamps on hose (8).
10. Loosen the clamps on hose (9).
11. Loosen the clamps on two hoses (10).
12. Remove four nuts, bolts and washers (11) that fasten the trunnion to the engine front support.
13. Disconnect hose (12) from the bracket. Remove the fitting from the bracket.
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There is very little clearance between the fan blades, fan guard and the radiator. Also there is not much allowance for movement in the various lines and hoses that are still connected to the engine. Pay close attention to clearances as the front of the engine is raised. Raise the engine only enough to remove the support. Remove or loosen additional parts as required. |
14. Remove the bolts and bracket (13). Attach a hoist to the front engine lifting eye. Lift the front of the engine off the engine front support. The total weight of the engine is approximately 8875 kg (19500 lb).
15. Remove the two nuts, washers and bolts that fasten engine front support (14) to the frame.
16. Attach a hoist to the engine front support. Raise the engine front support enough to move it from the cradles on the frame side rails, then lower it to the ground. The engine front support weighs 260 kg (572 lbs.).
17. Remove two mount assemblies (15) and remove sleeve (16) from the engine front support.
NOTE: The following steps are for installation of the engine front support.
18. Make sure the mating surfaces of the engine front support, trunnion and the frame are free of paint.
19. Place lower mount assemblies (15) in position on the frame.
20. Use a hoist and put engine front support (14) in position on the mount assemblies.
21. Install sleeve (16) upper mount assemblies along with the bolts, washers and nuts that hold engine front support (14) to the frame.
22. Lower the engine on to the engine front support.
23. Install bolts, washers and nuts (11) through the trunnion and engine front support. Tighten bolts (11) to a torque of 475 ± 50 N·m (350 ± 37 lb ft).
24. Reverse the procedures and Steps 2 through 14.
| NOTICE |
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Bracket (13) must be installed before the truck is put back into service. Damage to the turbochargers could result if the bracket is not in place while the truck is in service. |
25. Fill the cooling system with coolant to the correct level. Refer to the Operation & Maintenance manual for this information.