Required Tools | |||
Tool | Part Number | Part Description | Qty |
A | 138-7573 | Link Bracket | 2 |
B | 138-7575 | Link Bracket | 3 |
ZZ | 6V-9511 | Face Seal Plug | 1 |
9U-7085 | Cap | 2 | |
9U-7095 | Cap | 4 | |
9U-7096 | Cap | 1 |
Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL OR THE INSTALLATION. THIS TOOLING IS SHOWN IN ORDER TO ASSIST THE EXPERIENCED SERVICEMAN.
- Attach Tooling (B) to modular front end (60). Attach a suitable lifting device to Tooling (B). Attach the lifting device to a suitable crane. The weight of the complete modular front end is approximately
4826 kg (10640 lb) .Show/hide tableIllustration 2 g00917169 - Align modular front end (60) with truck frame (62).
- Secure the modular front end to the truck frame with bolts (61).
- Repeat Steps 2 and 3 for opposite side of the modular front end.
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Illustration 3 g00917170 - Align the center frame of the modular front end to truck frame (59).
- Secure the modular front end with bolts (58).
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Illustration 4 g00917172 - Secure electrical box (56) to the front bumper with bolts (57).
Note: Ensure that the harness assembly for warning light (53) is properly routed during installation. Also ensure that the harness assembly for the warning light is not damaged during installation.
Show/hide tableIllustration 5 g00917174 - Position right panel (55) and warning light (53) on the modular front end. Secure the panel with bolts (52).
- Repeat Step 8 in order to install left panel (54) on the modular front end.
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Personal injury can result from contact with refrigerant.
This system is under pressure at all times, even if the engine is not running. Heat should never be applied to a charged system.
Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury.
Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant.
Always use caution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, evacuate the system recovering the refrigerant before removing the fitting.
Personal injury or death can result from inhaling refrigerant through a lit cigarette.
Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death.
Do not smoke when servicing air conditioners or wherever refrigerant gas may be present.
Before any checks of the air conditioning and heating system are made, move the machine to a smooth horizontal surface. Lower all implements to the ground. Make sure the transmission is in NEUTRAL or PARK and that the parking brake is engaged. Keep all other personnel away from the machine or where they can be seen.
Show/hide tableIllustration 6 g00917177 - Connect hose assemblies (50) and (51) at the quick connect ports.
Note: It is not necessary to recharge the air conditioning system after the installation.
Show/hide tableIllustration 7 g00917179 - Connect hose assembly (49) to tee (48).
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Illustration 8 g00917180 - Connect hose assembly (46) to piston pump (47).
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Illustration 9 g00917181 - On the left side of the truck, align top mounting flange (45) to the modular front end. Secure the top mounting flange to the radiator by installing bolts (44).
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Illustration 10 g00917182 - Position upper panel (42) on the truck. Secure the panel with bolts (43).
- Install air inlet elbow (40). Position u-bolt assembly (41). Secure the inlet elbow by tightening hose clamps (39). Tighten the u-bolt.
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Illustration 11 g00917183 - Position and secure lower panels (37) with bolts (38).
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Illustration 12 g00917184 - Position and secure middle panel (36) with bolts (35).
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Illustration 13 g00917185 - Position bracket (34) on truck frame (32). Secure the bracket to the truck frame with bolts (33).
- Repeat the following Steps for the opposite side of the truck: 13, 14, 15, 16, 17 and 18.
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Illustration 14 g00917186 - Connect hose assembly (30) to hydraulic tank filler neck (31). Secure the hose with the bolts.
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Illustration 15 g00917188 - Attach a suitable lifting device to catwalk assembly (29). The weight of the catwalk assembly is approximately
50 kg (110 lb) . - Position catwalk assembly (29) on the truck frame. Secure the catwalk assembly to the truck frame with bolts (28).
- Repeat Step 21 for the catwalk assembly on the opposite side of the truck.
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Illustration 16 g00917189 - Connect hose assembly (27) to the modular front end. Connect top tubes (26) to the modular front end. Tighten hose clamps (25) in order to secure top tubes.
- Install Tooling (A) to the expansion tank, as shown. Install a suitable lifting device to Tooling (A). Attach the lifting device to a suitable crane. The combined weight of the expansion tank and hood assembly is approximately
227 kg (500 lb) .Show/hide tableIllustration 17 g00917190 - Lift expansion tank (15) and the hood assembly as a unit into the correct position.
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Illustration 18 g00917192 - Install the following parts in order to secure the hood assembly: bolts (20), nuts (24), washers (21), mounting (22) and spacers (23).
- Repeat Step 27 for the opposite side of the hood assembly mounting.
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Illustration 19 g00917210 - Secure hood assembly (19) to the modular front end with bolts (18).
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Illustration 20 g00917196 - Connect hoses (17) to the expansion tank. Tighten hose clamps (16).
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Illustration 21 g00917198 - Connect hose assembly (14) to expansion tank (15).
- Repeat Step 31 for the hose assembly on the opposite side of the expansion tank.
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Illustration 22 g00917199 - Position cover (12) on the expansion tank. Secure the cover by installing bolts (13).
- Repeat Step 33 for the cover on the opposite side of the expansion tank.
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Illustration 23 g00917201 - Connect harness assembly (11) that is located on top of the radiator tanks.
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Illustration 24 g00917203 - Slide radiator hose (10) in order to connect tube (8) to the radiator (7). Secure the radiator hose by tightening hose clamps (6).
Note: Ensure that drain plug (9) is tight.
- Repeat Step 36 for the opposite radiator hose.
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Illustration 25 g00917204 - Connect the harness assembly for warning light (5).
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Illustration 26 g00917206 - Connect harness assembly (3). Secure harness assembly with cable straps (4).
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Illustration 27 g00917208 - With the assistance of another person, position panel (2) on the truck frame. The weight of each panel is approximately
53 kg (117 lb) . - Secure panels (2) to the frame of the truck by installing bolts (1).
- Repeat Step 40 for the panel on the opposite side of the truck.
- Refill the engine cooling system to the correct level with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant (DEAC) - Change" for the correct procedures and for the correct fluid capacities. The capacity of the cooling system is
775 L (205 US gal) .
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Illustration 1 | g00917168 |
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- Install the hood. Refer to Disassembly and Assembly, "Hood - Remove and Install" for the correct procedure.
- Remove the truck body retaining cable. Lower the truck body. Refer to Disassembly and Assembly, "Truck Body Retaining Cable - Remove and Install" for the correct procedure.