Engine Component

Hydraulic/Transmission/Axle Cooler
Installation
FIG. 153: Install hydraulic cooler.
Connect proper lifting device to the two eyelets (1) on the
Hydraulic cooler (2). The weight of the hydraulic cooler is
approximately 33 kg (73 lb). 1

N021906004

FIG. 153
FIG. 154: Install hydraulic cooler.
Install hydraulic cooler (1) into cooling assembly (2).
Ensure hydraulic cooler remains straight up and down
during installation. 1

N021906003

FIG. 154
FIG. 155: Install exterior mounting bolts.
Install four bolts, washers and nuts (1).

N021906001

FIG. 155

79033095 D Rev. 02-59

Engine Component
FIG. 156: Install interior mounting bolts.
Install four bolts and washers (1), access from the top or
through the access holes (2).
1

2
1

N021606007

FIG. 156
FIG. 157: Connect interior hydraulic lines.
Remove plugs in the end of lines that prevent fluid from
escaping and dirt entering the system. Connect hydraulic
lines (2). Install two bolts, washers and nuts (1) to the
P-clips. Access from the top or through the access holes
(3). 2
3

N021606006

FIG. 157
FIG. 158: Install rear mounting bolts.
Install four bolts and washers (1).

N021406003

FIG. 158

02-60 79033095 D Rev.

 Engine Component
FIG. 159: Install the fuel cooler (2). Install two washers
and two bolts (1) on each side and tighten.
2

P100506006

FIG. 159
FIG. 160: Install fuel lines (2) and fasten to clips with
cable straps (1).

2
1

1
P100506005

FIG. 160
FIG. 161: Remove plugs from hoses. Install fuel lines (1)
onto fuel cooler core (2) in there original location.

P100506004

FIG. 161
FIG. 162: Install cover plate.
Apply anti-seize to threaded studs before installing knobs. 1
Install cover plate (2) and install knobs (1).

N021606005

FIG. 162

79033095 D Rev. 02-61

Engine Component
FIG. 163: Open fuel shut off.
At the primary fuel filter / water separator (1) on the left
side of the engine, turn shut off valve handle (2) 90
degrees counter clockwise. Shut off valve handle (2)
should be parallel to the valve. 2
1

N033006001

FIG. 163
FIG. 164: Install cover plate.
Apply anti-seize to threaded studs before installing knobs. 1
Install cover plate (2) and install knobs (1).

N021606005

FIG. 164
FIG. 165: Install upper brace.
Install upper brace (2) and install four bolts and washers
(1). Tighten the four bolts to 55 Nm (40 lbf ft).

1
2

N021406006

FIG. 165
FIG. 166: Install upper brackets.
Install brackets (2) and install bolts and washers (1). 2
Tighten the four bolts to 29 Nm (21 lbf ft).

N021306001

FIG. 166

02-62 79033095 D Rev.

 Engine Component
FIG. 167: Install lower brace.
Install lower brace (2) and install four bolts and washers
(1). Tighten the four bolts to 55 Nm (40 lbf ft).

1 2 1
N021406007

FIG. 167
FIG. 168: Fasten lower bracket.
1
Install bolts and washers (1) into bracket (2). Tighten the
four bolts to 29 Nm (21 lbf ft).

N020606003

FIG. 168
FIG. 169: Install oil cooler hoses.
Remove plugs in the end of hose that prevent fluid from
escaping and dirt entering the system. Install hydraulic
line (1).

N020606005

FIG. 169

79033095 D Rev. 02-63

Engine Component
FIG. 170: Install left side of fan shroud.
Install left half of shroud (2).
IMPORTANT: Do not tighten the bolts at this time. After
the other side is installed, adjust the shroud to
provide symmetrical clearance with fan. 1
Install bolts and washers (1) that fasten air conditioning
line to the shroud.
1

N012606005

FIG. 170
FIG. 171: Install right side of fan shroud.
Install right half of shroud (3).
Install bolts and washers (2) that fasten it to the cooler
assembly.
Install bolts, nuts and washers (1) that hold the two halves 2
of the shroud together and tighten. 1
IMPORTANT: Do not tighten the bolts that attach the
shroud to the cooler assembly at this time. Adjust
the shroud to provide symmetrical clearance with
fan.
After the shroud has a symmetrical clearance to the fan,
tighten the bolts (2) on each side of the shroud. 3

1
N011906002

FIG. 171

02-64 79033095 D Rev.

 Engine Component
FIG. 172: Install right guard.
Install guard (2) and install bolts and washers (1) and
tighten. Tighten the four bolts to 55 Nm (40 lbf ft).

N011906001

FIG. 172
FIG. 173: Install left guard.
Install guard (2) and install bolts and washers (1) and
tighten. Tighten the four bolts to 55 Nm (40 lbf ft).

1
1

N012606004

FIG. 173

79033095 D Rev. 02-65

Engine Component
FIG. 174: Install right side charge air tube.
IMPORTANT: Make sure that there is no dirt or debris in 1
2 2
the charge air tube, charge air cooler or intake
manifold.
IMPORTANT: Remove all the cloths that plug the turbo
outlet and hole in the charge air cooler to prevent
dirt entering the system.
Install charge air tube (1) and tighten bolts (2) on hose
clamps. Tighten to 7 Nm (61 lbf in).

N012606007

FIG. 174
FIG. 175: Install air intake.
Install air intake (2). Slide seal (3) back to its original
position. 3
Install bolts and washers (1). Tighten the four bolts to 29
Nm (21 lbf ft).
2

1 1

N012606006

FIG. 175
FIG. 176: Remove fanblast guard.
Install fanblast guard (2) and install four bolts (1). The
1
weight of the fanblast guard is approximately 58 kg (128 2
lb). Tighten bolts to 100 Nm (74 lbf ft).

1
P100506002

FIG. 176

02-66 79033095 D Rev.

 Engine Component
FIG. 177: Install hood.
Install hood (1). Refer to Removal and Installation - Hood
- Installation. 1

P100506003

FIG. 177
FIG. 178: Connect battery power at battery disconnect
switch.
Install key (1) and rotate to connect the battery power.
Refill system with approved hydraulic fluid.
Start engine and check all hoses and hose connections
for leaks.
1

N012206002

FIG. 178

79033095 D Rev. 02-67

Engine Component
COOLING ASSEMBLY - CHARGE AIR
COOLER REMOVAL AND
INSTALLATION

Charge Air Cooler Removal

m
WARNING: Hot engine components can
cause injury from burns. Before performing
maintenance on the engine, allow the
engine and the components to cool.

NOTE: Put identification marks on all hoses, on all hose

assemblies, on all wires, and on all tube
assemblies for installation purposes. Plug all
hose assemblies and all tube assemblies. This
helps to prevent fluid loss, and helps keep
contaminants from entering the system.
IMPORTANT: Care must be taken to ensure that fluids
are contained during performance of inspection,
maintenance, testing, adjusting, and repair of the
machine. Be prepared to collect the fluid with
suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations
and mandates.
FIG. 179: Battery disconnect switch
IMPORTANT: Park the machine on a hard, level surface.
Location of battery disconnect switch (1).
1

P100506001

FIG. 179
FIG. 180: Disconnect battery power at battery
disconnect switch.
Rotate and remove key (1) to disconnect the battery
power.

N012206002

FIG. 180

02-68 79033095 D Rev.

 Engine Component
FIG. 181: Remove hood.
Remove hood (1). Refer to Removal and Installation -
Hood - Removal. 1

P100506003

FIG. 181
FIG. 182: Remove air intake.
Remove bolts (1).
3
Slide air intake (2) forward. Carefully pull it out of its seal
(3).

1 1

N012606006

FIG. 182
FIG. 183: Remove right side charge air tube.
Clean dirt off of charge air tube (1) and its connections to 1
2 2
prevent dirt entering the system.
Loosen nuts (2) on hose clamps.
Remove charge air tube (1).
IMPORTANT: Plug turbo hole and hole in the charge air
cooler with clean cloth towels to prevent dirt
entering the system.

N012606007

FIG. 183

79033095 D Rev. 02-69

Engine Component
FIG. 184: Remove left side charge air tube.
Clean dirt off of charge air tube (1) and it connections to 2 1
prevent dirt entering the system.
Loosen nuts (2) on hose clamps.
Remove charge air tube (1).
IMPORTANT: Plug intake manifold and hole in the
charge air cooler with clean cloth towels to
prevent dirt entering the system. 2

N020606001

FIG. 184
FIG. 185: Fuel shut off.
At the primary fuel filter / water separator (1) on the left
side of the engine, turn shut off valve handle (2) 90
degrees clockwise. Shut off valve handle (2) should be
perpendicular to the valve. 2
1

N033006001

FIG. 185
FIG. 186: Remove fuel lines (1) from fuel cooler core (2).
Plug hoses to prevent fuel loss.
NOTE: Mark hoses to ensure that hoses are connected
to original location. 2

P100506004

FIG. 186
FIG. 187: Remove cover plate.
Remove knobs (1) and remove cover plate (2). 1

N021606005

FIG. 187

02-70 79033095 D Rev.

 Engine Component
FIG. 188: Remove plastic cable straps (1) from fuel lines
(2) and fasten out of the way.

2
1

1
P100506005

FIG. 188
FIG. 189: Remove the two bolts (1) from each side and
remove fuel cooler (2).
2

P100506006

FIG. 189
FIG. 190: Remove left side cover plate.
Remove knobs (1) and remove cover plate (2).
1

N021306002

FIG. 190
FIG. 191: Remove right side cover plate.
Remove knobs (1) and remove cover plate (2). 1

N022106001

FIG. 191

79033095 D Rev. 02-71

Engine Component
FIG. 192: Remove bottom fasteners on charge air
cooler.
Remove two bolts (1) on the bottom of the charge air
cooler (2).

2
1 1

N022106002

FIG. 192
FIG. 193: Connect lifting device.
Connect proper lifting device to the two eyelets (1) on the
charge air cooler (2). The weight of the charge air cooler
is approximately 34 kg (75 lb).

1 1
2
N022106003

FIG. 193
FIG. 194: Remove upper fasteners on charge air cooler.
Remove two bolts (1) on the charge air cooler (2).

2
1 1

N022106004

FIG. 194
FIG. 195: Remove charge air cooler.
Lift charge air cooler (1) straight up and forward, out of the
cooling assembly (2). The weight of the charge air cooler
is approximately 34 kg (75 lb).
2 1

P100506007

FIG. 195

02-72 79033095 D Rev.

 Engine Component
Charge Air Cooler Installation
FIG. 196: Install charge air cooler.
Connect proper lifting device to the two eyelets (1) on the
charge air cooler (2). The weight of the charge air cooler
is approximately 34 kg (75 lb).

1 1

N022106006

FIG. 196
FIG. 197: Install charge air cooler.
Install charge air cooler (1) into cooling assembly (2).

2 1

P100506007

FIG. 197
FIG. 198: Install upper fasteners on charge air cooler.
Install two bolts, spacers and washers (1) on the charge
air cooler (2).

2
1 1

N022106004

FIG. 198

79033095 D Rev. 02-73

Engine Component
FIG. 199: Install bottom fasteners on charge air cooler.
Install two bolts, spacers and washers (1) on the bottom
of the charge air cooler (2).

2
1 1

N022106002

FIG. 199
FIG. 200: Install right side cover plate.
Apply anti-seize to threaded studs before installing knobs. 1
Install cover plate (2) and install knobs (1), hand tighten.

N022106001

FIG. 200
FIG. 201: Install left side cover plate.
Apply anti-seize to threaded studs before installing knobs.
Install cover plate (2) and install knobs (1), hand tighten. 1

N021306002

FIG. 201
FIG. 202: Install the fuel cooler (2). Install two washers
and two bolts (1) on each side and tighten.
2

P100506006

FIG. 202

02-74 79033095 D Rev.

 Engine Component
FIG. 203: Install fuel lines (2) and fasten to clips with
cable straps (1).

2
1

1
P100506005

FIG. 203
FIG. 204: Remove plugs from hoses. Install fuel lines (1)
onto fuel cooler core (2) in there original location.

P100506004

FIG. 204
FIG. 205: Install cover plate.
Apply anti-seize to threaded studs before installing knobs. 1
Install cover plate (2) and install knobs (1).

N021606005

FIG. 205
FIG. 206: Open fuel shut off.
At the primary fuel filter / water separator (1) on the left
side of the engine, turn shut off valve handle (2) 90
degrees counter clockwise. Shut off valve handle (2)
should be parallel to the valve. 2
1

N033006001

FIG. 206

79033095 D Rev. 02-75

Engine Component
FIG. 207: Install left side charge air tube.
IMPORTANT: Make sure that there is no dirt or debris in 2 1
the charge air tube, charge air cooler or intake
manifold.
IMPORTANT: Remove all the cloths that plug the intake
manifold and hole in the charge air cooler to
prevent dirt entering the system.
Install charge air tube (1) and tighten nuts (2) on hose
clamps. Tighten to 7 Nm (61 lbf in). 2

N020606001

FIG. 207
FIG. 208: Install right side charge air tube.
IMPORTANT: Make sure that there is no dirt or debris in 1
2 2
the charge air tube, charge air cooler or turbo.
IMPORTANT: Remove all the cloths that plug the turbo
outlet and hole in the charge air cooler to prevent
dirt entering the system.
Install charge air tube (1) and tighten nuts (2) on hose
clamps. Tighten to 7 Nm (61 lbf in).

N012606007

FIG. 208
FIG. 209: Install air intake.
Install air intake (2). Slide seal (3) back to its original
position. 3
Install bolts and washers (1). Tighten the four bolts to 29
Nm (21 lbf ft).
2

1 1

N012606006

FIG. 209

02-76 79033095 D Rev.

 Engine Component
FIG. 210: Install hood.
Install hood (1). Refer to Removal and Installation - Hood
- Installation. 1

P100506003

FIG. 210
FIG. 211: Connect battery power at battery disconnect
switch.
Install key (1) and rotate to connect the battery power.

N012206002

FIG. 211

79033095 D Rev. 02-77

Engine Component
COOLING ASSEMBLY - AIR
CONDITIONING CONDENSER
REMOVAL AND INSTALLATION

Air Conditioning Condenser Removal

m
WARNING: Hot engine components can
cause injury from burns. Before performing
maintenance on the engine, allow the
engine and the components to cool.

NOTE: Put identification marks on all hoses, on all hose

assemblies, on all wires, and on all tube
assemblies for installation purposes. Plug all
hose assemblies and all tube assemblies. This
helps to prevent fluid loss, and helps keep
contaminants from entering the system.
IMPORTANT: Care must be taken to ensure that fluids
are contained during performance of inspection,
maintenance, testing, adjusting, and repair of the
machine. Be prepared to collect the fluid with
suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations
and mandates.

m
WARNING: Personal injury can result from
contact with refrigerant.
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 precaution when a fitting is
removed. Slowly loosen the fitting. If the
system is still under pressure, release it
slowly in a well ventilated area.
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.
Use a certified recovery and recycling cart
to properly remove the refrigerant from the
air conditioning system.

02-78 79033095 D Rev.