30 - 2
Removal and Replacement
Removal
1
Park the machine on firm level ground, engage the
parking brake and set the transmission to neutral.
Chock the road wheels.
2
Raise the loader arms and fit the loader arm safety
strut.
Note:
In the event of engine failure, the loader arms will have
to be raised using suitable lifting equipment. Make sure that
the loader control lever is in the ‘raise arms’ position before
manually lifting the loader arms.
3
Remove the engine side panels
4
Remove the engine cover (including the exhaust stack).
5
Disc onnec t t he b at t ery. When d isc onnec t ing t he
battery, take off the earth (black) lead first.
6
Remove retaining bolts and then lift off the front grille.
7
Remove retaining bolts
A
and
B
(both sides) and lift off
the front nose guard.
8
Disconnect the hydraulic oil cooler hoses
C
from the
hydraulic oil cooler. Plug and cap open ports to prevent
ingress of dirt.
Note:
When installing and removing hoses from the cooler, it
is essential to note that adaptor
D
must be held with a
spanner whilst installing or removing the hose. It may be
easier to remove the top hose connection once the cooler
has been removed from the machine.
9
Drain the cooling system.
10
Remove the transmission oil cooler hoses
E
.
11
Remove the radiator top hose and bottom hose.
12
Remove the coolant bottle pipe.
13
M ake a suit ab le alignment mark t o allow c orrec t
repositioning of the radiator shroud, as shown at
F
.
14
If an engine fan guard is fitted, remove retaining bolts
and lift off the guard.
15
Remove retaining bolts
G
(both sides) and lift off the
radiator sub-assembly including radiator, hydraulic and
transmission coolers, and shroud. Take care not to
d am ag e t he eng ine f an, no t e also t hat t he sub -
assembly is heavy, use suitable lifting equipment.
Note:
If required, the shroud, radiator and coolers can be
removed as individual items.
16
Loosen and remove the exhaust silencer retaining
bolts, remove the silencer.
17
Loosen and remove the retaining clamp for the heater
hose. Remove the hose.
18
Loosen and remove the retaining clamp for the air filter
intake hose.
19
Remove the air intake filter. Use tape to close the
opening in the air intake manifold, this will prevent
ingress of dirt.
20
Loosen and remove the brake master cylinder reservoir
retaining bolts. Do not remove the pipes attached to
the master cylinder reservoir but put the reservoir out
of the way. Make sure that the fluid level does not drain
down.
21
Lab el and remove all elec t ric al c onnec t ions, t he
number of connectors will vary depending on the
anc illary eq uip ment fit t ed t o t he engine. Typ ic al
electrical connectors are:
i) starter
motor
ii) alternator
iii)
coolant pressure switch
iv)
coolant temperature sender
v)
engine oil pressure switch
vi)
engine temperature sender
vii)
engine shut off solenoid
viii)
ether cold start (if fitted)
ix)
air conditioning compressor (if fitted)
22
If air conditioning is fitted:
Note:
The air conditioning is a pressurised closed loop
system, do not disconnect the hoses to the compressor.
Leave the hoses to the compressor intact.
a
Rem o ve t he b elt f ro m t he c lut c h o f t he air
conditioning compressor.
b
Disc o nnec t t he elec t ric al c o nnec t o rs at t he
compressor.
c
Lo o sen and rem o ve t he air c o nd it io ning
compressor retaining bolts.
d
Put the air conditioning compressor out of the way
(do not allow the compressor to ‘ hang’ on its
hoses).
23
Loosen and disconnect the fuel lines
J
from the fuel
sedimenter. Plug and cap open orifices to prevent
ingress of dirt and loss of fuel.
24
Loosen and remove the retaining bolts for the fuel
sedimenter, remove the sedimenter
K
.
......cont’d
Section K
9803/3280
Section K
30 - 2
Issue 1
Engine
