Form No. 3434-448 Rev A Heater Kit Liquid-Cooled Workman® MD/HD Utility Vehicle Model No. 07349—Serial No. 405500001 and Up Installation Instructions Loose Parts Use the chart below to verify that all parts have been shipped.
Description Qty.
For HDX, HDX-D, and HDX-Auto Vehicles Assembling the Heater 1. Loosely attach the elbow hose to the bottom fitting of the heater assembly with a hose clamp (Figure 2). Preparing the Machine 1. Park the machine on a level surface. 2. Engage the parking brake. 3. Shut off the engine and remove the key. 4. Raise the bed and insert the safety bar. 5. Remove the battery cover and disconnect the positive battery cable. 6. Drain the engine coolant; refer to the Operator’s Manual. 7.
Installing the Heater and Heater Control 1. Attach the heater bracket to the heater using the screws supplied with the heater (Figure 3). g023414 Figure 5 g018041 Figure 3 1. Self-tapping screw (#12 x 1/2 inch) 1. Heater bracket 2. 2. Flange-head bolt (5/16 x 3/4 inch) Attach the heater and bracket assembly onto the front frame tube using the U-bolts and flange nuts (Figure 4). g017984 Figure 4 1. U-bolt 3. R-clamp 2. Flange nut 3.
g269459 Figure 8 1. Adapter fitting 2. Tee fitting g017986 Figure 6 3. 1. Heater-control cable Install the temperature switch and the hose (3/8 inch) and adapter fitting (5/8 inch) with hose clamps as shown in Figure 9. Installing the Hoses for the HDX-Auto 1. Remove the temperature switch from the thermostat housing (Figure 7). g268910 Figure 9 g268912 1. Tee fitting 3. Adapter fitting 2. Temperature switch 4. Hose clamp Figure 7 4. 1. Temperature switch 2.
Installing the Hoses for the HDX and HDX-D 1. Remove the plug or temperature switch depending on the type of engine. For gasoline engines: A. Remove the plug in the thermostat housing (Figure 12). g025970 g268914 Figure 10 1. Short hose Figure 12 2. Tee fitting 1. Plug 5. Cover the hoses (5/8 inch) with split corrugated tubing. 6. 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). B.
For diesel engines: A. 2. Remove the temperature switch from the thermostat housing (Figure 14). 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). g017988 Figure 17 g268920 Figure 14 1. Tee fitting 2. Lower radiator hose 1. Temperature switch B. Install a tee fitting (Figure 15). C. Install the temperature switch (Figure 15). 3.
For the MDX-D Vehicle Connecting the Wiring 1. Connect the pink wire from the heater wire harness to an open lead on the fuse block. Preparing the Machine 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. 2. 1. 2. 3. 4. 5. Connect the black wire from the heater wire harness to the ground block. Finishing and Checking the Installation 1. Tie all the hoses and wires away from sharp edges and moving parts. 2.
4. Connect the white fill tee, gasket, and cap to the upper heater hose with a hose clamp (Figure 19). 3. For 2015 and older machines—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). Installing the Heater and Heater Control 1. 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). g018025 Figure 20 2.
4. For 2016 and newer machines— A. C. Remove the 2 screws (5/16 x 3/4 inch) securing the dash to the machine frame (Figure 23). Using the heater bracket as the template, drill 2 holes (5/16 inch) into the dash support (Figure 25). Retain the screws. g296659 Figure 23 1. Dash 2. Screw (5/16 x 3/4 inch) g296658 B. Figure 25 Secure the right side of the heater bracket to the dash using the previously removed 2 screws (5/16 x 3/4 inch) as shown in Figure 24. D.
E. Secure the heater to the heater bracket using 4 hex-head bolts (3/8 x 3/4 inch) and 4 flange nuts (3/8 inch) as shown in Figure 27. 7. Connect the heater-control cable and black wire-harness connector to the heater control and the white wire-harness connector to the heater (Figure 28). 8. Attach the heater control to the heater-control mount using 4 sheet metal screws (Figure 28). 9. Route and connect the heater-control cable to the heater valve (Figure 29). g296660 Figure 27 1.
Installing the Hoses 1. Mark and drill 2 holes in the seatbase using a hole saw (1 inch) as shown in Figure 30. Ensure that you drill through both layers of plastic. g017991 Figure 32 g017990 Figure 30 2. 1. Tee fitting in the lower radiator hose 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 31). 4.
Connecting the Wiring 1. 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. 2. Connect the black wire from the heater wire harness to the ground block. Finishing and Checking the Installation 1. Cover the exposed hoses (5/8 inch) with split corrugated tubing. 2. Tie all the hoses and wires away from sharp edges and moving parts. 3.
Declaration of Incorporation Model No. 07349 Serial No. Product Description Invoice Description General Description Directive 405500001 and Up Heater Kit, Liquid-Cooled Workman MD/HD Utility Vehicle MD/HD HEATER KIT-LIQUID COOLED ENGINES Utility Vehicle Accessory 2006/42/EC Relevant technical documentation has been compiled as required per Part B of Annex VII of 2006/42/EC.
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