Removal Procedure
| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Part Description | Qty |
| A | 138-7575 | Link Bracket | 2 |
| B | 138-7574 | Link Bracket | 2 |
| C | 1U-9200 | Lever Puller Hoist | 1 |
| D | 1U-9760 | Jack Stand | 4 |
Start By:
- Apply the foot brake valve several times in order to relieve the pressure in the brake system. Refer to Systems Operation, Testing and Adjusting, RENR5156, "Machine Preparation for Troubleshooting".
- Turn the battery disconnect switch to the OFF position. Refer to Operation and Maintenance Manual, "Battery Disconnect Switch (if equipped)".
- Release the hydraulic system pressure. Refer to Disassembly and Assembly Manual, "Hydraulic System Pressure - Release".
- Remove the bottom guard. Refer to Disassembly and Assembly Manual, "Sump Guard - Remove and Install".
- Recover the air conditioner refrigerant from the air conditioner system if the machine is equipped with an air conditioning system. The correct charge is 1.1 kg (2.45 lb). Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the correct procedure. Refer to Special Publication, NEDG5065, "Air Conditioning Tools" for the correct tools.
- Drain the fuel tank. Refer to Operation and Maintenance Manual, "Fuel Tank Water and Sediment - Drain".
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Personal injury or death can result from a fire. Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Clean up all leaked or spilled fuel. Do not smoke while working on the fuel system. Turn the disconnect switch OFF or disconnect the battery when changing fuel filters. |
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Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed. |
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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. |
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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the cooling system pressure cap is cool enough to touch with your bare hand. Remove the cooling system pressure cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury. |
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| NOTICE |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
- Put identification marks on all lines, hoses, wires and tubes for installation purposes. Plug all lines, hoses and tubes. This helps prevent fluid loss and contamination of the coolant system, the fuel system, the hydraulic oil system and the refrigerant system.
- Disconnect hoses (1) for the coolant. Drain any coolant from the heater into a suitable container. Plug the hoses and ensure that the ends of the hoses are elevated. Keep the hoses elevated in order to stop any coolant from draining out.
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| Illustration 1 | g00941414 |
- Disconnect hoses (2) for the refrigerant.
Note: Hoses (2) will only be found on machines that are equipped with an air conditioning system.
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| Illustration 2 | g00941415 |
- Remove panel (3) .
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| Illustration 3 | g00941416 |
- Place identification marks on control cable (4) and control cable (5) for the purpose of installation.
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| Illustration 4 | g00941417 |
- Disconnect control cable (4) and control cable (5) from control valve (6). Perform the following steps in order to disconnect the control cables from the control valve.
- Loosen locknut (7) until the locknut is disengaged from the thread on control cable (4). Move the locknut out of the way along the control cable.
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Illustration 6 g00941419
- Remove bolts (9) that secure sleeve (8) to control valve (6) .
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Illustration 7 g00941420
- Loosen sleeve (8) until the sleeve is disengaged from the thread on control cable (4). Move the sleeve out of the way along the control cable.
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Illustration 8 g00941421
- Use a soft drift to remove pin (10) that joins control cable (4) to control valve (6) .
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Illustration 9 g00941422
- Lay control cable (4) aside.
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Illustration 10 g00941423
- Repeat Step 6.a to Step 6.e in order to disconnect control cable (5) .
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| Illustration 5 | g00941418 |
- Trace control cable (4) and control cable (5) from control valve (6) through the cab and to the joystick. For the purpose of installation, make a note of the path of the control cables.
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| Illustration 11 | g00941424 |
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| Illustration 12 | g00941425 |
Inside of the cab | |
- Carefully feed control cable (4) and control cable (5) into the cab.
- Disconnect electrical connector (11) for the rear axle. Stow the cab part of the electrical connector inside the cab.
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| Illustration 13 | g00941426 |
- Disconnect fuel lines (12). Move the fuel lines aside.
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| Illustration 14 | g00941427 |
- Remove cover (13) .
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| Illustration 15 | g00941428 |
- Disconnect electrical wires (15) from brake pedal (14). Place identification marks on all the electrical wires in order to identify the correct positions of the electrical wires for the purpose of installation.
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| Illustration 16 | g00941480 |
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| Illustration 17 | g00941482 |
- Loosen nut (17) and the bolt in order to disconnect electrical wire (16) from brake pedal (14) .
- Disconnect harness (18) from the cab at bulkhead fitting (19) .
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| Illustration 18 | g00941483 |
- Disconnect harness (20) at bulkhead fittings (21) .
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| Illustration 19 | g00941495 |
- Disconnect electrical connectors (23) from metering pump (22). Place identification marks on all the electrical connectors in order to identify the correct positions of the electrical connectors for the purpose of installation.
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| Illustration 20 | g00941496 |
- Disconnect electrical wires (25) from electric horn (24). Place identification marks on all the electrical wires in order to identify the correct positions of the electrical wires for the purpose of installation.
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| Illustration 21 | g00941497 |
- Disconnect cable (27) for the throttle from accelerator control (26). Perform the following steps in order to disconnect the cable.
- Remove nut (29) and the washer in order to disconnect spring (28) .
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Illustration 23 g00941499
- Remove bolts (30), the nuts and the washers in order to remove clamp (31) and plate (32) .
- Remove clip (34) before removing pin (33) that secures cable (27) to accelerator control (26) .
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Illustration 24 g00941500
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| Illustration 22 | g00941498 |
- Disconnect hose (35) and hose (36) from brake pedal (14). Move hose (36) aside.
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| Illustration 25 | g00941501 |
- Disconnect hose (37) from metering pump (23). Move the hose aside.
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| Illustration 26 | g00941866 |
- Disconnect hoses (38) from metering pump (23). Move the hoses aside.
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| Illustration 27 | g00941867 |
- Disconnect hose (39) from metering pump (23). Move the hose aside.
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| Illustration 28 | g00941868 |
- Disconnect hoses (40) from metering pump (23). Move the hoses aside.
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| Illustration 29 | g00941870 |
- For the purpose of installation, make a note of the path of hose (35) that was connected to brake pedal (14). Note the path of the hose behind metering pump (23). Carefully draw the hose from behind the metering pump and move the hose aside.
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| Illustration 30 | g00941872 |
- Disconnect hose (41) from metering pump (23). Move the hose aside.
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| Illustration 31 | g00941873 |
- Trace the path of lines (42) for the window washers from the underside of the cab to the underside of the engine enclosure. Make a note of the path of the lines for the purpose of installation.
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| Illustration 32 | g00941874 |
Underside of the cab | |
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| Illustration 33 | g00941875 |
location of cable straps | |
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| Illustration 34 | g00942109 |
Underside of the engine enclosure | |
- Disconnect lines (42) for the window washers from nonreturn valves (43). Cut the cable straps that secure the lines in place. Make a note of the number and the location of all the cable straps for the purpose of installation.
- Gather lines (42) for the window washers together and secure the lines in a safe position to the underside of the cab.
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| Illustration 35 | g00942110 |
- Remove cover (44) .
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| Illustration 36 | g00942112 |
- Remove cotter pin (45). Remove pin (48) and the washer and loosen adjusting nuts (46) in order to disconnect parking brake control cable (47) from the parking brake control.
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| Illustration 37 | g00942113 |
- Disconnect electrical wires (49) from the parking brake control. Place identification marks on the electrical wires in order to clearly identify the correct electrical wires that must be connected to the correct terminals for the purpose of installation. Move the electrical wires aside.
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| Illustration 38 | g00942114 |
- Reinstall cover (44) .
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| Illustration 39 | g00942115 |
- Remove bolts (50) and washers (51) .
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| Illustration 40 | g00942116 |
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| Illustration 41 | g00942117 |
- Install Tooling (A), washers (51) and 8T-4196 Bolts .
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| Illustration 42 | g00942118 |
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| Illustration 43 | g00942293 |
- Install Tooling (B), 8T-7338 Bolts, 8T-4122 Hard Washer, and spacers. Use a sufficient number of suitable spacers under the Tooling in order to keep the Tooling level.
- Attach a suitable double chain lifting sling between Tooling (B) and a suitable hoist. Attach Tooling (C) to the hoist and use suitable nylon lifting slings to attach Tooling (C) to Tooling (A) .
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| Illustration 44 | g00942317 |
- Use the attached lifting equipment to support the weight of the cab. The weight of the cab is approximately 700 kg (1540 lb).
- Remove bolts (53), the washers and washers (52) that secure the cab to the frame of the machine.
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| Illustration 45 | g00942306 |
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| Illustration 46 | g00942309 |
- Use the attached lifting equipment to carefully lift the cab from the machine. Ensure that the bosses on the cab are clear of the mounting points on the machine.
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| Illustration 47 | g00942323 |
Bosses at the front mounting points | |
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| Illustration 48 | g00942325 |
Bosses at the rear mounting points | |
- Remove the cab carefully from the machine.
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| Illustration 49 | g00943440 |
- Lower the cab carefully onto Tooling (D). Ensure that there is sufficient clearance between the ground and cover (44) .
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| Illustration 50 | g00943441 |
- Remove all the lifting equipment, the hoist, Tooling (B), the bolts and the hard washers from the cab.
- Remove Tooling (A), the bolts and washers (51).
- Reinstall bolts (50) and washers (51) .
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| Illustration 51 | g00942116 |
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| Illustration 52 | g00942117 |