Removal Procedure
| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A | 138-7575 | Link Bracket | 1 |
| B | 6V-6146 | Load Leveling Beam | 1 |
| ZZ | 5H-4019 | Cover | 2 |
Start By:
- Remove the rear chassis support. Refer to Disassembly and Assembly, "Rear Chassis Support - Remove".
- Remove the pump drive shaft. Refer to Disassembly and Assembly, "Pump Drive Shaft - Remove and Install".
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.
Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.
| 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. |
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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. |
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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 fill cap is cool enough to touch with your bare hand. Remove the fill 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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Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, hoses, and tubes. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.
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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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- Recover the air conditioner refrigerant from the air conditioner system. 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 coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".
- Remove bolts (1) and remove cover (2) .
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| Illustration 1 | g01020313 |
- Loosen bolt (3). Do not remove bolt (3) at this time. Repeat this step for the opposite side.
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| Illustration 2 | g01020314 |
- Attach Tooling (A) and a suitable lifting device to dash assembly (4). The weight of dash assembly (4) is approximately 68 kg (150 lb).
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| Illustration 3 | g01020316 |
- Remove bolt (3). Repeat this step for the opposite side.
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| Illustration 4 | g01020314 |
- Remove dash assembly (4) .
- Remove bolts (5) .
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| Illustration 5 | g01025160 |
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| Illustration 6 | g01025161 |
- Disconnect hose assemblies (6) from support (7) .
- Disconnect harness assemblies (9) and (10) .
- Attach Tooling (A) and a suitable lifting device to support (7). Remove bolts (8) and remove support (7) .
- Disconnect harness assembly (11) .
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| Illustration 7 | g01025162 |
- Disconnect hose assembly (12) .
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| Illustration 8 | g01020321 |
- Disconnect valve (12A) .
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| Illustration 9 | g01020322 |
- Disconnect hose assemblies (13) .
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| Illustration 10 | g01020323 |
- Disconnect harness assembly (14) and the retaining hardware.
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| Illustration 11 | g01020324 |
- Disconnect hose assembly (15) .
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| Illustration 12 | g01025163 |
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| Illustration 13 | g01025164 |
- Disconnect harness assembly (16) .
- Disconnect three wire assemblies (20) from relay (21) .
- Remove clamp (21A) .
- Remove bolts (18) .
- Attach Tooling (A) and a suitable lifting device to support (17) .
- Remove bolts (19) .
- Remove support (17) .
- Disconnect hose assemblies (22) and (23). Remove clip (23A) .
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| Illustration 14 | g01020331 |
- Remove bolts (24) .
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| Illustration 15 | g01020332 |
- Disconnect hose assembly (25) .
- Disconnect harness assemblies (28) .
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| Illustration 16 | g01020334 |
- Remove clip (29) .
- Remove clip (30) .
- Remove bolts (31) .
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| Illustration 17 | g01020335 |
- Remove yoke (32) and damper assembly (33) .
- Remove bolts (34) .
- Attach Tooling (B) to engine (35). The weight of engine (35) is approximately 1361 kg (3000 lb).
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| Illustration 18 | g01025165 |
- Remove bolts (36) .
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| Illustration 19 | g01025166 |
- Remove engine (35) .