Removal Procedure
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Table 1
| Required Tools |
| Tool |
Part Number |
Part Description |
Qty |
| A |
8T-5255 |
Hydraulic Jack |
1 |
| B |
1U-9200 |
Lever Puller Hoist |
1 |
| C |
180-3033 |
Repair Stand Set |
2 |
| D |
185-3630 |
Strap Wrench As |
1 |
| ZZ |
9U-7067 |
Tapered Cap/Plug |
1 |
| 9U-7069 |
Tapered Cap/Plug |
2 |
| 9U-7071 |
Tapered Cap/Plug |
1 |
| 9U-7073 |
Tapered Cap/Plug |
4 |
| 9U-7075 |
Tapered Cap/Plug |
2 |
| 9U-7079 |
Tapered Cap/Plug |
1 |
| 9U-7081 |
Tapered Cap/Plug |
1 |
Start By:
- Remove the fan guard. Refer to Disassembly and Assembly, "Fan Guard - Remove and Install".
- Remove the radiator. Refer to Disassembly and Assembly, "Radiator - Remove and Install".
- Remove the muffler. Refer to Disassembly and Assembly, "Muffler - Remove and Install".
- Remove the air cleaner. Refer to Disassembly and Assembly, "Air Cleaner - Remove and Install".
- Remove the electric starting motor. Refer to Disassembly and Assembly, "Electric Starting Motor - Remove and Install".
- Remove the floorplate. Refer to Disassembly and Assembly, "Floorplate - Remove and Install".
- Remove the fuel filter and the water separator. Refer to Disassembly and Assembly, "Fuel Filter and Water Separator - 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.
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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. The correct charge is 1.4 kg (3.1 lb). Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the procedure. Refer to Special Publication, NEDG5065, "Air Conditioning Tools" for the correct tools.
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| NOTICE |
|---|
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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- Drain the transmission oil into a suitable container. Refer to Operation and Maintenance Manual, "Transmission Oil - Change".
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| Illustration 1 | g01039942 |
- Disconnect harness assemblies (1). Disconnect harness assemblies (2). Position harness assembly (3) out of the way. Remove bolts (4) and position manifold (5) out of the way.
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| Illustration 2 | g01040203 |
- Disconnect hose assemblies (6). Disconnect hoses (7). Disconnect fuel hoses (8). Disconnect governor linkage (9) .
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| Illustration 3 | g01040206 |
- Disconnect harness assemblies (10). Position harness assemblies (10) out of the way.
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| Illustration 4 | g01040208 |
- Remove bolts (11) and bolt (12) .
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| Illustration 5 | g01040210 |
- Disconnect ground cable (13) .
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| Illustration 6 | g01040211 |
- Remove hose clips (14) .
- Repeat Step 6 for the other side of the engine.
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| Illustration 7 | g01040231 |
- Use cable straps (15) in order to hold hydraulic tank (16) in position.
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| Illustration 8 | g01040236 |
- Remove bolts (17) and plate (18) .
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| Illustration 9 | g01040238 |
- Remove bolts (19) .
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| Illustration 10 | g01040239 |
- Position Tooling (A) under transmission (20) and apply slight tension. Remove bolts (21). Position tube assembly (22) out of the way.
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| Illustration 11 | g01040240 |
- Attach Tooling (B) and a suitable lifting device onto engine (23) .
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| Illustration 12 | g01040241 |
- Remove bolt (24) .
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| Illustration 13 | g01040242 |
- Remove bolt (25). Use Tooling (D) and remove oil filter (26) .
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| Illustration 14 | g01040243 |
- Remove bolts (27). The weight of engine (23) is approximately 422 kg (930 lb). Remove engine (23) from the machine.
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| Illustration 15 | g01040247 |
- Lower engine (23) onto Tooling (C) and suitable cribbing.
