Removal Procedure
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Table 1
| Required Tools |
| Tool |
Part Number |
Part Description |
Qty |
| ZZ |
6V-9508 |
Tapered Cap/Plug |
9 |
| 6V-9512 |
Tapered Cap/Plug |
7 |
| 6V-9513 |
Tapered Cap/Plug |
1 |
| 6V-9829 |
Tapered Cap/Plug |
9 |
| 6V-9833 |
Tapered Cap/Plug |
7 |
| 6V-9834 |
Tapered Cap/Plug |
1 |
| 6V-9511 |
Tapered Cap/Plug |
2 |
| 6V-9509 |
Tapered Cap/Plug |
1 |
| 6V-9832 |
Tapered Cap/Plug |
3 |
| 6V-9830 |
Tapered Cap/Plug |
2 |
| 6V-9509 |
Tapered Cap/Plug |
1 |
| 6V-9831 |
Tapered Cap/Plug |
1 |
| 9U-7079 |
Tapered Cap/Plug |
1 |
| 9U-7087 |
Tapered Cap/Plug |
1 |
| 9U-7075 |
Tapered Cap/Plug |
4 |
| 9U-7073 |
Tapered Cap/Plug |
4 |
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Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand. Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns. Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes. |
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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. |
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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.
- Move the battery disconnect switch to the OFF position.
- Drain the hydraulic fluid from the hydraulic tank into a suitable container for proper storage or proper disposal. The capacity of the hydraulic tank is 318 L (84 US gal).
- Drain the fuel from the fuel tank into a suitable container for proper storage or proper disposal. The capacity of the fuel tank is 1135 L (300 US gal).
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| Illustration 1 | g01126133 |
- Disconnect hoses (1). Disconnect hose assembly (3). Disconnect harness assembly (2) .
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| Illustration 2 | g01126156 |
- Disconnect hose assemblies (7). Disconnect harness assembly (5). Remove bolt (6) (not shown). Disconnect clip (4) .
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| Illustration 3 | g01126332 |
- Disconnect hose assemblies (8), (9), (10), and (11) .
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| Illustration 4 | g01126353 |
- Disconnect hose assemblies (12) and (13) .
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| Illustration 5 | g01126657 |
- Disconnect clip (19). Remove step (20). Remove hand rail (18). Loosen clamps (16). Remove bolts (14). Remove elbow (15). Disconnect tube assembly (17) from the pump.
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| Illustration 6 | g01128338 |
- Disconnect hose assemblies (21) and (22) .
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| Illustration 7 | g01128344 |
- Disconnect hose assembly (27) from the clipand harness assembly (28). Disconnect hose assembly (23). Disconnect hose assemblies (24), (25), (26) and (27) .
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| Illustration 8 | g01128367 |
- Disconnect harness assembly (29). Remove cable straps that secure harness assembly (30) to the fuel tank.
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| Illustration 9 | g01128381 |
- Disconnect hose assemblies (31), (32) and (33). Disconnect tube assembly (34) .
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| Illustration 10 | g01128389 |
- Disconnect harness assemblies (35) and (36). Move harness assemblies (35) and (36) away from the fuel tank. Disconnect hose assemblies (37) .
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| Illustration 11 | g01128396 |
- Remove bolts (38) from both sides of the fuel tank.
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| Illustration 12 | g01128401 |
- Install a suitable lifting device in order to remove fuel tank (39). Shorten one portion of the lifting device by 38 mm (1.5 inch) in order to allow a level removal. Remove fuel tank (39). The weight of fuel tank (39) is approximately 2495 kg (5500 lb).
