Removal Procedure
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Table 1
| Required Tools |
| Tool |
Part Number |
Description |
Qty |
| A |
1U-9200 |
Lever Puller Hoist |
1 |
| ZZ |
6V-9508 |
Plug Assembly |
1 |
| 6V-9829 |
Cap Assembly |
1 |
Start By:
- Remove the reversible fan. For additional information, refer to Disassembly and Assembly, "Reversible Fan - Remove".
- Remove the muffler. For additional information, refer to Disassembly and Assembly, "Muffler - Remove and Install".
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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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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 filler cap is cool enough to touch with the bare hand. Remove the filler cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent personal injury. |
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Note: Put identification on all lines, hoses, wires, and tubes for installation purposes. Use caps and plugs on all lines, hoses, and tubes in order to prevent fluid loss or contamination of the systems.
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.
- Drain the engine coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for more information.
- Move the battery disconnect switch to the OFF position.
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| Illustration 1 | g01135322 |
- Remove bolts (1). Move panel (2) out of the way.
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| Illustration 2 | g01135235 |
- Disconnect CABLE ASSEMBLY (3) and clips (5) that retain the wire and harness assembly (4). Disconnect any clips for the air conditioner hose assemblies. Disconnect hoses (7) and (9) that are attached to the water pump. Disconnect harness assembly (8). Remove mounting bolts (6) for the compressor. Move the compressor out of the way.
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| Illustration 3 | g01135350 |
- Disconnect heater hose (10) at the valve. Disconnect upper radiator hose (11) at the engine. Disconnect aftercooler hose (12) at the radiator and hydraulic oil cooler.
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| Illustration 4 | g01135354 |
- Disconnect battery cable assemblies (14). Disconnect clip (13) .
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| Illustration 5 | g01135361 |
- Remove bolts (15). Remove bracket (16) .
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| Illustration 6 | g01135362 |
- Disconnect hose assembly (17). Disconnect clip (18). Disconnect harness assembly (19) .
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| Illustration 7 | g01135365 |
- Disconnect clip (23) and (21). Disconnect hose assembly (22). Disconnect hose (20) .
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| Illustration 8 | g01135368 |
- Disconnect clip (24).
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| Illustration 9 | g01135374 |
- Install proper cribbing under the rear of the main hydraulic pump (25), as shown. Remove the mounting bolts (26) for the main hydraulic pump.
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| Illustration 10 | g01135371 |
- Attach a suitable lifting device and Tooling (A) to engine (27) .
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| Illustration 11 | g01135372 |
- Remove engine mounting bolts (28) and remove the engine. The engine must be moved forward approximately 76 mm (3.0 inch) before the engine is lifted from the machine. The engine must be moved forward so that the flywheel housing will clear the drive gear for the main hydraulic pump. The approximate weight of engine (27) is 950 kg (2100 lb).
