Removal Procedure
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Table 1
| Required Tools |
| Tool |
Part Number |
Part Description |
Qty |
| A |
1U-9202 |
Lever Puller Hoist |
1 |
Start By:
- Remove the crankcase guards. Refer to Disassembly and Assembly, "Crankcase Guards - Remove and Install".
- Remove the crankshaft vibration damper and pulley. Refer to Disassembly and Assembly, "Crankshaft Vibration Damper and Pulley- Remove and Install".
- Remove the engine oil filter base. Refer to Disassembly and Assembly, "Engine Oil Filter and Oil Filter Base - Remove and Install".
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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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| 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: Put identification marks on all hoses, on all hose assemblies, on all wires, and on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies. This helps to prevent fluid loss, and this helps to keep contaminants from entering the system.
- Drain the coolant into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change".
- Recover the air conditioner refrigerant from the air conditioner system. Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant". Refer to Special Publication, NEDG5065, "Air Conditioning Tools".
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| Illustration 1 | g01163275 |
- Remove hose (1) and tube (2) .
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| Illustration 2 | g01163280 |
- Remove bolts (4) and guard assembly (3) .
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| Illustration 3 | g01163282 |
- Disconnect hose assemblies (5) and hoses (6). Remove all mounting hardware from hose assemblies (5) and hoses (6) .
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| Illustration 4 | g01163285 |
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| Illustration 5 | g01163288 |
- Disconnect tube assemblies (7) and (8) .
- Remove tube assembly (8). Disconnect harness assembly (9) and remove tube assembly (7) .
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| Illustration 6 | g01163292 |
- Loosen clamp (11) and reposition tube assembly (10) .
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| Illustration 7 | g01163300 |
- Disconnect harness assemblies (12). Disconnect cable assembly (13) .
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| Illustration 8 | g01163320 |
- Disconnect all mounting hardware from cable assemblies (14) and disconnect cable assemblies (14) .
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| Illustration 9 | g01163330 |
- Remove cover (15). Disconnect harness assembly (16) .
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| Illustration 10 | g01163331 |
- Disconnect harness assemblies (17) and (18). Remove all mounting hardware from harness assemblies (17) and (18) .
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| Illustration 11 | g01163332 |
- Disconnect harness assembly (19) .
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| Illustration 12 | g01163334 |
- Disconnect hose assemblies (20) .
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| Illustration 13 | g01163336 |
- Disconnect hose assemblies (21) .
- Tilt the cab upward. Refer to Operation and Maintenance Manual, "Cab - Tilt".
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| Illustration 14 | g01163339 |
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| Illustration 15 | g01163341 |
- Remove all mounting hardware from tube (22). Remove tube (22) .
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| Illustration 16 | g01163342 |
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| Illustration 17 | g01163343 |
- Remove all mounting hardware from tube (23). Remove tube (23) .
- Remove the air cleaner. Refer to Disassembly and Assembly, "Air Cleaner - Remove and Install".
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| Illustration 18 | g01163345 |
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| Illustration 19 | g01163347 |
- Remove all mounting hardware from tube (24). Remove tube (24) .
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| Illustration 20 | g01163359 |
- Remove clamp (25) .
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| Illustration 21 | g01163362 |
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| Illustration 22 | g01163363 |
- Disconnect hoses (26) and (27) .
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| Illustration 23 | g01163365 |
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| Illustration 24 | g01163368 |
- Remove plug (28). Remove eight bolts (29) (not shown). Rotate the engine until a total of eight bolts (29) (not shown) are removed.
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| Illustration 25 | g01163372 |
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| Illustration 26 | g01163374 |
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| Illustration 27 | g01163376 |
- Attach Tooling (A) and a suitable lifting device to engine (30). Remove bolts (31) and (33). Remove support (32). Remove bolts (34). Remove engine (30). The weight of engine (30) is approximately 1134 kg (2500 lb).
