Removal Procedure
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Table 1
| Required Tools |
| Tool |
Part Number |
Part Description |
Qty |
| A |
189-0412 |
Clevis |
1 |
| B |
FT-1114 |
Vacuum Cap |
1 |
| C |
138-7573 |
Link Bracket |
4 |
Start By:
- Release the pressure in the hydraulic system. Refer to Disassembly and Assembly, "Hydraulic System Pressure - Release".
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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| 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 Dealer Service Tool Catalog" 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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- Install Tooling (B) onto the hydraulic tank. Attach an air supply hose onto Tooling (D). Apply 276 to 414 kPa (40 to 60 psi) of air. This procedure will pull a vacuum on the hydraulic system.
- Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change".
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Personal injury can result from contact with refrigerant. This system is under pressure at all times, even if the engine is not running. Heat should never be applied to a charged system. 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 caution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, evacuate the system recovering the refrigerant before removing the fitting. 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. Before any checks of the air conditioning and heating system are made, move the machine to a smooth horizontal surface. Lower all implements to the ground. Make sure the transmission is in neutral or park and that the parking brake is engaged. Keep all other personnel away from the machine or where they can be seen. |
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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, NEDG2500, "Air Conditioning Tools" for the correct tools.
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| Illustration 1 | g01121513 |
- Disconnect ground cable (1) .
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| Illustration 2 | g01121542 |
- Open the engine hood. Remove panel (2) .
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| Illustration 3 | g01121549 |
- Disconnect hoses (4) from tank (3) .
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| Illustration 4 | g01121551 |
- Remove bolts (7) and plate (6). Repeat for the other side. Remove floor mat (5) .
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| Illustration 5 | g01121929 |
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| Illustration 6 | g01121930 |
- Remove bolts (8) and lift floorplate (9). Disconnect harness assemblies (10) and (11). Remove floorplate (9) .
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| Illustration 7 | g01121566 |
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| Illustration 8 | g01121573 |
- Remove bolts (12). Remove panels (13) and (14) from the steering column.
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| Illustration 9 | g01520422 |
- Remove bolts (16) and panel (15) .
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| Illustration 10 | g01241316 |
- Remove bolts (17) .
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| Illustration 11 | g01520431 |
- Remove bolts (19) and panel (18) .
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| Illustration 12 | g01121581 |
- Remove bolts (20) and (21) .
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| Illustration 13 | g01240749 |
- Remove bolts (22) and (24). Remove panel (23) .
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| Illustration 14 | g01240751 |
- Disconnect hose assemblies (25), (26), (27), and (28) .
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| Illustration 15 | g01121588 |
- Disconnect hose (33). Disconnect hose assemblies (30), (31), and (32) from steering metering valve (29).
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| Illustration 16 | g01520433 |
- Disconnect harness assemblies (34) .
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| Illustration 17 | g01520453 |
- Disconnect harness assemblies (35) and (36) .
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| Illustration 18 | g01520456 |
- Disconnect linkage assemblies (37) .
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| Illustration 19 | g01520463 |
- Remove bolts (38) and clips (39) .
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| Illustration 20 | g01520752 |
- Disconnect hose assembly (40) from the dryer (41) .
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| Illustration 21 | g01121761 |
- Remove cover (42) .
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| Illustration 22 | g01121764 |
- Remove cotter pin (43) and pin (44) .
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| Illustration 23 | g01121769 |
- Disconnect parking brake cable assembly (45) from parking brake lever assembly (46) .
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| Illustration 24 | g01121790 |
- Remove bolts (47) and floorplate (48) .
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| Illustration 25 | g01520472 |
- Remove bolts (49) and panel (50) .
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| Illustration 26 | g01520479 |
- Disconnect harness assembly (51). Pull harness assembly (51) through the bottom of the cab.
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| Illustration 27 | g01520500 |
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| Illustration 28 | g01121844 |
- Disconnect the harness assemblies (52) that are located on the right side of the cab above the battery compartment if the harness assemblies are installed.
- Disconnect cables (53) and (54). Pull cables (53) and (54) into the cab.
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| Illustration 29 | g01520511 |
- Remove bolts (55) and panel (56) .
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| Illustration 30 | g01520513 |
- Remove louver (57) .
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| Illustration 31 | g01520518 |
- Remove bolt (58) .
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| Illustration 32 | g01520519 |
- Remove bolts (60) and cover (59) .
- Repeat Steps 31 through 33 for the other side.
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| Illustration 33 | g01520520 |
- Remove bolts (61). Repeat for the other side. Remove panel (62) .
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| Illustration 34 | g01520521 |
- Disconnect hose assembly (63) from refrigerant accumulator (64) .
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| Illustration 35 | g02015473 |
- Disconnect all hose assemblies (66). (67). Disconnect the harness assemblies (67) .
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| Illustration 36 | g01520703 |
- Disconnect harness assemblies (72) .
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| Illustration 37 | g01520706 |
- Disconnect harness assembly (75) .
- Remove bolt (73) in order to disconnect ground strap (74) .
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| Illustration 38 | g01520712 |
- Remove bolt (77) in order to disconnect cable (76) .
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| Illustration 39 | g01520714 |
- Remove bolt (82) and loosen nuts (81). Disconnect cable assembly (80). Disconnect harness assembly (78) (not shown). Remove clamp (79) .
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| Illustration 40 | g01520722 |
- Lift panel (84) and disconnect harness assembly (86). Remove panel (84) .
- Repeat Steps 43 through 43 for the other side.
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| Illustration 41 | g02014296 |
- Attach Tooling (C), and a suitable lifting device to cab (87). The weight of cab (87 ) is approximately 907 kg (2000 lb).
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| Illustration 42 | g01520726 |
- Remove cap (88). Repeat for the other side.
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| Illustration 43 | g01520728 |
- Remove bolt (89). Repeat for the other side.
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| Illustration 44 | g01520729 |
- Remove bolt (90). Repeat for the other side.
- Remove the cab.
