MH3049 Material Handler C9 Engine Supplement Caterpillar

Removal Procedure

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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.

1. Recover the A/C. Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the recovery and the charging procedure. Refer to Special Publication, NENG2500, "Air Conditioning Tools" for the correct tools.

2. Drain the coolant. Refer to Operation and Maintenance Manual, " Engine Oil and Oil Filter - Change " for draining and filling procedures.

3. Drain the engine oil. Refer to Operation and Maintenance Manual, " Engine Oil and Oil Filter - Change " for draining and filling procedures.

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Illustration 1	g03096800

4. Remove panels (1) .

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Illustration 2	g03096804

5. Disconnect hose assemblies (2) and remove hoses (3) .

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Illustration 3	g03096807

6. Disconnect cable assembly (6). Remove bolt (5) and cable assembly (4) .

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Illustration 4	g03096808

7. Remove dipstick (7) .

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Illustration 5	g03096810

8. Remove bolts (8) and oil pan (9) .

Installation Procedure

1. Install oil pan (9) in the reverse order of removal.

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Illustration 6	g03317635

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Illustration 7	g03317636

2. Clean the mating surface of engine oil pan (9) and the cylinder block. Apply Tooling (A) to four areas on the sealing surface of the oil pan. The areas are Marked Location (Y) .

3. Place a new gasket and engine oil pan (9) on the cylinder block.

4. Tighten four Oil Pan Bolts (X) .

5. Start with Bolt (Z) and tighten all remaining bolts (8) in a counterclockwise sequence.

6. Tighten bolts (8) to a torque of 31 ± 1 N·m (23 ± 1 lb ft).

7. Start again with Bolt (Z) and tighten all remaining bolts in a counterclockwise sequence.

8. Tighten bolts (8) again to a torque of 31 ± 1 N·m (23 ± 1 lb ft).

9. Fill the engine with oil to the correct level. Refer to Operation and Maintenance Manual, "Engine Oil - Change" and Operation and Maintenance Manual, "Capacities (Refill)".