725C Articulated Truck Caterpillar

Removal Procedure

Start By:

1. Remove starter.

2. Remove air cleaner.

3. Tilt cab.

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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. Release hydraulic system pressure.

2. 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, NEDG2500, "Air Conditioning Tools"for the correct tools.

3. Drain the coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct draining and filling procedures.

4. Drain the transmission oil. Refer to Operation and Maintenance Manual, "Transmission Oil - Change" for the correct draining and filling procedures.
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   Illustration 1	g03671732

5. Disconnect tube assemblies (1) and (2) from transmission cooler.
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   Illustration 2	g03671734

6. Disconnect tube (3).
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   Illustration 3	g03671871

7. Disconnect harness assembly (4).
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   Illustration 4	g03671873

8. Disconnect hose assembly (5).
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   Illustration 5	g03671878

9. Remove ATAAC tubes (6).
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   Illustration 6	g03671892

10. Disconnect harness assembly (8). Disconnect hose assemblies (7) and (9).
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    Illustration 7	g03671977

11. Disconnect hose clamp (10).
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    Illustration 8	g03671988

12. Disconnect hose assemblies (11) and (12).
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    Illustration 9	g03671991

13. Disconnect hose assembly (13).
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    Illustration 10	g03671995

14. Disconnect clip (15) and cable assembly (14).
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    Illustration 11	g03672047

15. Disconnect clip (16).
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    Illustration 12	g03672049

16. Disconnect clip (17).
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    Illustration 13	g03672068

17. Disconnect cable straps (18) and (19).
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    Illustration 14	g03672069

18. Remove clip (20).
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    Illustration 15	g03672259

19. Disconnect clip (21) and harness assembly (24). Remove cable straps (22) and (23).
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    Illustration 16	g03672261

20. Remove bolts (25) and (26). Reposition bracket assembly (27).
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    Illustration 17	g03672263

21. Remove bolts (28), (29), and (30).
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    Illustration 18	g03672264

22. Remove bolts (32) and (33). Reposition bracket (31).
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    Illustration 19	g03672332

23. Remove bolts (34) and (35).
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    Illustration 20	g03672382

24. Disconnect clip (36).
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    Illustration 21	g03672383

25. Disconnect clip (37). Disconnect hose assemblies (38) and (39).
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    Illustration 22	g03672384

26. Remove nut (41) and bracket assembly (40).
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    Illustration 23	g03672386

27. Disconnect harness assemblies (42) and (43).
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    Illustration 24	g03672408

28. Disconnect harness assembly (44) and cable straps (45) from harness assembly (44).
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    Illustration 25	g03672414

29. Disconnect clip (46).
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    Illustration 26	g03672417

30. Disconnect harness assembly (47).
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    Illustration 27	g03672418

31. Disconnect harness assemblies (48) and (49).
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    Illustration 28	g03672500

32. Disconnect hose clamp (51) and clip (50). Disconnect hose assemblies (52), (53), and (54).
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    Illustration 29	g03672501

33. Disconnect clip (55) and reposition tube (56).
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    Illustration 30	g03672504

34. loosen clamps (57) and (59). Reposition exhaust tube (58).
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    Illustration 31	g03672525

35. Disconnect hose assemblies (60) and (61).
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    Illustration 32	g03672831

36. Disconnect hose assemblies (62) and (63).
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    Illustration 33	g03672832

37. Disconnect hose assembly (64).
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    Illustration 34	g03672834

38. Remove plug (65).
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    Illustration 35	g03672838

39. Install Tooling (B).
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    Illustration 36	g03672842

40. Turn engine over to remove eight bolts (66).
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    Illustration 37	g03672844

41. Remove bolts (67). Reposition bracket assembly (68).
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    Illustration 38	g03672922

42. Use Tooling (C) and suitable cribbing to hold up the rear of the transmission.
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    Illustration 39	g03672924

43. Attach Tooling (A) and a suitable lifting device to engine (69). The weight of engine (69) is approximately 1043 kg (2300 lb).
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    Illustration 40	g03672925

44. Remove all bell housing bolts (70).
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    Illustration 41	g03673032

45. Remove bolts (71).

46. Remove engine (69).
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    Illustration 42	g03673036

47. Set engine (69) down onto Tooling (D) and suitable blocking.

Installation Procedure

1. Install engine (69) in the reverse order of removal.