Required Tools | |||
Tool | Part Number | Part Description | Qty |
A | 386-6032 | Lever Puller Hoist Gp | 1 |
B | 5P-7306 | Shaft Housing | 1 |
5P - 7305 | Engine Turning Tool | 1 |
Start By:
- Release system pressure.
- Remove the air cleaner.
- Remove the starter.
- Remove the exhaust elbow.
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. |
Personal injury or death may result from failure to adhere to the following procedures. Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Clean up all leaked or spilled fuel. Do not smoke while working on the fuel system. Turn the disconnect switch OFF or disconnect the battery when changing fuel filters. |
Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand. Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns. Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes. |
- Drain the coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct draining and filling procedures.
- Recover the air conditioner refrigerant. Refer to Service Manual, SENR5664, "All Products Air Conditioning and Heating Systems with R134a for All Caterpillar Machines". Refer to Special Publication, NENG2500, "Air Conditioning Tools" for the correct tools.
- Tilt the cab. Refer to Operations and Maintenance Manual, "Cab - Tilt" for the correct procedure.
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Illustration 1 g03697291 - Remove tube assemblies (1).
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Illustration 2 g03689077 - Remove clips (4) and (5). Disconnect hose assembly (3) and remove the seal. Disconnect hose assemblies (2), (6) and (7).
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Illustration 3 g03689084 - Remove the cable straps from harness assembly (8). Disconnect clamps (9) and (10).
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Illustration 4 g03689086 - Disconnect harness assembly (11). Disconnect hose assemblies (12).
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Illustration 5 g03689159 - Disconnect bracket (14). Remove bolts (13) and remove bracket (15).
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Illustration 6 g03689174 - Disconnect all harness assemblies connected to harness assembly (16) and remove all cable straps connecting harness assembly (16) to the engine. Disconnect cable assembly (17) from the frame.
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Illustration 7 g03689176 - Disconnect harness assembly (18). Disconnect hose assembly (19). Remove cable straps (20).
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Illustration 8 g03689216 - Disconnect harness assemblies (21) and remove cable straps (22).
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Illustration 9 g03689239 Show/hide tableIllustration 10 g03697666 Harness assemblies and tube assemblies removed for clarity. - Remove bolts (23) and (24).
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Illustration 11 g03689305 Behind engine. - Remove bolts (25).
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Illustration 12 g03689335 - Disconnect harness assembly (27). Disconnect harness assembly (26) from the bracket.
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Illustration 13 g03689742 - Disconnect clamp (28). Disconnect hose (29). Disconnect hoses (30).
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Illustration 14 g03689748 - Disconnect hoses (31).
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Illustration 15 g03689753 - Remove bolts (32).
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Illustration 16 g03689760 - Disconnect hose assemblies (33). Loosen clamp (34).
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Illustration 17 g03689773 - Remove tube assembly (35) and disconnect tube assembly (36).
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Illustration 18 g03689797 - Attach a suitable lifting device to engine (37). The weight of engine (37) is approximately
1270 kg (2800 lb) .Show/hide tableIllustration 19 g03689826 - Install Tooling (B).
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Illustration 20 g03689830 Show/hide tableIllustration 21 g03689844 - Remove plug (38).
- Use Tooling (B) to rotate the engine and remove 12 bolts (39).
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Illustration 22 g03689851 Show/hide tableIllustration 23 g03698080 - Remove bolts (41) and (40). Remove bolts (42).
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Illustration 24 g03689857 - Remove engine (37).
- Install engine (37) in the reverse order of removal.