Removal Procedure
Start By:
- Remove the fan. Refer to Disassembly and Assembly, "Fan - Remove and Install" in this manual.
| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A | 138-7574 | Link Bracket | 2 |
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At operating temperature, the hydraulic oil is hot and under pressure. Hot oils can cause burns. To prevent possible personal injury, release the pressure in the implement hydraulic circuit (boom, stick, bucket, and swing), travel circuits, and the hydraulic oil tank at the filler cap before any hydraulic lines or components are disconnected or removed. Remove the filler cap only when the engine is stopped and the filler cap is cool enough to touch. |
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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 machine. 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 in Caterpillar machines. Dispose of all fluids according to local regulations and mandates. |
- Release the pressure in the hydraulic system. Refer to Disassembly and Assembly, "Hydraulic System Pressure - Release" in this manual.
- Drain the oil from the hydraulic tank into a suitable container for storage or disposal. The capacity of the hydraulic oil tank is 90 L (24 US gal).
- Drain the coolant from the cooling system into a suitable container for storage or disposal. The capacity of the cooling system is 17 L (4.5 US gal).
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At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the filler cap is cool enough to touch with the bare hand. Remove the filler cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent personal injury. |
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- Remove four bolts (1) and the four washers. Remove sheet (2) .
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| Illustration 1 | g00365357 |
This view is under the machine. | |
- Remove five bolts (3) and the five washers. Remove sheet (4) .
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| Illustration 2 | g00365532 |
This view is under the machine. | |
- Remove bolt (5) and the washer. Disconnect ground wire (6) from the engine.
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| Illustration 3 | g00365572 |
This view is under the machine. | |
- Loosen two hose clamps (7). Remove radiator top hose (8) from the engine and the radiator.
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| Illustration 4 | g00365576 |
- Remove fan shroud (9) .
- Loosen hose clamp (10). Disconnect radiator bottom hose (11) from the radiator.
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| Illustration 5 | g00365583 |
- Remove two hose clamps (12). Disconnect air intake hose (13) .
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| Illustration 6 | g00365585 |
- Loosen nut (14). Remove bolts (17) and (23). Disconnect governor control cable (25) from the governor assembly.
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| Illustration 7 | g00365692 |
- Disconnect solenoid wire (18) from the energize-to-run solenoid.
- Remove nut (16) and bolts (15) and (27) that hold wiring harness (19) to the engine. Disconnect wire (21). Reposition the wiring harness away from the engine.
- Disconnect hose assemblies (24) and (26). Plug the hose assemblies. Cap the fittings on the engine block. Plugs and caps prevent fluid loss. Plugs and caps prevent fluid contamination.
- Loosen hose clamp (20). Disconnect hose (22) .
- Disconnect hose assemblies (23) and (24). Put plugs in the ends of the hose assemblies. Plugs prevent fuel loss. Plugs prevent contaminating the fuel system.
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| Illustration 8 | g00366172 |
- Put identification marks on all wires and cables that are connected to the starting motor. Identification marks are for installation purposes. Disconnect wires and cables (29) from the starting motor.
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| Illustration 9 | g00366173 |
- Disconnect wiring harness connector (28) .
- Remove bolt (27). Remove cover (26). Remove wire (25) .
- Put identification marks on all alternator wires. Identification marks are for installation purposes. Disconnect alternator wires (30) and (33). Disconnect cables (31) and (34) .
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| Illustration 10 | g00366642 |
- Remove bolt (32) .
- Put identification marks on two wires (37). Identification marks are for installation purposes. Disconnect two wires (37) from the water temperature sending unit.
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| Illustration 11 | g00366692 |
The alternator is removed for photographic purposes. | |
- Loosen hose clamp (36). Disconnect heater hose (35) .
- Recover the refrigerant.
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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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Effective July 1, 1992 regulations prohibit the venting of any refrigerant into the atmosphere. Refer to Caterpillar publications Service Manuals, SENR3334, SENR5664, and NEDG5065 for the proper procedure, the proper equipment, and the proper tools needed in order to reclaim refrigerant from any Caterpillar equipment. |
- Disconnect two hose assemblies (38). Disconnect wire (39) .
- Remove two bolts (40) and the two washers from the support assembly.
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| Illustration 12 | g00366957 |
- Remove five bolts (42) and the five washers. Remove sheet (41) .
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| Illustration 13 | g00366958 |
- Remove four bolts (47). Remove sheet (48) .
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| Illustration 14 | g00367045 |
- Remove bolts (43) and (46) and the washers. Remove three bolts (45). Remove support assembly (44) .
- Remove four socket head bolts (49). Disconnect pipe assembly (50) from the bottom of the main hydraulic pump. Put a plug in the pipe assembly. Plugs prevent oil loss. Plugs prevent contaminating the hydraulic system.
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| Illustration 15 | g00367092 |
- Remove five bolts (51). Remove sheet (52) .
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| Illustration 16 | g00367152 |
- Put identification marks on all hose assemblies that are connected to the pilot pump and to the main hydraulic pump. Identification marks are for installation purposes. Disconnect hose assemblies (53), (56), (57), and (58) from the pumps. Put plugs in the hose assemblies. Put caps on the pumps. Plugs and caps prevent oil loss. Plugs and caps prevent contaminating the hydraulic system.
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| Illustration 17 | g00367215 |
- Remove bolt (54). Disconnect solenoid wire (55) .
- Remove bolts (60) and (61). Remove two sheets (59) through the bottom of the machine.
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| Illustration 18 | g00367219 |
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| Illustration 19 | g00367221 |
- Remove two bolts (63). Reposition the governor cable away from the engine.
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| Illustration 20 | g00367372 |
- Put identification marks on the rubber engine mounts. Identification marks are for installation purposes.
Note: The front rubber engine mounts and the rear rubber engine mounts have different part numbers. The rubber engine mounts must not be mixed.
- Remove four engine mounting bolts (62) and the four washers. Remove the front rubber engine mounts. Remove the rear rubber engine mounts. Remove the support assemblies that are located at each engine mount.
- Fasten Tooling (A) and a suitable lifting device to the front and rear lifting eyes, as shown. Carefully remove the engine and main hydraulic pump (64) from the machine. The combined weight of the engine and main hydraulic pump is 590 kg (1300 lb).
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| Illustration 21 | g00367412 |
Note: Be careful to not damage the radiator core during the removal of the engine and main hydraulic pump from the machine. The engine must be kept level during the removal in order to prevent possible interference between the components.
- Remove the lower rubber engine mounts from the frame of the machine.
- Remove the front and rear engine mounting brackets from the engine, if necessary.