Removal Procedure
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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. |
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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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- Release hydraulic system pressure. Refer to Disassembly and Assembly, "Hydraulic System Pressure - Release" in this manual.
- Drain the oil from the hydraulic oil tank into a suitable container for storage or disposal. The capacity of the hydraulic oil tank is 105 L (27.7 US gal).
- Open the right rear access door of the engine compartment.
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| Illustration 1 | g00368699 |
- Remove five bolts (1) and the washers from plate (2) above the main hydraulic pump.
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| Illustration 2 | g00368700 |
- Remove two bolts (3) and the washers. Remove plate (2) .
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| Illustration 3 | g00368701 |
- Remove six bolts (4), the washers and support assembly (5) .
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| Illustration 4 | g00368702 |
- Remove hose assembly (8) .
- Remove six bolts (6), the washers and upper plate (7) .
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| Illustration 5 | g00368703 |
- Put identification marks on all of the hose assemblies and on all of the tube assemblies that are connected to the main hydraulic pump and the pilot pump for installation purposes.
- Disconnect four hose assemblies (10), four hose assemblies (12), and connector (11) from the main hydraulic pump. Put plugs in the hose assemblies in order to prevent oil loss and keep dirt out of the hydraulic system.
- Disconnect two hose assemblies (13) from the pilot pump.
- Remove two bolts and bracket (9) .
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| Illustration 6 | g00368704 |
- Remove the four bolts in order to disconnect pipe assembly (14) from the bottom of the main hydraulic pump.
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| Illustration 7 | g00368705 |
- Remove the two bolts (16), six bolts (17), the washers and two lower plates (15) .
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| Illustration 8 | g00493281 |
- Slide lower plates (15) through the opening in the upper frame of the machine.
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| Illustration 9 | g00368707 |
Note: Do not attempt to remove the main hydraulic pump by removing four bolts (19), the washers and nuts. Four bolts (19), the washers and the nuts hold the cover on the main hydraulic pump. Access for loosening and tightening the bolts is made from the back side of cover. The main hydraulic pump must be kept level during the removal in order to prevent the binding of the pump drive coupling.
- Fasten lifting slings and a hoist to main hydraulic pump (17), as shown. Remove twelve bolts (18) and the washers that hold the main hydraulic pump to the flywheel housing.
- Keep the main hydraulic pump level in order to remove the pump and the drive coupling from the engine flywheel and the flywheel housing. The combined weight of the main hydraulic pump, cover and the pump drive coupling is 107 kg (235 lb).
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| Illustration 10 | g00368708 |
- Remove four socket head bolts (20), four inserts (21), and coupling element (22) from the flywheel.
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| Illustration 11 | g00368709 |
- Loosen two setscrews (23), and remove coupling assembly (24) from the main hydraulic pump.
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| Illustration 12 | g00493211 |
- Use the following procedure in order to disassemble coupling assembly (24) .
- Remove socket head bolt (25) and coupling (26) from hub (28) .
- If necessary, remove two locating pins (27) from the hub.
- Repeat Step 20.a and Step 20.b in order to remove the remaining three coupling assemblies.
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| Illustration 13 | g00368711 |
- Put an alignment mark on cover (30) and on the main hydraulic pump for assembly purposes. Remove four bolts (29), the washers and the nuts that hold cover (30) to the main hydraulic pump. Remove the cover from the pump.
