Removal Procedure
Start By:
- Remove the muffler. Refer to Disassembly and Assembly, "Muffler - Remove and Install".
- Remove the fan guard. Refer to Disassembly and Assembly, "Fan Guard - Remove and Install".
- Remove the fan. Refer to Disassembly and Assembly, "Fan - Remove and Install".
- Remove the engine enclosure. Refer to Disassembly and Assembly, "Engine Enclosure Group - Remove and Install".
- Remove the gear pump (fan drive). Refer to Disassembly and Assembly, "Gear Pump (Fan Drive) - Remove".
- Remove the coolant tank. Refer to Disassembly and Assembly, "Coolant Tank (Expansion) - Remove and Install".
Note: Put identification marks on all hoses, on all hose assemblies, on all harness assemblies, and on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies. This helps to prevent fluid loss, and this helps to keep contaminants from entering the system.
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| NOTICE |
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Keep all parts clean from contaminants. Contamination of the hydraulic system with foreign material will reduce the service life of the hydraulic system components. To prevent contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected. Cover any disassembled components and clean them properly before assembly. Clean the hydraulic system properly after any major component exchange or especially after a component failure, to remove any contamination. |
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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 product. 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 Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. 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 work tool 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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- Move the battery disconnect switch to the OFF position.
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| Illustration 1 | g01175739 |
- Loosen hose clamps (2) and (4). Disconnect hoses (1) and (3) .
- Disconnect the lower radiator hose.
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| Illustration 2 | g01175740 |
- Loosen hose clamps (5) and (7). Disconnect hoses (6) and (8) .
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| Illustration 3 | g00918360 |
- Disconnect harness assembly (9) and remove clip (10) .
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| Illustration 4 | g00918361 |
- Disconnect hose assemblies (11) .
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| Illustration 5 | g01167621 |
- Disconnect harness assemblies (12) and (13) and ground strap (14) .
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| Illustration 6 | g01167622 |
- Disconnect four hose assemblies (15) .
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| Illustration 7 | g01167624 |
- Loosen bolts (17) in order to remove guard (18) .
- Disconnect harness assemblies (16) .
- Loosen bolt (19) and remove the belt.
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| Illustration 8 | g01167625 |
- Remove bolts (21) .
- Position compressor (20) out of the way.
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| Illustration 9 | g01167626 |
- Disconnect harness assembly (24) from alternator (25) .
- Remove clip (26). Loosen clamp (22) and disconnect hose (23) .
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| Illustration 10 | g01167630 |
- Loosen clamp (29) and disconnect hose (28) from hose (31) .
- Disconnect harness assemblies (27) and (30) .
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| Illustration 11 | g01167631 |
- Remove bolts (32) and reposition junction box (33) .
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| Illustration 12 | g01167632 |
- Remove bolts (34) and panel (35) .
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| Illustration 13 | g01167633 |
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| Illustration 14 | g01167634 |
- Remove bolts (36) and (38) and panel (37) .
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| Illustration 15 | g01167635 |
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| Illustration 16 | g01167636 |
- Attach a suitable lifting device to main pump (40). The weight of main pump (40) is approximately 159 kg (350 lb).
- Disconnect hose assemblies (39) .
- Loosen clamp (42) and disconnect tube (43) .
- Remove bolts (41) .
- Disconnect main pump (40) from the engine.
- Position suitable blocking under main pump (40) .
- Position main pump (40) onto the frame.
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| Illustration 17 | g01167637 |
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| Illustration 18 | g01167638 |
- Attach a suitable lifting device to engine (45). The weight of engine (45) is approximately 612 kg (1350 lb).
- Remove clip (46). Remove bolts (44) and bolts (47) .
- Remove engine (45) .
