538 Forest Machine Engine Supplement Caterpillar

Removal Procedure

Start By:

1. Remove the hood.

2. Remove the fuel cooler.

3. Remove the aftercooler.

4. Remove the air cleaner.

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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 fill cap is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.

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

2. Drain the hydraulic oil. Refer to Operation and Maintenance Manual, "Hydraulic System Oil - Change" for the correct draining and filling procedures.
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   Illustration 1	g06078073

3. Remove cover assembly (1).
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   Illustration 2	g06078089

4. Remove bolts (2) and sheet assembly (3).
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   Illustration 3	g06078105

5. Remove bolts (4), bolts (6), and support bracket (5).
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   Illustration 4	g06078608

6. Disconnect hoses (7), (9), and (11).

7. Disconnect harness assembly (12).

8. Remove bolts (10) and coolant tank assembly (8).
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   Illustration 5	g06078666

9. Disconnect hoses (13) and (14).

10. Remove bolts (15) and (16). Reposition hose (11) out of the way.
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    Illustration 6	g06078682

11. Remove bolts (18).

12. Disconnect pipe assemblies (17) and (19).
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    Illustration 7	g06078791

13. Remove guard (20).
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    Illustration 8	g06078824

14. Disconnect tube assembly (21).
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    Illustration 9	g06078830

15. Disconnect hose (22).
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    Illustration 10	g06078956
    View from the bottom.

16. Remove bolts (23) from shroud assembly (24).
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    Illustration 11	g06078959

    Note: Shroud assembly (24) can be rested on the fan and fan drive.

17. Separate seal (26) and shroud assembly (24) from radiator shroud (25).
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    Illustration 12	g06079004

18. Remove the bolts and sheet assembly (28).

19. Remove bolts (30) and tube assembly (27).

20. Remove bolts (31) and tube assembly (29).
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    Illustration 13	g06079314

21. Remove bolts (32) and handrail assembly (33).
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    Illustration 14	g06079334

22. Remove bolts (34) and support assembly (35).
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    Illustration 15	g06079354

23. Remove bolts (37) and reposition refrigerant dryer (36) out of the way.
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    Illustration 16	g06079377

24. Remove bolts (38) and sheet assembly (39).
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    Illustration 17	g06079389

25. Remove bolts (41). Use two people to remove door assembly (40). The weight of door assembly (40) is approximately 45 kg (99 lb).
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    Illustration 18	g06079412

26. Remove bolts (42) and reposition battery terminal assembly (43) out of the way.

27. Remove screws (44) and reposition control (45) out of the way.
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    Illustration 19	g06079432

28. Remove bolts (46), bolts (48), and support assembly (47).
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    Illustration 20	g06079491
    Counterweight removed for photographic purposes.

29. Remove bolts (49).
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    Illustration 21	g06079513

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    Illustration 22	g06079546
    View from the bottom.

30. Attach Tooling (A) and a suitable lifting device to cooling system package (50). The weight of cooling system package (50) is approximately 163 kg (360 lb).

31. Remove bolts (51) and cooling system package (50).

Installation Procedure

1. Install cooling system package (50) in the reverse order of removal.