Removal Procedure
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Table 1
| Required Tools |
| Tool |
Part Number |
Part Description |
Qty |
| A |
138-7576 |
Link Bracket |
1 |
| B |
6V-6146 |
Load Leveling Beam |
1 |
Start By:
- Remove the muffler. Refer to Disassembly and Assembly, "Muffler - Remove and Install" for the machine that is being serviced.
- Remove the front and rear hood panels. Refer to Disassembly and Assembly, "Hood Panels (Front and Rear) - Remove" for the machine that is being serviced.
- Remove the hood and engine enclosure. Refer to Disassembly and Assembly, "Hood and Engine Enclosure - Remove" for the machine that is being serviced.
- Remove the input drive shaft. Refer to Disassembly and Assembly, "Input Drive Shaft - Remove and Install" for the machine that is being serviced.
- Remove the power train guard. Refer to Disassembly and Assembly, "Power Train Guard (Transmission) - Remove and Install" for the machine that is being serviced.
- Remove the implement piston pump. Refer to Disassembly and Assembly, "Piston Pump (Implement) - Remove" for the machine that is being serviced.
- Remove the steering pump. Refer to Disassembly and Assembly, "Piston Pump (Steering) - Remove" for the machine that is being serviced.
- Remove the pump for pilot and braking. Refer to Disassembly and Assembly, "Gear Pump (Pilot and Braking) - Remove" for the machine that is being serviced.
- Remove the axle oil cooler pump. Refer to Disassembly and Assembly, "Gear Pump (Axle Oil Cooler) - Remove and Install" for the machine that is being serviced.
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Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool. |
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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. |
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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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Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Cap all lines, all hoses, and all tubes and plug all lines, all hoses, and all tubes. This will help to prevent fluid loss and this will help to keep contaminants from entering the system.
- Move the machine to a smooth, level surface.
- Engage the parking brake.
- Drain the oil from the transmission into a suitable container for storage or for disposal. The capacity of the transmission is 70 L (18.5 US gal).
- Drain the implement hydraulic tank into a suitable container for storage or for disposal. The capacity of the implement hydraulic tank is 380 L (100 US gal).
- Drain the coolant from the cooling system into a suitable container for storage or for disposal. The capacity of the cooling system is 135 L (35 US gal).
- Recover the air conditioner refrigerant from the air conditioner system. Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the correct procedure. Refer to Special Publication, NEDG5065, "Air Conditioning Tools" for the correct tools.
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| Illustration 1 | g00635646 |
- Remove two bolts (1) from lower front panel assembly (2) .
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| Illustration 2 | g00635647 |
- Remove bolt (3) from bracket (4) .
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| Illustration 3 | g00635648 |
- Remove bolt (5) and the clamp.
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| Illustration 4 | g00635649 |
- Remove two bolts (6) and (7) .
- Remove lower front panel assembly (2) .
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| Illustration 5 | g00635650 |
- Remove bolt (8) and two clamps (9) .
- Place the hose assemblies aside.
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| Illustration 6 | g00635652 |
- Disconnect four hose assemblies (10) .
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| Illustration 7 | g00635653 |
- Disconnect hose assembly (11) .
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| Illustration 8 | g00635655 |
- Disconnect coolant drain line (12) from engine oil cooler (13) .
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| Illustration 9 | g00635656 |
- Disconnect hose assemblies (14) and (15) from the power train oil cooler (16) .
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| Illustration 10 | g00635657 |
- Disconnect hose assemblies (17) and (18) .
- Loosen clamp (19) and disconnect tube assembly (20) .
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| Illustration 11 | g00635658 |
- Remove clamp (21) .
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| Illustration 12 | g00635659 |
- Loosen clamp (22) and remove tube assembly (23) .
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| Illustration 13 | g00635660 |
- Loosen clamps (24) and (25). Slide the rubber sleeve down tube assembly (26) .
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| Illustration 14 | g00635661 |
- Loosen eight clamps (27) and remove tube section (28) .
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| Illustration 15 | g00635662 |
- Disconnect four hose assemblies (29) from fan drive pump (30) .
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| Illustration 16 | g00635664 |
- Disconnect cables (31) and (32) from starting motor (33) .
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| Illustration 17 | g00635665 |
- Disconnect inlet line (34) for the fuel filter.
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| Illustration 18 | g00635667 |
- Disconnect two hose assemblies (35) from refrigerant compressor (36) .
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| Illustration 19 | g00635668 |
- Remove clamp (37) and place inlet line (34) aside.
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| Illustration 20 | g00635669 |
- Loosen eight clamps (38) and remove tube section (39) .
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| Illustration 21 | g00635670 |
- Remove four bolts and clamps (40) from wire harness (41) .
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| Illustration 22 | g00635671 |
- Remove bolt (42) and the clamp from wire harness (43) .
- Disconnect two electrical connectors (44) .
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| Illustration 23 | g00635674 |
- Remove two bolts (45) and the clamps.
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| Illustration 24 | g00635675 |
- Remove bolt (46) and the clamp.
- Place wiring harness (47) aside.
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| Illustration 25 | g00635676 |
- Remove two bolts (48). Remove trunnion cap (49). Repeat this procedure for the opposite side.
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| Illustration 26 | g00635677 |
- Remove bolt (50) and engine mount (51). Repeat this procedure for the opposite side.
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| Illustration 27 | g00635679 |
- Remove bolt (52) and clamp.
Note: Prior to the removal of the engine and torque converter from the rear main frame, make sure that all hose assemblies, all tube assemblies and all wires have been disconnected.
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| Illustration 28 | g00635680 |
- Install Tooling (A) to the torque converter, as shown.
- Attach a suitable hoist and lifting chains to Tooling (B), as shown.
Note: It may be necessary to adjust Tooling (B) several times. This is done in order to achieve proper balance of the engine and the torque converter.
- Use the hoist in order to carefully remove the engine and the torque converter as a unit. The combined weight of the engine and torque converter is 2495 kg (5500 lb).
