2010/08/19 Caterpillar

Underground Articulated Truck:

AD55B (S/N: JNW1-181)

Disassembly and Assembly, KENR6707, "Engine and Torque Converter Updrive Gears - Remove". This manual is part of Service Manual, KENR6715 Volume I.

Replace the existing information with the following information.

Removal Procedure

Table 1

Required Tools
Tool	Part Number	Part Description	Qty
A	6V-6146	Load Leveling Beam	1

Start By:

a. Connect the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect".

b. Release the pressure in the braking system. Refer to Disassembly and Assembly, "System Pressure - Release".

c. Remove the rear hood. Refer to Disassembly and Assembly, "Hood (Rear) - Remove and Install".

d. Remove the engine bottom guard. Refer to Disassembly and Assembly, "Bottom Guard (Engine) - Remove and Install".

e. Remove the transmission bottom guard. Refer to Disassembly and Assembly, "Bottom Guard (Transmission) - Remove and Install".

f. Remove the cooling system package. Refer to Disassembly and Assembly, "Cooling System Package (Radiator, Fan, Aftercooler) - Remove".

g. Remove the firewalls. Refer to Disassembly and Assembly, "Firewall - Remove".

h. Remove the upper drive shaft. Refer to Disassembly and Assembly, "Drive Shaft (Upper) - Remove and Install".

Note: Cleanliness is an important factor. Before the removal procedure, clean the exterior of the component thoroughly. Cleaning the exterior of the component will help to prevent dirt from entering the internal mechanism.

Note: Put identification marks on all hoses, on all hose assemblies, on all wires and on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies to prevent fluid loss, contaminants from entering the system.

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NOTICE
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, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates.

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Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak.

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Personal injury or death can result from sudden suspension cylinder movement. Sudden movement, up or down, can cause the clearance above your head to change rapidly. Read all warning labels on the suspension cylinders before servicing. Do not check the oil in the suspension cylinder until all the nitrogen pressure has been released. Do not, under any condition, remove valves, cover or plugs from the cylinder unless the rod is fully retracted and all the nitrogen pressure is released. Do not stand under the machine when testing or adjusting the suspension cylinders.

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Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

1. Turn the battery disconnect switch to the OFF position.

2. Discharge the front suspension system. Refer to Systems Operation, Testing and Adjusting, Suspension Cylinder, "Suspension System (Front) - Purge and Charge".

3. Drain the hydraulic tank into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Capacities (Refill)" for the capacity of the hydraulic tank. Refer to Operation and Maintenance Manual, "Hydraulic System Oil - Change" for the proper draining procedure.

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Illustration 1	g01441487

4. Move cover (1) aside.

5. Remove four bolts (2) .

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Illustration 2	g01441488

6. Remove clamp (3) below cover (1) .

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Illustration 3	g01441489

7. Use two people to remove tube assembly (4). The weight of tube assembly (4) is approximately 27 kg (60 lb).

8. Remove tube assembly (4) .

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Illustration 4	g02184673

9. Remove cover (5) .

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Illustration 5	g01441492

10. Loosen clamp (6) .

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Illustration 6	g01441494

11. Remove clamp assembly (7) .

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Illustration 7	g01441495

12. Loosen clamp (9) and remove tube assembly (8) .

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Illustration 8	g01441493

13. Loosen clamp (10) .

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Illustration 9	g01441496

14. Loosen clamp (12) and remove tube assembly (11) .

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Illustration 10	g01984454

15. Remove four bolts (13) and mount (14) .

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Illustration 11	g01984455

16. Disconnect harness assembly (15) and position out of the way.

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Illustration 12	g01984456

17. Close valves (16) and (17) for the left fuel tank.

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Illustration 13	g01984457

18. Close valve (18) for the right fuel tank.

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Illustration 14	g02184693

19. Disconnect hose assemblies (19), (20), (21), (22) and (23) .

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Illustration 15	g02186233

20. Disconnect two hose assemblies (24) (if equipped). Remove four clips (25), move assemblies (24) out of the way.

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Illustration 16	g02186234

21. Remove cover (26) .

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Illustration 17	g02186235

22. Remove clip (28). Cut cable straps (29) that hold hose assembly (27) to hose assembly (30). Disconnect hose assembly (27) from the fuel priming pump. Position hose assembly (27) out of the way.

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Illustration 18	g02186236

23. Disconnect harness assembly (31). Disconnect electrical cable (32), two electrical cables (34) and three electrical cables (33) from the starting motor.

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Illustration 19	g02186253

24. Remove three clips (35) from electrical cable (36) .

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Illustration 20	g02186254

25. Remove electrical cable (36) from the alternator.

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Illustration 21	g02186255

26. Disconnect four hose assemblies (38). Remove three clamp assemblies (39) and clamp assembly (37) (not shown). Remove bracket (40) .

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Illustration 22	g02186256

27. Remove four tube assemblies (41) .

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Illustration 23	g02186257

28. Disconnect three hose assemblies (44). Remove three clamp assemblies (43) and bracket (42) .

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Illustration 24	g02186293

29. Remove three tube assemblies (45) .

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Illustration 25	g02186294

30. Disconnect hose assemblies (46), (47) and (48) .

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Illustration 26	g02186315

31. Remove clamp assembly (52) and tube assembly (49) .

32. Remove two bolts (51) and tube assembly (50) .

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Illustration 27	g02186333

33. Disconnect hose assembly (53). Remove 15 bolts (56) and shields (54) .

34. Disconnect tube assemblies (57) and (55) .

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Illustration 28	g02186353

35. Disconnect three hose assemblies (58), (60) and (61). Disconnect harness assembly (62). Remove pilot valve (59) .

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Illustration 29	g02186354

36. Disconnect hose assembly (63) .

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Illustration 30	g02206053
Tube assembly removed for photographic purposes

37. Disconnect hose assemblies (64), (65) and (66) .

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Illustration 31	g02206073

38. Disconnect hose assembly (67). Remove clips (69), (70) and clamp assembly (68) (not shown).

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Illustration 32	g02206074

39. Disconnect hose assembly (71) from the steering gear pump. Disconnect hose assembly (72) .

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Illustration 33	g02206075

40. Remove tube assembly (73) .

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Illustration 34	g02206093

41. Disconnect tube assemblies (74) and (75), and position out of the way.

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Illustration 35	g02206094

42. Remove clips (76) and (77).

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Illustration 36	g02206095

43. Remove clamp assembly (79). Disconnect hose assembly (78) .

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Illustration 37	g02206096

44. Remove two bolts (80) and plate (81) .

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Illustration 38	g02206097

45. Attach Tooling (A) and a suitable lifting device to engine and torque converter updrive gears (82). The weight of engine and torque converter updrive gears (82) is approximately 4000 kg (8900 lb).

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Illustration 39	g02206098

46. Remove bolt (83), the nut, and the mount.

47. Repeat Step 46 for the other side front engine mount.

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Illustration 40	g02206099

48. Remove two bolts (85) and cap (84) .

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Illustration 41	g02206100

49. Remove the nuts, bolts (86) and cap (87) .

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Illustration 42	g02206101
Typical example

50. Use a suitable lifting device to remove mount assembly (88). Remove six bolts (89) and mount assembly (88) .

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Illustration 43	g02206097

51. Remove engine and torque converter updrive gears (82) .