525D, 535D, 545D and 555D Wheel Skidders C7.1 Engine Supplement Caterpillar

Removal Procedure

Start By:

1. Connect the steering frame lock.

2. Release the system pressure.

3. Remove the bottom guard (engine).

4. Remove the battery.

5. Remove the sweeps.

6. Remove the hood side panel and side doors.

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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. 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 cooling system pressure cap is cool enough to touch with your bare hand. Remove the cooling system pressure cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.

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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.

1. Recover the refrigerant. Refer to Service Manual, SENR5664, "All Products Air Conditioning and Heating R-134a for All Caterpillar Machines" for the recovery and the charging procedure. Refer to Special Publication, NENG2500, "Air Conditioning Tools" for the correct tools.

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

3. Drain the coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct draining and filling procedures.
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   Illustration 1	g06216396

4. Attach Tooling (A) and a suitable lifting device to plate (1). The weight of plate (1) is approximately 54 kg (120 lb).

5. Remove bolts (2) and plate (1).
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   Illustration 2	g06195491

6. Disconnect hose assemblies (3) and harness assemblies (4).
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   Illustration 3	g06193880

7. Cut cable strap (5).

8. Remove bolts (6) and reposition the bracket out of the way.
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   Illustration 4	g06194193

9. Remove nuts (7) and (8).

10. Disconnect cables (9) and (10).
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    Illustration 5	g06193885

11. Loosen clamps (12) and disconnect hose (11).
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    Illustration 6	g06216424

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    Illustration 7	g06193936

12. Attach a suitable lifting device to guard assembly (13). The weight of guard assembly (13) is approximately 190 kg (420 lb).

13. Remove six bolts (14) and guard assembly (13).
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    Illustration 8	g06194226

14. Remove support assembly (15).
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    Illustration 9	g06194283

15. Loosen clamp (16) and remove tube assembly (17).
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    Illustration 10	g06216488

16. Remove nut (18) and disconnect the harness assembly.
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    Illustration 11	g06216491

17. Disconnect harness assemblies (20) and (21).

18. Remove the nuts and disconnect hose assemblies (19).
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    Illustration 12	g06216494

19. Remove bolt (22) and disconnect the cable assemblies.

20. Disconnect harness assembly (23).
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    Illustration 13	g06216503

21. Remove nut (25).

22. Disconnect cable assemblies (24) and (26).

23. Remove bolts (28) and bus bar assembly (27).
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    Illustration 14	g06216719

24. Disconnect harness assembly (29).

25. Remove nut (30) and bolt (31) and disconnect the ground straps.
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    Illustration 15	g06194558

26. Loosen clamps (32) and (34).

27. Remove tube assembly (33).

28. Remove the muffler.
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    Illustration 16	g06194575

29. Remove bolts (35) and loosen clamp (36).
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    Illustration 17	g06194581

30. Loosen clamp (37) and remove tube assembly (38).
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    Illustration 18	g06216727
    Typical Example

31. Disconnect harness assemblies (39) and (40).

32. Disconnect hose assemblies (41).
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    Illustration 19	g06194643
    Hose assemblies have been made transparent for clarity.

33. Remove four bolts (43) and reposition drive shaft (42) out of the way.

34. Discard four bolts (43).
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    Illustration 20	g06194638

35. Cut three cable straps (45) and reposition harness assembly (44) out of the way.
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    Illustration 21	g06216743

36. Remove bolts (47) and reposition bracket (46) out of the way.
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    Illustration 22	g06194702

37. Loosen the clamps and disconnect hoses (48).
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    Illustration 23	g06194734

38. Loosen clamps (50) and disconnect hose (49).
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    Illustration 24	g06194758
    View from the bottom of the engine.

39. Loosen the clamp and disconnect hose assembly (51).
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    Illustration 25	g06194765

40. Disconnect hose assembly (52) from the engine oil pan.
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    Illustration 26	g06194814

41. Remove two bolts (55) and lifting plate (53). Repeat for the opposite side.

42. Remove four bolts (54).
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    Illustration 27	g06194828

43. Remove bolts (57) and plate assembly (56).
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    Illustration 28	g06194854

44. Install lifting plate (53) and two bolts (55). Repeat for the opposite side.
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    Illustration 29	g06195093

45. Attach Tooling (B) and a suitable lifting device to engine (58). The weight of engine (58) is approximately 780 kg (1720 lb).

46. Remove four mounting bolts (not shown) (59) and engine (58).

Installation Procedure

1. Install engine (58) in the reverse order of removal.

   1. Install new bolts (43).

   2. Tighten bolts (43) in an "X" pattern to a torque of 120 ± 20 N·m (89 ± 15 lb ft).

   3. Tighten harness assembly (40) to a torque of 5 ± 1 N·m (44 ± 9 lb in).

   4. Tighten bolts (35) to a torque of 30 ± 7 N·m (266 ± 62 lb in).

   5. Tighten nut (30) to a torque of 21 ± 4 N·m (186 ± 31 lb in).

   6. Tighten bolts (28) to a torque of 30 ± 7 N·m (266 ± 62 lb in).

   7. Tighten nut (25) to a torque of 50 ± 10 N·m (37 ± 7 lb ft).

   8. Tighten bolt (22) to a torque of 6 ± 1 N·m (53 ± 9 lb in).

   9. Tighten the nuts for hose assemblies (19) to a torque of 21 ± 3 N·m (186 ± 27 lb in).

   10. Tighten nut (18) to a torque of 4 ± 1 N·m (35 ± 9 lb in).

   11. Tighten nuts (8) and (7) to a torque of 12 ± 1 N·m (106 ± 9 lb in).