986K Wheel Loader Engine Supplement Caterpillar

Removal Procedure

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Personal injury can result from hot oil spray. Make sure all attachments have been lowered, oil is cool and the pressure has been released from the hydraulic system before removing any components or lines. Be sure there is no pressure in the tubing before it is disconnected from the fitting. Do not allow hot oil or components to contact skin.

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Personal injury can result from hot coolant, steam, and alkali. At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and allow sufficient time for the cooling system to cool. Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns. Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes.

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Illustration 1	g06275053

1. Remove bolts (2) and use two people to remove grill assembly (1). The weight of grill assembly (1) is approximately 24 kg (53 lb).
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   Illustration 2	g06275054

2. Remove bolts (3), bolts (4), and door assembly (5).
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   Illustration 3	g06275055

3. Remove bolts (6) and use two people to remove grill assembly (7). The weight of grill assembly (7) is approximately 34 kg (75 lb).
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   Illustration 4	g06275056

4. Remove bolts (8) and grill assembly (9).
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   Illustration 5	g06275057

5. Remove bolts (10) and left-hand side door assembly (11).
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   Illustration 6	g06275058

6. Remove bolts (13) and door (12).
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   Illustration 7	g06275059

7. Remove bolts (14) and shield assembly (15).
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   Illustration 8	g06275060

8. Remove bolts (17) and shield assembly (15).
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   Illustration 9	g06275061

9. Remove bolts (18) and shield assembly (19).
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   Illustration 10	g06275062

10. Loosen clamps (21) and remove hose (20).
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    Illustration 11	g06275064

11. Remove nuts (22) and U-bolt (23).

12. Remove bolts (25) and bracket (24).
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    Illustration 12	g06275065

13. Remove bolts (26) and cover (27).
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    Illustration 13	g06275063

14. Remove bolt (31) and disconnect bracket (28).

15. Remove bolts (30) and shield assembly (29).
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    Illustration 14	g06275066

16. Remove bolts (32) and shield assembly (33).
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    Illustration 15	g06275067

17. Loosen clamp (35) and remove tube (34).

18. Loosen clamp (36) and remove hose (37).
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    Illustration 16	g06275068

19. Remove bolts (39) and disconnect clips (38).
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    Illustration 17	g06275069

20. Loosen clamp (41) and disconnect hose (40). Remove bolt (43) and disconnect clip (42). Reposition hose (40).
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    Illustration 18	g06275070

21. Loosen clamps (44) and remove hose (45).
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    Illustration 19	g06275071

22. Remove bolts (46) and cover assembly (47).
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    Illustration 20	g06275072

23. Remove bolts (48) and shield assembly (49).
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    Illustration 21	g06275073

24. Disconnect hose (50). Remove bolts (52) and disconnect clips (51). Reposition hose (50).
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    Illustration 22	g06275074

25. Remove strap (54) and disconnect harness assembly (53).
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    Illustration 23	g06275075

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    Illustration 24	g06275076

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    Illustration 25	g06275077

26. Remove bolt (55) and disconnect clip (56). Disconnect sensor assembly (57).

27. Remove bolt (58) and disconnect clip (59). Disconnect sensor assembly (60).

28. Remove bolts (62) and (61). Remove sensor assemblies (57) and (60).
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    Illustration 26	g06275078

29. Remove bolts (64) and shield assembly (63).
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    Illustration 27	g06275079

30. Remove bolts (65) and shield assembly (66).
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    Illustration 28	g06275080

31. Remove nuts (68) and U-bolt (67).

32. Loosen clamps (70) and remove hose (69).
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    Illustration 29	g06275081

33. Loosen clamps (72) and (73). Remove tube (71) and elbow (74).
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    Illustration 30	g06275082

34. Remove nuts (76) and U-bolt (75).

35. Remove bolts (78) and bracket (77).
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    Illustration 31	g06275083

36. Remove bolts (79). Loosen clamp (81) and remove hose (80).
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    Illustration 32	g06275084

37. Disconnect hose assembly (83).

38. Remove bolt (84) and disconnect clips (85).

39. Remove bolts (85) and shield assembly (82).
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    Illustration 33	g06275085

40. Remove bolts (87) and shield assembly (88).
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    Illustration 34	g06275086

41. Remove bolt (90) and disconnect clip (92).

42. Remove bolts (91) and shield assembly (89).

Installation Procedure

1. Install the engine enclosure in the reverse order of removal.

   1. Tighten nuts (76) to a torque of 30 ± 7 N·m (266 ± 62 lb in).

   2. Tighten nuts (68) and (22) to a torque of 11.0 ± 1.5 N·m (97.4 ± 13.3 lb in).

   3. Tighten sensor assemblies (60) and (67) to a torque of 50 ± 10 N·m (37 ± 7 lb ft).