Usage:
Start By:
a. Install the steering frame lock pin. Refer to Disassembly and Assembly, "Steering Frame Lock Pin - Remove and Install" for the machine that is being serviced.
b. Release the pressure from the hydraulic system. Refer to Disassembly and Assembly, "Hydraulic System Pressure - Release" for the machine that is being serviced.
c. Remove the service brake control valve. Refer to Disassembly and Assembly, "Brake Control Valve (Service) - Remove" for the machine that is being serviced.
d. Disarm the fire suppression system (if equipped). For the correct procedure, refer to the fire system manufacturer's service information.
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose of fluids according to local regulations and mandates. |
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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered, and the oil is cool before removing any component or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. |
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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. |
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NOTE: Put identification marks on all lines, on all hoses, on all wires and on all tubes for installation purposes. Plug all lines, all hoses and all tubes. This will help to prevent fluid loss and this will help to prevent contaminants from entering the system.
NOTE: On machines equipped with the optional cab heating system, it will be necessary to drain a small amount of coolant from the radiator into a suitable container for storage or disposal. This will allow the coolant that is in the cab to drain back into the radiator.
1. Install Tooling (A) on rear fender assembly (1), as shown. Attach a hoist and suitable lifting chains to Tooling (A).
2. Remove four bolts (2), the washers and retainer strip (3) that hold fender assembly (1) to the cab. Remove the fender assembly. The weight of the fender assembly is 52 kg (115 lb).
NOTE: Perform Steps 3 and 4 on machines equipped with an enclosed cab.
3. Remove four bolts (4), the nuts and the washers that hold pressurizer assembly (5) to the cab.
4. Remove the cable strap and disconnect the wiring harness at connector (6). Remove cab pressurizer assembly (5).
5. Remove two bolts (7) and the washers that hold cover (8) to the cab. Remove cover (8).
6. Remove three bolts (9) and the washers that hold cover (10) to the rear frame. Remove cover (10).
7. Remove two hose clips (11) that secure the air conditioning hoses (if equipped) to the rear frame.
8. Remove bolt (12) and the washer to disconnect the earth cable from the cab.
9. Disconnect harness connectors (13), (14) and (15) from the cab.
10. Disconnect cable (16) from the cab.
11. Disconnect the windshield washer hoses (if equipped) from three connectors (17).
12. Disconnect two heater hoses (18) (if equipped) from the cab.
NOTE: It is necessary to recover the air conditioner refrigerant from the air conditioner system before disconnecting two hose assemblies (19). 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.
13. Disconnect two air conditioning hose assemblies (19) (if equipped) from the cab.
14. Disconnect the upper seven hose assemblies (20) from the bulkhead on the cab.
NOTE: On machines equipped with an optional fire suppression system, it is necessary to disarm the system before disconnecting hose assembly (21). Disconnecting hose assembly (21) without disarming the system will cause the fire retardant foam to be discharged. Refer to the fire system manufacturer's service information for the correct procedure.
15. Disconnect fire suppression system hose assembly (21) (if equipped) from the bulkhead on the cab.
16. Disconnect the remaining five hose assemblies (22) from the bulkhead on the cab.
17. Remove two bolts (23) and the washers that hold cover (24) to the cab. Remove cover (24).
18. Remove four bolts (25) and the washers that hold cover (26) to the cab. Remove cover (26).
19. Remove bolt (27), nut (28) and the washers that hold the rear cab mount assembly to the rear frame.
20. Remove three bolts (29) and the washers that hold cover (30) to the cab. Remove cover (30).
21. Remove three bolts (31) and the washers that hold the front mounting bracket to the cab.
22. Install Tooling (B) on the top of the cab, as shown. Attach a hoist and suitable lifting chains to Tooling (B).
23. Remove four bolts (32), the washers and cover (33).
24. Remove bolts (34) and (35), the nuts and the washers that hold the lower cab mount assemblies to the rear frame. Remove the nuts and the washers from the access area where cover (33) was removed.
25. Using the hoist, carefully remove the cab from the loader frame. The weight of the cab assembly is 1250 kg (2756 lb).