Usage:
Start By:
a. remove fuel tank *
b. remove battery and battery box
*Refer to Disassembly And Assembly Manual for 16H Motor Grader Machine Systems SENR8599.
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Effective July 1, 1992 regulations prohibit the venting of any refrigerant into the atmosphere. Refer to Caterpillar publication SENR3334, SENR5664 and NEDG5065 for the proper procedure, equipment and tools to reclaim refrigerant from any Caterpillar machine. |
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Always wear goggles when working on air conditioning systems. The system is under pressure at all times, engine running or not. Escaping refrigerant R-12 (C C12 F2 Dichloro Difluoro Methane) and refrigerant R-134A can cause freezing of human flesh. Do not smoke while working on air conditioning system. Inhaling Refrigerant R-12 or R-134A through any smoking material, although not toxic or flammable, can cause violent illness. Also heat must never be applied to a charged system. Refer to the "Air Conditioning And Heating Service Manual Form No. SENR3334 and SENR5664," for more information on removal and installation of lines and refrigerant from the system. |
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1. Remove the refrigerant from the air conditioning system using a refrigerant reclaimer.
2. Remove the engine side covers.
3. Disconnect two wire connectors (1) from the mounting bracket.
4. Remove bolts (3) and washers from dash assembly (2). One of the bolts is on the right side of the machine, The other is on the left side of the machine. Remove dash assembly (2) from the mounting brackets.
5. Disconnect cable (7) from electric starting motor (8).
6. Remove bolt and clip (5) from the mounting. Disconnect two wire terminals (4) from starter solenoid (6).
7. Disconnect two air conditioner hose assemblies (10) from air conditioner compressor (13).
8. Put identification marks on three wire connectors for installation purposes. Remove three connectors (12) from their mounting brackets. Disconnect three wire connectors (12).
9. Disconnect cable (9) from relay (11).
10. Disconnect two wire connectors (14) from the side of the engine.
11. Remove bolts (15) from governor control housing (16).
12. Remove governor control housing (16) and cable (17) from the side of the engine.
13. Remove bolts (18) and washers from guard (19). Remove the two halves of guard (19) from implement pump drive shaft (21).
14. Remove bolts (20) from implement pump drive shaft (21). Remove implement pump drive shaft (21) from between the engine and the implement pump.
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Do not remove air lines until air pressure is to zero. Personal injury could result if the air pressure is not released. |
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15. Release pressure in the air system by opening the two valves on the bottom of the air tank. The air tank is located behind the rear bumper.
16. Disconnect three hose assemblies (23) from air compressor (22). Remove three hose assemblies (23) from two clips (24) and position the hoses assemblies away from the engine.
17. Remove plug (27) from tube (30). Drain the coolant from tube (30) into a suitable container for storage or disposal. Install plug (27) to tube (30).
18. Loosen clamp (26). Remove bolt and clip (28) from the engine block.
19. Remove tube assembly (30) from the engine compartment.
20. Loosen the clamps, and disconnect heater hoses (25) and (29) from the fittings.
21. Remove bolts (33) and washers from flanges (32). Remove two flanges (32) and hose assemblies (31) from the transmission oil cooler. Plug the fittings of hose assemblies (31) and the oil cooler in order to prevent the loss of oil, and to keep dirt out of the oil system.
22. Disconnect fitting of tube (34) from the ether starting aid.
23. Attach Tool (A) and a hoist to the lifting lugs on the engine.
24. Remove mounting bolts (35) and washers from the front engine mounts.
25. Remove bolts (36) and washers from flange (37).
26. Raise the hoist slightly in order to separate the engine flywheel housing from the transmission. Disengage the splined shaft on the transmission from the torsion coupler on the engine. Carefully remove the engine from the machine. The weight of the engine is 1090 Kg (2400 lb).
Install Engine
1. Clean all components of the engine and mating components before you install the engine. Check the condition of all O-ring seals used in the hose assemblies that were disconnected. If any of the O-ring seals are damaged, use new parts for replacement.
2. Attach Tool (A) and a hoist to the lifting lugs on the engine. Use Tool (A) to position the engine to the transmission. The splined shaft on the transmission must be aligned with the torsion coupling on the engine.
3. Install bolts (36) and washers to flange (37) in order to secure the engine to the transmission.
4. Install mounting bolts (35) and washers to the front engine mounts.
5. Connect fitting of tube (34) to the ether starting aid.
6. Position two flanges (32) and hose assemblies (31) to the transmission oil cooler. Install bolts (33) and washers to flanges (32) in order to secure the hoses assemblies to the transmission oil cooler.
7. Install heater hoses (25) and (29) to the fittings. Tighten the clamps.
8. Position tube assembly (30) to its original location. Install bolt and clip (28) to the engine block in order to secure tube assembly (30) to the engine. Tighten clamp (26) and plug (27).
9. Connect three hose assemblies (23) to air compressor (22). Install hose assemblies (23) into clips (24).
10. Install implement pump drive shaft (21) between the engine and the pump. Install bolts (20) to implement pump drive shaft (21). Tighten bolts (20) to 75 ± 10 N·m (55 ± 7 lb ft).
11. Install two guard halves (19) to implement pump drive shaft (21). Install bolts (18) to secure the guard to the mounting and the two halves together. The bolts that hold the guard to the mounting must be tightened to a torque of 135 ± 20 N·m (100 ± 15 lb ft).
12. Position governor control housing (16) and cable (17) to the side of the engine. Install bolts (15) in order to secure governor control housing (16) to the side of the engine.
13. Connect two wire connectors (14) to the side of the engine.
14. Connect three wire connectors (12). Install three wires (12) to their mounting brackets.
15. Connect two air conditioner hose assemblies (10) to air conditioner compressor (13).
16. Connect cable (9) to relay (11).
17. Connect cable (7) to electric starting motor (8).
18. Install bolt and clip (5) to the mounting. Connect two wire terminals (4) to solenoid (6).
19. Position dash assembly (2) to the mounting brackets. Install bolts (3) and washers to dash assembly (2). One of the bolts is on the right side of the machine, the other is on the left side of the machine.
20. Connect two wire connectors (1) to the mounting bracket.
21. Install the engine side covers.
22. Fill the air conditioning system with refrigerant to the correct pressure level. Refer to "SENR3334, SENR5664 and NEDG5065" for the proper filling procedure.
End By:
a. install battery and battery boxes
b. install fuel tank *
*Refer to Disassembly And Assembly Manual for 16H Motor Grader Machine Systems SENR8599.