Required Tools | |||
---|---|---|---|
Tool | Part Number | Part Description | Qty |
A | 8S-7640 | Stand | 2 |
A | 8S-7611 | Tube | 2 |
A | 8S-7615 | Pin | 2 |
B | 8T-5255 | Hydraulic Jack | 1 |
C | 6V-6146 | Load Leveler | 1 |
D | 138-7574 | Link Bracket | 1 |
Start By:
- Purge the air from the air tanks. Refer to Disassembly and Assembly, SENR1561, "Air Tanks (Brake) - Purge".
- Remove the radiator. Refer to Disassembly and Assembly, "Radiator - Remove".
- Remove the rear hood. Refer to Disassembly and Assembly, "Hood (Rear) - Remove and Install".
- Remove the front drive shaft. Refer to Disassembly and Assembly, SENR1551, "Drive Shaft (Front) - Remove and Install".
NOTICE |
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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 product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, PERJ1017, "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. |
Removing the engine from the truck with the body of the truck in the Up position will change the balance point of the truck. The shift in the balance point could allow the front of the truck to unexpectedly raise off the ground. This unexpected movement could cause injury or death. To stabilize the truck, always install the specified tooling to stabilize the truck before removing the engine and torque converter. |
Personal injury can result from hot oil or hot components. At operating temperature, oil is hot and under pressure. Hot oil can cause burns. Remove the fill cap only when the engine is stopped, and the fill cap is cool enough to touch with your bare hand. Do not allow hot oil or components to contact skin. |
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 filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand. Cooling System Conditioner contains alkali. Avoid contact with skin and eyes. |
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, oil is cool before removing any components 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. |
- Drain the oil from the engine. Refer to Operation and Maintenance Manual, SEBU7092, "Engine Oil and Filter - Change".
- Drain the oil from the torque converter. Refer to Operation and Maintenance Manual, SEBU7092, "Torque Converter Sump Oil - Change".
- Drain the oil from the hoist and brake. Refer to Operation and Maintenance Manual, SEBU7092, "Hoist and Brake Tank Oil - Change".
- Drain the oil from the steering hydraulic tank. Refer to Operation and Maintenance Manual, SEBU7092, "Steering System Oil - Change".
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Illustration 1 g00461867 - Put Tooling (A) in position under the body of the truck, as shown.
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Illustration 2 g00461871 - Open cover assembly (1).
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Illustration 3 g00556846 - Put identification on cable assemblies (2) and (3). Disconnect cable assemblies (2) and (3) from the batteries.
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Illustration 4 g00556848 - Remove three bolts (4) and the washers that hold battery cable (3) in position. Feed cable assembly (3) through the platform assembly.
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Illustration 5 g00557555 - Remove four bolts (5) from signal lamp (6). Remove signal lamp (6) from bracket assembly (7).
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Illustration 6 g00557556 - Put identification on wires (8) and (10) for assembly purposes. Disconnect wire harnesses (8) and (10) from signal lamp (6). Pull wire harness (9) through bracket assembly (7).
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Illustration 7 g00462716 - Remove all the clips and the tie straps that hold wire harness (9) to the frame assembly. Disconnect wire harness (9) from payload sensor (11) at the electrical connection. Position wire harness (9) out of the way.
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Illustration 8 g00466988 - Disconnect wiring harness (13) from brake overstroke switch (12) at the electrical connection.
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Illustration 9 g00467187 - Remove tie strap (15) and (16) in order to free wire harness (14) from frame assembly (17).
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Illustration 10 g00467193 - Remove nut (19) and the washer from air dryer (18). Place the wire harness out of the way.
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Illustration 11 g00557228 - Remove bolt (20) and the washer.
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Illustration 12 g00557232 - Disconnect wire harness (21) at the electrical connection.
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Illustration 13 g00556859 - Remove bolt (22) and the washer. Position wire harness (23) and the clip out of the way.
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Illustration 14 g00467396 - Remove bolt (24) and the washer. Position four wire harnesses (25) out of the way.
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Illustration 15 g00467403 - Disconnect wire harness (27) at the electrical connection. Loosen hose clamps (26). Remove elbow (28).
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Illustration 16 g00467613 - Remove two tie straps (30). Disconnect wire harness (31) at the electrical connection. Disconnect tube assembly (29) from the gear pump (hoist and brake).
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Illustration 17 g00556906 - Disconnect wire harness (33) from lockup clutch control valve (32) at the electrical connection.
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Illustration 18 g00556907 - Remove bolt (34) and the washer. Position the clip and wire harness (35) out of the way.
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Illustration 19 g00467649 - Disconnect hose assembly (37) from secondary steering pump (36).
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Illustration 20 g00467815 - Disconnect hose assembly (38) from secondary steering pump (36).
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Illustration 21 g00467821 - Disconnect two hose assemblies (39) and (40) from secondary steering pump (36).
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Illustration 22 g00467824 - Disconnect hose assembly (41) from the engine oil pan.
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Illustration 23 g00467826 - Remove bolt (42), the washer, and clip (43) from the frame assembly. Place hose assembly (44) aside.
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Illustration 24 g00556917 - Disconnect hose assembly (45) from nipple assembly (46).
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Illustration 25 g00467855 - Position cover (48) out of the way. Remove two nuts (47) (not shown). Remove cable assembly (50) from electric starting motor (49).
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Illustration 26 g00467860 - Position cover (53) out of the way. Remove nut (52) (not shown). Disconnect cable assemblies (55) and wire assembly (54) from left hand electric starting motor (51).
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Illustration 27 g00467863 - Position cover (57) out of the way. Remove nut (56) (not shown). Disconnect wire assembly (58).
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Illustration 28 g00556956 - Remove bolt (60), the clips and the washers. Position cable assemblies (55) out of the way. Remove bolt (59) (not shown) and the washer. Position clips (61) and cable assemblies (62) out of the way.
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Illustration 29 g00556962 - Disconnect three hose assemblies (64), (65) and (66) from piston pump (63).
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Illustration 30 g00557004 - Remove bolt (67) and the washer. Position hose assembly (64) out of the way. Disconnect hose assembly (68) from the air compressor.
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Illustration 31 g00557014 - Disconnect hose assembly (69) from the torque converter.
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Illustration 32 g00468036 - Disconnect hose assembly (70) from the gear pump (hoist and brake). Disconnect hose assembly (71) from the piston pump (steering).
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Illustration 33 g00468038 - Remove bolt (72) and the washer. Position hose assembly (73) and the clip out of the way.
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Illustration 34 g00468039 - Loosen two clamps (74). Separate tube assembly (76) from hose (75).
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Illustration 35 g00557034 - Remove bolt (78) and the washer. Remove bolt (79) and the washer. Position two hose assemblies (77) and (80) out of the way.
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Illustration 36 g00468313 - Disconnect hose assembly (81) from the gear pump (power train).
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Illustration 37 g00468512 Inboard side of the fuel tank - Turn ball valve (82) to the OFF position.
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Illustration 38 g00468348 - Disconnect hose assembly (83) from fuel/water separator (84).
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Illustration 39 g00468349 - Disconnect tube assembly (85) from the gear pump (power train).
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Illustration 40 g00557035 - Remove bolt (87), the washer and the two clips. Position hose assembly (86) out of the way.
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Illustration 41 g00468352 - Disconnect tube assembly (88) from the gear pump (hoist and brake).
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Illustration 42 g00557048 - Disconnect hose assembly (89) from the oil cooler (power train).
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Illustration 43 g00468354 Show/hide tableIllustration 44 g00557049 - Remove bolt (90), the washers, and the clips. Disconnect hose assembly (91) from the oil cooler (power train).
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Illustration 45 g00557050 - Disconnect wire harness (92) at the electrical connection. Remove bolt (95). Position clip (94) and hose assembly (93) out of the way. Disconnect hose assembly (96).
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Illustration 46 g00468359 - Remove nut (97). Remove bolt (99) and the washer. Position wire harness (98) aside.
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Illustration 47 g00468362 - Disconnect two hose assemblies (100) from the engine oil cooler.
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Illustration 48 g00557054 - Disconnect t-fitting (101) from the oil cooler (power train).
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Illustration 49 g00468407 Show/hide tableIllustration 50 g00468409 Note: It is not necessary to recover the refrigerant from the air conditioning system. Do not disconnect the hose assemblies from the air conditioning compressor. Position the air conditioning compressor while the hose assemblies are still attached.
- Put identification on two electrical connections (103) for installation purposes. Remove the tie strap and disconnect two electrical connections (103) from air conditioning compressor (105).
- Loosen two bolts (107).
- Loosen two adjusting nuts (102). Remove the nut and the bolt that holds the rod to air conditioner compressor (105). Move the air conditioning compressor toward the engine and remove V-belt (104).
- Disconnect wiring harness (106) at the electrical connection (106). Remove two bolts (107) and the washers. Position the air conditioning compressor out of the way.
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Illustration 51 g00557116 - Remove three bolts (108), and the washers from the bracket assembly.
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Illustration 52 g00557112 - Remove two bolts (112). Disconnect wire harness (111) at the electrical connection. Remove four bolts (110) and the washers from bracket assembly (109). Remove bracket assembly (109).
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Illustration 53 g00468459 - Remove four bolts (114), the nuts and the washers. Remove bracket assembly (113).
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Illustration 54 g00557558 - Remove tie straps (116) and (118). Remove bolt (115) (not shown) and the washer. Remove bolt (119) and the washer. Remove shield assembly (117).
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Illustration 55 g00468497 Show/hide tableIllustration 56 g00468499 - Remove bolt (120) and the washer.
- Disconnect hose assembly (121) from air compressor (123). Position hose assembly (121) and clip (122) aside.
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Illustration 57 g00468500 - Disconnect hose assembly (125) from governor assembly (124).
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Illustration 58 g00557161 - Disconnect hose assembly (126) from governor assembly (124).
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Illustration 59 g00557166 - Remove four bolts (128) and the hard washers. Remove filler (127) and the O-ring seal from torque converter (129).
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Illustration 60 g00586458 - Disconnect two hoses (130) and (131) from the valve assemblies.
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Illustration 61 g00737885 - Disconnect hose (132) from the adapter.
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Illustration 62 g00737886 - Remove cotter pin (133) from slotted nut (134). Loosen slotted nut (134) that is on ball stud (135). Do not remove slotted nut (134) at this time.
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Illustration 63 g00737942 - Place Tool (B) under the ball stud and apply force. Hit the center arm with a soft faced hammer until the ball stud is loose. Remove Tool (B) from the ball stud. Remove the slotted nut from the ball stud.
- Repeat Steps 67 and 68 for the other ball stud.
- Use two people in order to remove the tie rod from the machine. The weight of the tie rod is
25 kg (55 lb) . Repeat the procedure for the other tie rod.Show/hide tableIllustration 64 g00737889 Right Side - Remove two nuts (136), the bolts and the hard washers. Remove cap (137) from the mount assembly.
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Illustration 65 g00737890 Left Side - Remove two full nuts (138), the bolts, and the hard washers. Remove the cap from mount assembly (139).
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Illustration 66 g00737891 - Remove four bolts (140), the nuts, and the washers from engine front support (141).
- Remove two bolts (142), the nuts, and the washers from engine support assembly (143).
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Illustration 67 g00737892 Show/hide tableIllustration 68 g00737893 Show/hide tableIllustration 69 g00737894 - Attach Tool (C) to the engine, as shown. Attach Tool (D) to the rear, right side of the torque converter in order to prevent the engine from rotating. Secure Tool (C) and Tool (D) to a suitable hoist.
- Carefully raise the engine and the torque converter. Be sure that all wire harnesses, hose assemblies and tube assemblies will not interfere with removal of the engine and the torque converter.
- Remove engine support assembly (143) from the machine.
- Check that there is proper clearance and remove the engine and the torque converter from the machine. Position the engine and torque converter on a suitable stand (not shown). The weight of the engine and torque converter is
2404 kg (5300 lb) .
Note: Install caps and plugs to all connections in order to prevent system contamination.