Removal Procedure
Show/hide table
Table 1
| Required Tools |
| Tool |
Part Number |
Part Description |
Qty |
| A |
6V-0006 |
Governor Pliers |
1 |
| B |
8S-7640 |
Stand |
4 |
| B |
8S-7611 |
Tube |
4 |
Start By:
- Install the retaining cable. Refer to Disassembly and Assembly, "Truck Body Retaining Cable - Remove and Install".
- Release the air system pressure. Refer to Disassembly and Assembly, "Air Tanks - Purge".
Show/hide table
|
| NOTICE |
|---|
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, NENG2500, "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. |
|
Show/hide table
 |
In order to prevent possible personal injury, release the air pressure from the air tank before disconnecting any components of the air system. |
 |
Show/hide table
|
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. |
|
Note: Cleanliness is an important factor. Before the removal procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.
Note: Put identification marks on all hose assemblies, on all tube assemblies and on all wire harnesses for installation purposes. Plug all hose assemblies and all tube assemblies. This helps to prevent fluid loss and this helps to prevent contaminants from entering the system.
- Drain the hydraulic oil from the steering hydraulic tank. The steering hydraulic tank contains approximately 91 L (24 US gal). Refer to Operation and Maintenance Manual, "Steering System Oil - Change" for the correct procedure.
Show/hide table
|
 |
|
| Illustration 1 | g00522283 |
- Remove three bolts (1) and the washers in order to remove cover (2) from the frame assembly.
Show/hide table
|
 |
|
| Illustration 2 | g00522287 |
- Disconnect hose assembly (3) .
- Disconnect hose assembly (4) .
- Disconnect hose assembly (5) .
- Disconnect hose assembly (6) .
Show/hide table
|
 |
|
| Illustration 3 | g00522338 |
- Disconnect hose assembly (7) .
- Disconnect wire harness (8) at the electrical connection.
- Disconnect wire harness (9) at the electrical connection.
Show/hide table
|
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. |
|
- Recover the refrigerant from the air conditioning system. Refer to Air Conditioning and Heating, Testing and Adjusting, SENR5664, "Refrigerant Recovery" for the correct procedure.
- Evacuate the air conditioning system. Refer to Air Conditioning and Heating, Testing and Adjusting, SENR5664, "Refrigerant System - Evacuate" for the correct procedure.
Show/hide table
|
 |
|
| Illustration 4 | g00522349 |
- Disconnect hose assembly (10) at the air conditioner quick disconnect.
- Disconnect hose assembly (11) at the air conditioner quick disconnect.
Show/hide table
|
 |
|
| Illustration 5 | g00522353 |
Show/hide table
|
 |
|
| Illustration 6 | g00522356 |
Note: Close the valves on the engine before two hoses (12) and (13) are disconnected.
- Mark the location of two hoses (12) and (13) for installation purposes. Loosen the two hose clamps in order to disconnect two hoses (12) and (13) .
- Remove bolt (14) , the washer, and the clamp.
- Roll up two hoses (12) and (13) and secure two hoses (12) and (13) with a wire tie.
Show/hide table
|
 |
|
| Illustration 7 | g00522358 |
- Disconnect wire harness (15) at the electrical connection.
- Disconnect wire harness (16) at the electrical connection.
Show/hide table
|
 |
|
| Illustration 8 | g00522362 |
- Loosen two screws (not shown) in order to disconnect wire harness (17) .
Show/hide table
|
 |
|
| Illustration 9 | g00522367 |
- Disconnect wire harness (18) at the electrical connection.
- Disconnect wire harness (19) at the electrical connection.
Show/hide table
|
 |
|
| Illustration 10 | g00522390 |
- Remove four bolts (20) and the washers.
Show/hide table
|
 |
|
| Illustration 11 | g00522405 |
- Disconnect wire harness (21) from the cab at the electrical connection.
- Disconnect wire harness (22) from the cab at the electrical connection.
Show/hide table
|
 |
|
| Illustration 12 | g00522407 |
- Use Tool (A) in order to disconnect wire harness (23) from the cab at the electrical connection.
Show/hide table
|
 |
|
| Illustration 13 | g00522409 |
- Disconnect wire harness (24) from the cab at the electrical connection.
- Disconnect wire harness (25) from the cab at the electrical connection.
Show/hide table
|
 |
|
| Illustration 14 | g00522476 |
- Remove bolt (27) and the washer in order to disconnect ground strap (26) from the cab.
Show/hide table
|
 |
|
| Illustration 15 | g00522482 |
- Disconnect hose assembly (28) .
- Disconnect hose assembly (29) .
- Disconnect hose assembly (30) .
- Disconnect hose assembly (31) .
Show/hide table
|
 |
|
| Illustration 16 | g00522489 |
- Disconnect hose assembly (32) .
- Disconnect hose assembly (33) .
- Disconnect hose assembly (34) .
- Disconnect hose assembly (35) .
Show/hide table
|
 |
|
| Illustration 17 | g00575406 |
- Remove four bolts (37) and the washers. Remove plate (36) and the air horn from the ladder assembly. Position plate (36) and the air horn out of the way.
Show/hide table
|
 |
|
| Illustration 18 | g00522497 |
- Remove four bolts (39) and the washers in order to separate ladder assembly (38) from the cab.
Show/hide table
|
 |
|
| Illustration 19 | g00522502 |
Show/hide table
|
 |
|
| Illustration 20 | g00575554 |
- Remove two bolts (41) , the hard washers, the plate, and the nuts in order to separate deflector (42) from the frame assembly.
- Attach a suitable lifting device and a hoist to cab (40) .
Show/hide table
|
 |
|
| Illustration 21 | g00522504 |
- Remove six bolts (43) and the washers from the outside rear cab mounts.
Show/hide table
|
 |
|
| Illustration 22 | g00522508 |
- Remove six bolts (44) and the washers from the inside rear cab mounts.
Show/hide table
|
 |
|
| Illustration 23 | g00522552 |
- Remove four bolts (45) and the washers from the outside front cab mounts.
Show/hide table
|
 |
|
| Illustration 24 | g00522559 |
- Remove four bolts (46) and the washers from the inside front cab mounts.
Show/hide table
|
 |
|
| Illustration 25 | g00522561 |
Show/hide table
|
 |
|
| Illustration 26 | g00518019 |
- Use the hoist in order to remove cab (40) from the frame assembly. The weight of cab (40) is 1814 kg (4000 lb).
- If necessary, remove shims (47) from the cab mounts.
- Position cab (40) onto Tooling (B) (not shown) or the equivalent. Remove the lifting device and the hoist.
