Removal Procedure
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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, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all 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 to the ground, and the 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. |
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- Use the following procedure to release the pressure in the hydraulic system:
- Lower the implements to the ground.
- Shut off the engine.
- Move the control levers through the full travel distance of the levers. This will relieve any pressure in the pilot system.
- Slowly loosen the filler cap on the hydraulic oil tank in order to release the pressure.
- Tighten the filler cap on the hydraulic oil tank.
- The pressure in the hydraulic system has now been relieved. Lines and components can now be removed.
Note: Put identification on all lines, hoses, wires, and tubes for installation purposes. Install a cap or plug on all lines, hoses, and tubes that are disconnected. The caps and/or plugs prevent the loss of fluid and contaminants cannot enter the system.
Note: The removal procedure is similar for the two-stem control valve, the three-stem control valve, and the four-stem control valve. Only the three-stem bulldozer control valve is shown.
- Remove the bolts and screen (1) .
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| Illustration 1 | g00621511 |
- Recover the air conditioner refrigerant from the air conditioner system. 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.
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Effective July 1, 1992 regulations prohibit the venting of any refrigerant into the atmosphere. Refer to Caterpillar publications Service Manuals, SENR3334, SENR5664, and NEDG5065 for the proper procedure, the proper equipment, and the proper tools needed in order to reclaim refrigerant from any Caterpillar equipment. |
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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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| Illustration 2 | g00621512 |
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| Illustration 3 | g00621513 |
- Disconnect two air conditioning lines (2). Disconnect two air conditioning hose assemblies (4) from cover (3) .
- Remove the bolts and cover (3) .
- Remove the bolts and cover assembly (5) .
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| Illustration 4 | g00621514 |
- Disconnect hose assembly (7) from bulldozer control valve (6) .
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| Illustration 5 | g00621517 |
- Disconnect hose assembly (8), two hose assemblies (10), and four hose assemblies (9) from the grapple control.
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| Illustration 6 | g00621518 |
- Remove bolt (11) from the rod end of the control rod. Remove the nuts, the bolts, and control rod (12) .
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| Illustration 7 | g00621521 |
- Remove the bolts that hold relays (13) to the frame.
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| Illustration 8 | g00621522 |
- Disconnect two electrical connectors (14) and electrical connector (15) .
- Disconnect three electrical connectors (16) .
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| Illustration 9 | g00621525 |
- Disconnect hose assemblies (17), (18), (19), and (20) .
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| Illustration 10 | g00621528 |
- Remove the cotter pins and three pins (21) that secure the rods to the bulldozer control valve.
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| Illustration 11 | g00621530 |
- Start on the outside and disconnect tube assemblies (23). Remove connectors (22) .
- The weight of the bulldozer control valve is 25 kg (55 lb). Remove bolts (24) and use two people to remove the bulldozer control valve from the machine.
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| Illustration 12 | g00621531 |