Removal Procedure
Start By:
- Remove the exhaust extension. Refer to Disassembly and Assembly, "Exhaust Extension - Remove and Install".
- Remove the window guard. Refer to Disassembly and Assembly, "Window Guard - Remove".
- Remove the radiator guards. Refer to Disassembly and Assembly, "Radiator Guard - Remove".
- Remove the coolant tank. Refer to Disassembly and Assembly, "Coolant Tank - Remove".
- Remove the suction fan and the gear motor. Refer to Disassembly and Assembly, "Suction Fan and Gear Motor (Hydraulic Fan) - Remove".
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. |
 |
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, "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. |
|
Note: Put identification marks on all hoses, on all hose assemblies, on all wires, and on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies. This helps to prevent fluid loss, and this helps to keep contaminants from entering the system.
- Tilt the cab. Refer to Operation and Maintenance Manual, "Cab - Tilt".
- Recover the air conditioner refrigerant from the air conditioner system. Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant". Refer to Special Publication, NEDG5065, "Air Conditioning Tools".
Show/hide table
|
 |
|
| Illustration 1 | g00758816 |
- Loosen nuts (1) in order to disconnect hose assemblies (2) from air conditioner condenser (3).
Show/hide table
|
 |
|
| Illustration 2 | g00758818 |
- Remove bolt (4), washers (5), nut (6), and clips (7). Carefully feed hose assemblies (2) through bushings (8) .
Show/hide table
|
 |
|
| Illustration 3 | g00758856 |
- Remove bolt (9), washers (10), nut (11), and clips (12) in order to disconnect hose assembly (14) from bar (13) .
Show/hide table
|
 |
|
| Illustration 4 | g00758857 |
- Loosen nut (15) in order to disconnect tube assembly (16) from tee (17) and hose assembly (18) .
Show/hide table
|
 |
|
| Illustration 5 | g00758888 |
- From the underside of the cab, remove clamps (19) and disconnect hose (20) from tube (21) .
Show/hide table
|
 |
|
| Illustration 6 | g00758889 |
- Remove clamps (22). Slide hose (23) onto tube (21) until the hose is fully disconnected from aftercooler (24). Carefully remove tube (21) .
Show/hide table
|
 |
|
| Illustration 7 | g00758927 |
- Remove clamps (25) and hose (20) .
Show/hide table
|
 |
|
| Illustration 8 | g00758928 |
- Remove clamps (26). Slide hose (27) onto tube (28) until the hose is fully disconnected from aftercooler (24) .
Show/hide table
|
 |
|
| Illustration 9 | g00759125 |
- Remove bolts (29), washers (30), and top plate (31) that retains bracket (32) to radiator duct (33). Lower bracket (32) onto the chassis.
Show/hide table
|
 |
|
| Illustration 10 | g00759128 |
- Remove clamps (34) in order to remove hose (35) from radiator (36) and tube (37).
Show/hide table
|
 |
|
| Illustration 11 | g00759129 |
Show/hide table
|
 |
|
| Illustration 12 | g00759130 |
- Loosen nut (39) and remove tube assembly (40) from valve (38). Loosen nut (41) and disconnect tube assembly (42) from valve (38). Remove bolts (43), washers (44), and clips (45) .
Show/hide table
|
 |
|
| Illustration 13 | g00759131 |
- Loosen nut (46) and remove tube assembly (42). Lay tube assembly (47) aside. Remove bolts (48), washers (49), and clips (50). Lay harness assembly (51) aside.
Show/hide table
|
 |
|
| Illustration 14 | g00759132 |
- Remove clamps (52). Slide hose (53) down tube (54) until the hose is fully disconnected from radiator (36) .
Show/hide table
|
 |
|
| Illustration 15 | g00759137 |
- Attach a suitable lifting device to the lifting point on radiator (36). Take up the tension in order to support radiator (36) .
Show/hide table
|
 |
|
| Illustration 16 | g00759136 |
- Remove bolt (55), washers (56), nut (57), washer (59), and the lower half of mount (58) from the right side of radiator (36) .
Show/hide table
|
 |
|
| Illustration 17 | g00759430 |
- Remove bolt (60), washer (61), washer (62), and the upper half of mount (63) from the left side of radiator (36) .
Show/hide table
|
 |
|
| Illustration 18 | g00759431 |
- Remove bolts (64), washers (65), and nuts (66) from support bracket (67) .
Show/hide table
|
 |
|
| Illustration 19 | g00759444 |
- Carefully lift radiator (36). The weight of radiator (36) is approximately 250 kg (551 lb). At the same time feed hose (14) through radiator duct (33). Remove radiator (36) from the machine.
Show/hide table
|
 |
|
| Illustration 20 | g00759457 |
- Remove the upper half of mount (58) from mounting bracket (68) on the right side.
Show/hide table
|
 |
|
| Illustration 21 | g00759459 |
- Remove the lower half of mount (63) and washer (69) from the left side mount (70) .
