Removal Procedure
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Table 1
| Required Tools |
| Tool |
Part Number |
Part Description |
Qty |
| A |
6V-6146 |
Load Leveling Beam |
1 |
| B |
138-7573 |
Link Bracket |
4 |
| ZZ |
6V-9507 |
Face Seal Plug (9/16 - 18 THD) |
3 |
| 6V-9828 |
Cap Assembly (9/16 - 18 THD) |
3 |
| 6V-9508 |
Face Seal Plug (11/16 - 16 THD) |
2 |
| 6V-9829 |
Cap Assembly (11/16 - 16 THD) |
2 |
| 6V-9509 |
Face Seal Plug (13/16 - 16 THD) |
7 |
| 6V-9830 |
Cap Assembly (13/16 - 16 THD) |
7 |
| 9U-7071 |
Tapered Cap/Plug |
2 |
| 9U-7068 |
Tapered Cap/Plug |
2 |
Start By:
- Remove the air cleaner. Refer to Disassembly and Assembly, "Air Cleaner - Remove and Install".
- Remove the engine enclosure. Refer to Disassembly and Assembly, "Engine Enclosure - Remove and Install".
Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL OR THE INSTALLATION. THIS TOOLING IS SHOWN IN ORDER TO ASSIST THE EXPERIENCED SERVICEMAN.
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Accidental machine starting can cause injury or death to personnel working on the machine. To avoid accidental machine starting, turn the battery disconnect switch to the OFF position and remove the key. If the machine is not equipped with a battery disconnect switch, disconnect the battery cables from the battery and tape the battery clamps. Place a do not operate tag at the battery disconnect switch location to inform personnel that the machine is being worked on. |
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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the cooling system pressure cap is cool enough to touch with your bare hand. Remove the cooling system pressure cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury. |
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| 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, 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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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.
- Drain the cooling system. Refer to Operation and Maintenance, "Cooling System Coolant (ELC) - Change". The capacity of the cooling system is approximately 18 L (4.8 US gal).
- Drain the hydraulic oil tank. Refer to Operation and Maintenance, "Hydraulic System Oil - Change". The capacity of the hydraulic oil system is approximately 50 L (13 US gal).
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| Illustration 1 | g01088056 |
- Remove bolt (1) .
- Loosen clamp (5) and disconnect hose (4) from the engine.
- Remove bolt (2) and guard (3) from the engine.
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| Illustration 2 | g01088068 |
- Disconnect harness assemblies (7) from alternator (6) .
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| Illustration 3 | g01088084 |
- Disconnect cable assembly (8) from electric starting motor (9) .
- Move harness assembly (10) away from the engine.
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| Illustration 4 | g01088100 |
- Disconnect hose assemblies (12) from gear motor (11) .
- Disconnect hose assembly (13) from gear motor (11) .
- Loosen clamp (14) and disconnect hose (15) .
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| Illustration 5 | g01088112 |
- Remove bolts (17) and panel (16) .
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| Illustration 6 | g01088176 |
- Disconnect harness assemblies (18) from the engine.
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| Illustration 7 | g01088190 |
- Disconnect harness assemblies (19) and move the main harness assembly out of the way.
- Turn fuel valves (22) to the OFF position.
- Loosen clamps (20) and disconnect hoses (21) .
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| Illustration 8 | g01088202 |
- Disconnect harness assemblies (23) from the engine.
- Disconnect hose assemblies (24) from the engine.
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| Illustration 9 | g01088221 |
- Disconnect hose assembly (26) from hydraulic oil filter assembly (25) .
- Remove bolts (27) and hydraulic oil filter assembly (25) from the machine.
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| Illustration 10 | g01088245 |
- Disconnect harness assembly (29) .
- Disconnect hose assemblies (28) .
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| Illustration 11 | g01088258 |
- Remove bolts (31) .
- Disconnect harness assembly (32). Remove cable (33) .
- Move bracket (30) out of the way.
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| Illustration 12 | g01088279 |
- Remove bolts (35), tube assembly (34), and gasket (36) .
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| Illustration 13 | g01088290 |
- Move cable assemblies (37) and (38) out of the way.
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| Illustration 14 | g01088303 |
- Remove bolts (39) from engine support assembly (40) that are located on both sides of the engine.
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| Illustration 15 | g01088317 |
- Attach Tooling (A) and Tooling (B) to the engine.
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| Illustration 16 | g01088347 |
- Remove bolt (41) and remove the engine from the machine. The weight of the engine is approximately 350 kg (772 lb).
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| Illustration 17 | g01101418 |
- Remove mounts (42) from the frame.
