854K Wheel Dozer and 992K Wheel Loader Caterpillar

Removal Procedure

Start By:

1. Remove the hood and the engine enclosure

2. Remove the input drive shaft.

3. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change".

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Illustration 1	g02283537

1. Attach a suitable lifting device to door assembly (1). The weight of door assembly (1) is approximately 45 kg (100 lb). Remove door assembly (1).
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   Illustration 2	g02283841

2. Remove panel assemblies (2).
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   Illustration 3	g02361015

3. Turn battery disconnect switch (3) to the OFF position.
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   Illustration 4	g02283974

4. Disconnect harness assembly (4) and the clip. Disconnect tube assemblies (5) and hose assemblies (6).
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   Illustration 5	g02284014

5. Attach a suitable lifting device to tank assembly (7). The weight of tank assembly (7) is approximately 125 kg (275 lb). Remove bolts (8) and use the suitable lifting device in order to remove tank assembly (7).
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   Illustration 6	g02289573

6. Remove bolts (10) and set test ports assembly (9) aside.
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   Illustration 7	g02290115

7. Disconnect hose assemblies (11) and hose clips (12).
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   Illustration 8	g02290237

8. Disconnect harness assemblies (15) and (16). Disconnect brackets (13) and (14). Set brackets (13) and (14) and the filter assemblies out of the way.
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   Illustration 9	g02290537

9. Disconnect hose assemblies (17) and hose assemblies (18). Remove hose assembly (19) and the hose clamps.
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   Illustration 10	g02290574

10. Disconnect hose assemblies (20), hose assemblies (21), and hose assemblies (22).
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    Illustration 11	g02290653

11. Disconnect hose assembly (23), hose assemblies (24), and hose assembly (25).
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    Illustration 12	g02290713

12. Disconnect harness assembly (26).
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    Illustration 13	g02290835

13. Attach Tooling (A) and a suitable lifting device to door assembly (27). The weight of door assembly (27) is approximately 102 kg (225 lb). Use Tooling (A) and the suitable lifting device in order to remove door assembly (27).
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    Illustration 14	g02291101

14. Disconnect hose assemblies (28) and hose assemblies (29).
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    Illustration 15	g02291135

15. Disconnect hose assemblies (30).
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    Illustration 16	g02291253

16. Attach Tooling (B) and a suitable lifting device to support assembly (31). The weight of support assembly (31) is approximately 34 kg (75 lb). Remove bolts (32) and bolts (33). Remove support assembly (31).
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    Illustration 17	g02291528

17. Disconnect hose assemblies (34). Disconnect harness assemblies (35). Remove hose assembly (36).
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    Illustration 18	g02291602

18. Disconnect hose assemblies (37). Disconnect sensor (38).
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    Illustration 19	g02291653

19. Disconnect hose assembly (39). Remove tube assembly (40).
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    Illustration 20	g02291674

20. Disconnect hose clamp (41). Disconnect hose assemblies (42) and (43).
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    Illustration 21	g02292033

21. Disconnect harness assemblies (44). Disconnect hose assembly (45).
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    Illustration 22	g02292073

22. Disconnect the hose clamp and hose assembly (46). Disconnect hose assembly (47).
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    Illustration 23	g02292753

23. Remove tube assemblies (48) and (49).
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    Illustration 24	g02293075

24. Disconnect harness assembly (50). Disconnect cable assemblies (51) and (52). Disconnect cable clamps (53).
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    Illustration 25	g02310253

25. Disconnect harness assembly (54) and clamp (55).
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    Illustration 26	g02298222

26. Use two people in order to lower guard assembly (57). The weight of guard assembly (57) is approximately 79 kg (175 lb).

27. Disconnect hose clamp (56) from the engine.
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    Illustration 27	g02298494

28. Disconnect cable assemblies (58) and (60). Disconnect ground strap (59). Disconnect cable clamps (61).
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    Illustration 28	g02309716

29. Disconnect harness assembly (63) and clamp (62).
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    Illustration 29	g02310475

30. Turn valves (66) to the OFF position. Disconnect hoses (67) and hose clamp (68).

31. Disconnect hose clamp (64) and hose assembly (65).
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    Illustration 30	g02310695

32. Attach Tooling (C), Tooling (D), and a suitable lifting device to the engine and torque converter (69). The weight of the engine and torque converter (69) is approximately 5580 kg (12,300 lb).
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    Illustration 31	g02310873

33. Remove bolts (70) and remove cap (71). Repeat this step for the opposite side.
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    Illustration 32	g02310877

34. Remove bolts (72). Remove the engine and torque converter (69).
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    Illustration 33	g02310879

35. Position the engine and torque converter (69) onto Tooling (E) and suitable cribbing.