Removal Procedure
Start By:
- Remove the engine enclosure (hood). Refer to Disassembly and Assembly, "Engine Enclosure (Hood) - Remove and Install".
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.
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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. |
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Hot oil and components can cause personal injury. Do not allow hot oil or components to contact the skin. Be sure that the engine and components are cool enough to touch with your bare hand prior to performing any service work. |
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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 work tools 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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Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand. Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns. Cooling System Conditioner contains alkali. Avoid contact with skin and eyes. |
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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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- Drain the fuel from the fuel tank into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual for the correct procedure.
- Drain the hydraulic oil from the hydraulic oil tank into a suitable container. Refer to Operation and Maintenance Manual for the correct procedure.
- Drain the coolant into a suitable container. Refer to Operation and Maintenance Manual for the correct procedure.
- Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the recovery and the charging procedure. Refer to Special Publication, NENG2500, "Air Conditioning Tools" for the correct tools.
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Illustration 1 | g03727402 |
- Loosen the two clamp and remove hose (1) .
- Remove three bolts (3), the three washers, and cover (2) .
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Illustration 2 | g03727403 |
- Remove three bolts (5), the three washers, and cover (4) .
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Illustration 3 | g03727404 |
- Loosen the two clamps and remove hose (10) .
- Loosen the clamp on the end of tube (6). Remove the two bolts, the two washers, the two clamps, and tube (6) .
- Loosen the two clamps and remove hose (7) .
- Loosen the two clamps and remove hose (8) .
- Loosen the two clamps and remove hose (9) .
- Loosen the clamp on exhaust pipe (11). Remove the three nuts, the three washers, and exhaust pipe (11) .
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Illustration 4 | g03727405 |
- Remove the nut, the washer, and cable assemblies (12) from electric starting motor (15) .
- Remove the nut, the washer, and harness assembly (14) from electric starting motor (15) .
- Remove the nut, the washer, and cable assembly (13) from electric starting motor (15) .
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Illustration 5 | g03727406 |
- Remove the nut, the washer, and cable assembly (17) from alternator (16) .
- Remove the nut, the washer, and harness assembly (18) from alternator (16) .
- Remove the nut, the washer, and cable assembly (19) from alternator (16) .
- Remove two cable straps (20) .
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Illustration 6 | g03727407 |
- Disconnect the connectors on harness assembly (14) from the bottom of refrigerant compressor (21) .
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Illustration 7 | g03727409 |
- Remove cable strap (22) and reposition harness assembly (14) behind refrigerant compressor (21) .
- Disconnect the hose assemblies from refrigerant compressor (21) .
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Illustration 8 | g03727410 |
- Remove the bolt, the plate, cable assembly (13), cable assembly (17), and clamps (23). Lay cable assembly (13) and cable assembly (17) out of the way.
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Illustration 9 | g03732441 |
- Remove cable strap (24) securing harness assembly (14) to the side of the engine.
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Illustration 10 | g03732442 |
- Remove cable strap (25) securing harness assembly (14) to the side of the engine.
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Illustration 11 | g03732444 |
- Remove cable strap (26) securing harness assembly (14) to the side of the engine.
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Illustration 12 | g03732446 |
- Remove bolt (28) and hose (27). Lay hose (27) under the engine.
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Illustration 13 | g03732447 |
- Loosen clamps (29) and remove hose (30) .
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Illustration 14 | g03732448 |
- Disconnect fuel line (31) .
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Illustration 15 | g03732449 |
- Disconnect fuel line (32) .
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Illustration 16 | g03732450 |
- Loosen the bolt and disconnect harness assembly (33) from the engine ECM.
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Illustration 17 | g03732452 |
- Loosen the clamp and remove hose (34) .
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Illustration 18 | g03732453 |
- Disconnect harness assembly (35) .
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Illustration 19 | g03732454 |
- Remove the bolt, the plate, and clamps (36) .
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Illustration 20 | g03732459 |
- Remove the nut, the wire, and wire assembly (37) from the top of the engine.
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Illustration 21 | g03732461 |
- Loosen the clamps and remove tube (38) .
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Illustration 22 | g03732462 |
- Remove the bolt, the plate, and clamps (40). Move hose assemblies out of the way.
- Remove 12 bolts (41) .
- Place suitable blocks under pump stack (42). Separate pump stack (42) from engine (39) .
- Reposition harness assembly (14) out of the way.
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Illustration 23 | g03732464 |
- Loosen the clamp and remove hose (43)
- Attach suitable lifting device to engine assembly (39). The weight of engine assembly (39) is approximately 1100 kg (2425 lb).
- Remove four bolts (44), the washers, and the flexible mounts. Remove engine assembly (39) .
Installation Procedure
- Install engine assembly (39) in the reverse order of removal.
- Tighten the nut for wire assembly (18) to a torque of 2.25 ± 1 N·m (20 ± 9 lb in).
- Tighten the nut for cable assembly (17) to a torque of 7.75 ± 0.25 N·m (69 ± 2 lb in).
- Tighten the nut for wire assembly (14) to a torque of 5.8 ± 1 N·m (51 ± 9 lb in).
- Tighten the nut for cable assembly (13) to a torque of 18 ± 1 N·m (159 ± 9 lb in).
- Tighten the nut for cable assembly (12) to a torque of 15 ± 3 N·m (133 ± 27 lb in).
End By:
Install the engine enclosure (hood). Refer to Disassembly and Assembly, "Engine Enclosure (Hood) - Remove and Install".