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Table of Contents

Table of Contents
Disassembly and Assembly Section
Alternator - Remove and Install ........................... 4
Electric Starting Motor - Remove and Install ....... 5
Fuel Filter and Fuel Filter Base - Remove (Primary
and Secondary Fuel Filters) ................................ 6
Fuel Filter and Fuel Filter Base - Install (Primary and
Secondary Fuel Filters) ....................................... 8
Cooling Assembly - Remove ................................. 10
Cooling Assembly - Install .................................... 12
Hydraulic Oil Cooler - Remove and Install ........... 15
Air Cleaner - Remove and Install .......................... 18
Aftercooler - Remove and Install .......................... 20
Muffler - Remove and Install ................................ 21
Water Temperature Regulator - Remove and Install
............................................................................. 22
Radiator - Remove ............................................... 24
Radiator - Install ................................................... 26
Fan - Remove and Install ..................................... 29
Fan Drive - Remove ............................................. 30
Fan Drive - Disassemble ...................................... 31
Fan Drive - Assemble .......................................... 32
Fan Drive - Install .................................................. 33
Water Pump - Remove and Install ....................... 33
Crankshaft Front Seal - Remove and Install ......... 35
Air Compressor - Remove and Install .................. 37
Refrigerant Compressor - Remove and Install ..... 38
Refrigerant Accumulator (With Desiccant) - Remove
and Install ............................................................ 39
Refrigerant Condenser - Remove and Install ....... 41
Hood - Remove .................................................... 42
Hood - Install ........................................................ 44
Drive Shaft - Remove and Install ......................... 46
Engine - Remove ................................................. 47
Engine - Install ..................................................... 51

Index Section
Index ..................................................................... 56

Accidental machine starting can cause injury or
death to personnel working on the machine.

To avoid accidental machine starting, turn the bat-
tery disconnect switch to the OFF position and re-
move the key. If the machine is not equipped with
a battery disconnect switch, disconnect the bat-
tery cables from the battery and tape the battery
clamps.

Place a do not operate tag at the battery discon-
nect switch location to inform personnel that the
machine is being worked on.

Place alternator (2) in position on the bracket. Remove bolts (5). Remove wiring (1). Remove the guard assembly on the right side of the radiator. (3). g00839856 Illustration 3 1. Remove alternator (2) from the bracket. Turn the disconnect switch to the Off position.Replace”. 6.4 Disassembly and Assembly Section Disassembly and Assembly Section i01616001 Alternator . Installation Procedure g00839840 Illustration 1 4. and (5) in order to hold the alternator in position. (8). “Guards . and (4) from alternator (2).Remove and Install”. 3.Remove and Install SMCS Code: 1405-010 Removal Procedure 1. “Belt (Alternator and Water Pump) . Install bolts (7). Refer to Operation and Maintenance Manual. Refer to Operation and Maintenance Manual. (6). 2. (7). Remove the belt. . 2. and (8). (6). Illustration 2 g00839856 5.

(5). (3). Compartment) . 6.Replace”. Refer to Operation and 2. position. Refer to Operation and threads of bolts (3) before the installation procedure. Turn the battery disconnect switch to the OFF position. Connect wires (6). Maintenance Manual. . Install electric starting motor (4) in the tractor Removal Procedure with bolts (3). 4. Remove bolts (3) and electric starting motor (4) from the machine. “Hood (Engine starting motor.Raise/Lower”. Note: Remove the paint from the bores and the 4. Refer to Operation and Maintenance Manual. 1. Install the guard assembly on the right side of the radiator. Raise the hood. (2). and (6). Disconnect wires (1). i01626476 Electric Starting Motor - Remove and Install g00842304 SMCS Code: 1453-010 Illustration 6 1. (2).Raise/Lower”. Refer to Operation and Maintenance Manual. 5 Disassembly and Assembly Section g00842304 Illustration 5 3. g00839840 Illustration 4 Installation Procedure 3. “Guards . 4. Turn the disconnect switch to the On position. Turn the battery disconnect switch to the ON 2. “Belt (Alternator and Water Pump) . (5). Install wiring (4). Lower the hood.Remove and Install”. 5. 3. and (1) to alternator (2). and (1) to the electric Maintenance Manual. “Hood (Engine Compartment) . Install the belt.

ing any compartment or disassembling any compo- nent containing fluids. SMCS Code: 1261-011. the hood. Be prepared to 1. g00869265 Illustration 7 NOTICE (1) Secondary fuel filter and filter base Care must be taken to ensure that fluids are contained (2) Primary fuel filter and filter base during performance of inspection. 1262-011 Removal Procedure Table 1 Required Tools Part Tool Description Qty Number 9U-7070 Cap 4 A 9U-7072 Cap 4 Note: Mark the location and the orientation of all hose assemblies for reassembly purposes before the removal of any components. Refer to Special Publication. To help pre- (Primary and Secondary Fuel vent possible injury. NENG2500. Park the machine on a level surface and raise collect the fluid with suitable containers before open. Dispose of all fluids according to local regulations and mandates.6 Disassembly and Assembly Section i01685068 Fuel Filter and Fuel Filter Base Fuel leaked or spilled onto hot surfaces or elec- . allow the engine and the components to cool. maintenance. Turn fuel valve (5) to the OFF position. Plugs and caps help prevent fluid spills. “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. test- ing. Hot engine components can cause injury from burns. Plug all hose assemblies and cap all fittings. 2.Remove trical components can cause a fire. turn the start switch off when changing fuel filters or water separator elements. . Before performing maintenance on the engine. Plugs and caps also help prevent dirt and debris from entering the fuel system. adjusting and repair of the product. Filters) Clean up fuel spills immediately.

Remove stud (8A) from filter base (8). . Remove O-ring seals (17) from the port connectors. Remove the filter base. 3. g00869131 2. Remove two port connectors (18) from filter base Illustration 8 (15). Disconnect two hose assemblies (6) and (7) from filter base (8). 1. 2. remove five plugs (10) and remove O-ring seals (11) from the plugs. 6. Cap the hose assemblies with Tooling (A). 7. (8). Cap the hose assemblies and 3. (15) to the machine. 7 Disassembly and Assembly Section Primary Fuel Filter and Filter Base Secondary Fuel Filter and Filter Base g00869008 Illustration 9 1. 4. 4. 5. If necessary. Disconnect hose (14) from water separator bowl (13). If necessary. Remove filter element (19) from filter base (15). Remove stud (15A) from filter base (15). Remove four bolts (9) which fasten filter base (8) to the machine. Remove O-ring seals (20) from the plugs. Remove fuel filter element (12) from filter base 6. Remove water separator bowl (13) from fuel filter 5. Remove four bolts (16) which fasten filter base element (12). base (15). Disconnect hose assemblies (3) and (4) from filter base (15). remove four plugs (21) from filter plug the filter base with Tooling (A).

Install O-ring seals (11) on plugs (10). adjusting and repair of the product. turn the start switch off when changing fuel filters or water separator elements. burns.Install (Primary and Secondary Fuel Filters) SMCS Code: 1261-012. Tighten the stud to 70 ± 15 N·m (52 ± 11 lb ft). Dispose of all fluids according to local regulations and mandates. plugs (10) in filter base (8). Refer to Special Publication. allow the engine and the components to 2. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- nent containing fluids. install new parts. 6. Install four washers and bolts (9) which fasten trical components can cause a fire. 3. To help pre. 5. maintenance. Connect hose (14) to water separator bowl (13). “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Install cool. 1262-012 Installation Procedure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Inspect all of the O-ring seals for wear or for Hot engine components can cause injury from damage. vent possible injury. 4. g00869131 Illustration 10 1. Install water separator bowl (13) on fuel filter Clean up fuel spills immediately. NENG2500. filter base (8) to the machine. . Install fuel filter element (12) and water separator bowl (13) on filter base (8). Before performing maintenance on the engine. Fuel leaked or spilled onto hot surfaces or elec. Install stud (8A) in fuel filter base (8). If necessary.8 Disassembly and Assembly Section i01686105 Primary Fuel Filter and Filter Base Fuel Filter and Fuel Filter Base . test- ing. element (12).

Refer to the Operation and Maintenance Manual. Install plugs (20) in filter base (15). Inspect all of the O-ring seals for wear or for damage. Tighten the stud to a torque of 70 ± 15 N·m (52 ± 11 lb ft). Both of the filters must be primed. SEBU7431. Connect hose assemblies (6) and (7) to filter base (8). 9. Connect hose assemblies (3) and (4) to filter base (15).Replace”. Install filter base (15) and secure the filter base with four washers and bolts (16). 6. Inspect both fuel filters and filter bases for leaks. 11. Refer to the Operation and Maintenance Manual. Install the port connectors in filter base (15).Clean/Replace”. 5. Install filter element (19) on filter base (15). Close the hood. “Fuel Filter (Primary) . g00869265 Illustration 11 (1) Secondary fuel filter and filter base (2) Primary fuel filter and filter base 7. Turn the fuel valve (5) to the ON position. Install O-ring seals (20) on plugs (21). . g00869008 Illustration 12 1. 8. 10. 2. 9 Disassembly and Assembly Section 4. “Fuel Filter (Secondary) . 3. SEBU7431. Install O-ring seals (17) on port connectors (18). Prime the fuel system and start the engine. Install stud (15A) in filter base (15). g00869265 Secondary Fuel Filter and Filter Base Illustration 13 (1) Secondary fuel filter and filter base (2) Primary fuel filter and filter base 7.

1374-011.2 kg collect the fluid with suitable containers before open. 6V-9512 2 Plug Cap Personal injury or death can result from inhaling 6V-9833 2 refrigerant through a lit cigarette. and this helps to keep Maintenance Manual. Remove the hood. 3.Remove and Install”. NEDG5065. NENG2500. This 37 L (10 US gal). 1. (4. a. Start By: Do not smoke when servicing air conditioners or wherever refrigerant gas may be present. “Cooling System Extended Life Coolant - NOTICE Change” for the machine that is being serviced.Remove and Assembly. “Guards . Refer to Special Publication. Number Description Slowly loosen the fitting. A Assembly 6V-9513 Plug 2 Inhaling air conditioner refrigerant gas through a Cap lit cigarette or other smoking method or inhaling 6V-9834 2 fumes released from a flame contacting air con- Assembly ditioner refrigerant gas. on all 2. Plug all capacity of the cooling system is approximately hose assemblies and all tube assemblies. “Air ing any compartment or disassembling any compo. Keep face and hands away to help prevent injury. SENR5664.Remove”. Refer to Disassembly and Assembly. . Part Part Tool Qty Always use precaution when a fitting is removed.Remove”. Dispose of all fluids according to local regulations and mandates. If the system is still under Face Seal pressure. Recover the air conditioner refrigerant from the air ing. The correct charge is 2. Refer to Service Manual. “Air Cleaner . even if the gauges in- Required Tools dicate the system is empty of refrigerant. can cause bodily harm or B 138-7573 Link Bracket 2 death. “Air Conditioning Tools” Refer to Special Publication. 1810-011 Contact with refrigerant can cause frost bite. (DEAC) . “Caterpillar for the tools. maintenance.Change” or Operation and Maintenance Manual. “Batteries . Refer to Operation c. “Cooling System Coolant contaminants from entering the system.10 Disassembly and Assembly Section i01654132 Cooling Assembly . Be prepared to conditioner system. Removal Procedure Protective goggles must always be worn when re- Table 2 frigerant lines are opened. The assemblies for installation purposes. Remove the batteries. Care must be taken to ensure that fluids are contained during performance of inspection. Remove the air cleaner. Refer to Disassembly and Maintenance Manual. “Hood . Note: Put identification marks on all hoses. release it slowly in a well ventilated area. Assembly. and Install”.Remove Personal injury can result from contact with refrig- SMCS Code: 1063-011. Use a certified recovery and recycling cart to prop- erly remove the refrigerant from the air condition- b. Refrigerant” for the procedure. on all wires. adjusting and repair of the product. and on all tube suitable container for storage or disposal. Drain the coolant from the cooling system into a hose assemblies. 1351-011. erant. Conditioning and Heating Systems with R-134a nent containing fluids. Refer to Disassembly and ing system. Remove the engine guards. test. Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Refer to Operation and helps to prevent fluid loss.9 lb).

Disconnect tubes (11) and (13). . (15). g00854182 Illustration 14 4. 11. Loosen the clamps on hoses (16) and (17). g00854276 Illustration 17 13. Remove bolts (3) from the bracket assembly. (12). Remove hose assemblies (1). 12. (12). Disconnect hoses (10). (15). Plug hose assemblies with Tooling (A) and cap Illustration 16 g00854275 all fittings with Tooling (A). assemblies. Remove the support assembly on the other side of the engine. Remove bolts (9) from the radiator. Remove bolt (7) on the other side of the bracket. Illustration 15 7. Remove bolt (8) and the bracket. Remove clamp (6) and refrigerant accumulator (5) from the bracket. 5. 10. g00854212 Remove hoses (16) and (17). and (14). Loosen the clamps on hoses (10). 11 Disassembly and Assembly Section 9. 6. Disconnect hose assemblies (2) and cap hose and (14). Remove support assembly (4). 8.

Attach Tooling (B) to cooling package (20). 1810-012 Installation Procedure Table 3 Required Tools Part Part Tool Qty Number Description Face Seal 6V-9512 2 Plug Cap 6V-9833 2 A Assembly 6V-9513 Plug 2 Cap 6V-9834 2 Assembly B 138-7573 Link Bracket 2 g00854279 Illustration 19 Note: Check the O-ring seals for wear or for 15.12 Disassembly and Assembly Section g00854278 g00854290 Illustration 18 Illustration 20 14. chains and a suitable lifting device to support the cooling package. 1351-012.Install SMCS Code: 1063-012. Remove four bolts (21). Replace the O-ring seals. i01711902 Cooling Assembly . Loosen the clamp on hose (18) and hose (19) 16. 1374-012. if necessary. Remove hoses (18) and (19) from the radiator. Remove cooling package (20). 17. that is connected to the radiator. . The weight of the cooling package is approximately 127 kg (280 lb). Use damage.

Contact with refrigerant can cause frost bite. Use Slowly loosen the fitting. Dispose of all fluids according to local regulations and mandates. Keep face and hands away to help prevent injury. Install four bolts (21). . “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. adjusting and repair of the product. Protective goggles must always be worn when re- frigerant lines are opened. test- ing. 1. to place the cooling package in the original position. The weight of the cooling package is Personal injury or death can result from inhaling approximately 127 kg (280 lb). Attach Tooling (B) to cooling package (20). Do not smoke when servicing air conditioners or wherever refrigerant gas may be present. and Tooling (B) pressure. maintenance. Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air con- ditioner refrigerant gas. release it slowly in a well ventilated area. refrigerant through a lit cigarette. g00854290 Illustration 22 2. NENG2500. If the system is still under chains. Personal injury can result from contact with refrig- erant. can cause bodily harm or death. Use a certified recovery and recycling cart to prop- erly remove the refrigerant from the air condition- ing system. even if the gauges in- g00854279 dicate the system is empty of refrigerant. Refer to Special Publication. a suitable lifting device. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- nent containing fluids. 13 Disassembly and Assembly Section NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Illustration 21 Always use precaution when a fitting is removed.

Install the support assembly on the other side of the engine. Install support assembly (4). Install bolt (7) on the other side of the bracket.14 Disassembly and Assembly Section g00854182 g00854212 Illustration 23 Illustration 25 3. Connect hoses (10). Install bolt (8) and the bracket. and (14). g00854275 Illustration 24 5. (12). Tighten the clamps on hoses (16) and (17). (12). Tighten the clamps on hoses (10).30 lb in). .7 N·m (59. radiator. 9. Connect hose assemblies (1). 10. Install hoses (16) and (17). Install bolts (3) on the bracket assembly. Install bolts (9) on the 4. 7. 12. Illustration 26 g00854276 6. Connect tubes (11) and (13). Connect hose assemblies (2). (15). and (14) to 6. 11. Install clamp (6) and refrigerant accumulator (5) on the bracket. 8. (15).

c. Charge the refrigerant system. “Hood . Refer to Disassembly and Assembly. “Refrigerant System . i01632630 Hydraulic Oil Cooler . “Cooling System Coolant (DEAC) .Remove and Install”. Refer to Disassembly and Assembly. 14. Refer to Disassembly and Assembly. Refer to Disassembly and Tighten the clamp on hose (18) and hose (19) Assembly. that is connected to the radiator. “Air Cleaner . Refer to Disassembly and Illustration 27 g00854278 Assembly. 13. “Refrigerant Condenser . Plug all hose assemblies. Note: Put identification marks on all hose assemblies g00854279 for installation purposes. Illustration 28 This helps to prevent fluid loss. 17.Remove and Install SMCS Code: 1374-010 Removal Procedure Start By: a. . “Hood . Install the air cleaner. RENR1860. Remove the aftercooler. “Batteries . Refer to Operation and Maintenance Manual. “Cooling System Extended Life Coolant . The correct charge is 2.Charge” for the procedure. Refer to Operation and Maintenance Manual. b. Install the batteries. Remove Tooling (B) from the cooling package (20).Remove”. Install the hood.9 lb).Remove and Install”. Refill the cooling system. “Aftercooler . c. Remove the hood. b. Refer to Special Publication.Remove and Install”. Install hoses (18) and (19) to the radiator.Remove and Install”. The capacity of the cooling system is approximately 37 L (10 US gal). Refer to Disassembly and Assembly.2 kg (4. 15 Disassembly and Assembly Section 15. “Guards .Remove”.Remove and Install”. Refer to Service Manual.Change” for the machine that is being serviced.Change” or Operation and Maintenance Manual. Remove the refrigerant condenser. and this helps to keep contaminants from entering the system. NEDG5065. “Air Conditioning Tools” for the tools. Install the engine guards. 16. End By: a.

and bolts (7) on each side of hydraulic oil cooler (8). the spacers. Attach a suitable lifting device to the hydraulic oil cooler. adjusting and repair of the product. “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. The weight of the hydraulic oil cooler is approximately 38 kg (83 lb). (2).16 Disassembly and Assembly Section NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Refer to Special Publication. (3). . g00845680 Illustration 31 2. maintenance. Disconnect hose assemblies (1). Remove bolts (9). NENG2500. 3. Dispose of all fluids according to local regulations and mandates. test- ing. and (4) under the hydraulic oil cooler. g00845673 Illustration 30 g00845664 Illustration 29 1. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- nent containing fluids.

17
Disassembly and Assembly Section

4. Remove bolts (6) on each side of the hydraulic
oil cooler. Remove plate (5) and hydraulic oil
cooler (8) from the bracket.

Installation Procedure
Note: Check the O-ring seals for wear or for
damage. Replace the O-ring seals, if necessary.

1. Attach a suitable lifting device to the hydraulic
oil cooler. The weight of the hydraulic oil cooler
is approximately 38 kg (83 lb).

g00845673
Illustration 33

2. Place hydraulic oil cooler (8) in position in the
bracket. Install plate (5) with bolts (6) on each
side of the hydraulic oil cooler.
g00845680 3. Install bolts (7), bolts (9), and the spacers to
Illustration 32
each side of the hydraulic oil cooler.

g00845664
Illustration 34

4. Connect hose assemblies (4), (3), (2), and (1).

End By:

a. Install the refrigerant condenser. Refer to
Disassembly and Assembly, “Refrigerant
Condenser - Remove and Install”.

b. Install the aftercooler. Refer to Disassembly and
Assembly, “Aftercooler - Remove and Install”.

18
Disassembly and Assembly Section

c. Install the hood. Refer to Disassembly and
Assembly, “Hood - Remove and Install”.

i01633596

Air Cleaner - Remove and
Install
SMCS Code: 1051-010; 1054-010

Removal Procedure

Hot engine components can cause injury from
burns. Before performing maintenance on the
engine, allow the engine and the components to
cool.

g00846098
1. Open the hood. Refer to Operation and Illustration 36
Maintenance Manual, “Hood (Engine
Compartment) - Raise/Lower”. 4. Remove bolts (5) on each side of plate (6).
Remove plate (6).

5. Remove bolts (4) on each side and remove
brace assembly (3).

6. Remove bolts (8) and support assembly (7).

g00846108
g00846087 Illustration 37
Illustration 35
Note: The turbocharger was removed for illustrative
2. Loosen clamp (1) and remove clamp (1) from the purposes.
turbocharger inlet and the air cleaner.
7. Remove bolt (9), the bracket, and hose assembly
3. Loosen clamp (2) and slide the clamp down the (10) from the support.
hose.

The hose will be removed from the dust ejector
when the air cleaner is removed from the
machine.

19
Disassembly and Assembly Section

g00846119 g00846119
Illustration 38 Illustration 41

8. Remove bolts (13), support (11), and air cleaner
(12) from the machine.

g00846882
Illustration 39

9. Remove bolts (15), washers (14), and support
(11) from air cleaner (12). Illustration 42 g00846087

Installation Procedure 2. Place air cleaner (12) and support (11) in
position on the machine. Place the hose to the
ejector in position. Install bolts (13).

3. Place clamp (2) in position and tighten the
clamp.

4. Install clamp (1) to the turbocharger inlet and the
air cleaner. Tighten the clamp.

g00846882
Illustration 40

1. Install support (11) to air cleaner (12) with
washers (14) and bolts (15).

Refer to Operation and Maintenance Manual. Repeat this Step for the hose and the clamp on the other side of the aftercooler.20 Disassembly and Assembly Section i01632126 Aftercooler . Remove aftercooler (4). g00846098 Illustration 44 3. Close the hood. aftercooler. . “Hood (Engine Compartment) .Raise/Lower”. Place plate (6) in position and install bolts (5) on 5. Place hose assembly (10) and the bracket in position and install bolt (9) to the support.Remove and Install SMCS Code: 1063-010 Removal Procedure 1.Raise/Lower”. 7. aftercooler is approximately 11 kg (25 lb). Remove the hose from the elbow of aftercooler (4). Refer to Operation and Maintenance Manual. Loosen the clamp on hose (3). Place brace assembly (3) in position and install 4. 8. g00846108 Illustration 43 5. Raise the hood. Install support assembly (7) with bolts (8). assemblies. Remove clips (1) and pins (2) from the brace bolts (4). The weight of the each side of the plate. 9. Release latch assembly (5) on both sides of the 6. g00845394 Illustration 45 2. “Hood (Engine Compartment) .

The weight of the aftercooler is approximately 11 kg (25 lb). Slide hoses (3) on the elbows of aftercooler (4). Remove bolts (4) and muffler assembly (1) from the lower support assembly and exhaust tube assembly (3). Tighten the clamps on the hoses.Remove and Install SMCS Code: 1062-010 Removal Procedure g00845416 Illustration 46 g00842404 Illustration 48 1. Lower the hood. Place aftercooler (4) in position and install pins (2) and clips (1). Fasten latch assemblies (5). 3. Remove the sealant from the muffler and the support assembly. Refer to Operation and g00843329 Illustration 49 Maintenance Manual. Apply a bead of 211-8713 Sealant on surface (A) of the lower support assembly. 4.Raise/Lower”. 1. . 3. “Hood (Engine Compartment) . Loosen clamp (2). 2. 21 Disassembly and Assembly Section Installation Procedure i01626563 Muffler . 2. Installation Procedure g00845394 Illustration 47 1.

Refer to Special Publication. Remove the fill cap slowly to relieve pressure. Check the coolant level only after the engine has been stopped and the fill cap is cool enough to 3. i01624505 Cooling system conditioner contains alkali. Install bolts (4). Remove and Install 1. the engine coolant is Illustration 50 g00842404 hot and under pressure.Change” or Operation and Maintenance Required Tools Manual. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- nent containing fluids. test- ing. support assembly and exhaust tube assembly (3). Remove the alternator. maintenance. “Alternator . Refer to Operation and Maintenance Manual. The capacity of the cooling system is approximately Removal Procedure 37 L (10 US gal). Refer to Disassembly and Assembly. Dispose of all fluids according to local regulations and mandates.Remove and Install”. (52 ± 7 lb ft). injury. Position muffler assembly (1) on the lower Steam can cause personal injury. Tighten clamp (2) to a torque of 70 ± 10 N·m touch with your bare hand. “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Drain the coolant from the cooling system into a SMCS Code: 1355-010 suitable container for storage or disposal. .22 Disassembly and Assembly Section NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. adjusting and repair of the product. “Cooling System Extended Life Coolant - Change” for the machine that is being serviced. At operating temperature. Avoid contact with the skin and eyes to prevent personal Water Temperature Regulator . “Cooling System Coolant Table 4 (DEAC) . Part Tool Number Part Description Qty A 1P-0510 Driver Gp 1 Start By: a. 2. NENG2500.

Slide the clamps away from the original position. 5. 1. 23 Disassembly and Assembly Section Installation Procedure g00840834 Illustration 51 g00877563 Illustration 53 2. 6. Remove the regulator housing assembly from hose (7). . Remove Gasket (8). g00877564 Illustration 54 g00840836 Illustration 52 7. water temperature regulator (9). 3. 4. Remove bolts (4). Loosen hose clamp (3) and clamp (6). Remove radiator hose (2) from regulator housing assembly (5). Disconnect tube assembly (1). Use Tooling (A) in order to install seal (10) in regulator housing assembly (5). and seal (10) from regulator housing assembly (5). as shown.

Remove and Install”.Change”.Remove”. gasket (8). “Caterpillar Tools and Shop Products Guide” for tools and supplies 7.Change” or Operation and Maintenance Manual. Dispose of all fluids according to local regulations and Refer to Operation and Maintenance Manual. 2. Refer to Special Publication. in the original position. This helps to prevent fluid loss. adjusting and repair of the product. Attach clamp (6) and hose clamp (3). test- 4. “Cooling System Coolant a. maintenance. Refer to Disassembly and (4) in the regulator housing assembly and install Assembly. Drain the coolant from the cooling system into a machine that is being serviced. 8. “Cooling System Extended Life Coolant .Change” for the 1. Slide radiator hose (2) on the regulator housing ing any compartment or disassembling any compo- assembly. Remove the air cleaner. “Alternator . NENG2500. nent containing fluids.Change” or Operation and Maintenance Assembly. Refer to Disassembly and (DEAC) . Refer to Disassembly and Assembly. Install the alternator. Position water temperature regulator (9) in regulator housing assembly (5). mandates. 6. Manual. and this helps to keep contaminants from entering the system. The capacity of the cooling system is approximately 37 L (10 US gal).24 Disassembly and Assembly Section i01638195 Radiator . ing. “Cooling System Extended Life Coolant . Position bolts c.Remove”. g00840834 Illustration 55 b. Connect tube assembly (1). the water temperature regulator should be positioned correctly NOTICE in the regulator housing assembly. Fill the cooling system. suitable to collect and contain fluids on Caterpillar products. Remove the fan. “Fan . Refer to Disassembly and Assembly. Care must be taken to ensure that fluids are contained during performance of inspection. The capacity of the cooling system is approximately End By: 37 L (9. Remove the hood. Tighten bolts (4). Note: Put identification marks on all hoses and on 3. suitable container for storage or disposal. Be prepared to collect the fluid with suitable containers before open- 5. Plug (7) and place the regulator housing assembly all hose assemblies. “Hood . Refer to Operation and Maintenance Manual. Note: Before bolts (4) are tightened. “Cooling System Coolant (DEAC) .Remove”.Remove SMCS Code: 1353-011 Removal Procedure Table 5 Required Tools Part Tool Number Part Description Qty A 138-7573 Link Bracket 2 Start By: a. Slide the regulator housing assembly on hose all hose assemblies for installation purposes. “Air Cleaner . .8 US gal).

Remove clamp (4) and refrigerant accumulator (3) from the bracket. tractor. Refer to Operation and Maintenance (12). hose 3. “Guards . 25 Disassembly and Assembly Section 2. Loosen the clamps on hoses (14) and (15). Loosen the clamp on hose (16) and hose (17) that is connected to the radiator. 5. g00848001 Illustration 58 9. Remove bolts (1) from the bracket assembly. (10). Remove bolts (7) from the radiator. hose (10). 6. Loosen the clamps on hoses (8). Remove the shroud on the right side of the (12). tube (9). Remove the support assembly on the other side of the engine. Remove bolt (5) on the other side of the bracket. Manual. and the tractor. Remove hoses (14) and (15). (13). g00847941 Illustration 57 . Remove support assembly (2).Remove and Install”. hose (13). g00839322 Illustration 56 4. g00847994 Illustration 59 10. and tube (11). Remove bolt (6) and the bracket. Remove hoses (16) and (17) from the radiator. 8. Remove the guard assembly on the right side of 7. Disconnect hose (8).

if necessary. chains and a suitable lifting device to support the radiator. Attach Tooling (A) to radiator (18). . Remove nuts (20) on both sides of the radiator. Remove the radiator from the tractor. 15.Install SMCS Code: 1353-012 Installation Procedure Table 6 Required Tools Part Tool Number Part Description Qty A 138-7573 Link Bracket 2 g00847985 Illustration 61 Note: Check the O-ring seals for wear or for damage. The weight of the radiator is 13. the aftercooler. i01644421 Radiator .26 Disassembly and Assembly Section g00848006 g00847979 Illustration 60 Illustration 62 11. Open approximately 45 kg (100 lb). Replace the O-ring seals. Remove nut (22) on both sides of the radiator. Use 12. Release latches (19) on aftercooler (21). 14.

27 Disassembly and Assembly Section NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. test- ing. Open the aftercooler. 3. g00848006 Illustration 63 g00847994 Illustration 66 5. g00847985 Illustration 65 1. 4. adjusting and repair of the product. Use a suitable lifting device and Tooling (A) to place the radiator in the original position. Secure latches (19) on aftercooler (21). Install nut (22) on both sides of the radiator. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- nent containing fluids. g00847979 Tighten the clamps on the hoses. NENG2500. Install nuts (20) on both sides of the radiator. Illustration 64 . Connect hoses (16) and (17) to the radiator. Refer to Special Publication. Attach Tooling (A) to radiator (18). 2. Dispose of all fluids according to local regulations and mandates. maintenance. “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. The weight of the radiator is approximately 45 kg (100 lb). Close the aftercooler.

Install the hood.Install”. (DEAC) . Install the support assembly on the other side of the engine. Install clamp (4) with bolt (5) on the other side of the bracket. Tighten the clamps Maintenance Manual. c.Change” or Operation and Maintenance Manual. Install the guard assembly on the right side of the tractor. “Guards .28 Disassembly and Assembly Section g00848001 Illustration 67 6. 9. Install the air cleaner. End By: a. “Hood . “Fan . hose (10). Refer to Disassembly and Assembly. Tighten the clamps on the hoses. Install bolts (7) to the radiator. The capacity of the cooling system is approximately 7.Remove and Install”. g00839322 Illustration 69 8. b. tube (11). Refer to Disassembly and Assembly. and tube (9). “Air Cleaner . Place refrigerant accumulator (3) in the original position on the bracket.Install”. 10. 12. Install support assembly (2). Install bolts (1) to the bracket assembly. g00847941 Illustration 68 13. Install the fan.8 US gal). Install the shroud on the right side of the tractor. Refer to Disassembly and Assembly. “Cooling System Extended Life Coolant - Change” for the machine that is being serviced. Connect hose (12). Connect hoses (15) and (14) to the radiator. hose 37 L (9. 11.Install”. . hose (13). Refer to Operation and (8). “Cooling System Coolant on the hoses to a torque of 5 N·m (44 lb in). Fill the cooling system with coolant. Install the bracket and bolt (6). Refer to Operation and Maintenance Manual.

shroud (3). g00836040 Illustration 71 Typical Example Note: A fan clutch is used on some models. Note: A fan clutch is used on some models. The fan 4. 1. Refer to Operation and Maintenance Manual. “Guards -Remove and Install”. 5. fan (5). Installation Procedure g00835987 g00836040 Illustration 70 Illustration 72 Typical Example 2. 29 Disassembly and Assembly Section i01614703 Fan . Remove bolts (7). Remove the left hand guard assembly. Remove bolts (4) on the bottom of shroud (3). The fan clutch has no separate spacer. Install fan spacer (6) and fan (5) with bolts (7). Remove bolts (1) on the top of shroud (3).Remove and Install SMCS Code: 1356-010 Removal Procedure 1. 3. Remove two nuts (2) and remove left hand clutch has no separate spacer. . and fan spacer (6).

1.Remove and Install”. Install left hand shroud (3) with two nuts (2).30 Disassembly and Assembly Section g00849504 Illustration 74 2. Remove the fan. i01637977 Fan Drive . 3. “Fan . Install bolts (1) at the top of shroud (3). Refer to Operation and Maintenance Manual.Remove and Install”. 4. Refer to Disassembly and Assembly. 5. Install the left hand guard assembly. Install bolts (4) at the bottom of shroud (3). g00835987 Illustration 73 Typical Example 2. Remove nuts (2) and shroud (1). . “Guards .Remove and Install”. “Guards . Remove the guard assembly on the right hand side. Refer to Operation and Maintenance Manual.Remove SMCS Code: 1359-011 Illustration 75 g00837046 Removal Procedure Start By: a.

4. Remove bolts (10) and plate (9) from fan shaft SMCS Code: 1359-015 (3). Refer to Disassembly and Assembly. Table 7 Required Tools Part Tool Number Part Description Qty A 8H-0663 Bearing Puller Gp 1 B 1P-0510 Driver Gp 1 Start By: a.Disassemble 3. Remove bolts (1). Remove belt (3).Replace”. “Belt (Alternator and Water Pump) . and roller bearing assembly (4) from fan bearing bracket (5). 5.Remove”. “Fan Drive . g00837047 2. Refer to Operation and Maintenance Manual. if necessary. 4. Remove bolts (4) and fan pulley (5). Remove the fan drive. Refer to Operation and Maintenance Manual. Remove bolts (7) and fan drive (8) from the engine. Remove belt (6). Remove grease fitting (6) from the fan bearing Illustration 76 bracket. 31 Disassembly and Assembly Section g00847593 Illustration 77 1. g00847595 Illustration 79 . 3. washers (2). i01638074 g00847594 Illustration 78 Fan Drive . Remove O-ring seal (8) from bearing retainer (7) Disassembly Procedure and the roller bearing assembly.Replace”. 6. fan shaft (3). “Belt (Air Conditioner and Fan) .

32 Disassembly and Assembly Section 5. Install washers (2) and bolts (1). Position fan shaft (3) and roller bearing assembly (4) in fan bearing bracket (5).Install”. Refer to Disassembly and Assembly. 1. a. 5. Install the fan drive. Install O-ring seal (8) to bearing retainer (7) and Part the roller bearing assembly. Install grease fitting (6) in the fan bearing bracket. Use a suitable press. Tool Number Part Description Qty 1P-0510 Driver Gp 1 3. Tooling (A). g00847593 Illustration 82 4. and Tooling (B) to remove the fan shaft from roller bearing assembly (4) and bearing retainer (7).Assemble SMCS Code: 1359-016 Assembly Procedure Table 8 g00847594 Illustration 81 Required Tools 2. Position plate (9) on fan shaft (3) and install bolts A (10). g00847772 Illustration 80 6. . Use a suitable press and Tooling (A) to install roller bearing assembly (4) and bearing retainer End By: (7) to fan shaft (3). i01638150 Fan Drive . “Fan Drive . Remove the bearing retainer from the roller bearing assembly.

Refer to Operation and Maintenance Manual. 3. Refer to Disassembly and Assembly. g00837047 Illustration 83 6. Install fan pulley (5) with bolts (4). Install belt (3).Replace”. Install belt (6). Refer to Disassembly and Assembly. Refer to Operation and Maintenance Manual. Refer to Operation and Maintenance Manual.Remove and Install SMCS Code: 1361-010 Removal Procedure Start By: g00837046 Illustration 84 a. End By: a. Position shroud (1) on the radiator and install nuts (2).Remove and Install”. “Alternator . Install the guard assembly on the right hand side. 2. “Belt (Alternator and Water Pump) .Remove and Install”. Install the fan. i01627648 Water Pump . “Belt (Air Conditioner and Fan Drive . “Fan . Position fan drive (8) on the engine and install bolts (7). 1. “Guards .Install Fan) .Remove and Install”. SMCS Code: 1359-012 Installation Procedure g00849504 Illustration 85 5. 33 Disassembly and Assembly Section i01638134 4. .Replace”. Remove the alternator.

Loosen the clamps on hoses (1) and (6). engine. “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. adjusting and repair of the product. Disconnect tube assembly (2). ing. Remove hose (6) from the water pump. if necessary. Care must be taken to ensure that fluids are contained during performance of inspection. Disconnect tube assembly (3). maintenance. Remove bolts (5) and mounting block (4). 5. if equipped.Change” for your system. 4. Refer to Operation and Maintenance Manual. 3.34 Disassembly and Assembly Section Note: Hose (1) can not be removed from the water NOTICE pump until the water pump is removed. Replace the components. Drain the coolant. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- nent containing fluids. “Cooling System Extended 6. Installation Procedure Note: Check the O-ring seals for wear or for damage. . NENG2500. Remove bolts (7) and water pump (8) from the Life Coolant . “Cooling System Coolant Illustration 87 g00843267 (DEAC) .Change” or refer to Operation and Maintenance Manual. 1. g00843267 Illustration 88 g00843262 Illustration 86 2. test. Dispose of all fluids according to local regulations and mandates. Refer to Special Publication.

Connect tube assembly (2). Refer to Disassembly and Assembly. Fill the coolant.Change” for your system. 5. g00852900 Illustration 90 1. Remove the fan drive. Remove the guard assemblies. 4. “Cooling System Extended Life Coolant .Remove”. Refer to Operation and Maintenance Manual. 3. 35 Disassembly and Assembly Section i01650330 Crankshaft Front Seal - Remove and Install SMCS Code: 1160-010 Removal Procedure Start By: a. “Fan Drive . Place hoses (6) and (1) in position and tighten the clamps. Install the alternator. Remove shrouds (3) and (4).Change” or refer to Operation and Maintenance Manual. Remove nuts (1) and bolts (2). Refer to Operation and Maintenance Manual. 2. “Cooling System Coolant (DEAC) . Install bolts (7). Refer to Disassembly and Assembly. Install hose (1) on water pump (8) as you place the water pump in position. Install mounting block (4) with bolts (5). End By: a.Remove and Install”. . b. Connect tube assembly (3).Remove and Install”. if equipped. “Guards . Table 9 Required Tools Part Tool Number Part Description Qty A 1U-7430 Front Seal Installer 1 g00843262 Illustration 89 1. “Alternator .

Position shrouds (3) and (4). plate (6). Installation Procedure g00852992 Illustration 92 1. Position damper (7) and plate (6). and 2. Install bolts (2) and nuts (1). Illustration 94 g00852900 3. bolts (5). Refer to Specifications. and install crankshaft front seal (8).36 Disassembly and Assembly Section g00852983 g00853048 Illustration 91 Illustration 93 2. Remove bolts (5). SENR9500. Clean crankshaft front seal (8) thoroughly and use Tooling (A) to install the seal. damper (7). .

Change” for your cooling system. 7. b. Refer to Operation and Maintenance Manual. Remove bolt (8). 2. “Guards . Replace the O-ring seals. Refer to Operation and damage. “Cooling System Extended Life Coolant .8 US gal). “Fan Drive . The capacity of the cooling system is approximately Note: Check the O-ring seals for wear or for 37 L (9. Raise the hood. Drain the coolant from the cooling system into a Installation Procedure suitable container for storage or disposal.Remove and Install”. Operation and Maintenance Manual. Install the fan drive. and (4). Loosen the clamp on hose (2) and remove the 1. “Caterpillar Illustration 95 g00844475 Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar 4. Manual. The weight of the air compressor is approximately “Guards . Maintenance Manual. Disconnect tube assemblies (1). 3. Move the bracket and tube Dispose of all fluids according to local regulations and assembly (4) out of the way. Disconnect hose assembly (6). i01629967 Air Compressor . mandates. “Cooling System Coolant (DEAC) . 6. 37 Disassembly and Assembly Section End By: a. NENG2500. Refer to Disassembly and Assembly. if necessary.Change” or Operation and Maintenance Manual. 5. maintenance. 11 kg (25 lb). Remove the guard assembly on the left hand 8. test- ing. Operation and Maintenance hose from the air compressor. (3). adjusting and repair of the product.Remove and Install”.Install”. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- nent containing fluids. Remove air compressor (7). “Hood (Engine Compartment) - Raise/Lower”. . side. products.Remove and Install SMCS Code: 1803-010 Removal Procedure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Refer to Special Publication. Remove bolts (5). Install the guard assemblies.

Replace”. 2.Remove and Install”. 5. Move tube assembly (4) and the bracket into erly remove the refrigerant from the air condition- position and install bolt (8). Do not smoke when servicing air conditioners or 3. release it slowly in a well ventilated area.Change” or Conditioner and Fan) . Refer to Operation and 6. “Hood (Engine Compartment) . Maintenance Manual. “Air Conditioning and Heating Systems with Operation and Maintenance Manual. Operation and Maintenance Manual. “Hood (Engine Compartment) - Raise/Lower”. NEDG5065. “Cooling System Extended Life Coolant . SENR5664. Slowly loosen the fitting. The weight of the air compressor is fumes released from a flame contacting air con- approximately 11 kg (25 lb).Raise/Lower”. Recover the air conditioner refrigerant from the cooling system. Protective goggles must always be worn when re- frigerant lines are opened. . The capacity is 2. Connect tube assembly (4).38 Disassembly and Assembly Section i01628603 Refrigerant Compressor - Remove and Install SMCS Code: 1802-010 Removal Procedure Personal injury can result from contact with refrig- erant. Place air compressor (7) in position and install lit cigarette or other smoking method or inhaling bolts (5). The capacity of the cooling system is approximately 37 L (9. ditioner refrigerant gas. Operation and Maintenance Manual. Refer to Service Manual. Lower the hood.85 lb). . Personal injury or death can result from inhaling g00844475 refrigerant through a lit cigarette. air conditioner system. 1. Use a certified recovery and recycling cart to prop- 4.8 US gal). Connect tube assemblies (3) and (1) to the air wherever refrigerant gas may be present. Fill the cooling system. “Belt (Air “Cooling System Coolant (DEAC) . Always use precaution when a fitting is removed. 2. Keep face and hands away to help prevent injury. 9. ing system. Install hose (2) and tighten the clamp. If the system is still under pressure. 8. “Guards R-134a Refrigerant”. 7. Raise the hood. compressor. can cause bodily harm or death. Illustration 96 Inhaling air conditioner refrigerant gas through a 1. Install the guard assembly on the left hand side.2 kg (4.Change” for your 3. Contact with refrigerant can cause frost bite. Refer to Refer to Operation and Maintenance Manual. Refer to Special Publication. “Air Conditioning Tools”. Connect hose assembly (6). even if the gauges in- dicate the system is empty of refrigerant. Operation and Maintenance Manual. Remove the air conditioner belt.

Refer to Service Manual. 2. Connect wiring (1) and install the cable strap. Personal injury can result from contact with refrig- Installation Procedure erant. Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air con- ditioner refrigerant gas. Keep damage. NEDG5065. The correct charge is 2. If the system is still under pressure. Connect hose assemblies (5) and (4). Replace the O-ring seals.Remove and g00844206 Install Illustration 97 SMCS Code: 7322-010-DSS 4.85 lb). Remove the cable strap and disconnect the Removal Procedure wiring (1). “Belt (Air Conditioner and Fan) . “Air Conditioning Tools” for the tools. Disconnect hose assemblies (4) and (5). Always use precaution when a fitting is removed.Raise/Lower”. face and hands away to help prevent injury. Use a certified recovery and recycling cart to prop- g00844206 Illustration 98 erly remove the refrigerant from the air condition- ing system. Personal injury or death can result from inhaling refrigerant through a lit cigarette. Compartment) . 6. . 6. Note: Check the O-ring seals for wear or for Contact with refrigerant can cause frost bite. can cause bodily harm or death. “Hood (Engine Compartment) . Install the air conditioner belt. 5. Charge the air conditioner system. SENR5664. Lower the hood. i01632787 Refrigerant Accumulator (With Desiccant) . Protective goggles must always be worn when re- frigerant lines are opened. Refer to Operation and Maintenance Manual. if necessary. even if the gauges in- dicate the system is empty of refrigerant. “Air Conditioning and Heating Systems with R-134a Refrigerant” for the procedure.Raise/Lower”. “Hood (Engine 3. Open the hood. Refer to Operation and Maintenance Manual. 5. Install refrigerant compressor (3) with bolts (2).2 kg (4. 1.Replace”. Remove bolts (2) and refrigerant compressor (3). 1. Refer to Operation and Maintenance Manual. release it slowly in a well ventilated area. Refer to Special Publication. 39 Disassembly and Assembly Section 4. Slowly loosen the fitting. Do not smoke when servicing air conditioners or wherever refrigerant gas may be present.

Recover the air conditioner refrigerant from the air conditioner system. “Hood (Engine Compartment) . Remove clamp (5) and refrigerant accumulator (1) from the bracket. “Air Conditioning Tools” for the tools. Disconnect hose assemblies (2) and (4). Refer to 2. “Guards . Replace the components. if necessary. Refer to Service Manual.85 lb). Installation Procedure Note: Check the O-ring seals for wear or for damage. the procedure. Install the right hand guard assembly.Remove and Install”. g00845715 Illustration 100 1. 3. 6. SENR5664. “Air Conditioning and Heating Manual. Refer to Operation and Maintenance Manual. . Remove the right hand guard assembly. “Air Conditioning Tools” for the tools. NEDG5065. Refer to Service SENR5664.2 kg (4. Charge the air conditioner system. “Air Conditioning and Systems with R-134a Refrigerant” for the Heating Systems with R-134a Refrigerant” for procedure. Install bolt (3) in the weld nut from the inside Operation and Maintenance Manual. NEDG5065. 3. Connect hose assemblies (4) and (2). Refer to Special Publication. “Guards side of the bracket.Remove and Install”.85 lb). Place refrigerant accumulator (1) and clamp (5) in position on the bracket. The correct charge 4. charge is 2. .40 Disassembly and Assembly Section 2. Close the hood. Remove bolt (3) on the back side of the bracket from the weld nut.Raise/Lower”.2 kg (4. Refer to Special Publication. Refer to Operation and Maintenance Manual. 6. 5. g00845715 Illustration 99 4. 5. The correct is 2.

Personal injury or death can result from inhaling refrigerant through a lit cigarette. refrigerant condenser. condenser is approximately 14 kg (30 lb). Do not smoke when servicing air conditioners or wherever refrigerant gas may be present. Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling 5. Installation Procedure Use a certified recovery and recycling cart to prop. Slide pressure. 4. if necessary. “Air Conditioning and Heating Systems with R-134a Refrigerant” for the procedure.85 lb). release it slowly in a well ventilated area. Replace the O-ring seals. The correct charge is 2. Refer to Special Publication. SENR5664. Refer to Operation and Maintenance Manual. 1. Recover the air conditioner refrigerant from the air conditioner system. Disconnect hose assemblies (3) and (5). g00845520 Illustration 101 Always use precaution when a fitting is removed. If the system is still under 3. Protective goggles must always be worn when re- frigerant lines are opened.2 kg (4. damage. can cause bodily harm or condenser.Raise/Lower”. 41 Disassembly and Assembly Section i01632308 Refrigerant Condenser - Remove and Install SMCS Code: 1805-010 Removal Procedure Personal injury can result from contact with refrig- erant. 2. Keep face and hands away to help prevent injury. Refer to Service Manual. Slowly loosen the fitting. Contact with refrigerant can cause frost bite. “Hood (Engine Compartment) . The weight of the refrigerant death. Remove the refrigerant ditioner refrigerant gas. g00845537 Illustration 102 . Open the hood. Note: Check the O-ring seals for wear or for erly remove the refrigerant from the air condition. ing system. hose assembly (3) out of the bottom of refrigerant condenser (1). Release latch assembly (2) from each side of the fumes released from a flame contacting air con. “Air Conditioning Tools” for the tools. NEDG5065. Remove bolts (4) from each side of the refrigerant condenser. even if the gauges in- dicate the system is empty of refrigerant.

Remove housing (2). . 2.2 kg (4. 4. Remove bolts (1) on housing (2). NEDG5065. Close the hood.Raise/Lower”. 3. Connect hose assemblies (3) and (5). The weight of the refrigerant condenser is approximately 14 kg (30 lb). “Hood (Engine 2. The correct charge is 2. Repeat for the other side.85 lb).42 Disassembly and Assembly Section i01657536 Hood . Fasten latch assembly (2) on each side of the refrigerant condenser. Refer to Service Manual. 5. Charge the air conditioner system. Place refrigerant condenser (1) in position and install bolts (4) on each side of the refrigerant condenser.Remove SMCS Code: 7251-011 Removal Procedure Table 10 Required Tools Part Part Tool Qty Number Description A 1U-8224 Lifting Sling 2 B 1U-8223 Lifting Sling 1 C 138-7575 Link Bracket 2 g00845520 Illustration 103 1. Refer to Special Publication. SENR5664. Note: Move hose assembly (3) into position before installing the refrigerant condenser. 1. “Air Conditioning Tools” for the tools. Compartment) . Refer to Operation and Maintenance Manual. “Air Conditioning and g00855514 Heating Systems with R-134a Refrigerant” for Illustration 104 the procedure.

6. Use a suitable lifting device and Tooling (A) in order to support the front of the hood. Repeat for the other side. 43 Disassembly and Assembly Section g00855527 Illustration 105 3. Attach Tooling (A) onto bar (4). g00855539 Illustration 106 g00855553 Illustration 108 5. g00855543 Illustration 107 4. . Lower the hood. Remove shock (5) from the bracket and the hood. Disconnect wiring harness (3).

Attach Tooling (B) to Tooling (C) and to the lifting device. the washers. 10. and C 138-7575 Link Bracket 2 bolts (6). Remove the hood (7). 8. 11. Raise the back of the hood and use a 152 mm (6 inch) block of wood to support the back of the hood.44 Disassembly and Assembly Section i01657940 Hood . Remove the nuts. g00855614 Illustration 110 9. g00855614 Illustration 111 1. Place hood (7) into the original position on the tractor. Attach Tooling (C).Install SMCS Code: 7251-012 Installation Procedure Table 11 Required Tools Part Part Tool Qty Number Description A 1U-8224 Lifting Sling 2 g00855568 Illustration 109 B 1U-8223 Lifting Sling 1 7. . the bushing.

4. and the nuts. Remove Tooling (A). 3. 45 Disassembly and Assembly Section g00855568 Illustration 112 2. the washers. Lower the hood. the bushings. Raise the front of the hood. Illustration 115 g00855527 10. Raise the back of the hood and use a 152 mm (6 inch) block of wood in order to support the back of the hood. g00855553 Illustration 113 7. Install bolts (6). Repeat for the other side. Connect wiring harness (3). 9. 5. g00855543 Illustration 114 6. . Remove Tooling (B) and (C) from the lifting device. Remove the block of wood. 8. Install shock (5) to the bracket with the clips.

Remove bolts (1) from drive shaft (2). Repeat for the other side. Remove bolts (3) and safety strap (4). Separate drive i01644775 shaft (2) from the flex-drive coupling and remove the drive shaft. Remove bolts (5) from the U-joint. 2. Install bolts (1).46 Disassembly and Assembly Section 1. Install housing (2).Remove and Install Installation Procedure SMCS Code: 3253-010 Removal Procedure g00850364 Illustration 119 View of the drive shaft under the tractor g00850177 Illustration 117 Bottom view under the tractor of the drive shaft . 12. 3. Drive Shaft . g00855514 Illustration 116 g00850364 Illustration 118 11.

b. test- ing.Remove” for the machine that is being serviced. 47 Disassembly and Assembly Section c. 3. or hoses Removal as they are disconnected. Refer to Disassembly and Assembly. “Drive Shaft . “Cooling Assembly - Remove” for the machine that is being serviced. . g00850177 Illustration 120 Refer to Special Publication. Remove the refrigerant compressor. Cover any disassembled components and clean them properly before assem- Table 12 bly. Remove the electric starting motor. i01711909 Contamination of the hydraulic system with foreign material will reduce the service life of the hydraulic Engine . Remove the muffler. 2. “Refrigerant compressor . Remove the drive shaft. Refer to Disassembly and Assembly. Remove the cooling assembly.Remove and Install” for the machine that is being serviced. Refer to Disassembly and Assembly. fittings. “Electric starting Motor . to remove any contamination. “Caterpillar Tools and Shop Products Guide” for tools and supplies 1. Refer to Disassembly and Assembly. always plug or cap the lines. 105 ± 20 N·m (77 ± 15 lb ft). maintenance.Remove and Install” for the machine that is being serviced. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- nent containing fluids. Position the drive shaft on the U-joint and Dispose of all fluids according to local regulations and install bolts (5). d. B 1U-9200 Lever Puller Hoist 1 C 6V-3145 Load Leveling Beam 1 Start By: a. Refer to Disassembly and Assembly. SMCS Code: 1000-011 To prevent contaminants from entering the hydraulic system. Position drive shaft (2) on the flex-drive coupling suitable to collect and contain fluids on Caterpillar and install bolts (1). adjusting and repair of the product. “Muffler . e.Remove and Install” for the machine that is being serviced. products. NENG2500. Required Tools Clean the hydraulic system properly after any major TOOL Part Number Part Description Qty component exchange or especially after a component A 1U-8223 Lifting Sling 2 failure. Tighten bolts (5) to a torque of mandates. Install safety strap (4) with bolts (3). NOTICE Keep all parts clean from contaminants.Remove system components.

Remove bolt (12) from light (13). Remove two clamps (7) and (9) on exhaust pipe (8). g00854415 Illustration 122 2. Remove light (13 ) from the engine. and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped. 4. Remove bolt (6) and the clip. Repeat light removal for opposite side of the engine. Remove bolt (1) and washers from the engine. Remove exhaust pipe (8) from the engine. (4) and (5) from alternator (2).48 Disassembly and Assembly Section Personal injury can result from hydraulic oil pres- sure and hot oil. Seri- ous injury can be caused if this pressure is not re- leased before any service is done on the hydraulic system. g00881005 Illustration 123 3. Remove two tube assemblies (10) and (11) from the engine. Remove alternator wires (3). . Make sure all of the work tools have been lowered to the ground. and the filler cap is cool enough to touch with your bare hand. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. g00854394 Illustration 121 1.

g00854518 Illustration 128 . 49 Disassembly and Assembly Section 8. Cut cable strap (16). g00855383 Illustration 125 6. g00854440 Illustration 124 5. 9. Remove connector (23). Remove bolt (20) on the engine. Remove one bolt in ECM connector (23). g00881012 Illustration 127 10. Disconnect the wire at the inlet air heater relay (18). Cut cable straps along harness (19). g00881006 Illustration 126 7. Remove air cleaner indicator (15). Remove hose (17). Cut cable straps on harness (19). 11. Remove two hose assemblies (21) and (22) from the engine. Remove hose assembly (24) from fuel filter (25). Remove nut (14) and the ground strap from the engine.

(27) from the engine. Remove fuel line (30) from the engine. Remove bolt (38) from priming pump (39). Remove bolt (37) from tube assembly (36). Remove nut (34) and clamp from tube assembly (33). Remove tube assembly (33) from the engine. Remove bolt (28) and washers. 17. Remove bolts (31) from disconnect switch (32). g00881020 Illustration 131 16. 14. Remove tube assembly (36) from the engine. dust ejector tube (27). Disconnect tube assembly (36). Remove tube (29) from the engine. g00881014 Illustration 129 13. g00854539 Illustration 130 .50 Disassembly and Assembly Section 12. 18. Disconnect tube assembly (33). Remove priming pump (39) from the engine. Remove dust ejector tube Move disconnect switch (32). Remove two dust ejector hose clamps (26) from 15. Remove two bolts (35) from the rear engine mount and two bolts (40) from the front engine mount.

Use Tooling (B) to adjust the engine. to remove any contamination. Cover any disassembled components and clean them properly before assem- bly. Attach a suitable lifting device to Tooling (C). i01712100 Engine . Install the engine B 1U-9200 Lever Puller Hoist 1 to the machine. . To prevent contaminants from entering the hydraulic system. The weight of the engine is C 6V-3145 Load Leveling Beam 1 approximately 839 kg (1850 lb). g00854629 Illustration 132 19. Attach a suitable lifting device to Tooling (C). The weight of the engine is approximately 839 kg (1850 lb). Attach Tooling (A) between the flywheel housing and rear of the oil pan to Tooling (C). Clean the hydraulic system properly after any major component exchange or especially after a component failure. Attach Tooling (A) between the flywheel housing TOOL Part Number Part Description Qty and the rear of the oil pan to Tooling (C). Use Tooling (B) to adjust the engine. Contamination of the hydraulic system with foreign material will reduce the service life of the hydraulic system components. Remove the engine from the machine. 51 Disassembly and Assembly Section NOTICE Keep all parts clean from contaminants. Attach Tooling (B) to the front of the engine. or hoses as they are disconnected. fittings.Install SMCS Code: 1000-012 Installation g00854629 Illustration 133 Table 13 Required Tools 1. Attach A 1U-8223 Lifting Sling 2 Tooling (B) to the front of the engine. always plug or cap the lines.

Install tube (29) to the engine. Connect tube assembly (36). 4. g00854539 Illustration 135 5. Install nut (34) and clamp to tube assembly (33).52 Disassembly and Assembly Section g00881020 Illustration 134 2. Install bolt (37) to tube assembly (36). Install tube assembly (33) to the engine. Install fuel line (30) to the engine. . Position disconnect switch (32). Connect tube assembly (33). 7. Install dust ejector tube (27) to the engine. Install bolt (38) to priming pump (39). Install priming pump (39) to the engine. Install bolt (28) and washers. Install two dust ejector hose clamps (26) to dust ejector tube (27). Install tube assembly (36) to the engine. 3. g00881014 Illustration 136 6. g00854518 Illustration 137 8. Install bolts (31) to disconnect switch (32). Install two bolts (40) to the rear engine mount and two bolts (35) to the front engine mount.

13. Install connector (23). Attach cable strap (16). g00881012 Illustration 138 9. Install hose (17). Install one bolt in ECM connector (23). Attach cable straps along harness (19). Install bolt (20) on the engine. Install hose assembly (24) to fuel filter (25). Connect the wire to the inlet air heater relay (18). Attach cable straps on harness (19). 53 Disassembly and Assembly Section g00881006 Illustration 139 11. . Install air cleaner indicator (15). 10. Install two hose assemblies (21) and (22) to the engine. g00855383 Illustration 140 14. 12.

Install alternator wires (3). g00854415 Illustration 143 18. Install the clip and bolt (6). b. Install two tube assemblies (10) and (11) to the engine. Install the refrigerant compressor. (4) and (5) to alternator (2). Repeat light installation for opposite side of the engine.Remove and Install” for the machine that is being serviced. 19. Install exhaust pipe (8) to the engine. Install light (13 ) to the engine.Remove and Install” for the machine that is being serviced.54 Disassembly and Assembly Section g00854440 Illustration 141 15. g00881005 Illustration 142 16. Install two g00854394 Illustration 144 clamps (7) and (9) to exhaust pipe (8). Install bolt (12) to light (13). Install the ground strap to the engine. . Refer to Disassembly and Assembly. Install the muffler. Install bolt (1) and washers to the engine. 17. Refer to Disassembly and Assembly. “Refrigerant compressor . “Muffler . Install nut (14). End By: a.

Install” for the machine that is being serviced. e. “Drive Shaft . Install the drive shaft.Remove and Install” for the machine that is being serviced. “Cooling Assembly . . Install the electric starting motor. d. Install the cooling assembly. 55 Disassembly and Assembly Section c.Install” for the machine that is being serviced. Refer to Disassembly and Assembly. “Electric Starting Motor . Refer to Disassembly and Assembly. Refer to Disassembly and Assembly.

..................... 35 M D Muffler ............................................ 37 H Alternator ................................................................................................................................................. 3 Disassembly Procedure .... 6 Air Compressor .. 18 Fuel Filter and Fuel Filter Base ................. 8 Air Cleaner ..........................................Remove and Install.......................................................................................... 47 Removal Procedure ........................................Install ........................ 4 Installation Procedure ....................................................... 6 Removal Procedure ........................Disassemble .....Remove and Install .............Assemble ................................................................................................................ 29 Fan Drive ................ 21 Secondary Fuel Filters) ..........................................Remove......... 5 Removal Procedure ................................................... 46 Removal Procedure ...........Remove and Install .........................Install (Primary and Installation Procedure ..Remove and Install...................................................................................... 37 Installation Procedure ......................................... 15 Installation Procedure ......... 39 Removal Procedure ........................... 38 Installation Procedure ....Remove and Install .......................................................................................................................... 41 Installation Procedure ............................. 20 Installation Procedure ...................................... 12 Removal Procedure ... 4 Installation Procedure ......................... 46 Removal Procedure ................................................ 31 Fan Drive ..................... 26 Installation Procedure ..............................Remove and Install .......... 32 Fan Drive ....Install .. 30 Removal Procedure ...................Remove and Install ................................................................................... 19 and Secondary Fuel Filters) .......................................................... 33 ........... 21 Installation Procedure .....................................................................Install ........ 5 Refrigerant Accumulator (With Desiccant) ............56 Index Section Index A Fan Drive .............Remove ......................................... 42 C Hydraulic Oil Cooler .......... 10 Removal Procedure ............................................................................................................................. 26 Electric Starting Motor ...........................Remove .......... 21 Disassembly and Assembly Section....................................................... 21 Drive Shaft .. 46 R E Radiator ........ 17 Cooling Assembly ................................................................................. 44 Removal Procedure ... 31 Table of Contents.................. 2 Removal Procedure ................... 51 and Install .......................... 42 Removal Procedure .................... 15 Installation Procedure ...Remove (Primary Installation Procedure ............................... 44 Hood ......................................................... 29 Removal Procedure ..........................Remove and Install..... 24 Removal Procedure ................Install................................ 30 Aftercooler ................................. 24 Installation Procedure .....Remove ....................... 41 Installation Procedure .Remove and Install...Remove and Install ........ 38 F Refrigerant Condenser ...........................Remove ................................... 4 Installation Procedure ....................................................... 18 Removal Procedure . 29 Removal Procedure .... 51 Installation Procedure ....... 8 Removal Procedure ................................................ 40 Engine ....................... 36 Important Safety Information .......................... 39 Installation..............Remove Engine ........ 10 I Crankshaft Front Seal .............................. 33 Installation Procedure .. 20 Fuel Filter and Fuel Filter Base .. 37 Removal Procedure .. 39 Removal.......................... 4 Hood ............Install.................. 41 Fan . 35 Installation Procedure ...........................Remove and Install.. 32 T Assembly Procedure.......................................................... 47 Refrigerant Compressor .......................... 5 Radiator ..............Remove and Install.......... 12 Cooling Assembly .........................................

..................................................................... 33 Water Temperature Regulator ........................................Remove and Install ........ 22 Installation Procedure ................................ 23 Removal Procedure ...........Remove and Install .... 22 .. 57 Index Section W Water Pump ............................. 33 Installation Procedure ................................................ 34 Removal Procedure ..................

58 Index Section .

59 Index Section .