Engine Component

FIG. 486: Remove muffler (3).

Loosen clamp (1) and remove flex exhaust tube (2).

3
1 P100506011

FIG. 486
FIG. 487: Remove flex exhaust tube.
Loosen clamp (1) and remove flex exhaust tube (2).
2

1
N022606001

FIG. 487
FIG. 488: Remove battery cable.
Remove positive battery cables (1) from starter (2) on left
side of machine.

1
2

P100506033

FIG. 488
FIG. 489: Remove cable.
Remove ground cable (1) from starter (2) on left side of
machine. Fasten out of the way.

1 2
P100506034

FIG. 489

79033095 D Rev. 02-179

Engine Component
FIG. 490: Remove solenoid wire.
Remove solenoid wire (1) from starter (2) on left side of
machine. Fasten out of the way.

1 2

P100506035

FIG. 490
FIG. 491: Remove battery cable.
Remove positive battery cable (1) from starter (2) on right
side of machine.
Remove P-clip (3) and fasten positive battery cable out of
the way.
3
1
2

N031706003

FIG. 491
FIG. 492: Remove cable.
Remove ground cable (1) from starter (2) on right side of 2
machine. Fasten out of the way.

1
N031706004

FIG. 492
FIG. 493: Remove solenoid wire.
Remove solenoid wire (1) from starter (2) on right side of 1
machine. Fasten out of the way.

N031706004

FIG. 493

02-180 79033095 D Rev.

 Engine Component
FIG. 494: Remove cable.
Remove positive battery cable (1) from alternator (2). 2
Remove P-clip (3) and fasten positive cable out of the
way.

1
3
N031706005

FIG. 494
FIG. 495: Remove cable.
Remove ground cable (1) from alternator (2) and fasten
out of the way.

1
2

N031706006

FIG. 495
FIG. 496: Remove terminal wire.
Remove terminal wire (1) from alternator (2).

2
1

N031706006

FIG. 496
FIG. 497: Remove chassis harness.
5
Remove air conditioning clutch and high pressure switch
wire (1).
Remove Alternator terminal wire (2). 3 7
Remove air intake restriction switch wire (3).
1
Remove ether start wire (4). 4
Remove front and rear washer pump wire (5).
Remove engine ECM wire (6). 2
Remove chassis harness (7) and neatly wrap all the wires 6 P100506036
up and fasten out of the way. FIG. 497

79033095 D Rev. 02-181

Engine Component
FIG. 498: Remove air conditioning lines.
IMPORTANT: Only a certified technician with certified
equipment should service the air conditioning
system.
IMPORTANT: Refer to Refrigerant section for proper
removal of hoses. 1
A certified technician must recover refrigerant and remove
air conditioning lines (1). Refer to Refrigerant section for
proper removal of hoses. Fasten air conditioning lines out
of the way.
N030806003

FIG. 498
FIG. 499: Remove air conditioning line.
Remove P-clip (1) and fasten air conditioning line (2) out
of the way.
2

N031706009

FIG. 499
FIG. 500: Serpentine belt removal.
Use a ratchet wrench in the square hole (1) on the belt
tensioner (2) and turn clockwise to relieve belt tension.
Remove serpentine belt (3). Slowly release the belt
tensioner to relax into a neutral position.
1 2

m
WARNING: Equipment or parts under
spring tension can cause bodily injury. Use
caution in releasing belt tension. 3

NOTE: Be sure to allow enough room for the swing of the

ratchet to allow belt tensioner to relax into a
neutral position.

N021606002

FIG. 500
FIG. 501: Remove air conditioning compressor.
Remove bolts (1) and compressor (2). The weight of the
air conditioning compressor is approximately 10 kg (21
lb). 2

N030806004

FIG. 501

02-182 79033095 D Rev.

 Engine Component
FIG. 502: Remove alternator.
Remove the two top bolts (1) and bottom bolt (2). Remove
alternator (3). The weight of the alternator is
approximately 27 kg (60 lb). 1

N031706008

FIG. 502
FIG. 503: Drain air from air reservoir.
Location of air reservoir tank (1) is located in the right front 1
frame rail (2).

P100506025

FIG. 503
FIG. 504: Drain air from air reservoir.
Pull pin (1) sideways on drain valve (2) and drain air from
system.

1
P100506026

FIG. 504
FIG. 505: Air compressor location. (If equipped)
The air compressor (1) is located on the left side of the
engine.

1
N032006001

FIG. 505

79033095 D Rev. 02-183

Engine Component
FIG. 506: Remove hose. (If equipped)
Remove oil hose (1) and fasten out of the way.

N032006002

FIG. 506
FIG. 507: Remove hose. (If equipped)
Remove hose (1) and fasten out of the way.

N032006003

FIG. 507
FIG. 508: Remove tube. (If equipped)
Remove air discharge tube (1).

N032006004

FIG. 508
FIG. 509: Remove coolant tube. (If equipped)
Remove coolant tubes (1).

1
1

N032006006

FIG. 509

02-184 79033095 D Rev.

 Engine Component
FIG. 510: Remove air inlet tube. (If equipped)
Remove air inlet tube (1).
1

N032006007

FIG. 510
FIG. 511: Remove support bracket. (If equipped)
Remove two bolts (1).
Loosen bolt (2) and rotate bracket (3) out of the way.
1

2
N032006010

FIG. 511
FIG. 512: Remove air compressor. (If equipped)
Remove three nuts (1) and remove air compressor (2).
The weight of the air compressor is approximately 21 kg
(46 lb).

2
1

N032006008

FIG. 512
FIG. 513: Remove air compressor hoses. (If equipped)
Disconnect hose (1) and remove P-clip (2).
Remove cable ties from hose (3). 1 3

2
N032606001

FIG. 513

79033095 D Rev. 02-185

Engine Component
FIG. 514: Remove air compressor hoses. (If equipped)
Disconnect tube (1), remove P-clip (2) and remove tube
(1).
2
2
2

1
P100506037

FIG. 514
FIG. 515: Air conditioning accumulator location.
The location of the air conditioning accumulator (1) is on
the left side of the machine and behind the step (2). The
step is behind the left front fender in front of the cab.
2

P100506015

FIG. 515
FIG. 516: Remove air conditioning lines.
Remove air conditioning lines (1) and disconnect low 2
pressure switch (2) from air conditioning accumulator (3).
IMPORTANT: Only a certified technician with certified 1
equipment should service the air conditioning
system.
IMPORTANT: Refer to Refrigerant section for proper
removal of hoses.
3
A certified technician must recover refrigerant and remove
air conditioning lines (1). Refer to Refrigerant section for 1
proper removal of hoses. Fasten air conditioning lines out P100506016

of the way. FIG. 516

FIG. 517: Remove accumulator.
Remove bolt (1), two piece clamp (2) and accumulator
(3).

2
P100506017

FIG. 517

02-186 79033095 D Rev.

 Engine Component
FIG. 518: Remove bolts and remove plate (1).

1
P100506038

FIG. 518
FIG. 519: Fuel shut off.
On the fuel tank (1) on the right side of the fuel tank, turn 1
shut off valve handles (2) 90 degrees clockwise. Shut off
valve handles (2) should be perpendicular to the valve.
2

P100506039

FIG. 519
FIG. 520: Fuel shut off.
At the primary fuel filter / water separator (1) on the left
side of the engine, turn shut off valve handle (2) 90
degrees clockwise. Shut off valve handle (2) should be
perpendicular to the valve. 2
1

N033006001

FIG. 520
FIG. 521: Remove fuel line.
Remove supply fuel lines (1) and fasten out of the way.

1
1

P100506040

FIG. 521

79033095 D Rev. 02-187

Engine Component
FIG. 522: Remove window washer hoses.
Disconnect window washer hoses (1) from pump (2).
2
Remove P-clip (3) and cable straps (4) and fasten washer 1
hoses (1) out of the way.
3 4

N031906005

FIG. 522
FIG. 523: Remove ether start hose.
Remove ether start hose (1) and fasten out of the way.

N031906006

FIG. 523
FIG. 524: Remove engine coolant fill hose.
Loosen hose clamp (1) and remove hose (2).

1
N031906007

FIG. 524
FIG. 525: Remove hose.
Loosen hose clamp (1) and remove hose (2).

1
N031906008

FIG. 525

02-188 79033095 D Rev.

 Engine Component
FIG. 526: Remove bracket.
Remove bolts (1) and remove bracket (2).

1
2

N032706003

FIG. 526
FIG. 527: Disconnect support.
Remove bolts (1) from bearing pad and cooling assembly
(2) on the right side of machine.

1
2

P100506041

FIG. 527
FIG. 528: Disconnect support.
Remove bolts (1) from bearing pad and cooling assembly
(2) on the right side of machine.
Remove the component support (3) and the components
still fastened to it.
3
2
1

P100506042

FIG. 528
FIG. 529: Disconnect the input shaft.
Remove bolts (1) and remove the input shaft (2).

2
1
P100506021

FIG. 529

79033095 D Rev. 02-189

Engine Component
FIG. 530: Attach lifting device.
Attach approved lifting device to the lifting brackets (1) at
the front and rear of engine. The weight of the engine is
approximately 1332 kg (2930lb).

1
P100506043

FIG. 530
FIG. 531: Remove engine mounting hardware.
Remove two bolts (1) on each side of engine.

P100506044

FIG. 531
FIG. 532: Remove engine.
Remove the engine (1). The weight of the engine is
approximately 1332 kg (2930 lb).

P100506043

FIG. 532
FIG. 533: Clean beneath engine mounting isolators.
Remove the four sets of mounting hardware (1). Clean
mounting surface to be free of rust and dirt.

1
1

P100506045

FIG. 533

02-190 79033095 D Rev.

 Engine Component
Engine Installation
FIG. 534: Install engine mounting hardware.
Ensure mounting surfaces (1) are clean and free of rust.
Install washer (2), primary support pad (3) and sleeve (4) 4
on the four engine mounting points, two on each side.
3

1 2

P100506046

FIG. 534
FIG. 535: Install engine.
Install the engine (1). The weight of the engine is
approximately 1332 kg (2930lb).

P100506043

FIG. 535
FIG. 536: Install engine mounting hardware.
Install rebound pad (1), washer (2), washer (3) and bolt
(4) on the four engine mounting points, two on each side. 3 4
Tighten bolts to 800 Nm (590 lbf ft).

1
P100506047

FIG. 536
FIG. 537: Connect the input shaft.
NOTE: If the bolt pattern on the input shaft and the input 3
coupling do not line up, then refer to the CAT
engine manual on how to rotate the flywheel.
Connect the input shaft (2) to the input coupling (3) and
install bolts and washers (1). Tighten to 350 Nm (258 lbf
ft).

2
1
P100506021

FIG. 537

79033095 D Rev. 02-191

Engine Component
FIG. 538: Connect support.
Install the component support (3) and the components
still fastened to it. 5
Install bolts and washers (1) into bearing pad (2) on the
right side of machine. Tighten to 240 Nm (177 lbf ft).
Install bolts and washers (4) onto cooling assembly (5) on 3
the right side of machine. Tighten to 55 Nm (40 lbf ft). 4
1 2

P100506042

FIG. 538
FIG. 539: Connect support.
Install bolts and washers (1) into bearing pad (2) on the
right side of machine. Tighten to 240 Nm (177 lbf ft).
Install bolts and washers (3) onto cooling assembly (4) on
the right side of machine. Tighten to 55 Nm (40 lbf ft).

2
3 4

1 P100506041

FIG. 539
FIG. 540: Install bracket.
Install bracket (2) and install four bolts and washers (1).
Tighten to 100 Nm (74 lbf ft).

1
2

N032706003

FIG. 540
FIG. 541: Install hose.
Install hose (2) and tighten hose clamp (1).

1
N031906008

FIG. 541

02-192 79033095 D Rev.

 Engine Component
FIG. 542: Install hose.
Install hose (2) and tighten hose clamp (1).

1
N031906007

FIG. 542
FIG. 543: Install ether start hose.
Install ether start hose (1).

N031906006

FIG. 543
FIG. 544: Install window washer hoses.
Install hose (1), P-clip (3) and cable straps (4).
2
Connect window washer hoses (1) to the pumps (2). 1

3 4

N031906005

FIG. 544
FIG. 545: Install fuel line.
Install supply fuel lines (1). Tighten to 55 Nm (40 lbf ft).

1
1

P100506040

FIG. 545

79033095 D Rev. 02-193

Engine Component
FIG. 546: Turn on fuel shut off.
At the fuel filter (1) on the left side of the engine, turn shut
off valve handle (2) 90 degrees counter clockwise. Shut
off valve handle (2) should be parallel to the valve.
2
1

N033006001

FIG. 546
FIG. 547: Turn on fuel shut off.
On the fuel tank (1) turn shut off valve handle (2) 90 1
degrees counter clockwise. Shut off valve handle (2)
should be parallel to the valve.
2

P100506039

FIG. 547
FIG. 548: Remove bolts and remove plate (1). Install
plate (1). Install washers and bolts, tighten to 55 Nm (40
lbf ft).

1
P100506038

FIG. 548
FIG. 549: Install accumulator.
Install two piece clamp (2) around accumulator (3) and
install on bracket (4). Install bolt and washer (1) and
tighten.
4
3

2
P100506017

FIG. 549

02-194 79033095 D Rev.

 Engine Component
FIG. 550: Install air conditioning lines.
IMPORTANT: Only a certified technician with certified 2
equipment should service the air conditioning
system.
1
IMPORTANT: Refer to Refrigerant section for proper
removal of hoses.
A certified technician must install air conditioning lines (1)
and charge the air conditioning system. Reconnect the
low pressure switch (2). Refer to Refrigerant section for
proper installation of hoses. 1
P100506016

FIG. 550
FIG. 551: Install air compressor hoses. (If equipped)
Connect tube (1) and tighten to 86 Nm (63 lbf ft). Install
P-clip (2) and tighten to 70 Nm (51 lbf ft).
2
2
2

1
P100506037

FIG. 551
FIG. 552: Install air compressor hoses. (If equipped)
Connect tube (1) and tighten to 86 Nm (63 lbf ft). Install
P-clip (2). 1 3
Install hose (3) and install cable ties for hose (3).

2
N032606001

FIG. 552
FIG. 553: Install air compressor. (If equipped)
Surfaces (1) must be free of primer, topcoat, cleaning
solutions and corrosion.
The weight of the air compressor is approximately 21 kg
(46 lb).
1

1
N032006009

FIG. 553

79033095 D Rev. 02-195

Engine Component
FIG. 554: Install air compressor. (If equipped)
Install air compressor (2) and install three nuts and
washers (1). Tighten bolts to 105 Nm (77 lbf ft).

2
1

N032006008

FIG. 554
FIG. 555: Install support bracket. (If equipped)
Rotate bracket (3) to the air compressor.
Install two bolts (1) into the air compressor. Tighten bolt to
55 Nm (40 lbf ft). 1
Tighten bolt (2) to 215 Nm (158 lbf ft).
3

2
N032006010

FIG. 555
FIG. 556: Install air inlet tube. (If equipped)
Install the connector (1). Tighten to 135 Nm (100 lbf ft).
Install air inlet tube (2). Tighten to 156 Nm (115 lbf ft).

N032106001

FIG. 556
FIG. 557: Install coolant tube. (If equipped)
Install 90 degree elbow (1). Tighten to 82 Nm (60 lbf ft).
Install coolant tubes (2). Tighten to 55 Nm (40 lbf ft).
1

N032106002

FIG. 557

02-196 79033095 D Rev.

 Engine Component
FIG. 558: Install coolant tube. (If equipped)
2
Install the connector (1). Tighten to 55 Nm (40 lbf ft).
Install coolant tubes (2). Tighten to 55 Nm (40 lbf ft).

N032106003

FIG. 558
FIG. 559: Install tube. (If equipped)
Install the connector (1). Tighten to 140 Nm (103 lbf ft).
Install air discharge tube (2). Tighten to 86 Nm (63 lbf ft).

1 2

N032006004

FIG. 559
FIG. 560: Install hose. (If equipped)
Install fitting and hose(1). Tighten to 16 Nm (11 lbf ft).

N032006003

FIG. 560
FIG. 561: Install oil hose. (If equipped)
Install the connector (1). Tighten to 22 Nm (16 lbf ft).
Install oil hose. Tighten to 18 Nm (13 lbf ft).

N032006002

FIG. 561

79033095 D Rev. 02-197

Engine Component
FIG. 562: Install oil hose. (If equipped)
Install the connector (1). Tighten to 22 Nm (16 lbf ft).
Install oil hose (2). Tighten to 18 Nm (13 lbf ft). 1

N032106004

FIG. 562
FIG. 563: Install alternator.
Place alternator (3) and install the two top bolts (1) and
bottom bolt (2). Tighten top two bolts to 71 N.m. (52 ft.lb.).
Tighten bottom bolt to 105 N.m. (77 lb.ft.). The weight of 1
the alternator is approximately 27 kg (60 lb).

N031706008

FIG. 563
FIG. 564: Install air conditioning compressor
Install compressor (2) and tighten bolts and washers (1).
Tighten to 28 Nm (20 lbf ft). The weight of the air
conditioning compressor is approximately 10 kg (21 lb). 2

N030806004

FIG. 564
FIG. 565: Belt install.
Install serpentine belt (3) over pulleys on front of engine,
leaving it off of alternator pulley. Ensure that belt ribs are
properly seated in pulley valleys.
Insert square drive of ratchet into square hole (1) on belt 1 2
tensioner (2) and rotate tensioner clockwise and hold.

m
WARNING: Equipment or parts under 3
spring tension can cause bodily injury. Use
caution in applying pressure to belt
tensioner.

Carefully place belt onto air conditioning compressor 4

pulley (4) ensuring belt ribs are properly seated in pulley
valleys and slowly allow belt tensioner to release until it
makes contact with belt. N021606002

FIG. 565

02-198 79033095 D Rev.