Remove & Install Engine & Pumps
Remove & Install Engine & Pumps
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Start By:
a. remove radiator
c. remove muffler
e. remove cab
g. remove batteries
Fluid Spillage Containment
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance,
testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component containing fluids. Refer to "Tools
And Shop Products Guide", NENG2500 for tools and supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local regulations and mandates.
Oil that is hot and under high pressure can cause injury. To prevent
injury, all pressure in the hydraulic system must be released before any
hydraulic lines are disconnected. To release the pressure in the
hydraulic system, stop the engine, and move implement control levers to
all positions. Let the hydraulic oil become cool before work is done on
the hydraulic system.
NOTICE
Be sure to clean all fittings and oil line connections before the lines are
disconnected. Install plugs in all openings to keep dirt out of the oil
lines and valves. Put identification marks on the lines, hoses and wiring
assemblies to assist during installation.
NOTE: Place identification marks on all lines, hoses, wires and tubes for installation purposes. Cap
and plug all lines, hoses and tubes to prevent fluid loss and contaminants from entering the system.
1. Drain the hydraulic tank. The capacity is approximately 83 liters (U.S. Gal).
2. Loosen clamp (1) and disconnect hose assembly (2) from block assembly.
3. Remove eight nuts (6), gasket (5) (not shown) and exhaust elbow (4) from the exhaust manifold.
4. Loosen clamp (7) and disconnect hose (8). Remove bolt (9) and clip (10) and reposition hose (8) to
the side.
5. Loosen clamp (11) and disconnect hose (12). Remove bolt (15) and clip (16) and reposition hose
(12) to the side.
6. Loosen clamp (13) and disconnect hose (14). Reposition hose (14) to the side.
7. Cut straps (22) and disconnect wire connectors (17), (18), (19), (20) and (21).
8. Remove cotter and pin (24) and disconnect rod end (25) from lever (23).
9. Loosen nut (27) and reposition cable group (26) to the side.
10. Disconnect two lube lines (28) and clips (not shown).
11. Disconnect wire connector (29). Disconnect hose assemblies (31) and (32) and tube assembly
(30).
14. Disconnect tube assembly (36) from hydraulic tank (38) by removing four bolts (37) and washers.
15. Remove bolt (39), washer and spacer (not shown). Reposition tube assembly (36) towards the
center of the tractor.
18. Remove bolt (42) and washer, and reposition hose (44) and clip (43) to the side.
19. Remove nut (46) and washer. Disconnect wires (45) and (49). Install nut (46) and washer to hold
remaining wires.
20. Remove nut (48) and washer. Disconnect wire (47) and install nut (48) and washer to hold
remaining wires.
21. Loosen clamp (49) and disconnect hose (50). Disconnect tubing assembly (51). Remove bolt (53),
washer and clip (52). Reposition wires (45) and (47), hose (50) and tube (51) to the side.
22. Remove four bolts (54), washers and two clips (55). Remove bolt (56), washer and clip (57).
Remove support (58).
24. Disconnect hose assembly (61) and reposition valve assembly (62) to the side.
25. Disconnect hose assemblies (63) and (64) and reposition to the side.
26. Remove bolt (65), washer and clip (66). Disconnect hose assembly (67) and reposition the hose
assembly under the pumps.
27. Disconnect hose assemblies (68) and (69) and reposition to the side.
29. Disconnect hose assemblies (71) and (72) and reposition to the side.
30. Remove bolt, washer (not shown) and clip (73). Disconnect hose assembly (74) and reposition the
hose assembly under the pumps.
32. Remove hose assembly (77). Disconnect hose assemblies (78), (79) and (80).
35. Remove two bolts (82), nuts, washers, sleeves and mount assemblies.
36. Using a hoist, carefully lift the engine and pumps from the machine onto tooling (E). The weight
of the engine and pumps are 727 kg (1389 lb).
40. Attach a strap and suitable lifting device to pump (90). Loosen four bolts (91) and slowly remove
pump (90) from pump (92). As the pump disengage, remove four bolts (91) and washers. The weight
of this pump is 75 kg (165 lb).
41. Attach a strap and suitable lifting device to pump (92). Remove two nuts (93) and washers.
Loosen four nuts (94) and slowly remove pump (92) from the engine. As the pump and the engine
disengage, remove four nuts (94) and washers. The weight of the pump is 75 kg (165 lb).
End By:
a. install radiator
c. install muffler
e. install cab
g. install batteries
NOTE: Fill the hydraulic tank to the proper level. See the Operation And Maintenance Manual for
proper level.
NOTE: Fill the Radiator to the proper level. See the Operation And Maintenance Manual for proper
level.
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