Removal Procedure
Start By:
- Remove the muffler. Refer to Disassembly and Assembly Manual, "Muffler - Remove".
- Remove the radiator. Refer to Disassembly and Assembly Manual, "Radiator - Remove".
| Required Tools | |||
| Tools | Part Number | Description | Qty |
| A | 208-5040 | Square tube | 1 |
| B | 185-0411 | Clevis | 1 |
| C | 1U-9200 | Lever Puller Hoist | 1 |
| D | 138-7575 | Link Bracket | 2 |
Note: Put identification marks on all hose assemblies, all wire assemblies and all tubes for installation purposes. Plug all hose assemblies and all tubes. This helps to prevent fluid loss, and this helps to keep contaminants from entering the system.
| NOTICE |
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Keep all parts clean from contaminants. Contamination of the hydraulic system with foreign material will reduce the service life of the hydraulic system components. To prevent contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected. Cover any disassembled components and clean them properly before assembly. Clean the hydraulic system properly after any major component exchange or especially after a component failure, to remove any contamination. |
| NOTICE |
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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, "AVSpare Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on AVSpare products. Dispose of all fluids according to local regulations and mandates. |
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At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury. |
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Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool. |
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Climbing equipment may be required to access this service point. Refer to the Operation and Maintenance Manual, "Mounting and Dismounting" topic for safety information. |
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- Move the battery disconnect switch to the "Off" position.
- Remove the battery cable from the positive terminal on the battery.
- Remove cover (1) which is located over the main control valve.
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| Illustration 1 | g00817362 |
- Loosen hose clamp (3). Remove bolts (2) from pipe assembly (4) .
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| Illustration 2 | g00817388 |
- Remove two hose clamps (5), and remove hose (6). Remove support assembly (7), and remove sheet assembly (8) .
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| Illustration 3 | g00817417 |
- Loosen the hose clamps (9), and disconnect hoses (10) .
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| Illustration 4 | g00817457 |
- Loosen two hose clamps (11), and disconnect two hoses (12). Remove hose clamp (13) from the bracket.
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| Illustration 5 | g00817464 |
- Remove bolts (15) which fasten bracket (17) to the governor housing. Loosen nuts (14), and remove two cables (16) from the bracket on the flywheel housing.
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| Illustration 6 | g00817500 |
- Disconnect electrical plug (21). Remove bolt (19), and remove ground strap (20). Remove the bolt and spacer (18) which secures the wiring harness to the mounting block.
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| Illustration 7 | g00817721 |
- Cut tie strap (22) which secures the wiring harness to the guide for the oil level gauge. Remove the boot and the wiring harness from terminal (23) on the air inlet heater.
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| Illustration 8 | g00817741 |
- Remove bolt (24) and the spacer. Remove screw (25) and the two wires.
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| Illustration 9 | g00817747 |
- Disconnect two electrical plugs (26) and (26a). Remove the boot, the nut and the wire from terminal (27) on the alternator.
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| Illustration 10 | g00817749 |
- Disconnect electrical plug (28). Loosen bolt (29). The bolt cannot be removed because of interference with the air conditioner lines. Remove bolts (30) .
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| Illustration 11 | g00817744 |
- Disconnect electrical plug (31). Remove two screws from switch (32), and cut four tie straps (33) .
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| Illustration 12 | g00817753 |
- Pull back the boot from the terminal (34). Remove the nut and two wires. Remove bolt (35), the spacer and the clip from the wiring harness. Remove screw (36) and the plastic cover from the starter.
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| Illustration 13 | g00817757 |
- Remove screw (37), and remove the wire.
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| Illustration 14 | g00817760 |
- Disconnect electrical plug (38). Remove bolt (39 ), washers and spacers (40) which secure battery cables (41) .
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| Illustration 15 | g00817764 |
- Remove sheet assembly (42) from below the engine. The component is part of the bottom guard group.
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| Illustration 16 | g00817768 |
- Remove two cable clips (43), and remove four tie straps (45). Remove sheet (44), upper sheet assembly (46), and lower sheet assembly (47) .
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| Illustration 17 | g00817775 |
- Install Tooling (A), (B), (C) and (D). Refer to Illustrations 18 and 19. The weight of the pump is approximately 136 kg (300 lb).
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| Illustration 18 | g00817771 |
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| Illustration 19 | g00817789 |
- Remove bolts (48) which secure the main hydraulic pump to the engine flywheel housing.
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| Illustration 20 | g00817792 |
- Attach a suitable lifting device to the engine. The engine weighs approximately 395 kg (870 lb). Mark the locations of the motor mounts for installation purposes. Remove four motor mounts (49). Lift the engine from the machine.
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| Illustration 21 | g00817796 |