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Product: TRACK-TYPE TRACTOR

Model: D3C III TRACK-TYPE TRACTOR 4KS
Configuration: D3C & D3C LGP, XL Series III Hystat Tractors 4KS00001-UP (MACHINE) POWERED BY 3046 Engine

Disassembly and Assembly

3046 ENGINE SUPPLEMENT FOR D3C, D4C & D5C SERIES III HYSTAT
Media Number -SENR1248-01 Publication Date -01/10/2004 Date Updated -27/01/2005

SENR12480040

Engine & Pumps

SMCS - 1012-010

Remove & Install Engine & Pumps

Start By:

a. remove radiator

b. remove air cleaner

c. remove muffler

d. remove air conditioning compressor

e. remove cab

f. remove front and rear guards (belly guards)

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.

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).

12. Remove two bolts (33), washers and nuts.

13. Remove clip (34) and remove tie wraps (35).

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.

16. Attach tooling (A) to firewall (40) as shown.

17. Remove eight bolts (41) nuts and washers (four on each side). Using a hoist and one additional
person, carefully lift the firewall off the machine. Make sure that all wires have been identified and
properly disconnected. The weight of the firewall is 197 kg (435 lb).
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).
23. Remove two tube assemblies (59) and (60) as a unit.

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.

28. Remove hose assembly (70).

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.

31. Disconnect hose assemblies (75) and (76).

32. Remove hose assembly (77). Disconnect hose assemblies (78), (79) and (80).

33. Attach tooling (B), (C) and (D) as shown.

34. Remove two bolts (81), nuts, washers, sleeves and mount assemblies.
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).

37. Remove tube assemblies (83) and (84).

38. Remove tube assembly (85).

39. Remove hose assembly (86). Remove cotter and pin (88), and disconnect rod end (89) from lever
(87).
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).

42. Loosen screw (96) and remove coupling (95).

NOTE: Install in reverse order.

End By:

a. install radiator

b. install air cleaner

c. install muffler

d. install air conditioning compressor

e. install cab
f. install front and rear guards (belly guards)

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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