KEY 8F7689 - Caterpillar

Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 4C-6357(1)
or
8T-3022(2) Connecting Rod Guide 1
B 235-0612 Lift Bracket 1
C 136-1452 Retaining Ring Pliers As 1
D 318-3117 Ring Expander Gp 1
E 443-4072(3) Cover 1
443-4073(4) Cover 1
F - Board
51 mm by 152 mm by 1.8 m (2 inch by 6 inch by 6.0 ft) 2
G 1U-8692 Piston Pin Guide 1
H 4C-5719 Piston Ring Compressor 1
J 8T-5096
or
1U-8869 Dial Indicator 1
K 498-6540(5) 498-6541(6) Tensioner Pump Group -
L 498-6542 Tensioner Group 1 Piece 1
M 498-6573 Nut - Plastic(7) 4
N - 3/8 drive ratchet 1
(1) Use with V-engines
(2) Use with in-line engines
(3) 3606 and 3608
(4) 3612 and 3616
(5) 115 Volt
(6) 230 Volt
(7) Part of the 498-6542 tensioner pump groupStart By:
Remove the cylinder heads.
Remove the piston cooling jets.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Personal injury or death can occur from not following the proper procedure or the recommended tooling.To prevent the possibility of injury or death, follow the established procedure using the recommended tooling.
If more than one piston is to be removed, the crankshaft can turn due to the weight of the remaining pistons. Lock the position of the crankshaft in in order to prevent unexpected movement, personal injury, or component damage.
Remove carbon accumulation from the cylinders before the pistons are removed.
Remove the crankcase covers from the cylinder block.
Clean the carbon ridge from the top of the cylinder liner.
Remove the cylinder liner sleeve.
Turn the crankshaft until the piston is at the TOP CENTER position.
Illustration 1 g06054464
Position Tooling (F) under connecting rod cap (1). Tooling (F) will span the engine to the openings of the inspection covers on the opposite side. The weight of connecting rod cap (1) is approximately 16 kg (35 lb).
Illustration 2 g06055562
Illustration 3 g06073954
Install Tooling (L) on bolt (1) and bolt (2) by locating the end of connecting rod bolt (3) with puller sleeves (L1) of Tooling (L) and rotating puller sleeves (L1). The adjustment wheel or a (3/8 inch) ratchet can be used. Tighten Tooling (L) puller sleeves (L1) by hand until rotation stops. Loosen puller sleeves (L1) by two rotations.Note: Puller sleeves (L1) must be loosened by two rotations to avoid Tooling (L) from locking up against the connecting rod cap (1) once nuts (2) have been loosened and the connecting rod bolts have been de-tensioned.
Insert Tooling (N) into the drive gear of the gearbox in Tooling (L). Rotate the drive gear until nut rotating socket (L2) is aligned and located around nut (2).Note: Nut rotating socket (L2) is spring loaded. A click will be heard when the socket moves into place.
Repeat Step 6 and Step 7 to install Tooling (L) on bolt (3) and bolt (4).
Connect Tooling (L) hoses and electrical connections between the tensioners and Tooling (K) tensioner pump.Note: Ensure proper connection of hydraulic hoses and couplers.
Enter corresponding engine information in Tooling (K). Press and hold the pendent down arrow key to apply pressure for de-tensioning. The screen will