0582499 JOHNSON LEAD AY., Bonding strap

Fluid Spillage ContainmentCare 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 Product Guide, NENG2500", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.Start By:a. remove unit injector hydraulic pump 1. Remove four bolts (1) and the washers that secure hose and electrical wire (2) to tube (3). 2. Attach a lifting sling to tube (3) as shown. Attach the lifting sling to an appropriate lifting device.3. Remove radiator hose (4) to facilitate removal of the fan guards. 4. Mark the orientation of tube (3) for installation purposes. Remove eight bolts (5), the washers and the shims between tube (3) and the frame. Make note of the number of shims on each end of tube (3). Remove tube (3) from the machine. The weight of tube (3) is approximately 23 kg (50 lb). 5. Use a pry bar and relieve tension on fan belts (6). Remove fan belts (6) from tightener pulley (7). 6. Remove two brackets (11) and (12) from fan guards (8) and (9). Remove 12 bolts (10) that secure fan guards (8) and (9) in position.7. Remove spring (13) from the fan drive.8. Remove fan guards (8) and (9) from the machine. Carefully set fan (14) down against the radiator to prevent damage to the radiator. Place a piece of cardboard between the fan and the radiator where they touch.9. Remove six bolts (15) that secure fan (14) to fan adapter (16). Use two people to lower fan (14) down against radiator. The weight of fan (14) is approximately 34 kg (74 lb). 10. Remove six bolts (17) and the nuts and remove fan adapter (16). Remove the O-ring seal from fan adapter (16).11. Remove V-belts (6) from the fan drive. 12. Attach a lifting sling to fan drive assembly (19) as shown. Attach the lifting sling to an appropriate lifting device.13. Remove the bolt that secures grease hose assembly (20).14. Remove four bolts (18) and remove fan drive assembly (19). 15. Disconnect three hoses (21) and disconnect turbocharger pressure sensor (23) at the electrical connection.16. Disconnect atmospheric pressure sensor (22) on top of the unit injector hydraulic pump drive at the electrical connection. 17. Remove ten bolts (25) and the two nuts that secure cover (24) to the front of the engine.18. Remove cover (24) from the engine. 19. Remove gasket (26). If necessary, use Tool (A) to remove stud (30) on the front of the engine, and to remove the stud in cover (24).20. Remove four bolts (29) and retainer (28). Remove gear (27) from the front of the engine. 21. Remove two timing sensors (32) from unit injector hydraulic pump drive (31).22. Remove four mounting bolts (34), two bolts (33), torque pin (35) and the seal.23. Remove unit injector hydraulic pump drive (31) from the engine. 24. Remove O-ring seals (36) from unit injector hydraulic pump drive (36). The following steps are for the installation of the unit injector hydraulic pump drive. Check all the O-ring seals for damage or wear, replace with new parts if necessary. 25. Place O-ring seals (36) in position on unit injector hydraulic pump drive (31).26. Lubricate the bore of the front housing and the seal on the unit injector hydraulic pump drive lightly with clean engine oil. Place unit injector hydraulic pump drive (31) in position on the engine. 27. Install two bolts (33).28. Install four mounting bolts (34). Tighten bolts (34) to a torque of 5 3 N m (4 2 lb ft). Install torque pin (35) and the O-ring seal. Tighten torque pin (35) to a torque of 105 10 Nm (75 7 lb ft). Tighten four mounting bolts (34) again to a torque of 55 7 N m 41 5 lb ft). With the number one piston at top center, align timing marks on gear (27) with the camshaft gear.29. Put gear (27) in position on the unit injector hydraulic pump drive. Install retainer plate (28) and four bolts (29). Tighten four bolts (29) to a torque of 132 20 N m (100 15 lb ft).30. If removed, use Tool (A) to install stud (30) on the front of the engine and in cover (24). Timing sensors (32) must be fully extended before they are installed.31. Install two timing sensors (32) in unit injector hydraulic pump drive (31). 32. Clean the mating surfaces of the front housing and cover (24). Place a new gasket (26) and cover (24) in position. Install ten bolts (25) and the two nuts. 33. Install three hoses (21). Connect turbocharger pressure sensor (23) at the electrical connection.34. Connect atmospheric pressure sensor (22) at the electrical connection. 35. Attach a lifting sling to fan drive assembly (19) as shown. Attach the lifting sling to an appropriate lifting device.36. Place fan drive assembly (19) in position and install four bolts (18) and the washers.37. Install the bolt that secures the grease hose assembly (20). 38. Place fan belts (6) in position on fan drive assembly (18).39. Put the O-ring seal in fan adapter (16). Place fan adapter (16) in position on fan drive assembly (18). Install six bolts (17) and the nuts. 40. Use two people to place fan (14) in position on fan adapter (16). Install six bolts (15) that secures fan (14) on fan adapter (16). 41. Install spring (13) on fan drive assembly (18).42. Install fan guards (8) and (9), two brackets (11) and 12 bolts (10). 43. Use a pry bar as shown and install V-belts (6) on tightener pulley (7). 44. Attach a lifting sling to tube (3). Attach lifting sling to an appropriate lifting device. Place tube (3) in position on the machine according to the location