R2900G Load Haul Dump C15 Engine Supplement Caterpillar

Removal Procedure

Start By:

1. Install the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Remove and Install".

2. Remove the air cleaner. Refer to Disassembly and Assembly, "Air Cleaner - Remove and Install".

Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL OR THE INSTALLATION. THIS TOOLING IS SHOWN IN ORDER TO ASSIST THE EXPERIENCED SERVICEMAN.

Note: Cleanliness is an important factor. Before the removal procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.

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NOTICE
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, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

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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.

1. Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Capacities (Refill)" for the capacity of the cooling system. Refer to Operation and Maintenance Manual, "Cooling System Coolant (DEAC) - Change" or Operation and Maintenance Manual, "Cooling System Extended Life Coolant - Change" for the proper draining procedure.
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   Illustration 1	g01152383

2. Remove heat shields (1) and (2).
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   Illustration 2	g01152804

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   Illustration 3	g01153421

3. Remove two bolts (4) and two retainers (5) from elbow (3).

4. Remove three bolts (6) from elbow (3).

5. Remove elbow (3).
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   Illustration 4	g01158488

6. Remove two metal seal rings (7) from elbow (3).
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   Illustration 5	g01158494

7. Remove two metal seal rings (8).

8. Loosen clamp (9).

9. Remove exhaust joint (11) and clamp (9) from turbocharger (10).
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   Illustration 6	g01153438

10. Loosen two clamps (12).
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    Illustration 7	g01153439

11. Loosen clamp (16).

12. Remove elbow (15) and clamp (16).

13. Disconnect tube assembly (14).

14. Disconnect hose assemblies (13) and (17).
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    Illustration 8	g01153440

15. Remove two bolts (18), two bolts (20) and tube assembly (19).
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    Illustration 9	g01153443

16. Attach a suitable lifting device to turbocharger (10). The weight of turbocharger (10) is approximately 34 kg (75 lb).

17. Remove four bolts (21) and the locknuts.

18. Remove turbocharger (10) and gasket (22).