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. Release the hydraulic system pressure. Refer to Disassembly and Assembly, "System Pressure - Release".

3. Remove the engine bottom guards. Refer to Disassembly and Assembly, "Bottom Guard (Engine) - Remove and Install".

4. Remove the hood. Refer to Disassembly and Assembly, "Hood - Remove".

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

6. Remove the radiator header tank. Refer to Disassembly and Assembly, "Radiator Tank (Header) - Remove".

7. Remove upper drive shaft. Refer to Disassembly and Assembly, "Drive Shaft (Upper) - 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.

Note: Put identification marks on all lines, on all hoses, on all wires and on all tubes for installation purposes. Plug all lines, all hoses and all tubes. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

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Personal injury can result from contact with refrigerant. This system is under pressure at all times, even if the engine is not running. Heat should never be applied to a charged system. Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury. Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant. Always use caution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, evacuate the system recovering the refrigerant before removing the fitting. Personal injury or death can result from inhaling refrigerant through a lit cigarette. Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death. Do not smoke when servicing air conditioners or wherever refrigerant gas may be present. Before any checks of the air conditioning and heating system are made, move the machine to a smooth horizontal surface. Lower all implements to the ground. Make sure the transmission is in neutral or park and that the parking brake is engaged. Keep all other personnel away from the machine or where they can be seen.

1. Drain the hydraulic tank into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Capacities (Refill)" for the capacity of the hydraulic tank. Refer to Operation and Maintenance Manual, "Hydraulic System Oil - Change" for the proper draining procedure.

2. Recover the air conditioner refrigerant from the air conditioner system. Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the procedure. Refer to Special Publication, NEDG5065, "Air Conditioning Tools" for the tools.
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   Illustration 1	g01107619

3. Remove cover (1).

4. Remove two bolts (2) and firewall (3).
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   Illustration 2	g01107963

5. Remove two bolts (4).

6. Remove two bolts (6) and firewall (5).
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   Illustration 3	g01107964

7. Remove three bolts (8) and firewall (7).
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   Illustration 4	g01107966

8. Remove bolts (10), (11) and firewall (9).
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   Illustration 5	g01107965

9. Remove bolts (12), (14) and firewall (13).
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   Illustration 6	g01155484

10. Remove heat shields (15) and (16).
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    Illustration 7	g01155485

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    Illustration 8	g01155486

11. Remove two bolts (18) and two retainers (19) from elbow (17).

12. Remove three bolts (20) from elbow (17).

13. Remove elbow (17).
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    Illustration 9	g01155516

14. Disconnect hose assembly (21).

15. Disconnect tube assembly (22).
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    Illustration 10	g01155517

16. Loosen four hose clamps (23) and remove hose (24).

17. Disconnect hose assemblies (25) and (26).
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    Illustration 11	g01155518

18. Disconnect hose assemblies (27) and (28) from the steering, pilot and braking pump.

19. Disconnect hose assembly (29).
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    Illustration 12	g01155519

20. Remove clip (31).

21. Position hose assembly (30) out of the way.
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    Illustration 13	g01155520

22. Disconnect hose assemblies (32) and (33).
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    Illustration 14	g01155521

23. Disconnect hose assemblies (34) and (35).
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    Illustration 15	g01155522

24. Disconnect hose assemblies (36) and (37).
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    Illustration 16	g01155524

25. Disconnect hose assemblies (38), (39), (40) and (41).
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    Illustration 17	g01155525

26. Attach a suitable lifting device to cross beam (42). The weight of cross beam (42) is approximately 50 kg (110 lb).

27. Remove four bolts (43) and cross beam (42).
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    Illustration 18	g01155526

28. Disconnect wiring harness (44).

29. Disconnect electrical connector (45).

30. Remove bolt (46) and the clips.

31. Disconnect hose assembly (47).
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    Illustration 19	g01155530

32. Disconnect electrical cables (48) and (49).
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    Illustration 20	g01155531

33. Close valve (51).

34. Disconnect hose assembly (50).
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    Illustration 21	g01155532

35. Disconnect hose assemblies (52) and (53).
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    Illustration 22	g01155533

36. Disconnect hose assemblies (54) and (55).
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    Illustration 23	g01155534

37. Remove four bolts (57) and cross beam (56).
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    Illustration 24	g01155540

38. Loosen two hose clamps (58).
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    Illustration 25	g01156721

39. Loosen two hose clamps (61).

40. Remove bolt (59) (not shown) and tube assembly (60).
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    Illustration 26	g01156722

41. Loosen two hose clamps (62).

42. Disconnect hose assemblies (63) and (64).
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    Illustration 27	g01107944

43. Loosen two hose clamps (65).

44. Remove tube assembly (66).
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    Illustration 28	g01107946

45. Loosen two hose clamps (67).
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    Illustration 29	g01107945

46. Loosen two hose clamps (69).

47. Remove bolt (70) and outlet tube (68).
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    Illustration 30	g01107949

48. Loosen hose clamps (71).
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    Illustration 31	g01107947
    Typical example

49. Loosen four hose clamps (72).

50. Remove inlet tube (73).
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    Illustration 32	g01157831

51. Remove four bolts (74), six bolts (75) and guard assembly (76).
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    Illustration 33	g01157838

52. Remove bolt (79), five bolts (77) and guard assembly (78).
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    Illustration 34	g01157841

53. Remove five bolts (80) and guard assembly (81).
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    Illustration 35	g01157845

54. Remove eight bolts (83) (not shown).

55. Use two people to remove fan spider (82) and secure to the radiator. The weight of fan spider (82) is approximately 45 kg (99 lb).
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    Illustration 36	g01157846

56. Install Tooling (A) and a suitable lifting device to engine, torque converter and updrive gears (84). The weight of engine, torque converter and updrive gears (84) is approximately 2310 kg (5092 lb).
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    Illustration 37	g01157848

57. Remove four bolts (85).
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    Illustration 38	g01157850

58. Remove two bolts (86) and mount (87).

59. Repeat Step 58 for the mount on the other side.

60. Remove engine, torque converter and updrive gears (84).