R1700G Load Haul Dump C11 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 pressure from the hydraulic system. 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".
8. Remove the steering, pilot and braking gear pump. Refer to Disassembly and Assembly, "Gear Pump (Steering, Pilot and Braking) - Remove".

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 transmission oil into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Capacities (Refill)" for the capacity of the transmission. Refer to Operation and Maintenance Manual, "Transmission 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	g01249425

3. Remove firewall (1) and firewall (2) .

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Illustration 2	g01249428

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Illustration 3	g01249429

4. Remove firewall (5), firewall (3) and firewall (4) .

5. Remove firewall (6) and cover (7) .

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Illustration 4	g01274747

6. Remove cover (8) .

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Illustration 5	g01274748

Note: Record the position of clamp (9) for installation purposes.

7. Remove clamp (9) .

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Illustration 6	g01248420

8. Remove three bolts (11) and tube assembly (10) .

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Illustration 7	g01274749

9. Remove gasket (12) .

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Illustration 8	g01249433

10. Remove cover (13) .

11. Remove four bolts (14) and crossbeam (15) .

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Illustration 9	g01249435

12. Disconnect hose assembly (16) and hose assembly (17) .

13. Remove three bolts (18) from the three clips. Move hose assembly (19) out of the way.

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Illustration 10	g01249438

14. Loosen the hose clamps. Remove outlet tube (20) and inlet tube (21) .

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Illustration 11	g01249439

15. Remove eight bolts (23). Remove upper guard assembly (22) .

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Illustration 12	g01280113

16. Remove 13 bolts (25). Remove right side top shroud (24) .

17. Remove 11 bolts (26). Remove left side top shroud (27) .

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Illustration 13	g01249440

18. Loosen the hose clamps and remove tube assembly (30) .

19. Attach a suitable lifting device to fan assembly (28). The weight of fan assembly (28) is approximately 39 kg (86 lb). Remove six bolts (29) (not shown). Remove fan assembly (28) .

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Illustration 14	g01249022

20. Loosen the hose clamp and disconnect hose assembly (31) from the tap.

21. Loosen the hose clamps. Remove tube assembly (32) .

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Illustration 15	g01249000

22. Disconnect hose assembly (33) and hose assembly (34) .

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Illustration 16	g01249019

23. Disconnect electrical connector (35) .

24. Disconnect two electrical cables (37) from the electric starting motor.

25. Disconnect two electrical cables (38) from the electric starting motor solenoid.

26. Disconnect hose assembly (36) .

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Illustration 17	g01249042

27. Disconnect electrical connector (39) .

28. Disconnect wire (41) from the fuel gauge.

29. Remove bolt (40) from the clip.

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Illustration 18	g01249024

30. Loosen the hose clamp and disconnect hose assembly (44) from the tap.

31. Remove bolt (45), bolt (46) and the two clips.

32. Disconnect electrical cable (43) .

33. Disconnect wiring harness (42) at the electrical connector.

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Illustration 19	g01249011

34. Remove four bolts (48) from elbow (47) .

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Illustration 20	g01249423

35. Disconnect hose assembly (49) .

36. Remove the four bolts from tube assembly (50). Remove tube assembly (50) .

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Illustration 21	g01260291

37. Disconnect hose assembly (51) .

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Illustration 22	g01249817

38. Disconnect hose assembly (52) .

39. Remove two bolts (53) and the clips. Move hose assembly (52) out of the way.

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Illustration 23	g01249030

40. Remove two bolts (55) and the clips.

41. Disconnect hose assembly (54) .

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Illustration 24	g01249044

42. Loosen two hose clamps (57). Disconnect hose assembly (56) .

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Illustration 25	g01248920

43. Attach Tooling (A) and a suitable lifting device to engine, torque converter and updrive gears (58). The weight of engine, torque converter and updrive gears (58) is approximately 1820 kg (4012 lb).

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Illustration 26	g01248421

44. Remove bolt (61), the nut the washer and upper rubber mount (59) .

45. Repeat Step 44 for the mount on the other side.

46. Remove bolt (64), the nut the washer and upper rubber mount (60) .

47. Repeat Step 46 for the mount on the other side.

48. Remove engine, torque converter and updrive gears (58) .

49. Remove lower rubber mounts (62) and (63) from both sides of the rear frame.