R1700G Load Haul Dump C11 Engine Supplement Caterpillar

Installation Procedure

Note: Check the condition of all O-ring seals, the gaskets, and the seals for wear or for damage. Replace the components, if necessary.

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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.

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Illustration 1	g01248920

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Illustration 2	g01248421

1. 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).

2. Install lower rubber mounts (62) and (63) in position on both sides of the rear frame.

3. Install the engine, torque converter and updrive gears in position in the rear frame.

4. Install upper rubber mount (60), bolt (64), the nut and the washer.

5. Repeat Step 4 for the mount on the other side.

6. Install upper rubber mount (59), bolt (61), the nut and the washer.

7. Repeat Step 6 for the mount on the other side.

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Illustration 3	g01249044

8. Install hose assembly (56). Tighten two hose clamps (57) .

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Illustration 4	g01249030

9. Connect hose assembly (54) .

10. Install two bolts (55) and the clips.

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Illustration 5	g01249817

11. Connect hose assembly (52) .

12. Install two bolts (53) and the clips.

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Illustration 6	g01260291

13. Connect hose assembly (51) .

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Illustration 7	g01249423

14. Install tube assembly (50) and the four bolts.

15. Connect hose assembly (49) .

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Illustration 8	g01249011

16. Install elbow (47) and four bolts (48) .

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Illustration 9	g01249024

17. Connect hose assembly (44) to the tap. Tighten the hose clamp.

18. Install bolt (45) and bolt (46) to the two clips.

19. Connect electrical wire (43) .

20. Connect electrical connector (42) .

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Illustration 10	g01249042

21. Connect wire (41) to the fuel gauge.

22. Install bolt (40) and the clip.

23. Connect electrical connector (39) .

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Illustration 11	g01249019

24. Connect hose assembly (36) .

25. Connect two electrical cables (38) to the electric starting motor solenoid.

26. Connect two electrical cables (37) to the electric starting motor.

27. Connect electrical connector (35) .

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Illustration 12	g01249000

28. Connect hose assembly (33) and hose assembly (34) .

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Illustration 13	g01249022

29. Install tube assembly (32). Tighten the hose clamps.

30. Connect hose assembly (31) to the tap. Tighten the hose clamp.

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Illustration 14	g01249440

31. Install tube assembly (30). Tighten the hose clamps.

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

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Illustration 15	g01280113

33. Position left side top shroud (27). Install 11 bolts (26) .

34. Position right side top shroud (24). Install 13 bolts (25) .

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Illustration 16	g01249439

35. Install upper guard assembly (22) and eight bolts (23) .

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Illustration 17	g01249438

36. Install outlet tube (20) and inlet tube (21). Tighten the hose clamps.

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Illustration 18	g01249435

37. Position hose assembly (19). Install three bolts (18) and the clips.

38. Connect hose assembly (16) and hose assembly (17) .

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Illustration 19	g01249433

39. Install crossbeam (15) and four bolts (14) .

40. Install cover (13) .

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Illustration 20	g01274749

41. Install gasket (12) .

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Illustration 21	g01248420

42. Install tube assembly (10) and three bolts (11) .

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Illustration 22	g01248419

43. Install clamp (9) in the position recorded in the removal procedure. Tighten clamp (9) .

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Illustration 23	g01248418

44. Install cover (8) .

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Illustration 24	g01249429

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Illustration 25	g01249428

45. Install cover (7) and firewall (6) .

46. Install firewall (4), firewall (3) and firewall (5) .

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Illustration 26	g01249425

47. Install firewall (2) and firewall (1) .

48. Charge 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.

49. Fill the transmission. 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 filling procedure.

End By:

1. Install the steering, pilot and braking gear pump. Refer to Disassembly and Assembly, "Gear Pump (Steering, Pilot and Braking) - Install".
2. Install upper drive shaft. Refer to Disassembly and Assembly, "Drive Shaft (Upper) - Remove and Install".
3. Install the radiator header tank. Refer to Disassembly and Assembly, "Radiator Tank (Header) - Install".
4. Install the air cleaner. Refer to Disassembly and Assembly, "Air Cleaner - Remove and Install".
5. Install the hood. Refer to Disassembly and Assembly, "Hood - Install".
6. Install the engine bottom guards. Refer to Disassembly and Assembly, "Bottom Guard (Engine) - Remove and Install".
7. Remove the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Remove and Install".