725C2, 730C2 Articulated Truck LRC Engine Supplement Caterpillar

Removal Procedure

Start By:

1. Remove the air cleaner.

2. Remove the starter.

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Personal injury can result from contact with refrigerant. 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 precaution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated area. 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. Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system.

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Personal injury or death may result from failure to adhere to the following procedures. Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Clean up all leaked or spilled fuel. Do not smoke while working on the fuel system. Turn the disconnect switch OFF or disconnect the battery when changing fuel filters.

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Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand. Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns. Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes.

1. Drain the coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct draining and filling procedures.

2. Recover the air conditioner refrigerant. Refer to Service Manual, SENR5664, "All Products Air Conditioning and Heating Systems with R134a for All Caterpillar Machines". Refer to Special Publication, NENG2500, "Air Conditioning Tools" for the correct tools.

3. Tilt the cab. Refer to Operations and Maintenance Manual, "Cab - Tilt" for the correct procedure.
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   Illustration 1	g03699572

4. Remove tube assemblies (1).
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   Illustration 2	g03689077

5. Remove clips (4) and (5). Disconnect hose assembly (3) and remove the seal. Disconnect hose assemblies (2), (6) and (7).
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   Illustration 3	g03689084

6. Remove the cable straps from harness assembly (8). Disconnect clamps (9) and (10).
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   Illustration 4	g03689086

7. Disconnect harness assembly (11). Disconnect hose assemblies (12).
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   Illustration 5	g03689159

8. Disconnect bracket (14). Remove bolts (13) and remove bracket (15).
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   Illustration 6	g03689174

9. Disconnect all harness assemblies connected to harness assembly (16) and remove all cable straps connecting harness assembly (16) to the engine. Disconnect cable assembly (17) from the frame.
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   Illustration 7	g03689176

10. Disconnect harness assembly (18). Disconnect hose assembly (19). Remove cable straps (20).
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    Illustration 8	g03689216

11. Disconnect harness assemblies (21) and remove cable straps (22).
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    Illustration 9	g03689239

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    Illustration 10	g03697666
    Harness assemblies and tube assemblies removed for clarity.

12. Remove bolts (23) and (24).
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    Illustration 11	g03689305
    Behind engine.

13. Remove bolts (25).
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    Illustration 12	g03689335

14. Disconnect harness assembly (27). Disconnect harness assembly (26) from the bracket.
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    Illustration 13	g03689742

15. Disconnect clamp (28). Disconnect hose (29). Disconnect hoses (30).
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    Illustration 14	g03689748

16. Disconnect hoses (31).
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    Illustration 15	g03689753

17. Remove bolts (32).
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    Illustration 16	g03689760

18. Disconnect hose assemblies (33). Loosen clamp (34).
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    Illustration 17	g03689773

19. Remove tube assembly (35) and disconnect tube assembly (36).
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    Illustration 18	g03689797
    Typical Example

20. Attach a suitable lifting device to engine (37). The weight of engine (37) is approximately 1270 kg (2800 lb).
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    Illustration 19	g03689826

21. Install Tooling (B).
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    Illustration 20	g03689830

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    Illustration 21	g03689844

22. Remove plug (38).

23. Use Tooling (B) to rotate the engine and remove 12 bolts (39).
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    Illustration 22	g03689851

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    Illustration 23	g03698080

24. Remove bolts (41) and (40). Remove bolts (42).
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    Illustration 24	g03689857
    Typical Example

25. Remove engine (37).

Installation Procedure

1. Install engine (37) in the reverse order of removal.