2004/04/19 Caterpillar

Load Haul Dump:

R2900G (S/N: GLK1-UP)

Reference: Maintenance Manual, RENR4700 (1DE0603), "Machine Repairs and Welding Procedures"

Description of Change: A firewall provides a barrier between the hydraulic hoses and the exhaust manifold.

Adaptable To: The firewall is effective with R2900G (S/N: GLK544-UP). The firewall is adaptable to R2900G (S/N: GLK1-543).

Modifications to the Rear Frame

1. Turn the battery disconnect switch to the OFF position.

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Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas.

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

2. Disarm the fire suppression system (if equipped). Refer to the manufacturer's service information.

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Illustration 1	g01060521
Right side view of the rear frame (1) 9EQ5169 Tapping Strip (A) 134 mm (5.27 inch) (B) 118 mm (4.64 inch)

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Illustration 2	g01061244
Left side view of the rear frame (1) 9EQ5169 Tapping Strip (C) 144 mm (5.66 inch) (D) 108 mm (4.25 inch)

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Illustration 3	g01061234
Plan view of the rear frame (1) 9EQ5169 Tapping Strip (E) 982 mm (38.66 inch) (F) 1021 mm (40.19 inch)

3. Weld 9EQ5169 Tapping Strips (1) in the positions shown in Illustration 1, Illustration 2 and Illustration 3.
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   Table 2

   Item	Dimension
   W1	6 mm (0.23 inch) Fillet Weld

Modifications to the Fire Suppression System (If Equipped)

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Illustration 4	g01060518
Underside view of the hood assembly (1) 0DE5819 Hose As (2) 0DE4949 Hose As (X) Joins nozzle on left side of rear frame (Y) Joins the detonating line

1. Remove 0DE5819 Hose As (1). Discard 0DE5819 Hose As (1) .

2. Remove 0DE4949 Hose As (2). Discard 0DE4949 Hose As (2) .

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Illustration 5	g01060519
Underside view of the hood assembly (3) 0DE5128 Hose As (4) 0DE5831 Hose As (X) Joins 1DE3664 Union (Y) Joins 1DE2528 Union

3. Connect new 0DE5128 Hose As (3) to the elbow.

4. Connect new 0DE5831 Hose As (4) to the tee.

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Illustration 6	g01060520
View of the new hose assembly connections (3) 0DE5128 Hose As (4) 0DE5831 Hose As (5) 9EQ4838 Firewall (6) 1DE3664 Union (7) 0DE5830 Hose As (8) 1DE2528 Union (9) 0DE5240 Hose As

5. Install 1DE3664 Union (6) to 9EQ4838 Firewall (5) .

6. Install 1DE2528 Union (8) to 9EQ4838 Firewall (5) .

7. Connect 0DE5831 Hose As (4) to 1DE2528 Union (8) .

8. Connect 0DE5128 Hose As (3) to 1DE3664 Union (6) .

9. Install new 0DE5830 Hose As (7) .

10. Install new 0DE5240 Hose As (9) .

Installation of the Firewall

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Illustration 7	g01061261
View of the firewall installation (C) Location of the fuel inlet at the rear of the engine (1) 5N-3175 Plug (2) 9X-2223 Button Plug (not used with a fire suppression system) (3) 5S-7379 Bolt (4) 8T-4896 Hard Washer (5) 7X-1442 Button Plug (6) 9EQ4838 Cover-Upper (7) 9EQ5461 Shroud (8) 5K-3546 Button Plug (not used with a fire suppression system) (9) 9EQ5474 Firewall (10) 8X-5156 Handhold (11) 9EQ5471 Lid (12) 9EQ5464 Firewall (13) 9EQ5466 Firewall (14) 9EQ5465 Firewall (15) 9EQ5470 Firewall (16) 9R-8537 Latch Socket (17) 4M-5281 Bolt (18) 8T-4205 Hard Washer (19) 6V-8185 Nut (20) 9EQ5135 Bracket (21) 8C-4427 Latch Plunger (22) 6V-7646 Hard Washer (23) 3E-9865 Locknut (24) 4M-5282 Bolt

1. Install the firewall. Refer to Illustration 7

Modifications to the Fuel Lines

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Illustration 8	g01062026
Left side view of the engine (1) 0DE5289 Hose As (2) 8M-0506 Connector

1. Remove 0DE5289 Hose As (1). Discard 0DE5289 Hose As (1) .

2. Remove 8M-0506 Connector (2). Discard 8M-0506 Connector (2) .

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Illustration 9	g01062029
Location of the 0DE5833 Hose As (3) 4K-6297 Flared Elbow (4) 6V-5049 O-Ring Seal (5) 0DE5833 Hose As (6) 6D-4246 Clip (7) 9EL6383 Bracket (8) 8T-4122 Hard Washer (9) 5C-6266 Bolt (10) 8T-4896 Hard Washer (11) 4L-6454 Bolt

3. Install new 0DE5833 Hose As (5). Refer to Illustration 9.

4. Arm the fire suppression system (if equipped). Refer to the manufacturer's service information.