KENR8384 July 2010 Disassembly and Assembly 797F Off-Highway Truck Engine Supplement LAJ1-Up (Machine) SAFETY.CAT.COM
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KENR8384 July 2010
Disassembly and Assembly 797F Off-Highway Truck Engine Supplement LAJ1-Up (Machine)
SAFETY.CAT.COM
i03991620
Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warning explains the hazard and can be either written or pictorially presented. A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. You must not use this product in any manner different from that considered by this manual without first satisfying yourself that you have considered all safety rules and precautions applicable to the operation of the product in the location of use, including site-specific rules and precautions applicable to the worksite. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that you intend to use. The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Cat dealers have the most current information available.
When replacement parts are required for this product Caterpillar recommends using Cat replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death. In the United States, the maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair establishment or individual of the owner's choosing.
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Table of Contents Disassembly and Assembly Section Aftercooler Core - Remove and Install .................. 4 Air Compressor - Remove and Install .................. 8 Air Starting Motor - Remove and Install ............... 9 Alternator - Remove and Install ........................... 9 Battery - Remove and Install ............................... 10 Electronic Control Module (Front Engine) - Remove and Install ............................................................ 11 Engine and Torque Converter - Remove and Install ............................................................................. 12 Engine Oil Cooler - Remove and Install ............... 18 Engine Oil Filter and Oil Filter Base - Remove and Install ................................................................... 21 Engine Oil Pump - Remove and Install ................ 22 Expansion Tank - Remove and Install ................. 24 Fan - Remove and Install ..................................... 25 Piston Motor (Fan Drive) - Remove and Install ..... 28 Piston Motor (Fan Drive) - Disassemble ............... 29 Piston Motor (Fan Drive) - Assemble .................... 32 Fuel Filter (Primary) and Fuel Filter Base - Remove and Install ............................................................ 34 Fuel Filter (Secondary) and Fuel Filter Base Remove and Install ............................................. 35 Fuel Priming Pump - Remove and Install ............ 37 Modular Front End - Remove and Install .............. 38 Radiator - Disassemble ....................................... 43 Radiator - Assemble ............................................ 49 Refrigerant Condenser - Remove and Install ...... 54 Turbocharger - Remove and Install ..................... 55 Damper - Remove and Install ............................... 56 Water Pump (Engine) - Remove and Install ......... 57 Thermostatic Valve - Remove and Install ............. 58 Thermostatic Valve - Disassemble ....................... 59 Thermostatic Valve - Assemble ............................ 61
Index Section Index ..................................................................... 63
Accidental machine starting can cause injury or death to personnel working on the machine. To avoid accidental machine starting, turn the battery disconnect switch to the OFF position and remove the key. If the machine is not equipped with a battery disconnect switch, disconnect the battery cables from the battery and tape the battery clamps. Place a do not operate tag at the battery disconnect switch location to inform personnel that the machine is being worked on.
3 Engine Supplement Table of Contents
4 Engine Supplement Disassembly and Assembly Section
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Disassembly and Assembly Section i03879375
Aftercooler Core - Remove and Install SMCS Code: 1063-010-KO
Removal Procedure Table 1
Illustration 2
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Required Tools Tool
Part Number
A
-
B
138-7575
C
1U-9203
Part Description
Qty
Guide Stud M10 x 150 mm
2
Link Bracket
2
Lever Puller Hoist Gp
2
1. Remove two of bolts (1). Install Tooling (A). Remove the remaining bolts (1). Attach Tooling (B) and a suitable lifting device onto guard (2). The weight of guard (2) is approximately 36 kg (80 lb). Remove guard (2). Repeat this Step for the remaining guards (2).
Start By: a. Remove the ladder.
Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool. Illustration 3
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2. Remove brackets (3).
Illustration 1
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Illustration 4
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3. Use Tooling (B) and a suitable lifting device in order to remove bracket assembly (4) and bracket assembly (5). The weight of bracket assembly (4) and bracket assembly (5) is approximately 45 kg (100 lb).
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Illustration 5
5 Engine Supplement Disassembly and Assembly Section
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Illustration 8
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7. Disconnect hoses (10).
Illustration 6
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4. Disconnect hose (6) and hose (7).
Illustration 9
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8. Remove cover (11).
Illustration 7
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5. Remove clamps (8). Remove tube (9).
Illustration 10
6. Repeat Step 4 and Step 5 for the opposite side.
9. Remove clamps (12) and clamps (13). Disconnect hoses (14). Remove tubes (15).
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6 Engine Supplement Disassembly and Assembly Section
Illustration 11
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Illustration 14
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Illustration 15
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10. Remove bolts (16), cap (17), mount assembly (18), bolts (19), and stabilizer (20). Repeat this step for the opposite side.
Illustration 12
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NOTICE Do not attempt to remove the aftercooler assembly until both of the spacers are removed. 12. Remove bolts (22). Raise the aftercooler assembly slightly in order to remove spacer (23). Repeat this step for the opposite side.
Illustration 13
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11. Attach Tooling (B), Tooling (C), and a suitable lifting device onto aftercooler assembly (21). The weight of aftercooler assembly (21) is approximately 1370 kg (3020 lb).
Illustration 16
13. Remove aftercooler assembly (21).
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Illustration 17
7 Engine Supplement Disassembly and Assembly Section
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14. Position aftercooler assembly (21) onto suitable blocking.
Illustration 18
Illustration 20
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17. Use Tooling (B) and a suitable lifting device in order to turn over aftercooler assembly (21). The weight of aftercooler assembly (21) is approximately 1370 kg (3020 lb).
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15. Remove bolts (24) and plate (25). Remove bolts (26). Note: Note the location of the oversized washers for installation purposes.
Illustration 21
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18. Remove bolts (29), plate (30), bolts (31), plate (32), bolts (33), and plate (34). Note: Note the location of the oversized washers for installation purposes. 19. Remove bracket assembly (35).
Illustration 19
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16. Remove bolts (27) and plate (28). Note: Note the location of the oversized washers for installation purposes.
Illustration 22
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8 Engine Supplement Disassembly and Assembly Section
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20. Use Tooling (A) and a suitable lifting device in order to remove aftercooler (36). The weight of aftercooler (36) is approximately 418 kg (922 lb).
Illustration 24
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2. Disconnect hose assemblies (1). Illustration 23
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21. Remove bracket assembly (37) and plate (38). The weight of aftercooler (39) is approximately 418 kg (922 lb).
Installation Procedure 1. Install aftercooler (39) and aftercooler (36) in the reverse order. i03869430
Air Compressor - Remove and Install SMCS Code: 1803-010
Removal Procedure
Illustration 25
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3. Disconnect hose assembly (2), hose assembly (3), and hose assembly (4). 4. Attach a suitable lifting device onto air compressor (5). The weight of air compressor (5) is approximately 27 kg (60 lb).
Personal injury can result from removing hoses or fittings in a pressure system. Failure to relieve pressure can cause personal injury. Do not remove or disconnect hoses or fittings until all pressure in the air system has been relieved.
Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool. 1. Release the air system pressure. Refer to Operation and Maintenance Manual, “System Pressure - Release”.
Illustration 26
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5. Remove bolts (6). Remove air compressor (5).
Installation Procedure 1. Install air compressor (5) in the reverse order.
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9 Engine Supplement Disassembly and Assembly Section i03872015
Air Starting Motor - Remove and Install SMCS Code: 1451-010
i03872050
Alternator - Remove and Install SMCS Code: 1405-010
Removal Procedure
Removal Procedure
Personal injury can result from removing hoses or fittings in a pressure system. Failure to relieve pressure can cause personal injury. Do not remove or disconnect hoses or fittings until all pressure in the air system has been relieved.
Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool. 1. Turn the power disconnect switch to the OFF position.
Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool. 1. Release the air system pressure. Refer to Operation and Maintenance Manual, “System Pressure Release”. Illustration 28
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2. Remove clips (1). Remove guard (2) and guard (3).
Illustration 27
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2. Disconnect hose assembly (1) and hose assembly (2). 3. Attach a suitable lifting device onto air starting motor (3). The weight of air starting motor (3) is approximately 34 kg (75 lb). Remove bolts (4) and the spacers. Remove air starting motor (3).
Installation Procedure 1. Install air starting motor (3) in the reverse order.
Illustration 29
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3. Remove belt (4). Disconnect cable assemblies (5).
10 Engine Supplement Disassembly and Assembly Section
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Battery - Remove and Install SMCS Code: 1401-010
Removal Procedure
Failure to properly service the batteries may cause personal injury.
Illustration 30
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4. Remove bolts (6), guard assembly (7), bolts (8), and alternator (9).
Installation Procedure 1. Install alternator (9) in the reverse order.
Prevent sparks near the batteries. They could cause vapors to explode. Do not allow the jump start cable ends to contact each other or the machine. Do not smoke when checking battery electrolyte levels. Electrolyte is an acid and can cause personal injury if it contacts the skin or eyes. Always wear eye protection when starting a machine with jump start cables. Improper jump start procedures can cause an explosion resulting in personal injury. When using jumper cables, always connect the positive (+) jumper cable to the positive (+) battery terminal first. Next, connect the negative (-) jumper cable to the frame away from the batteries. Follow the procedure in the Operation and Maintenance Manual. Jump start only with an energy source of the same voltage as the stalled machine. Turn off all lights and accessories on the stalled machine. Otherwise, they will operate when the energy source is connected. 1. Turn the power disconnect switch to the OFF position.
Illustration 31
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11 Engine Supplement Disassembly and Assembly Section
2. Remove bolts (1). Remove bracket (2). Remove cable assembly (3).
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Electronic Control Module (Front Engine) - Remove and Install SMCS Code: 1900-010
Removal Procedure
Illustration 32
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3. Disconnect cable assemblies (4).
Illustration 33
1. Turn the power disconnect switch to the OFF position.
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4. Use a suitable lifting device in order to remove battery (5). The weight of battery (5) is approximately 59 kg (130 lb). Repeat this step for the remaining battery.
Installation Procedure 1. Install battery (5) in the reverse order.
Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.
Illustration 34
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2. Remove bolts (3) in order to disconnect harness assembly (4). 3. Remove bolts (1). Remove electronic control (2).
Installation Procedure 1. Install electronic control (2) in the reverse order. a. Tighten bolts (1) to a torque of 7 ± 0.5 mm (0.276 ± 0.020 inch)
12 Engine Supplement Disassembly and Assembly Section
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Engine and Torque Converter Remove and Install SMCS Code: 1003-010
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin.
Removal Procedure
At operating temperature, the engine coolant is hot and under pressure.
Table 2
Steam can cause personal injury. Required Tools
Tool
Part Number
Part Description
Qty
9U-7489
Lift Stand
1
9U-7357
Tube As
1
9U-7405
Tube As
1
B
1U-9202
Lever Puller Hoist
1
C
138-7575
Link Bracket
1
D
309-2793
Load Leveler
1
E
323-1146
Lifting Gp
1
A
Start By: a. Remove the modular front end. b. Remove the gear pump (torque converter and transmission). c. Remove the pump drive shaft.
Check the coolant level only after the engine has been stopped and the cooling system pressure cap is cool enough to touch with your bare hand. Remove the cooling system pressure cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.
In order to prevent possible personal injury, release the air pressure from the air tank before disconnecting any components of the air system. 1. Turn the fuel supply to the OFF position. 2. Turn the power disconnect switch to the OFF position.
Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.
Illustration 35
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3. Use Tooling (A) in order to support frame assembly (1).
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Illustration 36
13 Engine Supplement Disassembly and Assembly Section
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4. Disconnect cable assembly (2). Remove clips (3).
Illustration 37
Illustration 39
7. Disconnect hose assemblies (6), hose assembly (7), and hose assembly (8).
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Illustration 40
5. Disconnect hose assembly (4).
Illustration 38
6. Disconnect hose assembly (5).
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8. Disconnect harness assembly (9) and harness assemblies (10).
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Illustration 41
9. Disconnect hose assemblies (11).
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14 Engine Supplement Disassembly and Assembly Section
Illustration 42
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10. Disconnect harness assembly (12) and remove the connecting hardware.
Illustration 43
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11. Disconnect hose assembly (13). Disconnect cable assembly (14).
Illustration 44
12. Disconnect hose assemblies (15).
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Illustration 45
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13. Remove clips (16). Disconnect hose (17).
Illustration 46
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14. Disconnect cable assembly (18) and remove the connecting hardware.
Illustration 47
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15. Remove bolts (19), plate (20), and mount assembly (21). Repeat this step for the opposite side.
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Illustration 48
15 Engine Supplement Disassembly and Assembly Section
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Illustration 51
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Illustration 52
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16. Remove tube assembly (22). Disconnect hose assembly (23). Remove tube assembly (24).
Illustration 49
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17. Remove tube assembly (25). Remove elbow (26). Disconnect hose assembly (27).
Illustration 50
18. Disconnect hose assembly (25).
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19. Attach a suitable lifting device onto exhaust tubes (26). The weight of exhaust tubes (26) is approximately 143 kg (315 lb). Disconnect bellows (27). Disconnect clamps (28). Remove exhaust tubes (26).
Illustration 53
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20. Attach a suitable lifting device onto cross tube (29). The weight of cross tube (29) is approximately 218 kg (481 lb). 21. Disconnect hoses (32) and hose assembly (33). 22. Remove bolts (30). Repeat this step for the opposite end of the cross tube.
16 Engine Supplement Disassembly and Assembly Section
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23. Remove shims (31). 24. Remove cross tube (29).
Illustration 57
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28. Disconnect hose assembly (37). Illustration 54
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25. Remove step assembly (34).
Illustration 58
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29. Disconnect hose assemblies (38). Illustration 55
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26. Attach Tooling (A) and Tooling (B) onto engine and torque converter (35). The weight of engine and torque converter (35) is approximately 18144 kg (40000 lb).
Illustration 59
30. Disconnect hose assembly (39).
Illustration 56
27. Disconnect hose assembly (36).
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Illustration 60
17 Engine Supplement Disassembly and Assembly Section
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31. Disconnect hose assemblies (40) and hose assembly (41).
Illustration 61
Illustration 63
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34. Attach a suitable lifting device onto drive shaft (44). The weight of drive shaft (44) is approximately 36 kg (80 lb). Remove bolts (45) in order to disconnect drive shaft (44).
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32. Disconnect hose assembly (42).
Illustration 64
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35. Remove drive shaft guard (46).
Illustration 62
33. Remove drive shaft guard assembly (43).
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Illustration 65
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36. Attach a suitable lifting device onto drive shaft (47). The weight of drive shaft (47) is approximately 295 kg (650 lb).
18 Engine Supplement Disassembly and Assembly Section
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i03949329
Engine Oil Cooler - Remove and Install SMCS Code: 1378-010
Removal Procedure
Hot oil and components can cause personal injury. Illustration 66
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37. Remove bolts (48). Use a suitable prybar in order to retract drive shaft (47).
Do not allow hot oil or components to contact the skin. Be sure that the engine and components are cool enough to touch with your bare hand prior to performing any service work.
At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Illustration 67
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38. Remove bolt (49), washer (50), and mount (51).Repeat this step for the remaining front engine mount.
Remove the fill cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury. 1. Release the system pressure. Refer to Operation and Maintenance Manual, “System Pressure Release”. 2. Drain the coolant into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant (ELC) - Change”.
Illustration 68
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39. Remove Engine and torque converter (35).
Installation procedure 1. Install the engine and torque converter (35) in the reverse order.
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Illustration 69
19 Engine Supplement Disassembly and Assembly Section
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Illustration 72
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Illustration 73
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3. Disconnect harness assemblies (1). Disconnect hose assembly (2). Disconnect hose (3).
Illustration 70
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Illustration 71
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4. Attach a suitable lifting device onto air inlet manifold (4). The weight of air inlet manifold (4) is approximately 79 kg (175 lb). Remove bolts (5). Remove air inlet manifold (4). Note: Inspect the gaskets for wear and damage. Replace the gaskets, if necessary.
5. Remove plug (6) in order to drain tube assembly (7). Remove tube assembly (7).
Illustration 74
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6. Attach a suitable lifting device onto tube assembly (8). The weight of tube assembly (8 ) is approximately 41 kg (90 lb). Remove bolts (9).
20 Engine Supplement Disassembly and Assembly Section
Illustration 75
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Illustration 78
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Illustration 79
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7. Disconnect tube (10). Remove tube assembly (8).
Illustration 76
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Illustration 77
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9. Disconnect hose assembly (15). Remove bolts (16). Remove elbow (17).
Illustration 80
8. Disconnect hose assemblies (11). Remove bolts (12) and bolts (13). Remove elbow (14).
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10. Attach a suitable lifting device onto oil coolers (18). The weight of oil coolers (18) is approximately 76 kg (168 lb).
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21 Engine Supplement Disassembly and Assembly Section
Hot oil and components can cause personal injury. Do not allow hot oil or components to contact the skin. Be sure that the engine and components are cool enough to touch with your bare hand prior to performing any service work.
Illustration 81
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Illustration 82
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1. Drain the engine oil filters into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Engine Oil and Filter Change”.
Illustration 83
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SMCS Code: 1306-010; 1308-010
Illustration 84
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Removal Procedure
2. Remove cover (1) in order to remove oil filter element (2). Repeat this step for the remaining oil filter and base.
11. Remove bolts (19) and the washers. Remove bolts (20) and the washers. 12. Remove oil coolers (18).
Installation Procedure 1. Install oil cooler (18) in the reverse order. i03880974
Engine Oil Filter and Oil Filter Base - Remove and Install
Note: The oil filter elements can be replaced without removing the entire oil filter and base assembly from the machine.
22 Engine Supplement Disassembly and Assembly Section
Illustration 85
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3. Disconnect tube assembly (3) and tube assembly (4).
Illustration 88
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6. Attach Tooling (A) and a suitable lifting device onto oil filter and base (7). The weight of oil filter and base (7) is approximately 73 kg (160 lb). 7. Remove bolts (8).
Illustration 86
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4. Disconnect hose assembly (5). Illustration 89
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8. Remove bolts (9). Remove oil filter and base (7).
Installation Procedure 1. Install oil filter and base (7) in the reverse order. i03952132
Engine Oil Pump - Remove and Install Illustration 87
5. Disconnect harness assembly (6).
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SMCS Code: 1304-010
Removal Procedure Start By: a. Remove the alternator.
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23 Engine Supplement Disassembly and Assembly Section
Hot oil and components can cause personal injury. Do not allow hot oil or components to contact the skin. Be sure that the engine and components are cool enough to touch with your bare hand prior to performing any service work.
At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury.
Illustration 91
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5. Remove hose assemblies (5), tube assembly (6), and tube assembly (7).
Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury. 1. Release the system pressure. Refer to Operation and Maintenance Manual, “System Pressure Release”. 2. Drain the coolant into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant (ELC) - Change”.
Illustration 92
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6. Disconnect hose assembly (6). Remove bolts (7), bolts (8), nut (9), and bolts (10). Remove elbow (11).
3. Drain the engine oil into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Engine Oil and Filter Change”.
Illustration 93
7. Remove bolts (12) and elbow (13).
Illustration 90
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4. Remove bolts (1), nuts (2), adapter (3), and elbow (4).
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24 Engine Supplement Disassembly and Assembly Section
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At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure. g02141303
Illustration 94
8. Attach a suitable lifting device onto oil pump (14). The weight of oil pump (3) is approximately 73 kg (160 lb). 9. Remove bolts (15). Remove oil pump (14).
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Illustration 95
10. Remove O-ring seals (16).
Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury. 1. Drain the coolant below the level of the tank into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant (ELC) - Change”.
Illustration 96
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2. Remove cover (1).
Installation Procedure 1. Install oil pump (14) in the reverse order. i03880924
Expansion Tank - Remove and Install SMCS Code: 1354-010
Removal Procedure Illustration 97
Table 3
Required Tools Tool
Part Number
A
138-7575
Part Description Link Bracket
Qty 2
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3. Disconnect harness assembly (2). Position harness assembly (2) out of the way.
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25 Engine Supplement Disassembly and Assembly Section i03881662
Fan - Remove and Install SMCS Code: 1356-010
Removal Procedure Table 4
Required Tools
Illustration 98
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4. Disconnect hose assemblies (3), hose assembly (4), and tube assembly (5).
Tool
Part Number
Part Description
A
-
Guide Stud M10 x 150 mm
2
B
226-2380
Lifting Bracket
1
C
138-7574
Link Bracket
1
D
189-0410
Shackle
1
Qty
Start By: a. Remove the modular front end.
Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool. Illustration 99
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5. Attach Tooling (A) and a suitable lifting device onto expansion tank (6). The weight of expansion tank (6) is approximately 84 kg (185 lb).
At operating temperature, the engine coolant is hot and under pressure.
6. Remove bolts (7). Remove expansion tank (6).
Steam can cause personal injury.
Installation Procedure 1. Install expansion tank (6) in the reverse order.
Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.
26 Engine Supplement Disassembly and Assembly Section
Illustration 100
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1. Disconnect hoses (1) and hose (4). Remove tube (2) and tube (3).
Illustration 101
Illustration 103
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5. Disconnect hose (11) and hose (12). Disconnect support bracket (13). Remove tube (14). Remove clamps (15). Remove tube (16).
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Illustration 104
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6. Disconnect tube assembly (17). Remove clamps (18). Remove tube assembly (17).
Illustration 102
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2. Disconnect hose (5). Remove clamps (6). Attach a suitable lifting device onto thermostatic valve (7). The weight of thermostatic valve (7) is approximately 104 kg (230 lb). 3. Disconnect harness assemblies (8). Disconnect bracket (9). Remove bolts (10). 4. Remove thermostatic valve (7).
Illustration 105
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27 Engine Supplement Disassembly and Assembly Section
7. Remove two of bolts (19). Install Tooling (A). Remove the remaining bolts (19). Use two people in order to remove guard assembly (20) and shield assembly (21). The weight of guard assembly (20) is approximately 41 kg (90 lb). The weight of shield assembly (21) is approximately 16 kg (35 lb). Repeat this step for the remaining guard assemblies and shield assemblies. 8. Remove upper cover (22).
Illustration 109
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10. Attach Tooling (B), Tooling (C), Tooling (D), and a suitable lifting device onto fan assembly (25). The weight of fan assembly (25) is approximately 703 kg (1550 lb). 11. Remove bolts (26).
Illustration 106
Illustration 107
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Illustration 110
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Illustration 111
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9. Disconnect harness assembly (23) and remove the connecting hardware. Remove lower cover (24).
12. Position fan assembly (25) onto suitable blocking. Attach a suitable lifting device onto fan spider(27). The weight of fan spider (27) is approximately 259 kg (570 lb). Remove bolts (28). Remove fan spider (27). Illustration 108
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28 Engine Supplement Disassembly and Assembly Section
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13. In order to prevent the deformation of the fan blades, position the fan spider flat on suitable blocking. Note: Improper handling or damage to the fan spider may affect the balance of the fan. This may result in a catastrophic failure during operation.
Installation Procedure 1. Install fan assembly (26) in the reverse order. i03881624
Piston Motor (Fan Drive) Remove and Install
Illustration 112
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1. Use Tooling (A) and Tooling (B) in order to remove bolt (1). Remove retainer (2) and shims (3).
SMCS Code: 1386-010-QP; 5058-010-FM
Removal Procedure Table 5
Required Tools Part Number
Tool A B
C
D
Part Description
Qty
1U-6221
Hydraulic Torque Wrench Gp
1
1U-6222
Wrench Link
1
6V-8154
Bolt
2
8T-0162
Bolt
2
6F-7831
Washer
1
126-7183
Crossblock
1
126-7182
Nut
1
6V-2360
Hard Washer
1
138-7575
Link Bracket
2
Illustration 113
g02129188
2. Use Tooling (C) in order to separate fan hub (4) from the piston motor.
Start By: a. Remove the fan.
Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.
Illustration 114
g02129193
3. Use Tooling (D) and a suitable lifting device in order to remove fan hub (4). The weight of fan hub (4) is approximately 50 kg (110 lb).
KENR8384
29 Engine Supplement Disassembly and Assembly Section i03881494
Piston Motor (Fan Drive) Disassemble SMCS Code: 1386-015-QP; 5058-015-FM
Disassembly Procedure Table 6
Required Tools Part Number
Tool Illustration 115
g02129223
5. Remove hose assemblies (7). Remove bolts (8). Use a suitable lifting device in order to remove piston motor (5). The weight of piston motor (5) is approximately 163 kg (360 lb).
Installation Procedure
Threaded Rod(1)
1
9X-8267
Hard Washer
1
6V-8225
Nut
1
B
7X-2535
Bolt (M6 x 1)
1
C
1U-8758
Retaining Ring Pliers
1
D
1P-1863
Retaining Ring Pliers
1
1U-9895
Crossblock
1
8B-7550
Puller Leg
2
5S-0003
Nut
2
3H-0465
Push-Puller Plate
4
4C-5669
Threaded Adapter
2
9U-7692
Threaded Rod (M16 x 2)(2)
2
1P-1861
Retaining Ring Pliers
1
E
1. Install piston motor (5) in the reverse order.
F (1) (2)
Qty
1U-6340 A
4. Use a suitable lifting device in order to turn over piston motor (5) and support assembly (6). The weight of piston motor (5) and support assembly (6) is approximately 336 kg (740 lb).
Part Description
Cut to length of 175 mm (7.0 inch) Cut to length of 127 mm (5.0 inch)
Start By: a. Remove the piston motor (fan drive).
Illustration 116
g01864093
30 Engine Supplement Disassembly and Assembly Section
KENR8384
Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. 1. Remove bolts (1) and head (2) from housing (3). Illustration 119
g01892813
5. Use Tooling (B) to remove key (7).
Illustration 117
g01892334
2. Remove port plate (4) from head (2). Illustration 120
g01892714
6. Use Tooling (C) to remove retaining ring (8). 7. Use Tooling (D) to remove retaining ring (9). 8. Remove cover (10) and the O-ring seal.
Illustration 118
g01864133
3. Remove O-ring seal (5). 4. Install Tooling (A). Note: Tooling (A) will keep the rotating group together while the rotating group is being removed from the pump housing.
Illustration 121
9. Remove seal (11) from cover (10).
g01892735
KENR8384
Illustration 122
31 Engine Supplement Disassembly and Assembly Section
g01910157
10. Use Tooling (E) in order to remove the rotating group from the pump housing.
Illustration 123
Illustration 125
g01892773
14. Use Tooling (F) to remove retaining ring (18) and shim (19).
g01892737
11. Remove Tooling (A) and barrel (6) from the rotating group. 12. Remove spring (12) and spacer (13) from barrel (6).
Illustration 126
g01892634
15. Remove O-ring seal (23). 16. Place shaft assembly (20) into a suitable press.
Illustration 124
g01892753
13. Remove bolts (14), pin (15), pistons (16), and plate (17).
17. Remove bearing (21), ring bearing (22), shims (24), bearing assembly (25) from shaft assembly (20). Note: The bearing cone will be destroyed when the bearing cup is separated from shaft assembly (20). 18. Remove slipper (26) and spring (27).
32 Engine Supplement Disassembly and Assembly Section
KENR8384
i03881501
2. Install bearing assembly(25).
Piston Motor (Fan Drive) Assemble
3. Install spring (27) and slipper (26) into shaft assembly (20).
SMCS Code: 1386-016-QP; 5058-016-FM
Note: Lubricate the face of slippers (26) with clean hydraulic oil.
Assembly Procedure Table 7
Required Tools Tool
Qty
Threaded Rod(1)
1
9X-8267
Hard Washer
1
6V-8225
Nut
1
C
1U-8758
Retaining Ring Pliers
1
D
1P-1863
Retaining Ring Pliers As
1
1U-9895
Crossblock
1
8B-7550
Puller Leg
2
5S-0003
Nut
2
3H-0465
Push-Puller Plate
4
4C-5669
Threaded Adapter
1
5P-8249
Hard Washer
1
9U-7692
Threaded Rod (M16 x 2)(2)
2
Illustration 128
1P-1861
Retaining Ring Pliers As
1
6. Use Tooling (F) to install retaining ring (18) and spacer (19).
E
F (2)
Part Description
1U-6340 A
(1)
Part Number
4. Install shims (24), ring bearing (22), and bearing (21) onto shaft assembly (20). Adjust shim kit (24) in order to obtain 135 ± 0.05 mm (5.3 ± 0.002 inch) for Dimension (A). Dimension (A) is taken from the top of retaining ring (8) to the base of shaft assembly (20).
Cut to length of 175 mm (7.0 inch) Cut to length of 127 mm (5.0 inch)
5. Install O-ring seal (23).
Illustration 129
g01892773
g01892753
7. Install pistons (16), pin (15), plate (17), and bolts (14).
Illustration 127
g01893355
1. Raise the temperature of bearing cone and bearing cup (25) and lower the temperature of shaft assembly (20).
KENR8384
33 Engine Supplement Disassembly and Assembly Section 12. Use Tooling (C) to install retaining ring (8). 13. Use Tooling (E) to pull the rotating group against retaining ring (8).
Illustration 130
g01892737
8. Install spacer (13) and spring (12) in barrel (6). Illustration 133
g01892735
14. Install seal (11) in cover (10).
Illustration 131
g01894534
9. Assemble barrel (6) to the rotating group. Install Tooling (A) to barrel (6). Note: Tooling (A) will keep the rotating group together while the rotating group is being installed into the pump housing.
Illustration 134
g01910641
15. Install cover (10). 16. Use Tooling (D) to install retaining ring (9).
Illustration 132
g01893653
10. Lower the temperature of the rotating group and raise the temperature of the pump housing. 11. Install the rotating group into the pump housing.
Illustration 135
17. Install key (7).
g01893676
34 Engine Supplement Disassembly and Assembly Section
KENR8384
Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.
Illustration 136
g01864133
18. Install O-ring (5). Remove Tooling (A) from barrel (6) .
20. Carefully install head (2) and bolts (1) to pump housing (3). Tighten bolts (4) to a torque of 250 N·m (185.0 lb ft). End By: a. Install the piston motor (fan drive).
Note: Lubricate the face of barrel (6) with clean hydraulic oil.
i03880805
Fuel Filter (Primary) and Fuel Filter Base - Remove and Install SMCS Code: 1260-010; 1262-010
Removal Procedure Table 8
Required Tools
Illustration 137
g01892334
19. Install port plate (4) onto head (2).
Tool
Part Number
Part Description
Qty
A
185-3630
Strap Wrench As
1
Note: The fuel filter elements can be serviced or replaced without removing the entire filter and base assembly from the machine.
Personal injury or death can result from a fire. 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. Illustration 138
g01864093
Turn the disconnect switch OFF or disconnect the battery when changing fuel filters. 1. Turn the power disconnect switch to the OFF position. 2. Turn fuel supply to the OFF position.
KENR8384
Illustration 139
35 Engine Supplement Disassembly and Assembly Section
g02126770
Illustration 142
g02126774
Illustration 143
g02126779
3. Disconnect sensor (1).
Illustration 140
g02126769
4. Drain filter assemblies (2) into a suitable container for storage or disposal. Disconnect hose assembly (3). 5. Use Tooling (A) in order to remove filter assembly (2).
7. Remove bolts (6). Remove filter base (7). Remove O-ring seals (8). Repeat this step for the remaining filter base.
Installation Procedure 1. Install filter base assembly (5) and filter assemblies (2) in the reverse order. i03880753
Fuel Filter (Secondary) and Fuel Filter Base - Remove and Install SMCS Code: 1261-010-SE; 1262-010
Removal Procedure Table 9 Illustration 141
Required Tools
g02126771
6. Remove bolts (4). Remove filter base assembly (5).
Tool
Part Number
A
185-3630
Part Description Strap Wrench
Qty 1
36 Engine Supplement Disassembly and Assembly Section
KENR8384
Note: The fuel filter elements can be replaced without removing the entire fuel filter and base assembly from the machine.
Personal injury or death can result from a fire. 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.
Illustration 145
g02126712
4. Disconnect hose assembly (3), harness assembly (4), and tube assembly (5). Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool. 1. Turn the power disconnect switch to the OFF position. 2. Turn the fuel supply to the OFF position.
Illustration 146
g02126714
5. Use Tooling (A) in order to remove fuel filters (6).
Illustration 144
g02126710
3. Disconnect harness assembly (1). Disconnect tube assembly (2).
Illustration 147
g02126718
6. Remove bolts (7). Remove filter bases (8).
KENR8384
Illustration 148
37 Engine Supplement Disassembly and Assembly Section
g02126753
7. Remove nuts (9). Remove filter base (10) and base (11).
Illustration 151
g02126756
9. Remove bolts (14) and filter base (15). Remove O-ring seals (16). Repeat this step for the remaining filter bases.
Installation Procedure 1. Install fuel filter bases (8) and fuel filters (6) in the reverse order. i03655253
Fuel Priming Pump - Remove and Install SMCS Code: 1258-010 Illustration 149
g02126754
8. Remove O-ring seals (12) from base (11). Remove O-ring seals (13) from filter base (10).
Removal Procedure 1. Turn the power disconnect switch to the OFF position. 2. Turn the fuel supply to the OFF position.
Illustration 150
g02126755
Illustration 152
g01961468
3. Disconnect hoses (1). Disconnect harness assemblies (2). Remove bolts (3). 4. Remove fuel priming pump (4).
38 Engine Supplement Disassembly and Assembly Section
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Installation Procedure 1. Install fuel priming pump (4) in the reverse order. i03881432
Modular Front End - Remove and Install SMCS Code: 1353-010; 1814-010
Removal Procedure
1. Install the truck body retaining cables. Operation and Maintenance Manual, “Cable (Truck Body Retaining)”. 2. Release the system pressure. Refer to Operation and Maintenance Manual, “System Pressure Release”.
Table 10
Required Tools Part Description
The space between the body and the frame becomes a zero clearance area when the body is lowered. Failure to install the retaining cable can result in injury or death to personnel working in this area.
Tool
Part Number
A
163-6455
Link Bracket
2
B
189-0410
Shackle As
2
C
1U-9203
Lever Puller Hoist
1
Qty
3. Drain the coolant into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant (ELC) - Change”.
Start By: a. Remove the bottom guards. b. Remove the front hood.
Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.
Illustration 153
g02127454
4. Disconnect hose assemblies (1).
At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.
Illustration 154
5. Disconnect hoses (2).
g02130417
KENR8384
Illustration 155
39 Engine Supplement Disassembly and Assembly Section
g02130421
6. Disconnect hose (3). Disconnect hose assembly (4).
Illustration 156
g02130432
8. Disconnect hose assemblies (6).
g02130305
9. Disconnect hoses (7).
Illustration 159
g02131093
10. Disconnect harness assembly (8). Disconnect hose assembly (9).
7. Disconnect hose assembly (5).
Illustration 157
Illustration 158
g02130457
Illustration 160
g02131173
11. Disconnect hose assembly (10) and remove the connecting hardware.
40 Engine Supplement Disassembly and Assembly Section
Illustration 161
KENR8384
g02131233
12. Disconnect brackets (11).
Illustration 162
Illustration 164
15. Disconnect rod (14). Repeat this step for the opposite side.
g02131259
Illustration 165
13. Disconnect hose (12).
Illustration 163
g02131386
16. Disconnect hoses (15).
g02131261
Illustration 166
14. Disconnect hose (13).
g02131266
17. Disconnect harness assemblies (16).
g02131454
KENR8384
Illustration 167
41 Engine Supplement Disassembly and Assembly Section
g02131457
18. Remove clamps (17). Disconnect hose (18). Disconnect harness assemblies (19).
Illustration 168
g02131538
g02131474
21. Remove clamps (24).
Illustration 171
g02131701
22. Remove brace (25).
19. Remove mud flaps (20).
Illustration 169
Illustration 170
g02131573
20. Remove bracket assembly (21) and bracket assembly (22). Loosen clamps (23).
Illustration 172
g02132494
23. Remove elbow (26). Use two people in order to remove tube assembly (27). The weight of tube assembly (27) is approximately 28 kg (62 lb).
42 Engine Supplement Disassembly and Assembly Section
Illustration 173
KENR8384
g02132555
24. Remove elbow (28). Use two people in order to remove tube assembly (29). The weight of tube assembly (29) is approximately 28 kg (62 lb). 25. Repeat Step 19 through Step 24 for the opposite side.
Illustration 176
26. Attach Tooling (A), Tooling (B), Tooling (C), and a suitable lifting device onto front module (30). The weight of front module (30) is approximately 6545 kg (14430 lb).
Illustration 177 Illustration 174
g02132593
Illustration 175
g02136554
g02136593
g02131281
27. Disconnect link (31).
Illustration 178
g02136601
28. Remove bolts (32). 29. Repeat Step 27 through Step 28 for the opposite side.
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43 Engine Supplement Disassembly and Assembly Section
Installation Procedure 1. Install front module (30) in the reverse order. i03903152
Radiator - Disassemble SMCS Code: 1353-015
Disassembly Procedure Table 11 Illustration 179
Required Tools
g02136618
Tool
Part Number
A
138-7573
Link Bracket
3
B
4Q-5222
Breaker Tool
1
C
4Q-5144
Installer Tool
1
D
1U-9202
Lever Puller Hoist Gp
1
E
163-6455
Link Bracket
2
30. Remove bolts (33).
Part Description
Qty
Start By: a. Remove the fan. b. Remove the aftercoolers. Illustration 180
g02136676
31. Remove bolts (34).
Illustration 181
Illustration 182
g02145432
Illustration 183
g02148134
g02136694
32. Remove front module (30).
44 Engine Supplement Disassembly and Assembly Section
KENR8384
1. Attach Tooling (A) and a suitable lifting device onto guard assembly (1). The weight of guard assembly (1) is approximately 82 kg (180 lb). 2. Remove bolts (2).
Illustration 187
g02148153
5. Remove bolts (5). Remove condenser (6).
Illustration 184
g02148052
Illustration 188
Illustration 185
g02148060
g02148180
6. Remove bolts (7). Remove bracket assembly (8).
3. Disconnect harness assembly (3) and remove the connecting hardware. Remove clips (4).
Illustration 189
Illustration 186
4. Remove guard assembly (1).
g02148776
g02148822
7. Remove support (9). Remove tension bars (10) from both sides of the radiator.
KENR8384
Illustration 190
45 Engine Supplement Disassembly and Assembly Section
g02148210
Illustration 193
g02148870
10. Remove bolts (15), shim (16), and tension bar (17).
Illustration 191
g02148211
8. Use Tooling (B) in order to loosen the upper radiator cores (11) at the top and the bottom. Use Tooling (C) in order to remove the upper radiator cores (11). Remove the felt liner from the radiator tubes. Repeat this step for the remaining radiator cores.
Illustration 192
g02148849
9. Remove bolts (12), shim (13), and tension bar (14).
Illustration 194
g02148399
11. Disconnect harness assembly (18) and remove the connecting hardware. Remove tube assembly (19).
Illustration 195
g02148437
46 Engine Supplement Disassembly and Assembly Section
Illustration 196
KENR8384
g02148828
Illustration 199
g02148568
Illustration 200
g02148571
12. Attach a suitable lifting device onto ladder assembly (20). The weight of ladder assembly (20) is approximately 41 kg (90 lb). Remove bolts (21), bolt (22), and bolts (23). Remove ladder assembly (20).
15. Remove bolts (28) and bolts (29). Remove cowl assembly (27).
Illustration 197
g02148440
13. Attach a suitable lifting device onto hand rail (24). Disconnect bracket (25) and remove bolts (26). Remove hand rail (24).
Illustration 201
g02148588
16. Attach Tooling (E) and a suitable lifting device onto top tank (30). The weight of top tank (30) is approximately 205 kg (452 lb).
Illustration 198
g02148558
14. Attach Tooling (A), Tooling (D), and a suitable lifting device onto cowl assembly (27). The weight of cowl assembly (27) is approximately 522 kg (1150 lb).
KENR8384
Illustration 202
47 Engine Supplement Disassembly and Assembly Section
g02148597
17. Remove bolts (31). Repeat this step for the opposite side.
Illustration 205
g02148615
20. Attach a suitable lifting device onto center tank (33). The weight of center tank (33) is approximately 73 kg (160 lb). Remove bolts (34) from both ends of the center tank. 21. Remove center tank (33).
Illustration 203
g02148605
18. Remove bolts (32). Repeat this step for the opposite side. Illustration 206
g02148623
22. Attach a suitable lifting device onto bottom tank (35). The weight of bottom tank (35) is approximately 227 kg (500 lb).
Illustration 204
g02148620
19. Remove top tank (30). Illustration 207
g02148647
48 Engine Supplement Disassembly and Assembly Section
Illustration 208
KENR8384
g02148703
Illustration 211
g02148705
Illustration 212
g02148222
23. Remove bolts (36) and bolts (37) from both sides of the bottom tank.
Illustration 209
g02148704
24. Remove bottom tank (35).
26. Attach Tooling (A) and a suitable lifting device onto channel assembly (39). The weight of channel assembly (39) is approximately 169 kg (373 lb). 27. Remove bolts (40). Remove channel assembly (39). 28. Repeat Step 26 through Step 27 for the remaining channel assembly.
Illustration 210
g02149071
Typical Example
25. Remove seals (38) from the bottom tank, the center tank, and the top tank. Note: Seals (38) are not reusable. Discard the seals.
KENR8384
49 Engine Supplement Disassembly and Assembly Section i03903153
Radiator - Assemble
2. Install bolts (40). 3. Repeat Step 1 through Step 2 for the remaining channel assembly.
SMCS Code: 1353-016
Assembly Procedure Table 12
Required Tools Tool
Part Number
A
138-7573
Link Bracket
4
C
4Q-5144
Installer Tool
1
D
1U-9202
Lever Puller Hoist Gp
1
E
163-6455
Link Bracket
2
342-2335
Brush
1
342-2346
Brush
1
342-2348
Brush
1
342-2349
Oil
1
342-2334
Installer
1
F
G
Part Description
Qty
Illustration 215
g02149071
Typical Example
Illustration 216
g02020717
Typical Example
Illustration 213
g02148705
4. Use a suitable plate and a soft mallet in order to install new seals (38). Install new seals (38) onto the bottom tank, the center tank, and the top tank. 5. Use Tooling (F) to clean seals (38). 6. Inspect seals (38) after the installation. The seals must be flush with the tank and flat across the top in order to be correctly installed.
Illustration 214
g02148222
1. Use Tooling (A) and a suitable lifting device in order to install channel assembly (39). The weight of channel assembly (39) is approximately 169 kg (373 lb).
50 Engine Supplement Disassembly and Assembly Section
Illustration 217
KENR8384
g02148623
7. Use a suitable lifting device in order to install bottom tank (35). The weight of bottom tank (35) is approximately 227 kg (500 lb).
Illustration 220
g02148615
9. Use a suitable lifting device in order to install center tank (33). The weight of center tank (33) is approximately 73 kg (160 lb). 10. Install bolts (34) onto both ends of the center tank.
Illustration 218
g02148647
Illustration 221
g02148588
11. Use Tooling (E) and a suitable lifting device in order to install top tank (30). The weight of top tank (30) is approximately 205 kg (452 lb).
Illustration 219
g02148703
8. Install bolts (37) and bolts (36) onto both sides of the bottom tank.
Illustration 222
g02148605
12. Install bolts (32). Repeat this step for the opposite side.
KENR8384
Illustration 223
51 Engine Supplement Disassembly and Assembly Section
g02148597
13. Install bolts (31). Repeat this step for the opposite side.
Illustration 224
g02148558
14. Use Tooling (A), Tooling (D), and a suitable lifting device in order to install cowl assembly (27). The weight of cowl assembly (27) is approximately 522 kg (1150 lb).
Illustration 226
15. Install bolts (29) and bolts (28).
Illustration 227
g02148571
g02148440
16. Use a suitable lifting device in order to install hand rail (24). Install bolts (26). Connect bracket (25).
Illustration 228
Illustration 225
g02148568
g02148437
52 Engine Supplement Disassembly and Assembly Section
Illustration 229
KENR8384
g02148828
17. Use a suitable lifting device in order to install ladder assembly (20). The weight of ladder assembly (20) is approximately 41 kg (90 lb). Install bolts (23), bolt (22), and bolts (21).
Illustration 232
g02148849
20. Install tension bar (14), shim (13), and bolts (12).
Illustration 233
g02149120
Typical Example Illustration 230
g02148399
18. Install tube assembly (19). Connect harness assembly (18) and install the connecting hardware.
Illustration 234 Typical Example
Illustration 231
g02148870
19. Install tension bar (17), shim (16), and bolts (15).
g02149123
KENR8384
Illustration 235
53 Engine Supplement Disassembly and Assembly Section
g02149129
Typical Example
Illustration 238
g02148153
24. Install condenser (6). Install bolts (5).
21. Use Tooling (C) and Tooling (G) in order to install radiator cores (11). Install the felt liner between the first row and the second row of the radiator cores.
Illustration 239
Illustration 236
g02148822
22. Install tension bars (10) onto both sides of the radiator. Install support (9).
25. Use Tooling (A) and a suitable lifting device in order to position guard assembly (1) onto the radiator. Install bolts (2). Do not tighten bolts (2) at this time.
Illustration 240 Illustration 237
g02148180
23. Install bracket assembly (8). Install bolts (7).
g02145432
g02148052
54 Engine Supplement Disassembly and Assembly Section
KENR8384
i03903274
Refrigerant Condenser Remove and Install SMCS Code: 1805-010
Removal Procedure
Personal injury can result from contact with refrigerant. Illustration 241
g02148060
26. Install clips (4). Connect harness assembly (3) and install the connecting hardware.
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.
Illustration 242
g02149144
27. Tighten bolts (2) at both ends of guard assembly (1).
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. 1. Recover the air conditioner refrigerant from the air conditioner system. Refer to Service Manual, SENR5664, “Air Conditioning and Heating Systems with R-134a Refrigerant”. Refer to Special Publication, NEDG2500, “Air Conditioning Tools” for the correct procedure.
KENR8384
55 Engine Supplement Disassembly and Assembly Section
At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure.
Illustration 243
g02145481
Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.
2. Remove grill (1). 1. Release the system pressure. Refer to Operation and Maintenance Manual, “System Pressure Release”. 2. Drain the coolant into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant (ELC) - Change”.
Illustration 244
g02145489
3. Disconnect hose assembly (2) and hose assembly (3). Remove bolts (4). Remove refrigerant condenser (5).
Installation Procedure 1. Install refrigerant condenser (5) in the reverse order.
Illustration 245
g02155457
3. Open front hood assemblies (1).
i03937349
Turbocharger - Remove and Install SMCS Code: 1052-010
Removal Procedure
Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.
Illustration 246
g02155460
4. Use brace (2) in order to secure front hood assemblies (1) in the open position.
56 Engine Supplement Disassembly and Assembly Section
KENR8384
Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.
Illustration 247
g02155474
5. Attach a suitable lifting device onto turbocharger (3). The weight of turbocharger (3) is approximately 79 kg (175 lb). 6. Disconnect hoses (4), hose assemblies (5), hose assembly (6), and clamps (7).
Illustration 249
g02114221
1. Remove bolts (1). Remove guard assembly (2).
Illustration 248
g02155478
7. Disconnect hose assemblies (8). Remove bolts (9). Remove turbocharger (3). Remove the gasket from turbocharger (3).
Illustration 250
g02126660
Installation Procedure
2. Attach Tooling (A) and a suitable lifting device onto vibration damper (2). The weight of vibration damper (2) is approximately 139 kg (306 lb).
1. Install turbocharger (3) in reverse order.
3. Remove bolts (3). i03872297
Damper - Remove and Install SMCS Code: 1205-010
Removal Procedure Start By: a. Remove the bottom guards. Illustration 251
g02126666
KENR8384
57 Engine Supplement Disassembly and Assembly Section
4. Remove vibration damper (2).
Installation Procedure 1. Install vibration damper (2) in the reverse order. a. Tighten bolts (3) to a torque of 700 ± 50 N·m (516 ± 37 lb ft). Repeat this step in order to ensure that bolts (3) are tightened to a torque of 700 ± 50 N·m (516 ± 37 lb ft) equally. i03872289
Water Pump (Engine) - Remove and Install SMCS Code: 1361-010
Illustration 252
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2. Disconnect hose (1). Remove bolts (2). Disconnect harness assembly (3). Remove elbow (4).
Removal Procedure Start By: a. Remove the bottom guards.
Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool. Illustration 253
At operating temperature, the engine coolant is hot and under pressure.
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3. Disconnect hose (5). Remove bolts (6). Remove elbow (7).
Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury. 1. Drain the coolant into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant (ELC) - Change”.
Illustration 254
4. Remove O-ring seal (8).
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58 Engine Supplement Disassembly and Assembly Section
KENR8384
i03901169
Thermostatic Valve - Remove and Install SMCS Code: 1355-010
Removal Procedure
Illustration 255
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Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.
5. Disconnect hose assembly (9).
At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure.
Illustration 256
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6. Remove bolts (10). Use two people in order to remove water pump (11). The weight of water pump (11) is approximately 39 kg (85 lb).
Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury. 1. Release the system pressure. Refer to Operation and Maintenance Manual, “System Pressure Release”. 2. Drain the coolant into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant (ELC) - Change”.
Illustration 257
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7. Remove O-ring seal (12).
Installation Procedure 1. Install water pump (11) in the reverse order.
Illustration 258
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3. Disconnect harness assembly (1) and remove the connecting hardware.
KENR8384
Illustration 259
59 Engine Supplement Disassembly and Assembly Section
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4. Disconnect hose (2). Remove bolts (3). Remove elbow (4) and O-ring seal (5).
Illustration 262
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7. Attach a suitable lifting device onto thermostatic valve (13). The weight of thermostatic valve (13) is approximately 40 kg (88 lb). Remove bolts (14). Remove thermostatic valve (13).
Installation Procedure 1. Install thermostatic valve (13) in the reverse order. i03901457
Thermostatic Valve Disassemble SMCS Code: 1355-015 Illustration 260
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5. Remove bolts (6) in order to disconnect tube assembly (7). Remove O-ring seal (8).
Disassembly Procedure Start By: a. Remove the thermostatic valve.
Illustration 261
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6. Disconnect hose (9). Remove bolts (10). Remove elbow (11) and O-ring seal (12).
Illustration 263
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1. Remove bolts (1). Disconnect harness assembly (2). Remove controller assembly (3). Remove bolts (4) and cap (5).
60 Engine Supplement Disassembly and Assembly Section
Illustration 264
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2. Remove bolts (6) and motor assembly (7).
Illustration 265
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3. Remove bolts (8) and motor housing (9). Remove gasket (10).
Illustration 266
Illustration 267
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5. Remove reaction dowel (14).
Illustration 268
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6. Remove piston assembly (15). Note: Note the orientation of piston assembly (15) on the shaft.
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4. Remove bolts (11). Remove adapter assembly (12) and O-ring seal (13).
Illustration 269
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7. Remove bolts (16), mount assembly (17), and O-ring seal (18).
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61 Engine Supplement Disassembly and Assembly Section i03901461
Thermostatic Valve - Assemble SMCS Code: 1355-016
Assembly Procedure Table 13
Required Tools Tool
Part Number
A
3S-6252
Part Description Sealant
Qty Illustration 272
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3. Install reaction dowel (14).
Illustration 270
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1. Install O-ring seal (18), mount assembly (17), and bolts (16).
Illustration 273
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4. Install O-ring seal (13). Install adapter assembly (12). Install bolts (11).
Illustration 271
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2. Install piston assembly (15). Illustration 274
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5. Install gasket (10). Install bolts (8). Install motor housing (9). Apply Tooling (A) onto the outer edge of motor housing (9). Note: Ensure that sealant is applied to the hole for the grommet.
62 Engine Supplement Disassembly and Assembly Section
Illustration 275
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6. Install motor assembly (7). Install bolts (6).
Illustration 276
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7. Apply Tooling (A) onto cap (5). Install cap (5) and bolts (4). Install controller assembly (3). Connect harness assembly (2). Install bolts (1). Note: Ensure that sealant is applied to the hole for the grommet. End By: a. Install the thermostatic valve.
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63 Engine Supplement Index Section
Index F
A Aftercooler Core - Remove and Install .................. Installation Procedure ........................................ Removal Procedure ........................................... Air Compressor - Remove and Install.................... Installation Procedure ........................................ Removal Procedure ........................................... Air Starting Motor - Remove and Install................. Installation Procedure ........................................ Removal Procedure ........................................... Alternator - Remove and Install ............................. Installation Procedure ........................................ Removal Procedure ...........................................
4 8 4 8 8 8 9 9 9 9 10 9
B
Fan - Remove and Install ...................................... 25 Installation Procedure ........................................ 28 Removal Procedure ........................................... 25 Fuel Filter (Primary) and Fuel Filter Base - Remove and Install ............................................................ 34 Installation Procedure ........................................ 35 Removal Procedure ........................................... 34 Fuel Filter (Secondary) and Fuel Filter Base Remove and Install .............................................. 35 Installation Procedure ........................................ 37 Removal Procedure ........................................... 35 Fuel Priming Pump - Remove and Install .............. 37 Installation Procedure ........................................ 38 Removal Procedure ........................................... 37
Battery - Remove and Install ................................. 10 Installation Procedure ........................................ 11 Removal Procedure ........................................... 10
I
D
M
Damper - Remove and Install................................ Installation Procedure ........................................ Removal Procedure ........................................... Disassembly and Assembly Section......................
56 57 56 4
E Electronic Control Module (Front Engine) - Remove and Install ............................................................ 11 Installation Procedure ........................................ 11 Removal Procedure ........................................... 11 Engine and Torque Converter - Remove and Install ................................................................... 12 Installation procedure......................................... 18 Removal Procedure ........................................... 12 Engine Oil Cooler - Remove and Install ................ 18 Installation Procedure ........................................ 21 Removal Procedure ........................................... 18 Engine Oil Filter and Oil Filter Base - Remove and Install ................................................................... 21 Installation Procedure ........................................ 22 Removal Procedure ........................................... 21 Engine Oil Pump - Remove and Install.................. 22 Installation Procedure ........................................ 24 Removal Procedure ........................................... 22 Expansion Tank - Remove and Install ................... 24 Installation Procedure ........................................ 25 Removal Procedure ........................................... 24
Important Safety Information ................................. 2
Modular Front End - Remove and Install............... 38 Installation Procedure ........................................ 43 Removal Procedure ........................................... 38 P Piston Motor (Fan Drive) - Assemble .................... Assembly Procedure.......................................... Piston Motor (Fan Drive) - Disassemble................ Disassembly Procedure ..................................... Piston Motor (Fan Drive) - Remove and Install ..... Installation Procedure ........................................ Removal Procedure ...........................................
32 32 29 29 28 29 28
R Radiator - Assemble .............................................. Assembly Procedure.......................................... Radiator - Disassemble ......................................... Disassembly Procedure ..................................... Refrigerant Condenser - Remove and Install ........ Installation Procedure ........................................ Removal Procedure ...........................................
49 49 43 43 54 55 54
T Table of Contents................................................... Thermostatic Valve - Assemble ............................. Assembly Procedure.......................................... Thermostatic Valve - Disassemble ........................ Disassembly Procedure .....................................
3 61 61 59 59
Thermostatic Valve - Remove and Install .............. Installation Procedure ........................................ Removal Procedure ........................................... Turbocharger - Remove and Install ....................... Installation Procedure ........................................ Removal Procedure ...........................................
58 59 58 55 56 55
W Water Pump (Engine) - Remove and Install .......... 57 Installation Procedure ........................................ 58 Removal Procedure ........................................... 57
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