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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.

KENR8384

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.

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Engine Supplement
Table of Contents

4
Engine Supplement
Disassembly and Assembly Section

KENR8384

Disassembly and Assembly


Section
i03879375

Aftercooler Core - Remove and


Install
SMCS Code: 1063-010-KO

Removal Procedure
Table 1

Illustration 2

g02125625

Required Tools
Tool

Part
Number

138-7575

1U-9203

Part Description

Qty

Guide Stud
M10 x 150 mm

Link Bracket

Lever Puller Hoist Gp

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

g02125627

2. Remove brackets (3).

Illustration 1

g02125622

Illustration 4

g02125666

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).

KENR8384

Illustration 5

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Engine Supplement
Disassembly and Assembly Section

g02125667

Illustration 8

g02125677

7. Disconnect hoses (10).

Illustration 6

g02125764

4. Disconnect hose (6) and hose (7).

Illustration 9

g02125727

8. Remove cover (11).

Illustration 7

g02125757

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).

g02125783

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Engine Supplement
Disassembly and Assembly Section

Illustration 11

KENR8384

g02125784

Illustration 14

g02125833

Illustration 15

g02125840

10. Remove bolts (16), cap (17), mount assembly


(18), bolts (19), and stabilizer (20). Repeat this
step for the opposite side.

Illustration 12

g02125785

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

g02125812

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).

g02125854

KENR8384

Illustration 17

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Engine Supplement
Disassembly and Assembly Section

g02125864

14. Position aftercooler assembly (21) onto suitable


blocking.

Illustration 18

Illustration 20

g02125889

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).

g02125870

15. Remove bolts (24) and plate (25). Remove bolts


(26).
Note: Note the location of the oversized washers for
installation purposes.

Illustration 21

g02125890

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

g02125885

16. Remove bolts (27) and plate (28).


Note: Note the location of the oversized washers for
installation purposes.

Illustration 22

g02125893

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Engine Supplement
Disassembly and Assembly Section

KENR8384

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

g02111955

2. Disconnect hose assemblies (1).


Illustration 23

g02125894

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

g02111954

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

g02111956

5. Remove bolts (6). Remove air compressor (5).

Installation Procedure
1. Install air compressor (5) in the reverse order.

KENR8384

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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

g02113846

2. Remove clips (1). Remove guard (2) and guard


(3).

Illustration 27

g02113795

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

g02113847

3. Remove belt (4). Disconnect cable assemblies (5).

10
Engine Supplement
Disassembly and Assembly Section

KENR8384

i03875674

Battery - Remove and Install


SMCS Code: 1401-010

Removal Procedure

Failure to properly service the batteries may cause


personal injury.

Illustration 30

g02113844

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

g02120096

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Engine Supplement
Disassembly and Assembly Section

2. Remove bolts (1). Remove bracket (2). Remove


cable assembly (3).

i03880720

Electronic Control Module


(Front Engine) - Remove and
Install
SMCS Code: 1900-010

Removal Procedure

Illustration 32

g02120279

3. Disconnect cable assemblies (4).

Illustration 33

1. Turn the power disconnect switch to the OFF


position.

g02120134

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

g02126678

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

KENR8384

i03912436

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

9U-7357

Tube As

9U-7405

Tube As

1U-9202

Lever Puller Hoist

138-7575

Link Bracket

309-2793

Load Leveler

323-1146

Lifting Gp

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

g02150556

3. Use Tooling (A) in order to support frame assembly


(1).

KENR8384

Illustration 36

13
Engine Supplement
Disassembly and Assembly Section

g02150560

4. Disconnect cable assembly (2). Remove clips (3).

Illustration 37

Illustration 39

7. Disconnect hose assemblies (6), hose assembly


(7), and hose assembly (8).

g02150566

Illustration 40

5. Disconnect hose assembly (4).

Illustration 38

6. Disconnect hose assembly (5).

g02150632

g02150636

8. Disconnect harness assembly (9) and harness


assemblies (10).

g02150631

Illustration 41

9. Disconnect hose assemblies (11).

g02150675

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Engine Supplement
Disassembly and Assembly Section

Illustration 42

KENR8384

g02150680

10. Disconnect harness assembly (12) and remove


the connecting hardware.

Illustration 43

g02150684

11. Disconnect hose assembly (13). Disconnect cable


assembly (14).

Illustration 44

12. Disconnect hose assemblies (15).

g02150692

Illustration 45

g02150699

13. Remove clips (16). Disconnect hose (17).

Illustration 46

g02153809

14. Disconnect cable assembly (18) and remove the


connecting hardware.

Illustration 47

g02153813

15. Remove bolts (19), plate (20), and mount


assembly (21). Repeat this step for the opposite
side.

KENR8384

Illustration 48

15
Engine Supplement
Disassembly and Assembly Section

g02153816

Illustration 51

g02153964

Illustration 52

g02153974

16. Remove tube assembly (22). Disconnect hose


assembly (23). Remove tube assembly (24).

Illustration 49

g02153958

17. Remove tube assembly (25). Remove elbow (26).


Disconnect hose assembly (27).

Illustration 50

18. Disconnect hose assembly (25).

g02153820

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

g02153978

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.

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Engine Supplement
Disassembly and Assembly Section

KENR8384

23. Remove shims (31).


24. Remove cross tube (29).

Illustration 57

g02154139

28. Disconnect hose assembly (37).


Illustration 54

g02154038

25. Remove step assembly (34).

Illustration 58

g02154141

29. Disconnect hose assemblies (38).


Illustration 55

g02154128

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).

g02154138

g02154173

KENR8384

Illustration 60

17
Engine Supplement
Disassembly and Assembly Section

g02154151

31. Disconnect hose assemblies (40) and hose


assembly (41).

Illustration 61

Illustration 63

g02154182

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).

g02154175

32. Disconnect hose assembly (42).

Illustration 64

g02154215

35. Remove drive shaft guard (46).

Illustration 62

33. Remove drive shaft guard assembly (43).

g02154181

Illustration 65

g02154223

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

KENR8384

i03949329

Engine Oil Cooler - Remove


and Install
SMCS Code: 1378-010

Removal Procedure

Hot oil and components can cause personal injury.


Illustration 66

g02154230

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

g02154236

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

g02154240

39. Remove Engine and torque converter (35).

Installation procedure
1. Install the engine and torque converter (35) in the
reverse order.

KENR8384

Illustration 69

19
Engine Supplement
Disassembly and Assembly Section

g02120353

Illustration 72

g02120414

Illustration 73

g02120396

3. Disconnect harness assemblies (1). Disconnect


hose assembly (2). Disconnect hose (3).

Illustration 70

g02120357

Illustration 71

g02120374

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

g02120442

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

KENR8384

g02120614

Illustration 78

g02121633

Illustration 79

g02121653

7. Disconnect tube (10). Remove tube assembly (8).

Illustration 76

g02120636

Illustration 77

g02121493

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).

g02120658

10. Attach a suitable lifting device onto oil coolers


(18). The weight of oil coolers (18) is approximately
76 kg (168 lb).

KENR8384

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

g02121655

Illustration 82

g02121657

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

g02127053

SMCS Code: 1306-010; 1308-010

Illustration 84

g02127054

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

KENR8384

g02126945

3. Disconnect tube assembly (3) and tube assembly


(4).

Illustration 88

g02126993

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

g02126957

4. Disconnect hose assembly (5).


Illustration 89

g02126995

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).

g02127052

SMCS Code: 1304-010

Removal Procedure
Start By:
a. Remove the alternator.

KENR8384

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

g02141279

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

g02141283

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

g02028631

4. Remove bolts (1), nuts (2), adapter (3), and elbow


(4).

g02141300

24
Engine Supplement
Disassembly and Assembly Section

KENR8384

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).

g02141305

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

g02126884

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

138-7575

Part Description
Link Bracket

Qty
2

g02126887

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

g02126889

4. Disconnect hose assemblies (3), hose assembly


(4), and tube assembly (5).

Tool

Part
Number

Part Description

Guide Stud
M10 x 150 mm

226-2380

Lifting Bracket

138-7574

Link Bracket

189-0410

Shackle

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

g02126892

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

KENR8384

g02128293

1. Disconnect hoses (1) and hose (4). Remove tube


(2) and tube (3).

Illustration 101

Illustration 103

g02128353

5. Disconnect hose (11) and hose (12). Disconnect


support bracket (13). Remove tube (14). Remove
clamps (15). Remove tube (16).

g02128376

Illustration 104

g02128574

6. Disconnect tube assembly (17). Remove clamps


(18). Remove tube assembly (17).

Illustration 102

g02128318

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

g02128841

KENR8384

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

g02128836

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

g02129894

Illustration 110

g02129154

Illustration 111

g02129013

g02128839

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

g02130299

28
Engine Supplement
Disassembly and Assembly Section

KENR8384

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

g02129180

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

Part Description

Qty

1U-6221

Hydraulic Torque Wrench


Gp

1U-6222

Wrench Link

6V-8154

Bolt

8T-0162

Bolt

6F-7831

Washer

126-7183

Crossblock

126-7182

Nut

6V-2360

Hard Washer

138-7575

Link Bracket

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)

9X-8267

Hard Washer

6V-8225

Nut

7X-2535

Bolt (M6 x 1)

1U-8758

Retaining Ring Pliers

1P-1863

Retaining Ring Pliers

1U-9895

Crossblock

8B-7550

Puller Leg

5S-0003

Nut

3H-0465

Push-Puller Plate

4C-5669

Threaded Adapter

9U-7692

Threaded Rod (M16 x 2)(2)

1P-1861

Retaining Ring Pliers

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)

9X-8267

Hard Washer

6V-8225

Nut

1U-8758

Retaining Ring Pliers

1P-1863

Retaining Ring Pliers As

1U-9895

Crossblock

8B-7550

Puller Leg

5S-0003

Nut

3H-0465

Push-Puller Plate

4C-5669

Threaded Adapter

5P-8249

Hard Washer

9U-7692

Threaded Rod (M16 x 2)(2)

Illustration 128

1P-1861

Retaining Ring Pliers As

6. Use Tooling (F) to install retaining ring (18) and


spacer (19).

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 Nm (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

185-3630

Strap Wrench As

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

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

KENR8384

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

163-6455

Link Bracket

189-0410

Shackle As

1U-9203

Lever Puller Hoist

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.

KENR8384

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

138-7573

Link Bracket

4Q-5222

Breaker Tool

4Q-5144

Installer Tool

1U-9202

Lever Puller Hoist Gp

163-6455

Link Bracket

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

138-7573

Link Bracket

4Q-5144

Installer Tool

1U-9202

Lever Puller Hoist Gp

163-6455

Link Bracket

342-2335

Brush

342-2346

Brush

342-2348

Brush

342-2349

Oil

342-2334

Installer

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 Nm
(516 37 lb ft). Repeat this step in order to
ensure that bolts (3) are tightened to a torque
of 700 50 Nm (516 37 lb ft) equally.
i03872289

Water Pump (Engine) - Remove


and Install
SMCS Code: 1361-010

Illustration 252

g02118753

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.

g02119856

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).

g02119859

58
Engine Supplement
Disassembly and Assembly Section

KENR8384

i03901169

Thermostatic Valve - Remove


and Install
SMCS Code: 1355-010

Removal Procedure

Illustration 255

g02118793

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

g02119882

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

g02119887

7. Remove O-ring seal (12).

Installation Procedure
1. Install water pump (11) in the reverse order.

Illustration 258

g02144066

3. Disconnect harness assembly (1) and remove the


connecting hardware.

KENR8384

Illustration 259

59
Engine Supplement
Disassembly and Assembly Section

g02144067

4. Disconnect hose (2). Remove bolts (3). Remove


elbow (4) and O-ring seal (5).

Illustration 262

g02144245

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

g02144239

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

g02144241

6. Disconnect hose (9). Remove bolts (10). Remove


elbow (11) and O-ring seal (12).

Illustration 263

g02144327

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

KENR8384

g02144329

2. Remove bolts (6) and motor assembly (7).

Illustration 265

g02144330

3. Remove bolts (8) and motor housing (9). Remove


gasket (10).

Illustration 266

Illustration 267

g02144336

5. Remove reaction dowel (14).

Illustration 268

g02144363

6. Remove piston assembly (15).


Note: Note the orientation of piston assembly (15)
on the shaft.

g02144334

4. Remove bolts (11). Remove adapter assembly


(12) and O-ring seal (13).

Illustration 269

g02144367

7. Remove bolts (16), mount assembly (17), and


O-ring seal (18).

KENR8384

61
Engine Supplement
Disassembly and Assembly Section
i03901461

Thermostatic Valve - Assemble


SMCS Code: 1355-016

Assembly Procedure
Table 13

Required Tools
Tool

Part
Number

3S-6252

Part Description
Sealant

Qty
Illustration 272

g02144336

3. Install reaction dowel (14).

Illustration 270

g02144367

1. Install O-ring seal (18), mount assembly (17), and


bolts (16).

Illustration 273

g02144334

4. Install O-ring seal (13). Install adapter assembly


(12). Install bolts (11).

Illustration 271

g02144363

2. Install piston assembly (15).


Illustration 274

g02144330

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

KENR8384

g02144329

6. Install motor assembly (7). Install bolts (6).

Illustration 276

g02144327

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.

KENR8384

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

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

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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