785D Off-Highway Truck Engine Supplement Caterpillar

Engine and Torque Converter - Remove

Usage:

785D MSY

Removal Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	8S-7640	Stand	2
	8S-7611	Tube	2
	8S-7615	Pin	4
	8S-8048	Saddle	2
B	439-3938	Link Bracket	2
C	1U-9200	Lever Puller Hoist	1
D	504-9826	Lift Gp (50/60 Hz)⁽¹⁾	1
	OR
	504-9827	Lift Gp (50/60 Hz)⁽²⁾	1
E	309-2793	Load Leveler	1

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⁽¹⁾	High-Voltage (380-500V)
⁽²⁾	Low-Voltage (180-300V)

Start By:

Release the air system pressure. Refer to Disassembly and Assembly, "Air Tanks (Brake) - Purge".
Remove the radiator. Refer to Disassembly and Assembly, "Radiator - Remove".
Remove the hood. Refer to Disassembly and Assembly, "Hood - Remove and Install".
Remove the pump drive shaft. Refer to Disassembly and Assembly, "Pump Drive Shaft (Hydraulic) - Remove and Install".

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat^® products. Dispose of all fluids according to local regulations and mandates.

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Removing the engine from the truck with the body of the truck in the Up position will change the balance point of the truck. The shift in the balance point could allow the front of the truck to unexpectedly raise off the ground.
This unexpected movement could cause injury or death.

To stabilize the truck, always install the specified tooling to stabilize the truck before removing the engine and torque converter.

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Personal injury can result from hot coolant, steam and alkali.
At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.
Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand.

Cooling System Conditioner contains alkali. Avoid contact with skin and eyes.

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Personal injury can result from hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.

Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

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NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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Illustration 1	g01728694

Use Tooling (A) to support the truck body.
Drain the hydraulic tank into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Hoist, Torque Converter and Brake Tank Oil - Change".
Turn the fuel supply to the OFF position.
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Illustration 2 g01723294
Remove guard assembly (1).
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Illustration 3 g01723313
Attach a suitable lifting device to support drive shaft (2). Remove bolts (3). Use a suitable prybar to disconnect drive shaft (2).
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Illustration 4 g01723343
Disconnect hose assemblies (4), hose assembly (5), and hose assembly (6).
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Illustration 5 g01723695
Disconnect hose assembly (7), hose assembly (8), and hose assembly (9).
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Illustration 6 g01725255
Disconnect hose assembly (10) and hose assembly (11).
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Illustration 7 g01723693
Disconnect hose assembly (12). Remove clamps (13).
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Illustration 8 g01726799
Remove clamps (14). Position hose assembly (15) out of the way. Reinstall clamps (14).
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Illustration 9 g01723733
Disconnect hose assembly (16) and block (17).
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Illustration 10 g01723793
Disconnect hose assembly (18).
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Illustration 11 g01723813
Disconnect hose assembly (19).
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Illustration 12 g01723354
Remove clamps (20).
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Illustration 13 g01723893

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Illustration 14 g01723899
Disconnect hose assembly (21). Disconnect hose assembly (22). Remove clamps (23).
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Illustration 15 g01723875
Disconnect hose assembly (24).
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Illustration 16 g01725493
Disconnect cable assembly (25).
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Illustration 17 g01725423
Disconnect hose assemblies (26).
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Illustration 18 g01725173
Disconnect harness assembly (27) and harness assemblies (28).
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Illustration 19 g01725256

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Illustration 20 g01725419
Disconnect hose (29). Remove clamps (31). Remove tube assembly (30).
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Illustration 21 g01725516
Disconnect hose assembly (32).
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Illustration 22 g01725533

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Illustration 23 g01725633
Remove clips (33).
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Illustration 24 g01725638
Disconnect hose assembly (34).
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Illustration 25 g01728973
Loosen bolts (36). Remove belt (35).
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Illustration 26 g01726254
Remove clips (37). Disconnect hose assembly (38) and hose assembly (39).
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Illustration 27 g01726299

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Illustration 28 g01728974
Disconnect harness assembly (40). Remove bolt (41).
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Illustration 29 g01726294
Remove bolt (42). Position compressor (43) out of the way.
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Illustration 30 g01726413
Remove bolts (44). Position accumulator (45) out of the way.
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Illustration 31 g01726433
Disconnect harness assembly (46). Remove clip (47) and position hose assemblies (48) out of the way.
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Illustration 32 g01726475
Remove clips (49). Disconnect bracket (51). Position work light (52) and harness assembly (50) out of the way. Repeat this step for the opposite side.
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Illustration 33 g01726574
Disconnect hose assembly (53).
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Illustration 34 g01726616
Disconnect cable assembly (54). Remove clips (55).
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Illustration 35 g01726637
Disconnect cable assembly (56).
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Illustration 36 g01726696
Remove hose (57). Disconnect hose assembly (58).
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Illustration 37 g01726715
Remove hose (59).
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Illustration 38 g01726760
Disconnect hose assembly (60).
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Illustration 39 g01726776
Disconnect hose assembly (61).
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Illustration 40 g01726781
Disconnect hoses (62).
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Illustration 41 g01785720
Disconnect hose assembly (63).
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Illustration 42 g01727038
Disconnect hose assembly (64).
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Illustration 43 g01727041
Disconnect harness assembly (65). Remove clips (66).
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Illustration 44 g01727194
Remove clips (67). Disconnect harness assembly (68).
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Illustration 45 g01727236
Remove clip (69), spacer (70), and clip (71).
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Illustration 46 g01727373
Remove clips (72) and cable straps (73).
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Illustration 47 g01727379
Remove clips (74). Disconnect harness assembly (75).
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Illustration 48 g01727416

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Illustration 49 g01727937
Remove clips (76). Position harness assembly (65) out of the way.
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Illustration 50 g01727954

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Illustration 51 g01727993
Disconnect hoses (77).
Remove clips (78). Position hoses (77) out of the way.
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Illustration 52 g01728034

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Illustration 53 g01728153
Remove bolts (79). Attach Tooling (B), Tooling (C), and a suitable lifting device onto platform (80). The weight of platform (80) is approximately 64 kg (140 lb). Remove bolts (81).
Remove platform (80).
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Illustration 54 g01728214
Remove clamps (82).
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Illustration 55 g01728233
Remove clamps (83).
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Illustration 56 g01728357
Disconnect hose (84). Disconnect bracket (85). Repeat this step for the opposite side.
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Illustration 57 g01728395
Disconnect hose assembly (86).
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Illustration 58 g01728398

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Illustration 59 g01728434
Disconnect hose (87). Disconnect bracket (89). Remove tube (88). Repeat this step for the opposite side.
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Illustration 60 g01728473
Remove bolts (90). Remove tube assembly (91) and the gasket.
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Illustration 61 g01728474
Remove bolts (92) and retainers (93) to disconnect tube assembly (94).
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Illustration 62 g01728478
Disconnect hose (95). Remove tube (94).
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Illustration 63 g01728481

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Illustration 64 g01728514
Attach a suitable lifting device onto exhaust assembly (96). The weight of exhaust assembly (96) is approximately 56.69875 kg (125 lb).
Disconnect bracket (97). Disconnect clamp (98) and clamps (99).
Remove exhaust assembly (96).
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Illustration 65 g06339420

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NOTICE

Do not raise the machine. The jack supports the frame from stress when the tube assembly is removed.
Position Tooling (D) under the machine frame. Refer to Tool Operating Manual, NEHS1328, "Lift Group (Stand - 60 Ton)" for more information on Tooling (D).
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Illustration 66 g01728534
Attach a suitable lifting device onto tube assembly (100). The weight of tube assembly (100) is approximately 66 kg (146 lb).
Remove bolts (101). Remove shims (102). Repeat this step for the opposite side.
Note: Note the quantity of the shims for installation purposes.
Remove tube assembly (100).
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Illustration 67 g01728513
Remove bolts (103). Remove cap (104). Repeat this step for the opposite side.
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Illustration 68 g01728573
Remove bolt (105), plate (106), and mount (107). Repeat this step for the opposite side.
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Illustration 69 g01728598

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Illustration 70 g01728993
Attach Tooling (E) and a suitable lifting device onto engine (108) and the torque converter. The weight of engine (108) and the torque converter is approximately 8391 kg (18500 lb).
Remove engine (108) and the torque converter.