785D Off-Highway Truck/Tractor Engine Supplement Caterpillar

Engine and Torque Converter - Install

Usage:

785D DMC

Installation 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⁽¹⁾	9U-7536	Lift Stand	1
	447-0910	Electric Hydraulic Pump Gp (115V)	1
	447-0911	Electric Hydraulic Pump Gp (230V)	1
D1	OR
	504-9826	Lift Gp (60Hz)⁽²⁾	1
	504-9827	Lift Gp (50Hz)⁽³⁾	1
E	309-2793	Load Leveler	1

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⁽¹⁾	Use Tooling (D) or (D1) based on requirements.
⁽²⁾	Operating-Voltage (380-500V)
⁽³⁾	Operating-Voltage (180-300V)

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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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NOTICE

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

Note: Put identification marks on all hoses, on all hose assemblies, on all harness assemblies, and on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies. This helps to prevent fluid loss, and this helps to keep contaminants from entering the system.

Note: Inspect the O-ring seals. Replace the O-ring seals that are worn or damaged.

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Illustration 1	g01728993

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Illustration 2	g01728598

Use Tooling (E) and a suitable lifting device to install engine (108) and the torque converter. The weight of engine (108) and the torque converter is approximately 8391 kg (18500 lb).
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Illustration 3 g01728573
Install mount (107), plate (106), and bolt (105). Repeat this step for the opposite side.
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Illustration 4 g01728513
Install cap (104). Install bolts (103). Tighten bolts (103) to a torque of 270 ± 25 N·m (200 ± 19 lb ft). Repeat this step for the opposite side.
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Illustration 5 g01728534
Use a suitable lifting device to position tube assembly (100). The weight of tube assembly (100) is approximately 66 kg (146 lb).
Install shims (102). Install bolts (101). Repeat this step for the opposite side.
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Illustration 6 g01728614

For Tooling (D)
Remove Tooling (D) from the machine frame.
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Illustration 7 g06406622

For Tooling (D1)
Remove Tooling (D1) from the machine frame. Refer to Tool Operating Manual, NEHS1328, "Lift Group (Stand - 60 Ton)" for more information on Tooling (D1).
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Illustration 8 g01728481

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Illustration 9 g01728514
Use a suitable lifting device to install exhaust assembly (96). The weight of exhaust assembly (96) is approximately 57 kg (125 lb).
Connect clamps (99) and clamp (98). Tighten clamps (99) and clamp (98) to a torque of 68 ± 12 N·m (50 ± 9 lb ft). Connect bracket (97).
Note: The top of the clamps must be assembled at the top of the captured slot.
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Illustration 10 g01728478
Install tube (94). Connect hose (95).
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Illustration 11 g01728474
Connect tube (94). Install retainers (93) and bolts (92).
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Illustration 12 g01728473
Install tube assembly (91) and the gasket. Install bolts (90).
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Illustration 13 g01728398

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Illustration 14 g01728434
Install tube (88). Connect bracket (89). Connect hose (87). Repeat this step for the opposite side.
Note: The hose clamps must be assembled 180° opposite each other. Tighten the hose clamps to a torque of 6.2 ± 0.8 N·m (55 ± 7 lb in).
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Illustration 15 g01728395
Connect hose assembly (86).
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Illustration 16 g01728357
Connect bracket (85). Connect hose (84). Repeat this step for the opposite side.
Note: The hose clamps must be assembled 180° opposite each other. Tighten the hose clamps to a torque of 6.2 ± 0.8 N·m (55 ± 7 lb in).
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Illustration 17 g01728233
Install clamps (83).
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Illustration 18 g01728214
Install clamps (82).
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Illustration 19 g01728034

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Illustration 20 g01728153
Use Tooling (B), Tooling (C), and a suitable lifting device to install platform (80). The weight of platform (80) is approximately 64 kg (140 lb). Install bolts (81). Install bolts (79).
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Illustration 21 g01727954

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Illustration 22 g01727993
Position hoses (77) and install clips (78). Connect hoses (77).
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Illustration 23 g01727416

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Illustration 24 g01727937
Remove clips (76). Position harness assembly (65) and install clips (76).
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Illustration 25 g01727379
Connect harness assembly (75). Install clips (74).
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Illustration 26 g01727373
Install cable straps (73) and clips (72).
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Illustration 27 g01727236
Install clip (71), spacer (70), and clip (69).
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Illustration 28 g01727194
Connect harness assembly (68). Install clips (67).
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Illustration 29 g01727041
Install clips (66). Connect harness assembly (65).
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Illustration 30 g01727038
Connect hose assembly (64).
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Illustration 31 g01785720
Connect hose assembly (63).
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Illustration 32 g01726781
Connect hoses (62).
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Illustration 33 g01726776
Connect hose assembly (61).
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Illustration 34 g01726760
Connect hose assembly (60).
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Illustration 35 g01726715
Install hose (59).
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Illustration 36 g01726696
Connect hose assembly (58). Install hose (57).
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Illustration 37 g01726637
Connect cable assembly (56).
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Illustration 38 g01726616
Install clips (55). Connect cable assembly (54).
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Illustration 39 g01726574
Connect hose assembly (53).
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Illustration 40 g01726475
Position work light (52) and harness assembly (50). Connect bracket (51). Install clips (49). Repeat this step for the opposite side.
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Illustration 41 g01726433
Position hose assemblies (48) and install clip (47). Connect harness assembly (46).
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Illustration 42 g01726413
Position accumulator (45) and install bolts (44).
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Illustration 43 g01726294
Position compressor (43) and install bolt (42).
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Illustration 44 g01726299

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Illustration 45 g01728974
Install bolt (41). Connect harness assembly (40).
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Illustration 46 g01726254
Connect hose assembly (39) and hose assembly (38). Install clips (37).
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Illustration 47 g01728973
Install belt (36). Tighten bolts (35).
Tension the belt. Refer to Operation and Maintenance Manual, "Belts - Inspect/Adjust/Replace".
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Illustration 48 g01725638
Connect hose assembly (34).
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Illustration 49 g01725533

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Illustration 50 g01725633
Install clips (33).
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Illustration 51 g01725516
Connect hose assembly (32).
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Illustration 52 g01725256

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Illustration 53 g01725419
Install tube assembly (30). Install clamps (31). Connect hose (29).
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Illustration 54 g01725173
Connect harness assemblies (28) and harness assembly (27).
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Illustration 55 g01725423
Connect hose assemblies (26).
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Illustration 56 g01725493
Connect cable assembly (25).
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Illustration 57 g01723875
Connect hose assembly (24).
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Illustration 58 g01723893

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Illustration 59 g01723899
Install clamps (23). Connect hose assembly (22). Connect hose assembly (21).
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Illustration 60 g01723354
Install clamps (20).
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Illustration 61 g01723813
Connect hose assembly (19).
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Illustration 62 g01723793
Connect hose assembly (18).
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Illustration 63 g01723733
Connect block (17) and hose assembly (16).
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Illustration 64 g01726799
Remove clamps (14). Position hose assembly (15) and reinstall clamps (14).
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Illustration 65 g01723693
Install clamps (13). Connect hose assembly (12).
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Illustration 66 g01725255
Connect hose assembly (11) and hose assembly (10).
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Illustration 67 g01723695
Connect hose assembly (9), hose assembly (8), and hose assembly (7).
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Illustration 68 g01723343
Connect hose assembly (6), hose assembly (5), and hose assemblies (4).
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Illustration 69 g01723313
Use a suitable lifting device to support drive shaft (2). Use a suitable pry bar to connect drive shaft (2). Install new bolts (3). Tighten new bolts (3) to a torque of 550 ± 20 N·m (406 ± 15 lb ft).
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Illustration 70 g01723294
Install guard assembly (1).
Turn the fuel supply to the ON position.
Fill the hydraulic tank. Refer to Operation and Maintenance Manual, "Hoist, Torque Converter and Brake Tank Oil - Change".
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Illustration 71 g01728694
Remove Tooling (A).
Charge the air pressure in the air reservoir. Refer to Operation and Maintenance Manual, "Starting with an External Air Supply" to refill the air tanks.