773G and 775G OFF-Highway Trucks Engine Supplement Caterpillar

Engine and Torque Converter - Remove and Install

Usage:

773G JWS

Removal Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	283-1495	Stand Assembly	2
	8S-7611	Tube	2
	8S-7615	Pin	2
B	504-9791	Lift Gp (60 Hz)⁽¹⁾	2
	OR
	504-9793	Lift Gp (50 Hz)⁽²⁾	2

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⁽¹⁾	High-Voltage (480V) Low-Voltage (240V)
⁽²⁾	High-Voltage (400V) Low-Voltage (200V)

Start By:

Remove the radiator.
Remove the cab.
Remove the drive shaft.
Remove the muffler.

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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, NENG2500, "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.

Refer to Operation and Maintenance Manual, "Hydraulic System Oil - Change" for the correct draining and filling procedures.
Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct draining and filling procedures.
Refer to Operation and Maintenance Manual, "Engine Oil and Filter - Change" for the correct draining and filling procedures.
Refer to Operation and Maintenance Manual, "Power Train Oil - Change" for the correct draining and filling procedures.
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Illustration 1 g00461867
Put Tooling (A) in position under the body of the truck, as shown.
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Illustration 2 g01319186
Turn fuel shutoff valve (1) to the OFF position.
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Illustration 3 g01319159
Disconnect hose assemblies (2) and hose assemblies (3).
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Illustration 4 g01319163
Disconnect hose assemblies (4), (5), (6), and (7). Disconnect tube assembly (8).
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Illustration 5 g01319164
Loosen clamp (10) and remove tube assembly (8). Disconnect tube assembly (9). Disconnect hose assemblies (11) and (12).
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Illustration 6 g01319166
Remove bolts (14) and filler assembly (13). Disconnect clamp (15) from hose assembly (16).
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Illustration 7 g01319173
Disconnect clamp (17) and reposition hose assembly (16) out of the way.
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Illustration 8 g01319170
Disconnect ground cable (18) from the frame of the machine. Repeat for the opposite side.
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Illustration 9 g01319171
Remove harness assembly (19) and cable assembly (20). Disconnect hose assembly (21).
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Illustration 10 g01319181
Disconnect hose assemblies (23). Remove clamps (22) and reposition the hose assemblies out of the way.
Remove clamp (27). Loosen clamps (25). Remove tube assemblies (24) and (26).
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Illustration 11 g01319187
Disconnect hose assembly (29). Remove clamp (31). Disconnect hose assembly (28). Disconnect screen assembly (30).
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Illustration 12 g01319189
Remove hose (33). Remove clamps (34). Disconnect hoses (32). Reposition hoses (32) out of the way.
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Illustration 13 g01319229
Disconnect hose assemblies (35) and (36). Remove clamp (37). Position hose assemblies (35) and (36) out of the way.
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Illustration 14 g01319342
Disconnect hose assemblies (38).
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Illustration 15 g01319343
Disconnect cable assembly (40). Remove clamp (39).
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Illustration 16 g01319344
Loosen clamp (41). Remove tube assembly (42). Remove bracket assembly (43).
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Illustration 17 g01319440
Disconnect hose assembly (48). Remove clamp (45). Loosen clamps (44) and (46). Remove tube assemblies (47).
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Illustration 18 g01319445

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Illustration 19 g01319457
Remove bolts (53). Loosen clamp (50) and clamps (55). Remove tube assemblies (49) and (56).
Loosen clamps (52). Remove tube assembly (51). Remove clamp (54).
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Illustration 20 g01319526
Remove elbow (57) and heat shield (58) to provide clearance for the removal of the engine and the torque converter.
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Illustration 21 g01319540
Disconnect hose assemblies (60). Remove bracket (59) and the attached components.
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Illustration 22 g01319565
Remove bolt (61) and reposition dipstick (62). Disconnect hose assembly (68). Loosen clamp (64) and disconnect hose (63).
Disconnect harness assembly (67). Remove bolts (65). Remove bracket (66) and the attached components.
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Illustration 23 g01319567
Disconnect harness assemblies (69). Remove three bolts (71) and reposition bracket assembly (70). Remove cable straps (72).
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Illustration 24 g01319569
Disconnect harness assembly (73). Remove cable straps (74).
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Illustration 25 g01319608
Disconnect harness assembly (75). Remove cable straps (76).
Reposition harness assemblies (69), (73), and (75) out of the way. Refer to Steps 29 through 31.
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Illustration 26 g06281123

Typical example

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Illustration 27 g01319618
Position Tooling (B) under the frame of the machine as shown in Illustration 26. Refer to Tool Operating Manual , NEHS1303, "Lift Group (Stand - 25 Ton)" for more information on Tooling (B).
Attach a suitable lifting device to tube assembly (79). The weight of tube assembly (79) is approximately 27 kg (60 lb).
Note the location of shims (77) for assembly purposes. Loosen bolts (78). Use Tooling (B) to apply lifting tension to the machine to relieve the tension on shims (77). Remove bolts (78), shims (77), and tube assembly (79). Remove bracket assembly (80).
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Illustration 28 g01319620
Attach a suitable lifting device to the engine and torque converter (81). The weight of the engine and torque converter (81) is approximately 3946 kg (8700 lb).
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Illustration 29 g01319633
Remove bolts (82) and caps (83) from both sides of the engine and torque converter (81).
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Illustration 30 g01319676
Remove front mounting hardware (84) from the engine and torque converter (81).
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Illustration 31 g01319884

Note: The engine and the torque converter must be carefully moved, both in a forward direction and an upward direction, to be positioned as shown.
Carefully remove the engine and torque converter (81) to avoid damage from machine frame (85).