793F Series AC Off-Highway Truck Engine Supplement Caterpillar

Installation procedure

Note: Before installing the engine, check the engine crankshaft end play. Refer to Specifications, KENR9187, "C175-16 Engine for 795F Series AC Off-Highway Trucks", Crankshaft -Type 1 and Crankshaft - Type 2 for specific values.

Note: Before installing the engine, inspect the rubber blocks of the coupler adapter. Refer to Reuse And Salvage Guidelines, SEBF9338, "Inspection of Rubber Blocks for 793F AC, 794 AC, 795F AC, and MT4400D AC Off-Highway Trucks" and Disassembly and Assembly, KENR8715, Coupler Adapter and Mounting - Disassemble and Coupler Adapter and Mounting - Assemble.

Show/hide table

Illustration 1	g03425734

Show/hide table

Illustration 2	g03425127

1. Install Tooling (B) onto the engine. Use Tooling (B), Tooling (C), and a suitable lifting device to install engine (38). The weight of engine (38) is approximately 11,612 kg (25,600 lb).
   Show/hide table

   Illustration 3	g03425126

2. Connect ground strap (37). Install washer (36) and bolt (35).
   Show/hide table

   Illustration 4	g03425119

3. Install washer (34) and bolt (33). Connect harness assembly (32) and remove the connecting hardware.
   Show/hide table

   Illustration 5	g03425125

4. Install cap (31). Install bolts (30). Tighten bolts (30) to a torque of 300 ± 40 N·m (221 ± 30 lb ft). Repeat this step for the remaining rear engine mount.
   Show/hide table

   Illustration 6	g03424866

5. Remove Tooling (C) from Tooling (B).
   Show/hide table

   Illustration 7	g03425116
   Front of Engine

   Show/hide table

   Illustration 8	g03425112
   Rear of Engine

6. Remove Tooling (B) from the engine.
   Show/hide table

   Illustration 9	g03424838

7. Install clamps (29). Repeat this step for the opposite side.
   Show/hide table

   Illustration 10	g03424782

8. Connect hose assemblies (28).
   Show/hide table

   Illustration 11	g03424762

9. Connect hose assembly (27).
   Show/hide table

   Illustration 12	g03424757

   Show/hide table

   Illustration 13	g03424737

10. If equipped with an electric starting motor, connect cable assemblies (26) and cable assembly (25). Install clip (24) and connect harness assembly (23).
    Show/hide table

    Illustration 14	g03424174

11. Use a suitable lifting device to position drive shafts (20) onto the yoke of the coupling adapter and the auxiliary pump drive.
    Show/hide table

    Illustration 15	g03424421

    Show/hide table

    Illustration 16	g03424423

12. Install new bolts (22) and new bolts (21), loosely.

13. Use the following procedure to mate the universal joint onto the yoke of the coupling adapter.

    Note: Prior to the drive shaft installation, make sure that the coupler adapter yoke and the power generator yoke are aligned with each other.

    1. Mate the key and pilot diameter of the universal joint with the yoke of the coupler adapter. Use a suitable rubber or wooden hammer to completely seat the universal joint.

    2. Use Tooling (D) to tighten bolts (22) to a torque of 777 ± 40 N·m (571 ± 30 lb ft) in an alternating (X) pattern.

    3. Use Tooling (D) to tighten bolts (22), again, to a torque of 777 ± 40 N·m (571 ± 30 lb ft) in an alternating (X) pattern to ensure that the correct torque has been achieved.

14. Tighten bolts (21) to a torque of 135 ± 20 N·m (100 ± 15 lb ft).
    Show/hide table

    Illustration 17	g03424149

15. Install drive shaft covers (19).
    Show/hide table

    Illustration 18	g03424077

16. Install bellows (18). Connect V-band clamps (17) and V-band clamps (16).
    Show/hide table

    Illustration 19	g03424032

17. Connect harness assemblies (15).
    Show/hide table

    Illustration 20	g03423993

18. Connect hose assembly (14).
    Show/hide table

    Illustration 21	g03424137

19. Connect hose assemblies (13).
    Show/hide table

    Illustration 22	g03424136

20. Connect hose assemblies (12).
    Show/hide table

    Illustration 23	g03424135

21. Connect hose assemblies (11).
    Show/hide table

    Illustration 24	g03422898

    Show/hide table

    Illustration 25	g03422939
    Right Hand Side

22. Position tubes assemblies (10) and install clamps (9). Connect hoses (8).
    Show/hide table

    Illustration 26	g03423941
    Right Hand Side

23. Connect harness assemblies (7).
    Show/hide table

    Illustration 27	g03423903

24. Connect hoses (6) and hoses (5),
    Show/hide table

    Illustration 28	g03263262

25. Use a suitable lifting device to position cross member (3). The weight of cross member (3) is approximately 116 kg (256 lb).

26. Install shims (4) at Location (A) and Location (B).

    Note: In the event that shims (4) were lost or damaged during removal procedure or the engine cross tube is replaced with new, refer to "Engine and Torque converter - Install", "Engine Cross Tube Shimming procedure" section for the correct installation procedure.

    Note: The total number of required shims must not exceed ten.

27. Install bolts (4). Tighten bolts (4) to a torque of 520 ± 70 N·m (384 ± 52 lb ft) in a crisscross pattern.
    Show/hide table

    Illustration 29	g03422712

28. Connect hose assemblies (2) and install the connecting hardware.
    Show/hide table

    Illustration 30	g06214700
    For Tooling (A).

29. Remove Tooling (A) from front frame assembly (1).
    Show/hide table

    Illustration 31	g06385904
    For Tooling (A1).

30. Remove Tooling (A1) from front frame assembly (1).

31. Turn the power disconnect switch to the ON position.

32. Turn the fuel supply to the ON position.

33. Refer to Operation and Maintenance Manual, "Cable (Truck Body Retaining)".

End By:

1. Install the inverter cabinet.

2. Remove the modular front end.

3. Install the rear hood.

4. Install the front hood.

Engine Cross Tube Shimming procedure

The following procedure is only to be used if the shims that the machine was shipped with have been lost during the removal procedure or the engine cross tube is replaced with new. In these events the following procedure is to be used to determine the proper number and location of the shims used when replacing / installing the Engine Cross Tube.

Show/hide table

Illustration 32	g06214740

1. If the front suspension cylinders are installed, inspect the upper suspension mount, the shaft, and the bearing on both sides of the machine. If the front suspension cylinders are not installed skip to Step 5.

2. Fully collapse both of the front suspension cylinders. Refer to SEHS9411 Special Instructions Manual, "Servicing the Suspension Cylinders for Large Off-Highway Trucks", "Collapse the Front Suspension Cylinders" section for the correct procedure.

   Note: After collapsing the front suspension cylinders, ensure that the outlet charging valves remain open.

   Show/hide table

   Illustration 33	g06214700
   For Tooling (A).

3. Use Tooling (A) to lift the front frame assembly (1) until 25.4 mm (1 inch) of chrome is exposed on the front suspension cylinders from the fully collapsed position.
   Show/hide table

   Illustration 34	g06385904
   For Tooling (A1).

4. Use Tooling (A1) to lift the front frame assembly (1) until 25.4 mm (1 inch) of chrome is exposed on the front suspension cylinders from the fully collapsed position. Refer to Tool Operating Manual, NEHS1334, "Lift Group (Stand - 150 Ton)" for more information on Tooling (A1).
   Show/hide table

   Illustration 35	g06214817
   (Y) Right-Hand Side (Z) Left-Hand Side

   Show/hide table

   Illustration 36	g06215543

5. Install cross tube (2).

6. If cross tube (2) does not fit, continue to lift the machine until cross tube (2) fits and use zero shims (5).

7. Temporarily install the bolts and washers.

8. With cross tube flush against Side (Y), begin installing shims (5) at Side (Z).

   Note: If five or more shims are required, install the first five shims at Side (Z) and the remaining shims at Side (Y). If five or less shims are required, install all shims at Side (Z).

   Note: Do not force shims (5) into the gap between cross tube (2) and the frame. Only use enough shims (5) to fill the gap.

   Note: Document shim number and location for future reference.

   Note: The total number of shims (5) should not exceed ten.

   793 - 10 shims maximum

   797 - 10 shims maximum

   795 - 10 shims maximum

   789 - 8 shims maximum

   785 - 8 shims maximum

9. Lower the machine so that the front suspension cylinders are fully collapsed.

10. Once the shims are fitted, tighten the cross tube mounting bolts to a torque of 520 ± 70 N·m (384 ± 52 lb ft) in a crisscross pattern.

11. Charge the front suspension cylinders with oil and nitrogen. Refer to , SEHS9411 Special Instruction Manual , "Servicing the Suspension Cylinders for Large Off-Highway Trucks", "Charge the Front Suspension Cylinders with Oil" and "Charge the Front Suspension Cylinders with Nitrogen" sections for the correct procedure.