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Installation of the 513-4427 Engine Conversion Kit For 785C Off-Highway Truck Engines {1000, 1801} Caterpillar


Installation of the 513-4427 Engine Conversion Kit For 785C Off-Highway Truck Engines {1000, 1801}

Usage:

785C 1HW
Off-Highway Truck/Tractor
785C (S/N: 1HW1-UP; APX1-UP; 5AZ1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information. This Special Instruction covers the installation of the 513-4427 Engine Conversion Kit.

Important Safety Information

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

The information, specifications, and illustrations in this publication are based on 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.

General Information

Graphic Color Description

Color-coding of targeted components, or sections of a part, is used to communicate a required action.

The descriptions below illustrate the different colors and what is represented when used in a graphic.

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(Blue) The primary component of focus for a particular step. Target or primary component to be installed or removed. Installation implied unless otherwise noted with a symbol.

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(CAT® Yellow) Description of parts.

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(Yellow) Components placed aside for access, but not removed. Highlighted areas of adjustment, inspection, or special attention.

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(Cyan) Special tools or other equipment required for use in a particular step.

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(Light Gray) Components used for reference.

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(Magenta) Any fastener, retainer, or electrical connector used to install or remove the primary component.

Graphic Symbol Description

This section includes all the symbol graphics used throughout the Visual Service Procedure (VSP), along with a brief description of what the symbol represents.

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Repeat - To perform once more. Iterate to do, make, or perform again.

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Tighten - To make nearer to fully stretched, without slack, to apply tension or torque.

Torque Specifications

English (SAE) Fasteners

The following table has the recommended standard torque values.

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Table 1
Nuts and Bolts 
Thread Size
Inch 		 Standard Torque 
1/4  12 ± 3 N·m (9 ± 2 lb ft) 
5/16  25 ± 5 N·m (18 ± 5 lb ft) 
3/8  47 ± 10 N·m (35 ± 5 lb ft) 
7/16  70 ± 15 N·m (50 ± 10 lb ft) 
1/2  105 ± 20 N·m (75 ± 15 lb ft) 
9/16  160 ± 30 N·m (120 ± 20 lb ft) 
5/8  215 ± 40 N·m (160 ± 30 lb ft) 
3/4  370 ± 50 N·m (275 ± 37 lb ft) 
7/8  620 ± 80 N·m (460 ± 60 lb ft) 
1  900 ± 100 N·m (660 ± 75 lb ft) 
1 1/8  1300 ± 150 N·m (960 ± 110 lb ft) 
1 1/4  1800 ± 200 N·m (1320 ± 150 lb ft) 
1 3/8  2400 ± 300 N·m (1780 ± 220 lb ft) 
1 1/2  3100 ± 350 N·m (2280 ± 260 lb ft) 

Metric (ISO) Fasteners

The following table has the recommended standard torque values.

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Table 2
Nuts and Bolts 
Thread Size
Metric 		 Standard Torque 
M6  12 ± 3 N·m (9 ± 2 lb ft) 
M8  30 ± 5 N·m (20 ± 5 lb ft) 
M10  55 ± 10 N·m (40 ± 5 lb ft) 
M12  100 ± 20 N·m (75 ± 15 lb ft) 
M14  160 ± 30 N·m (120 ± 20 lb ft) 
M16  240 ± 40 N·m (175 ± 30 lb ft) 
M20  460 ± 60 N·m (340 ± 45 lb ft) 
M24  800 ± 100 N·m (590 ± 75 lb ft) 
M30  1600 ± 200 N·m (1180 ± 150 lb ft) 
M36  2700 ± 300 N·m (2000 ± 220 lb ft) 

Cylinder Block Cover Group

Parts Required

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Illustration 1g06110003

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Table 3
Item  Qty  Part Number  Part Name  Illustration (Sub-step) Location 
1  2  2J-3118  Locking Bolts  Illustration 3 (2.1) 
2  8  4L-9337  Bolts  Illustration 2 (1.2) 
3  4  310-3147  Plates  Illustration 2 (1.1) 

Installation Procedure

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Illustration 2g06110028
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Illustration 3g06110035

Sound Cover Group

Parts Required

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Illustration 4g06110140

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Table 4
Item  Qty  Part Number  Part Name  Illustration (Sub-step) Location 
1  48  1D-4538  Bolts  Illustration 5 (1.3), and 6 (2.3) 
2  3  202-9054  Insulator Assemblies  Illustration 5 (1.2), and 6 (2.2) 
3  9  399-4711  Insulator Assemblies  Illustration 5 (1.1), and 6 (2.1) 

Installation Procedure

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Illustration 5g06110149
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Illustration 6g06110160

Fan Drive and Fumes Disposal Groups

Parts Required

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Illustration 7g06110623

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Table 5
Item  Qty  Part Number  Part Name  Illustration (Sub-step) Location 
1  2  0S-1608  Bolts  Illustration 9 (2.1), (2.2) and 10 (2.1), (2.2) 
2  2  5P-4868  Hose Clamps  Illustration 9 (2.1), (2.2) and 10 (2.1), (2.2) 
3  1  311-8362  Crankshaft Pulley  Illustration 8 (1.1) 

Installation Procedure

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Illustration 8g06110672
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Illustration 9g06110677
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Illustration 10g06110678

Fuel Filter Base Group

Parts Required

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Illustration 11g06110784

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Table 6
Item  Qty  Part Number  Part Name  Illustration (Sub-step) Location 
1  7  1A-2029  Bolts  Illustration 12 (1.2) 
2  8  3B-1915  Bolts  Illustration 12 (1.3) 
3  25  5M-2894  Hard Washers  Illustration 12 (1.2), (1.3) 
4  1  5P-1075  Hard Washer  Illustration 12 (1.4) 
5  1  310-1119  Filter Support As  Illustration 12 (1.1) 

Installation Procedure

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Illustration 12g06110817

Oil Pan Group

Parts Required

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Illustration 13g06113919

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Table 7
Item  Qty  Part Number  Part Name  Illustration (Sub-step) Location 
1  2  2B-2006  Bolts  Illustration 15 (2.4) 
2  2  2M-9780  O-Ring Seals  Illustration 15 (2.6) 
3  15  3B-1915  Bolts  Illustration 14 (1.5), and 16 (3.4) 
4  38  3H-7654  Hard Washers  Illustration 14 (1.2), 15 (2.2), and 16 (3.2) 
5  1  4P-9853  Block  Illustration 15 (2.3) 
6  14  5J-5793  Bolts  Illustration 14 (1.2), 15 (2.2), and 16 (3.2) 
7  24  5P-5855  Bolts  Illustration 14 (1.2), 15 (2.2), and 16 (3.2) 
8  2  5P-8068  O-Ring Seals  Illustration 15 (2.3) 
9  2  5P-8245  Hard Washers  Illustration 15 (2.4) 
10  1  6I-0723  Oil Drain Plug  Illustration 15 (2.5) 
11  1  6I-0724  Plug Adapter  Illustration 15 (2.3) 
12  25  8M-3175  Hard Washers  Illustration 14 (1.5), and 17 (4.1) 
13  4  8T-6761  Pipe Plugs  Illustration 15 (2.6), and 16 (3.3) 
14  2  9L-9132  Washers  Illustration 14 (1.4) 
15  2  9S-4190  O-Ring Plugs  Illustration 15 (2.6), and 16 (3.3) 
16  2  165-3929  Bolts  Illustration 14 (1.4) 
17  2  200-8691  Bracket As  Illustration 15 (2.1), and 16 (3.1) 
18  2  310-3174  Bracket As  Illustration 14 (1.1) 
19  1  312-3523  Bracket As  Illustration 14 (1.3) 
20  1  319-8910  Bracket As  Illustration 16 (3.1) 
21  1  320-6610  Bracket As  Illustration 15 (2.1) 

Installation Procedure

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Illustration 14g06113961
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Illustration 15g06113969
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Illustration 16g06113987
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Illustration 17g06113995

Suppression Group

Parts Required

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Illustration 18g06114030

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Table 8
Item  Qty  Part Number  Part Name  Illustration (Sub-step) Location 
1  27  0L-2070  Bolts  Illustration 19 (1.2), and 20 (2.2) 
2  27  4B-5271  Washers  Illustration 19 (1.2), and 20 (2.2) 
3  6  205-4805  Cover As  Illustration 19 (1.1), and 20 (2.1) 
4  2  205-4810  Cover As  Illustration 19 (1.1), and 20 (2.1) 
5  1  209-5240  Cover As  Illustration 20 (2.1) 
6  1  287-7113  Cover As  Illustration 19 (1.1) 
7  1  309-8785  Cover As  Illustration 20 (2.1) 

Installation Procedure

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Illustration 19g06114077
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Illustration 20g06114086

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