Installation of the 513-4429 Engine Conversion Kit For 789D Off-Highway Truck Engines {1000} Caterpillar

Installation of the 513-4429 Engine Conversion Kit For 789D Off-Highway Truck Engines {1000}

Usage:

789D SHH

Off-Highway Truck/Tractor: 789D (S/N: SPD1-UP; SHH1-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 513-4429 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.

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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(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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Route - To install a harness, hose, or wire along a specific course or layout along or through a product, to direct along a predefined path.

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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)

Drive Group

Parts Required

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Illustration 1	g06115236

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Table 3
Item	Qty	Part Number	Part Name	Illustration (Sub-step) Location
1	1	9Y-8465	Crankshaft Pulley Group	Illustration 2

Installation Procedure

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Illustration 2	g06115246

Oil Pan and Plug Group

Parts Required

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Illustration 3	g06115526

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Table 4
Item	Qty	Part Number	Part Name	Illustration (Sub-step) Location
1	2	2M-9780	O-Ring Seals	Illustration 5 (2.3)
2	15	3B-1915	Bolts	Illustration 4 (1.5), and 6 (3.4)
3	14	5J-5793	12 Point Bolts	Illustration 4 (1.2), 5 (2.2), and 6 (3.2)
4	36	5P-5855	12 Point Bolts	Illustration 4 (1.2), 5 (2.2), and 6 (3.2)
5	25	8M-3175	Hard Washers	Illustration 4 (1.5), and 7 (4.1)
6	2	8T-6761	Pipe Plugs	Illustration 5 (2.3), and 6 (3.3)
7	2	9L-9132	Hard Washers	Illustration 4 (1.4)
8	3	9S-4190	Plugs	Illustration 5 (2.3), and 6 (3.3)
9	2	165-3929	Hex Head Bolts	Illustration 4 (1.4)
10	2	200-8688	Bracket Assemblies	Illustration 4 (1.1)
11	1	200-8690	Bracket Assembly	Illustration 6 (3.1)
12	2	200-8691	Bracket Assemblies	Illustration 5 (2.1), and 6 (3.1)
13	1	211-0721	Bracket Assembly	Illustration 5 (2.1)
14	1	211-0724	Bracket Assembly	Illustration 4 (1.3)
15	1	238-5081	O-Ring Seal	Illustration

Installation Procedure

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Illustration 4	g06115629

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Illustration 5	g06115666

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Illustration 6	g06115677

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Illustration 7	g06115684

Sound Suppression Group

Parts Required

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Illustration 8	g06115850

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Table 5
Item	Qty	Part Number	Part Name	Illustration (Sub-step) Location
1	31	0L-2070	Bolts	Illustration 11 (3.3), and 12 (4.6)
2	44	1D-4538	Bolts	Illustration 9 (1.3), and 10 (2.2)
3	31	4B-5271	Washers	Illustration 11 (3.3), and 12 (4.6)
4	5	4W-3027	Engine Breathers	Illustration 9 (1.4), and 10 (2.4)
5	5	4W-3034	Clamps	Illustration 9 (1.6), and 10 (2.6)
6	5	5P-0597	Hose Clamps	Illustration 9 (1.8), and 10 (2.8)
7	44	9M-1974	Hard Washers	Illustration 9 (1.3), and 10 (2.2)
8	5	033-6031	O-Ring Seals	Illustration 9 (1.4), and 10 (2.4)
9	11	101-4197	Covers	Illustration 9 (1.1), and 10 (2.1)
10	5	101-4199	Cover Assemblies	Illustration 9 (1.2), and 10 (2.3)
11	1	141-7143	Hose Elbow	Illustration 10 (2.5)
12	3	180-3007	Hose Clamps	Illustration 9 (1.7), and 10 (2.7)
13	5	205-4805	Cover Assemblies	Illustration 11 (3.2), and 12 (4.2)
14	4	205-4810	Cover Assemblies	Illustration 11 (3.1), and 12 (4.3)
15	1	209-5240	Cover Assemblies	Illustration 12 (4.1)
16	2	217-6692	Hose Tee's	Illustration 9 (1.5)
17	11	272-0760	Seals	Illustration 9 (1.1), (1.2), and 10 (2.1)
18	1	287-7114	Cover Assembly	Illustration 12 (4.4)
19	1	287-7117	Cover Assembly	Illustration 12 (4.5)
20	11	399-4711	Insulator Assemblies	Illustration 9 (1.1), and 10 (2.1)
21	5	399-4712	Insulator Assemblies	Illustration 9 (1.2), and 10 (2.3)

Installation Procedure

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Illustration 9	g06116101

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Illustration 10	g06116248

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Illustration 11	g06116199

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Illustration 12	g06116226

Engine Wiring Group

Parts Required

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Illustration 13	g06117238

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Table 6
Item	Qty	Part Number	Part Name	Illustration (Sub-step) Location
1	3	0L-2070	Bolts	Illustration 16 (3.1), and 18 (5.1)
2	10	0S-0509	Bolts	Illustration 15 (2.3), and 17 (4.2)
3	2	4B-5271	Washers	Illustration 16 (3.1)
4	25	4P-7581	Ladder Clips	Illustration 14 (1.4), 15 (2.4), 16 (3.3), and 18 (5.2)
5	50	5M-2894	Hard Washers	Illustration 14 (1.2), (1.3), 15 (2.3), 16 (3.3), 17 (4.2), and 18 (5.1)
6	2	8T-4136	Hex Head Bolts	Illustration 14 (1.2)
7	1	8T-4191	Hex Head Bolt	Illustration 14 (1.4)
8	72	9X-6772	Cable Straps	Illustration 14 (1.6), 15 (2.4), 16 (3.4), 17 (4.3), and 18 (5.4)
9	1	033-8248	Loop Clip	Illustration 14 (1.2)
10	3	130-5300	Clip	Illustration 14 (1.2), 16 (3.2), and 18 (5.3)
11	4	204-2281	Cable Straps	Illustration 15 (2.1)
12	2	415-2431	Temperature Sensor Groups	Illustration 15 (2.2), and 17 (4.1)