Procedure to Improve the Water Lines Group for the Turbo on Certain 785C Off-Highway Trucks {1052, 1380} Caterpillar

Truck

785C (S/N: APX1-UP)

Introduction

This Special Instruction contains instruction to improve the water lines group on the machines listed above. The improved water lines group will ensure that the turbo coolant line never gets to zero flow due to a closed thermostat.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Cat dealer for replacement manuals. Proper care is your responsibility.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

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Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

Required Parts

Rework Procedure

Rework Instructions for 170-3578 Water Lines Gp

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Illustration 1	g06098205

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Illustration 2	g06098208
View of area A (B) 148-8410 Plug As

1. Remove plug assembly (B) from the expansion tank assembly in the 170-3578 Water Lines Gp. Discard the part.
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   Illustration 3	g06098212

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   Illustration 4	g06098217
   View of area C (1) 260-9219 Connector As (2) 495-2743 Hose As (3) 174-5907 Clip (4) 5S-7379 Bolt (5) 8T-4896 Hard Washer (6) 6V-8801 Nut (7) 9L-1775 Bracket

2. Install connector assembly (1) to the expansion tank assembly. Connect one end of hose assembly (2) to connector assembly (1).

3. Secure hose assembly (2) using bracket (7), clip (3), two bolts (4), nut (6), and three hard washers (5) as shown in Illustration 4.

4. Connect the other end of hose assembly (2) to the water lines group in the engine arrangement at the same location where the 176-7703 Hose As was removed as shown in Illustration 4.

Rework Instructions for 309-7907 Radiator Gp, and 163-0810 Radiator Gp

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Illustration 5	g06098218

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Illustration 6	g06098221
View of area D (E) 176-7703 Hose As (F) 2N-1288 Elbow (G) 8S-0948 Clip (H) 4L-6454 Bolt (J) 8T-4896 Hard Washer (K) 9L-1775 Bracket (L) 5S-7379 Bolt (M) 6V-8801 Nut

1. Disconnect one end of hose assembly (E) from elbow (F). Remove elbow (F) from 2W-2910 Elbow in the 309-7907 Radiator Gp, and 163-0810 Radiator Gp. Discard the parts.

2. Remove clip (G), bracket (K), bolt (H), bolt (L), nut (M), and three hard washers (J) that secure hose assembly (E) as shown in Illustration 6.

3. Disconnect other end of hose assembly (E) from water lines group in the engine arrangement as shown in Illustration 6. Discard the part.
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   Illustration 7	g06098225
   (8) 3J-5390 Plug

4. Install new plug (8) on 2W-2910 Elbow in the 309-7907 Radiator Gp, and 163-0810 Radiator Gp.

Rework Instructions for Engine Water Lines Group

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Illustration 8	g06098227

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Illustration 9	g06098228
View of area N (P) 118-4728 Elbow (R) 3K-0360 O-Ring Seal (S) 112-6053 Tube As (T) 8M-0505 Adapter (U) 6V-6609 O-Ring Seal (V) 112-6054 Tube As

1. Remove tube assembly (S), tube assembly (V), two adapters (T), two elbows (P), two O-ring seals (U), and two O-ring seals (R) from the engine arrangement. Discard the parts.
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   Illustration 10	g06098229

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   Illustration 11	g06098231
   View of area X (Y) 113-8188 Elbow (Z) 241-3283 Gasket (AA) 0S-1608 Bolt (AB) 5M-2894 Hard Washer (AC) 2A-4639 Bolt (AD) 272-1777 Hard Washer (AE) 7N-7878 Cover Plate (AF) 3B-1915 Bolt

2. Remove two elbow (Y), two bolts (AA), eight hard washers (AB), two bolts (AF), four gaskets (Z), two cover plates (AE), four hard washers (AD), and four bolts (AC) from the engine arrangement. Discard the parts.
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   Illustration 12	g06098232
   (AG) 0S-0509 Bolt

3. Remove bolt (AG) from the engine arrangement. Discard the part.
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   Illustration 13	g06098234

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   Illustration 14	g06098237
   View of area AH (9) 0S-1594 Bolt (10) 8T-1889 Clip (11) 8T-1890 Clip (12) 353-7954 Grommet (13) 8U-4791 Washer (14) 476-6050 Hose and Tube As (15) 367-5990 Elbow As

4. Install two elbow assemblies (15) in the engine arrangement. Connect one end of each hose and tube assembly (14) to elbow assembly (15).

5. Secure each hose and tube assembly (14) using clip (10), clip (11), grommet (12), and washer (13) as shown in Illustration 14.

6. Attach bolt (9) on 8X-7008 Bracket as shown in Illustration 14.

7. Connect other end of each hose and tube assembly (14) to 6V-8626 Elbow as shown in Illustration 14.
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   Illustration 15	g06098249

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   Illustration 16	g06098253
   View of area AJ (16) 2A-4639 Bolt (17) 272-1777 Hard Washer (18) 5M-2894 Hard Washer (19) 7N-7878 Cover Plate (20) 341-9211 Gasket (21) 0S-1608 Bolt (22) 155-0515 Elbow (23) 6V-3251 O-Ring Seal (24) 6V-8626 Elbow (25) 6V-5138 O-Ring Seal (26) 3B-1915 Bolt

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   Illustration 17	g06098258
   View of area AK (16) 2A-4639 Bolt (17) 272-1777 Hard Washer (18) 5M-2894 Hard Washer (19) 7N-7878 Cover Plate (20) 341-9211 Gasket (21) 0S-1608 Bolt (22) 155-0515 Elbow (23) 6V-3251 O-Ring Seal (24) 6V-8626 Elbow (25) 6V-5138 O-Ring Seal (26) 3B-1915 Bolt

8. Install elbow (22), gasket (20), O-ring seal (23), bolt (21), bolt (26), O-ring seal (25), and hard washer (18) on each elbow (24).

9. Install two gaskets (20) on cover plates (19) using four bolts (16), four hard washers (17), and four hard washers (18) as shown in Illustration 16 and Illustration 17.

10. Install cover plate (19) along with gasket (20) near to each elbow (22) as shown in Illustration 16 and Illustration 17.