Command Package Installation On Certain C175 Engines {1000, 1358, 1397, 1405, 1408} Caterpillar

Off-Highway Truck/Tractor

793F (S/N: SSP1-UP; RBT1-UP)

Introduction

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

378-5492378-5492Required Parts for Installing the 378-5492 Engine Conversion Ar

Illustration 1	g03808700

Installation Procedure

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Illustration 2	g03808717
View of the left-hand side of the engine (A) Guard group

Note: Refer to Disassembly and Assembly, KENR8578, "Alternator - Remove and Install" for additional information.

1. Remove and discard guard group (A) around the alternator.
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   Illustration 3	g03808720
   View of the left-hand side of the engine (B) Wiring group

2. Remove wiring group (B) from the engine. Discard the cable assemblies. Retain the mounting hardware.
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   Illustration 4	g03808721
   View of the left-hand side of the engine (C) Alternator group (D) Plate

   Note: Refer to Disassembly and Assembly, KENR8578, "Alternator - Remove and Install" for additional information.

3. Remove alternator group (C). Retain plate (D). Discard all other components and hardware.
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   Illustration 5	g03808723
   View of the left-hand side of the engine (E) Alternator mounting group

4. Remove alternator mounting group (E) from the engine. Retain the mounting hardware. Discard the mount.

   Note: Retain the clipping for the existing wiring harness assembly that is secured to mounting group (E).

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   Illustration 6	g03808818
   View of the left-hand side of the engine (1) 420-7738 Support (2) 6V-5815 Bolt (3) 6V-5839 Washer (4) 6V-8836 Bolt (5) 5P-8245 Hard Washer

5. Secure support (1) to the side of the engine by using two bolts (2), two washers (3), two bolts (4), and two hard washers (5).

   Note: All hardware was retained from Step 4.

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   Illustration 7	g03808889
   View of the left-hand side of the engine (1) 420-7738 Support

6. Use the retained clipping from Step 4 to secure the existing wiring harness assembly to support (1).
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   Illustration 8	g03808829
   View of the left-hand side of the engine (6) 131-3718 O-Ring Seal (7) 235-2484 Lip Type Seal (8) 273-1104 Cover (9) 5A-3604 Bolt

7. Secure cover (8), lip type seal (7), and O-ring seal (6) to the oil pump cover by using two bolts (9).

   Note: Lubricate O-ring seal (6) lightly with the lubricant being sealed.

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   Illustration 9	g03808851
   View of the left-hand side of the engine (D) Plate (10) 350-2565 Pulley As (11) 6V-2317 Bolt (12) 154-1580 Hard Washer (13) 6V-3531 Bolt

   Note: Clean the inside diameter of pulley assembly (10), and the outside diameter of the taper on the pump drive shaft, thoroughly with an alcohol wipe before assembly.

8. Secure pulley assembly (10), and plate (D) to the engine by using bolt (13), and hard washer (12). Secure plate (D) to pulley assembly (10) by using four bolts (11).

   Note: Torque bolt (13) to 265 ± 10 N·m (195 ± 7 lb ft).

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   Illustration 10	g03809017
   (1) 420-7738 Support (3) 6V-5839 Washer (14) 322-9743 Charging Alternator Gp (15) 364-4337 Support (16) 8C-2926 Bolt (17) 6V-1819 Bolt (18) 6V-5839 Washer

9. Secure charging alternator group (14) and support (15) to support (1) by using two bolts (16), two washers (3), two bolts (17), and two hard washers (18). Torque bolts (16) and bolts (17) to 60 ± 10 N·m (44 ± 7 lb ft).
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   Illustration 11	g03809050
   (11) 6V-2317 Bolt (14) 322-9743 Charging Alternator Gp (15) 364-4337 Support (19) 325-4723 Pulley (20) 364-4357 Plate (21) 9M-1974 Hard Washer

10. Secure pulley (19) to the front of charging alternator group (14) by using the existing nut.

    Note: Tighten the nut to 102 ± 7 N·m (75 ± 5.1 lb ft).

11. Secure plate (20) to the front of support (15) by using two bolts (11) and two hard washers (21).
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    Illustration 12	g03809316
    (3) 6V-5839 Washer (10) 350-2565 Pulley As (15) 364-4337 Support (19) 325-4723 Pulley (22) 329-8797 Belt Tensioner (23) 350-7106 Serpentine Belt (24) 160-8492 Bolt

12. Secure belt tensioner (22) to support (15) by using bolt (24) and washer (3).

    Secure serpentine belt (23) between pulley assembly (10), pulley (19), and belt tensioner (22).

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    Illustration 13	g03809347
    (18) 198-4766 Hard Washer (25) 434-1013 Alternator Guard As (26) 6V-1820 Bolt

13. Secure alternator guard assembly (25) to the side of the engine by using five bolts (26) and five hard washers (18).
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    Illustration 14	g03809360
    (3) 6V-5839 Washer (5) 5P-8245 Hard Washer (14) 322-9743 Charging Alternator Gp (26) 6V-1820 Bolt (27) 356-7361 Cable As (28) 6V-7673 Bolt (29) 8Y-1816 Spacer (30) 7S-3916 Clip (31) 7S-3919 Clip (32) 5G-3676 Grommet

14. Secure one end of cable assembly (27) to charging alternator group (14) by using the existing bolt. Torque the existing bolt to 6.2 ± 0.6 N·m (55 ± 5.3 lb in).

    Slide the boot of cable assembly (27) over the connection.

15. Secure the other end of cable assembly (27) to the side of the engine by using bolt (28), hard washer (5), and spacer (29).

    Slide the boot of cable assembly (27) over the connection.

    Secure cable assembly (27) to the existing clip that was reinstalled in Step 6 by using bolt (26), hard washer (5), clip (30), clip (31), and grommet (32).

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    Illustration 15	g03809470
    (3) 6V-5839 Washer (14) 322-9743 Charging Alternator Gp (25) 434-1013 Alternator Guard As (26) 6V-1820 Bolt (30) 7S-3916 Clip (31) 7S-3919 Clip (32) 5G-3676 Grommet (33) 6V-4249 Bolt (34) 1V-6645 Spacer (35) 382-4652 Cable As

16. Secure one end of cable assembly (35) to the rear of charging alternator group (25) by using the existing hardware. Tighten the existing hardware to 11.25 ± 2.25 N·m (100 ± 20 lb in).

17. Secure cable assembly (35) to alternator guard assembly (25) by using bolt (26), two bolts (33), three washers (3), two spacers (34), three clips (30), three clips (31), and three grommets (32).
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    Illustration 16	g03809498
    (3) 6V-5839 Washer (30) 7S-3916 Clip (31) 7S-3919 Clip (32) 5G-3676 Grommet (35) 382-4652 Cable As (36) 132-5789 Clip (37) 2Y-5829 Nut (38) 9X-6772 Cable Strap

18. Secure cable assembly (35) to the existing stud on the engine by using clip (36), nut (37), cable strap (38), and washer (3).

    Secure cable assembly (35) in three other locations on the side of the engine by using the existing hardware, three clips (30), three clips (31), and three grommets (32).

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    Illustration 17	g03810139
    (30) 7S-3916 Clip (31) 7S-3919 Clip (32) 5G-3676 Grommet (35) 382-4652 Cable As (39) 154-6626 Bracket As (40) 8T-4136 Bolt (41) 8T-4121 Hard Washer

19. Secure cable assembly (35) to the frame in one location by using bracket assembly (39), bolt (40), hard washer (41), clip (30), clip (31), grommet (32), and the existing hardware from the chassis wiring group.

    Secure cable assembly (35) in two other locations by using two clips (30), two clips (31), two grommets (32), and the existing hardware from the chassis wiring group.

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    Illustration 18	g03810152
    (35) 382-4652 Cable As (42) 5P-6264 Grommet

20. Route cable assembly (35) through the available hole in the side breaker box assembly with grommet (42).
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    Illustration 19	g03810182
    (35) 382-4652 Cable As (A) Nut (B) Washer (C) Lockwasher

21. Secure cable assembly (35) to the breaker assembly by using the existing hardware from the breaker assembly. Tighten the nut to a torque of 6.3 ± 0.5 N·m (55 ± 4.4 lb in).

    Slide the boot of cable assembly (35) over the connection.