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2010/08/19 Caterpillar


Correction to Disassembly and Assembly , "Engine and Torque Converter Updrive Gears - Install" {1000, 3101, 3105, 3159}

Usage:

AD55B JNW
Underground Articulated Truck:
AD55B (S/N: JNW182-UP)
Disassembly and Assembly, KENR6707, "Engine and Torque Converter Updrive Gears - Install". This manual is part of Service Manual, KENR6715 Volume I.

Replace the existing information with the following information.

Installation Procedure

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Table 1
Required Tools    
Tool     Part
Number    		 Part Description     Qty    
A     6V-6146     Load Levelling Beam     1    

Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the components, if necessary.

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    Illustration 1g01874542

  1. Attach Tooling (A) and a suitable lifting device to engine and torque converter and updrive gears (79). The weight of engine and torque converter updrive gears (79) is approximately 4000 kg (8900 lb).

  1. Install engine and torque converter updrive gears (79) .
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    Illustration 2g02206134

    Typical example

  1. Use a suitable lifting device to install mount assembly (85). Install mount assembly (85) and six bolts (86). Tighten six bolts (86) to a torque of 475 ± 60 N·m (350 ± 44 lb ft).
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    Illustration 3g02206133

  1. Install cap (84), two bolts (83) and the two nuts .
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    Illustration 4g01874546

  1. Install cap (81) and two bolts (82) .
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    Illustration 5g01874545

  1. Install the mount, bolt (80) and the nut.

  1. Repeat Step 6 for the other side front engine mount.
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    Illustration 6g01874540

  1. Install plate (78) and two bolts (77) .
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    Illustration 7g01874539

  1. Connect hose assembly (75) and install clamp assembly (76) .
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    Illustration 8g01984459

  1. Connect tube assemblies (72) and (74) .

  1. Install tube assembly (73) .
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    Illustration 9g02188334

  1. Connect hose assembly (70) to the steering pump. Connect hose assembly (71) .
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    Illustration 10g02188333

  1. Install clamp assembly (67) (not shown). Connect hose assembly (66). Install clips (68) and (69) .
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    Illustration 11g02186380

  1. Connect hose assemblies (65) and (64) .
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    Illustration 12g02186354

  1. Connect hose assembly (63) .
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    Illustration 13g02186353

  1. Connect hose assemblies (61), (60) and three hose assemblies (58). Install pilot valve (59). Connect harness assembly (62) .
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    Illustration 14g02186333

  1. Connect tube assemblies (55) and (57) to the hydraulic tank.

  1. Install heat shields (54) and 15 bolts (56). Connect hose assembly (53) .
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    Illustration 15g02186315

  1. Install tube assembly (50) and two bolts (51) .

  1. Install tube assembly (49) and clamp assembly (52) .
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    Illustration 16g02186294

  1. Connect hose assemblies (47), (46) and (48) .
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    Illustration 17g02186293

  1. Install three tube assemblies (45) .
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    Illustration 18g02186257

  1. Install bracket (42) and three clamp assemblies (43). Connect three hose assemblies (44) .
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    Illustration 19g02186256

  1. Install four tube assemblies (41) .
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    Illustration 20g02186255

  1. Install bracket (40), three clamp assemblies (39) and clamp assembly (37) (not shown). Connect four hose assemblies (38) .
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    Illustration 21g02186254

  1. Connect electrical cable (36) to the alternator.
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    Illustration 22g02186253

  1. Install three clips (35) to electrical cable (36) .
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    Illustration 23g02186236

  1. Connect three electrical cables (33), two electrical cables (34) and electrical cable (32) to the starting motor. Connect harness assembly (31) .
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    Illustration 24g02186235

  1. Connect hose assembly (27) to the fuel priming pump. Install clip (28). Attach cable straps (29) as required to secure hose assembly (27) to hose assembly (30) .
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    Illustration 25g02186234

  1. Install cover (26) .
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    Illustration 26g02186233

  1. Connect hose assemblies (24) (if equipped). Install four clips (25) .
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    Illustration 27g02184693

  1. Connect hose assemblies (23), (22), (21), (20) and (19) .
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    Illustration 28g01984457

  1. Open valve (18) for the right side fuel tank.
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    Illustration 29g01984456

  1. Open valves (17) and (16) for the left side tank.
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    Illustration 30g01984455

  1. Connect harness assembly (15) .
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    Illustration 31g01984454

  1. Install mount (14) and four bolts (13) .

  1. Install the clip and connect harness assembly (14) .
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    Illustration 32g01441496

  1. Install tube assembly (11) and tighten clamp (12) .
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    Illustration 33g01441493

  1. Tighten clamp (10) .
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    Illustration 34g01441495

  1. Install tube assembly (8) and tighten clamp (9) .
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    Illustration 35g01441494

  1. Install clamp assembly (7) .
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    Illustration 36g01441492

  1. Tighten clamp (6) .
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    Illustration 37g02184673

  1. Install cover (5) .
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    Illustration 38g01441489

  1. Use two people to install tube assembly (4). The weight of tube assembly (4) is approximately 27 kg (60 lb).

  1. Install tube assembly (4) .
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    Illustration 39g01441488

  1. Install clamp (3) below cover (1) .
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    Illustration 40g01441487

  1. Install four bolts (2). Position cover (1), as shown.

  1. Fill the hydraulic tank. Refer to Operation and Maintenance Manual, "Capacities (Refill)" for the capacity of the hydraulic tank. Refer to Operation and Maintenance Manual, "Hydraulic Tank Oil - Change" for the correct filling procedure.

  1. Prime the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct priming procedure.

End By:

a. Install the cooling system package. Refer to Disassembly and Assembly, "Cooling System Package (Radiator, Fan, After Cooler) - Install".

b. Install the upper drive shaft. Refer to Disassembly and Assembly, "Drive Shaft (Upper) - Remove and Install".

c. Install the firewalls. Refer to Disassembly and Assembly, "Firewall - Install".

d. Install the engine bottom guard. Refer to Disassembly and Assembly, " Bottom Guard (Engine) - Remove and Install".

e. Install the transmission bottom guard. Refer to Disassembly and Assembly, "Bottom Guard (Transmission) - Remove and Install".

f. Install the rear hood. Refer to Disassembly and Assembly, "Hood (Rear) - Remove and Install".

g. Separate the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and connect".

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