797F Tier 4 Off-Highway Truck Engine Supplement Caterpillar

Removal Procedure

Start By:

1. Remove the modular front end.

2. Remove the rear hood.

3. Remove the exhaust bypass

4. Remove the pump drive shaft

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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the cooling system pressure cap is cool enough to touch with your bare hand. Remove the cooling system pressure cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

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In order to prevent possible personal injury, release the air pressure from the air tank before disconnecting any components of the air system.

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A high pressure fuel line must be disconnected. To avoid personal injury or fire from fuel spray, the engine must be stopped before the fuel line is disconnected.

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Contact to high pressure fuel can cause personal injury or death. Do not allow high pressure fuel to contact your skin.

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Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.

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The space between the body and the frame becomes a zero clearance area when the body is lowered. Failure to install the retaining cable can result in injury or death to personnel working in this area.

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Personal injury or death can occur from heavy components falling during removal or installation. Properly support the component with a suitable lifting device during removal or installation.

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Personal injury can result from contact with refrigerant. Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury. Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant. Always use precaution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated area. Personal injury or death can result from inhaling refrigerant through a lit cigarette. Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death. Do not smoke when servicing air conditioners or wherever refrigerant gas may be present. Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system.

1. Recover the air conditioner refrigerant from the air conditioner system. Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant". Refer to Special Publication, NEDG2500, "Air Conditioning Tools" for the correct procedure.

2. Turn the power disconnect switch to the OFF position.

3. Turn the fuel supply to the OFF position.

4. Release the system pressure. Refer to Operation and Maintenance Manual, SEBU8417, "System Pressure - Release" for the correct procedure.

5. If equipped with an oil renewal system (ORS), Drain the engine oil into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, SEBU8417, "Engine Oil and Filter - Change" for the correct procedure.

6. Purge the air pressure from the air tank. Refer to Operation and Maintenance Manual, SEBU8417, "Air Tank Moisture and Sediment - Drain" for the correct procedure.

7. Drain the torque converter and transmission oil into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, SEBU8417, "Torque converter and Transmission Oil - Change" for the correct procedure.
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   Illustration 1	g06337413

8. Install Tooling (A) under the frame assembly to neutralize the weight when the cross tube is removed.
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   Illustration 2	g06337430

9. Remove clamps (4) and disconnect hose (5). Disconnect hose assembly (3), hose assembly (6), and hose assembly (7). Remove clamps (1) and tube assembly (2).
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   Illustration 3	g06337734

10. Remove bolts (8) and cable assembly (9).
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    Illustration 4	g06337767

11. Disconnect hose assembly (10) and hose assembly (12). Remove clips (11).
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    Illustration 5	g06337876

12. Remove bolts (13) and bracket (14). Remove bolt (15).
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    Illustration 6	g06337877

13. Disconnect harness assembly (16) and harness assembly (17).
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    Illustration 7	g06337889

14. Remove bolt (18) and disconnect harness assembly (19).
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    Illustration 8	g06338137

15. Remove clamps (20) and clamps (22). Disconnect hose assembly (21) and hose assembly (23).
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    Illustration 9	g06338164

16. Remove hose assembly (24) and hose assemblies (25).
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    Illustration 10	g06338218

17. Disconnect hose assembly (26).
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    Illustration 11	g06338325

18. Disconnect hose assembly (27) and hose assembly (28).
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    Illustration 12	g06338372

19. Disconnect hose assembly (29), hose assembly (30), and hose assembly (31).
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    Illustration 13	g06338389

20. Disconnect hose assembly (32) and hose assembly (33).
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    Illustration 14	g06338415

21. Disconnect harness assembly (34). Disconnect hose assembly (35), hose assembly (36), hose assembly (37), and hose assembly (38).
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    Illustration 15	g06338592

22. Attach a suitable lifting device onto main drive shaft (40). The weight of main drive shaft (40) is approximately 295 kg (650 lb). Remove bolts (39), use a suitable prybar to retract main drive shaft (40) from the torque converter yoke.
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    Illustration 16	g06339101

23. Disconnect hose assembly (41) and hose assembly (42).
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    Illustration 17	g06339164

24. Remove bolts (43), clips (45), and handrail assembly (44).
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    Illustration 18	g06339173

25. Remove bolts (46) and plate (47).
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    Illustration 19	g06339740

26. Attach a suitable lifting device onto support assembly (49). The weight of support assembly (49) is approximately 34 kg (75 lb). Remove bolts (48) and support assembly (49).
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    Illustration 20	g06339331

27. Attach a suitable lifting device to exhaust group (51). Exhaust group (51) weighs approximately 125 kg (276 lb). Remove bolts (50).
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    Illustration 21	g06339334

28. Remove bolts (52).
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    Illustration 22	g06339354

29. Remove bolts (53) and exhaust group (51). Exhaust group (51) weighs approximately 125 kg (276 lb). Place exhaust group (51) on Tooling (B) for temporary storage.
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    Illustration 23	g06340019

30. Remove clamp (54) and hose assembly (55). Remove bolts (56).
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    Illustration 24	g06340027

31. Remove bolts (57) and bolts (58). Place harness assembly (59) to the side.
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    Illustration 25	g06340219

    Note: Mark the orientation of the cross tube on the frame for installation purposes.

    Note: Record the number of shims at each end of the cross tube for installation purposes. If the shims are lost or damaged during removal procedure, or if the engine cross tube is replaced, refer to the Engine Cross Tube Shimming Procedure section in this document for the correct installation procedure.

32. Attach a suitable lifting devices onto cross tube (62). The weight of cross tube (62) is approximately 218 kg (481 lb).

33. Remove bolts (61). Remove shims (60) from both sides of the cross tube as required. Retain shims (60) for installation purposes. Use suitable lifting devices to remove cross tube (62). The weight of cross tube (62) is approximately 218 kg (481 lb).
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    Illustration 26	g06340457

34. Use two people to remove step assembly (65). Step assembly (65) weighs approximately 25 kg (55 lb). Remove nuts (63), bolts (64), and step assembly (65).
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    Illustration 27	g06340646

35. Attach a suitable lifting device to tube assembly (67). Tube assembly (67) weighs approximately 42 kg (93 lb). Remove clamps (66) and tube assembly (67). Place tube assembly (67) on Tooling (B) for temporary storage.
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    Illustration 28	g06341123

36. Attach a suitable lifting device to tube assembly (70). Tube assembly (70) weighs approximately 52 kg (115 lb). Remove clamps (68), U-bolts (69), and tube assembly (70). Place tube assembly (70) on Tooling (B) for temporary storage.
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    Illustration 29	g06341149

37. Remove bolt (71) and clamps (72). Use two people to remove tube assembly (73). Tube assembly (73) weighs approximately 25 kg (55 lb). Place tube assembly (73) on Tooling (B) for temporary storage. Disconnect hose assembly (74).
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    Illustration 30	g06341896

38. Remove clamps (78) and hose (79). Loosen clamps (75), remove clips (76) and tube assembly (77). Tube assembly (77) weighs approximately 12 kg (26 lb).
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    Illustration 31	g06364998

39. Remove mounting bolts (80) and reposition electronic control module (81) and secure to the engine.
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    Illustration 32	g06342518

40. Use Tooling (C), Tooling (D), and Tooling (E) to support engine and torque converter (82). The weight of engine and torque converter (82) is approximately 17105 kg (37710 lb).
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    Illustration 33	g06342538

41. Remove bolts (83) and engine mount assembly (84).
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    Illustration 34	g06342540

42. Remove bolts (85) and engine mount assembly (86).
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    Illustration 35	g06342799

43. Remove bolts (87) and front engine mounts (88).
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    Illustration 36	g06342800

44. Use Tooling (C), Tooling (D), and Tooling (E) to remove engine and torque converter (82). The weight of engine and torque converter (82) is approximately 17105 kg (37710 lb).

Installation procedure

1. Install engine and torque converter (82) in the reverse order of removal.

   Note: Ensure that the bolts on clamps (72) are 180 degrees from each other.

   1. Tighten clamps (72) to a torque of 10 ± 2 N·m (89 ± 18 lb in).

      Note: Ensure that the bolts on clamps (68) are 180 degrees from each other.

   2. Tighten clamps (68) to a torque of 10 ± 2 N·m (89 ± 18 lb in).

   3. Tighten U-bolts (69) to a torque of 30 ± 7 N·m (266 ± 62 lb in).

   4. Install shims (60) onto Side (A) and Side (B).

   5. Apply Tooling (F) onto bolts (61) and under the head of bolts (61). Bolts (61) must be tightened in a crisscross pattern.

   6. Tighten bolts (39) in an alternating x pattern to a torque of 1000 ± 125 N·m (738 ± 92 lb ft).

   7. Tighten nuts on harness assembly (16) to a torque of 2.25 ± 0.25 N·m (20 ± 2.22 lb in).

   8. Tighten nuts on harness assembly (17) to a torque of 13 ± 2 N·m (115 ± 18 lb in).
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   Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Clean up fuel spills immediately.

2. Turn the fuel supply to the ON position. Refer to Operation and Maintenance Manual, "Fuel System - Prime".
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   Personal injury can result from contact with refrigerant. Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury. Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant. Always use precaution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated area. Personal injury or death can result from inhaling refrigerant through a lit cigarette. Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death. Do not smoke when servicing air conditioners or wherever refrigerant gas may be present. Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system.

3. Charge the air conditioner refrigerant to the air conditioner system. Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant". Refer to Special Publication, NEDG2500, "Air Conditioning Tools" for the correct procedure.

4. Fill the engine oil. Refer to Operation and Maintenance Manual, SEBU8417, "Capacities (Refill)" for the correct procedure.

5. Fill the torque converter and transmission. Refer to Operation and Maintenance Manual, SEBU8417, "Capacities (Refill)" for the correct procedure.

End By:

1. Install the modular front end.

2. Install the rear hood.

3. Install the exhaust bypass.

Engine Cross Tube Shimming procedure

Refer to the following procedure if the engine cross tube shims have been misplaced during the removal procedure or the engine cross tube is replaced. Use the following steps to determine the proper number and location of the shims used when replacing / installing the engine cross tube.

1. Fully collapse the front suspension cylinders. Refer to SEHS9411 Special Instructions Manual, "Servicing the Suspension Cylinders for Large Off-Highway Trucks", "Collapse the Front Suspension Cylinders" section for the correct procedure.

   Note: After collapsing the front suspension cylinders, ensure that the outlet charging valves remain open.

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   Illustration 37	g06343837

2. Use Tooling (A) to lift front frame assembly. Raise front frame assembly until 25.4 mm (1 inch) of chrome is exposed at Dimension (D1) on the front suspension cylinders.
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   Illustration 38	g06343645

3. Use a suitable lifting device to Install cross tube (62). The weight of cross tube (62) is approximately 218 kg (481 lb).

4. If cross tube (62) does not fit, continue to lift the machine until cross tube (62) fits between the frame without the use of shims (no shims required).

5. If cross tube (62) does fit, place one end of cross tube (62) flush against the frame at Side (B). Apply Tooling (F) onto bolts (61) and under the head of bolts (61). Install four bolts (61) on Side (A) and Side (B) loosely.

   Note: Side (A) is the cab side.

   Note: Do not tighten bolts (61) to a final torque.

6. With cross tube (62) flush against the frame at Side (B), begin installing shims (60) at Side (A). Install the required quantity of shims (60) at Side (A) and Side (B) as required.

   Note: Do not force the shims into the gap between the cross tube and the frame. Only use enough shims to fill the gap.

   Note: Add or remove bolts (61) to allow for the installation of shims (60).

7. If five or more shims are required, install the first five required shims on side (A) and the remaining required shims on side (B). If five or less shims are required, install all required shims on side (A).

   Note: Side (A) is the cab side.

   Note: The total number of shims should not exceed ten.

   Note: Document the shim number and location with the serial number of the truck for future reference.

8. Once the required shims are in place, Install the remaining bolts (61) in a crisscross pattern.

9. Lower the machine so that the front suspension cylinders are fully collapsed. Remove Tooling (A).
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   NOTICE
   Failure to charge the suspension cylinders properly can lead to damage to the frame.

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   Personal injury or death can result from sudden suspension cylinder movement. Sudden movement, up or down, can cause the clearance above your head to change rapidly. Read all warning labels on the suspension cylinders before servicing. Do not check the oil in the suspension cylinder until all the nitrogen pressure has been released. Do not, under any condition, remove valves, cover or plugs from the cylinder unless the rod is fully retracted and all the nitrogen pressure is released. Do not stand under the machine when testing or adjusting the suspension cylinders.

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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.

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   Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

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   Read all Warning labels on the suspension cylinders before servicing. The vehicle must be on level ground before releasing the nitrogen pressure. Do not check the oil in the suspension cylinder until all of the nitrogen pressure has been released. Do not remove valves, covers or plugs from the cylinder unless the rod is fully retracted and all of the nitrogen pressure has been released. Do not stand under the machine during suspension cylinder charging, discharging, or testing and adjusting procedures or while lifting or lowering the machine. Sudden movement upward or downward can cause the clearance above your head to change rapidly. Failure to heed this Warning could lead to injury or death.

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   Dry nitrogen is the only gas approved for use in the suspension cylinders. Charging the suspension cylinders with oxygen gas will cause an explosion. This danger will not happen if nitrogen cylinders with standard CGA (Compressed Gas Association, Inc.) Number 580 Connections are used. When you order nitrogen gas, be sure that the cylinders are equipped with CGA No. 580 Connections. Do not use color codes or other methods of identification to tell the difference between nitrogen cylinders and oxygen cylinders. Never use an adapter to connect your nitrogen charging group to a valve outlet used on both nitrogen, oxygen or other gas cylinders. Be sure you use dry nitrogen (99.8% purity).

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   When applying an oil charge or a nitrogen charge with the machine on the ground, the machine may suddenly move due to internal sticking of the suspension cylinders.

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   High Pressure Cylinder. Do not remove any grease fitting, valve or plug until the truck is supported and pressure is relieved or the truck may drop suddenly, resulting in personal injury. Suspension groups should only be serviced by properly trained personnel who have read and understand the service manual procedure to relieve pressure and to charge cylinders.

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   NOTICE
   Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates.

10. Charge the front suspension cylinders with oil and nitrogen. Refer to , SEHS9411 Special Instruction Manual , "Servicing the Suspension Cylinders for Large Off-Highway Trucks", "Charge the Front Suspension Cylinders with Oil" and "Charge the Front Suspension Cylinders with Nitrogen" sections for the correct procedure.