Usage:
Start By:
a. remove fan and adapter
b. remove supplemental steering and brake pump *
c. remove crankcase guards
*This operation can be found in the Machine Systems Disassembly And Assembly book, SENR6859.
NOTE: Drain the oil from the engine and hydraulic tank. Put identification on all hose assemblies and wires for assembly purposes.
1. Loosen clamps (1). Disconnect heater hoses (2) from the water pump cover.
2. Disconnect fuel lines (3).
3. Disconnect hose assembly (6) from the elbow.
4. Disconnect elbows (4) and (5) from the brake and torque converter oil cooler.
5. Disconnect hose assemblies (8) from the air conditioning compressor.
6. Disconnect wires (7).
7. Disconnect wire (11) from the starting motor.
8. Disconnect wires (9) from the solenoid. Disconnect clip (10) and pull the wires clear of the engine.
9. Disconnect hose assemblies (13) from the fitting. Disconnect clip (12) from the guard assembly and pull the hose assembly clear.
10. Disconnect hose assembly (14) from the pump drive group.
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Before any lines are disconnected from the air compressor, make sure the air pressure is zero. |
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11. Disconnect air lines (15) and (16) from the air compressor. Disconnect the clip (not shown) and pull the lines clear of the engine.
12. Remove bolts (17) that hold the spider to the yoke on each end of the drive shaft. Remove pump drive shaft (19).
13. Remove bolts (20) that hold the spider to the yoke on each end of the drive shaft. Remove pump drive shaft (19).
14. Fasten a hoist and tooling (A) to the guard assembly. Remove bolts (22). Remove guard assembly (21). The weight of the guard assembly is 29 kg (65 lb).
15. Disconnect hose assemblies (23) and (24) from the transmission and torque converter scavenge pump.
16. Disconnect hose assemblies (25) and (26) from the torque inlet relief valve.
17. Disconnect wire (27) from the torque converter oil temperature switch.
18. Disconnect hose assembly (28) from the torque converter outlet relief valve.
19. Disconnect clip (29) from the torque converter.
20. Disconnect hose assembly (30).
21. Disconnect clip (32) from the transmission and torque converter scavenge pump. Disconnect hose assembly (31) from the torque converter and pull clear.
22. Fasten a hoist to the drive shaft. Remove bolts (34) that hold the spider assembly to the yoke. Pull drive shaft (33) clear of the torque converter. Use the hoist to lower the weight of the drive shaft on the frame of the machine.
23. Remove the bolts. Remove pipe (35) from the manifold and air lines group.
24. Disconnect tachometer drive cable (38) from the cab.
25. Disconnect wiring harness assembly (36).
26. Disconnect air line (37) from the governor control cylinder.
27. Disconnect cables (39) from the batteries. Disconnect clips (40) from the pipe assembly. Pull cables (39) clear of the pipe assembly.
28. Fasten a hoist to the pipe assembly. Remove the bolts that hold it. Remove pipe assembly (41) and shims.
29. Disconnect wires (43) from switch (42).
NOTE: Put identification on wires (43) to make installation easier.
30. Remove bolts (45). Pull air lines group (44) up and toward the back of the engine.
NOTE: This will permit the hoist to be fastened to the rear lifting eye assembly without the removal of the air lines group.
31. Disconnect clips (46) from the oil pan. Pull hose assembly (6) clear of the engine.
32. Fasten tool (B) and a hoist to the engine. Remove bolts (48) and nuts. Remove caps (47) from each side of the flywheel housing.
33. Remove bolts (50) that hold the support assembly to the frame. Remove engine (49) and torque converter as a unit. The unit weight of the engine and torque converter is 2925 kg (6500 lb).
Install Engine And Torque Converter
1. Fasten tool (B) and a hoist to the engine. Put engine (1) and torque converter in position in the machine. Install the bolts that hold the front support to the frame. Tighten the bolts to a torque of 360 ± 50 N·m (265 ± 35lb ft).
2. Install caps (2) on each side of the flywheel housing. Install the bolts and nuts that hold them. Tighten the nuts to a torque of 435 ± 20N·m (320 ± 15 lb ft).
3. Put hose assembly (3) in position around the oil pan. Install clips (4) that hold it.
4. Put air lines group (5) in position on the aftercooler cover. Install the bolts that hold it.
5. Connect wires (7) to switch (6).
6. Fasten a hoist to the pipe assembly. Install pipe assembly (8) and shims (9).
7. Put battery cables (10) in position on the pipe assembly. Connect clips (11) that hold them.
8. Connect air line (13) from the governor control cylinder to the cab.
9. Connect tachometer drive cable (14).
10. Connect wiring harness assembly (12).
11. Connect pipe (15) to the manifold and air lines group.
12. Fasten a hoist to the drive shaft. Put drive shaft (16) in position on the torque converter yoke. Install the bolts that hold it. Tighten the bolts to a torque of 135 ± 14 kg (100 ± 10 lb).
13. Connect clip (18) to the transmission and torque converter scavenge pump. Connect hose assembly (17) to the torque converter.
14. Put the hose assembly in position and connect clip (19) to the torque converter.
15. Connect hose assembly (10) to the torque converter.
16. Connect hose assembly (24) to the torque converter outlet relief valve.
NOTE: Check the O-ring seals on all the hose assemblies for wear or damage. If necessary, make a replacement.
17. Connect wire (23) to the torque converter oil temperature switch.
18. Connect hose assemblies (21) and (22) to the torque converter inlet relief valve.
19. Connect hose assemblies (25) and (26) to the transmission and torque converter scavenge pump.
20. Fasten tool (A) and a hoist to the guard assembly. Put guard assembly (27) in position over the drive shaft. Install the bolts that hold it.
1. Put pump drive shaft (28) in position on the pump drive and engine. Install the bolts that hold it. Tighten the bolts to a torque of 55 ± 7 N·m (40 ± 5 lb ft).
22. Put guard assembly (29) in position over the pump drive shaft. Install the bolts that hold it.
23. Connect air lines (30) and (31) to the air compressor.
24. Connect hose assemblies (33) and (35) to the fitting. Connect clip (32) to the guard assembly.
25. Connect hose assembly (34) to the pump drive.
26. Connect wire (38) to the starting motor.
27. Connect wires (37) to the solenoid. Connect clip (36) to the engine.
28. Connect wires (39) to the air conditioning compressor.
29. Connect hose assemblies (40) and (41).
30. Connect elbows (42) and (43) to the brake and torque converter oil cooler.
31. Connect hose assembly (3) to the elbow.
32. Put heater hoses (45) in position on the water pump cover. Tighten clamps (44).
33. Connect fuel lines (46).
34. Fill the engine with oil to the correct level. See Operation And Maintenance Guide for the correct fluid levels.
35. Fill the hydraulic tank with oil to the correct level. See Operation And Maintenance Guide for the correct oil level.
End By:
a. Install crankcase guards
b. install supplemental steering and brake pump *
c. install fan and adapter
*This operation is in the Machine System, Disassembly And Assembly SENR6859.