Usage:
793 (3SJ),
793B (1HL) Off-Highway Trucks
- SUPPLEMENT: SEPTEMBER 15, 1997
Servcie Magazine; July 28, 1997; Page 10; "Rerouted Heater LInes Reduces 793 Engine Removal And Installation Time".
The chart, "Parts Required for Installation of Rerouted Heater Lines Group" needs additional infomration. It should read as follows:
Step 2, also needs additional infomation. It should read as follows: Cut 18 m (58 ft) of 5P-0767 Radiator Hosing (Bulk) [12.7 mm (.50 in) diameter] only sold in a 15 m (50.0 ft) length.
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Description of Change: Relocate heater lines group from roll over protection system (ROPS) tube to behind front bumper, reducing time required to remove and install 793 engines in the field.
Adaptable To: The 8X-0268 Heater Lines Group (not serviced) rerouting procedure is adaptable to all existing 793 (3SJ) and 793B (1HL) Off-Highway Trucks. (Refer to procedure for adaptability to all previous models).
Illustration 1. Former location of 8X-0268 Heater Lines Group.
Illustration 2. New location of 8X-0268 Heater Lines Group and View A-A.
Illustration 3. Inside left frame view of new location of 8X-0268 Heater Lines Group.
Installation of the Rerouted 8X-0268 Heater Lines Group
Fluid Spillage Containment
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "Tools and Shop Product Guide, NENG2500", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.
1. Disconnect and remove 5P-0767 Hose from the inlet port of the engines pump on the right side of the engine. (This hose presently runs up the left pedestal and runs across the roll over protection system (ROPS) tube and connects to the cab heater lines). (The lines will be full of coolant and needs to be captured in the appropriate container).
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At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot water or steam. Any contact can cause severe burns. Look at the sight gauge to check the coolant level. The coolant level should be in the green range. If necessary, remove the fill cap only after the engine has been stopped and the cap is cool enough to remove with your bare hand. Remove the cooling system fill cap slowly to relieve pressure. Cooling system condition contains alkali that can cause personal injury. Avoid contact with the skin and eyes and do not drink. Allow cooling system components to cool before draining.
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2. Cut 18 m (58 ft) of 5P-0767 Radiator Hosing (bulk) (12.7 mm (.50 in) diameter).
3. Connect one end of the cut off hosing to the inlet of the water pump. Secure with one 5D-1026 Hose Clamp (3).
4. Route the hosing to a boss on the left pedestal and connect the hosing to the backside of the front bumper at existing bosses with 13 6D-1641 Clips (2), 13 8T-4136 Bolts (4), and 13 8T-4121 Washers (5).
5. Connect the end of the hosing to the cab heater hosing at the inlet port with four 5D-1026 Hose Clamps (3) and one 6P-8855 Spacer (6).
6. Disconnect and remove 5P-0767 Hose from the outlet port of the engine's water pump on the right side of the engine. (This hose presently runs up the left pedestal and runs across the roll over protection system (ROPS) tube and connects to the cab heater hosing). (The lines will be full of coolant and needs to be captured in the appropriate container).
7. Connect one end of the cut off hosing to the outlet of the water pump. Secure with one 5D-1026 Hose Clamp (3).
8. Using the same hardware from Step 2, route the hosing to a boss on the left pedestal and then connect the hosing to the backside of the front bumper at existing bosses with 13 6D-1641 Clips (2), 13 8T-4136 Bolts (4) and 13 8T-4121 Washers (5).
9. Connect the end of the hosing to the cab heater lines at the outlet port with four 5D-1026 Hose Clamps (3) and one 6P-8855 Spacer (6).
10. Refill the radiator with coolant.