3512B and 3516B Engine Supplement for and 784C,, 785C and and 785C HAA Off-Highway Truck/Tractors Caterpillar

Engine and Torque Converter (High Altitude) - Remove

Usage:

785C 5AZ

Removal Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	8S-7640	Stand	2
	8S-7611	Tube	2
	8S-7615	Pin	4
	8S-8048	Saddle	2
B	138-7573	Link Bracket	2
C⁽¹⁾	9U-7489	Lift Stand (100 Ton)	1
	447-0910	Electric Hydraulic Pump Gp 115 V	1
	447-0911	Electric Hydraulic Pump Gp 230 V	1
	4C-6928	Dolly	1
C	OR
	504-9830	Lift Gp (50/60 Hz)⁽²⁾	1
	504-9831	Lift Gp (50/60 Hz)⁽³⁾	1
D	108-5453	Nozzle	1

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⁽¹⁾	Use Tooling (C) or (C1) based on requirements.
⁽²⁾	Operating Voltage (380V - 500V)
⁽³⁾	Operating Voltage (180V - 300V)

Start By:

Release the air system pressure.
Remove the radiator.
Remove the hood.
Remove air cleaners.
Install truck body retaining cable.

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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.

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Removing the engine from the truck with the body of the truck in the Up position will change the balance point of the truck. The shift in the balance point could allow the front of the truck to unexpectedly raise off the ground.
This unexpected movement could cause injury or death.

To stabilize the truck, always install the specified tooling to stabilize the truck before removing the engine and torque converter.

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Personal injury can result from hot coolant, steam and alkali.
At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.
Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand.

Cooling System Conditioner contains alkali. Avoid contact with skin and eyes.

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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.

Note: Install caps and plugs on all openings to prevent dirt or debris from entering the system. Cleanliness is an important factor. Before the removal procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.

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Illustration 1	g00483703

Position Tooling (A) (not shown), or suitable stands under the truck body, as shown.
Drain the oil from the torque converter. The capacity of the torque converter sump is 3.8 L (1 US gal).
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Illustration 2 g00572162
Turn ball valve (1) on the fuel tank to the OFF position.
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Illustration 3 g00572239
Disconnect hose assembly (2) from the fuel transfer pump.
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Illustration 4 g00490207
Remove cover (4). Use Tool (D) (not shown) to drain the hydraulic oil from the hoist, torque converter, and brake system. The capacity of the system is 640 L (169 US gal).Remove cap (3). Use Tool (D) (not shown) to drain the hydraulic oil from the hoist, torque converter, and brake tank. The capacity of the tank is 420 L (111 US gal). Refer to Operation and Maintenance Manual, SEBU7176, "Hoist, Torque Converter and Brake Tank Oil - Change" for the correct procedure.
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Illustration 5 g00489528
Disconnect wire harness (5) from the cab assembly.
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Illustration 6 g00489534
Loosen clip assembly (6). Disconnect wiring harness (7) at the electrical connections.
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Illustration 7 g00489536
Remove four bolts (8) to disconnect the clips and the wire harness from the frame assembly.
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Illustration 8 g00489585
Disconnect two wiring harnesses (9) at the electrical connection. Disconnect two tube assemblies (10).
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Illustration 9 g00489646
Place identification marks on two hoses (11) and (12) prior to the disconnection for installation purposes. Remove bolt (15) and the clip. Loosen four clamps (13) and (14) to disconnect two hoses (11) and (12).
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Illustration 10 g00489657
Remove five bolts (16) to remove the clips. Remove the wire harness and the heater hoses from tube assembly (17).
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Illustration 11 g00489689
Place identification marks at the locations of hoses (98) and (99) prior to removal for installation purposes. Turn two valve assemblies (21) and (22) to the OFF position. Loosen two hose clamps (20) and (23) to disconnect two hoses (18) and (19).
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Illustration 12 g00489723
Install Tooling (B) on tube assembly (17). Attach a suitable lifting device to Tooling (B). Attach the lifting device to a suitable hoist, as shown.
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Illustration 13 g00489786

For Tooling (C)
Position Tooling (C) under the front frame assembly. Tooling (C) will ease the removal process for tube assembly (17). Do not remove Tooling (C).
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Illustration 14 g06381131

For Tooling (C1)
Position Tooling (C1) under the front frame assembly. Tooling (C1) will ease the removal process for tube assembly (17). Do not remove Tooling (C1). Refer to Tool Operating Manual, NEHS1334, "Lift Stands (150 Ton)" for more information on Tooling (C1).

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NOTICE

Do not raise the machine off the floor. The jack supports the frame from stress when the tube assembly is removed.

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Illustration 15 g00489730
Remove four bolts (24) and the washers from each end of the tube assembly (17). Record the number of shims (25) on each end of tube assembly (17) for installation. Remove tube assembly (17) from the frame assembly. The weight of tube assembly (17) is 80 kg (175 lb).
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Illustration 16 g00489875
Disconnect wiring harness (26) at the electrical connection.
Repeat Step 17 for the remaining side.
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Illustration 17 g00489914
Loosen two clamp assemblies (27). Remove two elbows and tube assembly (28) as a unit.
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Illustration 18 g00489917
Remove two clamp assemblies (30) and remove two elbows (31).
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Illustration 19 g00489942
Remove four bolts (32) and the washers and remove exhaust elbow (31) from the frame assembly.
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Illustration 20 g00489948
Disconnect hose assembly (34) from air starter (33).
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Illustration 21 g00490107
Disconnect hose assembly (35) from air starter (33).
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Illustration 22 g00490123

Note: The engine can be removed by placing the air compressor aside. Do not disconnect the refrigerant hose assemblies from the refrigerant compressor. The air conditioning system must be purged and evacuated before the refrigerant hose assemblies are removed. If the refrigerant compressor must be removed from the machine, refer to Disassembly and Assembly, "Refrigerant Compressor - Remove" for the correct procedure.
Disconnect 3 wire harnesses (36), (38), and (40) that are on refrigerant compressor (39). Loosen nut (37) from the rod.
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Illustration 23 g00490138
Loosen two bolts (41) and (42) to remove the V-belt (43).
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Illustration 24 g00490171

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Illustration 25 g00490203
Remove mounting bolts (44) and (45) from refrigerant compressor (39) and position refrigerant compressor (39) out of the way.
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Illustration 26 g00490282
Remove bolt (46) to remove clip (47) from hose assembly (48) for the hydraulic system.
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Illustration 27 g00490301
Remove bolt (49), the washer, and the nut to remove the clip that is on the hose assembly (50) for the braking system.
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Illustration 28 g00490278
Remove hose assembly (51) from oil cooler (52).
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Illustration 29 g00490221
Remove hose assembly (53) from torque converter housing assembly (54).
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Illustration 30 g00490306
Remove three hose assemblies (55), (56), and (57) from torque converter and brake release gear pump (58).
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Illustration 31 g00490344
Remove bolt (59), the washer, and the clip from torque converter and brake release gear pump (58).
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Illustration 32 g00490353
Disconnect two hose assemblies (60), and (61) from torque converter and brake release gear pump (58).
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Illustration 33 g00490373
Disconnect two hose assembly (62) and (64) from torque converter outlet relief valve (63).
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Illustration 34 g00490422
Remove bolt (66), the washer, and the clip from the rear of torque converter housing assembly (54).
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Illustration 35 g00490611
Disconnect tube assembly (68) from the hose assembly. Remove two bolts (67), the washers, the nuts, and clip (69) to separate tube assembly (68) from the bracket.
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Illustration 36 g00490681
Remove tube assembly (70) from the torque converter filter.
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Illustration 37 g00490685
Remove bolt (71), the washer, and the clip from hydraulic oil cooler assembly (72).
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Illustration 38 g00490691
Remove hose assembly (73) from oil cooler (74).
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Illustration 39 g00490698
Disconnect hose assembly (75) from the outlet side of torque converter housing assembly (54). Disconnect hose assembly (76) from the inlet side of torque converter housing assembly (54).
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Illustration 40 g00490774
Remove hose assembly (78) from torque converter housing assembly (54). Disconnect four hose assemblies (77), (79), (81), and (82) from torque converter lockup clutch valve (80).
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Illustration 41 g00490788
Disconnect two wire harnesses (83) and (84) at the electrical connections.
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Illustration 42 g00490820
Remove hose assembly (78) from tee fitting on pump drive (85).
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Illustration 43 g00490840
Remove six bolts (86) to remove two guard assemblies (87) and (88).
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Illustration 44 g00490925
Remove four bolts (89) from spider and bearing assembly (90) and disconnect auxiliary drive shaft (91). Support auxiliary drive shaft (91) with wire. Discard bolts (88) now.
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Illustration 45 g00490944
Remove five bolts (93) to remove guard (92).
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Illustration 46 g00490959
Position a suitable lifting device around drive shaft (27). Secure the lifting sling to a hoist. Remove four bolts (95) and disconnect the drive shaft (93) from torque converter housing assembly (54). Slide drive shaft (94) toward the rear of the truck. Discard bolts (95) now. The weight of main drive shaft (94) is 138 kg (305 lb).
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Illustration 47 g00490968
Use a suitable lifting sling to support ladder assembly (96), as shown. Attach the lifting sling to a hoist. Remove eight bolts (97) and the washers and remove ladder assembly (96). The weight of ladder assembly (96) is 22 kg (49 lb).
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Illustration 48 g00491081
Disconnect tube assembly (98) from the rear of the engine. Disconnect wire harness (99) at the electrical connection.
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Illustration 49 g00491088
Disconnect hose assembly (100) for the coolant drain from the rear of the engine.
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Illustration 50 g00491098
Disconnect hose assembly (102) from oil cooler (101).
Repeat Step 51 for the remaining end of the hose assembly.
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Illustration 51 g00491185
Loosen four hose clamps (103). Separate two hoses (104) and (105) from transmission oil cooler (101).
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Illustration 52 g00491247
Disconnect cable assembly (106) from prelube switch (109). Remove two bolts (108), the washers and the clips to separate cable assembly (106) from front support assembly (107).
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Illustration 53 g00491283
Disconnect cable assembly (112) from prelube pump motor (110). Remove bolt (111) and the washer to remove the clip from front support assembly (107).
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Illustration 54 g00491290
Remove bolt (113), the washer, and the clip from front support assembly (107). Disconnect wire harness (114) at the electrical connection.
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Illustration 55 g00491242
Attach a suitable lifting device to the front and the rear lifting eyes (115). Attach the lifting device to a suitable hoist.
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Illustration 56 g00491246
Remove four bolts (117), the washers, and the nuts from cap (116) on the right rear frame support.
Repeat Step 58 for the left rear frame support.
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Illustration 57 g00491293
Remove bolt (118), the washer, and the nut. Remove plate (119) and mount assembly (120).
Repeat Step 60 for the right side.
Slowly remove the engine and the torque converter from the truck. Visually inspect the engine for any hoses, electrical connections, or components that need to be disconnected or removed before removing the engine and torque converter assembly completely. Carefully remove the engine. The weight of the engine and torque converter assembly is 8278 kg (18250 lb).