3408E Engine Supplement for 769D Off-Highway Trucks and 771D Off-Highway Quarry Trucks Caterpillar

Removal Procedure

Start By:

1. Purge the air from the air tanks. Refer to Operation and Maintenance Manual, "Air Tank Moisture and Sediment - Drain".
2. Remove the radiator. Refer to Disassembly and Assembly, "Radiator - Remove".
3. Remove the rear hood. Refer to Disassembly and Assembly, "Hood (Rear) - Remove and Install".
4. Remove the front drive shaft. Refer to Disassembly and Assembly, "Drive Shaft (Front) - Remove and Install".

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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 oil or hot components. At operating temperature, oil is hot and under pressure. Hot oil can cause burns. Remove the fill cap only when the engine is stopped, and the fill cap is cool enough to touch with your bare hand. Do not allow hot oil or components to contact skin.

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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 to all connections in order to prevent system contamination.

1. Drain the oil from the engine. Refer to Operation and Maintenance Manual, "Engine Oil and Filter - Change".

2. Drain the oil from the torque converter. Refer to Operation and Maintenance Manual, "Torque Converter and Transmission Oil - Change".

3. Drain the oil from the hoist and brake. Refer to Operation and Maintenance Manual, "Hoist and Brake Tank Oil - Change".

4. Drain the oil from the steering hydraulic tank. Refer to Operation and Maintenance Manual, "Steering System Oil - Change".

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Illustration 1	g00461867

5. Put Tooling (A) in position under the body of the truck, as shown.

   Note: Tooling (A) will stabilize the truck when the weight of the engine is removed.

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Illustration 2	g00461871

6. Open cover assembly (1) .

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Illustration 3	g00556846

7. Put identification on cable assemblies (2) and (3). Disconnect cable assemblies (2) and (3) from the batteries.

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Illustration 4	g00833242

8. Remove nut (4) (not shown) that holds battery cable (3) in position.

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Illustration 5	g00557555

9. Remove four bolts (5) from signal lamp (6). Remove signal lamp (6) from bracket assembly (7) .

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Illustration 6	g00557556

10. Put identification on wires (8) and (10) for assembly purposes. Disconnect wire harnesses (8) and (10) from signal lamp (6). Pull wire harness (9) through bracket assembly (7) .

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Illustration 7	g00462716

11. Remove all the clips and the tie straps that hold wire harness (9) to the frame assembly. Disconnect wire harness (9) from payload sensor (11) at the electrical connection. Position wire harness (9) out of the way.

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Illustration 8	g00831327

12. Disconnect wiring harness (13) from brake overstroke switch on air/hydraulic cylinder (12) at the electrical connection.

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Illustration 9	g00467187

13. Remove tie strap (15) and (16) in order to free wire harness (14) from frame assembly (17) .

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Illustration 10	g00831330

14. Disconnect wiring harness (19) from air dryer (18). Place the wire harness out of the way.

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Illustration 11	g00833243

15. Remove bolts (20) and the washers.

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Illustration 12	g00557232

16. Disconnect wire harness (21) at the electrical connection.

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Illustration 13	g00556859

17. Remove bolt (22) and the washer. Position wire harness (23) and the clip out of the way.

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Illustration 14	g00467396

18. Remove bolt (24) and the washer. Position four wire harnesses (25) out of the way.

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Illustration 15	g00831366

19. Disconnect wire harness (27) at the electrical connection. Loosen hose clamps (26). Remove elbow (28) .

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Illustration 16	g00467613

20. Remove two tie straps (30). Disconnect wire harness (31) at the electrical connection. Disconnect tube assembly (29) from the gear pump (hoist and brake).

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Illustration 17	g00556906

21. Disconnect wire harness (33) from lockup clutch control valve (32) at the electrical connection.

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Illustration 18	g00556907

22. Remove bolt (34) and the washer. Position the clip and wire harness (35) out of the way.

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Illustration 19	g00467649

23. Disconnect hose assembly (37) from secondary steering pump (36) .

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Illustration 20	g00467815

24. Disconnect hose assembly (38) from secondary steering pump (36) .

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Illustration 21	g00467821

25. Disconnect two hose assemblies (39) and (40) from secondary steering pump (36) .

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Illustration 22	g00467824

26. Disconnect hose assembly (41) from the engine oil pan.

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Illustration 23	g00467826

27. Remove bolt (42), the washer, and clip (43) from the frame assembly. Place hose assembly (44) aside.

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Illustration 24	g00556917

28. Disconnect hose assembly (45) from nipple assembly (46) .

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Illustration 25	g00467855

29. Position cover (48) out of the way. Remove two nuts (47) (not shown). Remove cable assembly (50) from electric starting motor (49) .

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Illustration 26	g00467860

30. Position cover (53) out of the way. Remove nut (52) (not shown). Disconnect cable assemblies (55) and wire assembly (54) from left hand electric starting motor (51) .

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Illustration 27	g00467863

31. Position cover (57) out of the way. Remove nut (56) (not shown). Disconnect wire assembly (58).

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Illustration 28	g00556956

32. Remove bolt (60), the clips and the washers. Position cable assemblies (55) out of the way. Remove bolt (59) (not shown) and the washer. Position clips (61) and cable assemblies (62) out of the way.

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Illustration 29	g00556962

33. Disconnect three hose assemblies (64), (65) and (66) from piston pump (63) .

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Illustration 30	g00557004

34. Remove bolt (67) and the washer. Position hose assembly (64) out of the way. Disconnect hose assembly (68) from the air compressor.

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Illustration 31	g00557014

35. Disconnect hose assembly (69) from the torque converter.

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Illustration 32	g00468036

36. Disconnect hose assembly (70) from the gear pump (hoist and brake). Disconnect hose assembly (71) from the piston pump (steering).

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Illustration 33	g00468038

37. Remove bolt (72) and the washer. Position hose assembly (73) and the clip out of the way.

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Illustration 34	g00468039

38. Loosen two clamps (74). Separate tube assembly (76) from hose (75) .

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Illustration 35	g00557034

39. Remove bolt (78) and the washer. Remove bolt (79) and the washer. Position two hose assemblies (77) and (80) out of the way.

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Illustration 36	g00468313

40. Disconnect hose assembly (81) from the gear pump (power train).

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Illustration 37	g00468512
Inboard side of the fuel tank

41. Turn ball valve (82) to the OFF position.

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Illustration 38	g00468348

42. Disconnect hose assembly (83) from fuel/water separator (84) .

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Illustration 39	g00468349

43. Disconnect tube assembly (85) from the gear pump (power train).

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Illustration 40	g00557035

44. Remove bolt (87), the washer and the two clips. Position hose assembly (86) out of the way.

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Illustration 41	g00468352

45. Disconnect tube assembly (88) from the gear pump (hoist and brake).

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Illustration 42	g00557048

46. Disconnect hose assembly (89) from the oil cooler (power train).

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Illustration 43	g00468354

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Illustration 44	g00557049

47. Remove bolt (90), the washers, and the clips. Disconnect hose assembly (91) from the oil cooler (power train).

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Illustration 45	g00557050

48. Disconnect wire harness (92) at the electrical connection. Remove bolt (95). Position clip (94) and hose assembly (93) out of the way. Disconnect hose assembly (96) .

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Illustration 46	g00468359

49. Remove nut (97). Remove bolt (99) and the washer. Position wire harness (98) aside.

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Illustration 47	g00468362

50. Disconnect two hose assemblies (100) from the hoist and rear brake oil cooler.

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Illustration 48	g00557054

51. Disconnect t-fitting (101) from the oil cooler (power train).

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Illustration 49	g00468407

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Illustration 50	g00468409

Note: It is not necessary to recover the refrigerant from the air conditioning system. Do not disconnect the hose assemblies from the air conditioning compressor. Position the air conditioning compressor while the hose assemblies are still attached.

52. Put identification on two electrical connections (103) for installation purposes. Remove the tie strap and disconnect two electrical connections (103) from air conditioning compressor (105) .

53. Loosen two bolts (107) .

54. Loosen two adjusting nuts (102). Remove the nut and the bolt that holds the rod to air conditioner compressor (105). Move the air conditioning compressor toward the engine and remove V-belt (104) .

55. Disconnect wiring harness (106) at the electrical connection (106). Remove two bolts (107) and the washers. Position the air conditioning compressor out of the way.

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Illustration 51	g00557116

56. Remove three bolts (108), and the washers from the bracket assembly.

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Illustration 52	g00557112

57. Remove two bolts (112). Disconnect wire harness (111) at the electrical connection. Remove four bolts (110) and the washers from bracket assembly (109). Remove bracket assembly (109) .

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Illustration 53	g00468459

58. Remove four bolts (114), the nuts and the washers. Remove bracket assembly (113) .

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Illustration 54	g00557558

59. Remove tie straps (116) and (118). Remove bolt (115) (not shown) and the washer. Remove bolt (119) and the washer. Remove shield assembly (117) .

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Illustration 55	g00468497

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Illustration 56	g00468499

60. Remove bolt (120) and the washer.

61. Disconnect hose assembly (121) from air compressor (123). Position hose assembly (121) and clip (122) aside.

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Illustration 57	g00468500

62. Disconnect hose assembly (125) from governor assembly (124) .

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Illustration 58	g00557161

63. Disconnect hose assembly (126) from governor assembly (124) .

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Illustration 59	g00557166

64. Remove four bolts (128) and the hard washers. Remove filler (127) and the O-ring seal from torque converter (129) .

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Illustration 60	g00586458

65. Disconnect two hoses (130) and (131) from the valve assemblies.

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Illustration 61	g00737885

66. Disconnect hose (132) from the adapter.

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Illustration 62	g00737886

67. Remove cotter pin (133) from slotted nut (134). Loosen slotted nut (134) that is on ball stud (135). Do not remove slotted nut (134) at this time.

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Illustration 63	g00737942

68. Place Tool (B) under the ball stud and apply force. Hit the center arm with a soft faced hammer until the ball stud is loose. Remove Tool (B) from the ball stud. Remove the slotted nut from the ball stud.

69. Repeat Steps 67 and 68 for the other ball stud.

70. Use two people in order to remove the tie rod from the machine. The weight of the tie rod is 25 kg (55 lb). Repeat the procedure for the other tie rod.

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Illustration 64	g00737889
Right Side

71. Remove two nuts (136), the bolts and the hard washers. Remove cap (137) from the mount assembly.

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Illustration 65	g00737890
Left Side

72. Remove two full nuts (138), the bolts, and the hard washers. Remove the cap from mount assembly (139).

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Illustration 66	g00737891

73. Remove four bolts (140), the nuts, and the washers from engine front support (141) .

74. Remove two bolts (142), the nuts, and the washers from engine support assembly (143) .

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Illustration 67	g00831368

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Illustration 68	g00737892

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Illustration 69	g00831391

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Illustration 70	g00737894

75. Attach Tool (C) to the engine, as shown. Attach Tool (D) to the rear, right side of the torque converter in order to prevent the engine from rotating. Secure Tool (C) and Tool (D) to a suitable hoist.

76. Carefully raise the engine and the torque converter. Be sure that all wire harnesses, hose assemblies and tube assemblies will not interfere with removal of the engine and the torque converter.

77. Remove engine support assembly (143) from the machine.

78. Check that there is proper clearance and remove the engine and the torque converter from the machine. Position the engine and torque converter on a suitable stand (not shown). The weight of the engine and torque converter is 2404 kg (5300 lb).