Engine and Torque Converter - Install
Installation Procedure
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| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Part Description | Qty |
| A | 8S-7640 | Stand | 2 |
| A | 8S-7611 | Tube | 2 |
| A | 8S-7615 | Pin | 2 |
| B | 6V-6146 | Load Leveler | 1 |
| C | 138-7574 | Link Bracket | 1 |
| C | 8S-9906 | Ratchet Puller | 1 |
| D | 162-8299 | Plate | 1 |
| E | FT-2625 | Rod Assembly | 2 |
| F | 8T-5096 | Dial Indicator | 1 |
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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, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
- Verify that all of the components of the engine are clean and free of foreign material prior to installation.
- Inspect all components for wear and replace the components, if necessary. Use new gaskets and seals when you install components.
- Position Tool (B) to the engine, as shown. Position Tooling (C) to the rear, right side of the torque converter in order to prevent the engine from rotating. Secure Tool (B) and Tooling (C) to a suitable hoist.
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| Illustration 1 | g00738018 |
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| Illustration 2 | g00833466 |
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| Illustration 3 | g00833475 |
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| Illustration 4 | g00833479 |
- Carefully lower the engine and the torque converter. Place engine support assembly (143) in position. Check that there is proper clearance and install the engine and the torque converter to the machine. The weight of the engine and torque converter is 2404 kg (5300 lb).
- Remove Tooling (B) and Tool (C) from the engine and the torque converter.
- Attach Tool (D) to the joint flange on the torque converter. Attach Tooling (E) to the yoke on the transfer gears.
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| Illustration 5 | g00582196 |
- Position Tool (F) onto Tooling (E), which is attached to the transfer gears.
- Rotate the yoke on the transfer gears. Record the reading at the two points on a horizontal centerline. Record the reading at two points on a vertical centerline.
- An 11.68 mm (0.460 inch) total indicator reading is permitted between the torque converter and the transmission input shaft on the vertical centerline. Error on the horizontal centerline must be reduced to a minimum by centering the engine in rear engine mounts.
- Install two bolts (142), the nuts, and the washers to engine support assembly (143). Tighten the full nuts to a torque of 900 ± 100 N·m (665 ± 75 lb ft).
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| Illustration 6 | g00737891 |
- Install four bolts (140), the hard washers, and the full nuts to engine front support (141). Tighten the full nuts to a torque of 475 ± 60 N·m (350 ± 44 lb ft).
- Install the cap onto mount assembly (139). Install the bolts, the hard washers, and full nuts (138). Tighten the full nuts to a torque of 475 ± 60 N·m (350 ± 44 lb ft).
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| Illustration 7 | g00737890 |
Left side | |
- Install cap (137) to mount assembly. Install the two bolts, the hard washers, and full nuts (136). Tighten full nuts to a torque of 475 ± 60 N·m (350 ± 44 lb ft).
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| Illustration 8 | g00737889 |
Right side | |
- Use two people in order to install the tie rod. The weight of the tie rod is 25 kg (55 lb).
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| Illustration 9 | g00737886 |
- Apply 4C-5593 Anti-Seize Compound to the taper of the ball stud before installation.
- Install slotted nut (134) to ball stud (135). Tighten the slotted nut to a torque of 1360 N·m (1003 lb ft). If the hole in the ball stud does not line up with a slot in the slotted nut, rotate the slotted nut to the next slot.
- Install cotter pin (133) to slotted nut (134) .
- Repeat Steps 15 to 17 for the other ball stud.
- Repeat the procedure for the other tie rod.
- Connect hose (132) to the adapter.
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| Illustration 10 | g00737885 |
- Connect two hoses (130) and (131) to the valve assemblies.
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| Illustration 11 | g00586458 |
- Position filler (127) and the O-ring seal on torque converter (129). Install four bolts (128) and the hard washers.
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| Illustration 12 | g00557166 |
- Connect hose assembly (126) to governor assembly (124) .
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| Illustration 13 | g00557161 |
- Connect hose assembly (125) to governor assembly (124) .
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| Illustration 14 | g00468500 |
- Connect hose assembly (121) to air compressor (123).
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| Illustration 15 | g00468499 |
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| Illustration 16 | g00468497 |
- Position hose assembly (121) and clip (122), as shown. Install bolt (120) and the washer.
- Position shield assembly (117), as shown. Install bolt (115) (not shown) and the washers. Install bolt (119) and the washer. Install new tie straps (116) and (118) .
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| Illustration 17 | g00557558 |
- Position bracket assembly (113), as shown. Install four bolts (114), the washers and the nuts.
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| Illustration 18 | g00468459 |
- Position bracket assembly (109), as shown. Install four bolts (110) and the washers onto bracket assembly (109). Connect wire harness (111) at the electrical connection. Install two bolts (112) .
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| Illustration 19 | g00557112 |
- Install three bolts (108) onto the bracket assembly.
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| Illustration 20 | g00557116 |
- Position the air conditioning compressor, as shown. Install two bolts (107), and the washers. Do not tighten bolts (107) at this time. Connect the wiring harness (106) at the electrical connection.
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| Illustration 21 | g00468409 |
- Position V-belt (104) on the pulleys. Install the nut and the bolt that holds the rod to air conditioner compressor (105). Install two nuts (102) on the rod.
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| Illustration 22 | g00468407 |
- Connect two wiring harnesses (103) to air conditioning compressor (105) at the electrical connection. Install a new tie strap.
- Tighten bolts (107) at this time.
- Refer to the Operation and Maintenance Manual, "Belts - Inspect/Adjust/Replace" for the correct procedure to adjust the V-belt.
- Connect t-fitting (101) to the oil cooler (power train).
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| Illustration 23 | g00557054 |
- Connect two hose assemblies (100) to the engine oil cooler.
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| Illustration 24 | g00468362 |
- Position wiring harness (98) on the alternator, as shown. Install nut (97). Install bolt (99) and the washer. Tighten nut (97) to a torque of 18.2 ± 2.4 N·m (161 ± 21 lb in).
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| Illustration 25 | g00468359 |
- Connect hose assembly (96). Position clip (94) and hose assembly (93), as shown. Install bolt (95). Connect wiring harness (92) at the electrical connection.
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| Illustration 26 | g00557050 |
- Connect hose assembly (91) to the oil cooler (power train). Install bolt (90), the washers, and the clips.
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| Illustration 27 | g00557049 |
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| Illustration 28 | g00468354 |
- Connect hose assembly (89) to the oil cooler (power train).
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| Illustration 29 | g00557048 |
- Connect tube assembly (88) to the gear pump (hoist and brake).
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| Illustration 30 | g00468352 |
- Position hose assembly (86), as shown. Install bolt (87), and the two clips. Hose assembly (86) is located behind the engine oil pan.
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| Illustration 31 | g00557035 |
- Connect tube assembly (85) to the gear pump (power train).
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| Illustration 32 | g00468349 |
- Connect hose assembly (83) to fuel/water separator (84) .
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| Illustration 33 | g00468348 |
- Turn ball valve (82) to the ON position.
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| Illustration 34 | g00468512 |
Inboard side of the fuel tank | |
- Connect hose assembly (81) to the gear pump (power train).
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| Illustration 35 | g00468313 |
- Position two hose assemblies (77) and (80), as shown. Install bolt (79) and the washer. Install bolt (78) and the washer.
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| Illustration 36 | g00557034 |
- Position tube assembly (76) into hose (75), as shown. Tighten clamps (74) .
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| Illustration 37 | g00468039 |
- Position hose assembly (73) and the clip, as shown. Install bolt (72) and the washer.
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| Illustration 38 | g00468038 |
- Connect hose assembly (71) to the piston pump (steering). Connect hose assembly (70) to the gear pump (hoist and brake).
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| Illustration 39 | g00468036 |
- Connect hose assembly (69) to the torque converter.
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| Illustration 40 | g00557014 |
- Connect hose assembly (68) to the air compressor. Position hose assembly (64), as shown. Install bolt (67) and the washer.
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| Illustration 41 | g00557004 |
- Connect three hose assemblies (64), (65) and (66) to piston pump (63) .
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| Illustration 42 | g00556962 |
- Position cable assemblies (62) and clips (61), as shown. Install bolts (59) (not shown) and the washer. Position cable assemblies (55), as shown. Install bolt (60), the clips and the washers.
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| Illustration 43 | g00556956 |
- Position wire assembly (58), as shown. Install nut (56) (not shown). Tighten nut (56) (not shown) to a torque of 2.25 ± .25 N·m (20 ± 2.2 lb in). Position cover (57), as shown.
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| Illustration 44 | g00467863 |
- Position cable assemblies (55), and wire assembly (54), as shown. Install nut (52) (not shown). Tighten nut (52) (not shown) to a torque of 30.5 ± 3.5 N·m (270 ± 31 lb in). Position cover (53), as shown.
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| Illustration 45 | g00467860 |
- Position cable assembly (50) on electric starting motor (49), as shown. Install two nuts (47) (not shown). Tighten nuts (47) (not shown) to a torque of 30.5 ± 3.5 N·m (270 ± 31 lb in). Position cover (48), as shown.
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| Illustration 46 | g00467855 |
- Connect hose assembly (45) to nipple assembly (46) .
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| Illustration 47 | g00556917 |
- Position hose assembly (44) and clip (43), as shown. Install bolt (42) and the washer.
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| Illustration 48 | g00467826 |
- Connect hose assembly (41) to the engine oil pan.
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| Illustration 49 | g00467824 |
- Connect two hose assemblies (39) and (40) to secondary steering pump (36) .
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| Illustration 50 | g00467821 |
- Connect hose assembly (38) to secondary steering pump (36) .
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| Illustration 51 | g00467815 |
- Connect hose assembly (37) to secondary steering pump (36) .
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| Illustration 52 | g00467649 |
- Position the clip and wiring harness (35), as shown. Install bolt (34) and the washer.
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| Illustration 53 | g00556907 |
- Connect wiring harness (33) at the electrical connection. Electrical connection (33) is located on lockup clutch control valve (32) .
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| Illustration 54 | g00556906 |
- Connect wiring harness (31) at the electrical connection. Install tie straps (30). Connect tube assembly (29) to the gear pump (hoist and brake).
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| Illustration 55 | g00467613 |
- Position elbow (28), as shown. Tighten hose clamps (26). Connect wiring harness (27) at the electrical connection.
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| Illustration 56 | g00831366 |
- Position four wire harnesses (25), as shown. Install bolt (24) and the washer.
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| Illustration 57 | g00467396 |
- Position wire harness (23) and the clip (23), as shown. Install bolt (22) and the washer.
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| Illustration 58 | g00556859 |
- Connect wire harness (21) at the electrical connection.
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| Illustration 59 | g00557232 |
- Install bolts (20) and the washers.
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| Illustration 60 | g00833243 |
- Connect wiring harness (19) at air dryer (18), as shown.
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| Illustration 61 | g00831330 |
- Position wire harness (14) on frame assembly (17), as shown. Install new tie straps (15) and (16) .
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| Illustration 62 | g00467187 |
- Connect wire harness (13) to brake overstroke switch (12) at the electrical connection.
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| Illustration 63 | g00831327 |
- Position wire harness (9), as shown. Connect wire harness (9) to payload sensor (11) at the electrical connection. Install all remaining clips and new tie straps that hold wire harness (9) to the frame assembly.
- Position wire harness (9) through bracket assembly (7). Connect wiring harnesses (8) and (10) to signal lamp (6) .
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| Illustration 64 | g00557556 |
- Position signal lamp (6) into bracket assembly (7). Install four bolts (5) onto signal lamp (6) .
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| Illustration 65 | g00557555 |
- Install cable assembly (3). Install nut (4) (not shown) to secure cable (3) .
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| Illustration 66 | g00833242 |
- Connect two cable assemblies (2) and (3) to the batteries. Tighten cable assemblies (2) and (3) to a torque of 7.2 ± 1.6 N·m (64 ± 14 lb in).
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| Illustration 67 | g00556846 |
- Close cover assembly (1) .
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| Illustration 68 | g00461871 |
- Fill the engine with oil. Refer to Operation and Maintenance Manual, "Engine Oil and Filter - Change".
- Fill the torque converter with oil. Refer to Operation and Maintenance Manual, "Torque Converter and Transmission Oil - Change".
- Fill the hoist and brake tank with oil. Refer to Operation and Maintenance Manual, "Hoist and Brake Tank Oil - Change".
- Fill the steering hydraulic tank with oil. Refer to Operation and Maintenance Manual, "Steering System Oil - Change".
- Prime the fuel system. Refer to the Operation and Maintenance Manual, "Fuel System - Prime".
- Remove Tooling (A) (not shown) after the following Steps have been completed.
End By:
- Install the front drive shaft. Refer to Disassembly and Assembly, "Drive Shaft (Front) - Remove and Install".
- Install the rear hood. Refer to Disassembly and Assembly, "Hood (Rear) - Remove and Install".
- Install the radiator. Refer to Disassembly and Assembly, "Radiator - Install".
- Close the air valves. Refer to Operation and Maintenance Manual, "Air Tank Moisture and Sediment - Drain".
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