Usage:
Start By:
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At operating temperature, the hydraulic lines are hot and under pressure. Before removing any lines, allow the machine to cool and bleed the pressure from the lines by slowly removing the caps from all of the hydraulic tanks. Hot hydraulic oil can cause severe personal injury. |
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Before removing any air lines, bleed the air pressure from the air tank. Compressed air can cause severe personal injury. See the Operation & Maintenance Manual. |
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a). remove radiator
b). remove fan and fan drive
c). remove steering pump *
d). remove torque converter and brake pump **
e). remove drive shaft **
*This operation is in the Machine Systems Disassembly & Assembly Manual.
**This operation is in the Power Train Disassembly & Assembly section.
1. Disconnect the batteries.
2. Fasten a hoist to each hood assembly (1). Remove the bolts and hood assemblies (1) from the machine. The weight of the rear hood assembly is 38 kg (83 lb). The weight of the middle hood assembly is approximately 46 kg (101 lb).
3. Tie up the exhaust piping that attaches to elbow (2). Attach a hoist to elbow (2). Remove the clamps and elbow (2).
4. Remove the shield assemblies from elbow (3). Attach a hoist to elbow (3). Remove the bolts holding elbow (3). Remove elbow (3), the springs and the ring seals. The weight of the elbow is approximately 55 kg (120 lb).
5. Remove the clamps, mounting bolts and elbow (4).
6. Attach a hoist to the exhaust piping held by clamp (5). Untie from the frame. Remove clamp (5) and the exhaust piping. The weight of the piping is approximately 47 kg (104 lb).
7. Remove clamp (6).
NOTE: Identify and mark all wires, connectors, hoses, lines and fittings for assure correct installation. Plug and cap all openings to prevent contamination and debris from entering the system.
8. Remove tube assembly (7).
9. Remove the mounting hardware and tube assembly (8).
10. Loosen the mounting clamps and remove elbow (9). Follow the same procedure on the other side of the machine also.
11. Remove the clamps and hose (10).
12. Remove the mounting clips and tube assembly (11).
13. Disconnect the ether aid tubes and wiring harness (15) from support (16).
14. Disconnect hose assembly (12).
15. Remove the clamps and hose (13).
16. Remove the bolts and clips that hold hoses (14) to tube assembly (16). Lower the wire harness and hoses to the frame.
17. Fasten a hoist to tube assembly (16). Remove the mounting bolts and tube assembly (16). The weight of tube assembly (16) is approximately 73 kg (160 lb). Make a note of which shims are removed from each end.
18. Remove tube assembly (17).
19. Disconnect hose assembly (18).
20. Disconnect hose assembly (19).
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Always wear goggles when working on air conditioning systems. The system is under pressure at all times, engine running or not. Escaping Freon-12 (C C12 F2 Dichloro Difluoro Methane) can cause freezing of human flesh. Do not smoke while working on air conditioning. Inhaling Freon-12 through any smoking material, although not toxic or flammable, can cause violent illness. Also heat must never be applied to a charged system. See Air Conditioning And Heating Service Manual Form No. SENR3334-01, for more information on removal and installation of lines and refrigerant from the system. |
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21. Disconnect hose assemblies (21) and (22) from air conditioning compressor (20).
22. Disconnect the engine wiring harness from the side of cab (23).
23. Disconnect three hoses from air dryer (24) and store them on the engine.
24. Disconnect the hoses from air starter (25).
25. Turn the fuel supply off at fuel tank shut-off valve (26).
26. Disconnect the hoses from the front of brake oil cooler (27).
27. Disconnect the hose from fuel transfer pump (28).
28. Loosen two hose clamps and remove hose (29) from the transmission oil cooler.
29. Loosen the hose clamps and disconnect hoses (30) and (31) from the valve assemblies.
30. Loosen two hose clamps and disconnect hose (32) from tube (33).
31. Disconnect hose assembly (34).
32. Disconnect hose assembly (35).
33. Disconnect hoses (36) and (37) located at the rear of brake oil cooler (27).
34. Disconnect hose (38) from the torque convertor.
35. Disconnect the hoses from torque convertor lockup clutch valve (39).
36. Disconnect hose assembly (42) from the side of the torque converter.
37. Disconnect hose assembly (40) from the torque converter inlet relief valve.
38. Disconnect hose assembly (41) from the torque converter housing.
39. Disconnect hose assembly (43).
40. Disconnect hose assembly (44).
41. Remove the bolts and drive shaft guard (46).
42. Remove bolts (47) and disconnect auxiliary drive shaft (45).
43. Disconnect ground wire (48) from the engine cylinder block.
| NOTICE |
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When installation of the engine is made, bracket (49) must be installed before the truck is put back into service. Damage to the turbochargers could result if the bracket is not in place while in service. |
44. Remove the bolts and bracket (49).
45. Mark for identification and disconnect wires (50).
46. Remove tube assembly (51).
47. Remove the washers, bolts, nuts (53) and caps (52) from the rear supports on each side of the engine.
48. Remove nuts, washers and bolts (55). Remove top cushions (54) from both sides of engine front support (56).
| NOTICE |
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Check to be sure all lines, hoses and wires are disconnected and out of the way before removing the engine. |
49. Fasten a hoist and tooling (A) to the engine. Remove the engine and torque converter, from the truck. The weight of the engine and torque converter is approximately 9625 kg (23,620 lb).
NOTE: The following steps are for installing the engine and torque converter
50. Fasten a hoist and tooling (A) to the engine. Install the engine and torque converter, to the truck. The weight of the engine and torque converter is approximately 9625 kg (23,620 lb).
51. Install the washers, bolts, nuts (53) and caps (52) onto the rear supports on each side of the engine. The torque for nuts (53) is 300 ± 40 N·m (220 ± 30 lb ft).
52. Install nuts, washers, bolts (55) and cushions (54) in both sides of engine front support (56). The torque for bolts (55) is 1600 ± 200 N·m (1200 ± 150 lb ft).
53. Reverse the procedures and Step 2 through Step 46 to install the engine.
NOTE: Refer to the Operation & Maintenance Manual for proper fluids and capacities after the engine installation is complete. Also see Air Conditioning And Heating Service Manual, Form No. SENR3334-01, for the correct procedure to evacuate and charge the air conditioning system.
End By:
a). install fan and fan drive
b). install radiator
c). install steering pump *
d). install torque converter and brake pump **
e). install drive shaft **
f). connect the batteries
*This operation is in the Machine Systems Disassembly & Assembly section.
**This operation is in the Power Train Disassembly & Assembly section.