Professional Documents
Culture Documents
July 2010
Disassembly and
Assembly
797F Off-Highway Truck
Engine Supplement
LAJ1-Up (Machine)
SAFETY.CAT.COM
i03991620
KENR8384
Table of Contents
Disassembly and Assembly Section
Aftercooler Core - Remove and Install .................. 4
Air Compressor - Remove and Install .................. 8
Air Starting Motor - Remove and Install ............... 9
Alternator - Remove and Install ........................... 9
Battery - Remove and Install ............................... 10
Electronic Control Module (Front Engine) - Remove
and Install ............................................................ 11
Engine and Torque Converter - Remove and Install
............................................................................. 12
Engine Oil Cooler - Remove and Install ............... 18
Engine Oil Filter and Oil Filter Base - Remove and
Install ................................................................... 21
Engine Oil Pump - Remove and Install ................ 22
Expansion Tank - Remove and Install ................. 24
Fan - Remove and Install ..................................... 25
Piston Motor (Fan Drive) - Remove and Install ..... 28
Piston Motor (Fan Drive) - Disassemble ............... 29
Piston Motor (Fan Drive) - Assemble .................... 32
Fuel Filter (Primary) and Fuel Filter Base - Remove
and Install ............................................................ 34
Fuel Filter (Secondary) and Fuel Filter Base Remove and Install ............................................. 35
Fuel Priming Pump - Remove and Install ............ 37
Modular Front End - Remove and Install .............. 38
Radiator - Disassemble ....................................... 43
Radiator - Assemble ............................................ 49
Refrigerant Condenser - Remove and Install ...... 54
Turbocharger - Remove and Install ..................... 55
Damper - Remove and Install ............................... 56
Water Pump (Engine) - Remove and Install ......... 57
Thermostatic Valve - Remove and Install ............. 58
Thermostatic Valve - Disassemble ....................... 59
Thermostatic Valve - Assemble ............................ 61
Index Section
Index ..................................................................... 63
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Engine Supplement
Table of Contents
4
Engine Supplement
Disassembly and Assembly Section
KENR8384
Removal Procedure
Table 1
Illustration 2
g02125625
Required Tools
Tool
Part
Number
138-7575
1U-9203
Part Description
Qty
Guide Stud
M10 x 150 mm
Link Bracket
Start By:
a. Remove the ladder.
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Illustration 1
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Illustration 4
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Illustration 5
5
Engine Supplement
Disassembly and Assembly Section
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Illustration 8
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Illustration 6
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Illustration 9
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Illustration 7
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Illustration 10
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6
Engine Supplement
Disassembly and Assembly Section
Illustration 11
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Illustration 14
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Illustration 15
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Illustration 12
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NOTICE
Do not attempt to remove the aftercooler assembly
until both of the spacers are removed.
12. Remove bolts (22). Raise the aftercooler
assembly slightly in order to remove spacer (23).
Repeat this step for the opposite side.
Illustration 13
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Illustration 16
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Illustration 17
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Engine Supplement
Disassembly and Assembly Section
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Illustration 18
Illustration 20
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Illustration 21
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Illustration 19
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Illustration 22
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Engine Supplement
Disassembly and Assembly Section
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Illustration 24
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Installation Procedure
1. Install aftercooler (39) and aftercooler (36) in the
reverse order.
i03869430
Removal Procedure
Illustration 25
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Illustration 26
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Installation Procedure
1. Install air compressor (5) in the reverse order.
KENR8384
9
Engine Supplement
Disassembly and Assembly Section
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Removal Procedure
Removal Procedure
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Illustration 27
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Installation Procedure
1. Install air starting motor (3) in the reverse order.
Illustration 29
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10
Engine Supplement
Disassembly and Assembly Section
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Removal Procedure
Illustration 30
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Installation Procedure
1. Install alternator (9) in the reverse order.
Illustration 31
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11
Engine Supplement
Disassembly and Assembly Section
i03880720
Removal Procedure
Illustration 32
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Illustration 33
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Installation Procedure
1. Install battery (5) in the reverse order.
Illustration 34
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Installation Procedure
1. Install electronic control (2) in the reverse order.
a. Tighten bolts (1) to a torque of 7 0.5 mm
(0.276 0.020 inch)
12
Engine Supplement
Disassembly and Assembly Section
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Removal Procedure
Table 2
Tool
Part
Number
Part Description
Qty
9U-7489
Lift Stand
9U-7357
Tube As
9U-7405
Tube As
1U-9202
138-7575
Link Bracket
309-2793
Load Leveler
323-1146
Lifting Gp
Start By:
a. Remove the modular front end.
b. Remove the gear pump (torque converter and
transmission).
c. Remove the pump drive shaft.
In order to prevent possible personal injury, release the air pressure from the air tank before disconnecting any components of the air system.
1. Turn the fuel supply to the OFF position.
2. Turn the power disconnect switch to the OFF
position.
Illustration 35
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Illustration 36
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Engine Supplement
Disassembly and Assembly Section
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Illustration 37
Illustration 39
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Illustration 40
Illustration 38
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Illustration 41
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14
Engine Supplement
Disassembly and Assembly Section
Illustration 42
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Illustration 43
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Illustration 44
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Illustration 45
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Illustration 46
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Illustration 47
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Illustration 48
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Engine Supplement
Disassembly and Assembly Section
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Illustration 51
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Illustration 52
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Illustration 49
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Illustration 50
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Illustration 53
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16
Engine Supplement
Disassembly and Assembly Section
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Illustration 57
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Illustration 58
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Illustration 59
Illustration 56
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Illustration 60
17
Engine Supplement
Disassembly and Assembly Section
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Illustration 61
Illustration 63
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Illustration 64
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Illustration 62
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Illustration 65
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18
Engine Supplement
Disassembly and Assembly Section
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Removal Procedure
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Illustration 68
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Installation procedure
1. Install the engine and torque converter (35) in the
reverse order.
KENR8384
Illustration 69
19
Engine Supplement
Disassembly and Assembly Section
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Illustration 72
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Illustration 73
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Illustration 70
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Illustration 71
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Illustration 74
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Engine Supplement
Disassembly and Assembly Section
Illustration 75
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Illustration 78
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Illustration 79
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Illustration 76
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Illustration 77
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Illustration 80
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Engine Supplement
Disassembly and Assembly Section
Illustration 81
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Illustration 82
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Illustration 83
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Illustration 84
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Removal Procedure
Installation Procedure
1. Install oil cooler (18) in the reverse order.
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22
Engine Supplement
Disassembly and Assembly Section
Illustration 85
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Illustration 88
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Illustration 86
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Installation Procedure
1. Install oil filter and base (7) in the reverse order.
i03952132
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Removal Procedure
Start By:
a. Remove the alternator.
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23
Engine Supplement
Disassembly and Assembly Section
Illustration 91
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Illustration 92
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Illustration 93
Illustration 90
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24
Engine Supplement
Disassembly and Assembly Section
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Illustration 94
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Illustration 95
Illustration 96
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Installation Procedure
1. Install oil pump (14) in the reverse order.
i03880924
Removal Procedure
Illustration 97
Table 3
Required Tools
Tool
Part Number
138-7575
Part Description
Link Bracket
Qty
2
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25
Engine Supplement
Disassembly and Assembly Section
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Removal Procedure
Table 4
Required Tools
Illustration 98
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Tool
Part
Number
Part Description
Guide Stud
M10 x 150 mm
226-2380
Lifting Bracket
138-7574
Link Bracket
189-0410
Shackle
Qty
Start By:
a. Remove the modular front end.
g02126892
Installation Procedure
1. Install expansion tank (6) in the reverse order.
26
Engine Supplement
Disassembly and Assembly Section
Illustration 100
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Illustration 101
Illustration 103
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Illustration 104
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Illustration 102
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Illustration 105
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Engine Supplement
Disassembly and Assembly Section
Illustration 109
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Illustration 106
Illustration 107
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Illustration 110
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Illustration 111
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28
Engine Supplement
Disassembly and Assembly Section
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Installation Procedure
1. Install fan assembly (26) in the reverse order.
i03881624
Illustration 112
g02129180
Removal Procedure
Table 5
Required Tools
Part
Number
Tool
A
B
Part Description
Qty
1U-6221
1U-6222
Wrench Link
6V-8154
Bolt
8T-0162
Bolt
6F-7831
Washer
126-7183
Crossblock
126-7182
Nut
6V-2360
Hard Washer
138-7575
Link Bracket
Illustration 113
g02129188
Start By:
a. Remove the fan.
Illustration 114
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29
Engine Supplement
Disassembly and Assembly Section
i03881494
Disassembly Procedure
Table 6
Required Tools
Part
Number
Tool
Illustration 115
g02129223
Installation Procedure
Threaded Rod(1)
9X-8267
Hard Washer
6V-8225
Nut
7X-2535
Bolt (M6 x 1)
1U-8758
1P-1863
1U-9895
Crossblock
8B-7550
Puller Leg
5S-0003
Nut
3H-0465
Push-Puller Plate
4C-5669
Threaded Adapter
9U-7692
1P-1861
F
(1)
(2)
Qty
1U-6340
A
Part Description
Start By:
a. Remove the piston motor (fan drive).
Illustration 116
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Engine Supplement
Disassembly and Assembly Section
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Illustration 117
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Illustration 118
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Illustration 121
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Illustration 122
31
Engine Supplement
Disassembly and Assembly Section
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Illustration 123
Illustration 125
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Illustration 126
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Illustration 124
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32
Engine Supplement
Disassembly and Assembly Section
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Assembly Procedure
Table 7
Required Tools
Tool
Qty
Threaded Rod(1)
9X-8267
Hard Washer
6V-8225
Nut
1U-8758
1P-1863
1U-9895
Crossblock
8B-7550
Puller Leg
5S-0003
Nut
3H-0465
Push-Puller Plate
4C-5669
Threaded Adapter
5P-8249
Hard Washer
9U-7692
Illustration 128
1P-1861
F
(2)
Part Description
1U-6340
A
(1)
Part
Number
Illustration 129
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Illustration 127
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33
Engine Supplement
Disassembly and Assembly Section
12. Use Tooling (C) to install retaining ring (8).
13. Use Tooling (E) to pull the rotating group against
retaining ring (8).
Illustration 130
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Illustration 131
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Illustration 134
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Illustration 132
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Illustration 135
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34
Engine Supplement
Disassembly and Assembly Section
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Illustration 136
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i03880805
Removal Procedure
Table 8
Required Tools
Illustration 137
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Tool
Part
Number
Part Description
Qty
185-3630
Strap Wrench As
g01864093
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Illustration 139
35
Engine Supplement
Disassembly and Assembly Section
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Illustration 142
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Illustration 143
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Illustration 140
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Installation Procedure
1. Install filter base assembly (5) and filter assemblies
(2) in the reverse order.
i03880753
Removal Procedure
Table 9
Illustration 141
Required Tools
g02126771
Tool
Part Number
185-3630
Part Description
Strap Wrench
Qty
1
36
Engine Supplement
Disassembly and Assembly Section
KENR8384
Illustration 145
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Illustration 146
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Illustration 144
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Illustration 147
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Illustration 148
37
Engine Supplement
Disassembly and Assembly Section
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Illustration 151
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Installation Procedure
1. Install fuel filter bases (8) and fuel filters (6) in the
reverse order.
i03655253
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Removal Procedure
1. Turn the power disconnect switch to the OFF
position.
2. Turn the fuel supply to the OFF position.
Illustration 150
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Illustration 152
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38
Engine Supplement
Disassembly and Assembly Section
KENR8384
Installation Procedure
1. Install fuel priming pump (4) in the reverse order.
i03881432
Removal Procedure
Table 10
Required Tools
Part Description
The space between the body and the frame becomes a zero clearance area when the body is lowered. Failure to install the retaining cable can result in injury or death to personnel working in this
area.
Tool
Part
Number
163-6455
Link Bracket
189-0410
Shackle As
1U-9203
Qty
Start By:
a. Remove the bottom guards.
b. Remove the front hood.
Illustration 153
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Illustration 154
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Illustration 155
39
Engine Supplement
Disassembly and Assembly Section
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Illustration 156
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Illustration 159
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Illustration 157
Illustration 158
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Illustration 160
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40
Engine Supplement
Disassembly and Assembly Section
Illustration 161
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Illustration 162
Illustration 164
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Illustration 165
Illustration 163
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Illustration 166
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Illustration 167
41
Engine Supplement
Disassembly and Assembly Section
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Illustration 168
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Illustration 171
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Illustration 169
Illustration 170
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Illustration 172
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42
Engine Supplement
Disassembly and Assembly Section
Illustration 173
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Illustration 176
Illustration 177
Illustration 174
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Illustration 175
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Illustration 178
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43
Engine Supplement
Disassembly and Assembly Section
Installation Procedure
1. Install front module (30) in the reverse order.
i03903152
Radiator - Disassemble
SMCS Code: 1353-015
Disassembly Procedure
Table 11
Illustration 179
Required Tools
g02136618
Tool
Part
Number
138-7573
Link Bracket
4Q-5222
Breaker Tool
4Q-5144
Installer Tool
1U-9202
163-6455
Link Bracket
Part Description
Qty
Start By:
a. Remove the fan.
b. Remove the aftercoolers.
Illustration 180
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Illustration 181
Illustration 182
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Illustration 183
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44
Engine Supplement
Disassembly and Assembly Section
KENR8384
Illustration 187
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Illustration 184
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Illustration 188
Illustration 185
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Illustration 189
Illustration 186
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Illustration 190
45
Engine Supplement
Disassembly and Assembly Section
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Illustration 193
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Illustration 191
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Illustration 192
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Illustration 194
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Illustration 195
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46
Engine Supplement
Disassembly and Assembly Section
Illustration 196
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Illustration 199
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Illustration 200
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Illustration 197
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Illustration 201
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Illustration 198
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Illustration 202
47
Engine Supplement
Disassembly and Assembly Section
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Illustration 205
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Illustration 203
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Illustration 204
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48
Engine Supplement
Disassembly and Assembly Section
Illustration 208
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Illustration 211
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Illustration 212
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23. Remove bolts (36) and bolts (37) from both sides
of the bottom tank.
Illustration 209
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Illustration 210
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Typical Example
KENR8384
49
Engine Supplement
Disassembly and Assembly Section
i03903153
Radiator - Assemble
Assembly Procedure
Table 12
Required Tools
Tool
Part
Number
138-7573
Link Bracket
4Q-5144
Installer Tool
1U-9202
163-6455
Link Bracket
342-2335
Brush
342-2346
Brush
342-2348
Brush
342-2349
Oil
342-2334
Installer
Part Description
Qty
Illustration 215
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Typical Example
Illustration 216
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Typical Example
Illustration 213
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Illustration 214
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50
Engine Supplement
Disassembly and Assembly Section
Illustration 217
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Illustration 220
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Illustration 218
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Illustration 221
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Illustration 219
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Illustration 222
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12. Install bolts (32). Repeat this step for the opposite
side.
KENR8384
Illustration 223
51
Engine Supplement
Disassembly and Assembly Section
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13. Install bolts (31). Repeat this step for the opposite
side.
Illustration 224
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Illustration 226
Illustration 227
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Illustration 228
Illustration 225
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52
Engine Supplement
Disassembly and Assembly Section
Illustration 229
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Illustration 232
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20. Install tension bar (14), shim (13), and bolts (12).
Illustration 233
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Typical Example
Illustration 230
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Illustration 234
Typical Example
Illustration 231
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19. Install tension bar (17), shim (16), and bolts (15).
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Illustration 235
53
Engine Supplement
Disassembly and Assembly Section
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Typical Example
Illustration 238
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Illustration 239
Illustration 236
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Illustration 240
Illustration 237
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54
Engine Supplement
Disassembly and Assembly Section
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Removal Procedure
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Illustration 242
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55
Engine Supplement
Disassembly and Assembly Section
Illustration 243
g02145481
Illustration 244
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Installation Procedure
1. Install refrigerant condenser (5) in the reverse
order.
Illustration 245
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i03937349
Removal Procedure
Illustration 246
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56
Engine Supplement
Disassembly and Assembly Section
KENR8384
Illustration 247
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Illustration 249
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Illustration 248
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Illustration 250
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Installation Procedure
Removal Procedure
Start By:
a. Remove the bottom guards.
Illustration 251
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57
Engine Supplement
Disassembly and Assembly Section
Installation Procedure
1. Install vibration damper (2) in the reverse order.
a. Tighten bolts (3) to a torque of 700 50 Nm
(516 37 lb ft). Repeat this step in order to
ensure that bolts (3) are tightened to a torque
of 700 50 Nm (516 37 lb ft) equally.
i03872289
Illustration 252
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Removal Procedure
Start By:
a. Remove the bottom guards.
g02119856
Illustration 254
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58
Engine Supplement
Disassembly and Assembly Section
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i03901169
Removal Procedure
Illustration 255
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Illustration 256
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Illustration 257
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Installation Procedure
1. Install water pump (11) in the reverse order.
Illustration 258
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Illustration 259
59
Engine Supplement
Disassembly and Assembly Section
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Illustration 262
g02144245
Installation Procedure
1. Install thermostatic valve (13) in the reverse order.
i03901457
g02144239
Disassembly Procedure
Start By:
a. Remove the thermostatic valve.
Illustration 261
g02144241
Illustration 263
g02144327
60
Engine Supplement
Disassembly and Assembly Section
Illustration 264
KENR8384
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Illustration 265
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Illustration 266
Illustration 267
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Illustration 268
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g02144334
Illustration 269
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61
Engine Supplement
Disassembly and Assembly Section
i03901461
Assembly Procedure
Table 13
Required Tools
Tool
Part
Number
3S-6252
Part Description
Sealant
Qty
Illustration 272
g02144336
Illustration 270
g02144367
Illustration 273
g02144334
Illustration 271
g02144363
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62
Engine Supplement
Disassembly and Assembly Section
Illustration 275
KENR8384
g02144329
Illustration 276
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7. Apply Tooling (A) onto cap (5). Install cap (5) and
bolts (4). Install controller assembly (3). Connect
harness assembly (2). Install bolts (1).
Note: Ensure that sealant is applied to the hole for
the grommet.
End By:
a. Install the thermostatic valve.
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Engine Supplement
Index Section
Index
F
A
Aftercooler Core - Remove and Install ..................
Installation Procedure ........................................
Removal Procedure ...........................................
Air Compressor - Remove and Install....................
Installation Procedure ........................................
Removal Procedure ...........................................
Air Starting Motor - Remove and Install.................
Installation Procedure ........................................
Removal Procedure ...........................................
Alternator - Remove and Install .............................
Installation Procedure ........................................
Removal Procedure ...........................................
4
8
4
8
8
8
9
9
9
9
10
9
56
57
56
4
E
Electronic Control Module (Front Engine) - Remove
and Install ............................................................ 11
Installation Procedure ........................................ 11
Removal Procedure ........................................... 11
Engine and Torque Converter - Remove and
Install ................................................................... 12
Installation procedure......................................... 18
Removal Procedure ........................................... 12
Engine Oil Cooler - Remove and Install ................ 18
Installation Procedure ........................................ 21
Removal Procedure ........................................... 18
Engine Oil Filter and Oil Filter Base - Remove and
Install ................................................................... 21
Installation Procedure ........................................ 22
Removal Procedure ........................................... 21
Engine Oil Pump - Remove and Install.................. 22
Installation Procedure ........................................ 24
Removal Procedure ........................................... 22
Expansion Tank - Remove and Install ................... 24
Installation Procedure ........................................ 25
Removal Procedure ........................................... 24
32
32
29
29
28
29
28
R
Radiator - Assemble ..............................................
Assembly Procedure..........................................
Radiator - Disassemble .........................................
Disassembly Procedure .....................................
Refrigerant Condenser - Remove and Install ........
Installation Procedure ........................................
Removal Procedure ...........................................
49
49
43
43
54
55
54
T
Table of Contents...................................................
Thermostatic Valve - Assemble .............................
Assembly Procedure..........................................
Thermostatic Valve - Disassemble ........................
Disassembly Procedure .....................................
3
61
61
59
59
58
59
58
55
56
55
W
Water Pump (Engine) - Remove and Install .......... 57
Installation Procedure ........................................ 58
Removal Procedure ........................................... 57
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