SENR8323-04

June 2013

Disassembly and Assembly

D8R Track-Type Tractor
Engine Supplement
7XM 1-Up (Machine)
9EM 1-Up (Machine)

SAFETY.CAT.COM
 i05296198

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards, including human factors
that can affect safety. This person should also have the necessary training, skills and tools to perform these
functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you verify
that you are authorized to perform this work, and have read and understood the operation,
lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on
the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must not
use this product in any manner different from that considered by this manual without first satisfying
yourself that you have considered all safety rules and precautions applicable to the operation of the
product in the location of use, including site-specific rules and precautions applicable to the
worksite. If a tool, procedure, work method or operating technique that is not specifically
recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others.
You should also ensure that you are authorized to perform this work, and that the product will not be
damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that
you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Cat dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts.
Failure to follow this warning may lead to pre-
mature failures, product damage, personal in-
jury or death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SENR8323 3
Table of Contents

Table of Contents Water Pump - Remove .................. ................. 59

Water Pump - Disassemble.............. .............. 60
Disassembly and Assembly Section Water Pump - Assemble................. ................ 62
Water Pump - Install .................... ................... 63
Alternator - Remove and Install ............ ............ 4
Hood and Dust Ejector - Remove........... .......... 5 Index Section
Hood and Dust Ejector - Install ............. ............ 6
Index................................ ............................... 65
Muffler - Remove and Install............... .............. 8
Electric Starting Motor - Remove and Install .. .. 9
Air Cleaner - Remove and Install.......... .......... 10
Engine Side Guards - Remove and Install.... ...11
Accidental machine starting can cause injury or
Fan - Remove and Install................ ................ 13
death to personnel working on the machine.
Fan Drive - Remove.................... .................... 13
Fan Drive - Disassemble ................ ................ 14 To avoid accidental machine starting, turn the
Fan Drive - Assemble ................... .................. 15 battery disconnect switch to the OFF position
Fan Drive - Install...................... ...................... 16 and remove the key. If the machine is not
equipped with a battery disconnect switch,
Belt Tightener - Remove................. ................ 17 disconnect the battery cables from the battery
Belt Tightener - Disassemble............. ............. 18 and tape the battery clamps.
Belt Tightener - Assemble ............... ............... 18
Belt Tightener - Install................... .................. 19 Place a do not operate tag at the battery
disconnect switch location to inform personnel
Radiator Core - Remove and Install ........ ....... 20 that the machine is being worked on.
Radiator Guard - Tilt .................... ................... 21
Radiator Guard - Remove................ ............... 28
Radiator Guard - Install.................. ................. 29
Engine and Torque Divider - Remove....... ...... 30
Engine and Torque Divider - Install......... ........ 35
Fuel Transfer Pump - Remove............ ............ 38
Fuel Transfer Pump - Disassemble ........ ........ 39
Fuel Transfer Pump - Assemble ........... .......... 41
Fuel Transfer Pump - Install.............. .............. 44
Engine Oil Filter and Base - Remove and
Install............................... .............................. 44
Engine Oil Filter Base - Disassemble ....... ...... 45
Engine Oil Filter Base - Assemble......... ......... 46
Fuel Shutoff Solenoid - Remove and Install .. . 47
Primary Fuel Filter and Base - Remove and
Install............................... .............................. 47
Fuel Ratio Control - Remove ............. ............. 48
Fuel Ratio Control - Disassemble.......... ......... 49
Fuel Ratio Control - Assemble............ ............ 50
Fuel Ratio Control - Install ............... ............... 52
Exhaust Manifold - Remove and Install ..... ..... 52
Turbocharger - Remove................. ................. 54
Turbocharger - Disassemble ............. ............. 55
Turbocharger - Assemble ................ ............... 55
Turbocharger - Install................... ................... 56
Crankshaft Vibration Damper - Remove and
Install............................... .............................. 56
Water Temperature Regulator - Remove and
Install............................... .............................. 57
4 SENR8323
Disassembly and Assembly Section

Disassembly and Assembly

Section
i01024947

Alternator - Remove and Install

SMCS Code: 1405-010

Removal Procedure
Note: Mark all electrical wires for correct installation.

Illustration 3 g00612712

4. Loosen two bolts (5) that are under alternator (4).

5. Loosen two adjusting nuts (7) and remove belt (8).

6. Remove bolt (6).

Note: The alternator weighs 12 kg (27 lb).

7. Remove bolts (5) and remove the alternator.

Installation Procedure
Illustration 1 g00612548

1. Open the door on the right side of the engine.

2. Remove five bolts (1) and open door (2).

Illustration 4 g00612720

Note: The alternator weighs 12 kg (27 lb).

1. Place alternator (4) on the engine and install two
bolts (5).

Illustration 2 g00612686 2. Tighten bolts (6).

3. Position belt (8) on the alternator. Then tighten two

3. Disconnect three electrical wires (3) from alternator
adjusting nuts (7).
(4).
4. Tighten two bolts (5) that are underneath alternator
(4).
SENR8323 5
Disassembly and Assembly Section

Illustration 5 g00612732 Illustration 7 g00612936

5. Connect three electrical wires (3) to alternator (4). 1. Remove guard (1) for the filter.

Illustration 6 g00612739 Illustration 8 g00612946

6. Close door (2) that is on the right side of the Note: The door weighs 32 kg (70 lb).
engine. Install five bolts (1). 2. Use a hoist and a nylon lifting strap in order to
support left side engine access door (2), as shown.
Reference: See Testing and Adjusting, SENR1028,
“Belt Tightening Chart” for the correct adjustment of 3. Remove four bolts (3) and left side engine access
the tension on the V-belts. door (2).

i01180376 4. Repeat Steps 2 and 3 for the opposite side door.

Hood and Dust Ejector -

Remove
SMCS Code: 7251-011

Removal Procedure
Table 1
Required Tools

Part
Tool Number Description Qty
A 138-7575 Link Bracket 3

Illustration 9 g00612984

5. Remove two bolts (5) under the hood.

6 SENR8323
Disassembly and Assembly Section

6. Remove two bolts (4).

7. Repeat Steps 5 and 6 for the other side of the

hood.

Illustration 12 g00613031

11. Loosen clamp (10) for the exhaust pipe. Remove

the exhaust pipe.

Illustration 10 g00612999

8. Remove bolt (6), the washer, and the spacer.

Illustration 13 g00613036

Note: The hood and the dust ejector weigh 80 kg

(176 lb).
12. Fasten a hoist to tool (A). Remove the hood and
Illustration 11 g00613015
the dust ejector.
9. Loosen clamp (7) for the precleaner.
i01180395
10. Loosen clamp (8) and disconnect hose (9).
Hood and Dust Ejector - Install
SMCS Code: 7251-012

Installation Procedure
Table 2
Required Tools

Part
Tool Number Description Qty
A 138-7575 Link Bracket 3
SENR8323 7
Disassembly and Assembly Section

Illustration 14 g00613092

Illustration 17 g00613144

Note: The hood with the dust ejector weighs 80 kg 5. Install bolt (6), the washer, and the spacer.
(176 lb).
1. Fasten a hoist to tool (A). Install the hood with the
dust ejector.

Illustration 18 g00613146

6. Install two bolts (4). Tighten two bolts (4).

Illustration 15 g00613057
7. Install two bolts (5) under the hood. Tighten the two
2. Install the exhaust pipe. Tighten clamp (10) for the bolts.
exhaust pipe.
8. Repeat Steps 6 and 7 for the other side of the
hood.

Illustration 16 g00613141

3. Connect hose (9) and tighten clamp (8). Illustration 19 g00613147

4. Tighten clamp (7) for the precleaner. Note: The door weighs 32 kg (70 lb).
8 SENR8323
Disassembly and Assembly Section

9. Use a hoist and a nylon lifting strap in order to Start By:

support left side engine access door (2), as shown.
Remove the hood and the dust ejector. See
10. Place the door in position and tighten four bolts Disassembly and Assembly, “Hood and Dust
Ejector - Remove”Disassembly and Assembly,
(3). Hood and Dust Ejector - Remove.
11. Repeat Steps 9 and 10 for the opposite side
engine access door.

Illustration 21 g00613838

1. Remove two bolts (2) and disconnect hose (1) .

Illustration 20 g00613151
2. Remove eight bolts (3) and two guards (4) .
12. Install guard (1) for the filter.

i01025227

Muffler - Remove and Install

SMCS Code: 1062-010

Removal Procedure
Table 3
Required Tools

Part
Tool Number Description Qty
A 138-7573 Link Bracket 2
Illustration 22 g00613845

Illustration 23 g00613850

Note: The muffler weighs 34 kg (75 lb).

SENR8323 9
Disassembly and Assembly Section

3. Fasten a hoist and a nylon lifting strap to tool (A).

See Illustration 22 . 4. Install two bolts (7) under the muffler.
4. Remove two bolts (7) under the muffler.

5. Remove eight bolts (5) from turbocharger guard (6)

.
6. Separate turbocharger guard (1) (if equipped) in
order to remove the clamp. Remove clamp (8) and
remove the muffler.

Installation Procedure
Table 4
Required Tools

Part
Tool Number Description Qty
A 138-7573 Link Bracket 2 Illustration 26 g00613875

5. Position two guards (4) and tighten eight bolts (3) .

6. Connect hose (1) and install two bolts (2) .

End By:
Install the hood and the dust ejector. See
Disassembly and Assembly, “Hood and Dust
Ejector - Install”Disassembly and Assembly,
Hood and Dust Ejector - Install.

i01025236

Electric Starting Motor -

Remove and Install
Illustration 24 g00613870 SMCS Code: 1453-010

Removal Procedure
Start By:
Remove the engine side guard on the left side.
See Disassembly and Assembly, “Engine Side
Guards - Remove and Install”Disassembly and
Assembly, Engine Side Guards - Remove and
Install.
Remove the bottom guard under the motor. See
Disassembly and Assembly, “Bottom Guard -
Remove and Install”.

Illustration 25 g00613867

Note: The muffler weighs 34 kg (75 lb).

1. Fasten a hoist and a nylon strap to tool (A).

2. Install clamp (8). Position muffler (8) and tighten

the clamp. Connect turbocharger guard (1) (if
equipped).

3. Install eight bolts (5) on turbocharger guard (6) .

10 SENR8323
Disassembly and Assembly Section

End By:
Install the bottom guard under the electric
starting motor. See Disassembly and Assembly,
“Bottom Guard - Remove and Install”.
Install the engine side guard on the left side. See
Disassembly and Assembly, “Engine Side
Guards - Remove and Install”Disassembly and
Assembly, Engine Side Guards - Remove and
Install.

i01024943

Air Cleaner - Remove and

Illustration 27 g00614052 Install
SMCS Code: 1051-010-HG
Note: Mark all the wires before removal for proper
installation.
1. Disconnect all wires (2) from the solenoid and from Removal Procedure
the starter. Start By:
2. Disconnect two hoses (1) under the prelube (if Remove the hood. See Disassembly and
equipped). Assembly, “Hood and Dust Ejector -
Remove”Disassembly and Assembly, Hood
and Dust Ejector - Remove.
Note: The electric starting motor weighs 34 kg (75 lb)
. 1. Open the doors to the engine compartment .
3. Remove three twelve point bolts (3). Use an
appropriate lifting device to remove the electric
starting motor.

Installation Procedure

Illustration 29 g00614142

Note: The air cleaner weighs 36 kg (80 lb).

2. Fasten a hoist and a nylon lifting strap to air
cleaner (1).
Illustration 28 g00614052

3. Remove the four mounting bolts (2).

Note: The electric starting motor weighs 34 kg (75 lb) 4. Remove three mounting bolts (3) and remove air
. cleaner (1).
1. Use an appropriate lifting device to install the
electric starting motor. Tighten three twelve point
bolts (3).

2. Install two hoses (1) on the prelube (if equipped).

3. Connect wires (2) to the solenoid and to the starter.

SENR8323 11
Disassembly and Assembly Section

Installation Procedure

Illustration 31 g00615471

Illustration 30 g00614142
Note: The door on the engine enclosure weighs
32 kg (70 lb).
Note: The air cleaner weighs 36 kg (80 lb). 1. Fasten a hoist and a nylon lifting strap to the left
1. Fasten a hoist and a nylon lifting strap to air side door.
cleaner (1). 2. Remove two bolts (1).
2. Install three mounting bolts (3) and install air 3. Remove two bolts (3) and remove the left side
cleaner (1). door.
3. Install four mounting bolts (2).
Reference: Refer to Operation and Maintenance
Manual, “Engine Air Filter Primary Element - Clean/
Replace” for the correct procedures for service of the
air cleaner.

End By:
Install the hood. See Disassembly and Assembly,
“Hood and Dust Ejector - Install”Disassembly
and Assembly, Hood and Dust Ejector - Install.

i01025223

Engine Side Guards - Remove Illustration 32 g00615483

and Install
4. Remove four bolts (3) and plate (4).
SMCS Code: 7263-010

Removal Procedure
Table 5
Required Tools

Part
Tool Number Description Qty
A 138-7573 Link Bracket 2
12 SENR8323
Disassembly and Assembly Section

Illustration 33 g00615492 Illustration 35 g00615483

5. Remove three bolts (5). 3. Position plate (4). Install four bolts (3).

Note: The engine side guard weighs 45 kg (100 lb).

6. Remove two bolts and install tool (A). Attach a
suitable lifting device. See Illustration 33 .

7. Remove seven bolts (6). Remove engine side

guard (7).

8. Repeat Steps 1 through 7 in order to remove the

engine side guard on the opposite side of the
machine.

Installation Procedure

Illustration 36 g00615471

Note: The door on the engine enclosure weighs

32 kg (70 lb).
4. Fasten a hoist and a nylon lifting strap to the left
side door.
5. Position the left side door and install two bolts (2).

6. Install two bolts (1).

7. Repeat Steps 1 through 6 for the installation of the

engine side guard on the opposite side of the
machine.
Illustration 34 g00615492

Note: The engine side guard weighs 45 kg (100 lb).

1. Use tool (A) and a suitable lifting device to install
the engine side guard. Install seven bolts (6).

2. Install three bolts (5).

SENR8323 13
Disassembly and Assembly Section

i01025218 End By:

Fan - Remove and Install Tilt back the radiator guard. See Disassembly and
Assembly, “Radiator Guard - Tilt”Disassembly
SMCS Code: 1356-010 and Assembly, Radiator Guard - Tilt.

Removal Procedure i01025973

Start By:
Fan Drive - Remove
Tilt the radiator guard. See Disassembly and SMCS Code: 1359-011
Assembly, “Radiator Guard - Tilt”Disassembly
and Assembly, Radiator Guard - Tilt.
Removal Procedure
Start By:
Remove the fan. See Disassembly and Assembly,
“Fan - Remove and Install”Disassembly and
Assembly, Fan - Remove and Install.

Illustration 37 g00616894

Note: The fan weighs 34 kg (75 lb).

1. Fasten a hoist and a nylon strap to fan (1) in order
to lift the fan.
2. Remove eight bolts (2). Remove fan (1) from the Illustration 39 g00616921
fan drive.
1. Remove the spring tension on belt tightener (1).
Installation Procedure Use a suitable wrench on the square section of the
belt tightener to move belt tightener (1) to the right.

2. Remove three V-belts (2).

Illustration 38 g00616894

Note: The fan weighs 30 kg (75 lb).

Illustration 40 g00616923
1. Fasten a hoist and a nylon strap to fan (1) in order
to lift the fan.
3. Loosen two bolts (4) on the bracket for air
2. Install eight bolts (2). Install fan (1) to the fan drive. conditioning compressor (5).
14 SENR8323
Disassembly and Assembly Section

4. Loosen adjusting rod (3). Remove the belt for air

conditioning (6).

Illustration 42 g00617023

1. Remove six bolts (2). Remove adapter (1).

Illustration 41 g00616925

Note: The fan drive weighs 39 kg (86 lb).

5. Fasten a hoist and a nylon lifting strap to the fan
drive. See Illustration 41 .
6. Remove lubrication line (8).

7. Remove bolt (7) from the bracket for air

conditioning compressor (5).

8. Remove screw (10) from belt tightener spring (9).

9. Remove two bolts and two nuts (11). Remove the

fan drive from the engine.

i01025250 Illustration 43 g00617032

Fan Drive - Disassemble 2. Remove bolt (3) and retaining washer (4).
SMCS Code: 1359-015

Disassembly Procedure
Start By:
Remove the fan drive. See Disassembly and
Assembly, “Fan Drive - Remove”Disassembly
and Assembly, Fan Drive - Remove.

Illustration 44 g00617033

3. Remove pulley (5) and hub (6) from support (7).

SENR8323 15
Disassembly and Assembly Section

i02560327

Fan Drive - Assemble

SMCS Code: 1359-016

Assembly Procedure

Illustration 45 g00617036

4. Remove six bolts (8). Separate pulley (5) from hub

(6).

5. Remove spacer (9).

Illustration 48 g00617041

1. Fill bearing cone (14) with 2S-3230 Bearing

Lubricant.
2. Install the bearing cup (not shown) and bearing
cone (14) on hub (6).

3. Install lip seal (13). Install the seal with the spring-
loaded lip away from the hub. Lightly lubricate
sealing lips of lip seal (13).

4. Apply 9 g (0.3 oz) of 2S-3230 Bearing Lubricant.

Place the bearing lubricant on the cavity of the lip
Illustration 46 g00617039
seal.

6. Remove these components from fan pulley hub (6)

: bearing cone (12), spacer (11) and bearing cup
(10).

Illustration 49 g00617039

5. Fill 50 g (1.8 oz) of 2S-3230 Bearing Lubricant in

the cavity between bearings.
Illustration 47 g00617041 6. Install bearing cup (10).
7. Remove lip seal (13) and bearing cone (14). 7. Install spacer (11) in hub (6).
Remove the bearing cup (not shown) from hub (6).
16 SENR8323
Disassembly and Assembly Section

8. Fill bearing cone (12) with 2S-3230 Bearing

Lubricant. Install bearing cone (12) in hub (6).

Illustration 52 g00617032

12. Apply 4C-4030 Thread Lock Compound on the

Illustration 50 g00617036 threads of bolt (3). Install retaining washer (4) and
bolt (3). Tighten bolt (3) to a torque of
9. Install pulley (5) on hub (6). Install six bolts (8). 212 ± 12 N·m (156 ± 9 lb ft).
10. Install spacer (9).

Illustration 53 g00617023

Illustration 51 g00617033
13. Fill 44 g (1.5 oz) of 2S-3230 Bearing Lubricant
in the cavity of adapter (1).
11. Install pulley (5) and hub (6) on support (7).
14. Install adapter (1). Install six bolts (2).
End By:
Install fan drive. See Disassembly and Assembly,
“Fan Drive - Install”Disassembly and Assembly,
Fan Drive - Install.

i01025977

Fan Drive - Install

SMCS Code: 1359-012

Installation Procedure
Reference: Refer to Testing and Adjusting,
SENR1028, “Belt Tightening Chart” in the Service
Manual for your machine.
SENR8323 17
Disassembly and Assembly Section

Illustration 54 g00616925 Illustration 56 g00616921

Note: The fan drive weighs 39 kg (86 lb). 8. Install three V-belts (2).
1. Fasten a hoist and a nylon lifting strap to the fan
drive. 9. Set the spring tension on belt tightener (1). Use a
suitable wrench on the square section of the belt
2. Position the fan drive on the engine. Install two tightener to move belt tightener (1) to the left.
bolts and two nuts (11).
Note: Replace the belts in sets only, if one or more
3. Install screw (10) to belt tightener spring (9). belts are worn or damaged.

4. Install bolt (7) to the bracket on the air conditioning End By:
compressor (5).
Install the fan. See Disassembly and Assembly,
5. Connect lubrication hose (8). “Fan - Remove and Install”Disassembly and
Assembly, Fan - Remove and Install.

i01025982

Belt Tightener - Remove

SMCS Code: 1358-011

Removal Procedure
Start By:
Remove the fan. See Disassembly and Assembly,
“Fan - Remove and Install”Disassembly and
Assembly, Fan - Remove and Install.

Illustration 55 g00616923

6. Install belt (6) for the air conditioning compressor.

Tighten adjusting rod (3).

7. Tighten two bolts (4) on bracket (5) for the air

conditioning compressor.
18 SENR8323
Disassembly and Assembly Section

Illustration 57 g00617136 Illustration 59 g00617384

1. Carefully use a suitable wrench to move belt 1. Remove four bolts (1). Remove cover (3). Remove
tightener (2) to the right. Remove three V-belts (1). the gasket (not shown).

2. Remove pulley (4) from shaft (2).

Illustration 58 g00617139

2. Remove screw (7) and disconnect spring (6). Illustration 60 g00617387

3. Remove lubrication tube (5). 3. Remove these components from pulley (4) : lip
seal (5), bearings (6) and (9) and spacer (8).
4. Remove four mounting bolts (4) and remove belt
tightener (2).
i01025249

i01025247 Belt Tightener - Assemble

Belt Tightener - Disassemble SMCS Code: 1358-016

SMCS Code: 1358-015

Start By:
Remove the belt tightener. See Disassembly and
Assembly, “Belt Tightener -
Remove”Disassembly and Assembly, Belt
Tightener - Remove.
SENR8323 19
Disassembly and Assembly Section

i01025983

Belt Tightener - Install

SMCS Code: 1358-012

Installation Procedure

Illustration 61 g00617387

1. Install spacer (8) in pulley (4).

2. Fill bearings (6) and (9) with 2S-3230 Bearing

Lubricant. Install the bearings in pulley (4).

3. Install lip seal (5). Install the seal with the spring
Illustration 63 g00617139
loaded lip toward the inside of the hub. Lightly
lubricate the sealing lips of lip seal (5) after
1. Position the belt tightener (2) on the engine. Install
installation.
four mounting bolts (4) .
4. Fill the cavity in pulley (4) with 38 g (1.3 oz) of
2S-3230 Bearing Lubricant. 2. Install lubrication tube (5).

3. Connect spring (6) and install screw (7).

Illustration 62 g00617384

Illustration 64 g00617136
5. Install pulley (4) on shaft (2).

6. Install the gasket (not shown) and cover (3). Install 4. Install three V-belts (1).
four bolts (1).
5. Carefully move belt tightener (2) to the left.
End By:
Reference: See Testing and Adjusting, SENR1028,
Install the belt tightener. See Disassembly and “Belt Tightening Chart” for the correct adjustment of
Assembly, “Belt Tightener - the tension on the V-belts.
Install”Disassembly and Assembly, Belt
Tightener - Install. End By:
Install the fan. See Disassembly and Assembly,
“Fan - Remove and Install”Disassembly and
Assembly, Fan - Remove and Install.
20 SENR8323
Disassembly and Assembly Section

i01025230

Radiator Core - Remove and

Install
SMCS Code: 1353-010

Removal Procedure

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 Illustration 65 g00617513
heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns. 3. Loosen two clamps (1) and disconnect two hoses
(2) from radiator core (4).
Remove cooling system pressure cap slowly to
relieve pressure only when engine is stopped and 4. Remove two bolts (3) from radiator core (4).
cooling system pressure cap is cool enough to
touch with your bare hand.
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.

Note: Clean the outside of the radiator before you

begin this procedure.

Note: Mark all lines, all hoses, and all tubes for
correct installation. Plug all lines, hoses, and tubes in
order to prevent fluid loss or contamination of the
cooling system.
Illustration 66 g00617516

Note: The cooling system has a capacity of 92 L 5. Carefully lift radiator core (4). Disconnect lower
(24.3 US gal). tubes (5). Separate the seal from the lower tank.
1. Drain the coolant from the ecology drain to a
suitable container for storage or for disposal. 6. Remove radiator core (4) from the machine.

2. Open the grill on the radiator guard. Installation Procedure

SENR8323 21
Disassembly and Assembly Section

i02189675

Radiator Guard - Tilt

SMCS Code: 1381-084

Procedure to Tilt Forward

Table 6

Required Tools
Pa-
Illustration 67 g00617516 De-
T- rt scrip-
1. Position radiator core (4) on the machine. Connect Nu-
oolmb- Qty
lower tubes (5). Install the seal on the lower tank.
tion
2. Install radiator core (4) on the machine.
er
13-
8- Link
A 75- Bracket 2
75
9U- Hand
66- Hydraul- 1
Illustration 68 g00617513 00 ic Pump
3. Install two bolts (3) to radiator core (4).
5P- Wear
4. Connect two hoses (2) and tighten two clamps (1)
B 72- 1
to radiator core (4).

5. Close the grill on the radiator guard. 95 Sleeve

6. Fill the cooling system with engine coolant.
Reference: Refer to Operation and Maintenance
5P- Hydraul-
Manual, “Lubricant Viscosities”. 52- ic Puller 1
Reference: Refer to Operation and Maintenance
Manual, “Refill Capacities”. 47
(continued)
22 SENR8323
Disassembly and Assembly Section

(Table 6, contd)

Required Tools Personal injury can result from contact with

refrigerant.

Pa- Contact with refrigerant can cause frost bite. Keep

face and hands away to help prevent injury.
De-
T- rt scrip- Protective goggles must always be worn when re-

Nu-
oolmb- Qty frigerant lines are opened, even if the gauges indi-
cate the system is empty of refrigerant.

tion Always use precaution when a fitting is removed.

er Slowly loosen the fitting. If the system is still

under pressure, release it slowly in a well venti-
lated area.

Thread- Personal injury or death can result from inhaling

refrigerant through a lit cigarette.
ed Rod Inhaling air conditioner refrigerant gas through a

(5/8 lit cigarette or other smoking method or inhaling

fumes released from a flame contacting air condi-
tioner refrigerant gas, can cause bodily harm or

inch by 1 death.
Do not smoke when servicing air conditioners or

11 by 18 wherever refrigerant gas may be present.

Use a certified recovery and recycling cart to

inch) properly remove the refrigerant from the air condi-

tioning system.

4K- 1. Remove the air conditioner condenser (if

equipped). In order to remove the condenser coil,

03- Full Nut 1 the refrigerant must be removed from the air
conditioning system.

67 Reference: Refer to Service Manual, SENR5664, Air

Conditioning & Heating Systems for the correct

5P- Hard procedures.

82- Washer 1 Note: If the bulldozer blade is installed on the

47
machine, disconnect the bulldozer lift cylinders from
the trunnions of the bulldozer blade. Make sure that
the rods of the bulldozer lift cylinders are retracted
before the radiator guard is tilted.
Start By:
Remove the front bottom guard. Refer to
Disassembly and Assembly, “Bottom Guard -
Remove”.
Remove the hood and the dust ejector. Refer to ,
“Hood and Dust Ejector - Remove”, Hood and
Dust Ejector - Remove.
Remove the engine side guards. See , “Engine
Side Guards - Remove and Install”, Engine
Side Guards - Remove and Install.
SENR8323 23
Disassembly and Assembly Section

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 cooling system pressure cap slowly to
relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
touch with your bare hand.
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing Illustration 70 g00617664
burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.

Note: Drain the coolant into a suitable container for

storage or disposal. The capacity of the cooling
system is approximately 92 L (24 US gal).

Illustration 71 g00617667

5. Remove bolts (6) and left fan guard (7).

6. Remove bolts (8) and right fan guard (9).

7. Remove the bolts from hose bracket (10) and

Illustration 69 g00617651 position hose bracket (10) out of the way.

2. Loosen hose clamp (2) and disconnect hose (3)

from tank (1). Position hose (3) out of the way.

3. Remove the bolt and the clamp (4). Position the

hose out of the way.

4. Remove hose (5) from tank (1).

Illustration 72 g00617674

8. Remove bolts (12) from elbows (11). Separate

elbows (11) from the lower radiator tank.
24 SENR8323
Disassembly and Assembly Section

9. Remove the nuts, the washers, and bolts (13) from

both of the rear hinge pins.

Illustration 75 g00617732

12. Remove the cover of the quick-drop valve (not

Illustration 73 g00617680 shown). Attach Tooling (A) and a suitable lifting
device to the radiator guard.
10. Remove fourteen bolts (14) from lower shield
assemblies (15). Remove lower shield assemblies
(15).

Illustration 76 g00617735

13. Use Tooling (B) in order to remove two rear hinge

Illustration 74 g00617687 pins (18).

11. Remove bolts (16) in order to remove plate (17).

Illustration 77 g00617741

14. Carefully tilt the radiator guard forward until

contact is made with the main frame.
SENR8323 25
Disassembly and Assembly Section

Procedure to Tilt Back (Table 7, contd)

Table 7

Required Tools Required Tools

Pa- Pa-
De- T- rt De-
T- rt scrip- Nu- scrip- Qty
Nu-
oolmb- Qty oolmb- tion
tion er
er
13- Thread-
8- Link ed Rod
A 75- Bracket 2 (5/8
75 inch by 1
9U- Hand 11 by 18
66- Hydraul- 1 inch)
00 ic Pump 4K-
5P- Wear 03- Full Nut 1
B 72- 1 67
95 Sleeve 5P- Hard
5P- Hydraul- 82- Washer 1
52- ic Puller 1 47
47 Note: The following steps are for tilting back the
radiator guard.

(continued)
26 SENR8323
Disassembly and Assembly Section

Illustration 78 g00617732 Illustration 80 g00617680

1. Attach Tooling (A) and a suitable lifting device to 6. Install lower shield assemblies (15) and fourteen
the radiator guard. bolts (14).

2. Carefully tilt the radiator guard to the upright

position.

3. Use Tooling (B) in order to install two rear hinge

pins (18).

4. Remove Tooling (A) and the suitable lifting device

and install the cover on the quick-drop valve.

Illustration 81 g00617674

7. Position elbows (11) to the lower radiator tank.

Install bolts (12). Replace the gaskets, if
necessary.

8. Install bolts (13), the nuts, and the washers in both

rear hinge pins (18). Tighten bolts (13) to a torque
of 430 ± 60 N·m (317 ± 44 lb ft).
Illustration 79 g00617687

5. Install plate (17) by using bolts (16).

SENR8323 27
Disassembly and Assembly Section

15. Fill the cooling system. Refer to Operation and

Maintenance Manual, “Refill Capacities”.

Personal injury can result from contact with

refrigerant.
Contact with refrigerant can cause frost bite. Keep
face and hands away to help prevent injury.
Protective goggles must always be worn when re-
frigerant lines are opened, even if the gauges indi-
cate the system is empty of refrigerant.
Illustration 82 g00617667 Always use precaution when a fitting is removed.
Slowly loosen the fitting. If the system is still
under pressure, release it slowly in a well venti-
lated area.
Personal injury or death can result from inhaling
refrigerant through a lit cigarette.
Inhaling air conditioner refrigerant gas through a
lit cigarette or other smoking method or inhaling
fumes released from a flame contacting air condi-
tioner refrigerant gas, can cause bodily harm or
death.
Do not smoke when servicing air conditioners or
wherever refrigerant gas may be present.
Use a certified recovery and recycling cart to
properly remove the refrigerant from the air condi-
Illustration 83 g00617664 tioning system.

9. Position hose bracket (10) and the bolts. 16. Install the air conditioner condenser and charge
the air conditioning system with refrigerant.
10. Install right fan guard (9) and install bolts (8).
Reference: Refer to Service Manual, SENR5664, Air
11. Install left fan guard (7) and bolts (6). Conditioning & Heating Systems for the correct
procedures.
End By:
Install the front bottom guard. See Disassembly
and Assembly, “Bottom Guard - Install” in the
Service Manual for your machine.
Install the hood and the dust ejector. See , “Hood
and Dust Ejector - Install”, Hood and Dust
Ejector - Install.
Install the engine side guards. See , “Engine Side
Guards - Remove and Install”, Engine Side
Guards - Remove and Install.

Illustration 84 g00617651

12. Install hose (5) to tank (1).

13. Position the hose and install clip(4) and the bolt.

14. Position hose (3). Tighten clamp (2) to tank (1).

28 SENR8323
Disassembly and Assembly Section

i02189635

Radiator Guard - Remove

SMCS Code: 1381-011

Removal Procedure
Start By:
Drain the hydraulic system and the cooling
system into a suitable container for storage or
disposal. Refer to Operation and Maintenance
Manual for the correct procedure.
Tilt back the radiator guard. Refer to Disassembly
and Assembly, “Radiator Guard - Tilt”. Illustration 86 g00618290

3. Carefully return the radiator guard from the tilt

position to the upright position. Refer to
At operating temperature, the hydraulic tank is Disassembly and Assembly, “Radiator Guard -
hot and under pressure. Tilt”.
Hot oil and components can cause personal in-
jury. Do not allow hot oil or components to con-
tact skin.
Remove the filler cap only when the engine is
stopped, and the filler cap is cool enough to touch
with your bare hand. Remove the filler cap slowly
in order to relieve pressure.

Personal injury or death can result from lifting a

heavy assembly.
The heavy assembly can fall if using an incorrect
hoist to lift the load. Illustration 87 g00618292

Be sure the hoist has the correct capacity to lift a

heavy assembly. Approximate weight of the as- 4. Remove the bolts and open radiator grills (3).
sembly is given below.
5. Remove bolts (5) from manifold (6). Position
manifold (6) out of the way.

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, 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 sup-
plies suitable to collect and contain fluids on Caterpil-
lar products.
Illustration 85 g00618288 Dispose of all fluids according to local regulations and
mandates.
1. Disconnect harness assembly (1).

2. Remove cable strap (2).

SENR8323 29
Disassembly and Assembly Section

Note: Mark the hoses for correct installation. Plug all

openings in order to prevent contamination or loss of
fluids.
6. Disconnect hydraulic hoses (4) from the quick-drop
valve.
7. Remove bolts (7) and clamp (8) from hydraulic
hoses (4).

Illustration 89 g00618299

1. Use a suitable lifting device to install the radiator

guard. Guide manifold (6) and hydraulic hoses (4)
through the opening in the radiator grill. The weight
of the radiator guard is approximately 1260 kg
(2770 lb).

2. Install hinge pins (10) in each side of the radiator

Illustration 88 g00618299
guard.
8. Remove the bolts and retainer (9) from each side 3. Install the bolts and retainer (9) to each side of the
of the radiator guard. radiator guard.
9. Remove hinge pins (10) from each side of the
radiator guard.

10. Use a suitable lifting device to remove the radiator

guard. Guide manifold (6) and hydraulic hoses (4)
through the opening in the radiator grill. The weight
of the radiator guard is approximately 1260 kg
(2770 lb).

i02189629

Radiator Guard - Install

SMCS Code: 1381-012

Installation Procedure Illustration 90 g00618292

4. Install bolts (7) and clamp (8) to hydraulic hoses

(4).
Personal injury or death can result from lifting a
5. Connect hydraulic hoses (4) to the quick-drop
heavy assembly.
valve.
The heavy assembly can fall if using an incorrect
hoist to lift the load. 6. Use bolts (5) to install manifold (6).

Be sure the hoist has the correct capacity to lift a 7. Close radiator grills (3) and install the bolts.
heavy assembly. Approximate weight of the as-
sembly is given below.
30 SENR8323
Disassembly and Assembly Section

i01025178

Engine and Torque Divider -

Remove
SMCS Code: 1003-011

Removal Procedure
Table 8
Required Tools

Tool Part Number Description Qty

A 6V-6146 Load Leveler 1

Illustration 91 g00618290
Start By:
8. Tilt the radiator guard forward. Refer to Tilt the radiator guard. See Disassembly and
Disassembly and Assembly, “Radiator Guard - Assembly, “Radiator Guard - Tilt”Disassembly
Tilt”Disassembly and Assembly, Radiator Guard - and Assembly, Radiator Guard - Tilt.
Tilt.
Remove the bottom guards. See Disassembly and
Assembly, “Bottom Guard - Remove and
Install” in the Service Manual for your machine.
Remove the main drive shaft. Refer to
Disassembly and Assembly, “Main Drive Shaft
- Remove and Install” in the Service Manual for
your machine.
Remove the air cleaner. See Disassembly and
Assembly, “Air Cleaner - Remove and
Install”Disassembly and Assembly, Air Cleaner
- Remove and Install.

Reference: Consult the Disassembly and Assembly,

SENR8327, “Power Train” manual for the D8R Track-
Type Tractors for additional information.
Illustration 92 g00618288
Reference: Consult the Disassembly and Assembly,
SENR8331, “Machine Systems” manual for D8R
9. Install cable strap (2). Track-Type Tractors for additional information.
10. Connect harness assembly(1).
End By:
Carefully return the radiator guard from the tilt At operating temperature, the hydraulic tank is
position to the upright position. Refer to hot and under pressure.
Disassembly and Assembly, “Radiator Guard -
Tilt”. Hot oil and components can cause personal in-
jury. Do not allow hot oil or components to con-
Fill the hydraulic system and the cooling system. tact skin.
Refer to Operation and Maintenance Manual for
the proper filling procedure and the proper Remove the filler cap only when the engine is
levels for the hydraulic system and the cooling stopped, and the filler cap is cool enough to touch
system. with your bare hand. Remove the filler cap slowly
in order to relieve pressure.
SENR8323 31
Disassembly and Assembly Section

Hot oil and components can cause personal Personal injury can result from contact with
injury. refrigerant.
Do not allow hot oil or components to contact Contact with refrigerant can cause frost bite. Keep
skin. face and hands away to help prevent injury.
Protective goggles must always be worn when re-
frigerant lines are opened, even if the gauges indi-
cate the system is empty of refrigerant.
Personal injury or death can result from lifting a Always use precaution when a fitting is removed.
heavy assembly. Slowly loosen the fitting. If the system is still
under pressure, release it slowly in a well venti-
The heavy assembly can fall if using an incorrect lated area.
hoist to lift the load.
Personal injury or death can result from inhaling
Be sure the hoist has the correct capacity to lift a refrigerant through a lit cigarette.
heavy assembly. Approximate weight of the body
assembly is given below. Inhaling air conditioner refrigerant gas through a
lit cigarette or other smoking method or inhaling
fumes released from a flame contacting air condi-
NOTICE tioner refrigerant gas, can cause bodily harm or
Care must be taken to ensure that fluids are con- death.
tained during performance of inspection, mainte- Do not smoke when servicing air conditioners or
nance, testing, adjusting and repair of the product. Be wherever refrigerant gas may be present.
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling Use a certified recovery and recycling cart to
any component containing fluids. properly remove the refrigerant from the air condi-
tioning system.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and sup- 3. Remove the air conditioner condenser (if
plies suitable to collect and contain fluids on Caterpil-
lar products. equipped). In order to remove the condenser coil,
the refrigerant must be removed from the air
Dispose of all fluids according to local regulations and conditioning system.
mandates.
Reference: Refer to Service Manual, SENR5664, Air
Conditioning & Heating Systems for the correct
Note: Mark all components for correct installation. procedures.
When you remove the components, cover the
openings in order to keep the system clean.
1. Drain the hydraulic tank oil from the hydraulic oil
drain into a suitable container for storage or for
disposal. The drain for the hydraulic oil is located
under the right fender.

2. Drain the power train oil into a suitable container

for storage or disposal. The drain for the power
train oil is located on the torque divider.

Illustration 93 g00618626

4. Remove nine bolts (1) and remove floorplate (2)

from the cab.
32 SENR8323
Disassembly and Assembly Section

Illustration 94 g00618628 Illustration 96 g00618631

5. Remove two hoses (9) from the steering pump. 13. Remove three bolts (12) and remove plate (13).

6. Disconnect hose (3) from the steering pump. 14. Remove three bolts that hold plate (14). Remove
plate (14).
7. Disconnect three hoses (8) from the steering
pump. 15. Repeat Steps 13 and 14 for the removal of plates
(13) and (14) on the opposite side of the machine.
8. Remove four bolts (4) and remove manifold (5)
from the implement pump.

9. Disconnect two hoses (6) from the implement

pump.

10. Disconnect two hoses (7) from the implement

pump.

Illustration 97 g00618658

16. Remove two bolts (15). Reposition the hose

bracket for clearance during the removal of the
engine and the torque divider.

17. Remove three hose clips (16) from the heater

hoses.
Illustration 95 g00618629
18. Close the shutoff cocks and remove two heater
11. Disconnect three hoses (10) from the torque hoses (17).
divider.
12. Disconnect four hoses (11) from the power train
pump.
SENR8323 33
Disassembly and Assembly Section

Illustration 98 g00618662 Illustration 100 g00618671

19. Disconnect four electrical connectors (18) under 22. Remove bolt (22) and the clip. Reposition the
the platform. Remove all the wire straps that hose out of the way.
secure the wire harness.
23. Close the valve under the fuel tank in order to
shut off the fuel supply.

24. Disconnect two fuel hoses (23).

25. Disconnect hose (24).

Illustration 99 g00618666

20. Disconnect hose (19) from the evaporator core (if

equipped). Remove rubber boot (20). Remove
hose (19) from the housing of the evaporator core.

21. Disconnect hose (21) from the air conditioning Illustration 101 g00618679

dryer (if equipped).

26. Remove two pins (25) and remove rod assembly
(26).
34 SENR8323
Disassembly and Assembly Section

30. Fasten tool (A) to the engine and the torque

divider. Attach a suitable lifting device to tool (A).
See Illustration 106 .
31. Remove two bolts (33) and rear mount (34) from
each side of the engine.

Illustration 102 g00618681

27. Disconnect five wires (28) from the starter.

28. Remove nut (30). Remove ground cable (27) from

the stud. Remove all the wire straps from the wire
harness.
Illustration 105 g00618734

32. Remove two front mount bolts (35) from the front
mount on each side of the engine.

Illustration 103 g00618689

29. Remove four bolts (31). Reposition auxiliary

starting receptacle (32).
Illustration 106 g00618695

33. Use tool (A) to carefully remove the engine and

the torque divider from the machine. Adjust the
angle of tool (A) during the removal of the engine
and the torque divider from the machine.

Illustration 104 g00618692

Note: The engine and the torque divider weigh

2360 kg (5200 lb).
SENR8323 35
Disassembly and Assembly Section

i01025179

Engine and Torque Divider -

Install
SMCS Code: 1003-012

Installation Procedure
Table 9
Required Tools

Tool Part Number Description Qty

A 6V-6146 Load Leveler 1

Illustration 108 g00618734

Personal injury or death can result from lifting a 3. Install two front mount bolts (35) on each front
heavy assembly. mount. Do not tighten front mount bolts (35) at this
time.
The heavy assembly can fall if using an incorrect
hoist to lift the load.
Be sure the hoist has the correct capacity to lift a
heavy assembly. Approximate weight of the body
assembly is given below.

Reference: Consult the Disassembly and Assembly,

SENR8327, Power Train in the Service Manual for
D8R Track-Type Tractor for further instructions.

Reference: Consult the Disassembly and Assembly,

SENR8331, Machine Systems in the Service Manual
for D8R Track-Type Tractor for further instructions.

Note: The engine and the torque divider weigh

Illustration 109 g00618692
2360 kg (5200 lb).
1. Install tool (A) on the engine and the torque divider.
4. Install rear mount (34) with bolts (33) on each side
Attach a suitable lifting device to tool (A).
of the engine.

5. Tighten rear mount bolts (33) and front mount bolts

(35) at this time.

6. Remove tool (A) from the engine and the torque

divider.

Illustration 107 g00618695

2. Use tool (A) to carefully install the engine and the

torque divider in the machine. Adjust the angle of
tool (A) during the installation of the engine and the
torque divider.
36 SENR8323
Disassembly and Assembly Section

Illustration 110 g00618689 Illustration 113 g00618671

7. Install auxiliary starting receptacle (32) with four 11. Inspect the O-ring seal and install hose (24).
bolts (31).
12. Install two fuel hoses (23).

13. Install bolt (22) and the clip.

Illustration 111 g00618681

8. Install five wires (28) to starter (29).

Illustration 114 g00618666
9. Install ground cable (27) and nut (30). Secure the
wire harness with wire straps. 14. Install hose (21) to the air conditioning dryer (if
equipped).

15. Install hose (19) on the evaporator (if equipped).

Install rubber boot (20).

Illustration 112 g00618679

10. Install rod assembly (26) with two pins (25).

SENR8323 37
Disassembly and Assembly Section

22. Install plate (13) with three bolts (12).

23. Repeat Steps 21 and 22 on the opposite side of

the machine.

Illustration 115 g00618662

16. Connect four electrical connectors (18) under the

platform. Secure the wire harness with wire straps.

Illustration 118 g00618629

24. Inspect the O-ring seals and install four hoses

(11) on the power train pump.

25. Inspect the O-ring seals and install three hoses

(10) on the torque divider.

Illustration 116 g00618658

17. Install two heater hoses (17) to the shutoff cocks.

18. Install three clips (16).

19. Install two bolts (15) in the hose bracket.

20. Open the shutoff cocks for heater hoses (17).

Illustration 119 g00618628

26. Inspect all the O-ring seals.

27. Install two hoses (7) on the implement pump.

28. Install two hoses (6) on the implement pump.

29. Install manifold (5) with four bolts (4).

30. Connect three hoses (8) to the steering pump.

31. Connect hose (3) to the steering pump.

32. Install two hoses (9) on the steering pump.

Illustration 117 g00618631

21. Install plate (14) with three bolts.

38 SENR8323
Disassembly and Assembly Section

Reference: Refer to Service Manual, SENR5664, Air

Conditioning & Heating Systems for the correct
procedures.
End By:
Install the air cleaner. See Disassembly and
Assembly, “Air Cleaner - Remove and
Install”Disassembly and Assembly, Air Cleaner
- Remove and Install.
Tilt back the radiator guard. See Disassembly and
Assembly, “Radiator Guard - Tilt”Disassembly
and Assembly, Radiator Guard - Tilt.
Install the main drive shaft. Refer to Disassembly
and Assembly, “Main Drive Shaft - Remove and
Illustration 120 g00618626 Install”.

33. Install floorplate (2) with bolts (1). Install the bottom guards. See Disassembly and
Assembly, “Bottom Guard - Remove and
34. Fill the hydraulic oil tank to the proper level. Install”.

Reference: Refer to the Operation and Maintenance i01024792

Manual for the proper filling procedure and the proper
levels for the hydraulic system and the power train Fuel Transfer Pump - Remove
system.
SMCS Code: 1256-011
35. Fill the power train with oil to the proper level.
Removal Procedure
Start By:
Remove the engine side guard on the left side.
Personal injury can result from contact with See Disassembly and Assembly, “Engine Side
refrigerant. Guards - Remove and Install”Disassembly and
Assembly, Engine Side Guards - Remove and
Contact with refrigerant can cause frost bite. Keep Install.
face and hands away to help prevent injury.
Note: Cleanliness is an important factor. Before the
Protective goggles must always be worn when re- removal procedure, clean the exterior of the
frigerant lines are opened, even if the gauges indi- component thoroughly in order to prevent
cate the system is empty of refrigerant.
contamination of the system.
Always use precaution when a fitting is removed.
Slowly loosen the fitting. If the system is still Note: Mark all hoses, wires, and tubes for correct
under pressure, release it slowly in a well venti- installation. Plug all openings in order to prevent fluid
lated area. loss and contamination of the system.

Personal injury or death can result from inhaling

refrigerant through a lit cigarette.
Inhaling air conditioner refrigerant gas through a
lit cigarette or other smoking method or inhaling
fumes released from a flame contacting air condi-
tioner refrigerant gas, can cause bodily harm or
death.
Do not smoke when servicing air conditioners or
wherever refrigerant gas may be present.
Use a certified recovery and recycling cart to
properly remove the refrigerant from the air condi-
tioning system.

36. Charge the air conditioning system with

refrigerant.
SENR8323 39
Disassembly and Assembly Section

Illustration 121 g00622968

Illustration 122 g00623041

NOTICE
Care must be taken to ensure that fluids are con- 1. Remove seal (1) from the fuel transfer pump.
tained during performance of inspection, mainte-
nance, 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 sup-
plies suitable to collect and contain fluids on Caterpil-
lar products.
Dispose of all fluids according to local regulations and
mandates.

1. Disconnect fuel line (3) from the fuel transfer pump.

Cap the openings immediately.
Illustration 123 g00623065
2. Disconnect fuel line (4) from the fuel transfer pump.
Cap the openings immediately.

3. Remove two bolts (1).

Personal injury can result from parts and/or cov-
4. Remove fuel transfer pump (2) from the engine. ers under spring pressure.
Spring force will be released when covers are
i01024793 removed.
Be prepared to hold spring loaded covers as the
Fuel Transfer Pump - bolts are loosened.
Disassemble
2. Remove three bolts (3) and cover (2) from the
SMCS Code: 1256-015 housing.

Disassembly Procedure
Start By:
Remove the fuel transfer pump. See Disassembly
and Assembly, “Fuel Transfer Pump -
Remove”Disassembly and Assembly, Fuel
Transfer Pump - Remove.
Note: Cleanliness is an important factor. Before the
disassembly procedure, clean the exterior of the
component thoroughly in order to prevent
contamination of the internal mechanism.
40 SENR8323
Disassembly and Assembly Section

Illustration 124 g00623128 Illustration 127 g00623189

3. Remove two O-ring seals (4) and valve (5) from 6. Remove piston (9) and sleeve (10) from the
cover (2). housing.

Illustration 125 g00623147 Illustration 128 g00623195

4. Remove spring (6) from the piston. 7. Remove O-ring seal (11) from sleeve (10).

Illustration 126 g00623174 Illustration 129 g00623199

Note: Before you remove the valve, mark the 8. Remove guide (15) and tappet (17) from the
orientation of the valve for correct installation. housing.
5. Remove washer (7) and valve (8) from the housing.
SENR8323 41
Disassembly and Assembly Section

Illustration 130 g00623200 Illustration 133 g00623360

9. Remove O-ring seal (14) from guide (15). 12. Remove seal (19) from cover (18).

Illustration 131 g00623251 Illustration 134 g00623367

Note: If tappet (17) or guide (15) are damaged or 13. Remove valve (20) from the housing.
worn, the replacement must be installed as a unit.
10. Remove ring (16) from tappet (17). Remove the i01024794
tappet from guide (15).
Fuel Transfer Pump -
Assemble
SMCS Code: 1256-016

Assembly Procedure
Note: Clean all components and dry all components
before assembly.

1. Inspect all O-ring seals. Replace any seals that are

worn or damaged.

Illustration 132 g00623304

11. Remove the two bolts and cover (18) from the
housing.
42 SENR8323
Disassembly and Assembly Section

Illustration 135 g00623367 Illustration 138 g00623251

2. Install valve (20) in the housing. 4. Install tappet (17) in guide (15). Install ring (16) on
tappet (17) in order to hold the tappet in the guide.

Illustration 136 g00623360

Illustration 139 g00623200

Illustration 137 g00623304

Illustration 140 g00623199
3. Put clean fuel on seal (19) and install the valve on
cover (18). Install the cover on the housing. 5. Put clean fuel on O-ring seal (14) and install the
seal on guide (15). Install the unit of guide (15) and
tappet (17) in the housing.
SENR8323 43
Disassembly and Assembly Section

Illustration 141 g00623195 Illustration 143 g00623174

6. Put clean fuel on O-ring seal (11) and install the

seal on sleeve (10).

Illustration 144 g00623147

8. Install valve (8) and washer (7) in the housing.

Illustration 142 g00623189 Make sure that the valve is in the correct
orientation. Install spring (6) in the piston.
7. Install piston (9) in the housing. Install sleeve (10)
in the housing.

Illustration 145 g00623128

9. Install valve (5) in cover (2).

10. Put clean fuel on two O-ring seals (4) and install
the seals on cover (2). Install cover (2) on the
housing.
44 SENR8323
Disassembly and Assembly Section

End By:
Install the engine side guard on the left side. See
Disassembly and Assembly, “Engine Side
Guards - Remove and Install”Disassembly and
Assembly, Engine Side Guards - Remove and
Install.

i01026063

Engine Oil Filter and Base -

Remove and Install
SMCS Code: 1306-010

Illustration 146 g00623041 Removal Procedure

Table 10
11. Install seal (1) on the fuel transfer pump.
Required Tools
End By:
Tool Part Number Description Qty
Install the fuel transfer pump on the engine. See
Disassembly and Assembly, “Fuel Transfer A 2P-8250 Strap Wrench 1
Pump - Install”Disassembly and Assembly,
Fuel Transfer Pump - Install. Note: Cleanliness is an important factor. Before the
removal procedure, the exterior of the component
i01024795 should be thoroughly cleaned in order to prevent
contamination of the internal mechanism.
Fuel Transfer Pump - Install
SMCS Code: 1256-012

Installation Procedure

Illustration 148 g00623569

1. Use tool (A) to remove oil filter (3) from oil filter
base (2).
Illustration 147 g00622968 2. Remove four bolts (1).
1. Inspect the O-ring seal on the fuel transfer pump. If 3. Remove oil filter base (2).
necessary, replace the seal. Apply clean engine oil
to the O-ring seal. Installation Procedure
Table 11
2. Install fuel transfer pump (2) on the engine.
Required Tools
3. Install two bolts (1). Description Qty
Tool Part Number
4. Connect fuel line (4) to the fuel transfer pump. A 2P-8250 Strap Wrench 1

5. Connect fuel line (3) to the fuel transfer pump.

SENR8323 45
Disassembly and Assembly Section

Illustration 149 g00623569 Illustration 150 g00623764

1. Inspect the gasket between the oil filter base and 1. Remove two bolts (1) and cover (2) from the oil
the adapter for wear or for damage. If the gasket is filter base.
worn, replace the gasket with a new gasket.

2. Install oil filter base (2).

3. Install four bolts (1).

4. Follow the instructions on the new oil filter for the

correct installation procedure. Use tool (A) to install
oil filter (3) to oil filter base (2).

5. Operate the engine at low idle for a short period of

time.
6. Check the engine oil level.
Reference: Refer to Operation and Maintenance
Manual, “Engine Oil Level - Check”. Illustration 151 g00623766

i01024838 2. Remove spring (3) and valve (4) from the oil filter
base.
Engine Oil Filter Base -
Disassemble
SMCS Code: 1306-015

Disassembly Procedure
Start By:
Remove the oil filter base. See Disassembly and
Assembly, “Engine Oil Filter and Base -
Remove and Install”Disassembly and
Assembly, Engine Oil Filter and Base - Remove
and Install.
Note: Cleanliness is an important factor. Before the
disassembly procedure, the exterior of the
Illustration 152 g00623770
component should be thoroughly cleaned in order to
prevent contamination of the internal mechanism.
3. Remove four bolts (5) and cover (6).
46 SENR8323
Disassembly and Assembly Section

Illustration 153 g00623773 Illustration 155 g00623770

4. Remove gasket (7). 2. Install four bolts (5) and cover (6).

i01024839

Engine Oil Filter Base -

Assemble
SMCS Code: 1306-016

Assembly Procedure

Illustration 156 g00623766

3. Install spring (3) and valve (4) on the oil filter base.

Illustration 154 g00623773

1. Inspect gasket (7). Replace the gasket if the gasket

appears worn. Install gasket (7).

Illustration 157 g00623764

4. Install two bolts (1) and cover (2) on the oil filter
base.
SENR8323 47
Disassembly and Assembly Section

End By:
Install the oil filter base on the engine. See
Disassembly and Assembly, “Engine Oil Filter
and Base - Remove and Install”Disassembly
and Assembly, Engine Oil Filter and Base -
Remove and Install.

i01026057

Fuel Shutoff Solenoid -

Remove and Install
SMCS Code: 1259-010

Removal Procedure Illustration 159 g00623823

The wires are not shown.
Start By:
Remove the engine side guard on the left side. 1. Install shutoff solenoid (4) on the fuel ratio control.
See Disassembly and Assembly, “Engine Side
Guards - Remove & Install”Disassembly and 2. Install two bolts (1) and spacers (2).
Assembly, Engine Side Guards - Remove &
Install. 3. Connect wires (3) to shutoff solenoid (4).

Note: Cleanliness is an important factor. Before the End By:

removal procedure, the exterior of the component Install the engine side guard on the left side. See
should be thoroughly cleaned in order to prevent Disassembly and Assembly, “Engine Side
contamination of the internal mechanism. Cover all Guards - Remove & Install”Disassembly and
openings in order to prevent contamination of the Assembly, Engine Side Guards - Remove &
system. Install.
Note: Mark all wires for proper installation.
i01024840

Primary Fuel Filter and Base -

Remove and Install
SMCS Code: 1260-010

Removal Procedure
Table 12
Required Tools

Tool Part Number Description Qty

A 2P-8250 Strap Wrench 1

Illustration 158 g00623823 NOTICE

The wires were previously disconnected. Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
1. Disconnect wires (3) to shutoff solenoid (4). nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
2. Remove two bolts (1) and spacers (2). before opening any compartment or disassembling
any component containing fluids.
3. Remove shutoff solenoid (4) from the fuel ratio
control. Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and sup-
plies suitable to collect and contain fluids on Caterpil-
Installation Procedure lar products.
Dispose of all fluids according to local regulations and
mandates.
48 SENR8323
Disassembly and Assembly Section

Illustration 160 g00619301 Illustration 162 g00619302

1. Disconnect fuel lines (1) and (2). Put a cap and 1. Install fuel filter base (5) and two nuts (4) to the
plug on all the openings immediately. aftercooler housing.

2. Install fuel filter (3) to the fuel filter base. Follow the
instructions on the fuel filter for the correct
procedure.

Illustration 161 g00619302

2. Remove fuel filter (3) from the fuel filter base with
tool (A).
Illustration 163 g00619301
3. Remove two nuts (4) and fuel filter base (5) from
the aftercooler housing. 3. Remove the caps and plugs. Connect fuel lines (1)
and (2) to the filter base.
Installation Procedure
i01025963
NOTICE
Fuel line to cold start heater in the intake manifold
must be primed each time the fuel system is serviced,
Fuel Ratio Control - Remove
fuel lines disconnected or after running out of fuel. SMCS Code: 1278-011
Operation of heater without fuel will distort the heater
and heater will have to be replaced. Removal Procedure
Table 13
Required Tools
NOTICE
Do not fill fuel filter housings with fuel before installing Part
elements. Tool Number Description Qty

A 3 mm (7/64 inch) Drill 1

Contaminated fuel will cause accelerated wear to fuel
system components. 4 mm to 5.5 mm 1
B (5/32 inch to 7/32 inch) Extractor

C 128-7985 Fuel System Protection Group 1

SENR8323 49
Disassembly and Assembly Section

Note: Cleanliness is an important factor. Before the i01025256

removal procedure, the exterior of the component
should be thoroughly cleaned in order to prevent Fuel Ratio Control -
contamination of the internal mechanism.
Disassemble
Note: Mark all lines and wires for correct installation. SMCS Code: 1278-015
Cover all openings in order to prevent contamination
of the system.
Disassembly Procedure
Table 14
Required Tools

Part
Tool Number Description Qty
A FT-1820 Fixture 1

B 1P-1855 Retaining Ring Pliers 1

Start By:
Remove the fuel ratio control. See Disassembly
and Assembly, “Fuel Ratio Control -
Remove”Disassembly and Assembly, Fuel
Ratio Control - Remove.
Illustration 164 g00622086
NOTICE
1. Disconnect air line (1) from the fuel ratio control. Adjustment of the fuel system outside Caterpillar
specified limits will not improve fuel efficiency and
2. Remove wire seal (4) from the bolts. could result in damage to the engine.
3. Remove four bolts (3) that hold fuel ratio control (2)
to the governor. Reference: Refer to the “Fuel Ratio Control
Adjustment” in Testing and Adjusting, SENR1028 for
the 3406C Engine.

1. Place tool (A) in a vise. The station of tool (A) for

this procedure must not be over the vise jaw. Place
the fuel ratio control over the pins in tool (A).

Illustration 165 g00622097

4. The two “tamperproof” bolts (5) and (6) require the

use of tool (A) and tool (B) for removal.

5. Remove the fuel ratio control from the engine. Pull

away from the collar at the same time as you pull
down from the collar.
50 SENR8323
Disassembly and Assembly Section

Illustration 166 g00622260

2. Remove bolts (3). Remove cover (26) and gasket 8. Remove spring (20), retainer (18) and spring (17)
(24). from housing (10).

9. Remove piston (12) and valve assembly (14) from

the housing.

Possible injury can result when removing nut, re- 10. Use tool (B) and remove snap ring (13) and
tainer and hold down spring. washer (15) from the valve assembly. Remove
piston (12) from the valve assembly.
Spring force will be released when nut and re-
tainer are removed. Be prepared to hold the re- 11. Remove seal (11) from piston (12).
tainer as the nut is loosened.
12. If necessary, remove the stem portion of valve
3. Hold cover (7) in position. Slowly remove the bolts assembly (14).
that hold the spring in place. The spring force will
then release.
i01025297
4. Remove bolts (6). Remove cover (7) from housing
(10). Fuel Ratio Control - Assemble
SMCS Code: 1278-016
5. Remove nut (5) and stop (4) from cover (7).

6. Remove spring (8), washer (9), and diaphragm (21) Assembly Procedure
from retainer (25). Remove retainer (25) from Table 15
housing (10).
Required Tools
7. Remove tube (1) from the end of extension (19). Part
Remove nut (2) from extension (19) and remove Tool Number Description Qty
the extension from retainer (25). Remove valve A FT-1820 Fixture 1
spool (16), spring (22), and O-ring seal (23) from
the extension. B 1P-1855 Retaining Ring Pliers 1

C 6V-9072 Piston Seal Guide 1

SENR8323 51
Disassembly and Assembly Section

NOTICE
Adjustment of the fuel system outside Caterpillar
specified limits will not improve fuel efficiency and
could result in damage to the engine.

Reference: Refer to the “Fuel Ratio Control

Adjustment” in Testing and Adjusting, SENR1028 for
the 3406C Engine.

Illustration 167 g00622260

1. Clean all of the parts and inspect all of the parts. 7. Install O-ring seal (23) on extension (19). Install
Replace any parts that are worn or damaged. spring (22) and valve (16) on the extension.

2. If the valve stem is removed during disassembly, 8. Lubricate the bore of retainer (25) and lubricate O-
assemble the stem portion of valve assembly (14) ring seal (23) with clean engine oil. Install
by using 9S-3265 Retaining Compound. extension (19) in retainer (25). Install nut (2) on
extension (19).
3. Lubricate seal (11) lightly. Install seal (11) on piston
(12) and install piston (12) on valve assembly (14). 9. Install diaphragm (21), washer (9) and spring (8) on
retainer (25). Install retainer (25) in housing (10).
4. Install washer (15) on the valve assembly and use
tool (B) to install snap ring (13) on the valve 10. Install stop (4) and nut (5) in cover (7). Hold
assembly. retainer (25) in position and install cover (7) on
housing (10). Install bolts (6) that hold the cover.
5. Place housing (10) on tool (A), and position tool (C) Tighten bolts (6) to a torque of 9 ± 3 N·m
in the bore of the housing. Lubricate tool (C) with (7 ± 2 lb ft).
clean engine oil.
11. Adjust the fuel ratio control.
6. Push piston (12) in position with a smooth swift
motion. Remove tool (C) from the housing. Install Reference: Refer to the “Fuel Ratio Control
spring (17), retainer (18) and spring (20) in housing Adjustment” in Testing and Adjusting, SENR1028 for
(10). the 3406C Engine.
52 SENR8323
Disassembly and Assembly Section

12. Place tube (1) on the end of extension (19). Heat

tube (1) to a temperature of 149 °C (300 °F) or
heat the tube until the tube shrinks.
13. Replace gasket (24). Install the gasket and cover
(26) with bolts (3).
End By:
Install the fuel ratio control. See Disassembly and
Assembly, “Fuel Ratio Control -
Install”Disassembly and Assembly, Fuel Ratio
Control - Install.

i01025966

Fuel Ratio Control - Install Illustration 169 g00622097

SMCS Code: 1278-012 3. Install 128-7794 Bolt in location (5). Install

128-7796 Bolt in location (6). Tamperproof bolts
Installation Procedure should be tightened until the head shears off
approximately 12 ± 3 N·m (9 ± 2 lb ft).

4. Standard bolts should be installed in the other

locations.
5. Install new lockwire (4) and the seal.
Reference: Refer to the “Fuel Ratio Control
Adjustment” in Testing and Adjusting, SENR1028 for
the 3406C Engine.

i01024846

Exhaust Manifold - Remove

and Install
Illustration 168 g00622086
SMCS Code: 1059-010
1. Install the fuel ratio control (2) on the governor.
Make sure that the valve head of the fuel ratio Removal Procedure
control is connected to the groove of the collar. Start By:
2. Install four bolts (3) that hold the fuel ratio control to Remove the turbocharger. See Disassembly and
the governor. Assembly, “Turbocharger -
Remove”Disassembly and Assembly,
Turbocharger - Remove.

Note: Cover all of the openings in order to prevent

contamination of the system.
SENR8323 53
Disassembly and Assembly Section

Illustration 170 g00623849 Illustration 172 g00623887

1. Loosen hose clamp (1). Remove bolt (2) that holds 1. Put new gaskets in position on the cylinder head.
the pipe to the engine block. Install exhaust manifold (5) on the studs.

2. Rotate breather tube (3) out of the way of the

exhaust manifold.

Illustration 173 g00623896

2. Apply 5P-3931 Anti-Seize Compound to the

Illustration 171 g00623887
studs. Install 12 spacers and nuts (4). These parts
hold the exhaust manifold. Tighten the nuts in the
3. Remove 12 nuts (4) and the spacers. These parts numerical sequence in Illustration 173 . Tighten the
hold the exhaust manifold to the cylinder head. nuts to a torque of 51 ± 7 N·m (38 ± 5 lb ft).
4. Remove exhaust manifold (5) and the gaskets.

Installation Procedure

Illustration 174 g00623849

3. Put breather tube (3) in position and install pipe

clamp with bolt (2) and hose clamp (1).
54 SENR8323
Disassembly and Assembly Section

End By: Note: Cover all openings in order to prevent loss of

fluids and contamination of the system.
Install the turbocharger. See Disassembly and
Assembly, “Turbocharger - 1. If the turbocharger is equipped with a thermal
Install”Disassembly and Assembly, shield, drain the radiator coolant below the
Turbocharger - Install.
turbocharger.
i01024847

Turbocharger - Remove
SMCS Code: 1052-011

Removal Procedure
Start By:
Remove the muffler. See Disassembly and
Assembly, “Muffler - Remove and
Install”Disassembly and Assembly, Muffler -
Remove and Install.
Remove the air cleaner. See Disassembly and
Assembly, “Air Cleaner - Remove and
Illustration 175 g00614646
Insall”Disassembly and Assembly, Air Cleaner
- Remove and Insall.
2. Remove coolant hose (1) (if equipped).

3. Remove coolant tube (2) (if equipped).

Personal injury can result from hot coolant, steam 4. Remove turbocharger shields (3) (if equipped).
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 cooling system pressure cap slowly to
relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
touch with your bare hand.
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
Illustration 176 g00614656

NOTICE 5. Disconnect two oil supply tubes (4) from

Care must be taken to ensure that fluids are con-
turbocharger (5).
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be 6. Remove the six mounting bolts and nuts (6) from
prepared to collect the fluid with suitable containers
the base of the turbocharger. Remove
before opening any compartment or disassembling
any component containing fluids. turbocharger (5).

Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide” for tools and sup-
plies suitable to collect and contain fluids on Caterpil-
lar products.
Dispose of all fluids according to local regulations and
mandates.
SENR8323 55
Disassembly and Assembly Section

i01066656 i01988526

Turbocharger - Disassemble Turbocharger - Assemble

SMCS Code: 1052-015 SMCS Code: 1052-016

Disassembly Procedure Assembly Procedure

Start By:
NOTICE
Remove the turbocharger. Refer to Disassembly Keep all parts clean from contaminants.
and Assembly, “Turbocharger - Remove”.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 178 g00555701

1. Check condition of all components. Use new parts

to replace worn parts or damaged parts.
Illustration 177 g00555701

1. Loosen the nuts on V-band clamps (2). NOTICE

The compressor housing must remain straight with
the turbocharger cartridge during disassembly and
NOTICE assembly. Tilting may cause damage to the tips of the
The compressor housing must remain straight with compressor wheel and the compressor shaft.
the turbocharger cartridge during disassembly and
assembly. Tilting may cause damage to the tips of the 2. Connect compressor housing (1) and turbine
compressor wheel and the compressor shaft.
housing (4) to turbocharger cartridge (3).

2. Separate compressor housing (1) and turbine 3. Tighten the nuts on V-band clamps (2) to a torque
housing (4) from turbocharger cartridge (3). of 14 ± 1 N·m (10 ± 1 lb ft). Lightly tap around the
diameter of band clamps (2) with a soft hammer.
3. Check the condition of all components. Use new
parts to replace worn parts or damaged parts. 4. Tighten the nuts on V-band clamps (2) again.
Tighten to a torque of 14 ± 1 N·m (10 ± 1 lb ft).
End By:
Install the turbocharger. Refer to Disassembly
and Assembly, “Turbocharger - Install”.
56 SENR8323
Disassembly and Assembly Section

i01024848 7. Install turbocharger shields (3) (if equipped).

Turbocharger - Install 8. Make sure that the coolant level is full. Refer to
Operation and Maintenance Manual, “Cooling
SMCS Code: 1052-012
System Level - Check”.

Installation Procedure End By:

1. For proper installation of the turbocharger, inspect Install air cleaner. See Disassembly and
Assembly, “Air Cleaner - Remove and
the gaskets and seals on the turbocharger. Install”Disassembly and Assembly, Air Cleaner
Replace any gaskets or seals that are damaged or - Remove and Install.
worn.
Install the muffler. See Disassembly and
Assembly, “Muffler - Remove and
Install”Disassembly and Assembly, Muffler -
Remove and Install.

i01026058

Crankshaft Vibration Damper -

Remove and Install
SMCS Code: 1205-010

Removal Procedure
Start By:

Illustration 179 g00614656 Remove the fan. See Disassembly and Assembly,
“Fan - Remove and Install”Disassembly and
2. Apply 5P-3931Anti-Seize Compound to the Assembly, Fan - Remove and Install.
threads of six mounting bolts (6) before installation.
Tighten mounting bolts (6) to a torque of
47 ± 9 N·m (35 ± 7 lb ft).

3. Connect two oil supply tubes (4) to turbocharger

(5).

4. Position turbocharger (5) on the engine. Install six

mounting bolts and nuts (6) to the base of the
turbocharger.

Illustration 181 g00623959

Photos were taken out of the chassis.

Note: The vibration damper weighs 25 kg (55 lb).

1. Attach a strap and a suitable lifting device to
vibration damper (1).

2. Remove six bolts (2) and the washers. Remove

vibration damper (1).

Illustration 180 g00614646

Installation Procedure
5. Install coolant hose (1) (if equipped).

6. Install coolant tube (2) (if equipped).

SENR8323 57
Disassembly and Assembly Section

i01026061

Water Temperature Regulator -

Remove and Install
SMCS Code: 1355-010

Removal Procedure

Personal injury can result from hot coolant, steam

and alkali.
At operating temperature, engine coolant is hot
Illustration 182 g00623959 and under pressure. The radiator and all lines to
Photos were taken out of the chassis. heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Note: The vibration damper weighs 25 kg (55 lb).
Remove cooling system pressure cap slowly to
1. Attach a strap and a suitable lifting device to relieve pressure only when engine is stopped and
vibration damper (1). cooling system pressure cap is cool enough to
touch with your bare hand.
2. Lubricate the threads of six bolts (2) with one of
these lubricants: clean engine oil, molybdenum Do not attempt to tighten hose connections when
disulfide and 5P-3931 Anti-Seize Compound. the coolant is hot, the hose can come off causing
burns.
3. Position vibration damper (1) on the engine. Install Cooling System Coolant Additive contains alkali.
six bolts (2) and washers. Avoid contact with skin and eyes.
End By:
Install the fan. See Disassembly and Assembly, NOTICE
“Fan - Remove and Install”Disassembly and Care must be taken to ensure that fluids are con-
Assembly, Fan - Remove and Install. tained during performance of inspection, mainte-
nance, 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 sup-
plies suitable to collect and contain fluids on Caterpil-
lar products.
Dispose of all fluids according to local regulations and
mandates.

Note: Cover all openings in order to prevent

contamination of the system.

1. Drain the engine coolant below the level of the

water temperature regulator. Store the engine
coolant in a suitable container or dispose of the
coolant.
58 SENR8323
Disassembly and Assembly Section

NOTICE
If the water temperature regulator is installed incor-
rectly, it will cause the engine to overheat.

Illustration 183 g00623984

The upper radiator hose was previously removed.

2. Disconnect the upper radiator hose.

3. Remove two bolts and elbow (2). Remove the Illustration 185 g00624165
gasket and the O-ring seal from the elbow.
1. Use tool (A) to install the seal in the housing if the
4. Disconnect turbocharger water line (1) from the seal is removed. Install the lip seal with the lip of
cover. the seal away from the regulator.
5. Remove three bolts (3) that hold the water 2. Inspect the gasket. Replace the gasket, if
temperature regulator housing (4) to cylinder head necessary. Install the gasket.
(5).
3. Install water temperature regulator (6) in the
housing.

Illustration 184 g00624165

6. Remove water temperature regulator (6) from the Illustration 186 g00623984
housing. Remove the gasket. Remove the lip seal
from the housing. 4. Install three bolts (3) that hold the water
temperature regulator housing (4) to cylinder head
Installation Procedure (5).
Table 16
Required Tools
5. Connect turbocharger water line (1) to the cover.

Part 6. Inspect the O-ring seal and the gasket for wear or
Tool Number Description Qty damage. Replace the parts, if necessary. Install
A 1P-0510 Driver Group 1 the gasket and the O-ring seal on the elbow. Install
two bolts and elbow (2) on the engine.

7. Connect the upper radiator hose.

SENR8323 59
Disassembly and Assembly Section

8. Fill the cooling system to the correct level.

NOTICE
Reference: Refer to the Operation and Maintenance Care must be taken to ensure that fluids are con-
Manual, “Cooling System Level - Check” for the tained during performance of inspection, mainte-
correct procedure. nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
i01024851
any component containing fluids.
Water Pump - Remove Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and sup-
SMCS Code: 1361-011 plies suitable to collect and contain fluids on Caterpil-
lar products.
Removal Procedure Dispose of all fluids according to local regulations and
Start By: mandates.
Remove the alternator. See Disassembly and
Assembly, “Alternator - Remove and Note: Mark all components for correct installation.
Install”Disassembly and Assembly, Alternator - When you remove the components, cover the
Remove and Install. openings in order to keep the system clean.
Remove the belt tightener. See Disassembly and
Assembly, “Belt Tightener - 1. Drain the coolant from the engine into a suitable
Remove”Disassembly and Assembly, Belt container for storage or disposal.
Tightener - Remove.

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 cooling system pressure cap slowly to
relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
touch with your bare hand.
Do not attempt to tighten hose connections when Illustration 187 g00624221
the coolant is hot, the hose can come off causing
burns. 2. Remove clips (4) and disconnect hose (5).
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.

Personal injury can result from being struck by

parts propelled by a released spring force.
Make sure to wear all necessary protective
equipment.
Follow the recommended procedure and use all
recommended tooling to release the spring force.

Illustration 188 g00624224

3. Disconnect harness (11) and remove clip (16).

4. Disconnect hoses (8), (9), (10), and (14).

60 SENR8323
Disassembly and Assembly Section

5. Remove elbow (7) and cover (12). Note: You can replace the water pump seal without
removing the water pump from the engine. Note that
6. Remove bolts (13) and disconnect bonnet (15). an intermittent leakage of a small amount of coolant
from the weep hole in the water pump housing is
normal. This flow is required in order to lubricate the
seal. Replace the water pump seal only if the flow is
constant or if the flow is excessive from the water
pump housing.

Illustration 189 g00624263

7. Remove bolts (18) for removal of water pump (17).

Note: The water pump weighs 20 kg (44 lb). Illustration 190 g00624319
8. Carefully remove the water pump from the
machine. 1. Remove O-ring seal (1) from the adapter.

i01024853 2. Remove adapter (2) from the housing. Remove the

O-ring seal from the outside diameter of the
Water Pump - Disassemble adapter.
SMCS Code: 1361-015 3. Remove bolt (3) and the washer that holds the
impeller on the shaft.
Disassembly Procedure
Table 17
Required Tools

Part Qty
Tool Description
Number
8S-2264 Puller Group 1

4B-3903 Bolt (5/16 inch by 18 by 102 mm

(4 inch)) 2
A
1P-0456 Drive Plate 1
4B-4277 Drive Plate 2

Start By:
Illustration 191 g00624351
Remove the water pump. See Disassembly and
Assembly, “Water Pump -
Remove”Disassembly and Assembly, Water 4. Use tool (A) to remove impeller (4) from the shaft.
Pump - Remove.
Note: Cleanliness is an important factor. Before the
disassembly procedure, the exterior of the
component should be thoroughly cleaned in order to
prevent contamination of the internal mechanism.
SENR8323 61
Disassembly and Assembly Section

9. Remove bolt (9) and the retainer from the shaft

assembly.

Illustration 192 g00624355

5. Remove the spring and seal (5) from the shaft.

Illustration 195 g00624365

10. Use a press to remove the shaft assembly from

gear (11). Remove the retainer from the shaft
assembly.

Illustration 193 g00624357

6. Remove four bolts (7) from retainer (6) that hold the
shaft assembly to the pump housing.

7. Remove O-ring seal (8) from the housing. Illustration 196 g00624369

11. Remove bearing (13), spacer (14) and bearing

(12) from the shaft.

Illustration 194 g00624359

8. Remove gear and shaft assembly (10) from the

housing. Illustration 197 g00624371

12. Remove lip seal (15) from the housing.

62 SENR8323
Disassembly and Assembly Section

13. Turn over the housing. Remove ceramic ring (16)

and the seal.

i01024854

Water Pump - Assemble

SMCS Code: 1361-016

Assembly Procedure
Table 18
Required Tools

Part
Tool Number Description Qty
Illustration 199 g00624380
A 1P-0510 Drive Plate 1
B 135-7629 Drive Plate 1
4. Use tool (A) to install the lip seal in the housing.
See Illustration 199 . Apply clean SAE 30 oil to the
lip of the seal.

Illustration 198 g00624379

Illustration 200 g00624383
1. Use 6V-1541 Quick Cure Primer to clean shaft (8)
and the seal counterbore in the pump housing. 5. Install a new O-ring seal (10) on the housing.

2. Install bearing (4), spacer (3) and bearing (2) on 6. Put shaft assembly (9) in position in the housing.
shaft (8). Install the four bolts that hold the retainer to the
housing.
3. Install retainer (1) and gear (7) on the shaft
assembly. Install retainer (6) and bolt (5).
NOTICE
Clean water only is permitted for use as a lubricant for
assistance at installation. Do not damage or put
hands on the wear surface of the carbon ring or the
ceramic ring. Install the ceramic ring with the smooth-
est face of the ring toward the carbon seal assembly.
SENR8323 63
Disassembly and Assembly Section

Illustration 201 g00684752 Illustration 203 g00684762

7. Install ceramic ring (12) in rubber seal (11). Use 9. Install spring (15) on the shaft.
hand pressure and tool (B) to install the ceramic
ring in the housing. 10. Install impeller (14) on the shaft. Install the
washer and the bolt that holds the impeller. Tighten
the bolt to a torque of 39 ± 3 N·m (29 ± 2 lb ft).

Illustration 202 g00624386

Illustration 204 g00624385

NOTICE
Avoid contaminating the seal faces with grease or oil.
11. Install O-ring seal (17) on the outside diameter of
Also, avoid stretching the rubber seal during
installation. the adapter. Put a small amount of clean SAE 30
oil on the O-ring seal.

Note: The carbon seal assembly must rotate with the 12. Install O-ring seal (18) on the adapter.
water pump shaft after installation.
8. Remove the spring from seal assembly (13). Use 13. Install adapter (16) on the housing.
hand pressure and tool (B) to install the seal End By:
assembly. Push the seal assembly on the shaft
until the seal faces make light contact. Install the water pump. See Disassembly and
Assembly, “Water Pump - Install”Disassembly
and Assembly, Water Pump - Install.

i01024852

Water Pump - Install

SMCS Code: 1361-012

Installation Procedure
64 SENR8323
Disassembly and Assembly Section

Illustration 205 g00624263 Illustration 207 g00624221

1. Replace the seals if the seals are damaged or 8. Connect hose (5) and install clips (4).
worn.
9. Fill the cooling system to the correct level.
Note: The water pump weighs 20 kg (44 lb). Reference: Refer to the Operation and Maintenance
2. Carefully position the water pump in the machine. Manual, “Cooling System Level - Check”.

3. Install the water pump (17) with bolts (18). End By:
Install the belt tightener. See Disassembly and
Assembly, “Belt Tightener -
Install”Disassembly and Assembly, Belt
Tightener - Install.
Install the alternator. See Disassembly and
Assembly, “Alternator - Remove and
Install”Disassembly and Assembly, Alternator -
Remove and Install.

Illustration 206 g00624224

4. Connect bonnet (15) and install bolts (13).

5. Install elbow (7) and cover (12).

6. Connect hoses (8), (9), (10), and (14).

7. Install clip (16) and connect harness (11).

SENR8323 65
Index Section

Index
A Exhaust Manifold - Remove and Install ........... 52
Installation Procedure .................................. 53
Air Cleaner - Remove and Install..................... 10
Removal Procedure ..................................... 52
Installation Procedure ...................................11
Removal Procedure ..................................... 10
Alternator - Remove and Install ......................... 4 F
Installation Procedure .................................... 4
Removal Procedure ....................................... 4 Fan - Remove and Install................................. 13
Installation Procedure .................................. 13
Removal Procedure ..................................... 13
B Fan Drive - Assemble ...................................... 15
Assembly Procedure.................................... 15
Belt Tightener - Assemble ............................... 18
Fan Drive - Disassemble ................................. 14
Belt Tightener - Disassemble........................... 18
Disassembly Procedure............................... 14
Belt Tightener - Install...................................... 19
Fan Drive - Install............................................. 16
Installation Procedure .................................. 19
Installation Procedure .................................. 16
Belt Tightener - Remove.................................. 17
Fan Drive - Remove......................................... 13
Removal Procedure ..................................... 17
Removal Procedure ..................................... 13
Fuel Ratio Control - Assemble......................... 50
C Assembly Procedure.................................... 50
Fuel Ratio Control - Disassemble.................... 49
Crankshaft Vibration Damper - Remove and
Disassembly Procedure............................... 49
Install.............................................................. 56
Fuel Ratio Control - Install ............................... 52
Installation Procedure .................................. 56
Installation Procedure .................................. 52
Removal Procedure ..................................... 56
Fuel Ratio Control - Remove ........................... 48
Removal Procedure ..................................... 48
D Fuel Shutoff Solenoid - Remove and Install .... 47
Installation Procedure .................................. 47
Disassembly and Assembly Section ................. 4 Removal Procedure ..................................... 47
Fuel Transfer Pump - Assemble ...................... 41
E Assembly Procedure.................................... 41
Fuel Transfer Pump - Disassemble ................. 39
Electric Starting Motor - Remove and Install ..... 9 Disassembly Procedure............................... 39
Installation Procedure .................................. 10 Fuel Transfer Pump - Install............................. 44
Removal Procedure ....................................... 9 Installation Procedure .................................. 44
Engine and Torque Divider - Install.................. 35 Fuel Transfer Pump - Remove......................... 38
Installation Procedure .................................. 35 Removal Procedure ..................................... 38
Engine and Torque Divider - Remove.............. 30
Removal Procedure ..................................... 30
Engine Oil Filter and Base - Remove and H
Install.............................................................. 44 Hood and Dust Ejector - Install .......................... 6
Installation Procedure .................................. 44 Installation Procedure .................................... 6
Removal Procedure ..................................... 44 Hood and Dust Ejector - Remove...................... 5
Engine Oil Filter Base - Assemble................... 46 Removal Procedure ....................................... 5
Assembly Procedure.................................... 46
Engine Oil Filter Base - Disassemble .............. 45
Disassembly Procedure............................... 45 I
Engine Side Guards - Remove and Install........11
Important Safety Information ............................. 2
Installation Procedure .................................. 12
Removal Procedure ......................................11
66 SENR8323
Index Section

M
Muffler - Remove and Install.............................. 8
Installation Procedure .................................... 9
Removal Procedure ....................................... 8

P
Primary Fuel Filter and Base - Remove and
Install.............................................................. 47
Installation Procedure .................................. 48
Removal Procedure ..................................... 47

R
Radiator Core - Remove and Install ................ 20
Installation Procedure .................................. 20
Removal Procedure ..................................... 20
Radiator Guard - Install.................................... 29
Installation Procedure .................................. 29
Radiator Guard - Remove................................ 28
Removal Procedure ..................................... 28
Radiator Guard - Tilt ........................................ 21
Procedure to Tilt Back.................................. 25
Procedure to Tilt Forward............................. 21

T
Table of Contents............................................... 3
Turbocharger - Assemble ................................ 55
Assembly Procedure.................................... 55
Turbocharger - Disassemble ........................... 55
Disassembly Procedure............................... 55
Turbocharger - Install....................................... 56
Installation Procedure .................................. 56
Turbocharger - Remove................................... 54
Removal Procedure ..................................... 54

W
Water Pump - Assemble.................................. 62
Assembly Procedure.................................... 62
Water Pump - Disassemble............................. 60
Disassembly Procedure............................... 60
Water Pump - Install ........................................ 63
Installation Procedure .................................. 63
Water Pump - Remove .................................... 59
Removal Procedure ..................................... 59
Water Temperature Regulator - Remove
and Install....................................................... 57
Installation Procedure .................................. 58
Removal Procedure ..................................... 57
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