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NEHS1096
July 2010
TOOL
OPERATING
MANUAL
335-1617 Rear Rail Group
335-1622 Front Rail Group
WARNING
The meaning of this safety alert symbol is as
follows:
Attention! Become Alert! Your Safety is
Involved.
2
Contents Literature Information
Literature Section This manual contains safety information,
Safety Section . . . . . . . . . . . . . . . . . . . . . . . . 3 operation instructions, and maintenance
information and should be stored with the tool
General Information Section . . . . . . . . . . . . . 3 group.
Operation Section . . . . . . . . . . . . . . . . . . . . . 3 Some photographs or illustrations in this
Maintenance Section . . . . . . . . . . . . . . . . . . . 3 publication show details that can be different
Parts Section . . . . . . . . . . . . . . . . . . . . . . . . . 3 from your service tool. Guards and covers
might have been removed for illustrative
Safety Section purposes.
Safety Icon Nomenclature . . . . . . . . . . . . . . . 4 Continuing improvement and advancement of
Personal Protection/Important Information. . . 4 product design might have caused changes to
Prohibited Action . . . . . . . . . . . . . . . . . . . . . 4 your service tool, which are not included in this
publication.
Hazard Avoidance . . . . . . . . . . . . . . . . . . . . 4
Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . 4 Whenever a question arises regarding your
service tool or this publication, please consult
Personal Protection . . . . . . . . . . . . . . . . . . . 4 Dealer Service Tools (DST) for the latest
Prohibited Action . . . . . . . . . . . . . . . . . . . . . 5 available information.
Hazard Avoidance . . . . . . . . . . . . . . . . . . . . 5
Safety Section
General Information Section
The Safety section lists basic safety
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 5 precautions.
References. . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Read and understand the basic precautions
Additional Contact information . . . . . . . . . . . 5 listed in the Safety section before operating or
Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . 6 performing maintenance and repair on this
Other Required Tooling . . . . . . . . . . . . . . . . . 7 service tool.
Operation Section General Information Section
Rear Rail Tool Group Only . . . . . . . . . . . . . . . 8
The General Information section describes
Front Rail Tool Group and tooling functions and features. It provides
Rear Rail Tool Group Used Together . . . . . . 11 useful information on individual parts,
Maintenance Section additional tooling, and resources.
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operation Section
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
The Operation section is a reference for the
Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 new operator and a refresher for the
Tool Disposal . . . . . . . . . . . . . . . . . . . . . . . . 14 experienced operator.
Parts Section Photographs and illustrations guide the
Service Parts . . . . . . . . . . . . . . . . . . . . . . . . 14 operator through correct procedures for using
the tool group.
Operating techniques outlined in this
publication are basic. Skill and techniques
develop as the operator gains knowledge of
the service tool and its capabilities.
Maintenance Section
The Maintenance section describes tool
inspection, cleaning, storage, and disposal.
Parts Section
The Parts section provides information about
available tooling service parts.
3
Safety Section Hazard Avoidance (continued)
Eye protection
Safety Warnings
Face protection Personal Protection
Foot protection WARNING
To avoid personal injury or death, carefully read
and understand all instructions before
Hand protection attempting to operate any equipment or tools.
Do not operate or work on a machine unless you read
and understand the instructions and warnings in this
Inspect equipment and all other applicable manuals. Contact Dealer
Service Tools for replacement manuals. Proper care is
AR N I
NG
your responsibility. Always follow all State and
Legible information Federal health and safety laws and/or local
regulations.
Multiple persons required To prevent possible damage to your hearing,
always wear ear protection when working
around noise generating tools.
Prohibited Action
To avoid eye injury, always wear
Do not weld protective glasses or face shield. Make
sure no one can be injured by flying
objects or debris when using tools or working on a
No smoking component.
To help avoid foot injury, always wear
protective footwear. To help avoid hand
Hazard Avoidance injury, where appropriate, wear protective
gloves when working with large components.
Crushing hazard
Clean up all leaked or spilled fluids
immediately. Oil, fuel, or cleaning fluid
Crushing hazard (body) leaked or spilled onto any hot surfaces or
electrical components can cause a fire, resulting in
personal injury or death.
Crushing hazard (foot) Personal injury can result from slips or
falls. DO NOT leave tools or components
laying around the work area. Clean up all
Crushing hazard (overhead) spilled fluids immediately.
Personal injuries can occur as a
Fire hazard result of using pressurized air.
Maximum air pressure at the nozzle
must be below 205 kPa (30 psi) for cleaning purposes.
Lifting hazard Wear protective clothing, protective glasses, and a
protective face shield when using pressure air.
Pinch point
4
Prohibited Action General Information Section
WARNING Introduction
To avoid serious injury or death, this tooling should This tooling is used to support the C175
never be used for any application other than its Engine during removal and installation in the
intended use; removal and installation of the 795F AC Off-Highway Truck.
engine on 795F AC Off-Highway Trucks.
To avoid personal injury or death, do not weld on the
This tooling consists of a rear rail tool group, a
rail system tool groups. Do not expose to front rail tool group, and various support
extreme heat, such as from a torch. brackets that are used with the two groups. It
is possible to use the rear rail tool group
AR N I
To avoid serious injury or death, do not used separately, without using the front rail tool
NG
5
Nomenclature
335-1617 Rear Rail Tool Group
1096-18
2
1a
3 4
6
6
335-1622 Front Rail Tool Group
1096-19
7c
7b
7a
7a
8
9
7
7
Operation Section NOTE: Install the bolts from the bottom up for
easy bolt removal after the engine is
Rear Rail Tool Group Only reinstalled. For clarity, the motor mount is
shown with engine lifted out of the way.
8
b. Position the rear of the rail above rear 6. Repeat Step 5 to install the remaining rear
support assembly (2). Install two frame rail.
7X-2554 M16 x 70 mm (2.75 in) Bolts
NOTE: For clarity, the rear rail is shown with
with two 9X-8275 M16 Washers.
engine removed.
9
8. Repeat Step 7 to install left-hand wheel 11. Secure each bracket using four each
assembly (4) to the remaining rear rail 7X-2576 M24 x 70 mm (2.75 in) Bolts,
assembly (1). 8T-4001 M24 Nuts, and eight 8T-4167 M24
Washers. Tighten to standard torque.
9. Use the tube stands to lower the engine Right-Hand Bracket Assembly shown.
until the two wheel assemblies set on both
rear rail assemblies (1). Remove the tube
stands. 12. Refer to the appropriate disassembly and
assembly service manual for information
10. Get assistance or use a suitable overhead on removing the front motor mounts.
lifting device to position right-hand
bracket assembly (5) and left-hand 13. Refer to the appropriate disassembly and
bracket assembly (6) on the front module assembly service manual for information
mounting pads (G). on using a suitable overhead lifting device
to lift the front of the engine and roll it
forward on the rear rail tool group.
14. Lower the front of the engine until the front
motor mount brackets (H) engage the
locator rings on top of engine support
brackets (5) and (6), as shown.
10
15. Refer to the appropriate disassembly and 3. Get assistance or use a suitable overhead
assembly service manual for information lifting device to position right-hand bracket
on the engine removal procedure. assembly (8) and left-hand bracket
assembly (9) on the front module mounting
pads (G).
NOTE: Installing the engine using the
335-1617 Rear Rail Tool Group is the reverse
of this procedure. Refer to the appropriate
disassembly and assembly service manual for
information on engine installation.
11
7. Secure front rail assembly (7) to motor 9. Repeat Step 6 through Step 8 to install the
mount bracket (J) using supplied M30 nut remaining front rail assembly (7) on the
and washer (K). Leave the nut loose until right-hand side of the machine frame.
the front hardware is installed in the next
step.
12
11. Remove both trolley hitch pins (7a) (not 1. Do not use any tool group unless load
shown). identification markings and warning films
are legible.
12. Refer to the appropriate disassembly and
assembly service manual for information
1096-26
on using a suitable forklift to roll the
engine forward on the front and rear rail
tool group.
)
74 5 kGKg)
1-86 17 (42
. 31 S (3 S
NO LB.5 LB
RT 00: 92
PA : 70 T ) E)
LL W E D
W OL NOT CO
TOATE LIER
(D PP
U
(S
PA
W RT
TOLL: NO
(D OL7000. 321
(S ATEWT LB -86
UP N : 1 S (308
PL OT 36 1
IER E) LB 75
CO S (6kG)
DE 2 K
) g)
Maintenance Section
WARNING
Engine removal tools are large and heavy. To
avoid serious injury or possible death during
maintenance procedures, read, understand, and
follow all applicable warnings listed in the Safety
Warnings section of this manual.
Inspection
Inspect prior to each use for nicks, burrs,
dents, cracks, bent, or worn parts. If damage
is found, discontinue use until inspected and
released for use by an approved inspector at
the dealership.
13
3. Inspect all hardware (link brackets, lock Service Parts
pins, bolts, and nuts, etc.)
a. Tighten any loose fasteners to standard 335-1617 Rear Rail Tool Group
torque.
1096-20
b. Do not use if any hardware is worn, 1a
damaged, or missing.
1c
1096-28
1b
Cleaning 5b 5c 5d
• Clean the tooling using a non-solvent 5e
based cleaner. 5a
Storage
• Store tooling indoors in a clean, dry
location to prevent rust or corrosion.
• Store the tool on firm level ground to
prevent tipping.
• Store all loose components, organized
Right-Hand Bracket Assembly (rear rail)
together by use, in suitable storage
containers. Item No. Part No. Description Qty.
5a 224-0554 Warning Film 1
Tool Disposal 5b 138-7573 Link Bracket 1
5c 0S-1588 3/8-16 Bolt 1
• At the end of the tools operational life, 5d 5M-2894 3/8 Washer 1
dismantle the tooling and recycle 5e 9S-8752 3/8-16 Nut 1
materials according to all regulations and
mandates. Destroy the remaining tooling
and dispose of as scrap.
14
1096-22 1096-24
8d 8c 8b
6d 6c 6b 8e
6e
6a
Left-Hand Bracket Assembly (rear rail) Right-Hand Bracket Assembly (front rail)
Item No. Part No. Description Qty. Item No. Part No. Description Qty.
6a 224-0554 Warning Film 1 8a 138-7573 Link Bracket 1
6b 138-7573 Link Bracket 1 8b 0S-1588 3/8-16 Bolt 1
6c 0S-1588 3/8-16 Bolt 1 8d 5M-2894 3/8 Washer 1
6d 5M-2894 3/8 Washer 1 8e 9S-8752 3/8-16 Nut 1
6e 9S-8752 3/8-16 Nut 1
1096-25
1096-23 9b 9c 9d
7e 9e
7d
15
For information on service tools or shop supplies,
contact Dealer Service Tools on: