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R

NEHS1096
July 2010

TOOL
OPERATING
MANUAL
335-1617 Rear Rail Group
335-1622 Front Rail Group

SMCS: 1000-011, 1000-012, 1003-011, 1003-012

Used to Remove and Install C175 Engine on 795F AC Off-Highway Trucks


Important Safety Information The message that appears under the warning
explains the hazard and can be either written
or pictorially presented.
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. If a tool, procedure, work
method, or operating technique that is not
specifically recommended by Caterpillar is
Think Safety used, you must satisfy yourself that it is
safe for you and for others. You should
also ensure that the product will not be
Most accidents that involve product operation, damaged or be made unsafe by the
maintenance, and repair are caused by failure operation, lubrication, maintenance or
to observe basic safety rules or precautions. repair procedures that you choose.
An accident can often be avoided by The information, specifications, and illustrations
recognizing potentially hazardous situations in this publication are on the basis of
before an accident occurs. A person must be information that was available at the time that
alert to potential hazards. This person should the publication was written. The specifications,
also have the necessary training, skills, and torques, pressures, measurements,
tools to perform these functions properly. adjustments, illustrations, and other items can
Improper operation, lubrication, change at any time. These changes can affect
maintenance, or repair of this product can the service that is given to the product. Obtain
be dangerous and could result in injury or the complete and most current information
death. before you start any job.
Do not operate or perform any lubrication,
maintenance, or repair on this product until
you have read and understood the WARNING
operation, lubrication, maintenance, and When replacement parts are required for this product,
repair information. Caterpillar recommends using Caterpillar replacement
parts or parts with equivalent specifications including,
Safety precautions and warnings are provided but not limited to, physical dimensions, type, strength,
in this manual and on the product. If these and material.
hazard warnings are not heeded, bodily injury
or death could occur to you or to other Failure to heed this warning can lead to premature
persons. failures, product damage, personal injury, or death.

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.

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)

Safety Icon Nomenclature Pressurized air

Personal Protection/Important Safety alert symbol


Information
Read the manual Slipping hazard

Ear protection Tripping hazard

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

any tool unless it has a working load limit (WLL) group.


identification that is clear and readable.
Using this tooling requires a multiple person
crew, a suitable overhead lifting device, and
Hazard Avoidance an appropriate lift truck.

WARNING NOTE: Continuing improvement and


To avoid personal injury or death, inspect advancement of product design can mean
tools before each use. Do not use any some photographs or illustrations in this
tool that is damaged, altered, or in
poor condition. Replace all worn, cracked, or
publication will show details that are different
damaged parts immediately. from your service tool. Photographs in this
manual show prototype tooling.
To avoid personal injury or death, the use
of rail tool groups requires a three or
more person crew. Technicians must be
trained and experienced in working around large
machines and possess a valid lift truck operators
References
license. KENR8726, 795F AC Off-Highway Truck,
Improper lifting procedures can create risk Engine Supplement, Disassembly and
for the operator and bystanders. DO NOT Assembly
use the rail tool groups before making
sure no one will be endangered.
To avoid personal injury or death, do not NOTE: The reference above may change.
exceed the rail tool groups working load Always refer to the appropriate disassembly
limit (WLL). Each Front Rail WLL - 2381kg and assembly service manual for information
(5250 lbs), each Rear Rail WLL - 3175 kg (7000 lbs) on engine service.
The engine removal rail components are
heavy and unwieldy. Always get
assistance or use an overhead lifting Additional Contact Information
device when moving and positioning components.
For additional product support questions
To avoid personal injury or death, all
hardware used with the rail tool group concerning this tool, contact the Caterpillar
must meet or exceed 10.9 Metric or Dealer Service Tools Hotline at:
Grade 8 (English) specifications.
Potential pinch points. To avoid personal U.S.A.: 1-800-542-8665
injury, use caution when attaching, Illinois: 1-800-541-8665
removing, and working around large, Canada: 1-800-523-8665
heavy components. World: 1-309-675-6277
Fax: 1-309-494-1355
dealerservicetool_hotline@cat.com

5
Nomenclature
335-1617 Rear Rail Tool Group
1096-18
2
1a

3 4
6

335-1617 Rear Rail Tool Group


Item Description Approximate Wt. (each) Qty
1 Rear Rail Assembly 42 kg (92 lbs) 2
1a Hitch Pin with Hairpin Clip — 2
2 Rear Support Assembly (bracket) 19 kg (42 lbs) 2
3 Right-Hand Wheel Assembly (trolley) — 1
4 Left-Hand Wheel Assembly (trolley) — 1
5 Right-Hand Bracket Assembly (engine support) 62 kg (136 lbs) 1
6 Left-Hand Bracket Assembly (engine support) 62 kg (136 lbs) 1

NOTE: Right-Hand and Left-Hand


components are referenced from the point of
view of the operator located in the cab of the
off-highway truck.

6
335-1622 Front Rail Tool Group
1096-19
7c

7b

7a

7a
8

9
7

335-1622 Front Rail Tool Group


Item Description Approximate Wt. (each) Qty
7 Front Rail Assembly 158 kg (349 lbs) 2
7a Hitch Pin with Hairpin Clip — 2
7b Trolley — 2
7c Round Plate, Washer, Nut — 2
8 Right-Hand Bracket Assembly (rail support) 47 kg (103 lbs) 1
9 Left-Hand Bracket Assembly (rail support) 65 kg (143 lbs) 1

Other Required Tooling (not shown)


Part No. Description Used With Qty
4C-6486 Stand 335-1617 Rear Rail Tool Group 2
8S-7641 Tube 335-1617 Rear Rail Tool Group 2
8S-7650 Hydraulic Cylinder 335-1617 Rear Rail Tool Group 2
8S-7625 Collar 335-1617 Rear Rail Tool Group 2
8S-7615 Pin 335-1617 Rear Rail Tool Group 1
9S-1557 Saddle 335-1617 Rear Rail Tool Group 1
277-7200 Hydraulic Pump 335-1617 Rear Rail Tool Group 1
309-2793 Load Tilter 335-1617 Rear Rail Tool Group and 335-1622 Front Rail Tool Group 1
323-1146 Lifting Bracket 335-1617 Rear Rail Tool Group and 335-1622 Front Rail Tool Group 2

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.

NOTE: Before using this tooling, completely


read and understand all Warnings, Notices,
and instructions in this manual.

The 795F AC Off-Highway Truck must be


positioned on a firm, level surface before
installing the rear rail tool group.
The C175 Engine weighs approximately 11.6 t
(25,600 lbs). It is the responsibility of the
technicians to use a suitable overhead lifting
device for engine removal and installation. In
addition, the lift truck must have adequate
capacity, and fork length to support the weight
of the engine when moving (rolling) it on the (A) Rear Motor Mount Saddle. (B) 100-8255 Bolt.
rear rail tool group. (C) 9X-8257 Washer. (D) 8T-4132 Nut.
(2) Rear Support Assembly.

1. Refer to the appropriate disassembly and


assembly service manual for information on 4. Repeat Step 3 to install the second rear
preparing the C175 Engine for removal, support assembly (2) on the remaining rear
including disconnecting all lines, fittings, motor mount.
wiring, and connections.
5. The rear rail assembly (1) weighs 42 kg
2. Refer to the appropriate disassembly and (92.5 lbs). Get assistance to install the rear
assembly service manual for information on rail assembly.
using tube stands to lift the rear of the
engine so the rear trunion mounts are out of a. Remove hitch pin (1a) (not shown) and
(above) the frame saddles. slide the front of the rail over the top of
steering cylinder (E) and position the
rail bracket onto the corresponding
frame bracket.
NOTICE
To avoid damage to tooling and equipment, and
to prevent movement of the engine, loosen but
DO NOT remove the front engine mount bolts.

3. Install rear support assembly (2) under rear


motor mount saddle (A) using four
100-8255 M16 x 240 mm (9.45 in) Bolts (B),
eight 9X-8257 M16 Washers (C), and four
8T-4132 M16 Nuts (D). Tighten to standard
torque.

(E) Steering Cylinder. (1) Rear Rail Assembly.

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.

(1) Rear Rail Assembly. (2) Rear Support Assembly.

c. Install hitch pin (1a) to secure the rail to


the truck frame.
d. Tighten rear rail assembly (1) to rear
support assembly (2) bolts to standard (1) Rear Rail Assembly. (1a) Hitch Pin.
torque. (2) Rear Support Assembly.

7. Install right-hand wheel assembly (3).


NOTE: For clarity, the rear rail is shown with
engine removed. a. Place the wheel assembly on the rear
rail assembly (1) and roll the wheel
assembly into position at the rear
engine mount bracket (F).
b. Bolt the wheel assembly to the rear
engine mount bracket with four 8T-4140
M16 x 60 mm (2.36 in) Bolts with four
9X-8257 M16 Washers. Tighten to
standard torque.

(1) Rear Rail Assembly. (1a) Hitch Pin.


(2) Rear Support Assembly.

(F) Rear Engine Mount Bracket. (1) Rear Rail Assembly.


(3) Right-Hand Wheel Assembly.

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.

(F) Rear Engine Mount Bracket. (1) Rear Rail Assembly.


(4.) Left-Hand Wheel Assembly.

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.

(G) Front Module Mounting Pad.


(5) Right-Hand Bracket Assembly.
(6) Left-Hand Bracket Assembly.

(H) Front Motor Mount Bracket.


(5) Right-Hand Bracket Assembly.
(6) Left-Hand Bracket Assembly.

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.

Front Rail Tool Group and


Rear Rail Tool Group Used
Together

(G) Front Module Mounting Pad.


NOTE: Before using this tooling, completely
(8) Right-Hand Bracket Assembly.
read and understand all Warnings, Notices,
(9) Left-Hand Bracket Assembly.
and instructions in this manual.

4. Secure each bracket using four each


The 795F AC Off-Highway Truck must be
7X-2576 M24 x 70 mm (2.75 in) Bolts,
positioned on a firm, level surface before using
8T-4001 M24 Nuts, and eight 8T-4167 M24
the rear rail and front rail tool groups.
Washers. Tighten to standard torque.
The C175 Engine weighs approximately 11.6 t
5. Refer to the appropriate disassembly and
(25,600 lbs). It is the responsibility of the
assembly service manual for information on
technicians to use a suitable overhead lifting
lifting the front of the engine approximately
device for engine removal and installation. In
30 cm (12 in) to provide clearance for the
addition, the lift truck must have adequate
installing the front rails.
capacity and fork length to handle the weight
of the engine when moving (rolling) it on the 6. Use a suitable overhead lifting device to
rail tool groups. position front rail assembly (7) on motor
mount bracket (J) and left-hand bracket
assembly (9).
1. Refer to the appropriate disassembly and
assembly service manual for information on
preparing the C175 Engine for removal,
including disconnecting all lines, fittings,
wiring, and connections.
2. Refer to the Rear Rail Tool Group section in
this manual and complete Step 1 through
Step 9 to install the 335-1617 Rear Rail Tool
Group.

(J) Motor Mount Bracket. (7) Front Rail Assembly.


(9) Left-Hand Bracket Assembly.

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.

(7) Front Rail Assembly.

(J) Motor Mount Bracket. (K) M30 Nut and Washer.


(7) Front Rail Assembly. 10. Refer to the appropriate disassembly and
assembly service manual for information
on lowering the front of the engine. Lower
8. Secure front rail assembly (7) to left-hand front motor mount (H) onto front rail
bracket assembly (9) using four 8T-4186 trolleys (7b). Secure the left-hand trolley
M10 x 40 mm (1.6 in) Bolts and four and the right-hand trolley with the large
8T-4121 M10 Washers. Tighten all front rail round plate, bolt and washer (7c), as
hardware to standard torque. shown. Tighten both bolts to standard
torque.

(7) Front Rail Assembly. (H) Front Motor Mount Bracket.


(9) Left-Hand Bracket Assembly. (7b) Front Rail Assembly Trolley.
(7c) Front Rail Assembly Round Plate, Bolt, and Washer.

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)

13. Refer to the appropriate disassembly and


2. Inspect all welds and check for damaged,
assembly service manual for information
bent, or cracked components.
on using a suitable overhead lifting device
to remove the engine.
1096-27

NOTE: Installing the engine using the


335-1617 Rear Rail Tool Group and 335-1622
Front Rail Group is the reverse of this
procedure. Refer to the appropriate
disassembly and assembly service manual for
information on engine installation.

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

Rear Rail Assembly


Item No. Part No. Description Qty.
1a 91594A335 1 Hitch Pin with Hairpin Clip 1
1b 224-0554 Warning Film 1
1c 4C-8359 Eyebolt 1
1 Available from McMaster Carr.

4. Have tools inspected annually by an


approved inspector at the dealership. 1096-21
Maintain a written record of all inspections.

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

335-1622 Front Rail Tool Group

1096-23 9b 9c 9d
7e 9e

7d

7a Left-Hand Bracket Assembly (front rail)


Item No. Part No. Description Qty.
9a 138-7573 Link Bracket 1
Front Rail Assembly 9b 0S-1588 3/8-16 Bolt 1
9d 5M-2894 3/8 Washer 1
Item No. Part No. Description Qty.
9e 9S-8752 3/8-16 Nut 1
7a 98412A231 1 Hitch Pin with Hairpin Clip 1
7d 93325A001 1 M30 x 3.5 Stud 1
7e 6321K41 1 Wheel 4
1 Available from McMaster Carr.

15
For information on service tools or shop supplies,
contact Dealer Service Tools on:

Dealer Service Tools


501 S. W. Jefferson
Peoria, IL U.S.A. 61630-2125
U.S.A.: 1-800-542-8665
Illinois: 1-800-541-8665
Canada: 1-800-523-8665
World: 1-309-675-6277
Fax: 1-309-494-1355
dealerservicetool_hotline@cat.com

©2010 Caterpillar NEHS1096


All Rights Reserved Printed in U.S.A.

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