7-7
TMS800E SERVICE MANUAL POWER TRAIN
Published 01-29-2014, Control # 496-00
20. Tag and disconnect all lines to the radiator and air
cooler. Remove the radiator assembly and fan. Cap or
plug all openings.
21. Tag and disconnect the heater hoses.
22. Tag and disconnect the fuel lines to the engine. Cap or
plug all openings.
23. Tag and disconnect all air lines to the engine
components and the transmission. Cap or plug all
openings.
24. Tag and disconnect the hydraulic lines to the No. 2 and 3
Pump (ISX) (or the two-section pump, QSM). Cap or
plug all lines and openings.
25. Tag and disconnect all cables to the engine, engine
components, and transmission.
26. Attach an adequate lifting device to the engine and
transmission sufficient to lift and support both the engine
and transmission. Locate the rear engine lifting bracket
bolted to the exhaust tube support bracket and install it
where the tubing clamp bracket was removed. Use the
hardware from the exhaust bracket and torque the bolts
to 113 Nm (83 lb ft)
NOTE: The engine and transmission weigh approximately
1800 kg (3968 lb).
27. With the lifting device supporting the weight of the
engine and transmission, remove the bolts, washers,
lockwashers and nuts from the front engine mounting
support and the transmission mounting brackets.
28. Carefully lift the engine assembly from the crane and
move it to a clean work area.
29. If a new engine is to be installed, remove the
transmission, pumps, and all engine installed
components, fittings, etc. from the old engine and install
them on the new engine in the same locations. Refer to
Removal of the Transmission, page 7-48 in this section
for transmission removal and installation. Use the same
grade hardware, torque values, and thread sealing
compound as the engine factory’s workers used.
Installation
1. Attach adequate lifting device to the engine and
transmission sufficient to lift and support both the engine
and transmission. With all components and fittings
installed on the engine, lift the engine assembly
(including the transmission) into the crane.
2. With the engine assembly in position, install the bolts,
washers, lockwashers, nuts, and bonded mounting
centers on the front engine mounting support and on the
transmission mounting brackets. Torque the bolts refer
to Fasteners and Torque Values, page 1-13.
3. Remove the lifting device from engine and transmission.
4. Connect all linkages and cables to the engine, engine
components, and transmission as tagged during
removal.
5. Connect all hydraulic lines to Pump No. 2 (the pump on
the engine) as tagged during removal.
6. Connect all air lines to the engine components and
transmission as tagged during removal. Also connect
the charge air cooler lines as tagged during removal.
7. Connect the fuel lines to the engine as tagged during
removal.
8. Connect the heater hoses as tagged during removal.
9. Install the radiator assembly and fan. Connect all lines to
the radiator and air cooler as tagged during removal.
10. Connect the drive line to the transmission. Refer to Drive
Train, page 7-33.
11. Connect the filter and oil cooler oil lines to the
transmission as tagged during removal.
12. As needed, install ether cylinder if removed earlier.
13. Connect the battery cables, starting aid valve connector,
and engine electrical connections as marked during
removal.
14. Attach lifting device to and install the boom rest and
aftertreatment assembly.
15. Connect propeller shaft to No. 1 pump coupler with bolts
and washers. Torque the bolts refer to Fasteners and
Torque Values, page 1-13.
16. Install the engine hood assembly, counterweight
stowage frame work, and the removed decking. If the
No. 1 pump was removed, reinstall it.
17. Connect hydraulic lines to Pump No. 1 as tagged during
removal.
18. Plug aftertreatment wiring harness to carrier harness
and aftertreatment assembly and install straps to the
boom rest tie bars.
19. Remove the rear engine lifting bracket from the engine
and bolt it on the frame. Install the exhaust tubing clamp
mounting bracket where the lifting bracket was removed.
Install the exhaust tubing and connect it to the engine.
20. Connect the starting aid tubing to the nozzle in the intake
manifold. Verify the nozzle orifice points upstream.
21. Connect the air cleaner tubing at the engine and air
cleaner.
22. Service the engine lubricating system, hydraulic
reservoir, and the engine cooling system.
23. Fill the transmission with SAE GRADE 50 synthetic gear
lubricant (Spec. 6829013433).
Reference Only
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