Procedure to Replace the Grounding Stud Assemblies for the Ground Level Control Box Assembly on Certain Large Off-Highway Trucks{1408, 7257, 7332, 7451} Caterpillar

Off-Highway Truck:

793F (S/N: SSP1-390)

795F AC (S/N: ERM1-177)

797F (S/N: LAJ1-273)

Introduction

The following procedure will cover the requirements to replace the grounding stud assemblies for the ground level control box on certain large off-highway trucks.

Safety

Show/hide table

Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine.

Show/hide table

Falling Hazard. May cause personal injury or death. Always attach safety lanyard to appropriate fixing point.

Required Parts

Prepare the Machine

Note: Permit only one operator on the machine. Either keep other personnel away from the machine, or keep other personnel in the sight of the operator.

1. Move the machine to a smooth horizontal location. Move away from any machines that are working and any personnel.

2. Move the transmission control to the P position.

3. Stop the engine.

4. Place blocks in front of the wheels and behind the wheels.

5. Turn off all power to the ground level control box by disconnecting the cable terminals on top of the battery. Refer to Operation and Maintenance Manual, SEBU8406, "Battery or Battery Cable - Inspect/Replace" for additional battery information.

Removal Procedure

Show/hide table



Illustration 1	g03426670
Typical view (A) Ground level control box

1. Disconnect all harness assemblies and cable to ground level control box (A) .

2. Remove ground level control box from the bumper (A). Retain ground level control box (A) and all mounting hardware.

Show/hide table



Illustration 2	g03426704
(B) Cover assembly (C) Bolt (D) Washer

3. Remove eight bolts (C) and eight washers (D) that secure cover assembly (B). Remove cover assembly (B). Retain cover assembly (B) and all mounting hardware.

Show/hide table



Illustration 3	g03426709
(E) Strap assembly (F) Stud assembly

4. Disconnect strap assembly (E) from the inside of stud assemblies (F) .

   Note: A bus bar may have been used instead of strap assembly (E) .

5. Remove stud assemblies (F). Discard stud assemblies (F) .

Installation Procedure

Show/hide table



Illustration 4	g03426770
View of the rear of the ground level control box (A) 40 mm (1.575 inch) Two holes (B) 5.5 mm (0.216 inch) Eight holes (C) 28.6 mm (1.127 inch) (D) 14.3 mm (0.563 inch) (E) 25.4 mm (1.000 inch) (F) 50.8 mm (2.000 inch)

1. Rework two existing holes on the rear of the ground level control box. Use the same center of axis as the existing holes for the new holes size. Enlarge the two existing holes and drill eight new smaller holes. Refer to Illustration 4.

Show/hide table



Illustration 5	g03426800
(1) 331-1066 Terminal Block As (2) 202-1129 Screw (3) 096-6166 Hard Washer (4) 5C-8312 Nut

2. Secure two terminal block assemblies (1) by using eight screws (2), eight hard washers (3), and eight nuts (4).

   Tighten screws (2) to a torque of 5 ± 0.4 N·m (44 ± 3.5 lb in).

Show/hide table



Illustration 6	g03427293
(E) Strap assembly (1) 331-1066 Terminal Block As (5) 8T-4179 Bolt (6) 8T-4223 Hard Washer

3. Secure strap assembly (E) to terminal block assemblies (1) by using two bolts (5) and two hard washers (6) .

   Tighten bolts (5) to a torque of 35 ± 5 N·m (25.8 ± 3.7 lb ft).

   Note: A bus bar may have been used instead of strap assembly (E). Secure a bus bar in the same manner as strap assembly (E) .

4. Reinstall the cover assembly that was removed in Step 3 of the ""Removal Procedure" ".

5. Reinstall the ground level control box that was removed in Step 2 of the ""Removal Procedure" ".

6. Reconnect all the wire harness assemblies and cable assemblies that were disconnected in Step 1 of the ""Removal Procedure" ".

   Use two bolts (5) and two hard washers (6) to reconnect the cable assemblies to terminal block assemblies (1). Tighten bolts (5) to a torque of 35 ± 5 N·m (25.8 ± 3.7 lb ft).

7. Reconnect the batteries that were disconnected in Step 5 of the ""Prepare the Machine" ".

   Refer to Operation and Maintenance Manual, SEBU8406, "Battery or Battery Cable - Inspect/Replace" for additional battery information.