794 AC Off-Highway Truck Machine Systems Caterpillar

Assembly Procedure

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Illustration 1	g02152558

1. Use Tooling (G) to install studs (27) and studs (26). Tighten studs (27) and studs (26) to a torque of 110 ± 20 N·m (81 ± 15 lb ft).
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   Illustration 2	g02152554

2. Install O-ring seals (25).
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   Illustration 3	g02152549

   Note: Locate the four holes in the brake anchor that do not require inner springs.

3. Install outer springs (23) and inner springs (22) onto brake anchor (24).
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   Illustration 4	g03731424

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   Illustration 5	g02152544

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   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.

4. Install guide spring (21) and guide (11) into piston (19). Use Tool (F) to compress guide spring (21). Install Tooling (E). Repeat this step for the remaining guide springs (21), guides (11), and Tooling (E).
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   Illustration 6	g02152537

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   Illustration 7	g02152602
   Correct installation of the D-ring seal.

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   Illustration 8	g03731416

5. Install D-ring seal (20) onto piston (19).

6. Use Tooling (C) and a suitable lifting device to install piston (19). The weight of piston (19) is approximately 118 kg (260 lb).
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   Illustration 9	g02152532

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   Illustration 10	g01968713
   Correct installation of the seal rings

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   Illustration 11	g03731411

7. Install rings (18) and seal rings (17) onto housing (16).

8. Install nuts (15).

9. Use Tooling (C) and a suitable lifting device to install housing (16). The weight of housing (16) is approximately 57 kg (126 lb).

10. Use individual turns to tighten nuts (15) to draw the housing downward evenly. After the nuts have bottomed out, tighten the nuts in a crisscross pattern to a torque of 110 ± 20 N·m (81 ± 15 lb ft).
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    Illustration 12	g02152508

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    Illustration 13	g01968713
    Correct installation of the seal rings

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    Illustration 14	g03731396

11. Install seal rings (14) and seal rings (13) onto piston (10).

12. Use Tooling (C) and a suitable lifting device to install piston (10). The weight of piston (10) is approximately 98 kg (215 lb).
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    Illustration 15	g03731450

13. Press down piston (10). Install pin (12) into guide (11).
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    Illustration 16	g02152483

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    Illustration 17	g02152492

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    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.

14. Install Tooling (D) onto piston (10). Tighten Tooling (D) to compress the guide springs.

15. Remove Tooling (E) from guide (11). Repeat this step for the remaining guides (11).

16. Remove Tooling (D).
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    Illustration 18	g03897807

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    Illustration 19	g03897803

    Note: Install the damper assembly with the friction material facing the piston.

    Note: Lubricate the damper assembly with the lubricant that is being sealed.

17. Install damper assembly (9).

    Note: Lubricate the plates and the discs with the lubricant that is being sealed.

    Note: The friction material must be facing upward.

18. Install plates (8) and discs (7) in the reverse order from the disassembly procedure.
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    Illustration 20	g03897802

    Note: Install the damper assembly with the friction material facing upward.

    Note: Lubricate the damper assembly with the lubricant that is being sealed.

19. Install damper assembly (6). Install O-ring seal (5).
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    Illustration 21	g03731389

20. Install nuts (3) onto plate (4). Use Tooling (C) and a suitable lifting device to install plate (4). The weight of plate (4) is approximately 231 kg (510 lb).

21. Use individual turns to tighten nuts (3) to draw the housing downward evenly. After the nuts have bottomed out, tighten the nuts in a crisscross pattern to a torque of 110 ± 20 N·m (81 ± 15 lb ft).
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    Illustration 22	g03731377

22. Install bolts (2). Use Tooling (A) and a suitable lifting device to remove service and parking brake (1) from Tooling (B). The weight of service and parking brake (1) is approximately 1581 kg (3486 lb).

End By:

1. Install the front service and parking brake