Procedure to Update Pump Electronic Tank Unit (PETU) Coolant Lines on Certain 797F and 793F Off-Highway Trucks {108H, 108J, 108K, 1091, 726A} Caterpillar

Mining Truck

794 AC (S/N: HRT1-UP)

Off-Highway Truck/Tractor

793F (S/N: D3T1-UP)

797F (S/N: LTZ1-UP)

Introduction

This special instruction contains the procedure to update Pump Electronic Tank Unit (PETU) Coolant Lines on certain 797F and 793F Off-Highway Trucks.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Cat dealers have the most current information available.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If the tools, the procedure, the work method, or your actions are not recommended by Caterpillar, ensure that the tools and your actions are safe for you and for others.

Ensure that all personnel are safe when using a tool, procedure, work method, or operating technique not recommended by Caterpillar. Ensure that the product will not be damaged or the product made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

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When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.

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Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below.

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Personal injury can result from improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.

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Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.

Required Parts

Removal Procedure

Perform the below procedure to update the Pump Electronic Tank Unit (PETU) coolant lines.

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Illustration 1	g06401657
(A) 439-3939 Link Bracket As (B) 8T-4193 Bolt (C) 198-4780 Hard Washer

1. Remove bolt (B) and hard washer (C), remove link bracket assembly (A).
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   Illustration 2	g06401658
   (E) 497-9315 Cover (F) 8T-4136 Bolt (G) 7X-7729 Washer (H) 497-9316 Cover

2. Remove bolts (F) and washer (G). Remove cover (E) and cover (H) to gain the access.
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   Illustration 3	g06401660
   (J) 507-2453 Cover (F) 8T-4136 Bolt (G) 7X-7729 Washer (K) 497-9311 Front Cover As

3. Remove bolts (F) and washer (G). Remove top cover (J) and side cover (K).
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   Illustration 4	g06401661
   (L) 7K-1181 Cable Strap (M) 8T-4137 Bolt (N) 8T-4121 Hard Washer (P) 1S-0994 Clip (Q) 462-4211 Hose As (R) 500-6218 Hose As (S) 462-4223 Hose As

4. Remove cable strap (L), bolt (M), hard washer (N), and clip (P).

5. Disconnect hose assembly (Q), hose assembly (R), and hose assembly (S).
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   Illustration 5	g06401662
   (T) 7K-1181 Cable Strap (U) 204-2281 Cable Strap

6. Remove all cable strap (T) and cable strap (U).
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   Illustration 6	g06401663
   (V) 379-5104 Plug As (W) 509-1330 Wiring Harness

7. Disconnect plug assembly (V) and wiring harness (W) by press and release the button to the direction shown in illustration
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   Illustration 7	g06401664
   (W) 509-1330 Wiring Harness

8. Remove wiring harness assembly (W).
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   Illustration 8	g06401665
   (X) 343-2388 Clip (Y) 8T-4189 Bolt (Z) 5P-4116 Hard Washer (AA) 462-4184 Hose (AB) 462-4185 Hose (AC) 9X-2488 Hose Clamp

9. Remove hose clamps (AC), clips (X), bolts (Y), and hard washer (Z).

10. Remove hose (AA) and hose (AB).
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    Illustration 9	g06401674
    (AD) 8T-4191 Bolt (AE) 8T-4121 Hard Washer (AF) 6D-4244 Clip (AG) 462-4198 Hose (AC) 9X-2488 Hose Clamp

11. Remove hose clamp (AC).

12. Remove bolt (AD), hard washer (AE), and clip (AF). Remove hose (AG). Discard the part.
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    Illustration 10	g06401675
    (AH) 8T-4908 Bolt (AJ) 8T-4224 Hard Washer

13. Remove four bolts (AH) and four hard washer (AJ).
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    Illustration 11	g06401676
    (AK) 477-7479 DEF Manifold Gp

14. Remove Diesel Exhaust Fluid (DEF) manifold group (AK). Discard the part.
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    Illustration 12	g06401678
    (AL) 8T-4136 Bolt (AE) 8T-4121 Hard Washer (AM) 433-6972 Solenoid Valve Gp (AN) 477-7482 Plate

15. Remove bolt (AL) and hard washer (AE). Remove plate (AN) and solenoid valve group (AM) on both sides and discard the part.
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    Illustration 13	g06412152
    (AP) 096-6166 Hard Washer (AQ) 221-3700 Bolt (AR) 389-3719 Elbow As

16. Remove eight bolt (AQ) and eight hard washer (AP).

17. Remove elbow assembly (AR) and discard the part.

Installation Procedure

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Illustration 14	g06412154
(1) 241-2451 Elbow (2) 3J-1907 O-Ring Seal (3) 7J-9108 O-Ring Seal (AP) 096-6166 Hard Washer (AQ) 221-3700 Bolt

1. Install one elbow (1) along with one O-Ring seal (2) and one O-Ring seal (3).

2. Tighten elbow to 27 ± 4 N·m (239 ± 35 lb in).

3. Reinstall eight bolts (AQ) and eight hard washer (AP).

4. Tighten the bolts to 3.7 ± 0.8 N·m (32.7 ± 7.1 lb in).
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   Illustration 15	g06412156
   (4) 568-2275 Plate As (5) 6V-9746 O-Ring Seal (6) 6V-8983 Elbow (7) 7J-9108 O-Ring Seal (8) 6V-8982 Elbow

5. Position plate (4) and Install one elbow (6) along with one O-Ring seal (5).

6. Install one elbow (8) and one O-Ring seal (7).

7. Ensure the orientation of the elbows as shown in Illustration 15.
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   Illustration 16	g06412158
   (9) 344-5674 Nut (AH) 8T-4908 Bolt (AJ) 8T-4224 Hard Washer

8. Install the plate onto the cabinet using four bolt (AH), four hard washer (AJ), and four nut (9).

9. Tight bolt (AH) to 28 ± 7 N·m (248 ± 62 lb in).
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   Illustration 17	g06414319
   (5) 6V-9746 O-Ring Seal (6) 6V-8983 Elbow (7) 7J-9108 O-Ring Seal (8) 6V-8982 Elbow (10) 2P-1293 Locknut (11) 6V-9170 Bulkhead Nut

10. Install locknut (10) to secure elbow (6) along with O-Ring seal (5). Tighten locknut (10) to 180 ± 27 N·m (133 ± 20 lb ft).

11. Install bulkhead nut (11) to secure elbow (8) along with O-Ring seal (7). Tighten bulkhead nut (11) to 130 ± 20 N·m (96 ± 15 lb ft).

12. Ensure the locknut orientation for tight clearance with tank assembly opening.
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    Illustration 18	g06412160
    (12) 571-9774 Hose As

13. Install one hose assembly (12) on to plugs. Tighten the hose assembly on plug end to 110 ± 17 N·m (81 ± 13 lb ft). Tighten the hose assembly on manifold end to 140 ± 21 N·m (103 ± 15 lb ft).
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    Illustration 19	g06412163

14. Mounting holes need to install the manifold inside the cabinet. Position the manifold and mark three mounting holes along the existing one hole on the cabinet.
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    Illustration 20	g06412164
    (D1) 6.6 mm (0.26 inch) (D2) Align with existing hole

15. Tap and drill three mounting holes in the cabinet. Refer to coolant manifold template as shown in Illustration 20.
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    Illustration 21	g06412165
    (13) 565-6045 Manifold Coolant (14) 6V-6609 O-Ring Seal (15) 180-8424 O-Ring Seal (16) 6V-8639 Connector (17) 6V-5138 O-Ring Seal (18) 6V-8632 Connector (19) 9S-8005 Plug

16. Position manifold coolant (13). Install four connector (16) along with O-Ring seal (14) and O-ring seal (15). Tighten connector (16) to 50 ± 12 N·m (37 ± 9 lb ft).

17. Install one connector (18) along with O-Ring seal (14) and O-ring seal (17). Tighten connector (18) to 50 ± 12 N·m (37 ± 9 lb ft).

18. Install two plugs (19) along with O-Ring seal (14). Tighten plug (19) to 40 ± 12 N·m (30 ± 9 lb ft).
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    Illustration 22	g06412166
    (20) 572-5025 Hose As (21) 571-9771 Hose As (22) 498-0307 Hose As (23) 482-3478 Hose As (24) 571-9773 Hose As

19. Connect hose assembly (20), (21), (22), (23), and (24) on to manifold coolant. Tighten hose assembly connector (20), (21), (23), and (24) to 65 ± 10 N·m (48 ± 7 lb ft).

20. Tighten hose assembly (22) to 100 ± 12 N·m (74 ± 9 lb ft).

21. Ensure the orientation of the hose assemblies as shown in Illustration 22.
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    Illustration 23	g06412167
    (25) 351-4315 Clip (26) 3U-2428 Pipe Clamp

22. Install three clips (25) and install one pipe clamp (26). Ensure the clips and clamps are loose fitted.
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    Illustration 24	g06412168
    (27) 538-1274 Solenoid Valve Gp (28) 5C-9553 Bolt (29) 9X-8256 Washer (AN) 477-7482 Plate

23. Install solenoid valve group (27) and two plate (AN) using 16 bolts (28) and 16 washers (29).

24. Connect solenoid valve group (27) onto hose assemblies as shown in Illustration 24.
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    Illustration 25	g06412171
    (30) 572-3145 Bracket As (32) 8T-4224 Hard Washer (31) 8T-7547 Bolt

25. Install one bracket assembly (30) using one bolt (31) and one hard washer (32).

26. Tighten bolt (31) to 28 ± 7 N·m (248 ± 62 lb in).
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    Illustration 26	g06412174
    (25) 351-4315 Clip (26) 3U-2428 Pipe Clamp (33) 8T-7547 Bolt (34) 8T-4224 Hard Washer (35) 8T-4189 Bolt (36) 6V-9632 Weld Nut (37) 9X-8256 Washer (38) 118-6503 Bolt (AL) 8T-4136 Bolt (AE) 8T-4121 Hard Washer

27. Install the manifold coolant assembly onto cabinet using four bolts (38), four washers (37), and four nut (36).

28. Secure the hose assemblies using clip (25) and pipe clamp (26).

29. Install two bolt (33) and two hard washer (34). Tighten bolt (33) to 28 ± 7 N·m (248 ± 62 lb in).

30. Install one bolt (35) and one hard washer (34). Tighten bolt (35) to 28 ± 7 N·m (248 ± 62 lb in).

31. Follow the reversal of "Removal Procedure" section for installation of removed parts.