794 AC Off-Highway Truck Field Assembly Caterpillar

Parts and Specification Information

Note: Verify that all parts are shipped and undamaged for preparation of assembly. Missing or damaged parts can be ordered prior to assembly to avoid delays during assembly.

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Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.

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Personal injury or death can occur from heavy components falling during removal or installation. Properly support the component with a suitable lifting device during removal or installation.

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Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

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Do not attempt to assemble this machine until you read and you understand the assembly instructions. Improper assembly procedures could result in injury or death.

Note: Remove all protective shipping covers, flanges, plugs, caps, clamps, cable straps, and material.

Note: Clean mounting and contact surfaces for major component installation free of wax, dirt, debris, paint, and grease.

Note: If necessary, chase unprotected threaded holes with an appropriately sized tap to remove paint, rust, or other debris.

Note: Unless otherwise specified, all torque requirements are Standard Torque values. Refer to the "General Information" section in this document for the correct torque values.

Note: Before tightening the cable straps (mounting hardware), remove the slack from the harness assemblies and allow adequate strain relief.

Note: Any tooling that is used for lifting the machine or for securing the machine in the raised position should be used on a concrete surface capable of supporting the weight of the machine.

Installation Procedure

Start By:

1. Assemble the platform

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Illustration 1	g06422668
Shipping Support Beam Typical Example (T1) 439-3940 Bracket As (A) 447-9191 Bracket As (B) 1K-6870 Locknut (C) 7X-0610 Hard Washer (D) 8T-9311 Bolt (E) 4L-9337 Bolt (F) 8T-4121 Hard Washer (G) 201-7354 Bolt (H) 7X-0515 Hard Washer (J) 7X-0448 Nut

1. Attach Tooling (T1) and a suitable lifting device onto bracket assembly (A). The weight of bracket assembly (A) is approximately 131 kg (289 lb).

2. Remove and keep two locknuts (B), six washers (C), and two bolts (D). Remove and keep eight bolts (G), sixteen washers (H), and eight nuts (J). Remove and keep sixteen bolts (E) and sixteen washers (F).
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   Illustration 2	g06316968
   (K) 8T-8924 Bolt (L) 7X-0582 Hard Washer (M) 1K-6870 Locknut (N) 475-8932 Brace

3. Remove two bolts (K), four washers (L), and two nuts (M) to disconnect two braces (N).
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   Illustration 3	g06422669
   (T1) 439-3940 Bracket As (A) 447-9191 Bracket As

4. Use Tooling (T1) and a suitable lifting device to remove and discard bracket assembly (A). The weight of bracket assembly
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   Illustration 4	g06420027
   (T2) 193-5474 Shackle (1) 552-0800 Platform Ar

5. Attach Tooling (T2) and suitable lifting devices onto platform arrangement (1). The assembled weight of platform arrangement (1) is approximately 21318 kg (47000 lb).
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   Illustration 5	g06316398
   Typical Example (1) 552-0800 Platform Ar

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   Illustration 6	g06316377

6. Use Tooling (T2) and two suitable cranes to lift the platform at the four lifting points indicated in Illustration 4. Use a suitable strap to secure the front platform extension during the lift.

7. Slowly position the platform so that the saddle mounts are centered on the tube and on each side of the location blocks on both sides of the chassis. Ensure that the front face mounting holes line up with the vertical support beams. Refer to Illustration 6.
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   Illustration 7	g06316459
   (2) 442-2820 Cap As (3) 8T-5361 Hard Washer (4) 8F-6124 Bolt

8. Mark the location of each cap assembly (2) as installed for future service purposes. Apply Tooling (T3) to twelve bolts (4). Use two people to install two cap assemblies (2), twelve washers (3), and twelve bolts (4). Repeat this step for the opposite side.
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   Illustration 8	g06317252
   (5) 7X-0515 Hard Washer (6) 201-7354 Bolt (7) 7X-0448 Nut

9. Install four washers (5), four bolts (6), and two nuts (7). Repeat this step for the opposite side.
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   Illustration 9	g06423470

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   Illustration 10	g06421523
   (K) 8T-8924 Bolt (L) 7X-0582 Hard Washer (M) 1K-6870 Locknut (N) 475-8932 Brace

10. Position two braces (N). Install four washers (L), two bolts (K), and two locknuts (M). Adjust the overall length of braces (K) to keep the radiator level and aligned vertically and horizontally.
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    Illustration 11	g06421526
    Outboard Side

11. Loosen bolt (P) and position hose assemblies (R) out of the way.
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    Illustration 12	g06322735

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    Illustration 13	g06322697
    SECTION A-A (B) 1K-6870 Locknut (C) 7X-0610 Hard Washer (D) 8T-9311 Bolt

12. Install four washers (C), bolt (D), and locknut (B). Repeat this step for the opposite side.
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    Illustration 14	g06421527
    Outboard Side

13. Position hose assemblies (R) and tighten bolt (P).

Platform Connect - Superstructure

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Illustration 15	g06422670
Outboard Side (10) 431-8539 Clamp (11) 512-9283 Rubber Elbow (12) 431-8541 Clamp

1. Install four elbows (11), eight clamps (10), and eight clamps (12).

2. Prior to assembly, clean the airline pipes. Check all the new pipes for the protective caps. Inspect the new pipes to ensure that the pipes are free of rust and debris. If debris and rust are found, clean inside the pipes until free of debris and rust.

3. Before installation, mark the hose overlap distance on all pipes.
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   Illustration 16	g06332622
   Hose and pipe overlap (D1) 60 ± 5 mm (2.4 ± 0.2 inch)

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   Illustration 17	g06411394
   Reduced diameter hose and pipe overlaps (D2) 67 ± 5 mm (2.6 ± 0.2 inch)

4. The overlap distance for the hose on the pipe to filter assembly connections, the pipe to pipe connections, and the pipe to elbow connection is 60 ± 5 mm (2.4 ± 0.2 inch) (D1). The overlap is on both ends of the hose. Both units are the same diameter.

5. During the pipe installation, leave the components loose to adjust the alignment of the pipes and hoses. Misalignment of the pipes should not exceed 3.0 mm (0.12 inch).
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   Illustration 18	g06421643
   Outboard Side

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   Illustration 19	g06422665
   Detail A (8) 512-9591 Pipe As (9) 512-9592 Pipe As (13) 8T-4195 Bolt (14) 7X-7729 Washer (15) 6V-7744 Locknut (16) 502-7103 Strap (17) 507-6294 Strap (18) 8T-2501 Bolt (19) 5P-1075 Hard Washer (20) 8T-4196 Bolt (21) 502-7105 Pipe Clamp (22) 502-7104 Pipe Clamp (23) 8T-6466 Bolt (24) 8T-4121 Hard Washer (25) 6V-7744 Locknut (26) 6V-8819 Self-Locking Bolt (27) 8T-4896 Hard Washer (28) 2Q-3691 Spacer (29) 442-2672 Washer (30) 434-5654 Nut

6. Install strap (16), strap (17), washer (14), bolt (13), locknut (15), two washers (19), two bolts (18).

7. Install two pipe clamps (21), four washer (14), bolt (20), bolt (13), and two locknuts (25).

8. Install pipe assembly (8), two pipe clamps (22), eight washers (24), four bolts (23), and four locknuts (25). Tighten four locknuts (25) to a torque of 30 ± 7 N·m (266 ± 62 lb in).

9. Install pipe assembly (9), pipe clamp (21), pipe clamp (22), four washers (24), two bolts (23), and two locknuts (25). Install washer (27), self-locking bolt (26), spacer (28), washer (29), and nut (30). Tighten two locknuts (25) to a torque of 30 ± 7 N·m (266 ± 62 lb in).

10. Repeat Step 6 through Step 9 for the opposite side.
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    Illustration 20	g06421608

11. Tighten eight clamps (10) to a torque of 10 ± 2 N·m (89 ± 18 lb in). Tighten eight clamps (12) to a torque of 10 ± 2 N·m (89 ± 18 lb in). Tighten eight clamps (S) to a torque of 10 ± 2 N·m (89 ± 18 lb in).

12. Check the overlap distance marks. If the assembly is within the specifications, tighten the clamps.

    Note: Position the clamps 180 degrees apart.

13. Once the turbo connections are made, pressure check the pipe assemblies. Refer to UENR2267, Air Inlet System - Test and Inspect
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    Illustration 21	g06421716
    (31) 488-9717 Hose (32) 313-5058 Clamp (33) 8T-4986 Hose Clamp (T) 488-9718 Hose

14. Install hose (31) with four clamps (32). Connect hose (T) with hose clamp (33).
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    Illustration 22	g06421723
    (34) 140-0860 Ground Strap (35) 479-2171 Bolt As

15. Install ground strap (34) and two bolt assemblies (35).
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    Illustration 23	g06421735
    (V) 563-1290 Hose As (W) 563-1292 Hose As (X) 461-7560 Hose As (Y) 461-6717 Hose As (Z) 461-6694 Hose As (AA) 461-6718 Hose As (AB) 461-6718 Hose As (AC) 461-6715 Hose As (AD) 461-6714 Hose As (AE) 461-6716 Hose As (AF) 461-6750 Hose As (AG) 461-6751 Hose As

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    Illustration 24	g06421755
    VIEW A-A (V) 563-1290 Hose As "Rear Service R1" (W) 563-1292 Hose As "Rear Park R2" (X) 461-7560 Hose As "Hoist Gauge R3" (Y) 461-6717 Hose As "Brake Supply R4" (Z) 461-6694 Hose As "Steering Gauge R5" (AA) 461-6718 Hose As "Brake Return R6" (AB) 461-6718 Hose As "Brake Accu Drain (Bad) R7" (AC) 461-6715 Hose As "Front Accu (FBA) R8" (AD) 461-6714 Hose As "Front Service R9" (AE) 461-6716 Hose As "Front Park R10" (AF) 461-6750 Hose As "Grease Supply R11" (AG) 461-6751 Hose As "Grease Fill R12"

16. Connect hose assemblies (V), hose assembly (W), hose assembly (X), hose assembly (Y), hose assembly (Z), hose assembly (AA), hose assembly (AB), hose assembly (AC), hose assembly (AD), hose assembly (AE), hose assembly (AF), hose assembly (AG).
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    Illustration 25	g06421916

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    Illustration 26	g06421922
    (W1) Tack Weld (AH) 549-6284 Support As (36) 565-5175 Pin (37) 565-5174 Pin Retainer (38) 8C-8722 Nut (39) 3E-9850 Bolt

17. Position two support assemblies (AH). Install two pins (36), four pin retainers (37), two bolts (39), and two nuts (38).

    Note: Tack weld nuts (38) to bolts (39) after tightening.

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    Illustration 27	g06421949
    (AJ) 446-8221 Bolt (AK) 7X-0579 Hard Washer (AL) 447-5090 Access Cover Gp and 447-5091 Access Cover Gp

18. Remove and keep twelve bolts (AJ), twelve washers (AK), and two access covers (AL).
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    Illustration 28	g06421958
    (40) 338-8490 Plate As (41) 338-8491 Plate As (42) 8T-4121 Hard Washer (43) 8T-4195 Bolt

19. Install plate assembly (40), plate assembly (40), four washers (42), and four bolts (43).
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    Illustration 29	g06420082
    (AM) 6V-5782 Bolt (AN) 7H-3937 Lockwasher (AP) 8T-4224 Hard Washer (AR) 390-2026 Plate

20. Remove and keep fourteen bolts (AM), fourteen lockwashers washers (AN), fourteen washers (AP), and plate (AR).
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    Illustration 30	g06420447
    (AS) 315-5391 Nut (AT) 304-4207 Grommet Assembly (44) 442-3740 Power Cable (45) 442-3738 Power Cable (46) 442-3736 Power Cable

21. Remove and keep three nuts (AS) and three grommets (AT) from power cable (44), power cable (45), and power cable (46).
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    Illustration 31	g06420460
    (AR) 390-2026 Plate (AS) 315-5391 Nut (AT) 304-4207 Grommet Assembly (44) 442-3740 Power Cable (45) 442-3738 Power Cable (46) 442-3736 Power Cable

22. Install plate (AR), three grommet assemblies (AT), and three nuts (AS) onto power cable (44), power cable (45), and power cable (46).
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    Illustration 32	g06420472
    (AV) 8T-9043 Bolt (AW) 7H-3937 Lockwasher (AX) 8T-4224 Hard Washer (AY) 390-2028 Plate (44) 442-3740 Power Cable (45) 442-3738 Power Cable (46) 442-3736 Power Cable

23. Position power cable (44), power cable (45), and power cable (46). Remove and keep eight bolts (AV), eight lockwashers (AW), eight washers (AX), and plate (AY).
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    Illustration 33	g06420145

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    Illustration 34	g06420127
    VIEW B-B 3 Places (44) 442-3740 Power Cable (45) 442-3738 Power Cable (46) 442-3736 Power Cable (47) 7X-7729 Washer (48) 179-2021 Belleville Washer (49) 344-5675 Nut (50) 8T-4186 Bolt

24. connect power cable (44) to terminal (C), power cable (45) to terminal (B), and power cable (46) to terminal (A). Install two washer (47), two belleville washers (48), two bolts (50), and two nuts (49) onto each terminal.
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    Illustration 35	g06420506

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    Illustration 36	g06420524
    (AR) 390-2026 Plate (AS) 315-5391 Nut (AT) 304-4207 Grommet Assembly

25. Position plate (AR) and three grommet assemblies (AT) and three nuts (AS). Install fourteen washers (AP), fourteen lockwashers (AN), and fourteen bolts (AM). Tighten three grommet assemblies (AT) and three nuts (AS) to a torque of 20 ± 2 N·m (177 ± 18 lb in).
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    Illustration 37	g06420527
    (AV) 8T-9043 Bolt (AW) 7H-3937 Lockwasher (AX) 8T-4224 Hard Washer (AY) 390-2028 Plate

26. Position plate (AY) and install eight washers (AX), eight lockwashers (AW), and eight bolts (AV).
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    Illustration 38	g06420171
    (AZ) 8T-4186 Bolt (BA) 8T-4121 Hard Washer (47) 7X-7729 Washer (49) 344-5675 Nut (51) 442-3742 Plate (52) 314-9323 Block (53) 314-9325 Block (54) 310-1703 Plate (55) 8T-4178 Bolt

27. Install plate (51), three washers (BA), and three bolts (AZ). Install block (52), block (53), plate (54), four washers (47), two bolts (55), and two nuts (49).
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    Illustration 39	g06420591
    (42) 8T-4121 Hard Washer (43) 8T-4195 Bolt (56) 311-7320 Plate As (57) 311-7319 Plate As

28. Install two plate assemblies (56), two plate assemblies (57), sixteen washers (42), and sixteen bolts (43).
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    Illustration 40	g06420167

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    Illustration 41	g06420905
    (AS) 315-5391 Nut (AT) 304-4207 Grommet Assembly (BB) 442-3732 Cable As (BC) 442-3730 Cable As (BD) 442-3734 Cable As (BE) 442-3728 Cable As (BF) 442-3724 Cable As (BG) 442-3726 Cable As (BH) Plate (44) 442-3740 Power Cable (45) 442-3738 Power Cable (46) 442-3736 Power Cable

29. Route power cable (44), power cable (45), and power cable (46) from the generator. Then route power cable (BB), power cable (BC), power cable (BD), power cable (BE), power cable (BF), and power cable (BG) from the traction motors.

30. Install nine grommet assemblies (AT) and nine nuts (AS). Tighten nine nuts (AS) to a torque of 20 ± 2 N·m (177 ± 18 lb in).

    Note: For ease of assembly, temporarily remove plate (BH) in order to install the grommet assemblies.

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    Illustration 42	g06422590
    (47) 7X-7729 Washer (49) 344-5675 Nut (52) 314-9323 Block (53) 314-9325 Block (54) 310-1703 Plate (55) 8T-4178 Bolt

31. Install block (52), block (53), plate (54), two washers (47), and two bolts (55).

32. Install two blocks (52), two blocks (53), two plates (54), four washers (47), and four bolts (55).

33. Install block (52), block (53), plate (54), two washers (47), two nuts (49), and two bolts (55).

34. Install two blocks (52), two blocks (53), two plates (54), four washers (47), four nuts (49), and four bolts (55).
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    Illustration 43	g06422605
    (47) 7X-7729 Washer (49) 344-5675 Nut (52) 314-9323 Block (53) 314-9325 Block (54) 310-1703 Plate (55) 8T-4178 Bolt (58) 8T-6408 Bolt

35. Install two blocks (52), two blocks (53), four plates (54), four washers (47), four nuts (49), four bolts (55).

36. Install two blocks (52), two blocks (53), plate (54), two washers (47), two bolts (58).
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    Illustration 44	g06421120
    Front View of Inverter Cabinet (47) 7X-7729 Washer (48) 179-2021 Belleville Washer (49) 344-5675 Nut (52) 314-9323 Block (53) 314-9325 Block (54) 310-1703 Plate (55) 8T-4178 Bolt (64) 8T-4182 Bolt

37. Install three blocks (52), three blocks (53), six washers (47), six bolts (55). Install thirty-six washers (47), thirty-six belleville washers (48), eight-teen bolts (64), and eight-teen nuts (49).
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    Illustration 45	g06422610
    SECTION B-B (AS) 315-5391 Nut (AT) 304-4207 Grommet Assembly (BB) 442-3732 Power Cable (BC) 442-3730 Power Cable (BD) 442-3734 Power Cable (BE) 442-3728 Power Cable (BF) 442-3724 Power Cable (BG) 442-3726 Power Cable (44) 442-3740 Power Cable (45) 442-3738 Power Cable (46) 442-3736 Power Cable (59) 312-8913 Clamp (60) 312-9093 Plate (61) 7X-0605 Hard Washer (62) 8T-4174 Bolt (63) 329-3356 Nut

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    Illustration 46	g06422611
    VIEW C-C (47) 7X-7729 Washer (48) 179-2021 Belleville Washer (49) 344-5675 Nut (64) 8T-4182 Bolt

    1. Install clamp (59), two plates (60), two washers (61), bolt (62), and nut (63). Connect power cable (BB), power cable (BC), power cable (BD), power cable (BE), power cable (BF), power cable (BG), power cable (44), power cable (45), and power cable (46). Tighten seven grommet assemblies (AT) and seven nuts (AS) to a torque of 20 ± 2 N·m (177 ± 18 lb in).

    2. Install four washers (47), four washers (48), two bolts (64), and two nuts (49). Repeat this step for the eight remaining terminals.
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    Illustration 47	g06422643
    (AJ) 446-8221 Bolt (AK) 7X-0579 Hard Washer (AL) 447-5090 Access Cover Gp and 447-5091 Access Cover Gp

38. Install two access covers (AR), twelve washers (AP), and twelve bolts (AN).
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    Illustration 48	g06422644
    Right Side Hose Connections (BH) 465-3652 Hose As (BJ) 461-6691 Hose As (BK) 461-6689 Hose As

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    Illustration 49	g06422645
    Left Side Hose Connections (BL) 461-6687 Hose As (BM) 461-6688 Hose As (BN) 461-6690 Hose As

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    Illustration 50	g06422646
    (BH) 465-3652 Hose As (BJ) 461-6691 Hose As (BK) 461-6689 Hose As (BL) 461-6687 Hose As (BM) 461-6688 Hose As (BN) 461-6690 Hose As

39. Connect hose assembly (BH), hose assembly (BJ), hose assembly (BK), hose assembly (BL), hose assembly (BM), and hose assembly (BN).
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    Illustration 51	g06422647
    (BP) 536-7102 Hose As (BR) 470-6345 Hose As

40. Connect hose assembly (BP) and hose assembly (BR).
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    Illustration 52	g06422652

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    Illustration 53	g06422980
    SECTION C-C (BS) 470-6347 Hose As (BT) 470-6346 Hose As (BV) 9X-2133 Hose (65) 517-5448 Half Clamp (66) 435-7441 Cover Plate (67) 206-7013 Fastener (68) 8T-4121 Hard Washer (69) 8T-6466 Bolt (70) 517-5505 Half Clamp (71) 435-0692 Cover Plate (72) 206-7013 Fastener (73) 8T-4121 Hard Washer (74) 8T-4182 Bolt (75) 3S-8664 Clip

41. Install two half clamps (65), cover plate (66), two fasteners (67), clip (75), two washers (68), and two bolts (69) to secure hose assembly (BS) and hose (BV). Install two half clamps (70), cover plate (71), two fasteners (72), two washers (73), and two bolts (74) to secure hose assembly (BT). Repeat this step for the two remaining clamp points.
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    Illustration 54	g06422983
    (BS) 470-6347 Hose As (BT) 470-6346 Hose As

42. Connect hose assembly (BS) and hose assembly (BT)
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    Illustration 55	g06422659
    ( BV) 483-2521 Cab Harness As

43. Connect harness assembly (BV).
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    Illustration 56	g06422663
    (76) 432-3697 Pipe Bushing (77) 7W-0629 Filter Adapter (78) 2N-1287 Flared Elbow

44. Install bushing (76), adapter (77), and elbow (78). Repeat this step for the three remaining tubes.
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    Illustration 57	g06422662

45. Connect two hose assemblies (BW) and two hose assemblies (BX).