Special Instruction 797f

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Special Instruction
Assembly Procedure for the 797F and the 797F XQ Off-Highway Truck{7000, 7006,
7960}
Media Number -REHS5063-09 Publication Date -25/07/2012 Date Updated -26/07/2012
i04909421
Assembly Procedure for the 797F and the 797F XQ Off-

Highway Truck{7000, 7006, 7960}
SMCS - 7000-016; 7006-016; 7960-016
Off-Highway Truck:
797F (S/N: LAJ1-UP; WSP1-UP)
Introduction
This Special Instruction contains the necessary procedures for the field assembly of 797F Off-
Highway Trucks.
Note: The photographs in this publication are for illustrative purposes. Some photographs may not
be in sequence for illustrative purposes.
The suggested tools and equipment should be present before assembly. If the recommended tools
and equipment are not present, assembly will be more difficult and more time will be necessary to
complete the assembly.
Do not perform any procedures or order any parts until you read this publication. Do not perform
any procedures or order any parts until you understand this publication thoroughly.
All of the parts that are contained within the shipping crate will be identified in blue bags. The
blue bags will be labeled with the next level part number for that particular part. When unpacking
the shipping containers, organize the parts by the group number or by the next level part number
("N/L"). This manual is organized by the assembly of the groups.
After assembly is complete, prepare the machine for use. The Operations and Maintenance
Manual, SEBU8417 shows the preparation of the machine. Use the Parts Manual, SEBP4986 and
the Service Manuals with this special instruction.
ReferenceOperations and Maintenance Manual, SEBU8417, "797F Off-Highway Truck "
ReferenceSpecial Instruction, SEHS9411, "Servicing the Suspension Cylinders for Off-Highway

Trucks"
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/s... 28/07/2012
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ReferenceSpecial Instruction, REHS1841, "General Welding Procedures"
ReferenceTesting and Adjusting, KENR8374, "797F Off-Highway Truck Braking System"
ReferenceService Manual, KENR8749, "797F Off-Highway Truck Automatic Lubrication

System for Electric Start and Air Start Equipped Trucks "
ReferenceTesting and Adjusting, KENR8734, "797F Off-Highway Truck Steering System "
ReferenceTesting and Adjusting, KENR8748, "797F Off-Highway Truck Air System "
ReferenceSpecial Instruction, SEHS7633, "Battery Maintenance Procedure"
ReferenceService Manual, KENR9023, "793F and 797F Off-Highway Truck/Tractors VIMS,

Monitoring, and Payload "
ReferenceSystems Operation, RENR2223, "Oil Renewal System"
ReferenceTesting and Adjusting, KENR8371, "797F Off-Highway Truck Power Train "
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.
The space between the body and the frame becomes a zero clearance
area when the body is lowered. Failure to install the retaining cable can
result in injury or death to personnel working in this area.
NOTICE
Do not allow any dirt or foreign material to get into the hydraulic
system during assembly, connection of lines, when components are
filled with fluid, or during any maintenance operation.
NOTICE
For a good and solid joint, clean all surfaces, remove burrs from all
areas where parts are to be installed, chase all tapped holes that are
used for mounting purposes, and remove the paint from all contacting
surfaces.
Parts List
Note: At the beginning of assembly, components in bags should be arranged by group numbers,
lowest to highest. Bags with individual part numbers should be placed in order with the group
numbers which will make these bags with a single component available. This method will
eliminate reaching into boxes and continuing to remove and replace the bags in the boxes.
Table 1
Parts that are Needed for Installation of the 189-2561 Rear Axle Housing Gp
Qty Part Number Description
2 200-0885 (1) Lower Link
16 112-1579 (1) O-Ring Seal

8 156-9804 (1) Pin
16 156-9803 (1) Collet
16 9X-8399 (1) Washer
16 8T-0368 (1) Bolt
2 306-8202 (1) Upper Link
(1)
Part of 149-3054 Rear Suspension Gp
Table 2
Parts that are Needed for Installation of 289-8618 Rear Suspension Ar
Rear Suspension Gp
1 289-8620
Left Hand
Rear Suspension Gp
1 289-8619
Right Hand
8 192-4309 (1) O-Ring Seal
4 191-3628 (1) Pin
8 191-3629 (1) Collet
8 9X-8399 (1) Washer
8 8T-0368 (1) Bolt
2 157-0221 (1) Suspension Cover

4 157-0222 (1) Hose Clamp
(1)
Table 3
Parts that are Needed for Installation of 284-4240 Transmission Ar
1 7X-4781 O-Ring Seal
38 9X-8399 Washer
38 8C-3236 Bolt
Table 4
Parts that are Needed for Installation of 272-3349 Drive Shaft
1 284-4881 Slip Joint
8 8T-0670 Bolt
Table 5
Parts that are Needed for the Installation of 336-7751 Drive Shaft Guard Gp
2 336-7746 Plate As
10 8T-4139 Bolt
10 8T-4223 Hard Washer

4 337-4319 Plate
40 8T-4136 Bolt

1 337-4313 Plate As
1 336-7754 Plate As
1 336-7757 Plate As
1 337-4316 Plate As
1 293-5510 Plate As
Table 6
Parts that are Needed for Installation of 272-3351 Power Train Oil Lines Gp

2 281-5972 Connector As
1 9R-4082 Hose As
8 8T-4956 Bolt
8 8T-4244 Nut
1 340-9832 Plate
2 5P-7466 Clip
2 5P-7467 Clip
2 5P-8112 Grommet
1 255-0786 Tube As
1 293-5042 Hose As
5 6V-4590 O-Ring Seal
4 7X-2553 Bolt
6 9X-8257 Washer
20 8T-4184 Bolt
8 1P-4582 Half Flange
1 120-5867 Clip
1 8T-6466 Bolt
1 9R-1439 Spacer
3 8T-4133 Nut
2 6V-1867 Clip
2 6V-1868 Clip
2 6V-1869 Grommet
1 342-6244 Hose As
2 033-6031 O-Ring Seal
5 8T-4194 Bolt
2 228-7120 Clamp
2 8T-4182 Bolt
1 415-4650 Plate
1 8T-4183 Bolt
2 5P-1076 Hard Washer
3 6V-4357 Clip
3 6V-4356 Clip
3 130-8433 Grommet
1 8T-4176 Bolt
1 9V-0999 Spacer
1 194-3450 Plate As
1 8T-4195
1 292-0092 Hose As
2 8T-9527 O-Ring Seal
4 118-4977 Bolt
4 8T-4140 Bolt
1 341-1437 Bracket
2 8T-4779 Bolt
1 216-7557 Clip
1 216-7558 Clip
1 218-3258 Grommet
1 293-3480 Hose As
4 5P-7468 Clip
4 5P-7469 Clip
4 5P-8444 Grommet
1 8T-6868 Bolt
1 1F-1609 Spacer
2 8T-4137 Bolt
1 341-0843 Hose As
1 106-5125 Clip
1 106-5126 Clip
1 9X-7456 Grommet
Table 7
Required Parts to Install the 272-3290 Power Train Oil Lines Gp
1 375-5403 Hose As
4 8T-4183 Bolt
1 5P-7470 Clip
1 5P-7471 Clip
1 5P-7703 Grommet
1 5P-7468 Clip
1 5P-7469 Clip
1 5P-8444 Grommet
1 8T-4183 Bolt
1 8T-4244 Nut
Table 8
Parts that are Needed for the Installation of 293-3447 Fan Drive Lines Gp to the Rear
Axle
1 188-2762 Hose As
1 348-9156 Hose As
1 348-9154 Hose As
1 348-9155 Hose As
1 298-7116 Hose As
Table 9
Parts that are Required to Install the 3785 L (1000 US gal) Fuel Tank (1)

4 7X-2489 Bolt
2 8X-2575 Cap
4 8X-2576 Shim Pack
1 297-4213 Plate As
2 7X-2564 Bolt
4 8N-1214 Mount
2 7N-5656 Sleeve
2 7X-2488 Bolt
2 6V-7688 Locknut
1 6G-7803 Vent As
1 9M-7958 Hose Clamp
1 205-7303 Fast Fill Fuel Adapter
297-4210 (2) Hose As
1 362-6658 (3) Hose As
1 348-3667 Support As
12 8T-4139 Bolt
1 317-6443 Plate
1 294-2865 Plate As
2 8T-4244 Nut
(1)
The 272-3453 Fuel Tank Ar uses the 292-1197 Fuel Tank Mounting Gp , and the 362-6670 Fuel Tank Ar uses
the 362-6671 Fuel Tank Mounting Gp .
(2)
Used with the 272-3453 Fuel Tank Ar
(3)
Table 10
Parts that are Required to Install the
5110 L (1350 US gal) Fuel Tank (1)
4 7X-2489 Bolt

2 8X-2575 Cap
4 8X-2576 Shim Pack
1 297-4213 Plate As
2 7X-2564 Bolt
4 8N-1214 Mount
2 7N-5656 Sleeve
2 7X-2488 Bolt
2 6V-7688 Locknut
1 6G-7803 Vent As
1 205-7303 Fast Fill Fuel Adapter
1 362-8377 Hose As
1 294-2865 Plate As
16 8T-4139 Bolt
1 362-8376 Plate
2 8T-4244 Nut
(1)
Both fuel tank arrangements use the 362-8385 Fuel Tank Mounting Gp .
Table 11
4 7X-2489 Bolts
4 8T-4167 Hard Washers
2 8X-2575 Caps
4 8X-2576 Shim Packs
3 7X-2488 Bolts
8 8T-5439 Hard Washers
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6 8N-1214 Mount As
3 6V-7688 Locknuts
3 7N-5656 Sleeves
1 196-9873 Plate As
2 7x-2564 Bolts
1 205-7303 Adapter
1 6G-7803 Vent As
297-4214 (2) Hose As
1
362-6656 (3) Hose As
1 294-2865 Plate As
16 8T-4139 Bolt
1 8T-4136 (2) Bolt
1 8T-4121 (2) Hard Washer
1 7D-1553 (2) Clip
4 8T-4244 Nut
1 317-6444 Plate
(1)
(2)
(3)
Table 12
Parts that are Needed to Install the 311-8657 Fuel Filter Lines Gp
7 8T-4196 Bolt
6 198-4777 Hard Washer
1 308-5290 Tube As
1 8C-3364 Elbow
3 5P-7701 O-Ring Seal
1 159-4724 Ball Valve

1 8T-7927 Connector
1 9T-3752 Check Valve
1 6V-9853 Elbow
1 178-2345 Liquid Level Sensor Gp (WATER SEPARATOR)
1 130-5300 Clip
1 337-8235 Bracket As
3 8T-4136 Bolt
1 5P-9085 Clip
Table 13
Parts that are Required to Connect the 272-5377 Service Center Gp or the 293-7875
Service Center Gp to the Fuel Tank
1 231-7582 Adapter
1 5H-6734 O-Ring Seal
6 8T-4185 Bolt
4 8T-4183 Bolt
1 4J-0527 O-Ring Seal
Table 14
Parts that are Needed for Installation of 289-8616 Hoist Cylinder Gp
2 297-7969 (1) Dust Cap
2 297-7968 (1) Fitting
2 319-6248 (1) Union As
(1)
Part of the 149-3117 Cylinder Mounting Gp
Table 15
Parts that are Needed for Installation of Hydraulic Tank Guard Group
8 8T-4196 Bolt
2 9T-3988 Filler
2 4M-0189 O-Ring Seal
2 9J-3047 Strainer (HYDRAULIC TANK)
2 2D-4202 Plate
2 7H-1447 Filler Cap (HYDRAULIC OIL)
2 8T-2275 Ball
2 9G-9288 Protection Cap Gp (HYDRAULIC TANK FILL CAP)
2 3G-0361 Gasket
2 9H-6454 Gasket
Table 16
Parts that are Needed for Installation of 217-3084 Suspension Mounting Gp (FRONT)
2 156-5444 Key
2 289-8629 Front Suspension Gp
16 3E-8029 Bolt
16 217-9902 Washer
16 9X-8399 Washer
16 8T-1583 Nut
24 224-8961 Bolt
24 217-9903 Washer
24 8C-4032 Nut
Table 17
Required Parts to Install the 291-4032 Brake Wear Indicator Gp
2 348-8324 Brake Wear Indicator As
Table 18
Parts that are Needed to Connect the 272-3306 Steering Cylinder and Mounting Gp
1 288-5537 Steering Cylinder Gp (1)
1 194-6171 Steering Cylinder Gp (2)
2 7J-9250 Locknut
(1)
Right hand
(2)
Left hand
Table 19
Parts that are Needed to Connect the 332-7420 Steering Link Gp

2 284-3123 Steering Link Gp
4 7J-9250 Locknut
Table 20
Parts that are Needed to Connect the 272-3369 Brake Cooling Lines Gp to the Front
Suspension Cylinders
2 334-8993 Hose As
2 334-8994 Hose As
Table 21
Parts that are Needed to Connect the 272-3295 Service Brake Control Gp to the Front
2 344-6665 Hose As
2 344-6666 Hose As
4 8T-4139 Bolt
2 7G-3833 Clip
2 7G-3834 Clip
2 7G-3832 Grommet
Table 22
Parts that are needed for Installation 296-5681 Rollover Protective Structure (ROPS)
Mounting Gp
33 147-0170 Bolt
Table 23
Parts that are Required to Connect the 272-3379 Air Cleaner Gp
2 277-0736 Air Cleaner Gp
32 8T-4139 Bolt
Table 24
Parts that are Required to Install the Right Hand Platform with the 272-3376 Platform
Mounting Gp
4 7X-2563 Bolt
1 306-9540 Plate
2 309-9101 Plate
1 384-7915 Plate As
1 384-7913 Plate
1 384-7928 Plate
1 384-7917 Plate
Table 25
Parts that are required to Install the Left Hand Walkway
10 8T-4136 (1) Bolt

6 8T-4195 (2) Bolt
16 8T-4194 (2) Bolt
6 8T-4136 (3) Bolt
12 8T-4194 (3) Bolt
12 198-4778 (3) Hard Washer
(1)
Part of 293-2952 Fender Gp
(2)
Part of 272-3329 Walkway Gp
(3)
Table 26
Parts that are Required to Install the 272-3355 Handrail Gp (1)

1 281-6798 Handrail As
26 8T-4136 Bolt
12 8T-4244 Nut
10 8T-4183 Bolt
14 8T-7087 Grommet
14 5P-7469 Clip
14 5P-7468 Clip
5 115-3580 Plate
2 8T-4184 Bolt
2 146-3287 Bolt
4 9X-8257 Washer
1 300-4511 Latch As
21 248-0102 U-Bolt
4 5C-7261 Nut
1 305-4458 Step Gp
12 8T-4195 Bolt
(1)
Some of the parts may be shipped already secured to the chassis or other components
Table 27
Parts that are Required to Install the 272-3408 Air Lines Gp
1 278-2481 Tube As (1)
4 273-3538 Hose
4 5T-6459 Elbow (1)
16 219-0313 Clamp
16 251-0039 Clamp
1 278-2482 Tube As (1)
1 278-2479 Tube As (1)
1 278-2480 Tube As (1)
4 201-1378 Spacer
2 233-6699 Rod As
2 242-0810 Clamp
2 242-9806 Clamp As
4 8T-4244 Nut
2 8T-4910 Bolt
2 8T-5041 Bolt
2 291-1412 Clamp As
2 291-1442 Clamp As
20 7X-7729 Washer
6 8T-4133 Nut
2 8T-4178 Bolt
2 8X-3635 Strip
2 291-1443 Plate
4 291-1444 Plate
4 6V-7744 Locknut
8 8T-4195 Bolt
2 9X-6605 U-Bolt
(1)
Thoroughly clean the inside of the component before installation.
Table 28
Parts that are Required to Install the 272-3248 Sensor Wiring Gp
2 277-7045 Sensor Harness As

22 1S-0994 Clip
32 8T-4137 Bolt
4 130-5300 Clip
4 9X-0262 Adapter
4 161-9926 Pressure Sensor Gp
4 328-2797 Plate As
1 4D-7794 Clip
Table 29
Parts that are Needed for Installation of the 272-3371 Mirror Gp
1 311-3276 Tube As
5 7D-9969 Support
5 8T-6868 Bolt
4 134-0989 Block
8 8T-4185 Bolt
1 311-7058 Mirror Gp
5 8T-4136 Bolt
1 311-3272 Tube As
2 7X-3391 Hard Washer
1 153-4010 Mirror As
1 265-6628 Bracket
2 7Y-5262 U-Bolt
4 8T-4133 Nut
1 275-5588 Mirror As
Table 30
Parts that are required to Install the 276-6080 Cab Mounting Gp
8 6Y-9950 Mount As
8 9W-7385 Sleeves
8 9W-7388 Washers
2 287-3037 Pin as
2 304-0299 Pin as
8 233-6978 Hard Washers
4 7X-7729 Washers
8 8T-0672 Bolts
4 8T-4195 Bolts
Table 31
Parts that are Required to Connect the 277-3328 Chassis Wiring Gp

4 8T-4137 Bolt
2 8T-6466 Bolt
2 6W-7636 Spacer
2 6D-4247 Clip
2 9D-1829 Clip
Table 32
Parts that are Required to Connect the 272-3251 Heater Lines Gp
2 9X-2488 Hose Clamp
1 8T-6466 Bolt
1 6W-7636 Spacer
2 9X-8250 Clip
Table 33
1 8T-4179 Bolt
1 8T-6466 Bolt
1 6W-7636 Spacer
2 2V-1771 Grommet
2 6D-4246 Clip
2 4D-7388 Clip
Table 34
Parts that are Needed for Installation of the Radiator Module

14 7X-2489 Bolt (1)
14 198-4782 Hard Washer (1)
6 8T-4956 Bolt (2)
6 5P-1076 Hard Washer (2)
4 8T-4186 Bolt (3)
8 8T-4121 Hard Washer (3)
4 8T-4133 Nut (3)
1 310-6863 Expansion Tank As (4)
8 8T-4186 Bolt (4)
4 8T-4910 Bolt (4)
1 1P-3709 Rectangular Seal (4)
1 217-4193 Hose (5)
4 239-5609 Clamp (5)

1 7D-8991 Hose (5)
4 220-4126 Clamp (5)
2 273-3538 Hose (6)
8 135-6261 Clamp (6)
(1)
Part of the 272-3254 Cowling Gp
(2)
Part of the 338-0001 Radiator Gp
(3)
Part of the 272-3255 Ladder Gp
(4)
Part of the 272-3257 Water Lines Gp
(5)
(6)
Part of the 289-3269 Air Lines Gp
Table 35
Parts that are Required for Installation of the 272-3409 Water Lines Gp
1 333-7690 Hose As
1 334-3678 Plate As
1 9X-2494 U-Bolt
2 2K-4973 Locknut
1 5P-7468 Clip
1 5P-7469 Clip
1 6V-4349 Grommet
1 8T-4139 Bolt
1 153-6237 Elbow As
1 148-8408 Plug As
Table 36
Parts that are Required for Installation of the 288-2624 Air Lines Gp
1 328-9073 Tube As
1 328-9072 Tube As
2 294-7373 Hose
8 135-6261 Clamp
2 334-3675 Hose
4 342-1323 Band Clamp
4 8T-4956 Bolt
1 328-9684 Plate As
1 329-3050 Plate As
8 8T-4183 Bolt
6 329-3555 Half Clip
8 8T-4195 Bolt
1 344-2658 Plate
6 8T-4186 Bolt

6 8T-4133 Nut
4 8T-4244 Nut
1 292-6724 Plate As
15 8T-4137 Bolt
Table 37
Parts that are Required for Installation of 272-3282 Truck Hood Gp
1 346-4338 Plate As
114 8T-4136 Bolt
50 7X-7729 Washer
1 346-4331 Plate As
1 346-4220 Plate As
1 346-4386 Plate As
1 346-4389 Plate As
4 8T-4195 Bolt
1 346-4392 Plate As
1 346-4226 Plate As
1 346-4342 Hood Panel As
5 347-4475 Strut
1 358-5498 Plate
2 347-1000 Plate As
14 8T-4133 Nut
3 320-6679 Prop Assembly
3 346-4337 Plate
3 9D-8353 Pin
3 3B-4627 Cotter Pin
6 8T-4189 Bolt
4 347-4474 Strut As
1 346-4411 Plate As
6 8Y-4000 Latch As
12 5B-2183 Jam Nut
12 3T-7857 Button Plug
2 358-9608 Plate
4 358-9609 Plate
Table 38
Required Parts to Install the 328-1180 Stairway Gp (Powered Access)
1 328-1150 Platform Gp
8 8T-7338 Bolt
1 328-1181 Stairway As
2 328-1178 Hub
2 5A-4885 Plug Button
16 8T-4182 Bolt
1 354-0504 Handrail Gp
1 354-0505 Handrail Gp
8 8T-4136 Bolt
1 347-2419 Pipe As
1 348-5606 Pipe As
2 348-5587 Pipe As
8 8C-8585 Screw
8 9X-2027 Washer
8 336-7053 Bushing
2 8T-4179 Bolt
1 341-5895 Strap
Table 39
Parts that are Required to Install the 272-3377 Walkway
3 8T-4956 Bolt
3 8T-4139 Bolt
Table 40
Parts that are Needed for Installation of the 293-0351 Step Gp
1 292-5639 Step As
8 8T-4186 Bolt
Table 41
Parts that are Needed for Installation of Grease Tank and the Fast Fill Control Box
4 8T-4956 Bolt
Table 42
Parts that are Needed for Installation of 293-2952 Fender Gp
1 345-9152 Plate As
21 8T-4136 Bolt
1 344-7325 Mud Guard
128 8T-4195 Bolt
125 8T-4222 Plated Washer

3 347-4043 Strip
1 345-9153 Plate As
4 8T-4779 Bolt
4 9X-8257 Washer
6 347-6605 Strip
14 8T-4139 Bolt
1 344-9298 Plate As
6 8T-4137 Bolt
1 341-2483 Plate As
1 306-7545 Mud Deflector
1 306-7555 Mud Deflector
1 321-7481 Plate As
1 305-5573 Plate As
1 321-7489 Plate
1 321-7490 Plate
1 348-3039 Strip
1 294-4886 Plate As
1 321-7480 Plate As
2 321-7487 Plate
1 321-7486 Strip
4 8T-4244 Nut
2 8T-4956 Bolt
2 306-9575 Plate As
16 8T-4137 Bolt
1 330-4316 Plate
Table 43
Required Parts to Install the 375-2497 Heat Shield Gp (TIRE)
6 372-3111 Gusset Assembly
2 372-3117 Angle As
50 8T-4136 Bolt
1 352-5028 Heat Shield As
1 371-5839 Baffle
1 387-7498
2 355-6155 Plate
8 6V-8214 Bolt
1 393-5257 Baffle
Table 44
Required Parts to Install the 139-7662 Rim Mounting Gp
324 8C-4032 Nut
2 282-6635 (1) Adapter As
96 147-0170 (1) Bolt
96 146-1799 (1) Hard Washer

2 146-4279 (2) Cap
2 203-4702 (2) Valve

2 201-6654 (2) Hose As
2 6V-9746 (2) O-Ring Seal
2 203-4703 (2) Adapter
4 8T-4910 Bolt
2 203-4705 Plate
4 3W-1100 Spacer
2 201-6656 Guard
8 7X-2555 Bolt
36 9X-8257 Washer
18 220-7281 Plate
18 8T-4779 Bolt
8 197-0620 Guard As
28 7X-2552 Bolt
12 197-0621 Bracket
4 148-0366 Bracket
(1)
Part of 292-2170 Final Drive, Brake, and Wheel Gp
(2)
Part of 176-8358 Rim Mounting Gp
Table 45
Parts that are Needed for Installation of 288-1161 Battery Box Gp
1 343-4611 Plate
1 341-9402 Plate
1 343-4610 Plate
25 8T-4137 Bolt
Table 46
Parts that are Needed for Installation of the 272-3245 Ether Starting Aid Gp

3 7X-1062 Ether Cylinder As
Table 47
Parts that are Needed to Install the Body
2 295-6917 Pin As (1)
10 154-1808 Plate (1)
4 295-6901 Plate (1)
16 7X-2553 Bolt (1)
16 9X-8257 Washer (1)
2 295-4144 Pin As (2)
4 151-0888 Spacer (2)

2 295-6881 Plate (2)
8 8T-4193 Bolt (2)
16 9X-8257 Washer (2)
2 295-6882 Plate (2)

8 8T-4140 Bolt (2)
2 153-7961 Plate (1)
1 153-7963 Deflector (1)
10 8T-4196 Bolt (1)

10 8T-4133 Nut (1)
1 172-4299 Deflector (1)
2 336-0743 Cable As (1)
2 219-5893 Clevis (1)
2 195-5952 Plate As (3)
2 207-2832 Ejector (1)
2 185-6715 Pin (1)
4 3B-4647 Cotter Pin (1)
2 3D-0404 Washer (1)
10 173-5403 Pad As (1)

30 8T-4910 Bolt (1)
30 7D-1649 Hard Washer (1)
30 8T-4244 Nut (1)
74 147-5073 Shim (1)
2 147-5075 Pad As (1)
2 192-5280 Plate As (1)
2 236-5558 Plate As (1)
2 149-1927 Pin (1)
4 149-1926 Plate (1)
8 8T-4192 Bolt (1)
6 8T-4184 Bolt (1)
2 149-4621 Guide (1)
1 158-0488 Rod As (4)
1 8T-4195 Bolt (4)
1 8T-4133 Nut (4)
1 8T-7547 Bolt (4)
2 9M-1974 Hard Washer (4)
1 5C-7261 Nut (4)

(1)
Part of the 293-5065 Truck Body Mounting Gp
(2)
(3)
Part of 290-6420 Body and Canopy As or 290-6421 Body and Canopy As
(4)
Part of 277-3328 Chassis Wiring Gp
Table 48
Parts that are Needed for the Installation of 295-0534 Film Gp
1 295-0537 Film
1 332-5861 Film
1 332-5860 Film
Table 49
Required Parts to Install the 353-8326 Sound Suppression Panel Gp for the Sound
Suppression Arrangement
1 371-5786 Sound Suppression Panel Gp
22 8T-4195 Bolt
11 393-5277 Plate
44 8T-4136 Bolt
2 193-9723 Washer
1 372-3117 Angle As
1 371-5839 Baffle

1 355-6155 Plate
4 6V-8214 Bolt
Table 50
1 371-5831 Plate
53 8T-4136 Bolt
37 8T-4137 Bolt
5 393-5277 Plate
1 354-6048 Cover
1 354-6049 Cover
7 7K-1181 Cable Strap
2 372-3117 Angle As
Table 51
Required Parts to Install the 353-8369 Sound Suppression Gp for the Sound Suppression
Arrangement
1 372-1969 Silencer
1 373-1400 Silencer
1 373-1401 Silencer
2 373-1402 Silencer
7 373-1403 Silencer
9 373-1404 Silencer
6 373-1405 Silencer
1 373-1406 Silencer
1 373-1407 Silencer
4 373-1408 Silencer
1 373-1409 Silencer
2 373-1410 Silencer
1 373-1957 Silencer
1 373-1958 Silencer
1 373-1959 Silencer
1 373-1960 Silencer
96 8T-4195 Bolt
96 8F-6437 Washer
22 8T-4171 Bolt
Table 52
2 386-5195 Plate As
60 8T-4136 Bolt
2 353-8365 Plate As
2 393-5277 Plate
1 (1) 3E-8349 Seal
20 8T-4138 Bolt
20 9X-8256 Washer
2 383-3318 Plate As
2 370-5894 Plate As
12 8T-4137 Bolt
2 383-2240 Strut
4 247-1913 Ball Stud
4 5C-7261 Nut
4 8T-4193 Bolt
(1)
835 cm (328.7 inch)
Table 53
Arrangement
1 353-8329 Cover As
6 8T-4189 Bolt
6 4B-4278 Washer
3 355-6162 Plate
1 353-8335 Cover As
1 353-8333 Cover As
1 353-8331 Cover As
18 191-8439 Boss
18 8T-4139 Bolt
Table 54
Arrangement
8 8T-4137 Bolt
2 354-5990 Strip
1 354-5984 Silencer
2 354-5985 Strip
10 8T-5005 Bolt
10 266-5360 Washer
Table 55
Arrangement
5 372-6349 Silencer
2 372-6350 Silencer
11 372-6352 Silencer
4 372-6354 Silencer
2 373-0028 Silencer
87 160-0240 Dowel
87 8T-4171 Bolt
Table 56
Arrangement
45 7K-1181 Cable Strap
1 355-6148 Silencer
1 355-6149 Silencer
1 355-6150 Silencer
1 355-6151 Silencer
1 355-6152 Silencer
1 373-0140 Silencer
1 373-0141 Silencer
Approximate Weights
Personal injury or death can result from lifting a heavy assembly.
The heavy assembly can fall if using an incorrect hoist to lift the load.
Be sure the hoist has the correct capacity to lift a heavy assembly.
Approximate weight of the assembly is given below.
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.
Table 57
Module Weight
Approximate Truck Chassis Shipped Weight

68050 kg (150000 lb)
Rear Axle Assembly

42200 kg (93000 lb)
Radiator Module
4720 kg (10400 lb)
Front Suspension Cylinder, Wheel, and Brake Assembly

9153 kg (20180 lb)
Transmission
6677 kg (14720 lb)
Right Side Platform Assembly

2800 kg (6140 lb)
Upper Rear Axle Link

460 kg (1020 lb)
Lower Rear Axle Link

454 kg (1000 lb)
Link Pins 52 kg (115 lb)
Rear Suspension Cylinder

862 kg (1900 lb)
Pins for the Rear Suspension

62 kg (137 lb)
Rear Axle Oil Cooler

59 kg (130 lb)
Hoist Cylinder
1425 kg (3150 lb)
Cab Support (front) 750 kg (1650 lb)
Cab Support (rear)

900 kg (1980 lb)
Cab Assembly
3100 kg (6840 lb)
Fuel Tank
7570 L (2000 US gal) 2900 kg (6400 lb)
Fuel Tank
3785 L (1000 US gal) 1800 kg (3975 lb)
Main Drive Shaft

290 kg (635 lb)
Tire and Rim Assembly

7484 kg (16500 lb)
Assembled Truck Body with liners 51256 kg (113000 lb)
Hinge Pin for the Truck Body

66 kg (146 lb)
Hoist Cylinder to Body Pin

47 kg (104 lb)
Mounting Bracket for the Rock Ejector

71 kg (157 lb)
Rock Ejector
75 kg (165 lb)
Specifications
Table 58
Areas that are Measured Specifications
Empty weight 252000 to 281000 kg (555550 to 619500 lb) (1)
Wheel Base
719 cm (283 inch)
Length
1509 cm (594 inch)
Loading Height
706 cm (278 inch)
Height at full dump (body raised)

1570 cm (618 inch)
Overall Outside Body Width 975 cm (384 inch)

(1)
The empty weight of the 797F will depend on the configuration and the options
Torque Specifications
Note: All of the fasteners will need to be tightened to the standard torque for that particular thread.
Do not use thread lock or thread lubricant. A tightening specification is provided only when a
special torque is required. The following items are examples of fasteners that require special
tightening specifications:
• High/low tightening specification
• Torque turn
• Thread lock
• Anti-seize
• Tighten 14 bolts for the radiator module (1) to a torque of 800 ± 100 N·m (590 ± 75 lb ft).
• Tighten clamps for the air lines to the radiator module to a torque of 7.5 ± 1 N·m (66 ± 8.8
lb in)
• Tighten two V-band clamps for the air lines to the radiator module to a torque of 7.5 ± 1
N·m (66 ± 8.8 lb in)
• Tighten two V-band clamps for the air lines to the radiator module to a torque of 17 ± 3
N·m (150 ± 26 lb in)
• Tighten 16 bolts for the rear axle housing group to a torque of 1800 ± 200 N·m (1320 ± 150
lb ft)
• Tighten eight bolts for the drive shaft to a torque of 1000 ± 125 N·m (740 ± 92 lb ft)
• Tighten the upper 16 nuts for front suspension group to a torque of 800 ± 80 N·m (590 ± 60
lb ft). After torque, turn an additional 120° +20° −0°.
• Tighten the lower 24 nuts for front suspension group to a torque of 1000 ± 100 N·m (740 ±
75 lb ft). After torque, turn an additional 120° +20° −0°.
• Tighten clamps for the air lines to the engine to a torque of 10 ± 2 N·m (88 ± 18 lb in)
• Tighten pressure sensor groups for the air lines to the engine to a torque of 10 ± 2 N·m (88
± 18 lb in)
• Tighten the locknut on mirror assembly to a torque of 25 ± 5 N·m (220 ± 44 lb in)
• Tighten 33 bolts for the cab mounting group to a torque of 2800 ± 350 N·m (2065 ± 260 lb
ft)
• Tighten eight bolts for the cab mounting group to a torque of 800 ± 100 N·m (590 ± 75 lb
ft).
• Tighten the hose assembly for the air conditioner lines group to a torque of 62 ± 1 N·m (550
± 9 lb in)
• Tighten the hose assembly for the air conditioner lines group to a torque of 49 ± 1 N·m (433
± 9 lb in)
• Tighten the clamps for the heater lines group to a torque of 4.5 ± 0.5 N·m (40 ± 4.5 lb in)
• Tighten the bracket assemblies for the exhaust lines group to a torque of 16 ± 4 N·m (142 ±
35 lb in)
• Tighten the band clamps for the exhaust lines group to a torque of 16 ± 4 N·m (142 ± 35 lb
in)
• Tighten the bolts that secure the fuel tank to a torque of 800 ± 100 N·m (590 ± 75 lb ft)
• Tighten liquid level sensor group for the fuel tank to a torque of 10 ± 3 N·m (88 ± 26 lb in)
Specifications for Cables, Chains, and Lifting Devices

Use approved cables, chains, and lifting devices in order to lift components. Refer to the literature
from the manufacturer in order to determine the application when you select the items that follow:
cable, chain and lifting devices. When you lift a component, the lift angle is critical. Refer to the
Illustration that follows in order to see the effect of the lift angle on the working load limit.
Illustration 1 g00629745
Lift angles for lifting slings.
(A) The load capacity is 100 percent of the working load limit for the sling.
(B) The load capacity is 86 percent of the working load limit for the sling.
(C) The load capacity is 70 percent of the working load limit for the sling.
(D) The load capacity is 50 percent of the working load limit for the sling.
Necessary Hoist Capacity

A minimum of two 72580 kg (160000 lb) hoists are needed to remove the truck frame from the
trailer.
Two 90720 kg (200000 lb) hoists are needed to lift the body assembly onto the truck.
797F Assembly Tips

Note: Follow the table of contents for the assembly sequence of the truck.
Note: Due to some shipping requirements, the engine may not be shipped already installed. If
needed, refer to Disassembly and Assembly, KENR8384, "Engine and Torque Converter -
Remove and Install" for instructions on installing the engine.
1. The assembly of the 797F requires four mechanics for a total of approximately 750 hours.
Two crane operators are required until the major components are installed.
2. After assembly is complete, prepare the machine for use. Refer to the following service
information: Operations and Maintenance Manual, SEBU8417 and Parts Manual,
SEBP4986.
Necessary Equipment and Supplies for Assembly

The following items are required for the field assembly of the 797F Off-Highway Truck:
• Nine 208 L (55 US gal) barrels of hoist, brake cooling, steering, and brake system oil
(TDTO, TO-4). SAE viscosity grade 10 is recommended. Refer to the Operation and
Maintenance Manual, SEBU8417 for more details.
• Six barrels of transmission, torque converter, and fan drive oil (TDTO, TO-4). Each barrel
is equivalent to 208 L (55 US gal). The recommended SAE viscosity grade is 30. Refer to
the Operation and Maintenance Manual, SEBU8417 for more details.
• Six barrels of extended life coolant (ELC) are required. Each barrel is equivalent to 208 L
(55 US gal). Commercial grade(ELC) that meets (EC-1) is acceptable. Refer to the
Operation and Maintenance Manual, SEBU8417 for more details.
• One 38 L (10 US gal) SAE viscosity grade 90 EP oil. This oil will be used for the
suspension pins and the suspension links. Refer to the Operation and Maintenance Manual,
SEBU8417 for more details.
• Cables, straps, and chains that have adequate capacity
• Two shackles with a load limit of 122460 kg (270000 lb)
• Two shackles with a working load limit of 72580 kg (160000 lb)
• One air compressor that has a minimum capacity of 3 CM (100 CFM) and capable of
operating two air driven tools
• Several hardwood blocks that are 203 mm (8 inch) square and 122 cm (48 inch) long
• Step ladders that are 1.8 m (6 ft) tall
• Step ladders that are 3.6 m (12 ft) tall
• At least 7.6 m (300 inch) of rope that is 19 mm (0.75 inch) in diameter
• 20 nitrogen bottles that are T-size
• A lift truck with a minimum capacity of 9072 kg (20000 lb)
• Tire handler that can lift a minimum of 9072 kg (20000 lb)
• Two man lifts with a minimum lift height of 6 m (20 ft)
• Four 7X-1062 Ether Cylinders
• Paint spray gun
• Four 138-7573 Link Brackets , four 138-7575 Link Brackets , four 138-7574 Link Brackets
and four 138-7576 Link Brackets
• Four metal stands that support the truck body
• Paint Remover
• Molybdenum Grease
• Thread Sealant
• Thread Lubricant
• Anti-Seize Compound
• O-Ring Assembly Compound
• Paint
• 376-4554 Pin As
Required Tools
The following tools are required for the field assembly of the 797F Off-Highway Truck:
• 176-6537 Spanner Wrench
• 194-7592 Pneumatic Wrench Gp
• 9U-5007 Torque Wrench Gp capable of measuring torque values under 810 N·m (600 lb ft).
• 132-8206 Hydraulic Torque Wrench capable of measuring torque values up to 4200 N·m
(3100 lb ft).
• 132-8159 Hydraulic Torque Wrench Gp capable of measuring torque values up to 5080

N·m (3750 lb ft).
• Use a 132-8112 Torque Wrench Gp to torque the 7J-9250 Locknut .
• 234-6041 Socket for the 7J-9250 Locknut
• 175-5507 Nitrogen Charging Group
• 175-7410 Nitrogen Charging Fitting Gp
• 6V-4040 Inflation Group
• 9U-5617 Oil Refill Pump
• 4C-4970 M36 X 4 Metric Thread Tap
• 156-0058 Hose Cleaner Gp
• 1P-3515 Open End Wrench Gp
• Two 127-2277 Open End Wrenches
• Two 4C-6951 Lever Pullers
• 8T-0447 Dial Caliper
• 8T-0447 Dial Caliper
• 4C-4911 Battery Load Tester
• 8T-0900 Ammeter
• 6V-7070 Digital Multimeter
• 376-4554 Pin As
• Lint free cloths
• Have a magnetic base level on hand in order to level the right-hand platform.
Site for the Assembly of the 797F Off-Highway Truck
Illustration 2
Typical view of the layout for the 797F Off-Highway Truck
(AA) Chassis
(AB) Cab
(AC) Radiator Module
(AD) Right Hand Platform
(AE) Front Suspension Cylinder
(AF) Links for the Rear Axle
(AG) Rear Suspension Cylinders
(AH) Parts box
(AJ) Parts box
(AK) Parts box
(AL) Rear Axle Assembly
(AM) Fuel Tank
(AN) Front Suspension Cylinder
(AP) Left Hand Walkway
(AR) Ari Cleaners
1. The work area for the truck chassis and the components should be level, flat, smooth, and
drained. An area of approximately 37 m (120 ft) by 37 m (120 ft) is needed for the assembly
of the truck.
Typical view of the lifting points for the 797F Off-Highway Truck
2. The truck chassis should be located in the center of the assembly area. Keep the assembly
area around the truck chassis clear. Also, the assembly area needs to be unobstructed in
order for the crane to lift the components correctly.
Unload the Components for Assembly

View of the Components
Typical view of the 797Fchassis
Typical view of the rear axle assembly
Typical view of a trailer with the radiator module and shipping crates
Typical view of a trailer with the front suspension cylinders
Typical view of a trailer with the transmission, fuel tank, rear suspension cylinders, cab mounts, and a shipping crate
Typical view of a trailer with the right-hand platform, left-hand walkway group, and the cab
Unload the Components
Typical view of a Lifting Diagram
The lifting diagram is located on the left frame rail near the front of the machine.
1. Attach a suitable cable or strap at four places on the chassis.
2. Use two cranes in order to lift the 797F chassis from the trailer. The approximate weight of
the chassis is 68050 kg (150000 lb).
3. Carefully lower the chassis onto support blocks or metal stands.
Note: 210 cm (6.9 ft) is the height that is required to install the rear tires.
Note: 210 cm (6.9 ft) is the height that is required to install the front tires.
View of the rear axle assembly
View of the fuel tank
View of the cab
View of the front suspension cylinders
View of the skid with the left-hand walkway and the air cleaners
View of the skid with the right-hand platform
View of the radiator module
View of the transmission
View of the cab mounts
View of the hoist cylinders
View of the rear suspension cylinders
4. Use a suitable lift truck or a suitable crane in order to remove the components from the
trailers.
Refer to Table 57 for the approximate weight of the components.
5. Refer to Illustration 2 for the suggested placement of the components.
6. Set the wooden boxes of smaller components out of the way. Open the boxes and check the
components that are in each box.
NOTICE
Do not open the contents of the plastic part bags until parts are ready
for assembly. Once the bags are opened and the parts are removed, the
identity of the part number and the next group level may be lost. Both
of these numbers are necessary in order to facilitate the assembly of the
truck.
7. Organize the hardware by the next group level. Do not open the bags of hardware.
Install the Components at the Rear End

Remove the Tie Down Eyes from the Frame
Typical view of the location of the tie down eyes to be removed
(A) 15 ± 2 mm (0.59055 ± 0.07874 inch)
NOTICE
Do not grind through the weld or the parent material of the frame.
1. Use a torch or a carbon arc method in order to remove the four eyes from the frame. Leave
the weld and the parent material to dimension (A) .
2. Clean all the areas that were affected in Step 1. Paint the areas in order to inhibit rust.
Use the 149-3054 Rear Suspension Gp to Secure the Rear Axle Housing Group
Table 59
Parts that are Needed for Installation of the 189-2561 Rear Axle Housing Gp
Item Qty Part Number Description
1 2 200-0885 (1) Lower Link
2 16 112-1579 (1) O-Ring Seal
3 8 156-9804 (1) Pin

4 16 156-9803 (1) Collet
5 16 9X-8399 (1) Washer
6 16 8T-0368 (1) Bolt
7 2 306-8202 (1) Upper Link
(1)
Table 60
Tools that are Needed for Installation of the 189-2561 Rear Axle Housing Gp
Tool Qty Tool Number Tool
A 1 4C-9485 Pin Driver Cap

B 1 176-6544 Collet Gauge
C 1 222-3055 Impact Wrench
D 1 331-3626
Note: The two lower links (1) should be installed first. The two upper links (7) should be installed
after the two lower links (1) are installed.
View of the links in the shipping container
1. Prepare links (1), links (7), and pins (3) for installation by removing any wax, debris,
grease, oil, or paint from the mating surfaces.
Note: The approximate weight of link (1) is 454 kg (1000 lb).
Note: The approximate weight of link (7) is 460 kg (1020 lb)
Note: The approximate weight of pin (3) is 53 kg (117 lb)
2. Install the four O-rings (2) into the grooves in the bores on link (1). After O-rings (2) are
installed, lubricate O-rings (2) with the fluid that is being sealed.
3. Use a suitable lifting device in order to lift link (1). The weight of link (1) is approximately
454 kg (1000 lb).
4. Position link (1) into the truck frame.
5. Use a suitable lifting device to lift pin (3). The weight of pin (3) is approximately 52 kg
(115 lb).
6. Install pin (3) into the bore of link (1) .
7. Use Tool (A) in order to drive pin (3) into the bore.
8. Use Tool (B) in order to center pin (3) into the pin bore.
9. Use Tool (C) in order to tighten the bolt for Tool (B). Once pin (3) has been centered
remove Tool (B) .
10. Clean the inside diameter and clean the outside diameter of collet (4). Lubricate the inside
diameter of collet (4) with 4C-5599 Anti-Seize Compound . Install collet (4) into the bore.
11. Apply 4C-5599 Anti-Seize Compound to bolt (6). Install bolt (6) and install washer (5).
Note: Bolt (6) requires a special torque procedure. This procedure must be followed in
order to ensure proper torque of the components. Refer to Step 11.a for the torque
procedure.
a. Tighten bolt (6) to a torque of 1800 ± 200 N·m (1320 ± 150 lb ft) and then strike the
joint in order to cause the torque to drop below 950 N·m (700 lb ft). Again torque bolt
(6) to a torque of 1800 ± 200 N·m (1320 ± 150 lb ft). Strike the joint in order to cause
the torque to drop below 1600 N·m (1180 lb ft). Final torque of bolt (6) is 1800 ± 200
N·m (1320 ± 150 lb ft).
12. Repeat Step 8 through Step 11 for the opposite collet (4) on the link bar.
13. Repeat Step 1 through Step 12 for the other lower link (1) .
14. Install four O-rings (2) into the grooves in the bores on upper link (7). After O-rings (2) are
installed, lubricate O-rings (2) with the fluid that is being sealed.
15. Use a suitable lifting device in order to lift link (7) to the truck. The weight of link (7) is
approximately 460 kg (1020 lb).
16. Position link (7) to the chassis.
(115 lb). Install pin (3) into the bore of upper link (7) .
remove Tool (B) .
22. Apply 4C-5599 Anti-Seize Compound to bolt (6). Install bolt (6) and install washer (5) .
procedure.
N·m (1320 ± 150 lb ft).
23. Repeat Step 20 through Step 22.a for the opposite collet (4) on the upper link.
24. Repeat Step 14 through Step 23 for the other upper link assembly.
Note: If the links will be sitting for an extended time, cover the bore in order to prevent
contamination.
25. Use a suitable device in order to support upper links (7). Upper links (7) must be supported
in order to install the rear axle.
26. Use a suitable lifting device in order to lift the rear axle assembly. The axle assembly
weighs 42184 kg (93000 lb).
27. Position the rear axle in order to connect upper links (7) .
Note: Moving or disconnecting some hose assemblies may be required in order to get the
rear axle to align properly.
(115 lb).
29. Install pin (3) into the bore.
30. Use Tool (B) in order to drive pin (3) into the bore.
remove Tool (B) .
34. Apply 4C-5599 Anti-Seize Compound to bolt (6). Install bolt (6) and install washer (5) .
procedure.
N·m (1320 ± 150 lb ft).
35. Repeat Step 30 through Step 20 for the opposite collet (4) on the link (7) .
36. Repeat Step 27 through Step 35 for the opposite upper link bar (7) .
37. Use a suitable lifting device in order to align lower link (1) with the rear axle housing.
Note: You may need to rotate the axle housing in order to align the axle housing with lower
link (1) .
38. Use a suitable lifting device in order to lift pin (3). The weight of pin (3) is approximately
52 kg (115 lb). Install pin (3) into the bore.
41. Use an air impact wrench in order to tighten the bolt for Tool (B). Once pin (3) has been
centered remove Tool (B) .
procedure.
N·m (1320 ± 150 lb ft).
44. Repeat Step 40 through Step 29 for the opposite collet (4) on link (1) .
45. Repeat Step 37 through Step 44 for the opposite lower link (1) .
Purge screw for lubricating the link
46. After lower links (1) and upper links (7) are installed, the links must be lubricated. Remove
the purge screws. The purge screws are on the top of the links. Removing the purge screws
will ensure that the link is filled with lubrication.
Filler plug for lubricating the links
47. Remove the plug that is located at the bottom of the links in order to access the fill port.
48. Fill the pin bores with oil that is EP SAE viscosity grade 90.
49. The pin bore is full when oil is coming out of the purge port. Install the purge screws.
Installing the purge screws will allow the filler tube to be removed without venting
lubrication from the pin bores.
50. Install the plug.
51. Repeat Step 46 through Step 50 for the other seven pin bores.
Install the 289-8618 Rear Suspension Ar

Table 61
Parts that are Needed for Installation of 289-8618 Rear Suspension Ar
Rear Suspension Gp
1 1 289-8620
Left Hand
Rear Suspension Gp
2 1 289-8619
Right Hand
3 8 192-4309 (1) O-Ring Seal
4 4 191-3628 (1) Pin

5 8 191-3629 (1) Collet
6 8 9X-8399 (1) Washer
7 8 8T-0368 (1) Bolt
8 2 157-0221 (1) Suspension Cover
9 4 157-0222 (1) Hose Clamp
(1)
Table 62
Tools that are Needed for Installation of 192-0559 Rear Suspension Gp and the 192-0560
Rear Suspension Gp
Tool Qty Tool Number Description
A 1 4C-9485 Pin Driver Cap
B 1 200-4279 Collet Gauge
1. Prepare the rear suspension cylinders for installation. Remove the shipping restraints.
Prepare to lift the suspension cylinders.
2. Use a suitable lifting device in order to lift suspension cylinder (1) from the shipping crate.
The approximate weight of each suspension cylinder is 860 kg (1900 lb). Remove any wax,
grease, dirt, paint, or debris from the bores on suspension cylinder (1) .
3. Install four O-rings (3) into the pin bores. Use two O-rings (3) per pin bore. After O-rings
(3) are installed, lubricate O-rings (3) with the fluid that is being sealed.
4. Use a suitable lifting device in order to lift suspension cylinder (1) up to the chassis. Each
suspension cylinder weighs approximately 860 kg (1900 lb).
5. Use a suitable lifting device in order to lift pin (4). The approximate weight of pin (4) is 62
kg (137 lb). Align pin (4) with the pin bore.
6. Install Tool (A) into pin (4). Drive pin (4) into the pin bore. Remove Tool (A) .
7. Use Tool (B) in order to center pin (4) into the pin bore. Use an air impact wrench in order
to tighten the bolt for Tool (B). Once pin (4) has been centered remove Tool (B) .
order to ensure proper torque of the components. Refer to Step 9.a for the torque procedure.
N·m (1320 ± 150 lb ft).
10. Repeat Step 7 through Step 9.a for the opposite collet (5) on suspension cylinder (1) .
11. Repeat Step 1 through Step 10 for suspension cylinder (2) on the opposite side.
12. Use a suitable lifting device in order to lift the rear axle housing. Lifting the rear axle
housing is necessary in order to install the pins into the suspension cylinders. The rear axle
weighs 42183 kg (93000 lb).
View of aligning the lower pin bore
13. Repeat Step 5 through Step 13 for both the lower pins.
Purge screws for the pin lubrication
Note: After the suspension cylinders are installed, the pin bores must be lubricated.
14. Remove the purge screws. The purge screws are on the top of the suspension cylinders.
Removing the purge screws will ensure proper oil level.
15. Remove the covers for the oil fill tap.
16. Fill the pin bores with oil that is EP SAE viscosity grade 90. The pin bore is full when oil is
coming out of the purge ports.
17. Install the covers for the oil fill tap.
18. Install the purge screws.
19. Repeat Step 14 through Step 18 for the upper pin bore on the opposite suspension cylinder.
20. Remove the purge screw for the lubrication of the lower pin bores.
21. Remove the covers for the oil fill tap. Fill the pin bores with oil that is EP SAE viscosity
grade 90. The pin bore is full when oil is coming out of the purge valve. Install the covers
for the oil fill tap.
22. Install the purge screw.
23. Repeat Step 20 through Step 22 for the opposite lower pin bore.
24. Remove the wax from the chrome on the suspension cylinder.
25. Install cover (8) onto the suspension cylinder.
26. Install clamps (9) onto cover (8) .
27. Connect the harness for the payload monitoring system.
28. Repeat Step 25 and Step 27 for the opposite suspension cylinder.
29. After the truck is assembled and the body has been installed, charge the suspension
cylinders. Refer to Special Instruction, SEHS9411, "Servicing the Suspension Cylinders for
Off-Highway Trucks" for the correct suspension cylinder charging procedure.
Install the 149-3100 Transmission Mounting Gp

Table 63
Parts that are Needed for Installation of 284-4240 Transmission Ar

1 1 7X-4781 O-Ring Seal
2 38 9X-8399 Washer
3 38 8C-3236 Bolt
Table 64
Tools that are Needed for Installation of 284-4240 Transmission Ar
A 1 169-3687 Lifting Bracket Gp
B 1 222-3055 Air Impact Wrench
1. If equipped, use a suitable lifting device in order to remove the rear axle oil cooler. The
weight of the oil cooler is 58 kg (130 lb).
2. Remove the shipping cover from the rear axle housing. Discard the shipping cover and the
hardware.
3. Remove the shipping plugs. Remove paint, dirt, debris, rust, or grease from the mating
surface.
4. Use a suitable lifting device to support the shipping cover on the rear of the transmission.
Remove and discard the shipping cover from the transmission.
5. Remove the shipping ring and the related hardware on the rear of the transmission. Discard
the shipping ring.
6. Install Tool (A) in order to lift the transmission from the shipping crate. Use a suitable
lifting device in order to lift the transmission. The weight of the transmission is
7. Remove paint, dirt, debris, rust, or grease from the mating surface of the transmission.
8. Install O-ring (1) into the groove on the transmission. Lubricate O-ring (1) with 1U-6396 O-
Ring Assembly Compound .
9. Lift the transmission to the top of the chassis. Slowly lower the transmission into the
chassis.
10. Slowly lower the transmission. Align the transmission output shaft to the input shaft of the
rear axle. The output shaft and the input shaft must be splined together. Slide the
transmission toward the rear axle.
(2) 9X-8399 Washer
(3) 8C-3236 Bolt
11. Install 38 washers (2) and install 38 bolts (3). Use Tool (B) in order to secure 38 bolts (3).
Final torque for 38 bolts (3) 1600 ± 200 N·m (1180 ± 150 lb ft). Remove Tool (A) .
12. Connect the harness assembly that is located at the rear of the transmission.
13. Connect the two transmission harnesses to the connectors that are located on the rear of the
torque converter.
14. If equipped, install the rear axle oil cooler after the transmission has been installed.
Install the 272-3349 Drive Shaft

Table 65
Parts that are Needed for Installation of 272-3349 Drive Shaft
1 1 284-4881 Slip Joint
2 8 8T-0670 Bolt
Typical view of the drive shaft
1. Cut the retaining straps from slip joint (1) .
2. Grind the welds for the retaining straps.
3. Support slip joint (1) with a suitable lifting device. The approximate weight of slip joint (1)
is 288 kg (635 lb).
4. Extend the slip yoke.
5. Remove any dirt, rust, grease, or debris from the mounting surface of slip joint (1) .
6. Remove any dirt, rust, grease, or debris from the yoke on the transmission and the yoke on
the torque converter.
7. Use a suitable lifting device in order to lift slip joint (1). The approximate weight of slip
joint (1) is 288 kg (635 lb).
Note: Orient slip joint (1) with the female end toward the transmission.
Typical view of the drive shaft that is installed
8. Use eight bolts (2) in order to secure slip joint (1). Tighten eight bolts (2) to a torque of
1000 ± 125 N·m (740 ± 92 lb ft).
Note: Bolts (2) should be tightened in an alternating fashion "X".
Install the 336-7751 Drive Shaft Guard Gp

Table 66
Parts that are Needed for the Installation of 336-7751 Drive Shaft Guard Gp
1 2 336-7746 Plate As
2 10 8T-4139 Bolt
3 10 8T-4223 Hard Washer
4 4 337-4319 Plate
5 40 8T-4136 Bolt
7 1 337-4313 Plate As
8 1 336-7754 Plate As
9 1 336-7757 Plate As
10 1 337-4316 Plate As
11 1 293-5510 Plate As
(1) 336-7746 Plate As
(2) 8T-4139 Bolt
(3) 8T-4223 Hard Washer
1. Install two plate assemblies (1) to two plate assemblies (A) by using eight bolts (2) and
eight washers (3) .
(1) 336-7746 Plate As
(4) 337-4319 Plate
(5) 8T-4136 Bolt
2. Install two plates (4) to the bottom of plate assemblies (1) by using eight bolts (5) and eight
washers (6) .
(1) 336-7746 Plate As
(4) 337-4319 Plate
(5) 8T-4136 Bolt
3. Install two plates (4) to the top of plate assemblies (1) by using eight bolts (5) and eight
washers (6) .
(1) 336-7746 Plate As
(5) 8T-4136 Bolt
(7) 337-4313 Plate As
(8) 336-7754 Plate As
4. Secure one plate assembly (7) and one plate assembly (8) to plate assemblies (1) by using
12 bolts (5) and 12 washers (6) .
(1) 336-7746 Plate As
(5) 8T-4136 Bolt
(9) 336-7757 Plate As
(10) 337-4316 Plate As
5. Secure one plate assembly (9) and one plate assembly (10) to plate assemblies (1) by using
12 bolts (5) and 12 washers (6) .
(2) 8T-4139 Bolt
(11) 293-5510 Plate As
6. Secure one plate assembly (11) to plate assembly (A) by using two bolts (2) and two
washers (3) .
Connect the 272-3351 Power Train Oil Lines Gp to the Transmission

Table 67
Parts that are Needed for Installation of 272-3351 Power Train Oil Lines Gp
1 2 281-5972 Connector As
2 1 9R-4082 Hose As
3 8 8T-4956 Bolt
5 8 8T-4244 Nut
6 1 340-9832 Plate
7 2 5P-7466 Clip
8 2 5P-7467 Clip
9 2 5P-8112 Grommet
10 1 255-0786 Tube As
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11 1 293-5042 Hose As
12 5 6V-4590 O-Ring Seal
13 4 7X-2553 Bolt
14 6 9X-8257 Washer
15 20 8T-4184 Bolt
16 8 1P-4582 Half Flange
17 1 120-5867 Clip
18 1 8T-6466 Bolt
20 1 9R-1439 Spacer
21 3 8T-4133 Nut
22 2 6V-1867 Clip
23 2 6V-1868 Clip
24 2 6V-1869 Grommet
25 1 342-6244 Hose As
26 2 033-6031 O-Ring Seal
27 5 8T-4194 Bolt
29 2 228-7120 Clamp
30 2 8T-4182 Bolt
31 1 415-4650 Plate
32 1 8T-4183 Bolt
33 2 5P-1076 Hard Washer
34 3 6V-4357 Clip
35 3 6V-4356 Clip
36 3 130-8433 Grommet
37 1 8T-4176 Bolt
38 1 9V-0999 Spacer
39 1 194-3450 Plate As
40 1 8T-4195
41 1 292-0092 Hose As
42 2 8T-9527 O-Ring Seal
43 4 118-4977 Bolt
44 4 8T-4140 Bolt
46 1 341-1437 Bracket
47 2 8T-4779 Bolt
48 1 216-7557 Clip
49 1 216-7558 Clip
50 1 218-3258 Grommet
51 1 293-3480 Hose As
52 4 5P-7468 Clip
53 4 5P-7469 Clip
54 4 5P-8444 Grommet
55 1 8T-6868 Bolt
56 1 1F-1609 Spacer
57 2 8T-4137 Bolt
58 1 341-0843 Hose As
59 1 106-5125 Clip
60 1 106-5126 Clip
61 1 9X-7456 Grommet
Illustration 119
View of the left side of the transmission and torque converter
(1) 281-5972 Connector As
(2) 9R-4082 Hose As
(3) 8T-4956 Bolt
(5) 8T-4244 Nut
(6) 340-9832 Plate
(7) 5P-7466 Clip
(8) 5P-7467 Clip
(9) 5P-8112 Grommet
1. Secure hose assembly (2) and two connector assemblies (1) between the back of the torque
converter and the left side of the transmission.
2. Secure one plate (6) to the front bracket above the drive shaft guard group by using one bolt
(3), two hard washers (4), and one nut (5) .
3. Secure hose assembly (2) to plate (6) and the rear bracket above the drive shaft guard group
by using two bolts (3), three hard washers (4), one nut (5), two clips (7), two clips (8), and
two grommets (9) .
Illustration 120
(A) Hose assembly
(10) 255-0786 Tube As
(11) 293-5042 Hose As
(12) 6V-4590 O-Ring Seal
(13) 7X-2553 Bolt
(14) 9X-8257 Washer
(15) 8T-4184 Bolt
(16) 1P-4582 Half Flange
(17) 120-5867 Clip
(18) 8T-6466 Bolt
(20) 9R-1439 Spacer
(21) 8T-4133 Nut
(22) 6V-1867 Clip
(23) 6V-1868 Clip
(24) 6V-1869 Grommet
4. Secure tube assembly (10) and one O-ring seal (12) to the oil filter on the outside of the left
side of the transmission by using four bolts (13) and four washers (14) .
5. Secure hose assembly (11) and two O-ring seals (12) to the rear of the torque converter and
to tube assembly (10) by using eight bolts (15), eight hard washers (4), and four half flanges
(16) .
6. Secure hose assembly (11) to existing hose assembly (A) by using one clip (17), one bolt
(18), two hard washers (19), one spacer (20), one nut (21), one clip (22), one clip (23), and
one grommet (24) .
Note: Hose assembly (A) is part of the 272-3290 Power Train Oil Lines Gp .
Illustration 121
(3) 8T-4956 Bolt
(5) 8T-4244 Nut
(15) 8T-4184 Bolt
(21) 8T-4133 Nut
(22) 6V-1867 Clip
(23) 6V-1868 Clip
(25) 342-6244 Hose As
(26) 033-6031 O-Ring Seal
(27) 8T-4194 Bolt
(29) 228-7120 Clamp
(30) 8T-4182 Bolt
(31) 415-8650 Plate
(32) 8T-4183 Bolt
(33) 5P-1076 Hard Washer
(34) 6V-4357 Clip
(35) 6V-4356 Clip
(36) 130-8433 Grommet
(37) 8T-4176 Bolt
(38) 9V-0999 Spacer
(39) 194-3450 Plate As
(40) 8T-4195 Bolt
7. Secure hose assembly (25) and two O-ring seals (26) to the side of the transmission and the
rear of the torque converter by using eight hard washers (4), four bolts (15), four bolts (27),
and four half flanges (28) .
8. Secure hose assembly (25) to the filter on the left side of the transmission by using two
clamps (29), two bolts (30), four hard washers (19), two nuts (21), one plate (31), one bolt
(32), two hard washers (33), one nut (5), one clip (34), one clip (35), and one grommet
(36) .
9. Secure hose assembly (25) to hose assembly (11) by using one clip (34), one clip (35), one
grommet (36), one bolt (37), two hard washers (4), one spacer (38), one nut (5), one clip
(22), one clip (23), and one grommet (24) .
10. Secure one plate assembly (39) to the front of the guard on the hoist control valve by using
two bolts (3) and two hard washers (4) .
11. Secure hose assembly (25) to plate assembly (39) by using one bolt (40), one hard washer
(19), one clip (34), one clip (35), and one grommet (36) .
Illustration 122
(B) Plate assembly
(3) 8T-4956 Bolt
(5) 8T-4244 Nut
(14) 9X-8257 Washer
(41) 292-0092 Hose As
(42) 8T-9527 O-Ring Seal
(43) 118-4977 Bolt
(44) 8T-4140 Bolt
(46) 341-1437 Bracket
(47) 8T-4779 Bolt
(48) 216-7557 Clip
(49) 216-7558 Clip
(50) 218-3258 Grommet
12. Secure hose assembly (41) and two O-ring seals (42) to the rear of the torque converter and
the left side of the transmission by using four bolts (43), four bolts (44), eight washers (14),
and four half flanges (45) .
13. Secure bracket (46) to existing plate assembly (B) by using two bolts (47) and two washers
(14) .
14. Secure hose assembly (41) to bracket (46) by using two bolts (3) four hard washers (4), four
nuts (5), one clip (48), one clip (49), and one grommet (50) .
Illustration 123
View of the right side of the transmission and torque converter
(C) Tee assembly
(3) 8T-4956 Bolt
(51) 293-3480 Hose As
(52) 5P-7468 Clip
(53) 5P-7469 Clip
(54) 5P-8444 Grommet
(55) 8T-6868 Bolt
(56) 1F-1609 Spacer
(57) 8T-4137 Bolt
15. Connect hose assembly (51) to tee assembly (C) at the rear of the torque converter and the
elbow assembly on the top of the transmission.
16. Secure hose assembly (51) to the front bracket assembly above the drive shaft guard group
by using one bolt (55), one hard washer (4), one spacer (56), one clip (52), one clip (53),
and one grommet (54) .
17. Secure hose assembly (51) to the rear bracket assembly above the drive shaft guard group
by using one bolt (3), one hard washer (4), one clip (52), one clip (53), and one grommet
(54) .
18. Secure hose assembly (51) to the two existing bosses on the top of the transmission by using
two bolts (57), two hard washers (19), two clips (52), two clips (53), and two grommets
(54) .
Illustration 124
(D) Hose assembly
(3) 8T-4956 Bolt
(5) 8T-4244 Nut
(15) 8T-4184 Bolt
(22) 6V-1867 Clip
(23) 6V-1868 Clip
(27) 8T-4194 Bolt
(58) 341-0843 Hose As
(59) 106-5125 Clip
(60) 106-5126 Clip
(61) 9X-7456 Grommet
19. Secure hose assembly (58) and two O-ring seals (12) to the right side of the transmission
and the rear of the torque converter. Use eight bolts (15), eight hard washers (4), and four
half flanges (16) to secure hose assembly (58) .
20. Secure hose assembly (58) to the right side of the bracket assembly above the drive shaft
guard group by using one bolt (3), one hard washer (4), one clip (22), one clip (23), and one
grommet (24) .
21. Secure hose assembly (58) to existing hose assembly (D) by using one bolt (27), two hard
washers (4), one nut (5), one clip (22), one clip (23), one grommet (24), one clip (59), one
clip (60), and one grommet (61) .
Note: Hose assembly (D) is part of the 272-3289 Hoist Lines Gp .
Connect the 272-3290 Power Train Oil Lines Gp to the Transmission

Table 68
Required Parts to Install the 272-3290 Power Train Oil Lines Gp
1 1 375-5403 Hose As
2 1 228-7095 O-Ring Seal
4 4 8T-4183 Bolt
7 1 5P-7470 Clip
8 1 5P-7471 Clip
9 1 5P-7703 Grommet
10 1 5P-7468 Clip
11 1 5P-7469 Clip
12 1 5P-8444 Grommet
13 1 8T-4183 Bolt
14 1 8T-4244 Nut
1. Remove the bolts, washers, and flanges from the bottom of the right side of the
transmission. Discard the hardware.
Illustration 126
View of the right side of the transmission
(1) 375-5403 Hose As
(2) 228-7095 O-Ring Seal
(4) 8T-4183 Bolt
(7) 5P-7470 Clip
(8) 5P-7471 Clip
(9) 5P-7703 Grommet
(10) 5P-7468 Clip
(11) 5P-7469 Clip
(12) 5P-8444 Grommet
(13) 8T-4183 Bolt
(14) 8T-4244 Nut
2. Secure hose assembly (1), O-ring seal (2), and O-ring seal (3) to elbow (B) on the side of
the transmission and elbow (A) on the pump drive. Use four bolts (4), four hard washers (5),
and two half flanges (6) to secure hose assembly (1) .
3. Secure hose assembly (1) to hose assembly (C) by using one clip (7), one clip (8), one
grommet (9), one clip (10), one clip (11), one grommet (12), one bolt (13). two hard
washers (5), and one nut (14) .
Note: Hose assembly (C) is part of the 272-3293 Rear Axle Lubrication Lines Gp .
Connect the Brake Oil Cooler Lines Group to the Rear Axle
Note: The 272-3430 Brake Oil Cooler Lines Gp is used on machines that are equipped with a
shallow grade arrangement. The 272-3419 Brake Oil Cooler Lines Gp is used on machines that are
equipped with a steep grade arrangement.
Connect the 272-3430 Brake Oil Cooler Lines Gp (If Equipped)
1. Remove bolts (A), washers (B), flanges (C), O-ring seals (D), and the shipping covers from
the end of hose assembly (E) and hose assembly (F). Discard the shipping covers. Retain the
remaining hardware.
2. Remove the hardware from the end of the brake cooling tubes on the rear axle. Discard the
hardware.
3. Use the hardware that was removed in Step 1 in order to secure hose assembly (E) and hose
assembly (F) to the rear axle.
Connect the 272-3419 Brake Oil Cooler Lines Gp (If Equipped)
Typical view of brake cooling hose assemblies on the right side
Typical view of brake cooling hose assemblies on the left side
1. Remove bolts (A), washers (B), flanges (C), and O-ring seals (D) from the end of hose
assembly (E), hose assembly (F), and hose assembly (G) .
2. Remove the shipping covers on the brake oil cooler lines that are located on the right side of
the truck. Discard the hardware and the shipping covers.
3. Remove the shipping cover for the brake oil cooler line that is located on the left side of the
truck. Discard the hardware and the shipping cover.
4. Secure hose assembly (E) and hose assembly (F) to the right side of the rear axle by using
the hardware that was removed in Step 1.
5. Secure hose assembly (G) to the left side of the rear axle by using the hardware that was
removed in Step 1.
Connect the 272-3293 Rear Axle Lubrication Lines Gp to the Rear Axle
1. Remove the tie straps and cap from hose assembly (A) .
2. Remove the cap from the left side of the rear axle lubrication motor.
3. Connect hose assembly (A) from the left side of the rear axle lubrication motor.
Connect the Power Train Filter Lines to the Rear Axle Lubrication Motor
Note: The 272-3424 Power Train Filter Lines is on machines that are equipped with a shallow
grade arrangement. The 272-3413 Power Train Filter Lines is on machines that are equipped with
a steep grade arrangement.
(A) 342-9062 Hose As is used on machines with steep grade arrangements and shallow grade arrangements
(B) 344-9308 Hose As is used on machines with steep grade arrangements and 345-0588 Hose As is used on
machines with shallow grade arrangements
1. Connect hose assembly (A) and hose assembly (B) to the rear axle lubrication motor.
Connect the 293-3447 Fan Drive Lines Gp to the Rear Axle (If Equipped)
Table 69
Parts that are Needed for the Installation of 293-3447 Fan Drive Lines Gp to the Rear
Axle
1 1 188-2762 Hose As
2 1 348-9156 Hose As
3 1 348-9154 Hose As
4 1 348-9155 Hose As
5 1 298-7116 Hose As
1. Connect hose assembly (1) and hose assembly (2) to the right side of valve assembly (A) .
2. Connect hose assembly (3) and hose assembly (4) to the left side of valve assembly (A) .
3. Connect hose assembly (5) to the right side of motor group (B) on the back of the cooling
assembly.
Connect the 287-1639 Service Brake Control Gp to the Rear Axle
Typical view
1. Remove the three shipping covers that are located at the rear of the truck.
(A) 156-3974 Hose As
(B) 156-3974 Hose As
(C) 293-4244 Hose As
2. Remove the caps and tie straps from hose assembly (A), hose assembly (B), and hose
assembly (C) .
3. Connect hose assembly (A), hose assembly (B), and hose assembly (C) to the rear axle.
4. Refer to Testing and Adjusting, KENR8374, "Brake System Air - Purge" for the correct
purging procedure.
Install the Fuel Tank

There are three sizes available for the fuel tank for the 797F.
• 3785 L (1000 US gal)
• 5110 L (1350 US gal)
• 7570 L (2000 US gal)
Table 70
Fuel Tank Options and Associated Part Numbers
Tank Size Tank Arrangement Tank Group Mounting Group
272-3453 Fuel Tank 280-1058 Fuel 292-1197 Fuel Tank

Ar Tank Gp Mounting Gp
3785 L (1000 US
gal) 362-6670 Fuel Tank 362-6650 Fuel 362-6671 Fuel Tank
5110 L (1350 US

7570 L (2000 US
Install the 3785 L (1000 US gal) Fuel Tank (If Equipped)
There are two 3785 L (1000 US gal) fuel tank options:
• 272-3453 Fuel Tank Ar
Table 71
1 4 7X-2489 Bolt
3 2 8X-2575 Cap
4 4 8X-2576 Shim Pack
5 1 297-4213 Plate As
6 2 7X-2564 Bolt
8 4 8N-1214 Mount
9 2 7N-5656 Sleeve
10 2 7X-2488 Bolt
11 2 6V-7688 Locknut
12 1 6G-7803 Vent As
13 1 9M-7958 Hose Clamp
14 1 205-7303 Fast Fill Fuel Adapter
297-4210 (2) Hose As
15 1
362-6658 (3) Hose As
16 1 348-3667 Support As
17 12 8T-4139 Bolt
19 1 317-6443 Plate
20 1 294-2865 Plate As
21 2 8T-4244 Nut
(1)
(2)
(3)
1. Remove the straps for shipping that secure the hoses for the fuel tank.
(1) 7X-2489 Bolt
(3) 8X-2575 Cap
(4) 8X-2576 Shim Pack
2. Remove four bolts (1), four washers (2), two caps (3), and four shim packs (4). Retain the
hardware.
Typical view
3. Remove paint and dirt from two fuel tank supports.
(3) 8X-2575 Cap
4. Remove paint and dirt from two the mounting surfaces of two caps (3) .
Typical view
(1) 7X-2489 Bolt
(3) 8X-2575 Cap
5. Position one cap (3) to fuel tank support. Install bolts (1) and washers (2) that were removed
in Step 2 in order to secure the cap. Tighten the bolts to a torque of 800 ± 100 N·m (590 ±
75 lb ft)
6. Measure and record inside diameter (AA) .
7. Repeat 5 and 6 for the other side.
8. Remove paint and dirt from mounting pin on the fuel tank.
9. Measure and record outside diameter (BB) .
11. Record the difference between measurement (AA) and measurement (BB) for both sides.
Note: The difference will determine the number of shims (4) that is required for the final
installation.
12. Repeat Step 2.
(5) 297-4213 Plate As
13. Remove paint and dirt from mounting surface on chassis and plate assembly (5) .
(5) 297-4213 Plate As
(6) 7X-2564 Bolt
14. Install bolts (6) and washers (7) in order to secure plate assembly (5) .
15. Use a suitable lifting device in order to lift the fuel tank to the frame. The fuel tank weighs
(5) 297-4213 Plate As
(8) 8N-1214 Mount As
(9) 7N-5656 Sleeve
(10) 7X-2488 Bolt
(11) 6V-7688 Locknut
16. Install mounts (8) and sleeves (9) between plate assembly (5) and the bracket.
17. Install mounts (8), bolts (10), washers (7) and nuts (11) in order to secure the fuel tank to
plate assembly (5). Tighten two bolts (10) to a torque of 460 ± 60 N·m (340 ± 45 lb ft).
18. Position shim (4) that is equal to the last recorded value in Step 11 to fuel tank support.
Note: Shim both sides of support equally.
(1) 7X-2489 Bolt
(3) 8X-2575 Cap
19. Install bolts (1), washers (2) and cap (3). Tighten the bolts to a torque of 800 ± 100 N·m
(590 ± 75 lb ft).
20. Repeat Step 18 and Step 19 for the other side of the fuel tank.
View of the 272-3453 Fuel Tank Ar
Note: Ensure the correct cover (C) is removed.
21. Remove six bolts (A), six washers (B), and one cover (C) from the top of the fuel tank.
Retain bolts (A) and washers (B). Discard the cover.
(12) 6G-7803 Vent As
(13) 9M-7958 Hose Clamp
(14) 205-7303 Fast Fill Fuel Adapter
(15) 297-4210 Hose As
(12) 6G-7803 Vent As
(15) 362-6658 Hose As
22. Secure one vent assembly (12), and one adapter (14) to the top of the fuel tank by using six
bolts (A) and six washers (B).
Note: Apply 5P-3413 Pipe Sealant to the threads of vent assembly (12) .
Note: Remove the rubber cover and the spring clip from vent assembly (12) before
installing hose assembly (15) .
23. Secure hose assembly (15) to adapter (14) by using one clamp (13). Secure the other end of
hose assembly (15) to elbow assembly (D) .
Typical view of the front of the fuel tank
(16) 348-3667 Support As
(17) 8T-4139 Bolt
24. Secure support assembly (16) to the front of the fuel tank by using four bolts (17) and four
hard washers (18) .
Typical view of the rear of the fuel tank
(17) 8T-4139 Bolt
(19) 317-6443 Plate
(20) 294-2865 Plate As
(21) 8T-4244 Nut
25. Secure plate (19) and plate assembly (20) to the rear of the fuel tank by using eight bolts
(17), ten hard washers (18), and two nuts (21) .
Table 72
1 4 7X-2489 Bolt
3 2 8X-2575 Cap
4 4 8X-2576 Shim Pack
5 1 297-4213 Plate As
6 2 7X-2564 Bolt
8 4 8N-1214 Mount
9 2 7N-5656 Sleeve
10 2 7X-2488 Bolt
12 1 6G-7803 Vent As
14 1 205-7303 Fast Fill Fuel Adapter
15 1 362-8377 Hose As
16 1 294-2865 Plate As
17 16 8T-4139 Bolt
19 1 362-8374 Support As
20 1 362-8376 Plate
21 2 8T-4244 Nut
(1)
Both fuel tank arrangements use the 362-8385 Fuel Tank Mounting Gp .
1. Remove the straps for shipping that secure the hoses for the fuel tank.
(1) 7X-2489 Bolt
(3) 8X-2575 Cap
2. Remove four bolts (1), four washers (2), two caps (3), and four shim packs (4). Retain the
hardware.
Typical view
(3) 8X-2575 Cap
Typical view
(1) 7X-2489 Bolt
(3) 8X-2575 Cap
75 lb ft)
installation.
12. Repeat Step 2.
(5) 297-4213 Plate As
13. Remove paint and dirt from mounting surface on chassis and plate assembly (5) .
(5) 297-4213 Plate As
(6) 7X-2564 Bolt
14. Install bolts (6) and washers (7) in order to secure plate assembly (5) .
15. Use a suitable lifting device in order to lift the fuel tank to the frame. The fuel tank weighs
(5) 297-4213 Plate As
(9) 7N-5656 Sleeve
(10) 7X-2488 Bolt
16. Install mounts (8) and sleeves (9) between plate assembly (5) and the bracket.
17. Install mounts (8), bolts (10), washers (7) and nuts (11) in order to secure the fuel tank to
plate assembly (5). Tighten two bolts (10) to a torque of 460 ± 60 N·m (340 ± 45 lb ft).
18. Position shim (4) that is equal to the last recorded value in Step 11 to fuel tank support.
Note: Shim both sides of support equally.
(1) 7X-2489 Bolt
(3) 8X-2575 Cap
19. Install bolts (1), washers (2) and cap (3). Tighten the bolts to a torque of 800 ± 100 N·m
(590 ± 75 lb ft).
20. Repeat Step 18 and Step 19 for the other side of the fuel tank.
Typical view of the top of the fuel tank
21. Remove six bolts (A), six washers (B), and one cover (C) from the top of the fuel tank.
Retain bolts (A) and washers (B). Discard cover (C) .
Typical view of the top of the fuel tank
(A) Bolt
(B) Washer
(D) Elbow assembly
(12) 6G-7803 Vent As
(15) 362-8377 Hose As
(16) 294-2865 Plate As
(17) 8T-4139 Bolt
22. Secure one vent assembly (12), and one adapter (14) to the top of the fuel tank by using six
bolts (A) and six washers (B).
23. Secure hose assembly (15) to adapter (14) by using one clamp (13). Secure the other end of
hose assembly (15) to elbow assembly (D) .
24. Secure two plate assemblies (16) to the top of the fuel tank by using four bolts (17) and four
hard washers (18) .
(17) 8T-4139 Bolt
(19) 362-8374 Support As
25. Secure support assembly (19) to the front of the fuel tank by using four bolts (17) and four
hard washers (18) .
(16) 294-2865 Plate As
(17) 8T-4139 Bolt
(20) 362-8376 Plate
(21) 8T-4244 Nut
26. Secure plate (20) to plate assembly (16) and the rear of the fuel tank by using ten bolts (17),
14 hard washers (18), and four nuts (21) .
Table 73

1 4 7X-2489 Bolts
2 4 8T-4167 Hard Washers
3 2 8X-2575 Caps
4 4 8X-2576 Shim Packs
5 3 7X-2488 Bolts
6 8 8T-5439 Hard Washers
7 6 8N-1214 Mount As
8 3 6V-7688 Locknuts
9 3 7N-5656 Sleeves
10 1 196-9873 Plate As
11 2 7x-2564 Bolts
12 1 205-7303 Adapter
13 1 6G-7803 Vent As
297-4214 (2) Hose As
14 1
362-6656 (3) Hose As
16 1 294-2865 Plate As
17 16 8T-4139 Bolt
19 1 8T-4136 (2) Bolt
20 1 8T-4121 (2) Hard Washer
21 1 7D-1553 (2) Clip
22 1 294-2067 Support As
23 4 8T-4244 Nut
24 1 317-6444 Plate
(1)
(2)
(3)
(1) 7X-2489 Bolt
(3) 8X-2575 Cap
1. Remove four bolts (1), four washers (2), two caps (3), and four shim packs (4) from the two
fuel tank supports. Retain the hardware.
Typical view
(3) 8X-2575 Cap
Typical view
(1) 7X-2489 Bolt
(3) 8X-2575 Cap
75 lb ft).
installation.
11. Repeat Step 1.
12. Remove paint and grease from the mounting surfaces of caps (2) .
(5) 7X-2488 Bolt
(8) 6V-7688 Locknut
(9) 7N-5656 Sleeve
(10) 196-9873 Plate As
13. Use bolts (5), washers (6), mounts (7), locknuts (8), and sleeves (9) in order to install plate
assembly (10) to the fuel tank.
14. Use a suitable lifting device in order to lift the tank up to the mounting location. The weight
of the tank is 2750 kg (6050 lb).
15. Mount the tank into the fuel tank supports.
(10) 196-9873 Plate As
(11) 7X-2564 Bolt
16. Use two bolts (11) and two washers (6) in order to secure plate assembly (10) to the frame.
(1) 7X-2489 Bolt
(3) 8X-2575 Cap
17. Secure the top of the fuel tank to the frame by using four bolts (1), four washers (2), two
caps (3), and four shim packs (4) .
18. Remove six bolts (A), six washers (B), and one cover. Retain six bolts (A) and six washers
(B). Discard cover.
(A) Bolt
(B) Washer
(D) Elbow assembly
(13) 6G-7803 Vent As
(14) 297-4214 Hose As
(16) 294-2865 Plate As
(17) 8T-4139 Bolt
(19) 8T-4136 Bolt
(21) 7D-1553 Clip
(A) Bolt
(B) Washer
(D) Elbow assembly
(13) 6G-7803 Vent As
(14) 297-4214 Hose As
(16) 294-2865 Plate As
(17) 8T-4139 Bolt
19. Use six bolts (A) and six washers (B) in order to install one adapter (12) and one vent
assembly (13) to the top of the fuel tank.
20. Secure hose assembly (14) to vent assembly (13) by using one clamp (15). Secure the other
end of hose assembly (14) to elbow assembly (D) .
21. Secure two plate assemblies (16) to the top of the fuel tank by using four bolts (17) and four
hard washers (18) .
Note: Step 22 only applies to the 272-3454 Fuel Tank Ar . Refer to Illustration 199.
22. Secure hose assembly (14) to the top of the fuel tank by using one bolt (19), one washer
(20), and one clip (21) .
(17) 8T-4139 Bolt
(22) 294-2067 Support As
23. Secure support assembly (22) to the front of the fuel tank by using six bolts (17) and six
hard washers (18) .
(16) 294-2865 Plate As
(17) 8T-4139 Bolt
(23) 8T-4244 Nut
(24) 317-6444 Plate
24. Secure plate (24) to two plate assemblies (16) and the rear of the fuel tank by using ten bolts
(17), 14 hard washers (18), and four nuts (23) .
Connect the Sensor for the Fuel Tank
Typical view
1. Remove bolts and washers in order to remove cover from the bottom of the fuel tank. Retain
hardware.
Note: The 322-6562 Sensor Harness as is part of the 277-3328 Chassis Wiring Gp - Rear .
2. Connect harness assembly to the electrical connections for the fuel tank sensor.
Note: Connection is behind the fuel tank on chassis.
3. Connect harness assembly to the electrical connections.
Typical view
4. Install the hardware that was removed in Step 1 in order to secure cover.
Install the 311-8657 Fuel Filter Lines Gp

Note: The 311-8657 Fuel Filter Lines Gp is used with both fuel tanks.
Table 74
Parts that are Needed to Install the 311-8657 Fuel Filter Lines Gp
1 7 8T-4196 Bolt
2 6 198-4777 Hard Washer
3 1 308-5290 Tube As
4 1 8C-3364 Elbow
5 3 228-7094 O-Ring Seal
6 3 5P-7701 O-Ring Seal
7 1 159-4724 Ball Valve
8 1 8T-7927 Connector
9 1 9T-3752 Check Valve
10 1 6V-9853 Elbow
11 1 228-7092 O-Ring Seal
13 1 178-2345 Liquid Level Sensor Gp (WATER SEPARATOR)
15 1 130-5300 Clip
16 1 337-8235 Bracket As
17 3 8T-4136 Bolt
18 1 5P-9085 Clip
(1) 8T-4196 Bolt
(2) 198-4777 Hard Washer
1. Secure the fuel filter assembly to the fuel tank by using six bolts (1) and six washers (2) .
(3) 308-5290 Tube As
(4) 8C-3364 Elbow
(5) 228-7094 O-Ring Seal
(6) 5P-7701 O-Ring Seal
2. Install one elbow (4), one O-ring seal (5), one O-ring seal (6), and one tube assembly (3) to
the fuel filter assembly.
(3) 308-5290 Tube As
(5) 228-7094 O-Ring Seal
(6) 5P-7701 O-Ring Seal
(7) 159-4724 Ball Valve
(8) 8T-7927 Connector
3. Install one O-ring seal (5), two O-ring seals (6), one ball valve (7), and one connector (8)
between the fuel tank and tube assembly (3) .
(9) 9T-3752 Check Valve
(10) 6V-9853 Elbow
(11) 228-7092 O-Ring Seal
4. Install one check valve (9), one elbow (10), one O-ring seal (11), and one O-ring seal (12)
onto the back of the fuel tank.
(1) 8T-4196 Bolt
(15) 130-5300 Clip
5. Install one liquid level sensor group (13) onto the bottom of the fuel filter assembly. Tighten
liquid level sensor group (13) to a torque of 10 ± 3 N·m (88 ± 26 lb in).
6. Connect the other end of liquid level sensor group (13) to harness assembly (A) .
7. Secure liquid level sensor group (13) to the fuel tank by using one bolt (1), one washer (14),
and one clip (15) .
(16) 337-8235 Bracket As
(17) 8T-4136 Bolt
8. Install one bracket assembly (16) to the bottom of the fuel tank by using two bolts (17) and
two washers (14) .
(13) 178-2345 Liquid Level Sensor Gp
(16) 337-8235 Bracket As
(17) 8T-4136 Bolt
(18) 5P-9085 Clip
9. Secure liquid level sensor group (13) to bracket assembly (16) by using one clip (18), one
bolt (17), and one washer (14) .
Connect the Hoses to the Fuel Tank

There are two lines groups that connect to the fuel tank.
• 272-3250 Fuel Lines Gp
• 272-5377 Service Center Gp or the 293-7875 Service Center Gp
Connect the 272-3250 Fuel Lines Gp to the Fuel Tank
1. Connect the 338-0086 Hose As (A) to valve group (B) .
2. Connect the 336-0919 Hose As (C) to the side of the fuel filter assembly.
3. Secure hose assembly (A) and hose assembly (C) with the existing clips.
Connect the 272-5377 Service Center Gp or the 293-7875 Service Center Gp to the Fuel
Tank
Note: The 272-5377 Service Center Gp is for machines that are not equipped with the Oil
Renewal System (ORS). The 293-7875 Service Center Gp is for machines that are equipped with
the Oil Renewal System (ORS).
Table 75
Parts that are Required to Connect the 272-5377 Service Center Gp or the 293-7875
Service Center Gp to the Fuel Tank

1 1 231-7582 Adapter
2 1 5H-6734 O-Ring Seal
3 6 8T-4185 Bolt
5 4 8T-4183 Bolt
8 1 4J-0527 O-Ring Seal
1. Install one adapter (1) and one O-ring seal (2) to the fuel tank by using six bolts (3) and six
washers (4) .
2. Secure one 334-5817 Hose As (A) to adapter (1) by using four bolts (5), four washers (6),
two half flanges (7), and one O-ring seal (8) .
Install 289-8616 Hoist Cylinder Gp

Table 76
Parts that are Needed for Installation of 289-8616 Hoist Cylinder Gp
1 2 297-7969 (1) Dust Cap
2 2 297-7968 (1) Fitting
3 2 319-6248 (1) Union As
(1)
1. Remove the shipping straps that secure the hoist cylinders to the shipping pallet.
2. Remove the tape from the trunnion. Remove any paint, rust, debris, grease, or wax from the
mounting surface with prior to assembly.
3. Remove three bolts (A) and three washers (B) from the hoist cylinder. Remove cover (C) .
4. Remove nine bolts (D) and nine washers (E) from the hoist cylinder.
5. Remove any paint, debris, rust, or grease from the mounting surface of the hoist cylinder.
6. Remove two plugs from the hoist cylinder.
Typical view
Note: Place the loop for the chain that is already attached to cap (1) between cap (1) and
union (3).
7. Assemble the following items in order to complete the assembly for the hydraulic fitting:
Cap (1), Fitting (2) and and Union (3) .
8. Install the two fittings that were assembled in Step 7 into the hoist cylinder.
Note: Step 6 through Step 8 applies to the left cylinder only.
9. Attach a suitable lifting device in order to lift the hoist cylinder. The weight of the hoist
cylinder is approximately 1425 kg (3150 lb).
10. Mount the hoist cylinder to the trunnion on the truck chassis.
11. Install nine bolts (D) and nine washers (E). Torque bolts (D) to a torque value of 460 ± 60
N·m (340 ± 45 lb ft).
12. Install cap (C) by using three bolts (A) and washers (B) .
13. Use a suitable device in order to secure the hoist cylinder while the truck is being
assembled.
14. Repeat Step 2 through Step 13 for the opposite cylinder.
Connect the 272-3289 Hoist Oil Lines Gp to the Hoist Cylinders
1. Remove the two shipping covers from the hoist cylinder. Discard the hardware.
2. Remove four bolts (C), four washers (D), two flanges (E), one O-ring seal (F), four nuts,
and one cover from hose assembly (A). Discard the cover and the nuts. Retain the remaining
hardware.
3. Remove four bolts (G), four washers (H), two flanges (J), one O-ring seal (K), four nuts,
and one cover from hose assembly (B). Discard the cover and the nuts. Retain the remaining
hardware.
4. Connect hose assembly (A) and hose assembly (B) to the hoist cylinder by using the
hardware that was removed in Step 2 and Step 3.
5. Repeat Step 1 through Step 4 for the opposite side.
Install the Hydraulic Tank Guard Group

There are two options available for the hydraulic tank guard group.
• 272-3347 Hydraulic Tank Guard Gp is for machines with a shallow grade retarding
arrangement
• 292-5153 Hydraulic Tank Guard Gp is for machines with a steep grade retarding
arrangement
Table 77
Parts that are Needed for Installation of Hydraulic Tank Guard Group
1 8 8T-4196 Bolt

3 2 9T-3988 Filler
4 2 4M-0189 O-Ring Seal
5 2 9J-3047 Strainer (HYDRAULIC TANK)
6 2 2D-4202 Plate
7 2 7H-1447 Filler Cap (HYDRAULIC OIL)
8 2 8T-2275 Ball
9 2 9G-9288 Protection Cap Gp (HYDRAULIC TANK FILL CAP)
10 2 3G-0361 Gasket
11 2 9H-6454 Gasket
Typical view
1. Remove the two covers from the side of the hydraulic tank.
Typical view
2. Use eight bolts (1) and eight washers (2) in order to install two fillers (3), two O-ring seals
(4), two strainers (5), two plates (6), two filler caps (7), two balls (8), two protection cap
groups (9), two gaskets (10), and two gaskets (11) .
Install the Components at the Front End

Install the 217-3084 Suspension Mounting Gp (FRONT)
Table 78
Parts that are Needed for Installation of 217-3084 Suspension Mounting Gp (FRONT)
1 2 156-5444 Key
2 2 289-8629 Front Suspension Gp
3 16 3E-8029 Bolt
4 16 217-9902 Washer
5 16 9X-8399 Washer
6 16 8T-1583 Nut
7 24 224-8961 Bolt
8 24 217-9903 Washer
10 24 8C-4032 Nut
Table 79
Tools that are Needed for Installation of 192-5826 Wheel, Brake, and Suspension Group

A 1 194-7586 Pneumatic Wrench Gp
B 2 334-8335 Reaction Arm Plate
C 2 334-8336 Reaction Arm Plate
D 1 335-6485 Reaction Arm Plate
1. Remove the shipping covers from the mounting areas.
2. Remove all paint, dirt, and grease from the mounting areas. Remove and nicks or burrs from
the mating surfaces.
(1) 156-5444 Key
3. Install key (1) .
(2) 289-8629 Front Suspension Gp
4. Use a suitable lifting device in order to lift front suspension (2). The weight of front
suspension group (2) is approximately 9153 kg (20180 lb).
5. Remove all paint, dirt, and grease from the mounting surface and the keyway of the front
suspension group. Clean the bolt holes. Make sure that the spot faces are clean. Clean the
shipping grease from the cylinder surface.
6. Position front suspension group (2) to the truck frame.
View of tooling (B)
View of tooling (C)
View of tooling (D)
(3) 3E-8029 Bolt
(4) 217-9902 Washer
(5) 9X-8399 Washer
(6) 8T-1583 Nut
(7) 224-8961 Bolt
(8) 217-9903 Washer
(10) 8C-4032 Nut
7. Secure front suspension group (2) to the frame by using the following items: eight bolts (3),
eight washers (4), eight washers (5), eight nuts (6), 12 bolts (7), 12 washers (8), 12 washers
(9) and 12 nuts (10) .
Note: Eight washers (4) and 12 washers (8) are installed on the inside. Eight washers (5)
and 12 washers (9) are installed on the outside.
Note: Apply 4C-5593 Thread Lubricant to the threads of eight bolts (3) and 12 bolts (7).
Also apply 4C-5593 Thread Lubricant to both sides of eight washers (4), eight washers (5),
12 washers (8), and 12 washers (9) .
View A-A
Note: Before the protorque is applied, place tool (B) and tool (C) on the back side of the
suspension group. The tools will not be able to used after the pretorque is applied.
Note: Pretorque all of the bolts for the suspension group to 405 N·m (300 lb ft).
Note: Pretorque bolts A, B, C, D, L, M, N, and P in that sequence to a torque of 800 ± 100

N·m (590 ± 75 lb ft). Pretorque bolts E, F, G, H, J, K, Q, R, S, T, U, and V in that sequence
to a torque of 1000 ± 100 N·m (740 ± 75 lb ft). After all bolts are pretorqued, then apply
120 deg +10 -0.
8. Tighten bolts to specifications. Use tool (A), tool (B), tool (C), and tool (D) in order to
torque the bolts. Tighten eight nuts (6) to a torque of 800 ± 80 N·m (590 ± 60 lb ft). After
torque, turn an additional 120° +20° −0°. Tighten the 12 nuts (10) to a torque of 1000 ± 100
N·m (740 ± 75 lb ft). After torque, turn an additional 120° +20° −0°.
Note: Tool (A) and tool (D) will be used to torque every bolt. Tool (B) and tool (C) will be
used to torque either the upper part of the suspension group or the lower part of the
suspension group. The number of bolts identifies which tool needs to be used.
9. Remove three bolts and remove three washers in order to remove the plate.
10. Connect the harness for the payload monitoring system.
11. Install three washers and install three bolts in order to secure the plate.
12. Repeat Step 1 through Step 11 for the opposite suspension cylinder.
13. Completely remove all the wax from the chrome of the suspension cylinders.
14. After the truck is assembled and the body has been installed, charge the suspension
cylinders. Refer to Special Instruction, SEHS9411, "Servicing the Suspension Cylinders for
Off-Highway Trucks" for the correct suspension cylinder charging procedure.
Install the 291-4032 Brake Wear Indicator Gp (If Equipped)

Table 80
Required Parts to Install the 291-4032 Brake Wear Indicator Gp
1 2 348-8324 Brake Wear Indicator As
View of the front of the right front wheel
(A) Plug
1. Remove plug (A) from port "S" on the front right wheel. Discard plug (A) .
View of the front of the right front wheel
(1) 348-8324 Brake Wear Indicator As
2. Install brake wear indicator (1) onto the front right wheel.
Note: Refer to Testing and Adjusting, KENR8374, "Service Brake Discs - Check -
Standard" for instructions to set the indicators.
3. Repeat Step 1 and Step 2 for the other side of the machine.
Connect the 272-3306 Steering Cylinder and Mounting Gp

Table 81
Parts that are Needed to Connect the 272-3306 Steering Cylinder and Mounting Gp
1 1 288-5537 Steering Cylinder Gp (1)
2 1 194-6171 Steering Cylinder Gp (2)
3 2 7J-9250 Locknut
(1)
Right hand
(2)
Left hand
Table 82
Tools that are Needed for Installation of 272-3306 Steering Cylinder and Mounting Gp
Tool Qty Tool Number Description
A 1 176-6537 Spanner Wrench As

B 1 132-8112 Torque Wrench Gp
C 1 234-6041 Socket
Typical view
1. Remove the shipping cover from the steering cylinder group (1) .
2. Remove nut (3) from the ball stud.
3. Remove dirt, paint, and grease from the ball stud and from the bores in the steering arm.
Also remove dirt, paint, and grease from the bottom of the bores.
4. Loosen the bolts that secure the hose assembly onto steering cylinder group (1). Loosing the
hose assembly will allow the cylinder to extend.
5. Remove the retaining ring and remove the plug.
6. Use a suitable lifting device in order to lift steering cylinder group (1). The approximate
weight of steering cylinder group (1) is 330 kg (725 lb). Steering cylinder group (1) can be
extended into position.
7. Apply 5P-3931 Anti-Seize Compound (HIGH TEMPERATURE) to the taper and to the
threads of the ball stud.
8. Install the ball stud into the steering arm.
9. Apply 5P-3931 Anti-Seize Compound (HIGH TEMPERATURE) to top of nuts (3) and to
the threads of nuts (3) .
10. Install nut (3) onto the ball stud. Use Tool (A) in order to hold the ball studs. Use Tool (B)
in order to torque nut (3). Use Tool (C) for nut (3). Tighten nut (3) to a value of 5000 ± 200
N·m (3680 ± 150 lb ft).
11. Install the plug and install the retaining ring that were removed in Step 5.
12. Secure the bolts for the hose assembly that were loosened in Step 4.
13. Repeat Step 1 through Step 12 for the opposite steering cylinder.
Connect the 332-7420 Steering Link Gp

Table 83
Parts that are Needed to Connect the 332-7420 Steering Link Gp
1 2 284-3123 Steering Link Gp
2 4 7J-9250 Locknut
Table 84
Tools that are Needed for Installation of 332-7420 Steering Link Gp
A 1 176-6537 Spanner Wrench As
B 1 132-8112 Torque Wrench Gp
C 1 234-6041 Socket
1. Remove link (1) from the shipping container. Remove nut (2) from the ball stud. Remove
the cover from the ball stud.
2. Remove the tie straps from the center arm.
3. Use a suitable lifting device to steering link group (1). The weight of steering link group (1)
is approximately 180 kg (400 lb). Apply 4C-5593 Thread Lubricant to the taper and to the
threads of the ball studs.
4. Remove the retaining rings and remove the plugs. Removing the retaining rings and the
plugs will allow access to the ball studs.
5. Remove dirt, paint, and grease from the ball stud and from the bores in the steering arm.
Also remove dirt, paint, and grease from the bottom of the bores.
6. Loosening the bolts that secure the hose assembly onto the steering cylinder may be
necessary. Loosening the bolts will allow the steering cylinder to be extended.
7. Apply 5P-3931 Anti-Seize Compound (HIGH TEMPERATURE) to the taper and to the
threads of the ball stud.
8. Install steering link group (1) into the center arm.
9. Apply 5P-3931 Anti-Seize Compound (HIGH TEMPERATURE) to top of nuts (3) and to
the threads of nuts (3) .
10. Install nut (2) onto the ball stud in the center arm.
11. Install nut (2) onto the ball stud. Use Tool (A) in order to hold the ball studs. Use Tool (B)
in order to torque nut (2). Use Tool (C) for nut (2). Torque nuts (2) to a value of 5000 ± 200
N·m (3680 ± 150 lb ft).
12. Tighten the bolts on the flange if the bolts were loosened.
13. Repeat Step 1 through Step 12 for the other side of the machine.
Connect the 272-3369 Brake Cooling Lines Gp to the Front Suspension

Cylinders
Table 85
Parts that are Needed to Connect the 272-3369 Brake Cooling Lines Gp to the Front
1 2 334-8993 Hose As
2 2 334-8994 Hose As
1. Remove eight bolts (A), eight washers (B), four half flanges (C), and two shipping covers
from the cooling lines groups for the brake. Retain bolts (A), washers (B), and half flanges
(C). Discard the covers.
2. Remove eight bolts (D), eight washers (E), four half flanges (F), and two shipping covers
from the wheel assembly. Retain bolts (D), washers (E), and half flanges (F). Discard the
covers.
3. Install one hose assembly (1) and one hose assembly (2) by using four O-ring seals (3),
eight bolts (A), eight washers (B), four half flanges (C), eight bolts (D), eight washers (E),
and four half flanges (F) .
4. Remove the straps that secure hose assembly (G) for the breather.
5. Remove the plug from the top of the wheel assembly.
6. Secure hose assembly (G) to the top of the wheel assembly.
Connect the 272-3295 Service Brake Control Gp to the Front Suspension

Cylinders
Table 86
Parts that are Needed to Connect the 272-3295 Service Brake Control Gp to the Front
1 2 344-6665 Hose As
2 2 344-6666 Hose As
3 4 8T-4139 Bolt
5 2 7G-3833 Clip
6 2 7G-3834 Clip
7 2 7G-3832 Grommet
1. Remove the two shipping covers from the lines group for the brakes. Discard the two
shipping covers.
2. Remove the two shipping covers from the rear of the wheel assembly for the brakes.
Discard the two shipping covers.
(1) 344-6665 Hose As
(2) 344-6666 Hose As
(3) 8T-4139 Bolt
(5) 7G-3833 Clip
(6) 7G-3834 Clip
(7) 7G-3832 Grommet
3. Install one hose assembly (1) and one hose assembly (2) .
4. Secure the inside portion of hose assembly (1) and hose assembly (2) to the machine by
using two bolts (3), two washers (4), one clip (5), one clip (6), and one grommet (7). Secure
the outside portion of hose assembly (1) and hose assembly (2) by using the existing clips
(A) .
Install the 296-5681 Rollover Protective Structure (ROPS) Mounting Gp

Table 87
Parts that are needed for Installation 296-5681 Rollover Protective Structure (ROPS)
Mounting Gp
1 1 297-9711 Support As
2 1 297-9712 Support As
3 33 147-0170 Bolt
Table 88
Tools that are Needed for Installation of 296-5681 Rollover Protective Structure (ROPS)
Mounting Gp
Tool Qty Part Number Description

A 1 4C-4970 Tap
B 1 145-7044 Caliper
1. Remove the shipping plugs from the front and rear mounting areas.
2. Remove and paint, rust, dirt, or debris from the mounting surfaces prior to assembly. This
procedure will ensure a clean mounting surface.
View of the top of the chassis
3. Clean the four holes on the chassis for the rear cab support mounting bolts.
4. Use Tooling (A) in order to clean the bolt holes for the cab mounts.
5. Remove and paint, rust, dirt, or debris from the mounting surfaces of the cab mounts and
dowels.
Typical view
6. Use Tooling (B) in order to measure dowels. Measure the dowels to ensure a proper fit with
the bore.
Note: The measurement for the dowels should be 90 ± 0.008 mm (3.5433 ± 0.00031 inch)
7. Use Tooling (B) in order to measure the size of the bore. The bore is being measured in
order to ensure a proper fit with the dowels.
Note: The measurement for the bores should be 90.055 ± 0.1 mm (3.5455 ± 0.00394 inch).
(1) 297-9711 Support As
8. Attach a suitable lifting device to support assembly (1). The weight of support assembly (1)
is approximately 900 kg (1980 lb).
(1) 297-9711 Support As
(3) 147-0170 Bolt
9. Apply 4C-5592 Anti-Seize Compound to the threads of 20 bolts (3). Secure support
assembly (1) to the chassis by using 20 bolts (3) and 20 washers (4). Tighten 20 bolts (3) to
a torque of 2800 ± 350 N·m (2065 ± 260 lb ft).
(2) 297-9712 Support As
10. Attach a suitable lifting device to support assembly (2). The weight of support assembly (2)
is approximately 750 kg (1650 lb).
(2) 297-9712 Support As
(3) 147-0170 Bolt
11. Apply 4C-5592 Anti-Seize Compound to the threads of 13 bolts (3). Secure support
assembly (2) to the chassis by using 13 bolts (3) and 13 washers (4). Tighten 13 bolts (3) to
a torque of 2800 ± 350 N·m (2065 ± 260 lb ft).
Install the Right-Hand Platform and Air Filter Box Assembly

Connect the 272-3379 Air Cleaner Gp
Note: The 277-0736 Air Cleaner Gp can be connected to the right-hand platform before the right-
hand platform is installed.
Note: The right-hand platform is shipped with the right-hand fender already attached.
Table 89
Parts that are Required to Connect the 272-3379 Air Cleaner Gp
1 2 277-0736 Air Cleaner Gp
2 32 8T-4139 Bolt
1. Attach a suitable lifting device to the right-hand platform.
Note: The weight of the right-hand platform is approximately 2785 kg (6140 lb).
2. Safely position the right-hand platform on top of air cleaner group (1) .
3. Secure air cleaner group (1) to the right-hand platform by using 16 bolts (2) and 16 washers
(3) .
Note: The rest of air cleaner group (1) on the right-hand side of the machine will be
installed in the Section ""Install the Right Hand Platform" ".
4. Attach a suitable lifting device to air cleaner group (1). The approximate weight of air
cleaner gp (1) is 318 kg (700 lb).
5. Position air cleaner group (1) on the left-hand platform support assembly.
6. Secure air cleaner group (1) to the support assembly by using 16 bolts (2) and 16 washers
(3) .
Right side
7. Use the existing hardware in order to secure brace assembly (A) and brace assembly (B) to
the chassis.
Left side
8. Use the existing hardware in order to secure brace assembly (C) and brace assembly (D) to
the chassis.
Install the Right Hand Platform with the 272-3376 Platform Mounting Gp
Note: The right-hand platform contains components that are from the 272-3232 Platform Ar and
the 293-2952 Fender Gp .
Note: Refer to Special Instruction, REHS1841, "General Welding Procedures" before performing
any welding.
Table 90
Parts that are Required to Install the Right Hand Platform with the 272-3376 Platform
Mounting Gp
1 4 7X-2563 Bolt
3 1 306-9540 Plate
4 2 309-9101 Plate
5 1 384-7915 Plate As
6 1 384-7913 Plate
7 1 384-7928 Plate
8 1 384-7917 Plate
View of the right side of the machine
1. Remove any paint, dirt, grease, or debris from the mounting surfaces on the chassis for the
right-hand platform.
2. Remove any paint, dirt, grease, or debris from the mounting surfaces on the right-hand
platform.
3. Attach a suitable lifting device to the right-hand platform. The weight of the right-hand
platform and the air cleaner assembly is approximately 3100 kg (6850 lb).
View of the right side of the machine
View of the bottom of the right-hand platform
4. Position the right-hand platform to the right-hand side of the chassis.
Ensure that the block in Illustration 311 contacts the frame.
Note: Do not weld the block to the frame. The block is for alignment purposes.
View of the top of the right-hand platform
5. Mark the locations where the supports for the right-hand platform contact the frame.
6. Remove the right-hand platform from the machine.
7. Remove any paint, dirt, grease, or debris from the mounting surfaces on that were located in
Step 5.
8. Position the right-hand platform to the right-hand side of the chassis.
(1) 7X-2563 Bolt
9. Secure the right-hand platform to the right side of the chassis by using four bolts (1) and
four washers (2) .
View of the left side of the right-hand platform
(3) 306-9540 Plate
View of the left side of the right-hand platform
(3) 306-9540 Plate
(AA) 45 ± 2 mm (1.77 ± 0.0787 inch)
10. Position plate (3) between the right-hand platform and the frame.
Note: Refer to Illustration 315 for a general location of plate (3) .
Note: Refer to Special Instruction, REHS1841, "General Welding Procedures" before

performing any welding.
(3) 306-9540 Plate
(3) 306-9540 Plate
(W1) 6 mm (0.236 inch) Fillet weld
11. Weld plate (3) to the frame from location (A) to location (B) .

(3) 306-9540 Plate
12. Weld plate (3) to the right hang platform from location (C) to location (D) .
Front view
(4) 309-9101 Plate
(AB) 10 mm (0.394 inch) (Approximate dimension)
(AC) 10 ± 2 mm (0.394 ± 0.0787 inch)
13. Position two plates (4) to the right-hand platform.
Note: Refer to Illustration 321 for a general location of plates (4) .
Note: The length of dimension (AB) is an approximate length. The actual length of
dimension (AB) can vary.

(4) 309-9101 Plate
(4) 309-9101 Plate
14. Weld two plates (4) from location (E) to location (F) to the right-hand platform.

(4) 309-9101 Plate
(W4) 6 mm (0.236 inch) Fillet weld with 1.5 mm (0.059 inch) Root penetration
15. Weld two plates (4) from location (G) to location (H) to the frame.

Side view from the top
Side view from the top
16. Weld the two support assemblies for the right-hand platform to the frame from location (J)
to location (K), and from location (L) to location (M) .

17. Weld three sides of the support assembly for the right-hand platform to the frame.
View of the rear of the right-hand platform
(5) 384-7915 Plate As
(6) 384-7913 Plate
(7) 384-7928 Plate
(8) 384-7917 Plate
(6) 384-7913 Plate
(7) 384-7928 Plate
(8) 384-7917 Plate
18. Position plate assembly (5), plate (6), plate (7), and plate (8) onto the rear support for the
right-hand platform.

View from the right side of the right-hand platform
(5) 384-7915 Plate As
(6) 384-7913 Plate
(7) 384-7928 Plate
(8) 384-7917 Plate
(W8) 8 mm (0.315 inch) Fillet weld with 1.5 mm (0.059 inch) penetration
(W9) 8 mm (0.315 inch) Fillet weld with 1.5 mm (0.059 inch) flare bevel groove
View of the top rear of the right-hand platform
(5) 384-7915 Plate As
(5) 384-7915 Plate As
(6) 384-7913 Plate
(7) 384-7928 Plate
(5) 384-7915 Plate As
(7) 384-7928 Plate
(8) 384-7917 Plate
19. Weld plate (5), plate (6), plate (7), and plate (8) to the rear support of the right-hand
platform. Refer to Illustration 329, Illustration 330, 331, and Illustration 332 for additional
information.
20. Paint the affected welding areas.
21. Connect the wiring harness for the right-hand platform.
Install the Left Hand Walkway

Table 91
Parts that are required to Install the Left Hand Walkway

1 10 8T-4136 (1) Bolt
2 10 8T-4121 (1) Hard Washer
3 6 8T-4195 (2) Bolt

4 6 8T-4121 (2) Hard Washer
5 16 8T-4194 (2) Bolt
6 16 8T-4223 (2) Hard Washer
7 6 8T-4136 (3) Bolt
8 6 8T-4121 (3) Hard Washer
9 12 8T-4194 (3) Bolt
10 12 198-4778 (3) Hard Washer

(1)
Part of 293-2952 Fender Gp
(2)
(3)
Note: The left-hand fender can be installed to the left-hand walkway prior to the installation
of the left-hand walkway. The left-hand fender is part of the 293-2952 Fender Gp .
1. For instructions on installing the left-hand fender to the left-hand walkway, refer to Step 1.a.
(1) 8T-4136 Bolt
a. Secure left-hand fender (A) to the left-hand walkway by using ten bolts (1) and ten
washers (2) .
2. Attach a suitable lifting device to the left-hand walkway. The approximate weight of the left
-hand walkway is 1630 kg (3600 lb).
(3) 8T-4195 Bolt
(5) 8T-4194 Bolt
3. Secure the left-hand walkway to the machine by using six bolts (3), six washers (4), 16 bolts
(5), and 16 washers (6) .
Note: The 292-5687 Handrail As (B) for the rear walkway can be attached before the rear
walkway is installed.
4. Attach a suitable lifting device to the rear walkway. The combined weight of the rear
walkway and handrail assembly (B) is approximately 135 kg (300 lb).
View of the bottom of the cab
(7) 8T-4136 Bolt
View of the rear of the cab
(9) 8T-4194 Bolt
5. Secure the rear walkway to the machine by using six bolts (7), six washers (8), 12 bolts (9),
and 12 washers (10) .
Install the 272-3355 Handrail Gp

Note: Parts of the handrail group can be installed at ground level.
Note: Some parts of the handrail group are already assembled to the machine.
Table 92
Parts that are Required to Install the 272-3355 Handrail Gp (1)

1 1 281-6798 Handrail As
4 26 8T-4136 Bolt
8 12 8T-4244 Nut
9 10 8T-4183 Bolt
10 14 8T-7087 Grommet
11 14 5P-7469 Clip
12 14 5P-7468 Clip
13 5 115-3580 Plate
14 2 8T-4184 Bolt
17 2 146-3287 Bolt
18 4 9X-8257 Washer
19 1 300-4511 Latch As
20 21 248-0102 U-Bolt
22 4 5C-7261 Nut
24 1 305-4458 Step Gp
25 12 8T-4195 Bolt
(1)
Some of the parts may be shipped already secured to the chassis or other components
(1) 281-6798 Handrail As
Note: Handrail assembly (2) is mounted to the ladder assembly before shipping. Handrail
assembly (1) is secured to handrail assembly (2) with cable straps before shipping.
1. Attach a suitable lifting device to handrail assembly (1). The weight of handrail assembly
(1) is approximately 15 kg (33 lb). Remove the cable straps that secure handrail assembly
(1) to handrail assembly (2) .
(4) 8T-4136 Bolt
2. Position handrail assembly (1) at the top of the ladder assembly. Use eight washers (3) and
eight bolts (4) in order to secure handrail assembly (1) to the top of the ladder assembly.
(4) 8T-4136 Bolt
3. Attach a suitable lifting device to handrail assembly (5). The weight of handrail assembly
(5) is approximately 10 kg (22 lb).
4. Use eight washers (3) and eight bolts (4) in order to secure handrail assembly (5) to the top
of the ladder assembly.
(8) 8T-4244 Nut
(9) 8T-4183 Bolt
(10) 8T-7087 Grommet
(11) 5P-7469 Clip
(12) 5P-7468 Clip
(13) 115-3580 Plate
5. Secure handrail assembly (1) to handrail assembly (2) with two hard washers (6), two hard
washers (7), two nuts (8), two bolts (9), two grommets (10), two clips (11), two clips (12),
and one plate (13) .
(8) 8T-4244 Nut
(11) 5P-7469 Clip
(12) 5P-7468 Clip
(14) 8T-4184 Bolt
6. Secure handrail assembly (5) to handrail assembly (1) with two hard washers (6), two hard
washers (7), two nuts (8), four grommets (10), four clips (11), and four clips (12), and two
bolts (14) .
(4) 8T-4136 Bolt
7. Attach a suitable lifting device to handrail assembly (15). The approximate weight of
handrail assembly (15) is 15 kg (33 lb).
8. Secure handrail assembly (15) to the side of the radiator module by using eight bolts (4) and
eight washers (3) .
(8) 8T-4244 Nut
(9) 8T-4183 Bolt
(11) 5P-7469 Clip
(12) 5P-7468 Clip
(13) 115-3580 Plate
9. Secure handrail assembly (15) to handrail assembly (A) by using four washers (6), four
washers (7), four nuts (8), four bolts (9), four grommets (10), four clips (11), four clips (12),
and two plates (13) .
(20) 248-0102 U-Bolt
(22) 5C-7261 Nut
10. Secure handrail assembly (15) to handrail assembly (B) by using two U-bolts (20), four
washers (21), and four nuts (22) .
Note: Two U-bolts (20), four washers (21), and four nuts (22) are part of the 335-6126
Handrail Gp or the 335-5220 Handrail Gp .
(20) 248-0102 U-Bolt
(22) 5C-7261 Nut
11. Secure handrail assembly (5) to handrail assembly (C) by using two U-bolts (20), four
Note: Two U-bolts (20), four washers (21), and four nuts (22) are part of the 335-6126
Handrail Gp or the 335-5220 Handrail Gp .
(17) 146-3287 Special Bolt
(18) 9X-8257 Washer
(19) 300-4511 Latch As
(20) 248-0102 U-Bolt
(22) 5C-7261 Nut
12. Install gate assembly (16) by using two bolts (17) and four washers (18) .
13. Install latch assembly (19) onto handrail assembly (15) by using two U-bolts (20), four
14. Attach a suitable lifting device to handrail assembly (23). The approximate weight of
handrail assembly (23) is 32 kg (70 lb).
(4) 8T-4136 Bolt
15. Secure handrail assembly (23) to the front of the radiator module by using ten bolts (4) and
ten washers (3) .
(8) 8T-4244 Nut
(9) 8T-4183 Bolt
(11) 5P-7469 Clip
(12) 5P-7468 Clip
(13) 115-3580 Plate
16. Secure handrail assembly (23) to handrail assembly (D) on the right-hand platform by using
four washers (6), four washers (7), four nuts (8), four bolts (9), four grommets (10), four
clips (11), four clips (12), and two plates (13) .
(24) 305-4458 Step Gp
(25) 8T-4195 Bolt
17. Install step group (24) to the chassis by using 12 bolts (25) and 12 washers (3) .
Install the 272-3408 Air Lines Gp

Table 93
Parts that are Required to Install the 272-3408 Air Lines Gp
1 1 278-2481 Tube As (1)
2 4 273-3538 Hose
3 4 5T-6459 Elbow (1)
4 16 219-0313 Clamp
5 16 251-0039 Clamp
6 1 278-2482 Tube As (1)
7 1 278-2479 Tube As (1)
8 1 278-2480 Tube As (1)
9 4 201-1378 Spacer
10 2 233-6699 Rod As
11 2 242-0810 Clamp
12 2 242-9806 Clamp As
14 4 8T-4244 Nut
15 2 8T-4910 Bolt
16 2 8T-5041 Bolt
17 2 291-1412 Clamp As
18 2 291-1442 Clamp As
19 20 7X-7729 Washer
20 6 8T-4133 Nut
21 2 8T-4178 Bolt
22 2 8X-3635 Strip
23 2 291-1443 Plate
24 4 291-1444 Plate
26 8 8T-4195 Bolt
27 2 9X-6605 U-Bolt
(1)
Thoroughly clean the inside of the component before installation.
(1) 278-2481 Tube As
1. Attach a suitable lifting device to tube assembly (1). The approximate weight of tube
assembly (1) is 27 kg (60 lb).
(1) 278-2481 Tube As
(2) 273-3538 Hose
(3) 5T-6459 Elbow
(4) 219-0313 Clamp
(5) 251-0039 Clamp
2. Install one hose (2) and one hose (3) onto tube assembly (1) by using two clamps (4) and
two clamps (5) .
Note: Tighten clamps (4) and clamps (5) to a torque of 10 ± 2 N·m (88 ± 18 lb in).
Note: Align clamps (4) and clamps (5) so that the T-bolts are approximate 180 degrees from
each other.
(1) 278-2481 Tube As
(4) 219-0313 Clamp
(5) 251-0039 Clamp
3. Secure tube assembly (1) to the engine and to the air cleaner by using two clamps (4) and
two clamps (5) .
Note: Tighten clamps (4) and clamps (5) to a torque of 10 ± 2 N·m (88 ± 18 lb in).
Note: Align clamps (4) and clamps (5) so that the T-bolts are approximate 180 degrees from
each other.
(1) 278-2481 Tube As
(6) 278-2482 Tube As
(7) 278-2479 Tube As
(8) 278-2480 Tube As
4. Repeat Step 1 through Step 3 for tube assembly (6), tube assembly (7), tube assembly (8) .
(1) 278-2481 Tube As
(9) 201-1378 Spacer
(10) 233-6699 Rod As
(11) 242-0810 Clamp
(12) 242-9806 Clamp As
(14) 8T-4244 Nut
(15) 8T-4910 Bolt
(16) 8T-5041 Bolt
(1) 278-2481 Tube As
(9) 201-1378 Spacer
(10) 233-6699 Rod As
(11) 242-0810 Clamp
(12) 242-9806 Clamp As
(14) 8T-4244 Nut
(15) 8T-4910 Bolt
(16) 8T-5041 Bolt
5. Secure tube assembly (1) to the chassis by using two spacers (9), one rod assembly (10), one
clamp (11), one clamp (12), four hard washers (13), two nuts (14), one bolt (15), and one
bolt (16) .
(1) 278-2481 Tube As
(17) 291-1412 Clamp As
(18) 291-1442 Clamp As
(19) 7X-7729 Washer
(20) 8T-4133 Nut
(21) 8T-4178 Bolt
6. Secure tube assembly (1) to the chassis by using one clamp assembly (17), one clamp
assembly (18), two washers (19), one nut (20), and one bolt (21) .
(1) 278-2481 Tube As
(6) 278-2482 Tube As
(19) 7X-7729 Washer
(20) 8T-4133 Nut
(22) 8X-3635 Strip
(23) 291-1443 Plate
(24) 291-1444 Plate
(26) 8T-4195 Bolt
(27) 9X-6605 U-Bolt
7. Secure tube assembly (6) to tube assembly (1) by using eight washers (19), two nuts (20),
one strip (22), one plate (23), two plates (24), two locknuts (25), four bolts (26), and one U-
bolt (27) .
Install the 272-3248 Sensor Wiring Gp for the Air Lines Group
Table 94
Parts that are Required to Install the 272-3248 Sensor Wiring Gp
1 2 277-7045 Sensor Harness As

3 22 1S-0994 Clip
4 32 8T-4137 Bolt
6 4 130-5300 Clip
7 4 9X-0262 Adapter
8 4 161-9926 Pressure Sensor Gp
10 4 328-2797 Plate As
11 1 4D-7794 Clip
(1) 277-7045 Sensor Harness As
1. Connect sensor harness assembly (1) and sensor harness assembly (2) to chassis harness
(A) .
(3) 1S-0994 Clip
(4) 8T-4137 Bolt
(6) 130-5300 Clip
2. Secure sensor harness assembly (1) to the top of tube assembly (B) by using five bolts (4),
five washers (5), four clips (3), and one clip (6) .
(4) 8T-4137 Bolt
(7) 9X-0262 Adapter
(8) 161-9926 Pressure Sensor Gp
(9) 3J-7354 O-Ring Seal
(10) 328-2797 Plate As
3. Install one adapter (7), one pressure sensor group (8), and one O-ring seal (9) to the top of
tube assembly (B). Connect pressure sensor group (8) to harness assembly (1) .
Note: Tighten pressure sensor group (8) to a torque of 10 ± 2 N·m (88 ± 18 lb in).
4. Secure one plate assembly (10) to the top tube assembly (B) by using two bolts (4) and two
washers (5) .
View of the right side
(4) 8T-4137 Bolt
(6) 130-5300 Clip
(7) 9X-0262 Adapter
(10) 328-2797 Plate As
(3) 1S-0994 Clip
(4) 8T-4137 Bolt
(11) 4D-7794 Clip
6. Secure sensor harness assembly (1) and sensor harness assembly (2) to tube assembly (B)
by using one clip (3), one bolt (4), one washer (5), and one clip (11) .
(3) 1S-0994 Clip
(4) 8T-4137 Bolt
7. Secure sensor harness assembly (2) to tube assembly (C) by using six clips (3), five bolts
(4), and five washers (5) .
(4) 8T-4137 Bolt
(7) 9X-0262 Adapter
(10) 328-2797 Plate As
8. Install one adapter (7), one pressure sensor group (8), and one O-ring seal (9) to the top of
tube assembly (C). Connect pressure sensor group (8) to harness assembly (2) .
Note: Tighten pressure sensor group (8) to a torque of 10 ± 2 N·m (88 ± 18 lb in).
(3) 1S-0994 Clip
(4) 8T-4137 Bolt
(7) 9X-0262 Adapter
(10) 328-2797 Plate As
Connect the 290-3507 Exhaust Pipe Gp to the Muffler Group

Note: The 290-3507 Exhaust Pipe Gp is already installed on the engine at the time of
shipping.
Note: The right-hand platform will need to be installed before connecting the 290-3507
Exhaust Pipe Gp .
Note: The muffler group is already installed on the right-hand platform at the time of
shipping.
1. Remove the shipping covers from the muffler group.
2. Remove the shipping covers from the 290-3507 Exhaust Pipe Gp . Retain the two band
clamps.
3. Secure tube assembly (A) and tube assembly (B) to the muffler group by using two clamps
(C) that were removed in Step 2.
Note: Do not tighten band clamps (C) to a final torque at this time.
4. Adjust bracket assemblies (D) for optimal lateral and axial alignment of the bellows
assemblies.
Note: Do not tighten bracket assemblies (D) to a final torque at this time.
Note: Do not start the engine until you have aligned the bellows assemblies and tightened
the bracket assembly and the band clamps to a final torque.
5. Tighten bracket assemblies (D) to a torque of 16 ± 4 N·m (142 ± 35 lb in). Tighten band
clamps (C) to a torque of 16 ± 4 N·m (142 ± 35 lb in). Lightly tap the bracket assemblies
(D) and both band clamps (C) in order to adjust the tube assemblies, as required.
Note: The static inspection torque for the band clamps (C) should be 9 N·m (80 lb in).
Install the 272-3371 Mirror Gp

Note: The right hand and left hand rear view mirrors can be installed to the handrails prior to
installing the right-hand platform and the left-hand walkway.
Table 95
Parts that are Needed for Installation of the 272-3371 Mirror Gp
1 1 311-3276 Tube As
2 5 7D-9969 Support
3 5 8T-6868 Bolt
5 2 134-0987 Bracket As
6 4 134-0989 Block
7 8 8T-4185 Bolt
9 1 311-7058 Mirror Gp
10 5 8T-4136 Bolt
12 1 311-3272 Tube As
13 2 7X-3391 Hard Washer
14 1 153-4010 Mirror As
15 1 265-6628 Bracket
16 2 7Y-5262 U-Bolt
17 4 8T-4133 Nut
18 1 275-5588 Mirror As
Note: Step 1 through Step 3 can be completed before the left-hand walkway is installed.
Left side
(1) 311-3276 Tube As
(2) 7D-9969 Support
(3) 8T-6868 Bolt
(5) 134-0987 Bracket As
(6) 134-0989 Block
(7) 8T-4185 Bolt
(9) 311-7058 Mirror Gp
(10) 8T-4136 Bolt
1. Secure one tube assembly (1) to handrail assembly (A) on the left-hand walkway by using
three supports (2), three bolts (3), and three washers (4) .
2. Secure one bracket assembly (5) to tube assembly (1) by using two blocks (6), four bolts
(7), and four washers (8) .
3. Secure one mirror group (9) to bracket assembly (5) by using three bolts (10), and three
washers (11) .
Note: Step 4 through Step 6 can be completed before the right-hand platform is installed.
Right side
(2) 7D-9969 Support
(3) 8T-6868 Bolt
(5) 134-0987 Bracket As
(6) 134-0989 Block
(7) 8T-4185 Bolt
(10) 8T-4136 Bolt
(12) 311-3272 Tube As
(13) 7X-3391 Hard Washer
(14) 153-4010 Mirror As
4. Secure one tube assembly (12) to handrail assembly (B) on the right-hand platform by using
two supports (2), two bolts (3), and two washers (13) .
5. Secure one bracket assembly (5) to tube assembly (12) by using two blocks (6), four bolts
6. Secure one mirror assembly (14) to bracket assembly (5) by using two bolts (10), and two
washers (11) .
Typical view of the location for the mirror assembly on the right-hand platform
Typical view
(15) 265-6628 Bracket
(16) 7Y-5262 U-Bolt
(17) 8T-4133 Nut
(18) 275-5588 Mirror As
7. Secure one bracket (15) to handrail assembly (C) on the right-hand platform by using two U
-bolts (16), four washers (11), and four nuts (17) .
8. Secure one mirror assembly (18) to bracket (15). Tighten the locknut on mirror assembly
(18) to a torque of 25 ± 5 N·m (220 ± 44 lb in).
Install the Cab

Install the 276-6080 Cab Mounting Gp
Table 96
Parts that are required to Install the 276-6080 Cab Mounting Gp
1 8 6Y-9950 Mount As
2 8 9W-7385 Sleeves
3 8 9W-7388 Washers
4 2 287-3037 Pin as
5 2 304-0299 Pin as
6 8 233-6978 Hard Washers
7 4 7X-7729 Washers
8 8 8T-0672 Bolts
9 4 8T-4195 Bolts
1. Remove paint, grease, dirt, and debris from the mating surfaces that are on the Rollover
Protective Structure (ROPS) Mounting Gp.
Note: Step 1 can be completed before the cab mounting group is installed.
(1) 6Y-9950 Mount As
2. Install the top of eight mount assemblies (1) into the top of the bores of the support
assemblies.
3. Remove the hardware that secures the cab to the pallet. Discard all the hardware that was
used for shipping.
4. Attach a suitable lifting device to the cab assembly. The weight of the cab assembly is
5. Position the cab assembly onto the support assemblies on the left side of the machine.
Sectional view
(2) 9W-7385 Sleeve
(3) 9W-7388 Washer
(8) 8T-0672 Bolt
(2) 9W-7385 Sleeve
(3) 9W-7388 Washer
(8) 8T-0672 Bolt
6. Install the bottom of eight mount assemblies (1), eight sleeves (2), eight washers (3), eight
washers (6), and eight bolts (8) to the bottom of the cab.
7. Tighten eight bolts (8) to a torque of 800 ± 100 N·m (590 ± 75 lb ft).
(4) 287-3037 Pin As
(7) 7X-7729 Washer
(9) 8T-4195 Bolt
8. Install two pin assemblies (4), two bolts (9), and two washers (7) in order to secure the left-
hand side of the cab.
(5) 304-0299 Pin As
(7) 7X-7729 Washer
(9) 8T-4195 Bolt
9. Install two pin assemblies (5), two bolts (9), and two washers (7) in order to secure the right
-hand side of the cab.
Install the Air Hoses and Install the Electrical Connection for the Cab
View of the right-hand side of the cab
1. Remove the tape and the plugs from the side of the cab assembly and remove the straps
from the hoses and harnesses that connect to the cab assembly.
View of cover (A)
2. Remove cover (A) by removing eight bolts (B) and eight washers (C) .
View of cover (A) removed
3. Insert four video cables (E) into the 348-9226 Grommet Assembly (D) and secure grommet
(D) into the second hole drilled in the plate that is located at the right rear corner of the cab.
Torque the nut of the 348-9226 Grommet Assembly to 20 ± 2 N·m (15 lb ft ± 1 lb ft). Pass
the excess video cable into the electronics bay.
Note: The ends of cables (E) are located in the cab.
4. Connect the four video cables from the cameras to the four video cables from the display.
Refer to Table 97.
Table 97
Video Cables to Display Video Cables to Camera Cable Color
1 Front Red
2 Right Blue
3 Rear Green
4 Left Yellow
5. Secure the harnesses in the electronics bay with the 3S-2093 Cable Strap .
6. Refer to the following sections in order to complete the connections to the side of the cab:
◦ ""Connect the 277-3328 Chassis Wiring Gp to the Cab" "
◦ ""Connect the 272-3249 Air Conditioner Lines Gp to the Cab" "
◦ ""Connect the 272-3251 Heater Lines Gp to the Cab" "
◦ ""Connect the 272-3313 Chassis Wiring Gp to the Cab" "
Note: Use tie straps to secure the loose hoses and harnesses.
Note: All the connectors and adjacent wires for the harness assemblies should be free of
paint, dirt, debris, or grease.
Connect the 277-3328 Chassis Wiring Gp to the Cab
Table 98
1 1 361-2206 Bracket As
2 1 293-6308 Bracket As
3 4 8T-4137 Bolt
5 2 8T-6466 Bolt
6 2 6W-7636 Spacer
7 2 6D-4247 Clip
8 2 9D-1829 Clip
(1) 361-2206 Bracket As
(2) 293-6308 Bracket As
(3) 8T-4137 Bolt
1. Secure one bracket assembly (1) and one bracket assembly (2) to the side of the cab by
using four bolts (3) and four hard washers (4) .
(A) 380-8411 Chassis Harness As
(B) 279-0488 Engine Harness As
(C) 278-7735 Chassis Harness As
2. Connect rear chassis harness assembly (A), engine harness assembly (B), and chassis
harness assembly (C) to the right side of the cab.
(1) 361-2206 Bracket As
(2) 293-6308 Bracket As
(5) 8T-6466 Bolt
(6) 6W-7636 Spacer
(7) 6D-4247 Clip
(8) 9D-1829 Clip
3. Use two bolts (5), two washers (4), two spacers (6), two clips (7), and two clips (7) in order
to secure the harnesses to bracket assembly (1) and bracket assembly (2) .
Connect the 272-3249 Air Conditioner Lines Gp to the Cab
1. Remove the shipping caps from the air conditioner lines.
(D) 338-0039 Hose As
(E) 338-0035 Hose As
2. Connect hose assembly (D) and hose assembly (E) to the side of the cab.
Note: Tighten hose assembly (D) to a torque of 62 ± 1 N·m (550 ± 9 lb in).
Note: Tighten hose assembly (E) to a torque of 49 ± 1 N·m (433 ± 9 lb in).
Connect the 272-3251 Heater Lines Gp to the Cab
Table 99
Parts that are Required to Connect the 272-3251 Heater Lines Gp
1 2 9X-2488 Hose Clamp

2 1 8T-6466 Bolt
4 1 6W-7636 Spacer
5 2 9X-8250 Clip
(F) Hose assembly with a 1V-1122 Identification Tag "SPL"
(G) Hose assembly with a 1V-1123 Identification Tag "RET"
Note: Each hose assembly has an identification tag.
NOTICE
Open the heater valves that are located on the engine after the
installation of the heater hoses to the cab.
1. Install heater hose assembly (F) and heater hose assembly (G) to the cab assembly. Use two
clamps (1) in order to secure hose assembly (F) and hose assembly (G). Tighten clamps (1)
to a torque of 4.5 ± 0.5 N·m (40 ± 4.5 lb in).
Note: Cutting the hoses to the proper length before installation may be necessary.
2. Secure hose assembly (F) and hose assembly (G) to the bracket assembly by using one bolt
(2), one washer (3), one spacer (4), and two clips (5) .
Connect the 272-3313 Chassis Wiring Gp to the Cab
Table 100
1 1 8T-4179 Bolt
3 1 8T-6466 Bolt
5 1 6W-7636 Spacer
6 2 2V-1771 Grommet
7 2 6D-4246 Clip
8 2 4D-7388 Clip
1. Connect harness (H) and cable (J) to the cab.
2. Secure cable (J) to cab by using one bolt (1) and one washer (2) .
3. Secure cable (J) to the top bracket assembly by using one bolt (3), one washer (4), one
spacer (5), one grommet (6), and one clip (7) .
4. Secure cable (J) to the bottom bracket assembly by using the existing bolt, washer, and
spacer from the 272-3251 Heater Lines Gp and one grommet (6), and one clip (7) .
5. Secure harness assembly (H) to the bracket assemblies by using the existing hardware from
the 277-3328 Chassis Wiring Gp and two clips (8) .
Connect the 272-3311 Steering Lines Gp to the Cab
View of the left-hand side of the chassis
1. Remove the ties that secure the hoses for the steering lines group.
View of the bottom right-hand side of the cab
(A) 345-7983 Hose As with 8R-4853 Identification Tag "P"
(B) 345-7981 Hose As with 1V-6274 Identification Tag "R"
(C) 345-7982 Hose As with 4J-6311 Identification Tag "11"
(D) 345-7980 Hose As with 1V-6276 Identification Tag "T"
(E) 335-6127 Hose As with 1V-6277 Identification Tag "L"
2. Use the identification tags that are on the hoses in order to connect the hoses to the cab.
Connect the 272-3295 Service Brake Control Gp to the Cab
View of the left-hand side of the chassis
1. Remove the ties that secure the hoses for the service brake control group.
View of the bottom right-hand side of the cab
(A) 345-7985 Hose As with 4J-6303 Identification Tag "3"
(B) 345-7986 Hose As with 4J-6302 Identification Tag "2"
(C) 336-8850 Hose As with 4J-6301 Identification Tag "1"
2. Use the identification tags that are on the hoses in order to connect the hoses to the cab.
Install the Cooling Module

Install the Radiator Module
Table 101
Parts that are Needed for Installation of the Radiator Module
1 14 7X-2489 Bolt (1)
2 14 198-4782 Hard Washer (1)
3 6 8T-4956 Bolt (2)
4 6 5P-1076 Hard Washer (2)
5 4 8T-4186 Bolt (3)
6 8 8T-4121 Hard Washer (3)
7 4 8T-4133 Nut (3)
8 1 310-6863 Expansion Tank As (4)
9 8 8T-4186 Bolt (4)
10 8 8T-4121 Hard Washer (4)
11 4 8T-4910 Bolt (4)
12 4 8T-4223 Hard Washer (4)
13 1 1P-3709 Rectangular Seal (4)
14 1 217-4193 Hose (5)
15 4 239-5609 Clamp (5)

16 1 7D-8991 Hose (5)
17 4 220-4126 Clamp (5)
18 2 273-3538 Hose (6)
19 8 135-6261 Clamp (6)
(1)
Part of the 272-3254 Cowling Gp
(2)
Part of the 338-0001 Radiator Gp
(3)
Part of the 272-3255 Ladder Gp
(4)
(5)
(6)
Part of the 289-3269 Air Lines Gp
1. Prepare the mating surfaces on both sides of the chassis by removing any paint, dirt, grease,
and rust.
2. Remove and discard the protective covers from the tube assemblies on the front of the
machine.
3. Remove and discard the protective covers from the tube assemblies and hose assemblies
from the radiator module.
Note: In order to install the radiator module, you may need to remove two tube assemblies
(BB) .
4. Attach a suitable lifting device with two suitable lifting eyes to the top of the radiator
module.
Note: The approximate weight of the radiator module is 4720 kg (10400 lb).
5. Position the radiator module onto the chassis.
(1) 7X-2489 Bolt
6. Secure the radiator module to the chassis by using 14 bolts (1) and 14 washers (2). Tighten
14 bolts (1) to a torque of 800 ± 100 N·m (590 ± 75 lb ft).
(3) 8T-4956 Bolt
7. Secure the radiator module to the chassis by using six bolts (3) and six washers (4) .
8. Secure the top of the radiator module to the chassis by using the two link groups.
Note: As needed, adjust the two link groups.
(5) 8T-4186 Bolt
(7) 8T-4133 Nut
(5) 8T-4186 Bolt
(7) 8T-4133 Nut
9. Secure the ladder group to the chassis by using four bolts (5), eight washers (6), and four
nuts (7) .
Connect the Hydraulic Fan Lines Group to the Radiator Module
Note: The 288-0492 Hydraulic Fan Lines Gp is on machines that are equipped with shallow grade
braking packages. The 272-3278 Hydraulic Fan Lines Gp is on machines that are equipped with
steep grade braking packages.
1. Use the existing hardware in order to secure hose assembly (B) and hose assembly (C) to
makeup valve (D) .
Typical view with then engine removed
View from the top of the machine
2. Secure hose assembly (E) to hose assembly (F) .
Connect the 272-3257 Water Lines Gp to the Radiator Module
1. Remove the shipping plate from tube assembly (G) at the top of the radiator module.
(8) 310-6863 Expansion Tank As
2. Attach a suitable lifting device to expansion tank assembly (8) .
Note: The approximate weight of expansion tank assembly (8) is 170 kg (375 lb).
(8) 310-6863 Expansion Tank As
(9) 8T-4186 Bolt
3. Secure expansion tank assembly (8) to the top of the radiator module by using eight bolts
(9) and eight washers (10) .
(11) 8T-4910 Bolt
(13) 1P-3709 Rectangular Seal
4. Connect tube assembly (G) to the bottom of tank assembly (8) by using the four bolts (11),
four washers (12), and one rectangular seal (13) .
5. Connect hose assembly (H) to the bottom of tank assembly (8) .
Connect the 272-3431 Water Lines Gp to the Radiator Module
(14) 217-4193 Hose
(15) 239-5609 Clamp
1. Connect tube assembly (J) from the radiator module to tube assembly (K) by using one hose
(14) and four clamps (15) .
Note: Assemble each pair of clamps (15) with the T-bolts 180 degrees away from each
other.
(16) 7D-8991 Hose
(17) 220-4126 Clamp
(16) 7D-8991 Hose
(17) 220-4126 Clamp
2. Connect tube assembly (L) from the radiator module to tube assembly (M) to the engine by
using one hose (16) and four clamps (17) .
other.
3. Secure hose assembly (N) to tube assembly (L) .
View of the front left-hand side of the radiator module
4. Connect hose assembly (P) to hose assembly (R) .
5. Connect hose assembly (S) to the bottom of the expansion tank assembly.
Note: Step 5 will have to be completed after the expansion tank assembly is installed.
Connect the Hose Assembly for the 272-5377 Service Center Gp to the Radiator Module
1. Connect hose assembly (T) to the bottom of the radiator module.
Connect the 289-3269 Air Lines Gp to the Radiator Module
Note: The tube assemblies that are located on the outside of the radiator may have been removed
in order to install the radiator module.
Note: Ensure that all tube assemblies are clean prior to installation.
View of the left-hand side of the radiator module
(18) 273-3538 Hose
(19) 135-6261 Clamp
1. Connect tube assembly (U) to tube assembly (V) by using one hose (18) and four clamps
(19) .
Note: Tighten four clamps to a torque of 7.5 ± 1 N·m (66 ± 8.8 lb in).
other.
View of the right-hand side of the radiator module
(18) 273-3538 Hose
(19) 135-6261 Clamp
2. Connect tube assembly (W) to tube assembly (X) by using one hose (18) and four clamps
(19) .
Note: Tighten four clamps to a torque of 7.5 ± 1 N·m (66 ± 8.8 lb in).
other.
Connect the 272-3313 Chassis Wiring Gp to the 272-3279 Sensor Wiring Gp for the Radiator
Module
1. Connect chassis wiring harness (Y) to sensor wiring harness (Z) for the radiator module.
Note: The connection for the two harnesses is located on the top left side of the radiator
module.
Install the 272-3409 Water Lines Gp to the Radiator Module

Table 102
Parts that are Required for Installation of the 272-3409 Water Lines Gp
1 1 333-7690 Hose As
2 1 334-3678 Plate As
3 1 9X-2494 U-Bolt
5 2 2K-4973 Locknut
6 1 5P-7468 Clip
7 1 5P-7469 Clip
8 1 6V-4349 Grommet
9 1 8T-4139 Bolt
11 1 153-6237 Elbow As
12 1 148-8408 Plug As
1. Install one hose assembly (1) between tee assembly (A) at the top of the engine and the
bottom of expansion tank assembly (B) .
2. Secure hose assembly (1) to the machine by using one plate assembly (2), one U-bolt (3),
two washers (4), two locknuts (5), one clip (6), one clip (7), one grommet (8), one bolt (9),
one hard washer (10), and one elbow assembly (11) .
3. Install one plug assembly (12) to the bottom of expansion tank assembly (B) .
Install the 288-2624 Air Lines Gp to the Radiator Module

Table 103
Parts that are Required for Installation of the 288-2624 Air Lines Gp
1 1 328-9073 Tube As
2 1 328-9072 Tube As
3 2 294-7373 Hose
4 8 135-6261 Clamp
5 2 334-3675 Hose
6 4 342-1323 Band Clamp

7 4 8T-4956 Bolt
9 1 328-9684 Plate As
10 1 329-3050 Plate As
11 8 8T-4183 Bolt
12 6 329-3555 Half Clip
13 2 344-2653 Bracket As
14 8 8T-4195 Bolt
15 14 198-4777 Hard Washer
16 1 344-2658 Plate
17 6 8T-4186 Bolt
19 6 8T-4133 Nut
21 4 8T-4244 Nut
22 1 292-6724 Plate As
23 15 8T-4137 Bolt
1. Remove the shipping covers from the top of tube assembly (AA) and tube assembly (AB) at
the top of the radiator module.
(1) 328-9073 Tube As
(2) 328-9072 Tube As
(3) 294-7373 Hose
(4) 135-6261 Clamp
2. Secure tube assembly (1) and tube assembly (2) to tube assembly (AC) and tube assembly
(AD) by using two hoses (3) and eight clamps (4) .
Note: Tighten eight clamps (4) to a torque of 7.5 ± 1 N·m (66 ± 8.8 lb in).
Note: Assemble each pair of clamps (4) with the T-bolts 180 degrees away from each other.
(1) 328-9073 Tube As
(2) 328-9072 Tube As
(5) 334-3675 Hose
(6) 342-1323 Band Clamp
3. Secure tube assembly (1) and tube assembly (2) to tube assembly (AA) and tube assembly
(AB) by using two hoses (5) and four band clamps (6) .
Note: Tighten four band clamps to a torque of 7.5 ± 1 N·m (66 ± 8.8 lb in).
Note: Install two hoses (5) at 10 mm (0.394 inch) axial compression.
(1) 328-9073 Tube As
(2) 328-9072 Tube As
(7) 8T-4956 Bolt
(9) 328-9684 Plate As
(10) 329-3050 Plate As
(11) 8T-4183 Bolt
(12) 329-3555 Half Clip
4. Secure tube assembly (1) and tube assembly (2) to the rear of the radiator module by using
four bolts (7), eight washers (8), one plate assembly (9), one plate assembly (10), four bolts
(11), and four half clips (12) .
Note: Do not final tighten bolts (7) and bolts (11) until all the tube assemblies are aligned
and all the hardware is installed.
(1) 328-9073 Tube As
(2) 328-9072 Tube As
(11) 8T-4183 Bolt
(12) 329-3555 Half Clip
(13) 344-2653 Bracket As
(14) 8T-4195 Bolt
(16) 344-2658 Plate
(17) 8T-4186 Bolt
(19) 8T-4133 Nut
(21) 8T-4244 Nut
5. Secure tube assembly (1) and tube assembly (2) to the top of the radiator module by using
two bracket assemblies (13), eight bolts (14), 14 washers (15), one plate (16), six bolts (17),
six washers (18), six nuts (19), two half clips (12), four bolts (11), four washers (8), four
Note: Do not final tighten bolts (11) and bolts (17) until all the tube assemblies are aligned
and all the hardware is installed.
(22) 292-6724 Plate As
6. Attach a suitable lifting device to plate assembly (22) .
Note: The approximate weight of plate assembly (22) is 45 kg (100 lb).
(22) 292-6724 Plate As
(23) 8T-4137 Bolt
7. Secure plate assembly (22) to the top of the radiator module by using 15 bolts (23) and 15
washers (18) .
Install the 272-3282 Truck Hood Gp

Table 104
Parts that are Required for Installation of 272-3282 Truck Hood Gp
1 1 346-4338 Plate As
2 114 8T-4136 Bolt
4 50 7X-7729 Washer
5 1 346-4331 Plate As
6 1 346-4220 Plate As
7 1 346-4386 Plate As
8 1 346-4389 Plate As
9 4 8T-4195 Bolt
10 1 346-4392 Plate As
11 1 346-4226 Plate As
12 1 346-4342 Hood Panel As
13 5 347-4475 Strut
14 1 358-5498 Plate
15 2 347-1000 Plate As
16 14 8T-4133 Nut
17 3 320-6679 Prop Assembly
18 3 346-4337 Plate
19 3 9D-8353 Pin
21 3 3B-4627 Cotter Pin
22 6 8T-4189 Bolt
25 4 347-4474 Strut As
27 1 346-4411 Plate As
28 6 8Y-4000 Latch As
29 12 5B-2183 Jam Nut
30 12 3T-7857 Button Plug
31 2 358-9608 Plate
32 4 358-9609 Plate
(1) 346-4338 Plate As
(2) 8T-4136 Bolt
1. Secure one plate assembly (1) to the frame by using eight bolts (2) and eight washers (3) .
(1) 346-4338 Plate As
(2) 8T-4136 Bolt
(4) 7X-7729 Washer
(5) 346-4331 Plate As
2. Attach a suitable lifting device to plate assembly (5). The approximate weight of plate
3. Secure plate assembly (5) to the frame by using three bolts (2) and three washers (4). Secure
the other side of plate assembly (5) to plate assembly (1) by using three bolts (2) and three
washers (4) .
(1) 346-4338 Plate As
(2) 8T-4136 Bolt
(4) 7X-7729 Washer
(6) 346-4220 Plate As
4. Attach a suitable lifting device to plate assembly (6). The approximate weight of plate
5. Secure plate assembly (6) to the front walkway assemblies by using five bolts (2) and five
washers (4). Secure the other side of plate assembly (6) to plate assembly (1) by using three
bolts (2) and three washers (4) .
(2) 8T-4136 Bolt
(7) 346-4386 Plate As
(8) 346-4389 Plate As
(9) 8T-4195 Bolt
6. Secure plate assembly (7) to the frame by using four bolts (9) and four washers (3) .
7. Secure plate assembly (8) to the frame by using eight bolts (2) and eight washers (3) .
(2) 8T-4136 Bolt
(4) 7X-7729 Washer
(10) 346-4392 Plate As
8. Secure one plate assembly (10) to the plate assemblies that were installed in Step 6 and Step
7 by using seven bolts (2) and seven washers (4) .
(2) 8T-4136 Bolt
(4) 7X-7729 Washer
(11) 346-4226 Plate As
9. Secure plate assembly (11) to the front walkway and to the plate assembly that was installed
in Step 7 by using eight bolts (2) and eight washers (4) .
(12) 346-4342 Hood Panel As
10. Attach a suitable lifting device to hood panel assembly (12). The approximate weight of
hood panel assembly (12) is 200 kg (440 lb).
(2) 8T-4136 Bolt
(4) 7X-7729 Washer
11. Secure the hinge assembly for hood panel assembly (12) to the frame by using 17 bolts (2)
(13) 347-4475 Strut
12. Install five struts (13) between plate assembly (12) and the brackets on the frame.
(2) 8T-4136 Bolt
(4) 7X-7729 Washer
(5) 346-4331 Plate As
(14) 358-5498 Plate
(15) 347-1000 Plate As
(16) 8T-4133 Nut
13. Secure plate (14) to the frame by using two bolts (2) and two washers (4) .
14. Secure one plate assembly (15) to plate (14) by using two bolts (2), two washers (4), and
two nuts (16). Secure plate assembly (15) to the bottom of plate assembly (5) by using four
bolts (2) and four washers (3) .
(15) 347-1000 Plate As
(17) 320-6679 Prop Assembly
(18) 346-4337 Plate
(19) 9D-8353 Pin
(21) 3B-4627 Cotter Pin
(22) 8T-4189 Bolt
15. Install one prop assembly (17) between plate assembly (15) and plate assembly (12) by
using one plate (18), one pin (19), one washer (20), one cotter pin (21), two bolts (22), and
two washers (23) .
(2) 8T-4136 Bolt
17. Secure hood panel assembly (24) to the machine by using 12 bolts (2) and 12 washers (3) .
(2) 8T-4136 Bolt
(11) 346-4226 Plate As
(15) 347-1000 Plate As
(25) 347-4474 Strut As
18. Install two struts (25) between hood panel assembly (24) and the brackets below the hood
panel assembly.
19. Install one plate assembly (15) to the bottom of plate assembly (11) by using four bolts (2)
and four washers (3) .
(15) 347-1000 Plate As
(18) 346-4337 Plate
(19) 9D-8353 Pin
(22) 8T-4189 Bolt
(18) 346-4337 Plate
(19) 9D-8353 Pin
(22) 8T-4189 Bolt
20. Install one prop assembly (17) between plate assembly (15) and hood panel assembly (24)
by using one plate (18), one pin (19), one washer (20), one cotter pin (21), two bolts (22),
and two washers (23) .
(2) 8T-4136 Bolt
22. Secure hood panel assembly (26) to the machine by using 12 bolts (2) and 12 washers (3) .
(25) 347-4474 Strut As
23. Install two struts (25) between hood panel assembly (26) and the two brackets that are
below hood panel assembly (26) .
(2) 8T-4136 Bolt
(6) 346-4220 Plate As
(18) 346-4337 Plate
(19) 9D-8353 Pin
(22) 8T-4189 Bolt
24. Secure plate assembly (27) to the bottom of plate assembly (6) by using four bolts (2) and
four washers (3) .
25. Install one prop assembly (17) between plate assembly (27) and hood panel assembly (26)
by using one plate (18), one pin (19), one washer (20), one cotter pin (21), two bolts (22),
and two washers (23) .
(2) 8T-4136 Bolt
(16) 8T-4133 Nut
(28) 8Y-4000 Latch As
(29) 5B-2183 Jam Nut
(30) 3T-7857 Button Plug
(31) 358-9608 Plate
(32) 358-9609 Plate
26. Install six latch assemblies (28), two plates (31), four plates (32), and 12 plugs (30) to the
top of the hood panel assemblies by using 12 bolts (2), 12 washers (3), 12 nuts (16), and 12
nuts (29) .
27. In needed, adjust the plates so that the hoods are level. Adjusting the plates must be
performed after all of the hoods are installed.
Install the 328-1180 Stairway Gp (Powered Access) (If Equipped)

Table 105
Required Parts to Install the 328-1180 Stairway Gp (Powered Access)
1 1 328-1150 Platform Gp
2 8 8T-7338 Bolt
4 1 328-1181 Stairway As
5 2 328-1178 Hub
6 2 5A-4885 Plug Button
7 16 8T-4182 Bolt
9 1 354-0504 Handrail Gp
10 1 354-0505 Handrail Gp
11 8 8T-4136 Bolt
13 1 347-2419 Pipe As
14 1 348-5606 Pipe As
15 2 348-5587 Pipe As
16 8 8C-8585 Screw
17 8 9X-2027 Washer
18 8 336-7053 Bushing
19 2 8T-4179 Bolt
21 1 341-5895 Strap
Typical view of the 328-1150 Platform Gp (4)
(A) Tread plate
(B) Bolt
(C) Washer
(1) 328-1150 Platform Gp
1. Remove tread plate (A) from the top of platform group (1) by removing eight bolts (B) and
eight washers (C). Retain all the hardware.
View of the right-hand side of the front bumper
(2) 8T-7338 Bolt
2. Attach a suitable lifting device to platform group (1).
Note: The approximate weight of platform group (1) is 235 kg (518 lb).
3. Secure platform group (1) to the right side of the bumper assembly by using eight bolts (2)
and eight hard washers (3) .
4. After platform group (1) has been secured, resecure tread plate (A) that was removed in
Step 1.
Typical view
(4) 328-1181 Stairway As
(5) 328-1178 Hub
(6) 5A-4885 Plug Button
(7) 8T-4182 Bolt
5. Attach a suitable lifting device to stairway assembly (4) .
The approximate weight of stairway assembly (4) is 115 kg (250 lb).
6. Secure stairway assembly (4) to platform group (1) by using two hubs (5), two plug buttons
(6), 16 bolts (7), and 16 hard washers (8) .
(4) 328-1181 Stairway As
(9) 354-0504 Handrail Gp
(11) 8T-4136 Bolt
7. Secure handrail group (9) and handrail group (10) to stairway assembly (4) by using eight
bolts (11) and eight hard washers (12) .
Typical view
(13) 347-2419 Pipe As
(14) 348-5606 Pipe As
(15) 348-5587 Pipe As
(16) 8C-8585 Screw
(17) 9X-2027 Washer
(18) 336-7053 Bushing
8. Secure pipe assembly (13) and one pipe assembly (15) between tube assembly (E) and
handrail group (9) by using four screws (16), four washers (17), and four bushings (18) .
9. Secure pipe assembly (14) and one pipe assembly (15) between pipe assembly (D) and
handrail group (10) by using four screws (16), four washers (17), and four bushings (18) .
(F) Cover
10. Remove cover (F) from the rear of the platform group. Retain cover (F) and all mounting
hardware.
Illustration 468
(G) Harness assembly
(H) Cable assembly
(19) 8T-4179 Bolt
(21) 341-5895 Strap
11. Connect cable assembly (H) and platform harness assembly (G) to the side of platform
group (1) .
Note: Tighten the bolt for cable assembly (H) to a torque of 35 ± 5 N·m (26 ± 3.7 lb ft).
12. Secure strap (21) to the platform group and the frame by using two bolts (19) and two hard
washers (20) .
13. Secure cable assembly (H) and platform harness assembly (G) by using the existing clips
that are shipped already secured to platform group (1) .
14. Resecure cover (D) that was removed in Step 10.
Install the 272-3377 Walkway Gp (Right Hand)

Table 106
Parts that are Required to Install the 272-3377 Walkway
1 3 8T-4956 Bolt
2 3 8T-4139 Bolt
1. Attach a suitable lifting device to walkway assembly (A). The approximate weight of
walkway assembly (A) is 83 kg (183 lb).
2. Position walkway assembly (A) against the right side of the bumper.
3. Use six hard washers (3), three bolts (1), and three bolts (2) in order to secure walkway
assembly (A) to the right side of the bumper.
Install the 300-4179 Walkway Gp (Left Hand)

Table 107
Parts that are Required to Install the 289-1018 Walkway (Left Hand)
1 6 5P-2566 Bolt
1. Attach a suitable lifting device to walkway assembly (A). The approximate weight of
walkway assembly (A) is 70 kg (155 lb).
2. Position walkway assembly (A) against the left side of the bumper.
3. Secure walkway assembly (A) to the left side of the bumper by using six bolts (1) and six
hard washers (2) .
Install the 293-0351 Step Gp

Table 108
Parts that are Needed for Installation of the 293-0351 Step Gp
1 1 292-5639 Step As
2 8 8T-4186 Bolt
1. Secure step assembly (1) to the right inside of the chassis by using eight bolts (2) and eight
washers (3) .
Install the Grease Tank and the Fast Fill Control Box
The grease tank for the autolubrication, the plate assemblies, and the control box for the fast fill
are all shipped connected to each other.
Note: The grease tank is part of the 288-2628 Air Starting Lines Gp .
Note: The plate assemblies that support the grease tank and the control box are part of the 272-
3252 Central Lubrication Lines Gp .
Note: The control box is part of the 293-7875 Service Center Gp or the 272-5377 Service Center
Gp . The 293-7875 Service Center Gp is for machines that are equipped with the Oil Renewal
System (ORS). The 272-5377 Service Center Gp is for machines that are not equipped with ORS.
Table 109
Parts that are Needed for Installation of Grease Tank and the Fast Fill Control Box
1 4 8T-4956 Bolt
1. Remove the ties that secure the hoses for the fast fill and the auto lubrication.
2. Remove the caps and covers from the back of the fast fill control box.
3. Attach a suitable lifting device to the grease tank and control box. The approximate weight
of the grease tank and control box is 120 kg (265 lb).
4. Secure the plate assembly to the chassis by using four bolts (1) and four washers (2) .
(A) 334-9099 Hose As
(B) 344-8620 Hose As
(C) 314-5277 Hose As
(D) 342-2790 Hose As
(E) 334-5817 Hose As
(F) 322-6520 Hose As for machines that are equipped with ORS, and 308-6925 Hose As for machines that
are not equipped with ORS
5. Connect the six hoses to the back of the control box for the fast fill.
Note: Refer to Service Manual, KENR8749, "797F Off-Highway Truck Automatic

Lubrication System for Electric Start and Air Start Equipped Trucks " for additional
information about the Automatic Lubrication System.
6. Connect the 336-0866 Hose As (G) to the grease tank.
Connect the Electrical Harnesses to the Grease Tank
Top view of an electrically controled grease tank
(H) Liquid level switch for the tank "802-YL", Normally Open
(J) Liquid level switch for the tank "674-BU", Common
(K) 277-5279 Chassis Harness As
Top view of an air controlled grease tank
(H) Liquid level switch for the tank "AC-T8", "802-YL" Normally Open
(J) Liquid level switch for the tank "AC-T4", "674-BU" Common
1. Connect the electrical harnesses to the grease tank.
Connect the Air Hose to the Grease Tank (If Equipped)
1. Connect the 340-5192 Hose As (L) to the grease tank.
Install the 293-2952 Fender Gp

Note: The 293-2955 Fender As is already installed on the right-hand platform.
Note: The 293-2956 Fender As is installed in the Section ""Install the Left Hand Walkway" ".
Table 110
Parts that are Needed for Installation of 293-2952 Fender Gp
1 1 345-9152 Plate As
2 21 8T-4136 Bolt
4 1 344-7325 Mud Guard
5 128 8T-4195 Bolt
6 125 8T-4222 Plated Washer
7 3 347-4043 Strip
8 1 345-9153 Plate As
9 4 8T-4779 Bolt
10 4 9X-8257 Washer
11 6 347-6605 Strip
12 2 338-5492 Mud Guard
13 1 340-8390 Bracket As
14 14 8T-4139 Bolt
16 1 344-9298 Plate As
17 6 8T-4137 Bolt
18 1 344-7324 Mud Guard
19 1 341-2483 Plate As
20 1 294-1986 Bracket As
21 1 306-7545 Mud Deflector
22 1 306-7555 Mud Deflector
23 1 321-7481 Plate As
24 1 305-5573 Plate As
25 1 321-7489 Plate
26 1 321-7490 Plate
27 1 348-2750 Mud Guard
28 1 348-3039 Strip
29 1 294-4886 Plate As
30 1 321-7480 Plate As
31 2 321-7487 Plate
32 1 294-4883 Mud Guard
33 1 321-7486 Strip
34 4 8T-4244 Nut
35 2 8T-4956 Bolt
36 2 306-9575 Plate As
37 16 8T-4137 Bolt
38 1 330-4316 Plate
Install the Mud Guards to the Front of the Left Fender
(1) 345-9152 Plate As
(2) 8T-4136 Bolt
(4) 344-7325 Mud Guard
(5) 8T-4195 Bolt
(6) 8T-4222 Plated Washer
(7) 347-4043 Strip
1. Secure plate assembly (1) to the bottom of the walkway assembly on the left side of the
machine by using seven bolts (2) and seven washers (3) .
2. Secure mud guard (4) to plate assembly (1) by using seven bolts (5), seven washers (6), and
one strip (7) .
(8) 345-9153 Plate As
(9) 8T-4779 Bolt
(10) 9X-8257 Washer
3. Secure plate assembly (8) to the back of the air cleaner by using two bolts (9) and two
washers (10) .
(5) 8T-4195 Bolt
(8) 345-9153 Plate As
4. Secure plate assembly (8) to fender assembly (A) on the left side of the machine by using
one bolt (5) and one washer (6) .
(4) 344-7325 Mud Guard
(5) 8T-4195 Bolt
(8) 345-9153 Plate As
(11) 347-6605 Strip
5. Secure plate assembly (8) to the bottom of mud guard (4) by using six bolts (5), six washers
(6), and one strip (11) .
(5) 8T-4195 Bolt
(8) 345-9153 Plate As
(11) 347-6605 Strip
(12) 338-5492 Mud Guard
(13) 340-8390 Bracket As
(14) 8T-4139 Bolt
6. Secure bracket assembly (13) to the left side of the radiator module by using six bolts (14)
and six washers (15) .
7. Secure mud guard (12) to plate assembly (8) by using six bolts (5), six washers (6), and one
strip (11) .
8. Secure mud guard (12) to bracket assembly (13) by using six bolts (5), six washers (6), and
one strip (11) .
Install the Mud Guards to the Front of the Right Fender
(16) 344-9298 Plate As
(17) 8T-4137 Bolt
1. Secure plate assembly (16) to the bottom of the right-hand platform by using six bolts (17)
and six washers (3) .
(5) 8T-4195 Bolt
(7) 347-4043 Strip
(16) 344-9298 Plate As
(18) 344-7324 Mud Guard
2. Secure mud guard (18) to the bottom of plate assembly (16) by using seven bolts (5), seven
washers (6), and one strip (7) .
(5) 8T-4195 Bolt
(9) 8T-4779 Bolt
(10) 9X-8257 Washer
(19) 341-2483 Plate As
3. Secure plate assembly (19) to the back of the air cleaner and the right-hand fender by using
two bolts (9), two washers (10), one bolt (5), and one washer (6) .
(5) 8T-4195 Bolt
(11) 347-6605 Strip
(18) 344-7324 Mud Guard
(19) 341-2483 Plate As
4. Secure mud guard (18) to plate assembly (19) by using six bolts (5), six washers (6), and
one strip (11) .
(5) 8T-4195 Bolt
(11) 347-6605 Strip
(12) 338-5492 Mud Guard
(14) 8T-4139 Bolt
(19) 341-2483 Plate As
(20) 294-1986 Bracket As
5. Install one bracket assembly (20) to the right side of the radiator module assembly by using
six bolts (14) and six washers (15) .
6. Secure one mud guard (12) to plate assembly (19) and bracket assembly (20) by using 12
bolts (5), 12 washers (6), and two strips (11) .
Install the Mud Guards to the Sides of the Fenders
(5) 8T-4195 Bolt
(21) 306-7545 Mud Deflector
1. Secure mud deflector (21) to the right side of the right-hand platform by using 16 bolts (5)
(5) 8T-4195 Bolt
(22) 306-7555 Mud Deflector
2. Secure mud deflector (22) to the left side of the left-hand walkway by using 16 bolts (5) and
16 washers (6) .
Install the Mud Guards at the Rear of the Cab
Top view
(5) 8T-4195 Bolt
(23) 321-7481 Plate As
(24) 305-5573 Plate As
(25) 321-7489 Plate
(26) 321-7490 Plate
(34) 8T-4244 Nut
(35) 8T-4956 Bolt
Bottom view
(5) 8T-4195 Bolt
(23) 321-7481 Plate As
(24) 305-5573 Plate As
1. Secure plate assembly (23), plate assembly (24), plate (25), and plate (26) to the rear cab
mount by using 16 bolts (5), 13 washers (6), three washers (3), two bolts (35), four washers
(15), and two nuts (34) .
(5) 8T-4195 Bolt
(23) 321-7481 Plate As
(27) 348-2750 Mud Guard
(28) 348-3039 Strip
2. Secure mud guard (27) to plate assembly (23) by using eight bolts (5), eight washers (6),
and one strip (28) .
Typical view of a machine with a 7570 L (2000 US gal) fuel tank
(5) 8T-4195 Bolt
(7) 347-4043 Strip
(27) 348-2750 Mud Guard
Typical view of a machine with a 3785 L (1000 US gal) fuel tank
(5) 8T-4195 Bolt
(7) 347-4043 Strip
(27) 348-2750 Mud Guard
3. Secure mud guard (27) to the front of the fuel tank by using seven bolts (5), seven washers
(6), and one strip (7) .
Note: For machines that are equipped with a 7570 L (2000 US gal) fuel tank, mud guard
will attach to the 294-2067 Support As . The 294-2067 Support As is part of the 288-4733
Fuel Tank Mounting Gp .
Note: For machines that are equipped with a 3785 L (1000 US gal) fuel tank, mud guard
will attach to the 348-3667 Support As . The 348-3667 Support As is part of the 292-1197
Fuel Tank Mounting Gp .
Install the Mud Guards at the Rear of the Right Hand Platform
(2) 8T-4136 Bolt
(29) 294-4886 Plate As
1. Secure one plate assembly (29) to the rear of the right-hand platform by using seven bolts
(2) and seven washers (3) .
(5) 8T-4195 Bolt
(14) 8T-4139 Bolt
(29) 294-4886 Plate As
(30) 321-7480 Plate As
(31) 321-7487 Plate
(34) 8T-4244 Nut
2. Secure plate assembly (30), and two plates (31) to plate assembly (29) by using 13 bolts (5)
13 washers (6), two bolts (14), four washers (15), and two nuts (34) .
(2) 8T-4136 Bolt
(31) 321-7487 Plate
(32) 294-4883 Mud Guard
(33) 321-7486 Strip
3. Secure mud guard (32) to plate assembly (30) by using seven bolts (2), seven washers (3),
and one strip (33) .
Install the Guards Near the Air Cleaners
(2) 8T-4136 Bolt
(36) 306-9575 Plate As
(37) 8T-4137 Bolt
(38) 330-4316 Plate
1. Secure one plate assembly (36) to the left side of the radiator by using eight bolts (37) and
eight washers (3) .
2. Secure one plate (38) to the front of the walkway above the air cleaner by using eight bolts
(2) and eight washers (3) .
(36) 306-9575 Plate As
(37) 8T-4137 Bolt
3. Secure one plate assembly (36) to the right side of the radiator module assembly by using
eight bolts (37) and eight washers (3) .
Install the 375-2497 Heat Shield Gp (TIRE)

Table 111
Required Parts to Install the 375-2497 Heat Shield Gp (TIRE)
1 6 372-3111 Gusset Assembly
2 2 372-3117 Angle As
3 50 8T-4136 Bolt
5 1 352-5028 Heat Shield As
6 1 371-5839 Baffle
8 1 387-7498
9 2 355-6155 Plate
10 8 6V-8214 Bolt
13 1 393-5257 Baffle
Install the Right Side Components
View of the front of the frame to the right of the engine
(1) 372-3111 Gusset Assembly
(2) 372-3117 Angle As
(3) 8T-4136 Bolt
1. Secure three gusset assemblies (1) and one angle assembly (2) to the frame by using eight
(2) 372-3117 Angle As
(3) 8T-4136 Bolt
(5) 352-5028 Heat Shield As
2. Secure heat shield assembly (5) to angle assembly (2) and two existing brackets by using
four bolts (3) and four hard washers (4) .
(3) 8T-4136 Bolt
(6) 371-5839 Baffle
3. Secure baffle (6) to the existing bracket on the frame by using one bolt (3) and one bolt (4) .
(3) 8T-4136 Bolt
(6) 371-5839 Baffle
(9) 355-6155 Plate
(10) 6V-8214 Bolt
4. Secure heat shield assembly (7) to two existing brackets on the frame and two gusset
assemblies that were installed in Step 1. Use eight bolts (3) and eight hard washers (4) to
secure heat shield assembly (7) .
5. Secure heat shield assembly (8) to one existing bracket on the frame and on gusset assembly
that was installed in Step 1. Use four bolts (3) and four hard washers (4) to secure heat
shield assembly (8) .
6. Secure heat shield assembly (5) and baffle (6) to heat shield assembly (7) by using one plate
(9), four bolts (10), and four hard washers (11) .
Install the Left Side Components
View of the front of the frame to the left of the engine
(2) 372-3117 Angle As
(3) 8T-4136 Bolt
(2) 372-3117 Angle As
(3) 8T-4136 Bolt
2. Secure heat shield assembly (12) to two existing brackets and angle assembly (2) by using
(3) 8T-4136 Bolt
(13) 393-5257 Baffle
3. Secure baffle (13) to the existing bracket on the frame by using one bolt (3) and one hard
washer (4) .
(3) 8T-4136 Bolt
(9) 355-6155 Plate
(10) 6V-8214 Bolt
(13) 393-5257 Baffle
4. Secure heat shield assembly (14) to two existing brackets on the frame and two gusset
assemblies that were installed in Step 1. Use eight bolts (3) and eight hard washers (4) to
secure heat shield assembly (14) .
5. Secure heat shield assembly (15) to one existing bracket on the frame and on gusset
assembly that was installed in Step 1. Use four bolts (3) and four hard washers (4) to secure
heat shield assembly (15) .
6. Secure heat shield assembly (12) and baffle (13) to heat shield assembly (14) by using one
plate (9), four bolts (10), and four hard washers (11) .
Install the Rims and Tires
Table 112
Required Parts to Install the 139-7662 Rim Mounting Gp
1 324 8C-4032 Nut
2 324 146-1799 Hard Washer
3 2 282-6635 (1) Adapter As
4 96 147-0170 (1) Bolt
5 96 146-1799 (1) Hard Washer
6 2 146-4279 (2) Cap
7 2 203-4702 (2) Valve
8 2 201-6654 (2) Hose As
9 2 6V-9746 (2) O-Ring Seal
10 2 203-4703 (2) Adapter
11 4 8T-4910 Bolt
13 2 203-4705 Plate
14 4 3W-1100 Spacer
15 2 201-6656 Guard
16 8 7X-2555 Bolt
17 36 9X-8257 Washer
18 18 220-7281 Plate
19 18 8T-4779 Bolt
21 8 197-0620 Guard As
22 28 7X-2552 Bolt
23 12 197-0621 Bracket
24 4 148-0366 Bracket
(1)
Part of 292-2170 Final Drive, Brake, and Wheel Gp
(2)
Part of 176-8358 Rim Mounting Gp
Table 113
Tools that are Needed for Installation of 139-7662 Rim Mounting Gp

A 1 194-7592 Pneumatic Wrench Gp
B 1 132-8206 Hydraulic Torque Wrench
Servicing and changing tires and rims can be dangerous. This work
must be done only by trained personnel with correct tools and
procedures. If correct procedures are not followed while servicing tires
and rims, the assemblies can burst with explosive force and cause
serious physical injury or death. Follow carefully the specification
information provided by your tire servicing person or dealer.
Install the Front Tires
1. Remove all of the shipping covers from the studs.
Typical view
2. Remove the grease and the metal burrs from the wheel and the mounting area. Remove
paint, grease, and debris from the parts. Failure to clean the parts will result in a poor joint.
3. Use a suitable lifting device in order to raise the front of the truck.
4. Use a suitable tire handler in order to lift the tire and rim assembly. The approximate weight
of the assembly is 7485 kg (16500 lb).
Note: The valve stem must face the outside.
5. Position the tire and rim onto the wheel assembly.
6. Use 54 nuts (1) and use 54 washers (2) in order to fasten the tire and rim assembly to the
wheel.
7. Use Tool (A) in order to torque the 54 nuts (1). Torque the 54 nuts (1) to a value of 3100 ±
350 N·m (2290 ± 260 lb ft).
8. Repeat Step 2 through Step 7 for the opposite front tire and rim assembly.
9. Align the front wheels. Refer to Testing and Adjusting, KENR8734, "Front Wheel - Align".
Install the Rear Tires
1. Remove all of the shipping covers from the studs.
2. Prepare to remove the two adapters (3). Mark the location of the two adapters (3) on the
final drive in order to ensure proper installation.
3. Attach a suitable lifting device to two adapters (3). Remove the 48 bolts (4) and 48 washers
(5). The weight of the adapter is approximately 167 kg (368 lb). Use a suitable lifting device
in order to remove two adapters (3). Set two adapters (3) aside for future use.
4. Use a suitable lifting device in order to lift the rear of the truck.
5. Use a suitable tire handler in order to install the tire and rim assembly. The assembly weighs
6. Position the tire and rim onto the wheel assembly.
7. Use 54 nuts (1) and use 54 washers (2) in order to fasten the tire and rim assembly to the
wheel. Use Tool (A) in order to torque the 54 nuts (1). Torque the 54 nuts (1) to a value of
3100 ± 350 N·m (2290 ± 260 lb ft).
8. Remove cap (6). Remove valve (7) that is located behind cap (6). Retain cap (6) and retain
valve (7) for future use.
9. Install hose (8) onto adapter (10) by using one O-ring (9) .
10. Install valve (7) to hose (8) by using one O-ring (9). Install cap (6) .
(17) 9X-8257 Washer
(21) 197-0620 Guard As
(22) 7X-2552 Bolt
(23) 197-0621 Bracket
(24) 148-0366 Bracket
11. Secure four guard assemblies (21) to the wheel by using 14 bolts (22), 14 washers (17), six
brackets (23), and two brackets (24) .
12. Use a suitable lifting device in order to install the two adapters (3). The weight of the
adapter is 167 kg (368 lb).
13. Install the 48 bolts (4) and 48 washers (5). Use Tool (B) in order to torque the 48 bolts (4) to
a value of 3100 ± 350 N·m (2290 ± 260 lb ft). Remove the lifting device from adapter (3).
Note: Adapters (3) must be installed in the position that was marked on the final drive in
Step 2.
14. Repeat Step 5 through Step 7 in order to install the outside rear tire.
15. Feed hose (8) through the outside tire and rim assembly. Secure hose (8) by using one plate
(13), two spacers (14), two bolts (11) and two washers (12) .
16. Use one plate (15), four bolts (16) and four washers (17) in order to secure hose (8) to the
final drive housing.
17. Repeat Step 15 through Step 16 for the opposite side.
18. Install three plates (18) by using three bolts (19) and washers (20). Repeat this step for the
other five rims.
19. Refer to Operation and Maintenance Manual, SEBU8417, "Tire Inflation with Nitrogen" for
the correct tire inflation procedure.
Align the Front Wheels
1. After the tires are installed, align the front wheels. Refer to Testing and Adjusting,
KENR8734, "Front Wheel - Align" for the correct procedure.
Install the 288-1161 Battery Box Gp

Table 114
Parts that are Needed for Installation of 288-1161 Battery Box Gp
1 1 343-4611 Plate
2 1 341-9402 Plate
3 1 343-4610 Plate
4 25 8T-4137 Bolt
1. Install one plate (1), one plate (2), and one plate (3) to the radiator module and the bumper
assembly by using 25 bolts (4) and 25 washers (5) .
Connect the 272-3441 Battery Gp

Note: Refer to Special Instruction, SEHS7633, "Battery Maintenance Procedure" for instructions
on charging, filling, or testing the batteries.
1. Connect the batteries.
Note: Charging or filling the batteries may be required.
Note: Refer to Special Instruction, SEHS7633, "Battery Maintenance Procedure" for

instructions on charging, filling, or testing the batteries.
Installation of the 272-3245 Ether Starting Aid Gp (If Equipped)
Breathing ether vapors or repeated contact of ether with skin can cause
personal injury. Personal injury may occur from failure to adhere to
the following procedures.
Use ether only in well ventilated areas.
Do not smoke while changing ether cylinders.
Use ether with care to avoid fires.
Do not store replacement ether cylinders in living areas or in the

operator's compartment.
Do not store ether cylinders in direct sunlight or at temperatures above

49 °C (120 °F).
Discard cylinders in a safe place. Do not puncture or burn cylinders.
Keep ether cylinders out of the reach of unauthorized personnel.
Table 115
Parts that are Needed for Installation of the 272-3245 Ether Starting Aid Gp

1 3 7X-1062 Ether Cylinder As
1. Remove three caps that cover the fittings.
2. Install three 7X-1062 Ether Cylinders (1). Secure the cylinders with the clamps.
Install the Truck Body

Use the 293-5065 Truck Body Mounting Gp and the 149-3117 Cylinder Mounting Gp in order to
secure the truck body to the chassis.
Use the 376-4554 Pin As to lift the body assembly.
Note: Refer to Special Instruction, REHS1841, "General Welding Procedures" before performing
any welding.
Table 116
Parts that are Needed to Install the Body
1 2 295-6917 Pin As (1)
2 10 154-1808 Plate (1)
3 4 295-6901 Plate (1)
4 16 7X-2553 Bolt (1)
5 16 9X-8257 Washer (1)
6 2 295-4144 Pin As (2)
7 4 151-0888 Spacer (2)
8 2 295-6881 Plate (2)
9 8 8T-4193 Bolt (2)
10 16 9X-8257 Washer (2)

11 2 295-6882 Plate (2)
12 8 8T-4140 Bolt (2)
13 2 153-7961 Plate (1)
14 1 153-7963 Deflector (1)
15 10 8T-4196 Bolt (1)
16 10 8T-4121 Hard Washer (1)
17 10 8T-4133 Nut (1)
18 1 172-4299 Deflector (1)
19 2 336-0743 Cable As (1)
20 2 219-5893 Clevis (1)
21 2 195-5952 Plate As (3)
22 2 207-2832 Ejector (1)
23 2 185-6715 Pin (1)
24 4 3B-4647 Cotter Pin (1)
25 2 3D-0404 Washer (1)
26 10 173-5403 Pad As (1)
27 30 8T-4910 Bolt (1)
28 30 7D-1649 Hard Washer (1)
29 30 8T-4244 Nut (1)

30 74 147-5073 Shim (1)
31 2 147-5075 Pad As (1)

32 2 192-5280 Plate As (1)
33 2 236-5558 Plate As (1)
34 2 149-1927 Pin (1)
35 4 149-1926 Plate (1)
36 8 8T-4192 Bolt (1)
37 6 8T-4184 Bolt (1)
38 2 149-4621 Guide (1)
39 1 158-0488 Rod As (4)
40 1 8T-4195 Bolt (4)

41 2 8T-4121 Hard Washer (4)
42 1 8T-4133 Nut (4)
43 1 8T-7547 Bolt (4)
44 2 9M-1974 Hard Washer (4)
45 1 5C-7261 Nut (4)
(1)
Part of the 293-5065 Truck Body Mounting Gp
(2)
(3)
Part of 290-6420 Body and Canopy As or 290-6421 Body and Canopy As
(4)
Part of 277-3328 Chassis Wiring Gp
Table 117
Weld Specifications
Weld Type Size Penetration
W1 Fillet
8 mm (0.32 inch) 1.5 mm (0.06 inch)
W2 Fillet 25 mm (1.0 inch) 1.5 mm (0.06 inch)
W3 Fillet
8 mm (0.32 inch) 8 mm (0.32 inch)
Install the Body Pins
Typical view
Typical view
1. Attach suitable lifting devices to the body. The body can be lifted by using the lifting points
at the top of the body that are shown in Illustration 537, or the body can be lifted by using
the lifting points at the bottom of the body that are shown in Illustration 538. The
approximate weight of the body is 51256 kg (113000 lb) with the liners and 44134 kg
(97300 lb) without the liners.
Note: The 376-4554 Pin As should be used to assist in lifting the truck body.
NOTICE
If you are lifting the body from the lifting points that are on the top of
the body, the body will need to be inspected for damage. If the top
lifting points are damaged, the lifting points will need to be repaired
before the body is lifted.
2. Use two suitable cranes in order to raise the body to the desired height.
Note: The 376-4554 Pin As should be used to assist in lifting the truck body.
3. After commissioning the truck, slowly drive the truck under the body.
4. Position the body and the truck in order to align the holes for the pivot pins.
5. Use a suitable lifting device in order to position the pin assembly (1) to the hole on the body
for the pin. The weight of pin assembly (1) is approximately 57 kg (125 lb).
(2) 154-1808 Plate
6. Center the body on the chassis by installing plates (2) that are required on pin assembly (1).
Install plates (2) between the frame rail of the body and the outside surface of the chassis
only. Do not install plates (2) on the inside of the body.
(1) 295-6917 Pin As
(2) 154-1808 Plate
7. Drive pin assembly (1) through the pin hole on the frame rail of the body until pin assembly
(1) is flush with the outside edge.
(1) 295-6917 Pin As
(3) 295-6901 Plate
(4) 7X-2553 Bolt
(5) 9X-8257 Washer
8. Secure the outside of pin assembly (1) to the chassis by using one plate (3), four bolts (4),
(1) 295-6917 Pin As
(3) 295-6901 Plate
(4) 7X-2553 Bolt
(5) 9X-8257 Washer
9. Secure the inside of pin assembly (1) to the chassis by using one plate (3), four bolts (4),
10. Repeat Step 4 through Step 9 for the other side of the body.
Install the Hoist Cylinder Pins
Typical view
(6) 295-4144 Pin As
1. Use a suitable lifting device in order to position pin assemblies (6) into the pin hole on the
body for the hoist cylinder. The weight of pin assemblies (6) for the hoist cylinder is 47 kg
(104 lb). Slowly lower the body.
Typical view
(6) 295-4144 Pin As
(7) 151-0888 Spacer
(6) 295-4144 Pin As
2. Stop the body. Slowly raise the hoist cylinder until the pin hole for the hoist cylinder on the
body and the hole on the hoist cylinder are aligned. Install two spacers (7) between the body
and the hoist cylinder. One spacer (7) is used on each side of the hoist cylinder. Drive pin
(6) through the hoist cylinder and the holes in the body.
(6) 295-4144 Pin As
(7) 151-0888 Spacer
(8) 295-6881 Plate
(9) 8T-4193 Bolt
(10) 9X-8257 Washer
3. Secure pin assembly (6) to the outside of the hoist cylinder by using one plate (8), four bolts
Typical view of the inside of the hoist cylinder
(6) 295-4144 Pin As
(10) 9X-8257 Washer
(11) 295-6882 Plate
(12) 8T-4140 Bolt
4. Secure pin assembly (6) to the inside of the hoist cylinder by using one plate (11), four bolts
5. Repeat Steps 2 through Step 4 for the installation of the pin for the other hoist cylinder.
Install the Mud Flaps
(13) 153-7961 Plate
(14) 153-7963 Deflector
(15) 8T-4196 Bolt
(17) 8T-4133 Nut
(18) 172-4299 Deflector
Note: One plate (13) and deflector (14) are shipped already connected. One plate (13) and
deflector (18) are shipped already connected.
1. Secure two plates (13) to the bottom right-hand side of the truck body by using ten bolts
(15), ten washers (16), and ten nuts (17) .
Install the Retaining Cables
(19) 336-0743 Cable As
(20) 219-5893 Clevis
1. Secure two cable assemblies (19) to the rear of the truck body by using two clevises (20) .
Install the Rock Ejectors
(21) 195-5952 Plate As
1. Use a suitable lifting device in order to position plate assembly (21) to the rear of the body.
2. Attach a string and a plumb bob to the center of plate assembly (21) for the mounting pin of
rock ejector. Position plate assembly (21) to the bottom of the body. Center the string
between the two rear tires. Once the string is centered mark the location of plate assembly
(21) on the body.
3. Remove the string from plate assembly (21).
(21) 195-5952 Plate As
4. Remove paint, grease, dirt, or debris from the mating surfaces of plate assembly (21) and
the truck body.
(21) 195-5952 Plate As
5. Position plate assembly (21) to the bottom of the body and tack weld plate assembly (21) to
the body.

(W1) 1.5 mm (0.059 inch) Weld penetration, and 8.0 mm (0.32 inch) fillet weld
(21) 195-5952 Plate As
6. Weld around the entire perimeter of plate assembly (21) in order to secure plate assembly
(21) to the body.
(21) 195-5952 Plate As
7. Use a grinder in order to remove any slag or debris from the affected area. Repaint the
welded area.
Typical view
(21) 195-5952 Plate As
(22) 207-2832 Ejector
8. Use a fork lift or a suitable lifting device in order to position ejector (24) to bracket (23).
The weight of ejector (24) is 75 kg (165 lb).
left-hand side
(21) 195-5952 Plate As
(22) 207-2832 Ejector
(23) 185-6715 Pin
(25) 3D-0404 Washer
9. Secure ejector (22) to plate assembly (21) by using one pin (23), one washer (25), and two
cotter pins (24) .
10. Repeat Step 1 through Step 9 for the other side of the body.
Install the Body Pad Assemblies

Note: Do not weld guides (38) or any body exhaust parts until all the body pad assemblies have
been installed.
(26) 173-5403 Pad As
NOTICE
On engines with air start, wait 30 seconds before attempting to start

the engine again in order to allow the starting system gears to come to
a complete stop. Gear damage could result if the starting system gears
are moving when the starter is engaged.
1. Position all ten pad assemblies (26) onto the frame rail in the corresponding contact areas.
Determine the highest pad assembly (26) on each frame rail. Remove all other pad
assemblies (26) from the frame rails. Lower the body. Observe the two pad assemblies (26)
and determine the first pad assembly that contacts the body rail. The first pad assembly that
contacts the body rail will be the highest pad assembly (26). Install this pad assembly (26)
with no shims. This pad assembly (26) will determine the down position of the body.
(26) 173-5403 Pad As
(27) 8T-4910 Bolt
(28) 7D-1649 Hard Washer
(29) 8T-4244 Nut
(30) 147-5073 Shim
2. Use 30 bolts (27), 30 washers (28), and 30 nuts (29) in order to install ten pad assemblies
(26) to the body rails. Use shims (30) on any pad that is not equal to the down position of
the body.
Note: Block the body in position when you install the shims and pads.
3. Paint the frame rail at the point of contact of pad assemblies (26). While the paint is still wet
lower the body. Raise the body and examine the contact area of ten pad assemblies (26) in
order to determine the correct contact area. Use shims (30) in order to acquire more area of
contact on pad assemblies (26) .
4. After pad assemblies (26) have been installed, the two guides and two slipper assemblies
must be installed.
5. Ensure that there is approximately 10 mm (0.40 inch) of shims (30) under each pad on the
slipper assemblies.
(28) 7D-1649 Hard Washer
(31) 147-5075 Pad As
(32) 192-5280 Plate As
(33) 236-5558 Plate As
(34) 149-1927 Pin
(35) 149-1926 Plate
(36) 8T-4192 Bolt
(37) 8T-4184 Bolt
6. Attach a suitable lifting device to the assembled components for the slipper assembly. The
approximate combined weight of the components is 150 kg (330 lb).
7. Position the slipper assembly onto the frame.
(38) 149-4621 Guide
8. Attach a suitable lifting device to guide (38). The approximate weight of guide (38) is 23 kg
(50 lb).
(E) 10 ± 1 mm (0.394 ± 0.039 inch)
(33) 236-5558 Plate As
(38) 149-4621 Guide
9. Position guide (38) onto the frame. Allow a small gap between the inside of the front body
rail and guide (38). Refer to Illustration 567 for gap dimension.
10. Lower the body. Install slipper assembly on the crossbeam under the front on the body
toward the centerline of the truck. Also, position the slipper assembly as far aft as possible
without welding on the radius of the crossbeam.
(33) 236-5558 Plate As
(38) 149-4621 Guide
11. Tack weld plate assembly (33) in position.
12. Tack weld guide (38) into position.

(W3) 10 mm (0.394 inch) both sides
(33) 236-5558 Plate As
(38) 149-4621 Guide
14. In two places, weld plate assembly (33) to the frame.
Note: Avoid starting and stopping the weld on the corners.
15. Create additional fillet welds in order to provide a tapered transition between the original
fillet weld and the main beam.
Note: Perform the additional welding on the two corners of plate assembly (33) that are
located toward the outside edge of the chassis.
Finish grinding is only required on the two outside corners.
16. Use a grinder in order to blend the additional welding area.
17. Use a grinder in order to blend any weld that is located by the drain opening.
Note: Ensure that the drain opening is free of obstructions.
18. After finish welding and grinding of plate assemblies (33) are completed, check in order to
make sure that there is no interference between the upper slipper pad and the fillet weld on
the base.
19. If interference occurs, use a grinder in order to remove the affected area.
20. Weld guide (38) to the frame in two places. Refer to Illustration 569 for the location of weld
(W3) .
Install the Body Positioning Linkage

1. Lower the body.
Typical view
(39) 158-0488 Rod As
(40) 8T-4195 Bolt
(42) 8T-4133 Nut
(43) 8T-7547 Bolt
(44) 9M-1974 Hard Washer
(45) 5C-7261 Nut
2. Position rod assembly (39) between the position switch and the body.
3. Install rod assembly (39) by using one bolt (40), two washers (41), one nut (42), one bolt
(43), two washers (44), and one nut (45) .
Note: The body position sensor will be calibrated later in the assembly procedure.
Install the 295-0534 Film Gp

Table 118
Parts that are Needed for the Installation of 295-0534 Film Gp
1 1 295-0537 Film
2 1 332-5861 Film
3 1 332-5860 Film
Note: Clean all surfaces with isopropyl alcohol. Thoroughly dry the surfaces before applying the
film.
Note: After applying the film, ensure that the film is free of air bubbles.
Note: If no dimension is given, center the films in the space that is available.
Illustration 575
1. Apply film (1) to the front of the canopy.
Illustration 576
2. Apply film (2) to the right side of the canopy.
Illustration 577
3. Apply film (3) to the left side of the canopy.
Connect the 272-3252 Central Lubrication Lines Gp
View of the rear of the machine
View of the right-hand front suspension cylinder
1. Remove the shipping restraints that secure the lubrication lines.
View of the right side of the body
View of the left side of the body
View of the right-hand side steering connection
View of the bottom of the hoist cylinder
Top view of the steering center arm
2. Connect all the hose assemblies for the lubrication lines.
Note: For additional information on the central lubrication lines group refer to Service
Manual, KENR8749, "797F Off-Highway Truck Automatic Lubrication System for Electric
Start and Air Start Equipped Trucks "
Installation of the Cat® Detect Object Detection

The information that is contained in this Special Instruction guides the user in the installation of
the Caterpillar Integrated Object Detection System for Off-Highway Trucks.
Do not perform any of the procedures until you have read the information in this publication.
ReferenceSpecial Instruction, REHS1841, "General Welding Procedures" for additional welding

instructions.
Illustration 585
View of the object detection locations
ReferenceRefer to Operation and Maintenance Manual, SEBU8454, "Cat® Integrated Object

Detection System for Off-Highway Trucks" for the orientation of the radar. The radar orientation
is critical for the operation of the object detection system.
Important Safety Information

Do not perform any procedure in this Special Instruction until you have read this Special
Instruction and you understand this information. Use only proper tools and observe all precautions
that pertain to the use of those tools. Failure to follow these procedures can result in personal
injury. The following procedures should also be observed.
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 in order 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. Ensure that any tool, procedure, work method, or operating technique you use that is not
recommended by Caterpillar is safe.
Ensure that the product will not be damaged or the product will not be made unsafe by the
operation, lubrication, maintenance, or repair procedures used.
Prepare the Machine
(1) Pin
(2) Cable
1. Raise the truck body and install both retaining cables (2) for the truck body.
2. Set the parking brake.
3. Turn the key start switch and the disconnect switch to the OFF position.
Required Parts for Installation of the Cat® Detect Object

Detection
Table 119
Required Parts for Assembling the 336-6684 Camera Gp to the Brackets

8 n/a (1) Cover
8 n/a (1) Bolt
4 n/a (1) Camera
8 n/a (1) Bolt
8 n/a (1) Nut
8 n/a (1) Nut
4 n/a (1) Camera Harness
1 305-3748 Plate As
2 288-4697 Plate As
1 348-9537 Plate As
3 8T-6466 Bolt
12 7X-7729 Washer
9 8T-4133 Nut
1 312-4475 Bracket
1 348-8145 Bracket
4 8T-4136 Bolt
(1)
Part of the 336-6684 Camera Gp
Table 120
Required Parts for Assembling the Radar Boxes to the Brackets
8 347-7917 Object Detection Box Gp (1)
4 379-8133 Plate As
16 8T-4137 Bolt
8 380-4489 Plate
16 7X-7729 Washer
16 8T-4195 Bolt
(1)
Each object detection box group includes a 365-1271 Object Detection Sensor Gp
Table 121
Required Parts for Installing the Front Hardware
2 - Radar Box Groups (1) (2)
1 - Camera Assembly (3)
2 (1) 371-7772 Plate As
1 (1) 379-8129 Plate As
8 8T-4195 Bolt
24 7X-7729 Washer
8 8T-4186 Bolt
8 6V-7744 Locknut
1 (2) 383-1162 Sensor Mount As
4 (1)
5 (2) 8T-4136 Bolt
4 (1)
8T-4121 Hard Washer
5 (2)
2 147-0385 Clip
1 (1)
033-8248 Clip
3 (2)
1 (2) 368-9816 Sensor Harness As
1 (1)
130-5300 Clip
2 (2)
4 8T-4183 Bolt
2 380-6932 Bracket
4 5C-9553 Bolt
4 9X-8256 Washer
1 336-8613 Clip
(1)
With 379-8133 Plate As
(2)
Previously assembled in ""Assemble the Radar Boxes to the Brackets" "
(3)
Previously assembled in ""Assemble the Front Camera to the Brackets" "
(1)
For use with standard trucks only.
(2)
For use with oil sands trucks only.
Table 122
Required Parts for Installing the Left Side Hardware
1 360-5282 Plate As
1 378-7007 Plate As
4 8T-4183 Bolt
5 8T-4195 Bolt
6 7X-7729 Washer
1 372-9143 Plate
4 8T-4189 Bolt
1 8T-6466 Bolt
1 9G-7101 Spacer
1 5P-9297 Clip
1 272-6641 Flood Lamp Gp
1 8M-2770 Clip
2 147-0385 Clip
(1)
With 378-6997 Bracket As
(2)
(3)
Previously assembled in ""Assemble the Camera Components" "
Table 123
Required Parts for Installing the Right Side Hardware
1 360-5282 Plate As
1 378-7007 Plate As
4 8T-4183 Bolt
2 8T-4195 Bolt
2 7X-7729 Washer
1 372-9143 Plate
4 8T-4189 Bolt
1 272-6641 Flood Lamp Gp
1 7N-3718 Clip
1 033-8248 Clip
2 4D-9517 Clip
(1)
(2)
(3)
Table 124
Required Parts for Installing the Rear Hardware
4 349-4915 Bracket
2 8T-4195 Bolt
42 7X-7729 Washer
16 8T-4186 Bolt
16 6V-7744 Locknut
4 380-6932 Bracket
8 5C-9553 Bolt
8 9X-8256 Washer
2 8T-4137 Bolt
4 147-0385 Clip
(1)
(2)
(1)
(2)
(3)
Install the Components for the Cat® Detect Object Detection

Assemble the Camera Components
Table 125
Required Parts for Assembling the 336-6684 Camera Gp to the Brackets
1 8 n/a (1) Cover
2 8 n/a (1) Bolt
3 4 n/a (1) Camera
4 8 n/a (1) Bolt
5 8 n/a (1) Nut
6 8 n/a (1) Nut
7 4 n/a (1) Camera Harness
8 1 305-3748 Plate As
9 2 288-4697 Plate As
10 1 348-9537 Plate As
11 3 8T-6466 Bolt
12 12 7X-7729 Washer
13 9 8T-4133 Nut
14 1 312-4475 Bracket
15 1 348-8145 Bracket
16 4 8T-4136 Bolt
(1)
Part of the 336-6684 Camera Gp
Note: An arrow is located at the top of the camera lens which indicates the up direction of the
camera. The camera that is going to be installed on the rear of the truck needs to have this arrow
installed facing up.
Camera Assembly and Mounting
(1) Cover
(2) Bolt
(3) Camera
(4) Bolt
(5) Nut
(6) Nut
1. Assemble the four cameras with the parts that are supplied with the cameras.
Refer to Illustration 587.
Note: Do not tighten the nuts (6). The nuts will be used in the following procedure in order
to attach the camera to the brackets for the camera.
View of the front camera
(4) Bolt
(6) Nut
(7) Camera harness
(8) 305-3748 Plate As
View of the side camera
(4) Bolt
(6) Nut
(7) Camera harness
(9) 288-4697 Plate As
(4) Bolt
(6) Nut
(7) Camera harness
(10) 348-9537 Plate As
2. Route the camera harness and the connector through the hole that is provided in plate
assemblies. Place the grommet that is provided on the harness for the camera through the
hole. Repeat this procedure for all the cameras.
3. Use bolts (4) and nuts (6) to secure the 336-6684 Camera Groups to the plate assemblies.
Refer to Illustration 588, Illustration 589, and Illustration 590 for each camera assembly.
Secure the Front Camera to the Brackets
Camera assembled to the front bracket
(8) 305-3748 Plate As
(11) 8T-6466 Bolt
(12) 7X-7729 Washer
(13) 8T-4133 Nut
(14) 312-4475 Bracket
1. Secure plate assembly (8) to bracket (14) by using three bolts (11), six washers (12), and
three nuts (13) .
Camera assembled to the front bracket
(12) 7X-7729 Washer
(13) 8T-4133 Nut
(14) 312-4475 Bracket
(15) 348-8145 Bracket
(16) 8T-4136 Bolt
2. Secure bracket (14) to bracket (15) by using four bolts (16), eight washers (12), and four
nuts (13) .
Assemble the Radar Boxes to the Brackets

Table 126
Required Parts for Assembling the Radar Boxes to the Brackets
1 8 347-7917 Object Detection Box Gp (1)
2 4 379-8133 Plate As
3 16 8T-4137 Bolt
4 8 380-4489 Plate
5 16 7X-7729 Washer
6 16 8T-4195 Bolt
7 2 372-9144 Bracket As

9 2 378-6997 Bracket As
(1)
Each object detection box group includes a 365-1271 Object Detection Sensor Gp
Note: Mounting location is important. Each radar box must be mounted in the designated location
that is labeled on the harness connector for each box.
The sensors for the Object Detection System are assembled before shipping. Use the following
procedure in order to assemble the mounting brackets to the radar boxes.
Note: Inspect the grommet on the bottom of the radar box to ensure that the sealant has not been
disturbed during shipment. If the seal is not intact, use silicone sealant in order to seal the
grommet.

Front and lower rear radar boxes
(1) 347-7917 Object Detection Sensor Gp
(2) 379-8133 Plate As
(3) 8T-4137 Bolts
(4) 380-4489 Plate
(5) 7X-7729 Washer
1. Locate four object detection sensor groups (1) and four plate assemblies (2) .
2. Secure four sensor groups (1) to four plate assemblies (2) by using 16 bolts (3), four plates
(4), and eight hard washers (5) .
Note: The four sensor groups assembled in Step 2 are for the front two locations and the
two lower rear locations.
Note: Ensure that each sensor group is assembled with two hard washers (5) and one plate
(4). Plates (4) should be located on the outside facing section of each sensor group.
Upper rear radar boxes
(4) 380-4489 Plate
(5) 7X-7729 Washer
(6) 8T-4195 Bolt
(7) 372-9144 Bracket As
3. Locate two object detection sensor groups (1) and two bracket assemblies (7) .
4. Secure two sensor groups (1) to two bracket assemblies (7) by using eight bolts (6), two
plates (4), eight hard washers (8), and four hard washers (5) .
Note: The two sensor groups assembled in Step 4 are for the upper two rear locations.
Note: Hard washers (8) are located between sensor group (1) and bracket assembly (7) .
Note: Ensure that each sensor group is assembled with two hard washers (5) and one plate
(4). Plates (4) should be located on the side of the sensor group that faces the right side of
the machine.
Side radar box
(4) 380-4489 Plate
(5) 7X-7729 Washer
(6) 8T-4195 Bolt
(9) 378-6997 Bracket As
5. Locate two object detection sensor groups (1) and two brackets (9) .
6. Secure two sensor groups (1) to two brackets (9) by using eight bolts (6), two plates (4),
eight hard washers (8), and four washers (5) .
Note: The two sensor groups assembled in Step 6 are for the two side locations.
Note: Hard washers (8) are located between sensor group (1) and bracket (9) .
Installation of the Front Hardware

Table 127
Required Parts for Installing the Front Hardware

- 2 - Radar Box Groups (1) (2)
- 1 - Camera Assembly (3)
1 2 (1) 371-7772 Plate As
2 1 (1) 379-8129 Plate As
3 8 8T-4195 Bolt
4 24 7X-7729 Washer
5 8 8T-4186 Bolt
6 8 6V-7744 Locknut
7 1 (2) 383-1162 Sensor Mount As
9 4 (1) 8T-4136 Bolt

5 (2)
4 (1)
5 (2)
11 2 147-0385 Clip
1 (1)
12 033-8248 Clip
3 (2)
13 1 (2) 368-9816 Sensor Harness As
1 (1)
14 130-5300 Clip
2 (2)
15 4 8T-4183 Bolt
17 2 380-6932 Bracket
18 4 5C-9553 Bolt
19 4 9X-8256 Washer
20 1 336-8613 Clip
(1)
(2)
(3)
Previously assembled in ""Assemble the Front Camera to the Brackets" "
(1)
For use with standard trucks only.
(2)
For use with oil sands trucks only.

Each radar box has a specific mounting location. The radar sensors have individual part numbers
located on the harnesses at the bottom of the box.
Installation of the Box Group for the Object Detection (Front)
Standard
(1) 371-7772 Plate As
(2) 379-8129 Plate As
(3) 8T-4195 Bolt
(4) 7X-7729 Washer
(5) 8T-4186 Bolt
(6) 6V-7744 Locknut
Oil sands
(4) 7X-7729 Washer
(5) 8T-4186 Bolt
(6) 6V-7744 Locknut
(7) 383-1162 Sensor Mount As
1. For standard trucks, secure two plate assemblies (1) to plate assembly (2) by using four
bolts (3) and four washers (4) .
2. For standard trucks, secure the two assembled sensor groups to plate assembly (2) by using
eight bolts (5), 16 washers (4), and eight locknuts (6) .
For oil sands trucks, secure the two assembled sensor groups to sensor mount assembly (7)
by using eight bolts (5), 16 washers (4), and eight locknuts (6) .
Standard
(1) 371-7772 Plate As
(2) 379-8129 Plate As
(9) 8T-4136 Bolt
(11) 147-0385 Clip
(12) 033-8248 Clip
Oil sands
(7) 383-1162 Sensor Mount As
(9) 8T-4136 Bolt
(11) 147-0385 Clip
(12) 033-8248 Clip
(14) 130-5300 Clip
3. Connect sensor harness assembly (7) to the sensor groups.
4. For standard trucks, secure sensor harness assembly (7) to plate assembly (2) and one plate
assembly (1) by using three bolts (9), three hard washers (10), two clips (11), and one clip
(12) .
For oil sands trucks, secure sensor harness assembly (7) and sensor harness assembly (13) to
sensor mount assembly (7) by using four bolts (9), four hard washers (10), two clips (11),
three clips (12), and one clip (14) .
Typical view
(A) Wiring harness assembly
(9) 8T-4136 Bolt
(14) 130-5300 Clip
(15) 8T-4183 Bolt
Note: The mounting hardware is the same for both standard and oil sands trucks.
5. Secure the mounting bracket to the front of the bumper assembly by using four bolts (15)
and four hard washers (16) .
6. Connect the sensor harness assembly to existing wiring harness assembly (A). Secure the
harness assemblies to the available boss on the top of the bumper by using one bolt (9), one
hard washer (10), and one clip (14) .
Typical view of the front of the bumper assembly
(17) 380-6932 Bracket
(18) 5C-9553 Bolt
(19) 9X-8256 Washer
7. Secure two brackets (17) onto the bracket assemblies for the radar boxes by using four bolts
(18) and four washers (19) .
Note: Brackets (17) must be installed to help ensure that the radars are oriented in the
proper location.
Installation of the Camera Group (Front)
Typical view
(B) Wiring harness assembly
(3) 8T-4195 Bolt
(4) 7X-7729 Washer
(20) 336-8613 Clip
1. Secure the front camera assembly that was previously assembled to the front of the platform
assembly at the top of the stairway by using four bolts (3) and four washers (4). Secure
existing cable assembly (B) to the front of the bracket assembly by using clip (20) .
2. Connect existing cable assembly (B) to the cable assembly for the camera assembly.
Installation of the Left Side Hardware

Table 128
Required Parts for Installing the Left Side Hardware
1 1 360-5282 Plate As
2 1 378-7007 Plate As
3 4 8T-4183 Bolt
5 5 8T-4195 Bolt
6 6 7X-7729 Washer
7 1 372-9143 Plate
8 4 8T-4189 Bolt
10 1 8T-6466 Bolt
11 1 9G-7101 Spacer
12 1 5P-9297 Clip
13 1 272-6641 Flood Lamp Gp
14 1 8M-2770 Clip
15 2 147-0385 Clip
(1)
(2)
(3)

Installation of the Radar Box Group for the Object Detection (Left-Hand Side)
View of the left side of the left-hand fender group
(1) 360-5282 Plate As
(2) 378-7007 Plate As
(3) 8T-4183 Bolt
1. Secure plate assembly (1) the left-hand side of the left-hand fender group by using six 8T-
4195 Bolts and six 8T-4121 Hard Washers .
Note: The six 8T-4195 Bolts and the six 8T-4121 Hard Washers are part of the 293-2952
Fender Gp .
2. Secure plate assembly (2) to plate assembly (1) by using four bolts (3) and four hard
washers (4) .
(2) 378-7007 Plate As
(5) 8T-4195 Bolt
(6) 7X-7729 Washer
(7) 372-9143 Plate
(8) 8T-4189 Bolt
3. Secure the radar bracket assembly, that was previously secured to the radar assembly, to
plate assembly (2). Use two bolts (5) and two washers (6) to secure the radar bracket
assembly.
4. Secure plate (7) to the top of the radar group by using four bolts (8) and four hard washers
(9) .
Installation of the Camera Group and Lamp Group (Left-Hand Side)
Illustration 605
(5) 8T-4195 Bolt
(6) 7X-7729 Washer
(10) 8T-6466 Bolt
(11) 9G-7101 Spacer
(12) 5P-9297 Clip
(13) 272-6641 Flood Lamp Gp
(14) 8M-2770 Clip
(15) 147-0385 Clip
1. Secure the previously assembled camera bracket assembly to the left side of the walkway by
using existing three bolts (5), four washers (6), one bolt (10), and one spacer (11) .
2. Secure flood lamp group (13) to the camera bracket with the hardware on flood lamp group
(13). Tighten the nut on flood lamp group (13) to a torque of 25 ± 7 N·m (221 ± 62 lb in).
3. Connect the existing cable assembly to the cable assembly for the camera.
4. Connect the existing wiring harness assembly to the harness assembly for the flood lamp
group and the radar assembly.
5. Secure the existing wiring harness assembly with one clip (12), one clip (14), and two clips
(15) .
Installation of the Right Side Hardware

Table 129
Required Parts for Installing the Right Side Hardware

1 1 360-5282 Plate As
2 1 378-7007 Plate As
3 4 8T-4183 Bolt
5 2 8T-4195 Bolt
6 2 7X-7729 Washer
7 1 372-9143 Plate
8 4 8T-4189 Bolt
10 1 272-6641 Flood Lamp Gp
11 1 7N-3718 Clip
12 1 033-8248 Clip
13 2 4D-9517 Clip
(1)
(2)
(3)

Installation of the Radar Box Group for the Object Detection (Right-Hand Side)
View of the right side of the right-hand fender group
(1) 360-5282 Plate As
(2) 378-7007 Plate As
(3) 8T-4183 Bolt
1. Secure plate assembly (1) to the right side of the right-hand fender group by using six 8T-
4195 Bolts and six 8T-4121 Hard Washers .
Note: The six 8T-4195 Bolts and the six 8T-4121 Hard Washers are part of the 293-2952
Fender Gp .
2. Secure plate assembly (2) to plate assembly (1) by using two bolts (3) and two hard washers
(4) .
(2) 378-7007 Plate As
(5) 8T-4195 Bolt
(6) 7X-7729 Washer
(7) 372-9143 Plate
(8) 8T-4189 Bolt
3. Secure the radar bracket assembly, that was previously secured to the radar assembly, to
plate assembly (2). Use two bolts (5) and two washers (6) to secure the radar bracket
assembly.
4. Secure plate (7) to the radar bracket assembly by using four bolts (8) and four hard washers
(9) .
Installation of the Camera Group and Lamp Group (Right-Hand Side)
Illustration 608
(10) 272-6641 Flood Lamp Gp
(11) 7N-3718 Clip
(12) 033-8248 Clip
(13) 4D-9517 Clip
1. Secure the bracket for the camera assembly that was previously assembled to the base of the
handrail assembly on the right-hand platform by using four existing bolts and washers.
2. Secure flood lamp group (10) to the camera bracket assembly by using the existing
hardware on flood lamp group (10). Tighten the nut for flood lamp group (10) to a torque of
25 ± 7 N·m (221 ± 62 lb in).
3. Connect the existing wiring harness assembly to flood lamp group (10) and the radar
harness assembly.
4. Connect the existing cable assembly to the cable assembly for the camera.
5. Secure the existing wiring harness assembly with one clip (12) and two clips (13) .
6. Secure the cable assemblies with one clip (11) between flood lamp group (10) and the
camera bracket assembly.
Installation of the Rear Hardware

Table 130
Required Parts for Installing the Rear Hardware
A 2 - Radar Box Groups (1) (2)
B 2 - Radar Box Groups (1) (2)
1 4 349-4915 Bracket
2 2 8T-4195 Bolt
3 42 7X-7729 Washer
4 16 8T-4186 Bolt
6 4 380-6932 Bracket
7 8 5C-9553 Bolt
8 8 9X-8256 Washer
9 2 8T-4137 Bolt
10 4 147-0385 Clip
(1)
(2)
(1)
(2)
(3)

Installation of the Radar Box Groups for the Object Detection (Rear)
Illustration 609
(1) 349-4915 Bracket
(2) 8T-4195 Bolt
(3) 7X-7729 Washer
1. Secure four brackets (1) to the rear of the frame by using eight bolts (2) and eight washers
(3) .
Illustration 610
(1) 349-4915 Bracket
(3) 7X-7729 Washer
(4) 8T-4186 Bolt
(5) 6V-7744 Locknut
2. Secure two radar boxes (A) to two upper brackets (1) and two radar boxes (B) to two lower
brackets (1) by using 16 bolts (4), 32 washers (3), and 16 locknuts (5) .
Typical view of the rear of the machine
(A) Upper radar box assembled with 372-9144 Bracket As
(6) 380-6932 Bracket
(7) 5C-9553 Bolt
(8) 9X-8256 Washer
3. Secure four brackets (6) onto all bracket assemblies for the rear radar boxes by using eight
bolts (7) and eight washers (8) .
Note: Brackets (6) must be installed to help ensure that the radars are oriented in the proper
location.
Installation of the Camera Group (Rear)
(3) 7X-7729 Washer
(9) 8T-4137 Bolt
1. Secure the rear camera group that was previously assembled to the rear of the frame by
using two bolts (9) and two hard washers (3) .
2. Connect the cable for the camera assembly to existing cable assembly.
Connect the Harness Assemblies (Rear)
Illustration 613
(10) 147-0385 Clip
1. Connect the four radars to the existing harness assembly.
2. Secure the wiring harness assembly to the bottom of the radar brackets by using the existing
hardware and four clips (10) .
Installation of the Hardware in the Cab

Install the components for the display. Refer to the Illustrations below.
Illustration 614
(A) Bracket assembly
(B) Bolt
(C) Washer
1. Remove two screws (2) and 2 washers (3) in order to hinge bracket assembly (1) down in
order to install the monitor display group (8) .
(A) Bracket As
(D) Screw
(E) Washer
(1) 188-0815
(3) 9X-2038 Washer
(4) 6V-8225 Nut
(5) 362-1249 Bracket
(6) 8T-4136 Bolt
(8) 362-2231 Bracket As
(9) 355-9048 Monitor Display Gp
2. Assemble the bracket for the display. Refer to Illustration 615.
3. Remove two bolts (D) and two washers (E). Retain the hardware.
4. Install bracket assembly (8) to monitor display group (9) with the hardware that was
removed in Step 3.
5. Install bracket (5) to bracket assembly (8) with two bolts (6) and two washers (7) .
6. Install bracket (5) to bracket assembly (A) with two bolts (1), two washers (3), two washers
(3) and 2 nuts (4) .
7. Install two bolts (B) and two washers (C) in order to reinstall bracket assembly (A) .
8. Connect the three 319-6830 Sensor Harness As 12-pin connectors to the corresponding
connectors on the back of the display. The video cable connects to the green connector. The
12-pin connector with two wires connects to the black connector and the 12-pin connector
with five wires connects to the gray connector.
(10) 213-0143 Connector
9. Locate the 19-pin bulkhead connector (10) of the 359-7645 Cab Harness As .
Flash the Software onto the Display

The display is shipped with the application software installed. Use the following procedure in
order to flash the application software into the display.
Note: The software may require flashing.
Required Material
• Caterpillar Electronic Technician CAT (ET)
• Communication Adapter
• 345-7489 Monitor Harness As
Software
Table 131
Part Number System Notes
387-3090 Cat® Detect Object Detection Radar and Camera
379-5109 Cameras only

Cat® Detect (Vision Only)
Perform the following procedure in order to flash program the ECM. The ECM is flashed in order
to upgrade the software. Flash programming of the ECM must be done if the ECM has been
replaced. Caterpillar Electronic Technician (Cat ET) contains the program WinFlash. WinFlash is
used in order to load the software into the ECM. The following procedure is used in order to flash
the software into the display.
Procedure
1. Ensure that the key start switch and the disconnect switch are in the OFF position.
2. Disconnect the center 12-pin connector from the display.
3. Connect the 345-7489 Monitor Harness As between the system harness for the display and
the center connector on the display.
4. Connect the 7X-1425 Data Link Cable As between the 7X-1700 Communication Adapter
Gp and Cat ET.
5. Connect the 139-4166 Data Link Cable As between the 7X-1700 Communication Adapter
Gp and the diagnostic connector of the 345-7489 Monitor Harness As .
6. Turn power back on to the display.
7. Use WinFlash in order to load the software.
8. Disconnect the 345-7489 Monitor Harness As from the system harness for the display and
the center connector on the display.
9. Connect the 12-pin connector of the system harness to the center connector of the display.
10. Turn the disconnect switch and the key start switch to the ON position.
11. Verify that the display turns on and the Cat® Detect Object Detection system starts.
Note: Refer to Special Instruction, REHS5191 regarding information for the Cat® Detect
Object Detection.
Object Detection Sensor - Adjust for Eight Sensors

There are two angle adjustments for the object detection sensors. The adjustments are the Azimuth
or horizontal adjustment and the Elevation or the vertical adjust. The angles that are provided in
the tables below are the angles that were found to work best. These angles are a guideline and are
adjusted a few degrees in order to bring the detection area of the system into an acceptable limit.
This adjustment is necessary because of differences in machines that are not controlled by
Caterpillar. The type of tires that are used on a machine may affect the height of the machine. This
procedure must be used with the Testing and Adjusting, KENR8668, "Object Detection Sensor -
Calibration".
Table 132
797F Front and Rear Radar Angles
Front Radar Rear Radar

Radar Elevation (deg) Elevation (deg)
Azimuth (deg) Azimuth (deg)
20 right of center
Left Upper N/A N/A 17 down
Right Upper
N/A N/A 20 left of center 15down
20 right of center
Left Lower 25 left of center 0 5 down
Right Lower 25 right of center 0 20 left of center 5 down
Table 133
797F Side Radar Angles
Radar Elevation (deg)
Left 60 down
Right 60 down
Table 134
797F Oil Sands Truck Front and Rear Radar Angles
20 right of center
Left Upper N/A N/A 20 down
Right Upper
N/A N/A 20 left of center 20 down
20 right of center
Left Lower 25 left of center 0 9 down
Right Lower 25 right of center

0 20 left of center 9 down
Table 135
797F Oil Sands Truck Side Radar Angles
Left 55
Right 55
Object Detection Sensor - Adjust for 12 Sensors

Table 136
797F Front and Rear Radar Angles
20 right of center
Left Upper 20 left of center 20 down 30 down
Right Upper 20 right of center

20 down 20 left of center 30 down
15right of center
Left Lower 30 left of center 6 down 9 down
Right Lower 30right of center

6 down 15left of center 9 down
Table 137
797F Side Radar Angles
Left Top 45
Right Top 65
Left Bottom 45
Right Bottom 65
Table 138
797F Oil Sands Truck Front and Rear Radar Angles
20 right of center
Left Upper 55 left of center 26 down 30 down
Right Upper 55 right of center

26 down 20 left of center 30 down
15 right of center
Left Lower 40 left of center 6 down 9 down
Right Lower 40 right of center 6 down 15 left of center 9 down
Table 139
797F Oil Sands Truck Side Radar Angles
Left Top 45 down
Left Bottom 65 down
Right Top 45 down
Right Bottom 65 down
Azimuth Adjustment Procedure
Azimuth adjustment for Short Range Radar and Medium Range Radar Brackets
Table 140
Required Tools
13mm Wrench 1
Protractor 1
1. Loosen the four azimuth adjustment bolts on the brackets for the radars.
2. Use a protractor to set the proper azimuth angle that is listed above or adjust the angle to
fine-tune the system.
3. Carefully tighten the four azimuth adjustment bolts on the brackets for the radars.
4. Check the angle again in order to verify that the bracket is set to the proper angle.
5. Tighten the bolts.
7. Proceed to the ""Procedure to Adjust the Elevation" ".
Elevation Adjustment Procedure
Elevation adjustment bolts for Long Range Radar
Table 141
Required Tools
10 mm Wrench 1
Inclinometer or Digital Level 1
1. Loosen the four adjustment bolts on the bracket for the radar.
2. Use an inclinometer or a digital level to set the proper elevation angle that is listed above or
adjust the angle to fine-tune the system.
3. Carefully tighten the four azimuth adjustment bolts on the brackets for the radars.
5. Tighten the bolts.
7. Perform the Testing and Adjusting, KENR8668, "Object Detection Sensor - Calibration" for
trucks with 12 sensors.
8. Perform the Testing and Adjusting, UENR2507, "Object Detection Sensor - Calibration" for
trucks with eight sensors.
Install the 351-3820 Sound Suppression Ar (If Equipped)

Install the 353-8326 Sound Suppression Panel Gp for the Sound Suppression
Arrangement
View of the three locations for the 353-8326 Sound Suppression Panel Gp on the right side of the machine
(A) Rear location
(B) Center location
(C) Front location
Table 142
1 1 371-5786 Sound Suppression Panel Gp
3 22 8T-4195 Bolt
5 11 393-5277 Plate
6 44 8T-4136 Bolt
7 2 193-9723 Washer
14 1 372-3117 Angle As
16 1 371-5839 Baffle

19 1 355-6155 Plate
20 4 6V-8214 Bolt
Area (A) Components of the 353-8326 Sound Suppression Panel Gp
Illustration 623
Right side view of rear location (A)
Refer to Illustration 622 for the location
(1) 371-5786 Sound Suppression Panel Gp
(3) 8T-4195 Bolt
(5) 393-5277
(6) 8T-4136 Bolt
(7) 193-9723 Washer
1. Secure sound suppression panel group (2) to the frame by using four bolts (3), four hard
washers (4), two plates (5), one bolt (6), and one washer (7) .
washers (4), and two plates (5) .
3. Secure sound suppression panel group (1) to sound suppression panel group (2) by using
three bolts (6) and three hard washers (4) .
Area (B) Components of the 353-8326 Sound Suppression Panel Gp
Illustration 624
Left side view of center location (B)
(3) 8T-4195 Bolt
(5) 393-5277
(6) 8T-4136 Bolt
(7) 193-9723 Washer
Note: The panels in location (B) are secured from the inside of the frame.
1. Secure sound suppression panel group (8) to the frame by using two bolts (3), two hard
washers (4), and one plate (5) .
3. Secure sound suppression panel group (8) to sound suppression group (9) by using two bolts
(6), and two hard washers (4) .
washers (4), two plates (5), one bolt (6), and one washer (7) .
5. Secure sound suppression panel group (10) to sound suppression panel group (8) and sound
suppression panel group (9) by using seven bolts (6) and seven hard washers (4) .
suppression panel group (11) by using six bolts (6) and six hard washers (4) .
Area (C) Components of the 353-8326 Sound Suppression Panel Gp
View of the front of the frame to the right of the engine
Left side view of front location (C)
(6) 8T-4136 Bolt
(14) 372-3117 Angle As
Right side view of front location (C)
(6) 8T-4136 Bolt
(14) 372-3117 Angle As
2. Secure sound suppression panel group (15) to angle assembly (14) and two existing brackets
by using four bolts (6) and four hard washers (4) .
(6) 8T-4136 Bolt
(16) 371-5839 Baffle
3. Secure baffle (16) to the existing bracket on the frame by using one bolt (6) and one bolt
(4) .
(6) 8T-4136 Bolt
(16) 371-5839 Baffle
(18) 387-7497
(19) 355-6155 Plate
(20) 6V-8214 Bolt
4. Secure sound suppression panel assembly (17) to two existing brackets on the frame and
two gusset assemblies that were installed in Step 1. Use eight bolts (6) and eight hard
washers (4) to secure sound suppression panel assembly (17) .
5. Secure sound suppression panel assembly (18) to one existing bracket on the frame and on
gusset assembly that was installed in Step 1. Use four bolts (6) and four hard washers (4) to
secure sound suppression panel assembly (18) .
6. Secure sound suppression panel assembly (15) and baffle (16) to sound suppression panel
assembly (17) by using one plate (19), four bolts (20), and four hard washers (21) .
Arrangement
View of the three locations for the 382-5245 Sound Suppression Panel Gp on the right side of the machine
(A) Rear location
(B) Center location
(C) Front location
Table 143

4 1 371-5831 Plate
7 53 8T-4136 Bolt

12 37 8T-4137 Bolt
19 5 393-5277 Plate
20 1 354-6048 Cover
21 1 354-6049 Cover
22 7 7K-1181 Cable Strap
24 2 372-3117 Angle As
Area (A) Components of the 382-5245 Sound Suppression Panel Gp
Note: The panels in location (A) are secured from the inside of the frame.
Illustration 630
(4) 371-5831 Plate
(7) 8T-4136 Bolt
1. Secure sound suppression panel group (1) to the frame by using two bolts (7) and two hard
washers (8) .
washers (8) .
3. Secure sound suppression panel group (3) to the frame by using four bolts (7) and four hard
washers (8) .
4. Secure plate (4) to the frame by using two bolts (7) and two hard washers (8) .
washers (8) .
washers (8) .
Illustration 631
(4) 371-5831 Plate
(12) 8T-4137 Bolt
suppression panel group (6) by using seven bolts (12) and seven hard washers (8) .
8. Secure sound suppression panel group (10) to plate (4) and sound suppression panel group
(3) by using five bolts (12) and five hard washers (8) .
Illustration 632
(4) 371-5831 Plate
(7) 8T-4136 Bolt
(12) 8T-4137 Bolt
six bolts (12) and six hard washers (8) .
Area (B) Components of the 382-5245 Sound Suppression Panel Gp
Illustration 633
Left side view of center location (B)
(7) 8T-4136 Bolt
(19) 393-5277 Plate
2. Secure sound suppression panel group (16) to the frame by using four bolts (7) four hard
4. Secure sound suppression panel group (17) to sound suppression panel group (15) and
sound suppression panel group (16) by using four bolts (7) and four hard washers (8) .
one bolt (7) and one hard washer (8) .
Illustration 634
View of the right side of the main air tank
(20) 354-6048 Cover
(21) 354-6049 Cover
(22) 7K-1181 Cable Strap
7. Wrap cover (20) around the main air tank. Secure cover (20) with three cable straps (22) .
8. Secure cover (21) on top of the main air tank to cover (20) by using four cable straps (22) .
Area (C) Components of the 382-5245 Sound Suppression Panel Gp
View of the front of the frame to the left of the engine
(7) 8T-4136 Bolt
(24) 372-3117 Angle As
(7) 8T-4136 Bolt
(24) 372-3117 Angle As
2. Secure sound suppression panel group (25) to two existing brackets and angle assembly (24)
by using four bolts (7) and four hard washers (8) .
(7) 8T-4136 Bolt
3. Secure sound suppression panel group (26) to two existing brackets on the frame and two
gusset assemblies that were installed in Step 1. Use nine bolts (7) and nine hard washers (8)
to secure sound suppression panel group (26) .
4. Secure sound suppression panel group (27) to one existing bracket on the frame and one
gusset assembly that was installed in Step 1. Use four bolts (7) and four hard washers (48)
to secure sound suppression panel group (26) .
5. Secure heat shield assembly (12) and baffle (13) to heat shield assembly (14) by using one
plate (9), four bolts (10), and four hard washers (11) .
Install the 353-8369 Sound Suppression Gp for the Sound Suppression

Arrangement
Illustration 638
View of the top of the hood assembly
The hood assemblies have been made transparent to show the rough locations of the sound panels
(A) Front hood assembly
(B) Rear hood assembly
Table 144
Arrangement
1 1 372-1969 Silencer
2 1 373-1400 Silencer
3 1 373-1401 Silencer
4 2 373-1402 Silencer
5 7 373-1403 Silencer
6 9 373-1404 Silencer
7 6 373-1405 Silencer
8 1 373-1406 Silencer
9 1 373-1407 Silencer
10 4 373-1408 Silencer
11 1 373-1409 Silencer
12 2 373-1410 Silencer
13 1 373-1957 Silencer
14 1 373-1958 Silencer
15 1 373-1959 Silencer
16 1 373-1960 Silencer
17 96 8T-4195 Bolt
18 96 8F-6437 Washer
19 22 8T-4171 Bolt
Illustration 639
View of the bottom of front hood assembly (A)
Refer to Illustration 638
(1) 372-1969 Silencer
(4) 373-1402 Silencer
(5) 373-1403 Silencer
(6) 373-1404 Silencer
(7) 373-1405 Silencer
(10) 373-1408 Silencer
(12) 373-1410 Silencer
(13) 373-1957 Silencer
(14) 373-1958 Silencer
(15) 373-1959 Silencer
(16) 373-1960 Silencer
(17) 8T-4195 Bolt
(18) 8F-6437 Washer
(19) 8T-4171 Bolt
Illustration 640
View of the bottom of rear hood assembly (A)
Refer to Illustration 638
(2) 373-1400 Silencer
(3) 373-1401 Silencer
(5) 373-1403 Silencer
(6) 373-1404 Silencer
(7) 373-1405 Silencer
(8) 373-1406 Silencer
(9) 373-1407 Silencer
(10) 373-1408 Silencer
(11) 373-1409 Silencer
(12) 373-1410 Silencer
(13) 373-1957 Silencer
(14) 373-1958 Silencer
(15) 373-1959 Silencer
(16) 373-1960 Silencer
(17) 8T-4195 Bolt
(18) 8F-6437 Washer
(19) 8T-4171 Bolt
1. Secure the silencer plates to the bottom and the sides of the hood group. Refer to Illustration
639 and Illustration 640.
Note: All silencer plates the are secured to the bottom of the hood group are secured with
bolts (17) and washers (18). All silencer plates that are secured to the sides of the hood
group are secured with bolts (19) and washers (20) .
Arrangement
Table 145
1 2 386-5195 Plate As
2 60 8T-4136 Bolt
4 2 353-8365 Plate As
6 2 393-5277 Plate
9 1 (1) 3E-8349 Seal
11 20 8T-4138 Bolt
12 20 9X-8256 Washer
14 2 383-3318 Plate As
15 2 370-5894 Plate As
16 12 8T-4137 Bolt
17 2 383-2240 Strut
18 4 247-1913 Ball Stud
20 4 5C-7261 Nut
22 4 8T-4193 Bolt
(1)
835 cm (328.7 inch)
Illustration 641
(A) Bolt
(B) Hard washer
(C) Nut
(1) 386-5195 Plate As
(2) 8T-4136 Bolt
(4) 353-8365 Plate As
1. Secure two plate assemblies (1) to the frame by using four bolts (2) and four hard washers
(3) .
2. Secure two plate assemblies (4) to the frame by using existing bolts (A), hard washers (B),
and nuts (C) .
View of the left side of the frame
(1) 386-5195 Plate As
(2) 8T-4136 Bolt
(6) 393-5277 Plate
3. Secure sound suppression panel group (5) to the frame and plate assembly (1) by using
seven bolts (2), seven hard washers (3), and one plate (6) .
View of the right side of the frame
(1) 386-5195 Plate As
(2) 8T-4136 Bolt
(6) 393-5277 Plate
4. Secure sound suppression panel group (7) to the frame and plate assembly (1) by using
seven bolts (2), seven hard washers (3), and one plate (6) .
Illustration 644
View of the bottom of sound suppression panel group
(9A) 3E-8349 Seal 650 ± 5 mm (25.59 ± 0.1967inch)
(9B) 3E-8349 Seal 2600 ± 5 mm (102.36 ± 0.197 inch)
(9C) 3E-8349 Seal 1850 ± 5 mm (72.83 ± 0.197 inch)
5. Secure seal (9) onto the bottom of sound suppression panel group (8) .
Note: The approximate weight of sound suppression panel group (8) is 75 kg (165 lb).
Illustration 645
6. Attach a suitable lifting device to sound suppression panel group (8) .
7. Position sound suppression panel group (8) onto the guards under the engine.
Illustration 646
Left side
(11) 8T-4138 Bolt
(12) 9X-8256 Washer
8. Secure the hinges from sound suppression panel group (10) to sound suppression panel
group (8) by using eight bolts (11) and eight washers (12) .
the existing latches.
Illustration 647
Right side
(11) 8T-4138 Bolt
(12) 9X-8256 Washer
eight bolts (11) and eight washers (12) .
the existing latches.
(2) 8T-4136 Bolt
(14) 383-3318 Plate As
12. Secure one plate assembly (14) to the left side of the guard group by using two bolts (2) and
two hard washers (3) .
(2) 8T-4136 Bolt
(14) 383-3318 Plate As
13. Secure one plate assembly (14) to the right side of the guard group by using two bolts (2)
and two hard washers (3) .
Illustration 650
(14) 383-3318 Plate As
(15) 370-5894 Plate As
(16) 8T-4137 Bolt
(17) 383-2240 Strut
(18) 247-1913 Ball Stud
(20) 5C-7261 Nut
14. Secure plate assemblies (15) onto the top of sound suppression panel group (10) and sound
suppression panel group (13) by using four bolts (16) and four hard washers (3) .
15. Secure two struts (17) between plate assemblies (14) and plate assemblies (15) by using four
bolts (18), four hard washers (19), and four nuts (20) .
Illustration 651
Left side
(2) 8T-4136 Bolt
(22) 8T-4193 Bolt
18. Secure sound suppression panel group (21) to the bracket on the frame by using two bolts
(22) and two hard washers (23) .
Illustration 652
Right side
(2) 8T-4136 Bolt
(22) 8T-4193 Bolt
21. Secure sound suppression panel group (24) to the bracket on the frame by using two bolts
(22) and two hard washers (23) .
Illustration 653
(2) 8T-4136 Bolt
(4) 353-8365 Plate As
22. Secure sound suppression panel group (25) to sound suppression panel group (8), plate
assembly (4), and the existing brackets on the frame by using eight bolts (2) and eight hard
washers (3) .
Note: Plate assembly (4) was installed in Step 2.
23. Secure sound suppression panel group (26) to sound suppression panel group (8), plate
assembly (4), and the existing brackets on the frame by using eight bolts (2) and eight hard
washers (3) .
Note: Plate assembly (4) was installed in Step 2.
Illustration 654
Left side
(2) 8T-4136 Bolt
24. Secure sound suppression panel group (27) to sound suppression panel groups (8), (21), and
(26) by using eight bolts (2) and eight hard washers (3) .
Illustration 655
Right side
(2) 8T-4136 Bolt
25. Secure sound suppression panel group (28) to sound suppression panel groups (8), (24), and
(25) by using seven bolts (2) and seven hard washers (3) .

Arrangement
Table 146
Arrangement
1 1 353-8329 Cover As
2 6 8T-4189 Bolt
3 6 4B-4278 Washer
4 3 355-6162 Plate
5 1 353-8335 Cover As
6 1 353-8333 Cover As
7 1 353-8331 Cover As
8 18 191-8439 Boss
9 18 8T-4139 Bolt
Illustration 656
View of the back of the rear axle housing
(A) Bolt
(B) Washer
(1) 353-8329 Cover As
(2) 8T-4189 Bolt
(3) 4B-4278 Washer
(4) 355-6162 Plate
1. Secure cover assembly (1) to the rear of the rear axle housing by using three exiting bolts
(A), three existing washers (B), six bolts (2), six washers (3), and three plates (4) .
Illustration 657
(5) 353-8335 Cover As
(6) 353-8333 Cover As
(7) 353-8331 Cover As
Illustration 658
View of the front of the rear axle housing
(C) 72 mm (2.83 inch)
(D) 149 mm (5.87 inch)
(E) 24 ± 10 mm (0.945 ± 0.394 inch)
(F) 251 mm (9.88 inch)
(G) 321 mm (12.64 inch)
(H) 820 mm (32.28 inch)
(J) 1997 mm (78.62 inch)
(K) 4.6 mm (0.18 inch)
(L) 42 mm (1.65 inch)
(M) 261.5 mm (10.29 inch)
(N) 324.6 mm (12.78 inch)
(P) 65.3 mm (2.57 inch)
(R) 315.4 mm (12.42 inch)
2. Position cover assembly (5), cover assembly (6), and cover assembly (7) onto the bottom of
the rear axle housing. Mark the locations of the holes on the cover assemblies. Refer to
Illustration 657.
Refer to Illustration 658 to verify the locations that were marked.
3. Remove the cover assemblies from the rear axle housing.
Illustration 659
View of the bottom of the rear axle housing
(8) 191-8439 Boss
(W1) 3 mm (0.118 inch) All around fillet weld

performing any welding on the machine.
4. Weld 18 bosses (8) to the locations from Step 2 on the rear axle housing. Use a 3 mm (0.118
inch) all around fillet weld for all bosses (8) .
Illustration 660
View of the bottom of the rear axle housing
(5) 353-8335 Cover As
(6) 353-8333 Cover As
(7) 353-8331 Cover As
(8) 191-8439 Boss
(9) 8T-4139 Bolt
5. Secure cover assembly (5), cover assembly (6), and cover assembly (7) to bosses (8) on the
rear axle housing by using 18 bolts (9) and 18 hard washers (10) .

Arrangement
Table 147
Arrangement
1 2 354-5989 Bracket As
2 8 8T-4137 Bolt
4 2 354-5990 Strip
5 1 354-5984 Silencer
6 2 354-5985 Strip
7 10 8T-5005 Bolt
8 10 266-5360 Washer
View of the top of the frame
(1) 354-5989 Bracket As
(2) 8T-4137 Bolt
1. Secure two bracket assemblies (1) to the top of the frame by using eight bolts (2) and eight
hard washers (3) .
(1) 354-5989 Bracket As
(4) 354-5990 Strip
(5) 354-5984 Silencer
(6) 354-5985 Strip
(7) 8T-5005 Bolt
(8) 266-5360 Washer
2. Secure silencer (5) to bracket assemblies (1) by using ten bolts (7), ten washers (8), two
strips (6), and two strips (4) .

Arrangement
Table 148
Arrangement

1 5 372-6349 Silencer
2 2 372-6350 Silencer
3 11 372-6352 Silencer
4 4 372-6354 Silencer
5 2 373-0028 Silencer
6 87 160-0240 Dowel
7 87 8T-4171 Bolt
Illustration 663
View of the front of the body assembly
(1) 372-6349 Silencer
(2) 372-6350 Silencer
(3) 372-6352 Silencer
(4) 372-6354 Silencer
(5) 373-0028 Silencer
1. Position the silencers on the front wall of the truck body and mark the hole locations.
Illustration 664
(6) 160-0240 Dowel
(W1) 3 mm (0.118 inch) All around fillet weld

performing any welding on the machine.
2. Weld 87 dowels (6) to the locations from Step 1 on the body assembly. Use a 3 mm (0.118
inch) all around fillet weld for all dowels (6) .
Illustration 665
(1) 372-6349 Silencer
(2) 372-6350 Silencer
(3) 372-6352 Silencer
(4) 372-6354 Silencer
(5) 373-0028 Silencer
(7) 8T-4171 Bolt
3. Secure the silencers to the dowels by using 87 bolts (7) and 87 hard washers (8) .

Arrangement
Table 149
Arrangement
1 45 7K-1181 Cable Strap
2 1 355-6148 Silencer
3 1 355-6149 Silencer
4 1 355-6150 Silencer
5 1 355-6151 Silencer
6 1 355-6152 Silencer
7 1 373-0140 Silencer
8 1 373-0141 Silencer
Illustration 666
View of the right side of the transmission
(2) 355-6148 Silencer
(3) 355-6149 Silencer
(4) 355-6150 Silencer
(5) 355-6151 Silencer
(6) 355-6152 Silencer
Illustration 667
View of the left side of the transmission
(3) 355-6149 Silencer
(4) 355-6150 Silencer
(5) 355-6151 Silencer
(6) 355-6152 Silencer
(7) 373-0140 Silencer
(8) 373-0141 Silencer
1. Position the silencers around the transmission arrangement. Secure the silencers with 45
cable straps (1) .
Check the Following Items Before Starting the Engine
NOTICE

• Air Tank
• Lubrication Viscosities
• Refill Capacities
• Check Coolant Level
• Check the Differential and Final Drive Oil Level
• Check the Engine Oil Level
• Fill the Fuel Tank
• Fill the Hydraulic Oil Tank
• Fill the Torque Converter and Fill the Transmission with Oil
Note: Do not start the engine until all fluids have been filled. Do not start the engine until all
fluids have been checked.
Air Tank
The air tank must be filled in order to start the engine. Refer to Operation and Maintenance
Manual, SEBU8417, "Engine Starting with an External Air Supply - If Equipped with Air Starting
Arrangement" for the proper procedure.
Lubrication Viscosities
Refer to Operation and Maintenance Manual, SEBU8417, "Lubrication Viscosities" in order to
determine the required oil.
Refill Capacities
Refer to Operation and Maintenance Manual, SEBU8417, "Capacities (Refill)" in order to

determine the capacities of the components.
Check Coolant Level

Refer to Operation and Maintenance Manual, SEBU8417, "Cooling System Coolant Level -
Check" for the proper procedure.
Check the Differential and Final Drive Oil Level

Refer to Operation and Maintenance Manual, SEBU8417, "Differential and Final Drive Oil Level
- Check" for the proper procedure.
Check the Engine Oil Level

Refer to Operation and Maintenance Manual, SEBU8417, "Engine Oil Level - Check" for the
proper procedure.
Fill the Fuel Tank

Fill the fuel tank. There should be an adequate amount of fuel in order to perform the
commissioning procedure.
Fill the Hydraulic Oil Tank

Fill the hydraulic tank. Refer to Operation and Maintenance Manual, SEBU8417, "Lubricant
Viscosities". Refer to Operation and Maintenance Manual, SEBU8417, "Capacities (Refill)".
Fill the Torque Converter and Fill the Transmission with Oil
Fill the torque converter sump. See Operation and Maintenance Manual, SEBU8417, "Lubricant
Viscosities". See Operation and Maintenance Manual, SEBU8417, "Capacities (Refill) "System
Capacities"".
Perform the Commissioning Procedure for the Machine

Note: Refer to Operations and Maintenance Manual, SEBU8417, "797F Off-Highway Truck" for
additional information on the oil recommendations.
Table 150
Dealer Information for Commissioning Procedure
Date
Serial Number
Service Meter Units
Name of the Technician
Unit Number
Engine Serial Number
Dealer
Dealer Code
Customer
Job Site
Transmission Serial Number

Torque Converter Serial Number
Fluid Level Checks

Note: Refer to Operation and Maintenance Manual, SEBU8417, "797F Off-Highway Truck" for
additional information on checking the fluid levels.
Table 151
Checking the Fluid Levels Check if OK
Engine Coolant System (1)
Transmission and Torque Converter

Hydraulic Tank
Engine Crankcase
Left Rear Final Drive
Right Rear Final Drive
Rear Axle
Grease for the Autolube
Left Front Wheel Station
Right Front Wheel Station

Window Washer Reservoir
Fuel
(1)
Check the Jacket Water level.
VIMS Self Test
Turn the ignition key from the OFF position to the ON position in order to activate the VIMS self
test. Do not start the truck.
Table 152
Check for the Illumination of the Lights in the instrument panel (1) Check if OK
Body indicator position
Action Indicator
Retarder Indicator
TCS Indicator
Alert Indicator
(1)
All of the indicator lights will illuminate at the same time for several seconds. After the lights illuminate, the
indicator lights will turn off.
Check the Configuration of the Electronic Control Modules

(ECM)
ReferenceService Manual, KENR9023, "793F and 797F Off-Highway Truck/Tractors VIMS,
Monitoring, and Payload "
(1) "CAT ET" connector
(2) 12 V connector
(3) "VIMS" connector
1. Connect a laptop computer to the Caterpillar Diagnostic Connector behind the seats of the
cab.
2. In order to power the electrical system of the truck, perform the steps that follow:
a. Connect the batteries.
Typical view of the ground level switches
b. Turn battery disconnect switch (14) to the ON position.
c. Switch manual engine shutdown switch (13) to the OFF position.
d. In the cab, turn the key to the ON position.
e. DO NOT START THE TRUCK.
Note: When the key is in the "ON" position, the VIMS will perform a 4 to 6 second self
test. Disregard the VIMS self test at this time.
3. Use your laptop computer in order to open Caterpillar Electronic Technician.
4. Select "C175 797". Click "OK".
5. The Electronic Technician "ET" Selector screen should display the truck model for each
control. Make sure that the model is correct for each of the controls.
6. From the toolbar, select "Service", and select "Configuration".
Illustration 673
Typical view
7. In the "ECM Identification Parameters" field, Select "Equipment ID".
8. Double click on "Equipment ID" in order to change the value for the equipment ID, or select
"change".
9. Verify that the equipment ID matches the machine serial number. If the Equipment ID does
not match, change the Equipment ID and click "OK".
Illustration 674
Typical view
10. Check the "Engine Serial Number". The "Engine Serial Number" must match the engine
serial number that is on the engine. If the Engine Serial Number is not correct, update the
Engine Serial Number.
Illustration 675
11. Verify the "Ether Control" setting. Set the "Ether Control" setting to the "Enabled" or the
"Disabled" position.
Note: Refer to Testing and Adjusting, KENR5397, "C175-16 and C175-20 Engines for
793F and 797F Off-Highway Truck/Tractors " for information on the engine.
Illustration 676
12. If equipped, verify that the "Oil Renewal Rate" control is correctly set. The "Oil Renewal
Rate" has an adjustable range from -50 to 50.
Note: Refer to Systems Operation, RENR2223, "Oil Renewal System".
Illustration 677
13. If equipped, verify the "Engine Pre-Lube" setting. A truck that is equipped with the engine
prelube can be "Enabled".
14. From the toolbar, select "Service". Then select "ECM Date/Time".
15. Input the correct time zone, the date, and the time.
Check for Active Diagnostic Codes and Logged Diagnostic Codes
1. From the toolbar, click on "Diagnostic". Click on "Active Diagnostic Codes".
2. Resolve any of the active diagnostic codes.
3. From the toolbar, click on "Diagnostics". Click on "Logged Diag. Codes".
Illustration 682
Typical view
4. Clear any logged diagnostic codes by highlighting an event. Next, click the "Clear" button
that is located in the lower left corner of the screen.
5. From the toolbar, click on "Diagnostics". Select "Events" and click on "Logged Events".
6. If necessary, resolve any logged events and clear any logged events.
7. Clear the logged event by selecting an event and clicking the "Clear" button that is located
in the lower left corner of the screen.
Note: A factory assigned password may be required in order to clear some events that are
logged on the engine "ECM".
Injector Code Setting and Calibration
1. From the toolbar, click on "Service". Select "Calibrations". Click on "Injector Trim
Calibration".
2. Confirm that all the injectors have trim files.
Ether Control Test (If Equipped)

Note: The ether control must be enabled in order to perform the ether control test.
Values for the injectors are typical.
1. Click on "Diagnostics". Select "Diagnostic Tests". click on "Override Parameters".
Illustration 686
Typical view
2. To test the ether control operation, select "Ether Injection". Click on the "Change" button
that is located in the lower left corner of the screen.
3. Click on the drop-down menu for the "New Value:" and change the selection from "Off" to
"On". Click "OK".
4. Click "OK" in the verification box.
Note: An audible click should be heard after clicking "Yes" on the verification box.
5. If the ether control test is acceptable, select "Ether Injection Override" in order to return the
mode to normal.
Setting for the Engine Prelube
Illustration 688
1. If equipped, select "Engine Pre-Lube". Click on the "Change" button that is located in the
lower left corner of the screen.
2. Click on the drop-down menu for the "New Value:" and change the selection from "Off" to
"On". Click "OK".
Note: The operator should hear the engine prelube system energize.
4. When the test for the engine prelube is completed, select "Disable Override" in order to
return the mode to normal.
Control Setting for the Oil Renewal System (If Equipped)

1. Click on the engine "ECM".
Illustration 689
2. To test the oil renewal system, select "Oil Renewal". Click on the "Change" button that is
located in the lower left corner of the screen.
3. Click on the drop-down menu for the "New Value:" and change the selection "Off" to "On".
Click "OK".
Note: An audible sound from the "Oil Renwal" system should be heard after clicking "OK"
on the verification box.
5. When the test for the oil renewal system is completed, click on "Disable Override" in order
to return the mode to normal.
6. From the toolbar, click on "Service". Click "Configuration" in order to go back to the main
configuration screen.
Chassis Control Settings
Illustration 690
1. Click on "Machine Configuration" under the heading "Chassis 797".
2. Click on "Starting System Configuration". Select the type of Starting System Configuration
that is on the machine.
Illustration 691
3. If the truck is equipped with the oil renewal system (ORS), verify that the control is set
correctly.
Illustration 692
4. Verify that the "Auto Lube" is set correctly.
Settings for the Transmission Control
Illustration 693
1. Click on "Configuration Group 1" under "Transmission 797".
2. Check the "Transmission Serial Number". The serial number should match the serial
number that is on the transmission. If the serial number is incorrect, input the correct
Transmission Serial Number.
Illustration 694
3. Check the "Machine Speed Limit". If there is a requirement for a speed limit, input the
correct speed limit.
Settings for the Brake Control
Illustration 695
1. Click on "Configuration Group 1" under "Brake 797".
2. Verify that the "Equipment ID" matches the machine serial number.
3. Set the "Maximum Desired Engine Retard Speed" between 1850 RPM and 1950 RPM.
Illustration 696
4. Verify that the correct "Differential High Speed Fan Install Status" is selected.
Settings for the VIMS Main Module
Illustration 697
1. Under "VIMS Main Module", select "General Information".
2. Verify that the "Product ID" matches the machine serial number.
Disconnect ET
1. Before disconnecting (ET), remove any logged diagnostic codes or active diagnostic codes
that may have occurred. Refer to the ""Check for Active Diagnostic Codes and Logged
Diagnostic Codes" " for instructions on removing diagnostic codes.
2. Disconnect (ET) from the laptop computer.
3. The Electronic Technician (ET) will be used again in the Section ""Hoist Enable System" ".
VIMS
Note: Ensure that the key is in the ON position.
Instrument cluster for the 797F
(1) Action Indicator
Illustration 699
1. Start the "VIMS" PC software.
Note: The low brake pressure indicator causes the alert indicator to flash. The "VIMS"
Message Center should provide the following instruction: Do Not Move The Machine. This
message is on display until the starting reservoir and the service reservoir are charged to one
half of the maximum operating pressure. Do not turn off the parking brake switch before the
pressure is obtained. The horn will sound a warning.
Note: Refer to Service Manual, KENR9023, "793F and 797F Off-Highway Truck/Tractors
VIMS, Monitoring, and Payload " for additional information on warnings.
Illustration 700
2. Click on "File". Click on "Connect Machine".
3. Select the "Cab" and click "OK".
4. After the connection is completed click on "Data" from the toolbar. Click on "Download".
Illustration 703
5. In the "Download Data" box, select all of the boxes under "Download".
6. In the "Download Data" box, select everything under "Reset After Download".
7. Click on "Download" after the download selections has completed.
8. From the toolbar, click on "Configure". Click on "Assign Serial/Equipment Number".
9. In the "Assign Serial/Equipment Number" box, verify that the serial number matches the
new serial number.
10. In the "Assign Serial/Equipment Number" box, change the "Equipment" number in order to
correspond to the new customer machine number. Click "OK".
11. From the toolbar, click on "Configure". Click on "Reset Date/Time/SMH".
12. Select "Reset Date/Time" and change, as necessary.
13. Select "Reset SMH" and set to Zero.
14. Click on OK.
Prepare to Start the Engine
NOTICE

1. Verify that all of the fluids are at an acceptable level.
Note: Refer to the Operation and Maintenance Manual, SEBU8417, "Capacities (Refill)"
for the fluid capacities.
2. Move manual engine shutdown switch (1) to the OFF position.
Note: The engine should be disabled so the engine will not start.
3. Chock the wheels.
4. Enable the parking brake.
5. Prime the pump drive housing and the hoist pump with the recommended oil or crank the
engine. Crank the engine over two times for 15 seconds in order to fill the compartments
with oil.
Engine Start-Up
NOTICE
A low brake pressure condition will cause the alert indicator to flash.
The "VIMS" message center should provide the following
instruction:"DO NOT MOVE THE MACHINE." This message is on
display until the starting reservoir and the service reservoir are
charged to one half of the maximum operating pressure. "DO NOT"
turn off the parking brake switch before the pressure is obtained. The
horn will sound a warning.
1. Verify that the fluids are at an acceptable level.
Note: See the checklist below.
Note: Refer to Operations and Maintenance Manual, SEBU8417, "Capacities (Refill)" for
the capacities for the 797F.
2. Move manual engine shutdown switch (1) to the ON position in order to prepare to start the
engine.
3. Start the engine. Refer to Operation and Maintenance Manual, SEBU8417, "Engine
Starting" for additional instructions on starting the engine.
Note: The Advisor may instruct the operator to shut down the engine in order to resolve any
issues. All issues must be resolved before restarting the engine.
4. Verify that the pressures are acceptable for operation.
5. Start the engine and run the engine for 10 seconds.
6. Turn the key to the OFF position.
7. Switch manual engine shutdown switch (1) to the OFF position.
8. Check for leaks.
9. As needed, check the following systems and fill the following systems:
◦ Transmission and Torque Converter
◦ Common Rail Tank
◦ Engine
◦ Separate Circuit Aftercooler (SCAC) and Water Jacket
◦ Brake and Hoist
10. Switch manual engine shutdown switch (1) to the ON position.
11. Restart the engine and operate the engine for 30 seconds.
12. With the engine on, turn the steering wheel from the center position three rotations to the
left. Next, turn the steering wheel back to the center position.
13. With the engine on, turn the steering wheel from the center position three rotations to the
right. Next, turn the steering wheel back to the center position.
14. Turn the key to the OFF position.
15. Switch manual engine shutdown switch (1) to the OFF position.
16. Check for leaks.
17. Restart the engine and operate the engine for 60 seconds.
18. Turn off the engine. Switch manual engine shutdown switch (1) to the OFF position.
19. Check for leaks.
20. Restart the engine. Operate the engine until normal operation temperatures are reached.
Check for leaks.
21. Adjust all of the fluid levels, as required.
Automatic Retarder Control (ARC) Purge Procedure

Refer to Testing and Adjusting, KENR8374, "797F Off-Highway Truck Braking System".
NOTICE
A procedure is required to purge any air that may be in the (ARC)

system. Purge air from the (ARC) system if the following events have
occurred:
• Initial assembly of the machine
• The automatic retarder control valve has been replaced
• Any hoses that supply oil to the automatic retarder control valve have been disconnected.
• Any hose that supplies oil from the automatic retarder control valve to the brakes is
disconnected.
Autolube
NOTICE
Be satisfied that all of the automated grease injectors are receiving a

sufficient supply of grease.
View of the left side grease injectors
View of the right side grease injectors
View of the rear grease injectors
1. Adjust the grease injectors, as required. Refer to Service Manual, KENR8749, "Off-
Highway Truck Automatic Lubrication System for Electric Start Equipped Trucks" for
information on adjusting the grease injectors.
2. Turn the key to the ON position.
Note: Do not start the truck.
3. Through the Advisor, select "Service".
4. Select "Service Tests".
5. Enter the code "00C9" in order to verify the settings for the lubrication.
6. Press OK on the Advisor.
7. Verify the autolube interval.
8. If necessary, use the left arrow or the right arrow to set the correct interval.
9. Press OK.
10. If necessary, repeat Step 8 and Step 9 for the autolube interval.
Prepare the Truck for Pressure Checks

1. The engine should be at normal operating temperature and the transmission should be in the
PARK position.
3. After the engine has started, the automatic elevated low idle will activate in 10 minutes.
When activated, the automatic elevated low idle increases the idle RPM gradually at a rate
of 33 RPM per second.
4. After the activation of the elevated idle speed, or if the coolant temperature rises above 70 °
C (158 °F), the operator may reset the 10 minute delay. Tapping the accelerator pedal to
more than 25 percent of the pedals total travel will reset the 10 minute delay and return the
engine to low idle.
Air Pressure Check (If Equipped)

1. Prepare to start the truck.
Note: The transmission control should be in the PARK position.
3. Start the engine.
4. In the Advisor, select "Monitor".
5. View the pressure of the "System Air Pressure".
6. Accelerate the engine to 1920 RPM.
Note: The air dryer should expel air at 827 ± 34 kPa (120 ± 5 psi).
Note: The air pressure that is shown on the Advisor should read 827 kPa (120 psi).
7. For adjustment of the air pressure, refer to Testing and Adjusting, KENR8748, "797F Off-
Highway Truck Air System ".
Heater Voltage Check
View of the left side of the machine
1. Locate the air dryers near the left front wheel
Typical view
2. Check the amount of voltage that is for the heater at the electrical connection of the dryer.
3. Use the table below in order to record your results.
Table 153
Air Dryer Check Actual Reading
24 V or more at the air dryer
Hoist Enable System

Note: The following procedure is only used when the hoist is not enabled.
1. Start Electronic Technician "ET" and select "Chassis 797".
2. From the toolbar, click on "Service". Click on "Configuration".
Illustration 721
3. Under the heading "Hoist System", click "Hoist System Enable Status".
4. Click on the"Change" button that is located at the bottom of the screen.
5. Use the drop-down menu in order to change the status of the hoist system to "Enabled".
Click "OK". Select "OK" in the verification box.
Steering System Test

ReferenceTesting and Adjusting, KENR8734, "797F Off-Highway Truck Steering System"
1. With the engine on, record the pressures in the table that is provided.
Table 154
Steering Pressure Test (1)
Test Actual
Test the pump high-pressure cut-off at low idle.
1.________________
Test the cycle time for the steering system at high idle. With all 2.________________
of the brakes released, turn the steering wheel from left to right. 3.________________
Then from right to left. Avg.______________
Left to Right
1.________________
Test the steering wheel turns from stop to stop at high idle.
2.________________
With all of the brakes released, turn the steering wheel at 1
3.________________
revolution per second
Avg.______________
Right to Left
1.________________
Test the steering wheel turns from stop to stop at high idle.
2.________________
With all of the brakes released, turn the steering wheel at 1
3.________________
revolution per second Avg.______________
Test the accumulator nitrogen charge pressure (2)

Test the accumulator nitrogen charge pressure (3)
(1)
Steering oil temperature during tests 90.5° ± 30.5°C (195° ± 55°F)
(2)
The first of two accumulators
(3)
The second of two accumulators
Torque Converter Test

ReferenceTesting and Adjusting, KENR8370, "797F Off-Highway Truck Power Train"
1. Use the table below to record the performance of the torque converter.
Note: Engine speed is reduced to 1600 rpm when the transmission is in reverse and the
body is in the raised position. The torque converter stall test must be performed when the
transmission is in the first gear and the body is in the lowered position.
Table 155
Test Actual
Torque Converter Oil Temperature (during tests)
80 °C (176 °F) <
121 °C (250 °F)
Low Idle
Torque Converter Inlet Pressure (1) High Idle
Stall
Torque Converter Stall RPM
Low Idle
Torque Converter Outlet Pressure at Stall RPM
High Idle
Low Idle
Transmission Charge Pressure (Converter Drive)
High Idle
Transmission Charge Pressure (Direct Drive)
Lockup Clutch Maximum Pressure
NEUTRAL/DIRECT DRIVE (2)
(1)
Maximum pressure at high idle with cold oil.
(2)
At 1300 RPM
Transmission Calibration Test

ReferenceTesting and Adjusting, KENR8370, "797F Off-Highway Truck Power Train"
1. Use the table below in order to record the transmission and torque converter pressures.
Table 156
Converter Drive Pressures
Actual
Low Idle High Idle

Pump Pressure (1)
Lube Pressure
Pilot Pressure (2)
>
Transmission Oil Temperature (during tests) 82 °C (180 °F)
<
121 °C (250 °F)
(1)
Adjust with the Transmission Relief Valve.
(2)
Result of setting Direct Drive Pump Pressure
2. Perform a transmission calibration test. Refer to Testing and Adjusting, KENR8370,

"Transmission - Test" for instructions on performing the transmission calibration.
Towing Motor Test

ReferenceIf needed, refer to Testing and Adjusting, KENR8374, "797F Off-Highway Truck
Braking System"
(1) Location of the pressure taps for the parking brake release pressure
View of the rear slack adjuster
(1) Pressure tap for the left rear parking brake release pressure
(2) Pressure tap for the right rear parking brake release pressure
1. Install a 8T-0857 Pressure Gauge (0 to 10000 kPa (0 to 1450 psi)) to the pressure taps for
the parking brake release pressure.
2. Turn the engine start switch to the ON position.
3. Place the transmission control into the NEUTRAL position.
4. Apply the manual retarder.
Switch for the electric powered parking and secondary brake release pump
5. Activate the switch for the towing motor.
Note: Hold the switch until the pressure that is shown on the pressure gauge stops rising.
6. Record the pressure for the left side and right side in the table that is provided.
Table 157
Towing Motor Pressure
Side Actual
Left
Right
Parking Brake Retract Pressure Test

ReferenceIf needed, refer to Testing and Adjusting, KENR8374, "797F Off-Highway Truck
Braking System".
This test will show if the parking brake release pump section is working properly. This test will
also show if the relief valve for the parking brake release system is set correctly.
1. Record the results of the pressure test in the table that is provided.
Table 158
Parking Brake Pressure
Setting Actual
Relief Valve
Transmission Field Test

1. Stop the engine.
2. Activate transmission lockout switch (1) .
3. When the transmission lockout switch is activated, indicator light (2) should be on.
4. With the truck in first gear, try to start the engine.
5. With the truck in reverse, try to start the engine.
6. Use the Table 159 to record the results of Step 4 and Step 5.
Table 159
Transmission Neutralizer Switch
Gear Switch Activated Engine does not start. Check if OK
First
Reverse
Traction Control System Field Test

Note: The steering system should be checked and adjusted as required before proceeding with the
test.
Note: Sound the horn for the all clear before starting the engine.
1. Start the engine.
2. Activate the TCS switch.
3. With the TCS switch activated and the engine at low idle, drive the machine to the right in a
tight circle.
Note: The rear wheels should lock and unlock.
4. With the TCS switch activated and the engine at low idle, drive the machine to the left in a
tight circle.
Note: The rear wheels should lock and unlock.
5. Compare the turning radius of Step 3 to the turning radius of Step 4.
Note: The size of the turning radius for both of the circles that were driven should be
similar.
Brake Field Test

ReferenceOperation and Maintenance Manual, SEBU8417, "797F Off-Highway Truck"
1. Perform the braking system tests. Refer to the Operation and Maintenance Manual,
SEBU8417, "Braking System - Test" for instructions on testing the service, secondary, and
parking brakes.
Truck Payload - Calibrate

The payload system must be calibrated if the "VIMS" software is used to assign a new serial
number to the VIMS electronic control module. If the suspension cylinder pressures are adjusted,
the payload system must be recalibrated. The payload system must also be calibrated after the
replacement of the following components:
• VIMS electronic control module
• Suspension Cylinders
• Suspension Cylinder Pressure Sensors
The Truck Payload System will not operate until a successful payload calibration has been
completed.
The following information describes the procedure for calibrating the payload by using CAT ET.
1. Ensure that the truck body is empty. Carryback weight will affect the payload measurement.
2. Use your laptop computer in order to open Caterpillar Electronic Technician.
3. Click on "Service". Select and click "Calibrations" and "Truck Payload Calibrations".
4. Following the instructions that are shown in CAT ET.
◦ To ensure calibration accuracy, the truck body must be empty.
◦ Operate the empty truck at a speed of at least 5 km/h (3 mph) on hard level ground.
◦ Move the transmission gear selector to the neutral position and allow the truck to
coast to a stop. DO NOT use the brakes to help slow down.
Note: This test must be done on a safe road.
Illustration 730
5. After all the conditions are met, click "Next".
6. After the calibration of the truck payload is successful, click "Finish".
If the calibration is not successful, repeat the procedure again.
Cab Instrumentation and Functional Checks
Operators Seat
Table 160
Check for Seat Adjustability Check if OK
Check the range of the light to heavy dampening for the seat
Full range of the back reclining positions
Full range of the seat suspension travel
Operators Seat Belt
Table 161
Check Seat Belt Latch and Seat Belt Adjustability Check if OK
Adjust the length of the seat belt
Fasten the seat belt catch into the buckle

The seat belt must not be able to slip after adjusting
The seat belt catch should unlatch from the buckle when required
Engine Start
Table 162
Check if OK
Check the Ignition Switch, Horn, and Engine Start
Turn the ignition key to the ON position (1)

Sound the horn for all clear
Turn the key to the START position in order to activate the starting motor.
After the diesel engine starts, release the key. The key should return to the ON
position
Turn the ignition key to the OFF position. The engine should stop
(1)
The key in the ON position will enable the electrical circuits in the cab and activate the VIMS self test
Pressurize the Cab
Table 163
Check the Operation of the Blower Motor in order to Pressurize the Check if OK
Cab (1)
Turn the ignition key to the ON position
Check the four settings for the blower speed (2)

Turn the ignition key to the OFF position
(1)
Pressurizing the Cab helps to eliminate dust in the operators compartment
(2)
There should be an audible sound between the different settings
Climate Control
Table 164
Check the operation of the Heater and the Air Conditioner Check if OK
Sound the horn for all clear
Start the engine
Turn the climate control to cool
Push the top of the A/C switch to activate
Air from the dash vents should be cold (1)
Push the top of the A/C switch to deactivate

Turn the climate control to warm
The lines for the heater valves should be open
Air from the dash vents should be warm (1)
(1)
When the engine is at operating temperature
Front Window Wipers
Table 165
Check the Operation of the Front Window Wiper and Washer Check if OK
From the OFF position, turn the front window wipers to the LOW setting
Turn the front window wiper to the HIGH setting
Press the button to activate the front window washer fluid
Turn the front window wiper to the first INTERMITTENT setting
Turn the front window wiper to the second INTERMITTENT setting

Turn the front window wiper to the third INTERMITTENT setting
Turn the front window wipers to the OFF position
Panel and Running Lights
(1) Switch for headlights, parking lights, and taillights
(2) Panel light switch
(3) Multifunction switch
Illustration 734
Typical view
(4) Low Beam
(5) High Beam
(6) Fog Light
Table 166
Check if
Check the operation of the Panel Lights and the Headlights (1)
OK
Push switch (1) in order to activate low beam headlights (4)
Push the top half of switch (2) to the first detent in order to activate the
instrument panel lights, marker lights, and the tail lights
Use multifunction switch (3) in order to toggle between low beam lights (4) and
high beam lights (5)
Push the bottom half of switch (1) to the OFF position in order to deactivate the
headlights
(1)
The tail lights should be on any time a light switch is activated
Hazard Lights
(7) Hazard flasher switch
Table 167
Check the operation of the hazard Lights Check if OK
Push the top half of switch (7) in order to activate the hazard lights
Push the bottom half of switch (7) in order to deactivate the hazard lights
Fog Lights
(8) Switch for the front fog lights
Table 168
Check the operation of the Fog Lights Check if OK
Push the top half of switch (8) in order to activate fog lights (6)
Push the bottom half of switch (8) in order to deactivate fog lights (6)
Access Lights
(9) Switch for the access lights in the cab
(10) Switch for the access lights at ground level
Table 169
Check if OK
Check the operation of the Auxiliary Lights (1)

Push the top half of switch (9) or switch (10) in order to activate the access
lights
If necessary, adjust the access light in order to provide light for the steps
Push the bottom half of switch (9) or switch (10) in order to deactivate the
access lights
(1)
The access lights can be activated from two places on the machine. The position of one switch will determine
whether the other switch is in the ON position or in the OFF position.
Engine Shutdown Switch
Table 170
Check the operation of the Engine Shutdown Switch Check if OK
Start the engine
Activate engine shutdown switch (11)
Engine shuts down
Deactivate engine shutdown switch (11)
Cab Dome Light
Table 171
Check the operation of the Cab Dome Light Switch (1) Check if OK
Push dome light switch to the ON position in order to turn on the light
Push dome light switch to the OFF position in order to turn off the light
(1)
The dome light and switch are located above the operator in the cab
Cigar Lighter
Table 172
Check the operation of the Cigar Lighter (1) Check if OK
Push the lighter inward and release the lighter
When the lighter is ready to use, the lighter will move outward.
(1)
The lighter can also be used as a 12 V power receptacle
Backup Alarm
Table 173
Check the operation of the backup alarm (1) Check if OK

Move the transmission direction and the speed control lever to the REVERSE
position
The backup alarm should sound immediately (2)
(1)
Make sure that the area behind the machine is clear of personnel and clear of obstacles
(2)
The backup alarm should sound until the transmission direction and speed control lever are moved to the
NEUTRAL position or the FORWARD
Calibrate the Body Position Sensor

Refer to Testing and Adjusting, KENR8381, "Position Sensor (Dump Body) - Adjust" for
instructions on calibrating the body position sensor.
Hoist Lower Valve Adjustment Status (Snub)

Refer to Testing and Adjusting, KENR8381 in order to test the hoist lower valve pressure.
Lowering the hoist is adjustable. An adjustable hoist compensates for the differences in valves.
The adjustment range is -5 to +5 with zero as the default. A positive adjustment factor will
increase the lower valve command. A positive adjustment factor causes the body to come down
harder. A negative adjustment factor will decrease the lower valve command. A negative
adjustment factor causes the body to come down softer.
Note: When the Hoist Lower Valve is adjusted too high, too much oil can be diverted to the hoist
system. If the hoist system is in the float mode, the brake oil heats up faster. Retarding capability
is also decreased. To set the Hoist Lower Valve, follow the procedure below.
1. Raise the truck body.
Typical view
2. Connect the safety retaining cables to the body.
View of the 6V-7830 Tetragauge
3. Connect a 6V-7830 Tetragauge to one of the outlet ports on the hoist pump.
4. Remove the safety retaining cables from the body.
5. With the engine that is running, place the hoist lever in the body float position.
6. With the engine operating at high idle and the body in the snub position, record the pressure.
Note: If the pressure at the hoist outlet port is more than 1723 kPa (250 psi), then proceed to
Step 7.
7. Start Cat "ET".
Illustration 742
8. In the "Chassis 797" tab click on "Hoist System".
9. Select "Hoist Lower Valve Adjustment Status".
10. Select "Change".
11. Insert the new value in the "Hoist Lower Valve Adjustment Status" box. Click "OK". Select
"OK" in the verification box.
12. Repeat Step 5 through Step 11 until the pressure is below 1724 kPa (250 psi).
Note: When the pressure is greater than 1724 kPa (250 psi), the adjustment is set too high. If the
adjustment is too high, too much oil can be diverted to the hoist valve. Too much oil to the hoist
valve causes the brake oil to overheat when the body is in the body float position. Reduce the
Hoist Lower Valve Adjustment in ET. Repeat Step 1 through Step 6 in order to lower the pressure
below 1724 kPa (250 psi).
Note: The body down snub function cushions the shock when the body hits the bed of the truck.
When the body is lowered, the body position sensor detects the position of the body. When the
body is close to the rail of the truck, the ECM will go into snub mode. When the operators request
is less than the snub mode, the ECM will use the operators request. When the ECM uses the
operators request, the ECM ensures that the snub function will never cause the body to go down
faster than the hoist lever modulation. The body snub function will be canceled as the operator
moves the hoist lever out of the body float position or the body lower position. The body snub
function will not start until the body is raised above the body position sensor activation point.
Suspension Charge
If needed, refer to Special Instruction, SEHS9411, "Servicing the Suspension Cylinders for Off-
Highway Trucks".
Typical view of the left front suspension cylinder
1. Measure the visible chrome on the four suspension cylinders in order to verify the charge.
2. Record the suspension cylinder measurements in the table provided.
Table 174
Exposed Chrome on the Suspension Cylinders
Left front suspension cylinder
Right front suspension cylinder

Left rear suspension cylinder
Right rear suspension cylinder
Body Installation
Table 175
Record Body information
Body Manufacturer/Part Number
Serial Number
Condition
Body to Chassis Interference
1. After the body is installed and properly shimmed, check the interference between the body
and the chassis.
2. If the truck is equipped with body heat, verify the proper adjustment of the body heat
connection.
3. Check the hoses on top of the hydraulic tank, fuel tank, and the hoses between the frame
rails. If necessary, adjust the grease line at the top of the hoist cylinder in order to prevent
any damage.
Tire Specifications
1. Record the tire specifications in the table provided.
Table 176
Tire Size Manufacturer
Left Front
Right Front
Left Rear Outside
Left Rear Inside
Right Rear Inside
Right Rear Outside
Miscellaneous Checks
If needed, refer to Operation and Maintenance Manual, SEBU8417, "797F Off-Highway Truck"
1. Perform the following checks and record your results in the table provided.
Table 177
Miscellaneous Checks
Take Digital Photos of Completed Truck
Missing Parts (1)
Assembly Issues
Performance Issues
Dealer Installed Attachments (2)
Dealer Comments (3)
Verify the function of all of Cab Controls
Payload Target
(1)
Develop a list of all of the part numbers and the next highest part number level.
(2)
Take digital photos of all dealer installed attachments.
(3)
Record positive and negative comments.
Copyright 1993 - 2012 Caterpillar Inc. Sat Jul 28 18:16:09 EST 2012
All Rights Reserved.
Private Network For SIS Licensees.

Special Instruction 797f

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Media Search - REHS5063 - Assembly Procedure for the 797F and the 797F XQ Of...

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Assembly Procedure for the 797F and the 797F XQ Off-

ReferenceOperations and Maintenance Manual, SEBU8417, "797F Off-Highway Truck "

ReferenceSpecial Instruction, SEHS9411, "Servicing the Suspension Cylinders for Off-Highway

ReferenceSpecial Instruction, REHS1841, "General Welding Procedures"

ReferenceTesting and Adjusting, KENR8374, "797F Off-Highway Truck Braking System"

ReferenceService Manual, KENR8749, "797F Off-Highway Truck Automatic Lubrication

ReferenceSpecial Instruction, SEHS7633, "Battery Maintenance Procedure"

ReferenceService Manual, KENR9023, "793F and 797F Off-Highway Truck/Tractors VIMS,

ReferenceSystems Operation, RENR2223, "Oil Renewal System"

Improper assembly procedures could result in injury or death.

16 112-1579 (1) O-Ring Seal

2 157-0221 (1) Suspension Cover

10 8T-4223 Hard Washer

40 8T-4121 Hard Washer

Qty Part Number Description

Qty Part Number Description

4 8T-4167 Hard Washer

1 159-4724 Ball Valve

2 348-8324 Brake Wear Indicator As

Qty Part Number Description

10 8T-4136 (1) Bolt

Qty Part Number Description

2 277-7045 Sensor Harness As

Parts that are Required to Connect the 277-3328 Chassis Wiring Gp

Parts that are Needed for Installation of the Radiator Module

4 239-5609 Clamp (5)

21 8T-4121 Hard Washer

125 8T-4222 Plated Washer

96 146-1799 (1) Hard Washer

2 203-4702 (2) Valve

Qty Part Number Description

4 151-0888 Spacer (2)

2 295-6882 Plate (2)

10 8T-4196 Bolt (1)

10 173-5403 Pad As (1)

1 5C-7261 Nut (4)

1 371-5834 Sound Suppression Panel Gp

Personal injury or death can result from lifting a heavy assembly.

Personal injury or death can result from improper lifting or blocking.

Approximate weights of the components are shown. Clean all surfaces

Approximate Truck Chassis Shipped Weight

Rear Axle Assembly

Front Suspension Cylinder, Wheel, and Brake Assembly

Right Side Platform Assembly

Upper Rear Axle Link

Lower Rear Axle Link

Link Pins 52 kg (115 lb)

Rear Suspension Cylinder

Pins for the Rear Suspension

Rear Axle Oil Cooler

Cab Support (front) 750 kg (1650 lb)

Cab Support (rear)

Main Drive Shaft

Tire and Rim Assembly

Assembled Truck Body with liners 51256 kg (113000 lb)

Hinge Pin for the Truck Body