- Off-Highway Truck:
- 797B (S/N: JSM1-UP)
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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. |
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Cylinders equipped with load control valves can remain pressurized, even with hoses removed. Failure to relieve pressure before removing a load control valve or disassembling a cylinder can result in personal injury or death. Ensure all pressure is relieved before removing a load control valve or disassembling a cylinder. |
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| NOTICE |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
The new hose assemblies and the new clips provide better clamping to the hoist line group so that the service life is improved. The single bolt clips are replaced with the two bolts clips in the 149-3063 Hoist Lines Gp .
Use the following rework procedure to replace the hose assemblies:
| Required Parts List | |||
| Item | Qty | Part Number | Description |
| 9 | 1 | 131-7862 | Block |
| 11 | 1 | 374-3637 | Hose As |
| 12 | 1 | 370-6154 | Clip |
| 13 | 1 | 370-6155 | Clip |
| 14 | 1 | 370-6218 | Grommet |
| 15 | 2 | 8T-4956 | Bolt |
| 16 | 1 | 370-6141 | Clip |
| 17 | 1 | 370-6142 | Clip |
| 18 | 1 | 370-6219 | Grommet |
| 19 | 2 | 8T-4139 | Bolt |
| 20 | 1 | 374-3636 | Hose As |
| 21 | 3 | 235-2480 | Rectangular Seal |
| 22 | 1 | 235-2476 | Rectangular Seal |
| 23 | 4 | 8T-4223 | Hard Washer |
- Remove the necessary mounting hardware for both the ends of 220-1028 Hose As (1) and save the parts.
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| Illustration 1 | g02622656 |
- Remove 220-1028 Hose As (1), 6V-1572 Clip (2), 6V-1573 Clip (3) and 6V-1574 Grommet (4), discard the parts.
- Remove the necessary mounting hardware for both the ends of 194-3451 Hose As (5) and save the parts.
- Remove the 194-3451 Hose As (5), 106-5125 Clip (6), 106-5126 Clip (7) and 9X-7456 Grommet (8) and discard the parts.
- Fabricate a block to the dimensions that are shown in Illustration 2. Drill two holes (D) in the fabricated block to a depth of 30.0 mm (1.18 inch). Then tap the drilled holes with M12 × 1.75 tap to a depth of 21.0 mm (0.83 inch).
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| Illustration 2 | g02632036 |
Specification to fabricate block (10) (A) 25.0 mm (0.98 inch) (B) 15.0 mm (0.59 inch) (C) 40.0 mm (1.57 inch) (D) 10.5 mm (0.41 inch) (E) 12.5 mm (0.49 inch) (F) 50.0 mm (1.97 inch) (G) 70.0 mm (2.76 inch) | |
- Locate and weld 131-7862 Block (9), and the fabricated block (10) to the frame assembly as shown, refer to Illustration 3 for the locations and dimensions.
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| Illustration 3 | g02622739 |
(H) Dimension is 125.3 ± 1.5 mm (4.93 ± 0.06 inch) (J) Dimension is 192.7 ± 1.5 mm (7.59 ± 0.06 inch) (K) Dimension is 15.6 ± 1.5 mm (0.61 ± 0.06 inch) (L) Dimension is 111.8 ± 1.5 mm (4.40 ± 0.06 inch) (M) Dimension is 5.3 ± 1.5 mm (0.21 ± 0.06 inch) (N) Dimension is 14.7 ± 1.5 mm (0.58 ± 0.06 inch) (W1) 6.0 mm (0.24 inch) fillet weld. | |
- Install 374-3637 Hose As (11) with two new 235-2480 Rectangular Seals (21). Secure the hose assembly using hardware retained from Step 3.
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| Illustration 4 | g02623170 |
- Secure 374-3637 Hose As (11) with new 370-6154 Clip (12), 370-6155 Clip (13), 370-6218 Grommet (14) and two new 8T-4956 Bolts (15) with two new 8T-4223 Hard Washers (23) to 131-7862 Block (9). Tighten the bolts.