Commissioning Procedure For the 797F and the 797F XQ Off-Highway Truck {0374, 1000, 7000, 7961} Caterpillar

Off-Highway Truck/Tractor

797F (S/N: LAJ1-UP; WSP1-UP; LTZ1-UP)

Introduction

Table 1

Revision History
Revision	Summary of Changes
17	The fuel priming procedure for LTZ machines has been updated to remove note about hose to purge air.

Show/hide table

Personal injury or death can result from air in the oil for the brake hydraulic system. Air in the system can prevent complete brake application and it is possible that the wheels on the machine can not be stopped. Air must not be in the oil for the brake hydraulic system to function properly.

Show/hide table

Personal injury or death can result from machine movement. Place blocks in front of and behind the wheels to make sure the machine does not move while the parking brakes are disengaged.

Show/hide table

Do not check for leaks with your hands. Pin hole (very small) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use cardboard or paper to locate pin hole leaks.

Illustration 1	g01962775

Show/hide table

When it is necessary to work under the machine with the body (bed) raised, attach the body (bed) retaining cables to the body retaining pins. Install the body retaining pins through the ends of the retaining cables. Always use both retaining cables. Failure to properly secure the body (bed) may result in personal injury or death.

Show/hide table

NOTICE
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, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates.

Show/hide table

NOTICE
This machine is equipped with a Tier 4 Certified Engine system that is configured to meet the emissions requirements mandated by the United States Environmental Protection Agency (EPA). Care must be taken to comply with all instructions within this document to ensure that the engine, as assembled (including the exhaust piping, DEF Fluid lines, and controls), performs as designed to meet and maintain Tier 4 emissions requirements. Also, to meet the EPA regulatory requirements related to recording the combination of engine and emissions components that will be placed into service with the machine. Return the required information to the address listed in the "Mandatory Reporting for T4 Machines" Section.

Reference: Operations and Maintenance Manual, SEBU8417, "797F Off-Highway Truck"

Reference: Special Instruction, REHS5464, "Accumulator Discharging and Charging Procedures"

Reference: Systems Operation and Testing and Adjusting, KENR5397, "C175-16 and C175-20 Engines for 793F and 797F Off-Highway Trucks"

Reference: Service Manual, KENR9023, "793F and 797F Off-Highway Truck/Tractors VIMS, Monitoring, and Payload"

Reference: Testing and Adjusting, KENR8374, "793F and 797F XQ Off-Highway Truck Braking System"

Reference: Service Manual, KENR8749, "797F and 797F XQ Off-Highway Truck Automatic Lubrication System for Electric Start and Air Start Equipped Trucks"

Reference: Testing and Adjusting, KENR8748, "797F Off-Highway Truck Air System"

Reference: Testing and Adjusting, KENR8394, "793F and 797F Off-Highway Trucks Power Train Electronic Control System"

Reference: Testing and Adjusting, KENR8371, "797F Off-Highway Trucks Power Train"

Reference: Testing and Adjusting, KENR8381, "797F and 797F XQ Off-Highway Truck Hydraulic System"

Reference: Testing and Adjusting, M0069782, "C175 Tier 4 Final Engines for Off-Highway Trucks"

Reference: Operations and Maintenance Manual, M0070546, "797F Off-Highway Truck"

Reference: Special Instruction, REHS8170, "Comm Adapter 3 and Computer Settings for Tier 4 Final Engines"

This Special Instruction contains the following necessary procedures for the 797F and the 797F XQ Off-Highway Truck commissioning procedure.

Note: The photographs in this publication are for illustrative purposes. Do not perform any procedures in this publication or order any parts until you understand the information that is contained in this publication.

Table 2

Dealer Information for Commissioning Procedure
Date
Serial Number
Service Meter Units
Name of the Technician
Unit Number
Engine Serial Number
Pump Electronic Tank Unit (PETU) Serial Number(1)
Clean Emissions Module (CEM) Serial Number(1)
Dealer
Dealer Code
Customer
Job Site
Transmission Serial Number
Torque Converter Serial Number
Right-Hand Wheel Station Serial Number
Left-Hand Wheel Station Serial Number
Rear Axle Serial Number
Body Manufacturer/Part Number
Body Serial Number
General Body Condition

(1)	If Tier 4 equipped

Table 3

Tire Information
	Tire Size	Manufacturer
Left Front
Right Front
Left Rear Outside
Left Rear Inside
Right Rear Inside
Right Rear Outside

Table 4

Miscellaneous Checks
Take Digital Photos of Completed Truck
Missing Parts(1)
Performance Issues
Dealer Installed Attachments(2)
Dealer Comments(3)
Verify the function of all Cab Controls
Payload Target

(1)	Develop a list of all 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.

Required Tooling

Illustration 2	g02571852
Tooling (A) 198-4240 Digital Pressure Indicator Gp

Table 5

Required Tools
Tool	Item	Qty	Part No	Description
A			198-4240	Digital Pressure Indicator Gp
	A1	1	198-4234	Digital Indicator
	A2	1	198-4237	Pressure Sensor Gp (0 to 3,445 kPa (0 to 500 psi))
	A2	1	198-4238(1)	Pressure Sensor Gp (0 to 34,450 kPa (0 to 5,000 psi))
	A2	1	198-4239	Pressure Sensor Gp (0 to 41,368 kPa (0 to 6,000 psi))
	A2	1	251-9600(2)	Pressure Sensor Gp (0 to 68,900 kPa (0 to 10,000 psi))
	A3	1	198-4236	Adapter Cable As

(1)	This sensor must be purchased separately, the sensor is not included in the 198-4240 Digital Pressure Indicator Gp
(2)	This sensor can only be used on large diameter pressure taps like 6V-3965 Fitting.

Illustration 3	g02726620

Table 6

Required Tools
Tool	Item	Qty	Part No	Description
B	B1	1	8T-0862	Pressure Gauge (-100 TO 500 kPa (-15 TO 72 psi))
	B1	1	8T-0863	Pressure Gauge (0 TO 250 kPa (0 TO 36 psi))
	B1	1	8T-0853	Pressure Gauge (0 TO 400 kPa (0 TO 58 psi))
	B1	1	8T-0854	Pressure Gauge (0 TO 1,000 kPa (0 TO 144 psi))
	B1	1	8T-0855	Pressure Gauge (0 TO 4,000 kPa (0 TO 580 psi))
	B1	1	8T-0856	Pressure Gauge (0 TO 6,000 kPa (0 TO 860 psi))
	B1	1	8T-0857	Pressure Gauge (0 TO 10,000 kPa (0 TO 1,450 psi))
	B1	1	8T-0858	Pressure Gauge (0 TO 16,000 kPa (0 TO 2,300 psi))
	B1	1	8T-0859	Pressure Gauge (0 TO 25,000 kPa (0 TO 3,600 psi))
	B1	1	8T-0860	Pressure Gauge (0 TO 40,000 kPa (0 TO 5,800 psi))
	B1	1	8T-0861	Pressure Gauge (0 TO 60,000 kPa (0 TO 8,600 psi))
	B2	1	6V-3989	Fitting
	B3	2	6V-4143	Quick Connect Coupler
	B4	1	177-7860	Hose As 3.0 m (10 ft)
	B4	1	177-7861	Hose As 4.3 m (14 ft)
	B4	1	177-7862	Hose As 5.5 m (18 ft)

Illustration 4	g02581096
Tooling (B) 317-7484 Communication Adapter III

Table 7

Required Tools
Tool	Item	Qty	Part Number	Description
B		1	317-7484(1)	Communication Adapter Gp
	B1	1	370-4617	Cable As (USB PC Communication)
	B2	1	317-7485	Communication Adapter III
	B3	1	327-8981	Cable As (Data Link)

(1)	Caterpillar Electronic Technician (Cat®ET) and Software CD, NETG5057 are required when using the communication adapter.

Note: With the release of Tier 4 Final engines, additional emissions control system components have been added to the engine to reduce the NOx output. The most recent version of Cat® Electronic Technician (ET) must be used when connecting to the Electronics Control Modules. Refer to Special Instruction, REHS8170 for instructions on properly setting up the computer and Comm3 adapter for use on Tier 4 applications.

Power the Electrical System

1. To power the electrical system of the truck, perform the steps that follow:
   Show/hide table

   Illustration 5	g03333169
   Batteries for serial number prefix LAJ and LTZ are located on the front bumper

   Show/hide table

   Illustration 6	g03333172
   Batteries for serial number prefix WSP are located on the right platform

   1. Connect the batteries.

      Refer to Operation and Maintenance Manual, SEBU8417, "Battery or Battery Cable - Inspect/Replace".

      For S/N:LTZ truck refer to Operation and Maintenance Manual, M0070546, "Battery or Battery Cable - Inspect/Replace".

      Show/hide table

      Illustration 7	g06183129

   2. Rotate battery disconnect switch (1) clockwise to the Energize the 24 V system.

   3. Switch manual engine shutdown switch (2) to the OFF position.

   4. In the cab, turn the key to the ON position.

      DO NOT START THE TRUCK.

      Note: When the key is in the "ON" position, VIMS will perform a self test. Each self test takes approximately 4 to 6 seconds to complete. Disregard the VIMS self test at this time.

Fluid Level Checks

Note: Refer to Operation and Maintenance Manual, SEBU8417, "Capacities (Refill)" for information on checking the fluid levels.For S/N:LTZ truck refer to Operation and Maintenance Manual, M0070546, "Capacities (Refill)" for information on checking the fluid levels.

Table 8

Compartment or System	Check if OK
Engine Oil with Filter
Torque Converter Sump (only)
Transmission and Torque Converter System (total)
Hoist and Brake System
Brake Activation Section
Hoist and Brake Cooling Oil Section
Steering Hydraulic System
Each Front Wheel
Differential (only)
Each Final Drive
Differential and Final Drive System (total)
Engine Cooling System
Fuel Tank
Fuel Tank(1)
Window Washer
Diesel Exhaust Fluid (DEF)(2)
Oil Reservoir for the Powered Stairway(3)

(1)	Optional high capacity
(2)	If Tier 4 equipped
(3)	If equipped

Cab Instrumentation and Functional Checks

Operators Seat

Table 9

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 10

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
Ensure that the seat belt alarm works properly

Pressurize the Cab

Table 11

Check the Operation of the Blower Motor to Pressurize the Cab(1)	Check if OK
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

Window Wipers

Table 12

Check the Operation of the Window Wiper and Washer	Check if OK
Turn the ignition key to the ON position
From the OFF position, turn the window wipers to the LOW setting by using multifunction switch (3) from Illustration 9
Turn the window wiper to the HIGH setting
Press the button to activate the window washer fluid
Turn the window wiper to the first INTERMITTENT setting
Turn the window wiper to the second INTERMITTENT setting
Turn the window wiper to the third INTERMITTENT setting
Turn the window wipers to the OFF position
Turn the ignition key to the OFF position

Panel and Running Lights

Illustration 8	g02074793
(1) Switch for headlights, parking lights, and taillights (2) Panel light switch

Illustration 9	g03319224
(3) Multifunction switch (4) Horn

Illustration 10	g06351643
(5) Low Beam (6) High Beam (7) Fog Light

Table 13

Check the Operation of the Panel Lights and the Headlights(1)	Check if OK
Turn the ignition key to the OFF position
Push switch (1) to activate low beam headlights (4)
Push the top half of switch (2) to the first detent to activate the instrument panel lights, marker lights, and the tail lights
Use multifunction switch (3) to toggle between low beam lights (5) and high beam lights (6)
Push the bottom half of switch (1) to the OFF position to deactivate the headlights
Ensure that all headlights are in the correct position, not to blind on coming traffic
Sound horn (4)

(1)	The tail lights should be on any time a light switch is activated

Hazard Lights

Illustration 11	g02075196
(7) Hazard flasher switch

Table 14

Check the Operation of the Hazard Lights	Check if OK
Turn the ignition key to the OFF position
Push the top half of switch (7) to activate the hazard lights
Push the bottom half of switch (7) to deactivate the hazard lights

Fog Lights

Illustration 12	g02075214
(8) Switch for the front fog lights

Table 15

Check the Operation of the Fog Lights	Check if OK
Turn the ignition key to the OFF position
Push the top half of switch (8) to activate fog lights (6)
Push the bottom half of switch (8) to deactivate fog lights (6)

Access Lights

Illustration 13	g02075275
(9) Switch for the access lights in the cab

Illustration 14	g06351726
(10) Switch for the access lights at ground level

Illustration 15	g03340308
Typical view of the access light

Table 16

Check the Operation of the Access Lights(1)	Check if OK
Turn the ignition key to the OFF position
Push the top half of switch (9) or switch (10) to activate the access lights
If necessary, adjust the access light to provide light for the steps
Push the bottom half of switch (9) or switch (10) 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.

Cab Dome Light

Table 17

Check the Operation of the Cab Dome Light Switch(1)	Check if OK
Turn the ignition key to the OFF position
Push dome light switch to the ON position to turn on the light
Push dome light switch to the OFF position to turn the light OFF

(1)	There are two lights above each door and a dome light in the center of the cab

Cigar Lighter

Table 18

Check the Operation of the Cigar Lighter(1)	Check if OK
Turn the ignition key to the ON position
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 19

Check the Operation of the backup alarm(1)	Check if OK
Turn the ignition key to the ON position
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

VIMS Self Test

1. Turn the ignition key from the OFF position to the ON position to activate the VIMS self test. Monitor the instrument cluster for the different lighted icons. Do not start the truck.

   The gauges should sweep from zero to half scale, then back to zero, and then all the way to the right or full scale. After the sweep test, the gauges should show the current values. Complete Table 20.

   Next, the fault levels will activate. The source of the configuration codes will display on the message center.

Illustration 16	g06146150
Diesel exhaust fluid level gauge

Illustration 17	g03319264
(1) Action light (2) Body up (3) Retarder (4) Traction Control System (TCS)

Table 20

Check for the Illumination of the Lights in the instrument panel(1)	Check if OK
Action Indicator (1)
Body Up indicator (2)
Retarder Indicator (3)
TCS Indicator (4)

(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.

Select the Display Preferences in Advisor

Show/hide table

Illustration 18	g03228258

1. From the home screen in Advisor, select "Settings".

2. Select "Display settings" and choose the desired value for the following options:

   • "Language" Adjust the display language

   • "Units" Set the display units

   • "Contrast" Adjust the display contrast

   • "Lights "ON"" Adjust backlight with lights "ON"

   • "Lights "OFF"" Adjust backlight with lights "OFF"

   • "Date Format" Select the desired format

   • "Time Format" Select desired format

Input the Machine Information in Advisor

Note: Inputting the machine information in advisor will automatically populate the information in each ECM.

1. From the home screen in Advisor, select "Settings".

2. Select "Machine" and enter the correct "Product ID" and "Equipment ID".

Check the Configuration of the Electronic Control Modules (ECM)

Reference: Service Manual, KENR9023 or M0082020 , "793F and 797F Off-Highway Truck/Tractors VIMS, Monitoring, and Payload"

Show/hide table

Illustration 19	g02134783
(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.
   Show/hide table

   Illustration 20	g03340985

2. Use your laptop computer to open Cat ^® ET.
   Show/hide table

   Illustration 21	g03340987

3. Select C175 797. Click "OK".

   The Cat ^® ET Selector screen should display the truck model for each control. Make sure that the model is correct for each of the controls.

   Show/hide table

   Illustration 22	g03340895

4. From the toolbar, select "Service", and select "Configuration".
   Show/hide table

   Illustration 23	g03340898
   Typical view

5. In the "ECM Identification Parameters" field, select "Equipment ID".

   Double-clickon "Equipment ID" to change the value for the equipment ID, or select "change".

6. Verify that the "Equipment ID" matches the machine serial number. If the "Equipment ID" does not match, change the "Equipment ID" and click "OK".
   Show/hide table

   Illustration 24	g03340899
   Typical view (LAJ and WSP machines)

7. For LAJ and WSP machines, 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".
   Show/hide table

   Illustration 25	g06190238

8. For LTZ machines, 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".

   Also check the serial number of the Pump Electronic Tank Unit (PETU) and the Clean Emissions Module (CEM). Update the serial numbers, as needed.

   Show/hide table

   Illustration 26	g03340900

9. Verify the "Ether Control" setting. Set the "Ether Control" setting to the "Enabled" or the "Disabled" position.

   Note: Refer to Systems Operation and Testing and Adjusting, KENR5397 or , M0069782 , "C175-16 and C175-20 Engines for 793F and 797F Off-Highway Trucks" for information on the engine.

10. Verify that the "Engine Coolant Temperature Control Module Installation Status" is set to "Installed".
    Show/hide table

    Illustration 27	g03340902

11. If equipped, verify that the "Oil Renewal Rate" control is correctly set to "0". The "Oil Renewal Rate" has an adjustable range from -50 to 50.
    Show/hide table

    Illustration 28	g03340904

12. If equipped, verify that the "Engine Pre-Lube" is enabled.
    Show/hide table

    Illustration 29	g06076986

13. If equipped, verify that the "Operator Final Inducement Action" is set to the desired value.
    Show/hide table

    Illustration 30	g06076994

14. If equipped, verify that the "Operator Inducement Regulation Configuration" is set to the desired value.
    Show/hide table

    Illustration 31	g06076990

15. If equipped, verify that the "Operator Inducement Progress Configuration" is set to the desired value.

16. From toolbar, select "Service". Then select "ECM Date/Time".

17. Input the correct time zone, date, and time.

Check for Active Diagnostic Codes and Logged Diagnostic Codes

Show/hide table

Illustration 32	g03340912

1. From the toolbar, click on "Diagnostic". Click on "Active Diagnostic Codes".
   Show/hide table

   Illustration 33	g03340909
   Typical view

2. Resolve any of the active diagnostic codes.

   For additional information on diagnostic codes, refer to Troubleshooting, KENR8395, "793F and 797F Off-Highway Truck/Tractors Braking System".

   Show/hide table

   Illustration 34	g03340916

3. From the toolbar, click on "Diagnostics". Click on "Logged Diagnostic Codes".
   Show/hide table

   Illustration 35	g03340918
   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.
   Show/hide table

   Illustration 36	g03340919

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 to clear some events that are logged on the engine "ECM".

Create a Product Status Report

Show/hide table

Illustration 37	g03340920

1. From the toolbar, click on "Information" and "Product Status Report".

   Run the product status report.

   Note: The Product Status Report will show the injector codes for Table 21.

Injector Trim File Setting and Calibration

Show/hide table

Illustration 38	g03340921

1. From the toolbar, click on "Service". Select "Calibrations". Click on "Injector Trim Calibration".

2. Confirm that all the injectors have trim files. Record all the injector trim calibration values in Table 21.
   Show/hide table

   Table 21

   Injector 1
   Injector 2
   Injector 3
   Injector 4
   Injector 5
   Injector 6
   Injector 7
   Injector 8
   Injector 9
   Injector 10
   Injector 11
   Injector 12
   Injector 13
   Injector 14
   Injector 15
   Injector 16
   Injector 17
   Injector 18
   Injector 19
   Injector 20

Ether Control Test (If Equipped)

Note: The ether control must be enabled to perform the ether control test.

Show/hide table

Illustration 39	g03349013

1. Click on "Diagnostics". Select "Diagnostic Tests".
   Show/hide table

   Illustration 40	g03340928

2. Under "C175 797" click on "Override Parameters" and click "Start".
   Show/hide table

   Illustration 41	g03349020

3. 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.

4. Click on the drop-down menu for the "New Value:" and change the selection from "Off" to "On". Click "OK".

5. Click "OK" again in the verification box.

   Note: An audible click should be heard after clicking "OK" on the verification box.

6. If the ether control test is acceptable, select "Ether Injection Override" to return the mode to normal.

Settings for the Engine Prelube

Show/hide table

Illustration 42	g03340968

1. 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".

3. Click "OK" in the verification box.

   Note: The operator should hear the engine prelube system energize.

4. When the test for the engine prelube is completed, select "Disable Override" to return the mode to normal.

Settings for the Oil Renewal System (If Equipped)

Show/hide table

Illustration 43	g03340969

1. 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.

2. Click on the drop-down menu for the "New Value:" and change the selection "Off" to "On". Click "OK".

3. Click "OK" in the verification box.

   Note: An audible sound from the "Oil Renwal" system should be heard after clicking "OK" on the verification box.

4. When the test for the oil renewal system is completed, click on "Disable Override" to return the mode to normal.
   Show/hide table

   Illustration 44	g03349033

5. From the toolbar, click on "Service". Click "Configuration" to go back to the main configuration screen.

Settings for the Chassis Control

Show/hide table

Illustration 45	g03340976

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. Click "OK".
   Show/hide table

   Illustration 46	g03340977

3. Verify that the "Auto Lube Interval" is set to the desired value.

   Note: 60 minutes is the default value.

   If the interval is not correct, change the "Auto Lube Interval" to the desired value.

Settings for the Transmission Control

Show/hide table

Illustration 47	g03340978

1. Click on "ECM Identification Parameters" 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.
   Show/hide table

   Illustration 48	g03349051

3. Check the "Torque Converter Serial Number". The serial number should match the serial number that is on the torque converter. If the serial number is incorrect, input the correct Torque Converter Serial Number.
   Show/hide table

   Illustration 49	g03340979

4. Check the "Machine Speed Limit". If there is a requirement for a speed limit, input the correct speed limit.

Settings for the Brake Control

Show/hide table

Illustration 50	g03340980

1. Click on "ECM Identification Parameters" under "Brake 797".

2. Verify that the "Equipment ID" matches the machine serial number.
   Show/hide table

   Illustration 51	g03349130

3. Set the "Maximum Desired Engine Retard Speed" between 1850 RPM and 1950 RPM.
   Show/hide table

   Illustration 52	g03340897

4. If equipped, verify that the correct "Differential High Speed Fan Install Status" is selected.
   Show/hide table

   Illustration 53	g03340982

5. Verify that the correct "Brake Cooling Pump Installation Status" is selected.

Settings for the VIMS Main Module

Show/hide table

Illustration 54	g03349138

1. Under "VIMS Main Module", select "General Information".

2. Verify that the "Product ID" matches the machine serial number. If the "Product ID" does not match, enter the correct "Product ID" through Advisor. Use the following steps:
   Show/hide table

   Illustration 55	g03355937

   1. In Advisor, select "Settings", "Machine", then "Product ID". Enter the correct "Product ID".

Settings for the Monitor Module

Set the "Service Mode" password for Advisor.

Show/hide table

Illustration 56	g03340988

1. In "Monitoring System Parameters", select "Service Mode Enable Code".

   Note: The default number is "0".

2. To set the password, input any five or less digit number, and click "OK".

   Note: The password can only be changed through Cat ^® ET.

   Show/hide table

   Illustration 57	g03349169

3. Click "Yes" on the verification window.

   Verify that the value has changed.

VIMS

Show/hide table

Illustration 58	g03076359
View of the back of the cab (1) Cat ® ET connector (2) 12 V Connector (3) "VIMS" Connector

1. Connect a laptop computer to "VIMS" connector (3).

   Note: Ensure that the key is in the ON position.

   Show/hide table

   Illustration 59	g02134815
   Instrument cluster for the 797F (1) Action Indicator

   Show/hide table

   Illustration 60	g06356031

2. Start the "VIMS" PC software.

   Note: Some alert messages should appear.

   Note: Refer to Service Manual, KENR9023 or M0082020 , "793F and 797F Off-Highway Truck/Tractors VIMS, Monitoring, and Payload" for additional information on warnings.

   Show/hide table

   Illustration 61	g06356047

3. Click on "Connect".

4. Select the "Cab" and click "OK".
   Show/hide table

   Illustration 62	g03349181

5. After the connection is completed click on "Download".
   Show/hide table

   Illustration 63	g03349192

6. In the "Download" window, select all the boxes under "Date Groups" and click "Download".
   Show/hide table

   Illustration 64	g03349211

7. After the download is complete, click on "Configure".
   Show/hide table

   Illustration 65	g03340992

8. Verify that the serial number, Equipment number, and the Date/Time are correct. Change, as necessary.

Advisor Panel Setup

Illustration 66	g03077840
Typical view of the "Home" menu from the Advisor panel

The profile of the operator is accessed from the "Home" menu.

Refer to Operation and Maintenance Manual, SEBU8417, "Monitoring System" for instructions on setting up the operator profiles.

Prepare to Start the Engine

1. Verify that all the machine fluids are at an acceptable level.

   Note: Refer to the Operation and Maintenance Manual, SEBU8417 or , M0070546, "Capacities (Refill)" for the fluid capacities.

   Show/hide table

   Illustration 67	g06351741
   (1) Manual engine shutdown switch (2) Battery disconnect switch

2. Move manual engine shutdown switch (1) to the OFF position.

   Note: The engine should be disabled so the engine will not start.

3. Rotate battery disconnect switch (2) clockwise to Energize the 24 V system.

4. Chock the wheels.

5. Ensure that the transmission control is in the "P" position.

Purge the Air from the Fuel System (LAJ and WSP Machines)

Show/hide table

NOTICE
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, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates.

Note: Due to the time required to charge the fuel system, there is an update to the low-pressure fuel system purging.

• Prerequisite is a minimum of 40% fuel level in the fuel tank.

• A hose with a shut off valve at one end and a hydraulic socket, which fits on a hydraulic quick disconnect, on the other end is required.

1. Assemble a hose to purge the air from the fuel system. A hose with a shut off valve at one end and a hydraulic socket, which fits on a hydraulic quick disconnect, on the other end is required.

2. Chock the wheels.

   Note: Ensure that the machine is not locked out.

   Note: Verify that there are no leaks in the fuel system.

   Show/hide table

   Illustration 68	g06183145
   (1) Engine lockout control

3. Move engine lockout control (1) clockwise to the engaged position.

   Note: You should have 24 VDC to the truck.

   Show/hide table

   Illustration 69	g06351849
   View of the right side of the fuel tank (2) Ball valve (3) Ball valve (4) Drain valve (5) Fuel filter assembly (6) Drain valve (7) Fuel filter assembly (8) Drain valve (9) Fuel filter assembly

4. Close ball valve (2) and ball valve (3)

5. Open ball valve (2).

6. Open drain valve (4) on fuel filter assembly (5) and drain the fuel into a suitable container.

   When fuel begins to flow and run clear of bubbles, close drain valve (4).

7. Open drain valve (6) on fuel filter assembly (7) and drain the fuel into a suitable container.

   When fuel begins to flow and run clear of bubbles, close drain valve (6).

8. Open drain valve (8) on fuel filter assembly (9) and drain the fuel into a suitable container.

   When fuel begins to flow and run clear of bubbles, close drain valve (8).

9. Open ball valve (3).
   Show/hide table

   Illustration 70	g03341111
   (10) Pressure tap (11) Pressure tap (12) Pressure tap (13) Fuel priming pump switch

10. Install the previously assembled hose and hydraulic socket to pressure tap (10) at the fuel priming pump outlet.

    Ensure that the hose drains the fuel into a suitable container.

11. Open the shutoff valve on the end of the hose, and activate fuel priming pump switch (13).

    When fuel begins to flow and run clear of bubbles, close the valve and release fuel priming switch (13).

12. Move the hose and hydraulic socket to pressure tap (11).

13. Open the shutoff valve on the end of the hose, and activate fuel priming pump switch (13).

    When fuel begins to flow and run clear of bubbles, close the valve and release fuel priming switch (13).

14. Move the hose and hydraulic socket to pressure tap (12).

15. Open the shutoff valve on the end of the hose, and activate fuel priming pump switch (13).

    When fuel begins to flow and run clear of bubbles, close the valve and release fuel priming switch (13).

16. Remove the hose and hydraulic socket from the quick disconnect.

    The fuel system should be purged of air.

17. Rotate engine lockout control (1) to the clockwise most position. Confirm manual engineshutdown switch is in the OFF or STOP position.

    Note: The engine should be disabled so the engine will not start.

18. Prime the pump drive housing, hoist, brake, and steering pumps with the recommended oil or crank the engine.

    Crank the engine over two times for 15 seconds to fill the compartments with oil.

Purge the Air from the Fuel System (LTZ Machines)

Show/hide table

NOTICE
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, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates.

• Prerequisite is a minimum of 40% fuel level in the fuel tank.

1. Chock the wheels.

   Note: Ensure that the machine is not locked out.

   Note: Verify that there are no leaks in the fuel system.

   Show/hide table

   Illustration 71	g06183145
   (1) Engine lockout control

2. Move engine lockout control (1) clockwise to the engaged position.

   Note: You should have 24 VDC to the truck.

   Show/hide table

   Illustration 72	g06351849
   View of the right side of the fuel tank (2) Ball valve (3) Ball valve (4) Drain valve (5) Fuel filter assembly (6) Drain valve (7) Fuel filter assembly (8) Drain valve (9) Fuel filter assembly

3. Close ball valve (2) and ball valve (3)

4. Open ball valve (2).

5. Open drain valve (4) on fuel filter assembly (5) and drain the fuel into a suitable container.

   When fuel begins to flow and run clear of bubbles, close drain valve (4).

6. Open drain valve (6) on fuel filter assembly (7) and drain the fuel into a suitable container.

   When fuel begins to flow and run clear of bubbles, close drain valve (6).

7. Open drain valve (8) on fuel filter assembly (9) and drain the fuel into a suitable container.

   When fuel begins to flow and run clear of bubbles, close drain valve (8).

8. Open ball valve (3).
   Show/hide table

   Illustration 73	g06353293
   Right side view of engine (10) Fuel pump priming switch

9. Push and hold fuel pump priming switch (10) to activate the electric fuel priming pump.

   The priming pump will fill the engine fuel lines and fuel filters with fuel.

10. As the air is purged from the fuel system, fuel pressure will increase.

    Listen for the electric fuel priming pump to come under load. Or, monitor fuel filter outlet pressure on ADVISOR screen and prime until pressure reaches 370 kPa (54 psi). Do not continue priming the fuel system after the priming pump is under load.

11. Rotate engine lockout control (1) to the clockwise most position. Confirm manual engineshutdown switch is in the OFF or STOP position.

    Note: The engine should be disabled so the engine will not start.

12. Prime the pump drive housing, hoist, brake, and steering pumps with the recommended oil or crank the engine.

    Crank the engine over two times for 15 seconds to fill the compartments with oil.

Engine Start-Up

Show/hide table

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. Chock the wheels.

2. Connect a laptop computer with Cat ^® ET to the machine.

3. In Cat ^® ET, verify that the Engine Pre-Lube is "Enabled".

   Refer to Illustration 28.

4. In Cat ^® ET, clear any Active, logged Diagnostic Codes and Events.

   Refer to Section "Check for Active Diagnostic Codes and Logged Diagnostic Codes".

5. Verify that the fluids are at an acceptable level.

   Note: See the checklist below.

   Note: Refer to Operations and Maintenance Manual, SEBU8417 , M0070546 , "Capacities (Refill)" for the capacities for the 797F.

   Show/hide table

   Illustration 74	g06356154
   Location of coolant valves

6. Verify that the coolant valves are open to PETU.

7. Disable engine shutdown switch (5) to allow the engine to be started.
   Show/hide table

   NOTICE
   Do not stop the prelube. If the prelube is stopped and restarted, the engine will bypass the prelube and start without having the appropriate oil to the engine. Early bearing failure can result from improper prelube.

   Show/hide table

   Illustration 75	g06353325
   (4) Engine lockout control (5) Engine shutdown switch

8. Turn engine lockout control (4) clockwise to turn the lockout OFF. The engine is now able to start.

   Note: The prelube pump should run until approximately 55 kPa (8 psi) is seen by the engine ECM.

9. Crank over the engine for 5 seconds to fill the pumps with oil. Turn off the engine and verify that the fluids are still at an acceptable level. Fill, as needed.

10. Repeat Step 9.

11. Crank over the engine for 10 seconds to fill the pumps with oil. Turn off the engine and verify that the fluids are still at an acceptable level. Fill, as needed.

12. Remove coolant filler cap.

13. Using Cat ET, override thermostat position, set to 100 percent open.

14. Turn the key to the ON position. Turn the key to the START position and start the engine.

    Note: If the engine is not started shortly after completing the fuel priming cycle, the system may need to be primed again once ready to start the engine. If engine starts but the engine runs rough, continue to run the engine at low idle until the engine runs smoothly.

    Note: If any issues occur, resolve the issues before proceeding.

15. Run the engine for 10 seconds and turn the key to the OFF position.

16. Enable engine shutdown switch (5) at ground level to stop the engine. Verify that the fluids are still at an acceptable level. Fill, as needed.

    Disable engine shutdown switch (5) to allow the engine to be started.

17. Start the engine and run the engine for 60 seconds and turn the key to the OFF position.

18. Repeat Step 16.

19. Start and run engine for two minutes at 1200 rpm.

20. Disable thermostat position override using Cat ET.

21. Repeat Step 16.

22. Turn the key to the ON position and run the engine until normal operating temperatures are reached.

Engine Start Checklist

Table 22

Check the Ignition Switch, Horn, and Engine Start	Check if OK
Turn the ignition key to the ON position(1)
Sound the horn for all clear
Turn the key to the START position 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

Engine Shutdown Switch Checklist

Illustration 76	g06353326

Table 23

Check the Operation of the Engine Shutdown Switch	Check if OK
Start the engine
Activate engine shutdown switch (5)
Engine shuts down
Deactivate engine shutdown switch (5)

User-Defined Shutdown Feature

Illustration 77	g02881797
Schematic of the User-Defined Shutdown feature

Illustration 78	g02868021
(1) Location of the User-Defined Shutdown connector in cab of OHT

Illustration 79	g02868023

The User-Defined Shutdown is a feature for Large Off Highway Trucks that will shutdown the engine when activated. The Engine ECM provides the User-Defined Shutdown feature with a connector for an activation device. The connector for the customer interface can be found in the side wall panel next to the driver seat of the truck. Refer to the illustrations 78 and 79.

When the User-Defined Shutdown switch wires are shorted together, for instance with a switch, the Engine ECM will perform the following:

1. Stops the injection of fuel to the engine when

   1. The shift lever is in the “P” position

   2. The park brake is applied and there is no ground speed

2. Logs an event code in the Engine ECM for "User Defined Shutdown Event"

   After the User-Defined Shutdown switch is activated, the wires need to be "open". Power to the Engine ECM must be cycled ON and OFF to reset the feature.

Climate Control

Illustration 80	g03340098
View of the left-hand side of the machine (1) Supply heater valve (2) Return heater valve

Table 24

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 (2)
The coolant valves should be open (For LTZ machines) (3)
Air from the dash vents should be warm (1)
Turn the ignition key to the OFF position

(1)	When the engine is at operating temperature
(2)	Refer to illustration 80
(3)	Refer to Illustration 74

Perform the Aftertreatment System Functional Test

Show/hide table

NOTICE
Confirm that the latest software vintage is flashed to the engine and aftertreatment prior to performing functional testing.

1. Use a laptop computer to open Cat Electronic Technician (ET).
   Show/hide table

   Illustration 81	g06076684

   Show/hide table

   Illustration 82	g06078034
   View of the serial number plate on the Clean Emissions Module (CEM)

   Note: The serial number plate for the Clean Emissions Module (CEM) is on the mounting structure (cradle) of the CEM.

2. Confirm correct serial numbers for the Clean Emissions Module (CEM) and Pump Electronic Tank Unit (PETU).

   1. Check the value of the "Factory Installed Aftertreatment #1 Identification Number" and ensure that the serial number is correct. If incorrect, enter the correct number.

   2. Check the value of the "Aftertreatment DEF Pump Electronics Tank Unit Identification Number" and ensure that the serial number is correct. If incorrect, enter the correct number.
   Show/hide table

   Illustration 83	g03825970

3. From the toolbar, select "Diagnostics" then "Diagnostic Tests".
   Show/hide table

   Illustration 84	g06076761

4. Select "Aftertreatment System Functional Test" and click "Start".
   Show/hide table

   Illustration 85	g03825152

5. Read and understand the warning. Click "OK" to proceed to the test.
   Show/hide table

   Illustration 86	g03825157

6. Click "Next" to proceed to the test.

Autolube

Show/hide table

NOTICE
Be satisfied that all the automated grease injectors are receiving a sufficient supply of grease.

Note: The autolube system only pumps when the machine is moving. The timer does not activate unless ground speed is detected.

Show/hide table

Illustration 87	g06385657
View of the left side of the machine

Show/hide table

Illustration 88	g06385676
View of the right side of the machine

Show/hide table

Illustration 89	g06385684
View of the rear of the machine

1. Purge the air from each individual grease line.

   Note: Purging the grease lines may require a hand pump.

2. Adjust the grease injectors, as required. Refer to Service Manual, KENR8749, "797F and 797F XQ Off-Highway Truck Automatic Lubrication System for Electric Start and Air Start Equipped Trucks"

3. Turn the key to the ON position.

   Note: Do not start the truck.

   Show/hide table

   Illustration 90	g02138313

4. Through the Advisor, select "Service".

5. Select "All Parameters", then "System Tests", and then "Manual Lube Mode".

6. If necessary, use the left arrow or the right arrow to set the correct interval.

7. Press OK.

8. If necessary, repeat Step 6 and Step 7 for the autolube interval.

Miscellaneous Checks

Prepare the Truck for Pressure Checks

Show/hide table

Illustration 91	g01340699

1. Chock the wheels.

2. 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 77° C (170° 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)

Note: Trucks that start electrically are not equipped with an air system.

1. Prepare to start the truck.

   Note: The transmission control should be in the P position.

   Show/hide table

   Illustration 92	g01340699

2. Chock the wheels.

3. Start the engine.
   Show/hide table

   Illustration 93	g02138319

4. In the Advisor, select "Monitor".

   Note: The "Monitor" menu is accessed from the "Home" menu. The "Monitor" menu allows the user to view the machine parameters that are being monitored. Four parameters are displayed on the Advisor screen at one time. To change a parameter, highlight the parameter and click "OK". Use the arrows buttons to scroll through the list of parameters. Select the desired parameter and click "OK".

5. View the pressure of the "System Air Pressure".

6. Accelerate the engine to high idle.

   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".

Air System Leak Test

Perform an air system integrity test. The air system integrity test will check the entire air system of the truck.

• The air tank should contain 827 kPa (120 psi).

• Truck should remain shutdown and undisturbed for 5-6 hours (recommended).

• Air system pressure drop should not exceed 138 kPa (20 psi).

• If the air system pressure drop exceeds 138 kPa (20 psi), refer to Troubleshooting Compressed Air System Components and Performance, REHS1428 for troubleshooting instructions.

Note: The truck requires 518 kPa (75 psi) to start the engine, if equipped with air start.

Heater and Air Dryer Voltage Check

Show/hide table

Illustration 94	g06353383

1. Locate the air dryer near the right side of the cab.
   Show/hide table

   Illustration 95	g01341861
   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 to record your results.
   Show/hide table

   Table 25

   Air Dryer Check	Actual Reading
   24 V or more at the air dryer

Check the Braking and Steering Accumulator Precharge Pressures

Illustration 96	g01962775

Show/hide table

When it is necessary to work under the machine with the body (bed) raised, attach the body (bed) retaining cables to the body retaining pins. Install the body retaining pins through the ends of the retaining cables. Always use both retaining cables. Failure to properly secure the body (bed) may result in personal injury or death.

1. Check the precharge pressures of the braking and the steering accumulators.

   Note: Refer to Special Instruction, REHS5464, "Accumulator Discharging and Charging Procedures" for instruction and tooling for checking the accumulator pressures.

   Show/hide table

   Table 26

   Braking Accumulator Precharge Pressure/Temperature Relationship
   Ambient Temperature	Pressure(1)
   −7 °C (20 °F)	6201 kPa (900 psi)
   −1 °C (30 °F)	6339 kPa (920 psi)
   4 °C (40 °F)	6477 kPa (940 psi)
   10 °C (50 °F)	6580 kPa (955 psi)
   16 °C (61 °F)	6718 kPa (975 psi)
   21 °C (70 °F)	6895 kPa (1000 psi)
   27 °C (81 °F)	7028 kPa (1020 psi)
   32 °C (90 °F)	7166 kPa (1040 psi)
   38 °C (100 °F)	7308 kPa (1060 psi)
   43 °C (110 °F)	7411 kPa (1075 psi)
   49 °C (120 °F)	7584 kPa (1100 psi)

   Show/hide table

   (1)	The allowable tolerance on nominal pressure is 345 kPa (50 psi).

   Show/hide table

   Table 27

   Steering Accumulator Precharge Pressure/Temperature Relationship
   Ambient Temperature	Charging Pressure(1)
   −7°C (20°F)	6735 kPa (977 psi)
   −1°C (30°F)	6790 kPa (985 psi)
   4°C (40°F)	6900 kPa (1000 psi)
   10°C (50°F)	7010 kPa (1016 psi)
   16°C (60°F)	7120 kPa (1032 psi)
   21°C (70°F)	7230 kPa (1050 psi)
   27°C (80°F)	7340 kPa (1064 psi)
   32°C (90°F)	7450 kPa (1080 psi)
   38°C (100°F)	7560 kPa (1096 psi)
   43°C (110°F)	7670 kPa (1112 psi)
   49°C (120°F)	7725 kPa (1120 psi)

   Show/hide table

   (1)	The allowable tolerance on nominal pressure is ± 345 kPa (± 50 psi).

Brake System Purge Procedure

Show/hide table

NOTICE
Purge any air that may be in the service brake system. Purge air from the service brake system if the following events have occurred:

• Initial assembly of the machine

• The brake manifold has been replaced

• Any hose that supplies oil to the brake manifold have been disconnected.

• Any hose that supplies oil to the brakes from the brake manifold have been disconnected.

Table 28

Tools Needed
Item	Part Number	Description	Qty
1	6V-3965	Fitting (TEST)	1
2	177-7862	Hose As	1
3	6V-4143	Coupler	2

There are purge valves for the hydraulic brakes on each wheel. Before you use the purge valves to remove air from the oil in the system, the tank for the hydraulic brakes must be full.

Note: Purge only one wheel at a time.

Brake Unloader Valve

1. Use 177-7862 Hose As (2) and two 6V-4143 Coupler Assemblies (3) to construct a bypass hose.
   Show/hide table

   Illustration 97	g03554219
   (1) Unloader valve

2. Connect the hose assembly to the bleeder valve on brake unloader valve (1).

3. Connect a drain hose from the port "A" to the hydraulic tank or to a suitable container.

4. Run the engine at low idle. Move the transmission lever to the NEUTRAL position.

5. Pull down the retarder control or pump the service brake pedal.

   Repeat this step until there is a continuous flow of oil.

6. Close the purge valve. Move the retarder control to the OFF position. Activate the parking brake to release the pressure. Remove the jumper hose from port (A).

Service Brakes and Retarder System

1. Chock the wheels.

2. Apply the parking brake. Applying the parking brake will release the pressure in the lines.
   Show/hide table

   Illustration 98	g03348464
   Typical view of a front wheel (A) Bleeder port (front wheel)

   Show/hide table

   Illustration 99	g03348537
   Typical view of the back of the rear axle (A) Bleeder port (rear wheel)

3. Connect a suitable drain hose to bleeder port (A) on one wheel.

4. Connect the drain hose from the port "A" to the hydraulic tank or to a suitable container.

5. Run the engine at low idle. Move the transmission control lever to the NEUTRAL position.

6. Use a wrench to open the bleeder screw.

7. Pull down the retarder control or depress the service brake pedal until there is a continuous flow of oil.

8. Close the bleeder screw. Move the retarder control to the OFF position or release the service brake pedal.

9. Move the transmission control to the P position.

10. Remove the drain hose from bleeder port (A).

11. Repeat these steps for the other three wheels.

12. After completing the purge, turn off the machine and remove all equipment.

Brake Pilot (Foot Pedal)

1. Assemble a hose to purge the air from the brake system. A hose with a shut off valve at one end and a hydraulic socket, which fits on a hydraulic quick disconnect, on the other end is required.
   Show/hide table

   Illustration 100	g03554577

2. Connect the hose that was assembled in Step 1 to tap (B).

3. Connect the drain hose from the port "B" to the hydraulic tank or to a suitable container.

4. Open the shutoff valve on the end of the hose.

5. Start the engine and run the engine at low idle.

6. Depress the service brake pedal until there is a continuous flow of oil.

   When oil begins to flow and run clear of bubbles, close the valve and release service brake pedal.

7. After completing the purge, turn off the machine and remove all equipment.

8. Repeat Step 2 through Step 7 for port (C).

   Note: The service brake pedal, or the manual retarder lever may be used.

Parking Brake

Though the parking brake application is mechanical, removing the air from the parking brake release system is important. Start the machine. Depress the service brake pedal and move the transmission lever from the P position, to the N position, and back to the P position five times. The air will be purged from the lines. Actuate the brake in intervals of approximately 1 minute.

Transmission - Test

Reference: Before performing any tests, refer to Operation and Maintenance Manual, SEBU8417, "Prepare the Machine for Maintenance".

Reference: For information on calibrating the engagement pressure for the transmission clutch, refer to Testing and Adjusting, KENR8394, "Engagement Pressure for the Transmission Clutch - Calibrate".

Note: Illustration 102 shows the location of the test ports for the transmission clutch pressures.

Reference: For information on calibrating the transmission clutch fill time, refer to Testing and Adjusting, KENR8394, "Fill Time for the Transmission Clutch - Calibrate".

Illustration 101	g01962775

Show/hide table

When it is necessary to work under the machine with the body (bed) raised, attach the body (bed) retaining cables to the body retaining pins. Install the body retaining pins through the ends of the retaining cables. Always use both retaining cables. Failure to properly secure the body (bed) may result in personal injury or death.

Table 29

Transmission Pump and Lubrication Pressure for "R1N" and "JH5" Transmissions
Engine Speed Transmission Control	Transmission Pump Pressure (Main Relief)		Rear Box Lubrication Pressure		Front Box Lubrication Pressure
	Target	Actual	Target	Actual	Target	Actual
Low Idle Transmission in Neutral	2275 ± 172 kPa (330 ± 25 psi)		90 ± 35 kPa (13 ± 5 psi)		70 ± 14 kPa (10 ± 2 psi)
Low Idle Transmission in Reverse	2275 ± 172 kPa (330 ± 25 psi)		90 ± 35 kPa (13 ± 5 psi)		70 ± 14 kPa (10 ± 2 psi)
Low Idle Transmission in First,	2275 ± 172 kPa (330 ± 25 psi)		90 ± 35 kPa (13 ± 5 psi)		70 ± 14 kPa (10 ± 2 psi)
High Idle Transmission in First	2655 ± 172 kPa (385 ± 25 psi)		550 ± 70 kPa (80 ± 10 psi)		455 ± 70 kPa (66 ± 10 psi)
High Idle Transmission in Fourth	2655 ± 172 kPa (385 ± 25 psi)		550 ± 70 kPa (80 ± 10 psi)		455 ± 70 kPa (66 ± 10 psi)
High Idle Transmission in Sixth	2655 ± 172 kPa (385 ± 25 psi)		575 ± 70 kPa (83 ± 10 psi)(1)		455 ± 70 kPa (66 ± 10 psi)

(1)	Machines S/N:LAJ263-UP are equipped with an updated lubrication manifold, and will show reduced lube pressure for clutches 6 and 7. For transmissions with an updated lubrication manifold, no lube test is now required for clutches 6 and 7.

Table 30

Transmission Clutch Pressures
Gear	Engine Speed	Lockup Clutch Pressure	Clutches Engaged and Pressures ± 138 kPa (± 20 psi)
			1	2	3	4	5	6	7
N	Low Idle	0 to 35 kPa (0 to 5 psi)		2068 kPa (300 psi)
R	Low Idle	0 to 35 kPa (0 to 5 psi)		2068 kPa (300 psi)					2310 kPa (335 psi)(1)
1	Low Idle	0 to 35 kPa (0 to 5 psi)			2068 kPa (300 psi)			2310 kPa (335 psi)
1	High Idle	2137 ± 138 kPa (310 ± 20 psi)			1725 kPa (250 psi)			1930 kPa (280 psi)
2	High Idle	2137 ± 138 kPa (310 ± 20 psi)		1725 kPa (250 psi)				1930 kPa (280 psi)
3	High Idle	2137 ± 138 kPa (310 ± 20 psi)	1550 kPa (225 psi)					1930 kPa (280 psi)
4	High Idle	2137 ± 138 kPa (310 ± 20 psi)		1725 kPa (250 psi)			1930 kPa (280 psi)
5	High Idle	2137 ± 138 kPa (310 ± 20 psi)	1550 kPa (225 psi)				1930 kPa (280 psi)
6	High Idle	2137 ± 138 kPa (310 ± 20 psi)		1725 kPa (250 psi)		1725 kPa (250 psi)
7	High Idle	2137 ± 138 kPa (310 ± 20 psi)	1550 kPa (225 psi)			1725 kPa (250 psi)

(1)	"R1N" and "JH5" Transmissions

Table 31

Shift Points
Shift	Engine Speed (rpm)	Transmission Output Speed (rpm)
1C-1D	1362	228
1-2	1834	307
2-3	1835	414
3-4	1834	556
4-5	1834	751
5-6	1833	1009
6-7	1835	1365
7-6	1293	1293
6-5	1293	962
5-4	1293	712
4-3	1294	530
3-2	1293	392
2-1	1294	292
1D-1C	1248	209

Illustration 102	g06353408
View of the right side of the transmission (1) Pressure tap for the clutch No. 1 modulating valve (2) Pressure tap for the clutch No. 2 modulating valve (3) Pressure tap for the clutch No. 3 modulating valve (4) Pressure tap for the clutch No. 4 modulating valve (5) Pressure tap for the clutch No. 5 modulating valve (6) Pressure tap for the clutch No. 6 modulating valve (7) Pressure tap for the clutch No. 7 modulating valve (8) Pressure tap for the transmission main relief pressure (9) Pressure tap for the torque converter inlet pressure (10) Pressure tap for the transmission lubrication pressure clutch (front box) (11) Pressure tap for the transmission lubrication pressure clutch (rear box)

Use the tables above to record the transmission and torque converter pressures.

Note: The main relief pressure should be checked prior to performing the calibration. If main relief pressure is too low, the calibrations would have to be rerun.

The transmission oil temperature during testing must be 80° to 120°C (176° to 248°F).

Main Relief Valve Pressure - Test

1. Connect tooling (A) or tooling (B) to pressure tap (8) for the main relief valve pressure. Refer to Illustration 102.

   Note: Refer to Table 5 for tooling (A) or Table 6 for tooling (B).

2. Start the engine and run the engine at low idle.

3. At low idle, apply the service brakes, and move the transmission control through the 1, the R, and the N positions. The main relief pressure should be 2275 ± 172 kPa (330 ± 25 psi) for all positions on "R1N" and "JH5" transmissions.

   If the pressure is not correct, adjust the main relief valve

4. Move the transmission control to the P position.

5. Turn off the machine and remove all test equipment.

Main Relief Valve Pressure - Adjust (If Needed)

Show/hide table

Illustration 103	g03347536
(12) Main relief valve (13) Cover (14) Adjustment screw

1. Remove cover (13) from main relief valve (12).

2. Turn adjustment screw (14) to adjust the pressure.

3. Reinstall cover (13) and retest the main relief valve pressure.

Transmission Clutch Engagement Pressure Calibration

Show/hide table

NOTICE
Before starting the transmission calibration test, oil temperature must be 70° to 85°C (158° to 185°F). After the test begins, temperature must stay at 65° to 105°C (149° to 221°F).

Note: The calibration of the lockup clutch is also completed during the transmission clutch engagement pressure calibration.

Illustration 104	g01962775

Show/hide table

When it is necessary to work under the machine with the body (bed) raised, attach the body (bed) retaining cables to the body retaining pins. Install the body retaining pins through the ends of the retaining cables. Always use both retaining cables. Failure to properly secure the body (bed) may result in personal injury or death.

Show/hide table

Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. Prevent possible injury by performing the procedure that follows before working on the machine.

Show/hide table

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 attachments have been lowered, 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.

Show/hide table

NOTICE
Do not connect or disconnect hose fittings to or from the quick disconnect nipples when there is pressure in the system. This will prevent damage to the seals that are in the fitting.

Show/hide table

NOTICE
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, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates.

Note: If you install a new transmission solenoid valve, shift the transmission into a gear that uses the solenoid valve. Shift the transmission at least 12 times. Allow sufficient time for the corresponding clutch to become fully pressurized. Refer to table 32 for information on the clutch solenoid assignments.

1. Park the machine on a smooth, level surface.

2. Chock the wheels.

3. Operate the machine to warm the transmission oil to at least 50 °C (122 °F).Caterpillar Electronic Technician (Cat ET) can be used to monitor the temperature of the oil. The transmission pump main relief valve (MRV) pressures need to be correct before proceeding to step 4.

   Refer to Testing and Adjusting, KENR8371, "Transmission - Test" for the correct main relief valve pump pressure specifications.

4. Install tooling (A) or tooling (B) on the pressure tap of the modulating valve for the transmission clutch. Installation is on the clutch that is being calibrated. Refer to Illustration 102 for the locations.

   Note: Refer to Table 5 for tooling (A) or Table 6 for tooling (B).

   Note: Multiple sensors and gauges from tooling (A) or tooling (B) will be required.

   Show/hide table

   Table 32

   Transmission Clutch Assignments
   Gear	Clutches
   Neutral	2
   Reverse	2 and 7
   1	3 and 6
   2	2 and 6
   3	1 and 6
   4	2 and 5
   5	1 and 5
   6	2 and 4
   7	1 and 4

5. Place the transmission gear lever in the PARK position.

6. Fully release the service brake pedal.

7. Set the engine speed to low idle.

   Note: During the calibration, Cat ET will alter the engine speed.

8. Connect Cat ET to the service connector.
   Show/hide table

   Illustration 105	g03349234

9. Choose "Transmission 797" from the list to select the calibration.
   Show/hide table

   Illustration 106	g03349241

10. From the toolbar, select "Service" then "Calibrations".
    Show/hide table

    Illustration 107	g03349588

11. Select the "Transmission Clutch Engagement Pressure Calibration" and click "Start".
    Show/hide table

    Illustration 108	g03349593

12. Select all the clutches and click "Begin".
    Show/hide table

    Illustration 109	g03349607
    Typical view (AA) Area (target clutch pressure)

    Note: During the "Engagement Calibration", a number that corresponds to the electrical current of the particular transmission solenoid valve is displayed. The electrical current of the transmission solenoid valve controls the transmission clutch pressure.

13. View tooling (A) or tooling (B) to view the clutch pressure. The target pressure for each clutch is controlled through the Cat ET screen and displayed in area (AA). Adjust the current by use of the increment and/or decrement buttons to select the target value. Observe the change in the value that is displayed on tooling (A) or tooling (B) until the target value is achieved.

14. After the correct pressure is reached, click "Next".
    Show/hide table

    Illustration 110	g03349616

15. The window that pops up should show a "CALIBRATION SUCCESSFUL" message. Click "Continue" to calibrate the next clutch pressure.
    Show/hide table

    Illustration 111	g03349629

16. Continue to calibrate all the clutch pressures until the last clutch has been calibrated. Click "Finish" to complete the calibration.

Reference: For more information, refer to Testing and Adjusting, "Fill Time for the Transmission Clutch - Calibrate" for the machine that is being tested.

If the clutch pressure is out of specification, refer to Testing and Adjusting, KENR8394, "Engagement Pressure for the Transmission Clutch - Calibrate" and Testing and Adjusting, KENR8394, "Fill Time for the Transmission Clutch - Calibrate".

Transmission Fill Calibration

Improper calibration of the transmission clutch fill will cause transmission shifting problems. The automatic calibration procedure for setting the transmission clutch fill will achieve greater consistency when the transmission is shifted. The main relief valve must be calibrated.

Show/hide table

Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. Prevent possible injury by performing the procedure that follows before working on the machine.

Show/hide table

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 attachments have been lowered, 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.

Show/hide table

NOTICE
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, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates.

Show/hide table

NOTICE
Before starting the transmission calibration test, oil temperature must be 70° to 85°C (158° to 185°F). After the test begins, temperature must stay at 65° to 105°C (149° to 221°F).

Cat ET is used to access the calibration procedures. A message on the Cat ET screen will give instructions that guide the user through the calibration procedure. Refer to the manual that is provided with the Cat ET for more information about Cat ET.

1. Chock the wheels.

2. Connect the communication cable between a laptop computer, equipped with a current version of Cat ET software, and the service connector of the truck.

3. Open the Cat ET. Select the transmission Electronic Control Module (ECM) for the machine that is being calibrated.
   Show/hide table

   Illustration 112	g03349241

4. From the toolbar, select "Service" then "Calibrations".
   Show/hide table

   Illustration 113	g03349640

5. Select "Transmission Fill Calibration" and click "Start".
   Show/hide table

   Illustration 114	g03349643

6. If the conditions listed above in Preparation for Calibration Procedure are met, the display will inform the technician to press NEXT to advance to the next step.

   Note: During the calibration of the transmission clutch fill, many transmission clutch fills are occurring. Remain seated. There will be some vibration and noise as the clutches are being calibrated. If any of the conditions for calibration are violated during the calibration, the calibration will be stopped. Do not operate the air conditioning or hydraulics during the calibration of the solenoids. During the automatic calibration function, avoid performing steering movements.

   Note: At any time during the calibration, the user can abort the calibration by pressing the CANCEL button. Depressing the service brake pedal will also abort the calibration.

   Note: The engine must achieve the requested speed in a maximum of 5 seconds. If the engine does not reach the requested rpm in the given amount of time, the ECM will abort calibration due to an incorrect engine speed.

7. The display will continuously display "Calibrating Clutch #1". The ECM will fill clutch 1 and the ECM will drain clutch #1 several times. The ECM will formulate the optimal hold current and the optimal ramp levels for the solenoid that operates the modulating valve for clutch #1. When the ECM has completed calibrating this clutch, Cat ET automatically moves to the next step.

   The procedure will continue for all clutches during the calibration process.

8. Once the calibration has been completed successfully, the ECM will write the calibration data to memory.

9. Operate the machinery to check the quality of transmission shift.

10. Resume normal operation of the machine.

Transmission Neutralizer

Ensure that the body is down before performing the following test.

1. Start the machine.

2. Apply the service brake pedal.

3. Shift the transmission control into the R position.

4. Move the hoist control lever to the RAISE position.

   Note: The transmission should shift into neutral.

5. Move the hoist control lever to the FLOAT or HOLD position.

   Note: The transmission should stay in neutral.

6. Move the transmission control into the N position. Move the transmission control to the R position.

   Note: The transmission should shift into reverse.

Transmission Field Test

1. Stop the engine.
   Show/hide table

   Illustration 115	g06353416

2. Rotate machine lockout control (1) counterclockwise to activate the lockout. Lockout indicator light (2) should illuminate.

3. With the truck in first gear, try to start the engine.

   Note: Engine should not start.

4. With the truck in reverse, try to start the engine.

   Note: Engine should not start.

5. Use the Table 33 to record the results of Step 3 and Step 4.
   Show/hide table

   Table 33

   Transmission Neutralizer Switch
   Gear		Switch Activated	Engine does not start. Check if OK
   First
   Reverse

Torque Converter - Test

Reference: Testing and Adjusting, KENR8371, "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 34

Torque Converter Specifications
	Specification	Actual
Torque Converter Oil Temperature (during tests)	> 80 °C (176 °F) < 121 °C (250 °F)
Torque Converter Inlet Pressure(1)	Low Idle 145 ± 50 kPa (21 ± 7 psi)
	High Idle 725 ± 105 kPa (105 ± 15 psi)
Torque Converter Outlet Pressure(1)	Low idle 110 ± 50 kPa (16 ± 7 psi)
	High idle 450 ± 105 kPa (65 ± 15 psi)
Maximum Torque Converter Stall RPM (2)	1600 ± 65 RPM
Transmission Charge Pressure	Low idle 2275 ± 172 kPa (330 ± 25 psi)
	High idle 2655 ± 172 kPa (385 ± 25 psi)
Lockup Clutch Maximum Pressure NEUTRAL/CONVERTER DRIVE/HIGH IDLE(3)	0 to 35 kPa (0 to 5 psi)

(1)	Refer to Illustration 119
(2)	Torque Limiting strategy reduces engine RPM.
(3)	Lockup Clutch maximum pressure in DIRECT DRIVE is set during the transmission calibration procedure.

1. Chock the wheels.
   Show/hide table

   Illustration 116	g03356614

2. On the Cat ^® ET screen toolbar, click "File" and "Select ECM".

   Choose the "Transmission ECM".

   Show/hide table

   Illustration 117	g03349646

3. Select "Torque Converter Monitoring".
   Show/hide table

   Illustration 118	g01962775

   Show/hide table

   When it is necessary to work under the machine with the body (bed) raised, attach the body (bed) retaining cables to the body retaining pins. Install the body retaining pins through the ends of the retaining cables. Always use both retaining cables. Failure to properly secure the body (bed) may result in personal injury or death.

   Show/hide table

   Illustration 119	g03348324
   View of the rear of the torque converter (1) Pressure tap for the outlet relief valve (2) Pressure tap for the Inlet relief valve (3) Pressure tap for the lockup clutch solenoid

   Note: The lockup clutch solenoid pressure is adjusted during the transmission clutch engagement pressure calibration.

4. Connect tooling (A) or tooling (B) to the appropriate test port.

   Note: Refer to Table 5 for tooling (A) or Table 6 for tooling (B).

5. Perform the torque converter tests and record the results in Table 34.

Torque Converter Stall - Test

Show/hide table

Personal injury can result if the machine moves during testing. If the machine begins to move during testing, reduce the engine speed immediately and place the transmission control in the P position in order to engage the parking brake.

The torque converter stall test must be performed when the transmission is in the first gear and the body is in the lowered position.

1. Chock the wheels.

2. Fasten the seat belt before you test the brakes.

3. Check the area around the machine. Make sure that the machine is clear of personnel and clear of obstacles.

4. Test the brakes on a dry, level surface.

5. Start the engine.
   Show/hide table

   Illustration 120	g01923774

6. From the home screen in Advisor, select "Monitor". Select "Parameters" and choose the "Actual Engine RPM".
   Show/hide table

   Illustration 121	g01519336

7. When the transmission control is in the P position, fully depress the service brake pedal. Then, depress button (3) for the high gear limit RAISE and depress button (4) for the high gear limit LOWER at the same time.

8. While both buttons are depressed, Move the transmission control to the D position.

   Note: The buttons can now be released and the parking brake will remain on.

9. With the service brake pedal still fully depressed, and fully depress the accelerator pedal. The machine should not move.

10. Check the engine rpm on Advisor. The torque converter should stall at 1600 RPM.

    Record the results in Table 34.

11. Reduce the engine speed to an idle. Move the transmission control to the P position. Stop the engine.

Brake System - Test

Illustration 122	g01962775

Show/hide table

When it is necessary to work under the machine with the body (bed) raised, attach the body (bed) retaining cables to the body retaining pins. Install the body retaining pins through the ends of the retaining cables. Always use both retaining cables. Failure to properly secure the body (bed) may result in personal injury or death.

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.

Brake oil testing temperature should be between 60° to 121°C (140° to 250°F).

Note: The service brake accumulators must be precharged to 6895 kPa (1000 psi), and the air must be purged from the brake system.

Table 35

Brake System Specifications
		Specification	Actual
Main Relief Pressure(1)		23100 ± 345 kPa (3350 ± 50 psi)
Service Brake Cut-In at Accumulator(2)		14480 + 1375 - 690 kPa (2100 + 200 - 100 psi)
Service Brake Cut-Out at Accumulator(2)		20684 ± 690 kPa (3000 ± 100 psi)
Pump Stand-By Pressure(1)		1034 ± 1034 kPa (150 ± 150 psi)
Brake Pilot Pressure (Foot Pedal)(3)		4950 ± 400 kPa (720 ± 58 psi)
Service and Secondary Brake Accumulator Pressure after Key Off(2)		0 kPa (0 psi) in less than 120 seconds
Parking Brake Release Pressure (Retarder Lever Applied, Transmission in N)(4)		4340 ± 480 kPa (630 ± 70 psi)
Parking Brake Pressure (Secondary Brake Pedal Applied)(4)		0 kPa (0 psi)
Parking Brake Pressure (Transmission Control in the P Position)(4)		0 kPa (0 psi)
Towing Motor(5)		3790 to 4480 kPa (550 to 650 psi) within 120 seconds
Brake Application Pressure at Slack Adjusters(6)	Service Brake Applied Front and Rear Slack Adjuster	6205 ± 275 kPa (900 ± 40 psi)
	Manual Retarder Lever Applied Front and Rear Slack Adjuster	4135 to 6480 kPa (600 to 940 psi)

(1)	Refer to Illustration 123
(2)	Refer to Illustration 127
(3)	Refer to Illustration 100
(4)	Refer to Illustration 131
(5)	Refer to Illustration 136
(6)	Refer to Illustration 139 and Illustration 140

Brake Valve Main Relief - Test

1. Chock the wheels.
   Show/hide table

   Illustration 123	g03348857
   (1) Pressure tap at the brake oil filter

2. Install tooling (A) or tooling (B) onto pressure tap (1).

   Note: Refer to Table 5 for tooling (A) or Table 6 for tooling (B).

3. Start the engine.
   Show/hide table

   Illustration 124	g03349659

4. From the toolbar in Cat ^® ET, select "Diagnostics" and "Diagnostic Tests".
   Show/hide table

   Illustration 125	g03348920

5. In the "Brake 797" section, select the "Override Parameters" and click "Start".
   Show/hide table

   Illustration 126	g03349664

   Show/hide table

   NOTICE
   Do not run the brake unloader override for more than 60 seconds. Unnecessary high brake oil temperature may result and system damage can occur.

6. Set the override for the brake unloader valve to ON. Check the pressure from pressure tap (1). Record the pressure in Table 35.

   Note: Pressure should be 23100 ± 345 kPa (3350 ± 50 psi).

7. Turn off the machine and remove all test equipment.

   Adjust the pressure and repeat the test, if required.

Service Brake Cut-In and Cut-Out at the Accumulators

1. Chock the wheels.
   Show/hide table

   Illustration 127	g03554599
   (1) Secondary brake accumulator pressure tap (2) Service brake accumulator pressure tap

2. Connect tooling (A) or tooling (B) to pressure tap (2) for the service brake accumulators.

   Note: Refer to Table 5 for tooling (A) or Table 6 for tooling (B).

3. Start the engine. Check the pressure on tooling (A) or tooling (B).

   Cut-in ... Start of charge

   Cut-out ... End of charge

   Brake Cut-in Cut-out Pressure

   Cut-In ... 14480 ± 483 kPa (2100 ± 70 psi)

   Cut-Out ... 20685 ± 483 kPa (3000 ± 70 psi)

   Record the pressures in Table 35.

4. Turn off the machine and remove all test equipment.

Brake Pump Stand-by Pressure - Test

1. Chock the wheels.

2. Install tooling (A) or tooling (B) onto pressure tap (1) from Illustration 123.

   Note: Refer to Table 5 for tooling (A) or Table 6 for tooling (B).

3. Start the engine. When the pump is not charging, check the pressure on tooling (A) or tooling (B).

   The pressure should be 1034 ± 1034 kPa (150 ± 150 psi). Record the pressure in Table 35.

4. Turn off the machine and remove all test equipment.

Brake Pilot Pressure (Foot Pedal) - Test

Illustration 128	g01962775

Show/hide table

When it is necessary to work under the machine with the body (bed) raised, attach the body (bed) retaining cables to the body retaining pins. Install the body retaining pins through the ends of the retaining cables. Always use both retaining cables. Failure to properly secure the body (bed) may result in personal injury or death.

1. Chock the wheels.
   Show/hide table

   Illustration 129	g03554604
   (1) Pressure tap near the brake control valve

2. Install tooling (A) or tooling (B) onto pressure tap (1) from Illustration 129.

   Note: Refer to Table 5 for tooling (A) or Table 6 for tooling (B).

3. Start the engine. Apply the service brake pedal several times. Then, apply the service brake pedal and hold. Check the pressure on tooling (A) or tooling (B).

   Note: The pressure should be 4950 ± 400 kPa (720 ± 58 psi).

   Record the pressure in Table 35.

4. Turn off the machine and remove all test equipment.

Service and Secondary Brake Accumulator Pressure - Test

1. Chock the wheels.

2. Install tooling (A) or tooling (B) onto pressure tap (1) and pressure tap (2).

   Note: Refer to Table 5 for tooling (A) or Table 6 for tooling (B).

3. Start the engine and let the accumulators charge completely.
   Show/hide table

   Illustration 130	g06353421

4. From the bumper, move engine shutdown switch (1) up to stop the engine.

   With engine shutdown switch (1) up, the accumulator pressure should not drain for several minutes.

   Record the results in Table 35.

5. Start the engine and let the accumulators charge completely.

6. From the cab, turn the key to the OFF position.

   With the key in the OFF position, the accumulator pressure should drop to approximately 0 kPa (0 psi) in less than 120 seconds.

   Record the results in Table 35.

7. Remove all test equipment.

Parking Brake Release Pressure - Test

1. Chock the wheels.
   Show/hide table

   Illustration 131	g03350846
   (1) Pressure taps for the rear parking brake release pressure

2. Install tooling (A) or tooling (B) onto pressure taps (1) from Illustration 131.

   Note: Refer to Table 5 for tooling (A) or Table 6 for tooling (B).

3. Start the engine.

   Check the pressure on tooling (A) or tooling (B).

   Note: The pressure should be 0 kPa (0 psi).

4. Apply the retarder lever and shift the transmission lever into the N position.

   Check the pressure on tooling (A) or tooling (B).

   Note: The pressure should be 4340 ± 480 kPa (630 ± 70 psi).

   Record the results in Table 35.

5. Apply the secondary brake pedal.

   Check the pressure on tooling (A) or tooling (B).

   Note: The pressure should be 0 kPa (0 psi).

   Record the results in Table 35.

6. Release the secondary brake pedal. Move the transmission lever into the P Position.

   Check the pressure on tooling (A) or tooling (B).

   Note: The pressure should be 0 kPa (0 psi).

   Record the results in Table 35.

7. Turn off the machine and remove all test equipment.

Traction Control Valve - Test

Illustration 132	g01962775

Show/hide table

When it is necessary to work under the machine with the body (bed) raised, attach the body (bed) retaining cables to the body retaining pins. Install the body retaining pins through the ends of the retaining cables. Always use both retaining cables. Failure to properly secure the body (bed) may result in personal injury or death.

1. Chock the wheels.

2. Connect a laptop computer and open Cat ^® ET. Navigate to the Brake ECM AETA valve solenoids.
   Show/hide table

   Illustration 133	g03350875
   (1) Pressure tap for the right wheel (2) Pressure tap for the left wheel

3. Install tooling (A) or tooling (B) onto pressure tap (1) and pressure tap (2) from Illustration 133.

   Note: Refer to Table 5 for tooling (A) or Table 6 for tooling (B).

   Show/hide table

   Illustration 134	g03185964
   The TCS test switch is located in the overhead controls in the operator station (3) TCS switch

4. Start the engine and run the engine at low idle. Apply the retarder lever, move the transmission lever to the N position, and ensure that the parking brake is off. Activate traction control switch (3).

   Check the pressure on tooling (A) or tooling (B). Record the results in Table 35.

   The hydraulic pressure at the left traction control valve will show a fall and rise in 30 seconds. Then, the right traction control valve will show a fall and rise over 30 seconds. The cycle will repeat.

   Note: The left side (lower pressure tap) must fall first if the hydraulic lines are connected correctly.

5. Turn off the machine and remove all test equipment.

Parking Brake Holding Ability Test

Reference: Operation and Maintenance Manual, SEBU8417, "Braking System - Test"

1. Chock the wheels.

2. Fasten the seat belt before you test the brakes.

3. Check the area around the machine. Make sure that the machine is clear of personnel and clear of obstacles.

4. Test the brakes on a dry, level surface.

5. Start the engine.
   Show/hide table

   Illustration 135	g01519336

6. When the transmission control is in the P position, depress button (3) for the high gear limit RAISE and depress button (4) for the high gear limit LOWER at the same time.

7. While both buttons are depressed, Move the transmission control to the D position.

   Note: The buttons can now be released and the parking brake will remain on.

8. Gradually increase the engine speed to 1300 rpm. The machine should not move.

9. Reduce the engine speed to an idle. Move the transmission control to the P position. Stop the engine.

Show/hide table

NOTICE
If the machine moved while testing the brakes, contact your Cat dealer. Have the Cat dealer inspect and, if necessary, repair the parking/secondary brakes before returning the machine to operation.

Towing Motor Test

1. Chock the wheels.
   Show/hide table

   Illustration 136	g03350921
   (1) Location of the pressure taps for the parking brake release pressure

2. Connect tooling (A) or tooling (B) to pressure tap (1).

   Note: Refer to Table 5 for tooling (A) or Table 6 for tooling (B).

3. Turn the engine start switch to the ON position. Place the transmission control into the NEUTRAL position.

   Note: Do not start the machine at this time.

   Show/hide table

   Illustration 137	g02074719
   Switch for the electric powered parking and secondary brake release pump

4. Activate the switch for the towing motor. Hold the switch until the pressure that is shown on the pressure gauge stops rising.

   The pressure on tooling (A) or tooling (B) should rise to 3790 to 4480 kPa (550 to 650 psi) within 120 seconds.

   Record the results in Table 35.

5. Turn off the machine and remove all test equipment.

Brake Application Pressure at the Slack Adjuster - Test

Illustration 138	g01962775

Show/hide table

When it is necessary to work under the machine with the body (bed) raised, attach the body (bed) retaining cables to the body retaining pins. Install the body retaining pins through the ends of the retaining cables. Always use both retaining cables. Failure to properly secure the body (bed) may result in personal injury or death.

1. Chock the wheels.
   Show/hide table

   Illustration 139	g03351131
   (1) Pressure tap at the front slack adjuster

   Show/hide table

   Illustration 140	g03351127
   (2) Pressure tap at the rear slack adjuster

2. Connect tooling (A) or tooling (B) to pressure tap (1) and pressure tap (2) from Illustration 139 and Illustration 140.

   Note: Refer to Table 5 for tooling (A) or Table 6 for tooling (B).

3. Start the engine and run the engine at low idle. Apply the service brake pedal.

   Check the pressure on tooling (A) or tooling (B).

   Brake pressure with service brake pedal applied

   Front and Rear Slack Adjuster ... 6205 ± 275 kPa (900 ± 40 psi)

4. Release the service brake pedal.

5. Apply the manual retarder.

   Check the pressure on tooling (A) or tooling (B).

   Brake pressure with retarder lever applied

   Front and Rear Slack Adjuster ... 4135 to 6480 kPa (600 to 940 psi)

6. Turn off the machine and remove all test equipment.

Automatic Retarder Control (ARC) - Test

1. Chock the wheels.

2. Ensure Cat ^® ET is connected.
   Show/hide table

   Illustration 141	g03187256
   (1) Switch for the automatic retarder control (ARC)

3. Start the engine and run the engine at low idle. Depress switch (1) for the ARC. Verify the ARC status in Cat ^® ET at the Brake ECM "Status" screen.

4. Turn off the machine.

Set the Front and Rear Brake Wear Indicators (If Equipped)

Location of the Front Brake Wear Indicators

Illustration 142	g03351281
Front wheel

Instructions to Set the Brake Wear Indicators on the Front Wheel

1. Chock the wheels.
   Show/hide table

   Illustration 143	g01974859
   Typical view of an installed brake wear indicator

2. Remove cap (A) from the brake wear indicator.
   Show/hide table

   Illustration 144	g01975013
   Typical view of newly installed brake discs

3. Apply forward pressure to indicator rod (B) so that the indicator rod contacts brake piston (C).
   Show/hide table

   Illustration 145	g01975034

4. Push dowel bushing (D) into the body until the end of dowel bushing (D) is flush with the notched shoulder that is on indicator rod (B).

5. Reinstall cap (A) that was removed in Step 2. Tighten cap (A) to a torque of 34 ± 4 N·m (300 ± 35 lb in).

6. Refer to Testing and Adjusting, KENR8374, "Service Brake Discs - Check - Standard" for instructions on checking the brake wear.

Location of the Rear Brake Wear Indicators

Illustration 146	g03365981
Rear wheel

Illustration 147	g06317032
Left-hand side brake wear indicator harness

Illustration 148	g06317034
Right-hand side brake wear indicator harness

Instructions to Set the Brake Wear Indicators on the Rear Wheel

Refer to Testing and Adjusting, KENR8374, "Service Brake Discs - Check" for additional instructions.

Note: The rear wheel brake wear indicators are electronic.

Note: This procedure should be performed at the initial delivery to establish a baseline. Also, perform this procedure again after any of the brakes are rebuilt. Rebuilding the brakes will change the piston travel and a new benchmark for the piston travel will be created. Record the measurements in the Testing and Adjusting, KENR8374, "Worksheets".

Table 36

Required Tooling
Item	Qty	Part Number	Description
1	1	257-9140	Digital Multimeter
2	1	276-7273	Sensor Test Box

Illustration 149	g01991683
Rear brake housing on right-hand side (S) Purge valve for service brake (P) Purge valve for parking brake

Illustration 150	g01991697
Brake wear gauge on the rear wheel (3) 286-1876 Position Sensor Gp

Show/hide table

Illustration 151	g02003914
View of the required tools that are used for checking the rear brakes (1) 257-9140 Digital Multimeter (2) 276-7273 Sensor Test Box

1. While the engine is off and the parking brake is engaged, plug test box (2) into digital multimeter (1).

2. Turn digital multimeter (1) to the "DC Voltage" setting.

3. Hold down the button that is on the side of test box (2). The value should be between 7 and 10 V.

   Note: If the value is outside the range, replace the battery in test box (2).

   Show/hide table

   Illustration 152	g01991793
   Location of the electronic sensor for the brake wear on the right-hand rear wheel (3) 286-1876 Position Sensor Gp (4) 324-3351 Integrated Brake Wiring Gp

4. Remove the dust plug from the connector receptacle on the integrated brake wiring group (4) that connects to position sensor (3).

5. Insert the 4-pin connector from test box (2) to the connector receptacle.

6. Check the value on digital multimeter (1). The value should be between 0.5 and 4.5 V.

   If the value is below 0.5 V or above 4.5 V, then the sensor is out of the range.

   If the value is in the correct range, record the baseline voltage/measurement (X).

7. Periodically repeat Step 1 through Step 6 for the brake wear. This measurement is measurement (Y).

8. Subtract measurement (Y) that was recorded in Step 7 from measurement (X) that was recorded in Step 6. This value is measurement (Z). Refer to Table 37 for the percentage of brake wear.

   Note: The brake assembly should be rebuilt when brake wear reaches 75 percent of the baseline value.

   Show/hide table

   Table 37

   Additional Sensor Voltage (Compared to the Baseline Voltage)
   Percentage of Brake Wear	Measurement (Z) (Voltage)
   0	0
   10	0.15
   20	0.30
   30	0.46
   40	0.61
   50	0.76
   60	0.91
   70	1.06
   75	1.13
   80	1.21
   90	1.36
   100	1.52

9. Remove all test equipment.

Brake Cooling System - Test

Table 38

Brake Cooling System Specifications
	Specification	Actual
Brake Cooling Pressure	480 ± 340 kPa (70 ± 50 psi)

1. Chock the wheels.
   Show/hide table

   Illustration 153	g03351317
   Brake cooling screens (1) Pressure tap on brake cooling screen

2. Connect tooling (A) or tooling (B) to pressure tap (1).

   Note: Refer to Table 5 for tooling (A) or Table 6 for tooling (B).

   Note: There aretwopressuretaps (1) on the extended life retarding arrangement.

3. Start the machine.
   Show/hide table

   Illustration 154	g03349659

4. From the toolbar in Cat ^® ET, select "Diagnostics" and "Diagnostic Tests".
   Show/hide table

   Illustration 155	g03348920

5. In the "Brake 797" section, select the "Override Parameters" and click "Start".
   Show/hide table

   Illustration 156	g03349668

6. Select the "Brake Cooling Pump Speed" and click "Change". Set the brake cooling pump speed to 1750 rpm.

7. Select the "Engine Speed" and click "Change". Set the engine speed to 1960 rpm (high idle).

8. Check the pressure at tooling (A) or tooling (B).

   The pressure should be 480 ± 340 kPa (70 ± 50 psi). Record the results in Table 38.

9. Turn off the machine and remove all test equipment.

Steering System and Hydraulic Fan System - Test

Ensure that the steering accumulators are at the correct precharge before performing any tests.

Reference: Testing and Adjusting, KENR8574, "797F Off-Highway Truck Hydraulic Fan and Steering System"

Table 39

Steering System and Hydraulic Fan System Specifications(1)
	Target	Actual
Accumulator Pressure(2)	22750 ± 500 kPa (3300 ± 72 psi)
Steering Pump Cut-In at Accumulator(1)	22060 ± 1375 kPa (3200 ± 200 psi)
Steering Pump Cut-Out at Accumulator(1)	24130 ± 1375 kPa (3500 ± 200 psi)
Accumulator Pressure (Charged, after engine shutdown with ground level shutdown switch)	Not below 17927 kPa (2600 psi) in 10 seconds
Accumulator Pressure (key switch to OFF position)	Below 345 kPa (50 psi) in less than 120 seconds
Cycle time for the steering system at high idle. With all of the brakes released, turn the steering wheel from left to right. Then from right to left.	11 to 13 seconds	1.________________ 2.________________ 3.________________ Avg.______________
Steering wheel turns from stop to stop at high idle. With all of the brakes released, turn the steering wheel at 1 revolution per second	3 to 5 seconds	Left to Right 1.________________ 2.________________ 3.________________ Avg.______________
Steering wheel turns from stop to stop at high idle. With all of the brakes released, turn the steering wheel at 1 revolution per second	3 to 5 seconds	Right to Left 1.________________ 2.________________ 3.________________ Avg.______________
Steering Pump Discharge Pressure(3)	28200 ± 690 kPa (4090 ± 100 psi)
Fan Pump high-pressure cutoff at low idle(4)	Less than 35000 kPa (5000 psi)

(1)	Steering oil temperature during tests 65° to 82°C (150° to 180°F)
(2)	Refer to Illustration 157
(3)	Refer to Illustration 159
(4)	Refer to Illustration 163

Steering Accumulator Pressure - Test

1. Chock the wheels.
   Show/hide table

   Illustration 157	g03351389
   (1) Pressure tap for the steering accumulator pressure

2. Connect tooling (A) or tooling (B) to pressure tap (1).

   Note: Refer to Table 5 for tooling (A) or Table 6 for tooling (B).

3. Start the engine. Turn the wheels all the way to the left. Check for leaks.

   Note: Accumulator pressure should be 22750 ± 500 kPa (3300 ± 72 psi).

4. Turn the wheels all the way to the right. Check for leaks.

   Note: Accumulator pressure should be 22750 ± 500 kPa (3300 ± 72 psi).

5. Check the Cut-In and Cut-Out pressures.

   Cut-In (Start of charge) ... 22060 ± 1375 kPa (3200 ± 200 psi)

   Cut-Out (End of charge) ... 24130 ± 1375 kPa (3500 ± 200 psi)

   Show/hide table

   Illustration 158	g06353423

6. With the accumulators fully charged, shut off the engine with manual engine shutdown switch (2). Monitor the pressure at pressure tap (1).

   Note: The pressure should not drop below 17927 kPa (2600 psi) in 10 seconds.

7. Return the ground level shutdown switch to the ON position, and turn the key switch to the OFF position. Monitor the pressure at pressure tap (1).

   Note: The pressure should drop to below 345 kPa (50 psi) in less than 120 seconds.

8. Verify that there are no leaks.

9. Start the engine and run the engine at full idle until the accumulators are charged again.

10. Shut off the engine with manual engine shutdown switch (2).

11. Turn the steering wheel from stop to stop to check the steering capacity.

    Machine should turn at least twice.

12. Return the ground level shutdown switch to the ON position, and turn the key switch to the OFF position. Monitor the pressure at pressure tap (1).

    Note: The pressure should drop to below 345 kPa (50 psi) in 120 seconds.

13. Remove all test equipment.

14. Record the results in Table 39.

Steering System Internal Leakage Test

1. Chock the wheels.

2. Start the engine and run the engine at high idle.

3. Turn the steering wheel from stop to stop at approximately one rotation per second. Record the results in Table 39.

   Note: Time should be approximately 3 to 5 seconds. If more time is required to complete the turn, there may be internal leakage in the steering system.

4. Turn off the machine.

Steering Pump Discharge Pressure - Test

1. Chock the wheels.
   Show/hide table

   Illustration 159	g03351490
   (1) Pressure tap for steering pump pressure

2. Connect tooling (A) or tooling (B) to pressure tap (1).

   Note: Refer to Table 5 for tooling (A) or Table 6 for tooling (B).

3. Disconnect the pressure sensor for the steering accumulators.

   Note: The steering accumulators should be charged.

4. Start the engine and run the engine at high idle.

5. Check the pressure on at pressure tap (1).

   Pressure should be 28200 ± 690 kPa (4090 ± 100 psi).

   Record the results in Table 39.

6. Turn off the machine and remove all test equipment.

Fan - Calibrate

After the Brake ECM has been programmed, the Brake ECM must be configured. The Brake ECM needs to know the configuration of the fan that is installed on the machine. The Brake ECM must support three different configurations of the fans, since there have been changes to the fan iron. The configurations are listed below:

• 2438.4 mm (95 inch) fan with planetary drive

• 2692.4 mm (106 inch) fan with planetary drive

• 2692.4 mm (106 inch) fan with the motor only

The following procedure must be performed when you first flash the software on the machine and whenever the fan iron is updated.

Follow this procedure to change the configuration of the fan.

1. Verify that the software for the Brake ECM is installed on the machine.

2. Start the Caterpillar Electronic Technician (ET) and connect the ET to the Brake ECM.

3. Go to the "Service" menu. Under that menu, select the "Configuration" entry from the menu.

4. ET will display all of the configuration data for the Brake ECM.

5. Select the parameter that is called "Fan w/PlanetaryDiam" from the menu.

6. Double-click on the parameter to change the value or select the "Change" button in the lower left-hand corner.

7. The values for this parameter are listed below.

   • "0". The fan has a diameter of 2692.4 mm (106 inch) and the fan comes with only a motor.

   • "96". The fan has a diameter of 2438.4 mm (96 inch) and the fan comes with a planetary drive that is installed.

   • "106". The fan has a diameter of 2692.4 mm (106 inch) and the fan comes with an old planetary drive that is installed.

8. Exit ET.

Note: The Brake ECM will not allow the parameter to be changed if the truck is moving.

This procedure is used to calibrate the fan.

1. Verify that the software for the Brake ECM is installed on the machine.

2. Start the Caterpillar Electronic Technician (ET) and connect the ET to the Brake ECM.

3. Go to the "Service" menu. Under that menu, select the "Configuration" entry.

4. ET will display all of the configuration data for the Brake ECM.

5. Use the mouse to select the parameter that is called "Fan Calibrate Start".

6. Double-click on the parameter to change the value or select the "Change" button in the lower left-hand corner.

   Note: Enter a value of 1 to start the calibration procedure.

7. The Brake ECM will refuse to start the calibration if any of the following items are true.

   • The engine is not running or the status is unknown.

   • The machine is moving or the status is unknown.

   • The requested gear command is unknown or the gear is not in "Neutral".

   • The actual gear is unknown or the gear is not in "Neutral".

   • The engine throttle is unknown.

   • Engine throttle above the 5% limit

   • The steering oil temperature is unknown.

   • Steering oil temperature is below 70 °C (158 °F) that is the minimum limit for starting.

   • Steering temperature is above 110 °C (230 °F) that is the maximum limit for calibrating.

   Note: If the user tries to trigger the calibration and any of the above conditions are not met, then ET will return an error message. The message will say. The value that was entered is not valid. The Brake ECM has adjusted the value.

   Once the calibration test begins, the calibration test will stop for the items that are listed below.

   • The engine is not running or the status is unknown.

   • The machine is moving or the status is unknown.

   • The requested gear command is unknown or the gear is not in "Neutral".

   • The actual gear is unknown or the gear is not in "Neutral".

   • The engine throttle is unknown.

   • Engine throttle above the 5% limit

   • Steering oil temperature is unknown.

   • Steering oil temperature is below 65 °C (150 °F) that is the minimum limit for starting.

   • Steering temperature is above 110 °C (230 °F) that is the maximum limit for calibrating.

   • A request from a service tool is received to stop the calibration.

   Note: The user may abort the calibration by changing any of the above conditions. Typically, the calibration is stopped by depressing the throttle.

8. Wait for the calibration test to be completed. At this time, the Brake ECM will take over the control of the throttle. At the same time, the Brake ECM will turn the fan ON to calibrate the output.

9. Change ET to "Status Group 7" to check the important speed information (not required).

   Note: When the engine speed goes back to LOW IDLE, the calibration is complete.

10. Check the error message from the calibration.

    After the engine speed is back at "Low Idle", the configuration screen must be refreshed. The screen can be refreshed by selecting the icon that is for the configuration on ET or you can select the tab "Service - Configuration" from the menu. The error status is contained in a parameter that is called "Fan Calibrate Error". The list is some possible values that are listed in the "Fan Calibrate Error" table that is on ET.

    • "0" Calibration was successful.

    • "1" Calibration failed because conditions were not correct.

    • "2" Calibration failed because the fan did not stabilize.

11. Check response of the fan.

    This may be done by overriding the fan speed and verifying the response. The response should be checked to ensure that the fan reaches the top desired speed and that the fan does not overspeed.

12. Exit ET.

    Note: Calibration will not be lost when you reflash the software in the Brake ECM.

Hydraulic Fan Pressure - Test

1. Chock the wheels.
   Show/hide table

   Illustration 160	g03349659

2. From the toolbar in Cat ^® ET, select "Diagnostics" and "Diagnostic Tests".
   Show/hide table

   Illustration 161	g03348920

3. In the "Brake 797" section, select the "Override Parameters" and click "Start".
   Show/hide table

   Illustration 162	g03349678

4. View the "Engine Speed" and the "Engine Fan Speed". Also, be prepared to adjust the "Desired Engine Cooling Fan Speed Override".

   Ensure that the correct cooling arrangement is configured in Cat ^® ET.

   Show/hide table

   Illustration 163	g03351737
   View of the front right side of the inner frame (1) Pressure tap for the hydraulic fan pressure

5. Connect tooling (A) or tooling (B) to pressure tap (1).

   Note: Refer to Table 5 for tooling (A) or Table 6 for tooling (B).

6. Start the engine and run the engine at high idle. Check the hydraulic fan system pressure at pressure tap (1).

   Note: The pressure can be between 0 to 35000 kPa (0 to 5000 psi).

7. Reduce the engine speed to 700 rpm (low idle). Turn on the A/C. Check the engine fan speed in Cat ^® ET.

   Note: The fan speed should be approximately 335 rpm.

   Show/hide table

   Table 40

   Incremental Fan Speed Overrides with the A/C Off.
   Engine Speed (High Idle/Low Idle)	Target Fan Speed (rpm)	Actual Fan Speed	Actual Pressure From Illustration 163
   HI	300 rpm
   HI	400 rpm
   HI	525 rpm Low Altitude
   HI	575 rpm High Altitude

   Show/hide table

   Illustration 164	g03352234
   (2) High-pressure cutoff adjustment screw

8. If the truck is equipped with Low Altitude Arrangement, adjust the pump high-pressure cutoff on the hydraulic fan pump to a maximum of 550 rpm.

   If the truck is equipped with High Altitude Arrangement, adjust the pump high-pressure cutoff on the hydraulic fan pump to a maximum of 600 rpm.

   Note: If the fan speed exceeds 600 rpm at 1300 engine rpm, return the engine speed to low idle. Then turn adjustment screw (2) one quarter turn counterclockwise. Continue to adjust screw (2) one quarter turn at a time until the fan speed is correct.

   Note: If the environmental conditions (sea level) limit the fan speed, do not adjust the high-pressure cutoff to above 35000 kPa (5000 psi).

9. Verify that there are no leaks.

10. Turn off the machine and remove all test equipment.

Hoist System - Test

The hoist oil temperature should be 60° to 82°C (140° to 180°F).

Table 41

Hoist System Specifications
	Specifications	Actual
Hoist Raise Pump Pressure(1)	23785 ± 690 kPa (3450 ± 100 psi)
Hoist Lower Pump Pressure(2)	Less than 7065 kPa (1025 psi)
Cycle Time for Raise (Full Lower to Full Raise)	22 - 27 seconds
Cycle Time for Raise (Full Raise to Full Lower)	16 - 21 seconds
Hoist Pilot Pressure(2)	3800 ± 345 kPa (550 ± 50 psi)

(1)	Refer to Illustration 174 and Illustration 175
(2)	Refer to Illustration 176 and Illustration 177

Hoist Enable System

Note: The hoist enable system must be enabled after the truck is assembled.

1. Chock the wheels.

2. Start Cat ^® ET.
   Show/hide table

   Illustration 165	g03340895

3. From the toolbar, click on "Service". Click on "Configuration".
   Show/hide table

   Illustration 166	g03349680

4. Under the heading "Hoist System", click "Hoist System Enable Status".

5. Click on the"Change" button that is located at the bottom of the screen.

6. Use the drop-down menu to change the status of the hoist system to "Enabled". Click "OK". Select "OK" again in the verification box.

Speed Correction Factor

If the machine is equipped with a tire size different from the original equipment, set the machine speed correction factor. To set the machine speed correction factor, refer to Systems Operation, KENR8394, "Machine Speed Correction".

Calibrate the Body Position Sensor

Refer to Testing and Adjusting, KENR8396, "Position Sensor (Body) - Calibrate" for additional instructions.

Illustration 167	g03352277
Typical rod linkage (6) Rod end (7) Nut (8) Rod (9) Body position sensor (10) Centers of the rod ends

Body position sensor (9) is located on the frame near the left pivot pin for the body. Rod (8) is connected between the body position sensor (9) and the body. When the body is raised, rod (8) rotates body position sensor (9). This action changes the PWM signal that is sent to the Chassis ECM. The adjustment of the rod between the sensor and the body is important. See "Body Position Sensor - Adjust" for the proper adjustment procedure.

The Chassis ECM is constantly checking for the need to calibrate body position sensor (9). Body position sensor (9) is calibrated by the Chassis ECM when all of the following conditions exist for 30 seconds:

• The engine is operating with no ground speed.

• The hoist control has been placed in the HOLD position before being placed in the FLOAT position.

• The duty cycle from the position sensor for the body is stable.

• The duty cycle from the position sensor for the body is within the specified range for the LOWER position.

The signal from the body position sensor is also used for the following items:

• Limit the top gear when the body is up.

• Snubbing for the body

• Starting a cycle for the Truck Payload Measurement System

• Signal a new load count. (The hoist control must be in the RAISE position for 10 seconds.)

• Illuminate the dash lamp that indicates that the body is not against the frame.

• Allow the VIMS to provide warnings when the body is up.

Body position sensor (9) is used to limit the top gear while the body is up. The Chassis ECM comes from the factory with the top gear value that is set to FIRST gear. The transmission will not shift past FIRST gear until the body is down. The top gear value is configurable and can be changed using Caterpillar® Electronic Technician (Cat® ET). The top gear value can be changed to SECOND gear or THIRD gear.

The signal from body position sensor (9) is also used to control the SNUB position of the hoist control valve. The Chassis ECM will signal the proportioning solenoids to move the hoist control valve to the SNUB position when the body nears the frame. The speed in FLOAT is reduced in the SNUB position to prevent the body from contacting the frame too hard.

Body Position Sensor - Adjust

Note: The body position sensor must be adjusted correctly for the proper gear limit operation when the body is raised. Also, the body position sensor is used to control the SNUB position of the hoist control valve.

The distance between the centers of the rod ends (10) must be 423 ± 3 mm (16.7 ± 0.1 inch).

Rod Adjustment

Perform the following to adjust the rod:

1. Disconnect rod (8) from the body.

2. Loosen nut (7) on rod (8).

3. Adjust rod end (6) to get a distance of 423 ± 3 mm (16.7 ± 0.1 inch) between the centers of the rod ends.

4. Tighten nut (7).

5. Reattach rod (8) to the body.

Angle Verification

Verify that the angle of the body is within tolerance when any of the following components are replaced:

• A sensor

• A body

• An ECM

Note: If the angle is not within tolerance, then the Chassis ECM cannot correctly calibrate the position sensor.

Lower the body to the frame rails. If the value is less than 7 degrees, the software in the Chassis ECM calibrates the sensor. The calibration is performed automatically by the Chassis ECM when the body is raised and lowered. If the value is not less than 7 degrees, then perform the Rod Adjustment in the "Body Position Sensor - Adjust" section.

Hoist Lower Calibration

Using the Caterpillar Electronic Technician

1. Lower the dump body. Stop the engine.

2. Connect the ET to the truck.

3. Connect a pressure gauge to the front section and to the rear section of the hoist pump. Use the highest pressure of the two sections to calibrate the pressure for the lower function of the hoist system.

4. On the ET screen, click File - Select ECM and choose Chassis ECM.

5. On the ET screen, click Service - Calibration - Hoist Calibration. The screen in Illustration 168 will appear.

6. Follow the instructions on the ET screen to set the pressure to 6890 kPa (1000 psi).

   Note: You will be instructed to hold the hoist lever in the LOWER position. The engine speed will increase to high idle. Use the arrows on the bottom of the ET screen to increase or decrease the pressure. The single arrow changes the pressure by 7 kPa (1 psi). The double arrows change the pressure by 70 kPa (10 psi).

Illustration 168	g01034002

Hoist Lower Valve Adjustment Status (Snub)

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.
   Show/hide table

   Illustration 169	g02075237
   Typical view

2. Connect the safety retaining cables to the body.
   Show/hide table

   Illustration 170	g01360179
   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".
   Show/hide table

   Illustration 171	g02162170

8. In the "Chassis 797" tab click on "Hoist System".

9. Select "Hoist Lower Valve Adjustment Status".

10. Select "Change".
    Show/hide table

    Illustration 172	g02139158

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 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.

Hoist Pump Pressure - Test

Illustration 173	g01962775

Show/hide table

When it is necessary to work under the machine with the body (bed) raised, attach the body (bed) retaining cables to the body retaining pins. Install the body retaining pins through the ends of the retaining cables. Always use both retaining cables. Failure to properly secure the body (bed) may result in personal injury or death.

1. Chock the wheels.
   Show/hide table

   Illustration 174	g03352357
   (1) Head end (2) Head end (3) Rod end (4) Rod end

2. Connect tooling (A) or tooling (B) to pressure tap (1), (2), (3), and (4).

   Note: Refer to Table 5 for tooling (A) or Table 6 for tooling (B).

3. With the transmission in the P position, start the machine and run the machine at high idle.

4. Shift the hoist lever to the RAISE position. Check the pressures on tooling (A) or tooling (B).

   Hoist raise pressure should be 23785 ± 690 kPa (3450 ± 100 psi).

   Record the results in Table 41.

5. Sift the hoist lever to the LOWER position. Check the pressures on tooling (A) or tooling (B).

   Hoist lower pressure should be less than 7065 kPa (1025 psi).

   Record the results in Table 41.

6. Sift the hoist lever to the HOLD position. Check the pressures on tooling (A) or tooling (B).

   HOLD pressure should be 7580 ± 69 kPa (110 ± 10 psi).

   Record the results in Table 41.

7. Check for leaks. Turn off the machine and remove all test equipment.
   Show/hide table

   Illustration 175	g03352503
   View of the front of the hoist control valve (5) Rod end relief (6) Head end relief

8. If required, adjust the pressure at the relief valve (5) and relief valve (6) on the hoist control valve.

Hoist Cycle Time - Test

1. Chock the wheels.

2. Start the machine and run the machine at high idle.

3. Shift the hoist lever to the RAISE position. Time the results from full down to full up. Record the results in Table 41.

   Verify that the snub feature is working correctly.

   The cycle time should be between 22 and 27 seconds.

4. Move the hoist lever to the LOWER position. Time the results from full up to full down. Record the results in Table 41.

   Verify that the snub feature is working correctly.

   The cycle time should be between 16 and 21 seconds.

5. Check for leaks. Turn off the machine.

Hoist Pilot Pressure - Test

1. Chock the wheels.
   Show/hide table

   Illustration 176	g03354360
   View of the front of the hoist control valve (1) Pilot pressure taps

2. Connect tooling (A) or tooling (B) to pressure taps (1) on each actuator on the front of the hoist control valve.

   Note: Refer to Table 5 for tooling (A) or Table 6 for tooling (B).

3. Start the machine. Shift the hoist lever to the HOLD position. Check the pressure on tooling (A) or tooling (B).

   The pressure should be approximately 3800 ± 345 kPa (550 ± 50 psi) at all taps.

   Record the results in Table 41.

4. Lower the body. Turn off the machine and remove all test equipment.
   Show/hide table

   Illustration 177	g03355402
   (2) Pressure reducing valve

5. If required, adjust the pressure at pressure reducing valve (2) on bottom of the brake control valve.

Hoist Electrical System - Test

Note: Refer to Testing and Adjusting, KENR8381, "Hoist Electrical System - Test" for additional information.

Note: Before performing this test, check the Vital Information Management System (VIMS) for diagnostics that are active or diagnostics that are inactive. Make all repairs necessary to the electrical system on the truck to clear all events in the VIMS.

Note: If there is a problem with the electrical system for the hoist, the Chassis Electronic Control Module (Chassis ECM) will cause the hoist control valve to remain in the HOLD position until the problem is fixed. When the problem is fixed, the hoist control must be placed in the HOLD position. With the hoist control in the HOLD position, the Chassis ECM will reset to allow normal operation of the hoist control valve.

Check the Input and Output of the Chassis Electronic Control Module

1. Turn the start switch key to the ON position.

2. Lower the dump body.

3. Use the VIMS to view the input and output of the Chassis ECM.

4. Type "787" on the keypad for the VIMS. Press the "GAUGE" key to view the input to the Chassis ECM.

5. Type "788" on the keypad for the VIMS. Press the "GAUGE" key to view the output from the Chassis ECM.

   Note: When the engine is not operating, the Chassis ECM causes the output to the hoist control valve to remain in the HOLD position. To override this condition, hold the hoist control in the RAISE position for 30 seconds.

6. Place the hoist control in the RAISE, HOLD, FLOAT, and LOWER positions.

7. Compare the message center for the VIMS with Table 42.

Table 42

Hoist Control Lever	ECM Input (Chassis)	ECM Output (Chassis)
RAISE	RAISE	RAISE
HOLD	HOLD	HOLD
FLOAT	FLOAT	FLOAT
LOWER	LOWER	FLOAT

Check the Hoist Control Lever

Note: Caterpillar Electronic Technician (ET) or the VIMS can be used to check the hoist control lever.

1. If the ET is available, connect the ET to the truck.

2. Turn the start switch key to the ON position.

3. View the "Hoist Lever Position" on Caterpillar ET.

   Note: If the VIMS is used, view the "Lever Position" for the hoist control lever on the VIMS. Type "787" and press the "GAUGE" key to view the position of the hoist control.

4. Move the hoist control through the four positions RAISE, HOLD, FLOAT, and LOWER.

5. Compare the display on the VIMS or on the ET with the position of the hoist control lever.

Hoist Lever Position Sensor

The hoist lever position sensor receives 24 V from the Chassis ECM. Refer to Step 1 and Step 2 to check the supply voltage to the sensor.

1. Connect a multimeter between Pin A and Pin B of the connector for the hoist lever position sensor.

2. Set the multimeter to read "DC Volts".

Refer to Step 1 through Step 4 to check the output signal of the hoist lever position sensor.

1. Connect a multimeter between Pin B and Pin C of the connector for the hoist lever position sensor.

2. Set the multimeter to read "Duty Cycle".

3. The duty cycle output of the sensor should be approximately 5 percent to 95 percent when the lever is between the full RAISE position and the full LOWER position.

4. The pull up voltage for the hoist lever position sensor should be approximately 7 V.

Note: The four positions for the hoist lever position sensor are constantly calibrated by the Chassis ECM during the operation of the machine.

Check the Proportional Solenoid Valves

Note: Using the ET to test the proportional solenoids on the hoist control valve is easier and faster than adjusting the position sensor for the dump body. The procedure that includes adjusting the position sensor for the dump body should only be done when all other test procedures have been completed.

Using the Caterpillar Electronic Technician

1. Lower the dump body. Stop the engine.

2. Connect the ET to the truck.
   Show/hide table

   Illustration 178	g00670472
   (1) Proportional solenoid valve for the bypass to brake cooling (2) Proportional solenoid valve for the bypass to brake cooling (3) Control valve for the hoist and for the brake cooling (4) Hoist control valve (5) Proportional solenoid valve for rod end oil that is flowing from the center of hoist control valve (4) to the hydraulic tank (6) Proportional solenoid valve for rod end oil that is flowing from the pump to the center of hoist control valve (4) ( 7) Proportional solenoid valve for head end oil that is flowing from the pump to the center of hoist control valve (4) ( 8) Proportional solenoid valve for head end oil that is flowing from the center of hoist control valve (4) to the hydraulic tank

3. Install a multimeter in series with proportional solenoid valve (1).

4. A list of overrides under the menu for diagnostics in the ET contains a test that can be used to override the Chassis ECM. The ET will send a current between 0 A and 2 A to the proportional solenoid valve that is selected.

5. Input 0 percent. The reading on the multimeter should be 0 A.

6. Input 100 percent. The reading on the multimeter should be 2.0 A.

7. Repeat Step 3 through Step 6 for proportional solenoid valve (2), and proportional solenoid valve (4) through proportional solenoid valve (8).

8. Disconnect the multimeter and the ET.

Using the Position Sensor for the Dump Body

1. Lower the dump body. Stop the engine.
   Show/hide table

   Illustration 179	g00670472
   (1) Proportional solenoid valve for the bypass to brake cooling (2) Proportional solenoid valve for the bypass to brake cooling (3) Control valve for the hoist and for the brake cooling (4) Hoist control valve (5) Proportional solenoid valve for rod end oil that is flowing from the center of hoist control valve (4) to the hydraulic tank (6) Proportional solenoid valve for rod end oil that is flowing from the pump to the center of hoist control valve (4) ( 7) Proportional solenoid valve for head end oil that is flowing from the pump to the center of hoist control valve (4) ( 8) Proportional solenoid valve for head end oil that is flowing from the center of hoist control valve (4) to the hydraulic tank

2. Install a multimeter in series with proportional solenoid valve (1).

   Note: When the engine is not operating, the Chassis ECM causes the output to the hoist control valve to remain in the HOLD position. To override this condition, hold the hoist control in the RAISE position for 30 seconds.

3. Move the hoist control lever to the RAISE position. Record the reading on the multimeter.

4. Move the hoist control lever to the HOLD position. Record the reading on the multimeter.

5. Use the message center for the Vital Information Management System (VIMS) to view the position of the position sensor for the dump body. Type "787" on the keypad for the VIMS. Press the "GAUGE" key.

6. Disconnect the linkage for the position sensor for the dump body. Move the linkage to rotate the position sensor for the dump body to approximately 40 degrees. Verify that the position sensor has been rotated to the second stage of the hoist cylinders on the VIMS message center. Type "708" on the keypad for the VIMS. Press the "GAUGE" key.

   Note: The hoist cylinders must be in the second stage or the dump body must be raised more than 40 degrees in order for the hoist control valve to be in the LOWER position.

7. Move the hoist control lever to the LOWER position. Record the reading on the multimeter.

8. Move the hoist control to the FLOAT position. Record the reading on the multimeter.

9. Connect the linkage for the position sensor onto the dump body. Check the reading on the multimeter within 20 seconds. Record the reading on the multimeter. The recorded value is for the SNUB position.

   Note: After the linkage is connected to the dump body, the hoist control valve will be in the SNUB position for 20 seconds. After 20 seconds, the hoist control valve will change to the low-power FLOAT position.

10. Disconnect the multimeter.

11. Repeat Step 1 through Step 10 for proportional solenoid valve (2), and proportional solenoid valve (4) through proportional solenoid valve (8).

12. Compare the recorded values with the values in Table 43.

Note: The proportional solenoid valves receive a maximum of 1.9 A current from the Chassis ECM when the proportional solenoid valves are fully activated.

Table 43

Hoist Control Lever	Solenoid (1)(1)	Solenoid (2)(2)	Solenoid (3)(3)	Solenoid (4)(4)	Solenoid (5)(5)	Solenoid (6)(6)
RAISE	High(7)	High(7)	High(7)	Off(8)	High(7)	Off(8)
HOLD	Off(8)	Off(8)	Off(8)	Off(8)	Off(8)	Off(8)
FLOAT	Low(9)	Low(9)	Off(8)	Off(8)	Off(8)	Low(9)
LOWER	High(7)	High(7)	Off(8)	High(7)	Off(8)	High(7)
SNUB	Low(9)	Low(9)	Off(8)	Low(9)	Off(8)	Low(9)

(1)	Proportional solenoid valve for the bypass to rear brake cooling
(2)	Proportional solenoid valve for the bypass to front brake cooling
(3)	Proportional solenoid valve for rod end oil that is flowing from the center of the hoist control valve to the hydraulic tank
(4)	Proportional solenoid valve for rod end oil that is flowing from the pump to the center of the hoist control valve
(5)	Proportional solenoid valve for head end oil that is flowing from the pump to center of the hoist control valve
(6)	Proportional solenoid valve for head end oil that is flowing from the center of the hoist control valve to the hydraulic tank
(7)	The current for this proportional solenoid valve will be high. The proportional solenoid valve will be fully activated.
(8)	The current for this proportional solenoid valve will be 0 A. The proportional solenoid valve will not be activated.
(9)	The current for this proportioning solenoid will be low. The proportioning solenoid will be modulated.

Rear Axle Lubrication System - Test

Chock the wheels prior to performing any tests.

Table 44

Rear Axle Lubrication System Specifications
Engine Speed	Rear Axle Oil Temp Range	Pump Diverter Valve Sol. Status	Final Drive Diverter Valve Sol. Status	Final Drive Filter Inlet Pressure		Differential Filter Inlet Pressure		Rear Axle Motor Inlet Pressure
				Spec	Actual	Spec	Actual	Spec	Actual
Low Idle	18° to 35° C (64° to 95°F)	ON	ON	0 to 70 kPa (0 to 10 psi)		0 to 210 kPa (0 to 30 psi)		Less than 4100 kPa (595 psi)
High Idle	18° to 35° C (64° to 95°F)	OFF	ON	70 to 240 kPa (10 to 35 psi)		1000 to 1400 kPa (145 to 200 psi)		17500 to 21000 kPa (2540 to 3045 psi)
High Idle	60° to 66° C (140° to 150°F)	OFF	OFF	550 to 1050 kPa (80 to 152 psi)		550 to 900 kPa (80 to 130 psi)		17500 to 19500 kPa (2540 to 2830 psi)
High Idle	60° to 66° C (140° to 150°F)	OFF	ON	0 to 210 kPa (0 to 30 psi)		550 to 900 kPa (80 to 130 psi)		13800 to 17600 kPa (2000 to 2550 psi)

1. Chock the wheels.
   Show/hide table

   Illustration 180	g03354724
   (1) Pressure tap at the pump outlet (2) Solenoid valve

   Show/hide table

   Illustration 181	g03354532
   View of the rear axle (3) Pressure tap for the bevel gear group filter (4) Pressure tap for the final drive filter (5) Solenoid valve

2. Connect tooling (A) or tooling (B) to pressure tap (1), pressure tap (3), and pressure tap (4).

   Note: Refer to Table 5 for tooling (A) or Table 6 for tooling (B).

   Show/hide table

   NOTICE
   The machine should be driven around to warm the oil prior to performing the test.

3. Start the engine. Run the engine at low idle.

   Note: The rear axle oil temperature should be approximately 25° C (77° F).

4. Check the pressures on tooling (A) or tooling (B). Refer to Table 44.

   Pressure at pressure tap (1) should be less than 4100 kPa (595 psi).

   Pressure at pressure tap (3) should be 0 to 210 kPa (0 to 30 psi).

   Pressure at pressure tap (4) should be 0 to 70 kPa (0 to 10 psi).

5. Disconnect the harness assembly from solenoid valve (2) and increase the engine speed to high idle.

   Note: The rear axle oil temperature should be approximately 25° C (77° F).

6. Check the pressures on tooling (A) or tooling (B). Refer to Table 44.

   Pressure at pressure tap (1) should be 17500 to 21000 kPa (2540 to 3045 psi).

   Pressure at pressure tap (3) should be 1000 to 1400 kPa (145 to 200 psi).

   Pressure at pressure tap (4) should be 70 to 240 kPa (10 to 35 psi).

7. Disconnect the harness assembly from solenoid valve (2) and disconnect the harness assembly from solenoid valve (5). Increase the engine speed to high idle.

   Note: The rear axle oil temperature should be 60° to 66° C (140° to 150° F).

8. Check the pressures on tooling (A) or tooling (B). Refer to Table 44.

   Pressure at pressure tap (1) should be 17500 to 19500 kPa (2540 to 2830 psi).

   Pressure at pressure tap (3) should be 550 to 900 kPa (80 to 130 psi).

   Pressure at pressure tap (4) should be 550 to 1050 kPa (80 to 152 psi).

9. Reconnect the harness assembly to solenoid valve (5). Disconnect the harness assembly from solenoid valve (2). Increase the engine speed to high idle.

   Note: The rear axle oil temperature should be 60° to 66° C (140° to 150° F).

10. Check the pressures on tooling (A) or tooling (B). Refer to Table 44.

    Pressure at pressure tap (1) should be 13800 to 17600 kPa (2000 to 2550 psi).

    Pressure at pressure tap (3) should be 550 to 900 kPa (80 to 130 psi).

    Pressure at pressure tap (4) should be 0 to 210 kPa (0 to 30 psi).

11. Reconnect all solenoid valves. Turn off the machine. Remove all test equipment.

Charge the Suspension Cylinders

Refer to Special Instruction, SEHS9411, "Servicing the Suspension Cylinders for Off-Highway Trucks" for the correct instructions.

Show/hide table

NOTICE
Care must be taken to maintain corner weights.

Show/hide table

Illustration 182	g02079473
Typical view of the left front suspension cylinder

1. Measure the visible chrome on the four suspension cylinders to verify the charge.

2. Record the suspension cylinder measurements in the table provided.
   Show/hide table

   Table 45

   	Exposed Chrome on the Collapsed Suspension Cylinders		Ride Height		Extended Charge Pressure
   	Target (for reference only)	Actual	Target	Actual	Target (for reference only)	Actual
   Left front suspension cylinder	20 mm (0.79 inch)		254 ± 13 mm (10 ± 0.5 inch)		2100 kPa (305 psi)
   Right front suspension cylinder
   Left rear suspension cylinder	78.5 mm (3.0 inch)		203 ± 13 mm (8.0 ± 0.5 inch)		1250 kPa (181 psi)
   Right rear suspension cylinder

   Note: Oil height should be 25.4 mm (1.0 inch).

Truck Payload - Calibrate

Testing and Adjusting, KENR9023, "Payload System - Calibrate" for instructions on calibrating the payload.

The following information describes the calibration for the truck payload.

Note: The TPMS will not operate until a successful payload calibration has been completed.

Note: For security, this service program code will only function while Cat ET is connected or the service mode in the Advisor is enabled.

1. The following conditions must be met to calibrate the payload system:

   1. Ensure that the truck body is empty. Carryback weight of the material that is stuck in the truck body can affect the payload measurements.

   2. Operate the empty truck to a minimum ground speed of 4 MPH on hard level ground.

   3. Move the shift control lever to the neutral position and allow the truck to coast to a stop. Do NOT use the service brakes or the retarder.

   4. After the truck stops moving, calibrate the payload system.
   Show/hide table

   Illustration 183	g03231436

2. From the Home Screen in Advisor, select "Service", then "Calibrations", then "Truck Payload" and hit "OK".

   The payload calibration will begin.

3. Follow the instructions on Advisor.

   The Advisor display will show a "Calibration Complete" message if the calibration was successful.

Traction Control System (TCS) - Test

Reference: Operation and Maintenance Manual, SEBU8417, "Traction Control System (TCS) - 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.

Note: This procedure determines if the Traction Control System (TCS) is functioning. This procedure also determines if the left rear brake and the right rear brake activate at the correct time.

1. Find a clear area and a level area that is large enough to turn the machine in a complete circle. Start the machine and move the transmission control to the 1 position.

2. Turn the steering wheel all the way to the left. With the engine at an idle, slowly drive forward in a complete circle.
   Show/hide table

   Illustration 184	g02004873
   The TCS test switch is located in the overhead controls in the operator station.

3. Continue to turn the machine and push the top half of TCS test switch (1). Hold the test switch down. Holding down the test switch will begin the test.

4. The machine will gradually slow down.

5. Release the test switch. The test will end and the machine will increase speed.

6. Turn the steering wheel all the way to the right. With the engine at an idle, slowly drive forward in a complete circle.

7. Continue to turn the machine and push the top half of the TCS test switch. Hold the test switch down. Holding down the test switch will begin the test.

8. The machine will gradually slow down.

9. Release the test switch. The test will end and the machine will increase speed.

10. If the TCS did not function properly, consult your Caterpillar dealer for information and service.

Transmission and Torque Converter Filters

The transmission system uses 340-0403 Oil Filter Element As, which have to be replaced by a service filter element after 50 hours of machine operation. Failure to change to a service element may result in clogging of the filter.

Replace the element assemblies with a new 340-0403 Oil Filter Element As.

Note: The 340-0403 Oil Filter Element As is for power train use only and not approved for hydraulic applications.

Illustration 185	g03355116

Obtain an S·O·S sample from sampling valve (1) prior to changing the oil filter element assemblies. Refer to Operation and Maintenance Manual, SEBU8417, "Torque Converter and Transmission Oil Sample - Obtain" for additional information about oil samples.

Contamination is one of the major causes of transmission control system failure. Some power train oil systems were cleaned with fine cleanout filters, which frequently caused oil to bypass the filter. The use of cleanout filters in power train oil systems is no longer recommended. A new line of advanced efficiencyCaterpillartransmission filters have been introduced for use in power train application.

Note: Replace all clean-out filters as specified by assembly procedure.

Engine Performance Footprint

Perform the following steps to create a baseline/footprint of the engine performance. This information will help to establish a baseline of information to help troubleshoot any future problems that might occur.

Create Performance Groups

1. Connect a laptop computer with Cat ^® ET to the machine.

2. Open Cat ^® ET.
   Show/hide table

   Illustration 186	g03349724

3. From the toolbar, select "Information" and "Status".
   Show/hide table

   Illustration 187	g03349729

4. Scroll to the bottom of screen and double-click on "TEMPORARY GROUP".
   Show/hide table

   Illustration 188	g03349735

5. Create Performance Group 1. One at a time, select each of the following parameters from the column on the left. Click on the right pointing arrow to add each parameter to the column on the right.

   Performance Group 1

   • Percent Fuel Command/Position

   • Fuel Actuator Position Command

   • Desired Fuel Rail Pressure

   • Fuel Rail Pressure

   • Engine Speed

   • Desired Engine Speed

   • Engine Load Factor

   • Throttle Position

   • Delivered Fuel Volume

   • Intake Manifold Pressure

   • Intake Manifold Pressure #2

   Note: The following two performance groups should also get created:

   Performance Group 2

   • Unfiltered Oil Pressure (Absolute)

   • Engine Oil Pressure (Absolute)

   • Right Exhaust Temperature

   • Left Exhaust Temperature

   • Unfiltered Fuel Pressure (absolute)

   • Fuel Pressure (Absolute)

   • Atmospheric Pressure

   • Engine Coolant Pump Outlet Temperature

   • Engine Coolant Temperature

   • Intake Manifold Air Temperature

   • Intake Manifold Air Temperature #2

   Performance Group 3

   • Air Filter #1 Restriction

   • Air Filter #2 Restriction

   • Air Filter #3 Restriction

   • Air Filter #4 Restriction

   • Fuel Rail Temperature

   • Fuel Temperature

   • Engine Oil Temperature

   • Fuel Transfer Pump Intake Pressure

   • Torque Limit Fuel Volume

   • Smoke Limit Fuel Volume

   • Crankcase Pressure

6. Click "OK".
   Show/hide table

   Illustration 189	g03349737

7. Click "Change"

8. Click "Save As".
   Show/hide table

   Illustration 190	g03349741

9. Type the new name for the group in the "Save As" window.

   The following three groups should be created:

   • Performance Group 1

   • Performance Group 2

   • Performance Group 3

10. Click "OK" to close the "Save As" window. Click "OK" to close the "Maintain Groups" window.

11. Repeat the above steps until the following three performance groups are created:

    • Performance Group 1

    • Performance Group 2

    • Performance Group 3

    Refer to Step 5 for a list of the parameters in each performance group.

Save the Performance Group Screen

Show/hide table

Illustration 191	g03349742

1. After the correct conditions are met, click "Hold" on the bottom of the screen.

   Note: Clicking "Hold" will stop the values from changing.

   Show/hide table

   Illustration 192	g03349747

2. From the toolbar, click "File" and "Print To File".

   Note: A wait of approximately 15 seconds may be required to process information.

   Show/hide table

   Illustration 193	g03349756

3. In the "Save As" window, select the location and file name and click "Save".

4. Repeat Step 1 through Step 3 for each performance group under low idle, high idle, and load stall test conditions.
   Show/hide table

   Illustration 194	g03349760

5. To view a saved file, from the toolbar, select "File", "Open", and "Report File".
   Show/hide table

   Illustration 195	g03349766

6. Select the file to open, and click "Open".

Emissions Compliance Report (Tier 4 Equipped Machines)

Show/hide table

Illustration 196	g06372137

1. From the toolbar, click "Information" and "Product Status Report".
   Show/hide table

   Illustration 197	g03394193

2. Run the Product Status Report.

   Note: The Product Status Report will show the injector codes for Table 21.

Pre-delivery Worksheet

Note: All product improvement programs (PIP) for safety must be completed.

Table 46

	Visual Inspection	Service Points and Fluid Levels	Operation	After Operation
Engine (1) (2)	_ Paint _ Outside Damage _ Leaks _ Torque marking of all aftertreatment joints	_ Oil _ Coolant _ Fuel _ Batteries OVC > (12.45) _ VDC1 _ VDC2 _ Air Filters _ Drain Water from Fuel Tank _ Drain Water Separator _ Open Coolant conditioner Valves _ Grease Fittings _ Diesel Exhaust Fluid	_ Priming Pump _ Governor Control _ Air Compressor _ Smoke Color _ Unusual Noise	_ Air Cleaner Indicator _ V-Belt Tension _ Leaks - Oil, Air, Fuel, Coolant _ Friction on Hoses _ Friction on Wires _ Loose Wire Connections _ Loose Fasteners or Lost Fasteners _ Diesel Exhaust Fluid
Power Train	_ Paint _ Outside Damage _ Tires - Cuts, gouges	_ Transmission _ Differential _ Final Drives _ Tire Pressure _ Grease Fittings _ Front and Rear Axle Bolt Torques _ Front and Rear Universal Torques _ Wheel to Rim Torques	_ Transmission - Each Gear _ Neutral Start _ Transmission Lever Lock _ Back - Up Alarm _ Neutralizer Valve _ Unusual Noise	_ Leaks - Oil _ Loose Fasteners or lost Fasteners _ Tires - Cuts, Gouges
Steering and Brakes	_ Paint _ Outside Damage	_ Brake Fluid _ Drain Water from Air Tank _ Grease Fittings	_ Steering _ Retarder _ Service Brakes _ Parking Brakes _ Air Dryer _ Unusual Noise	_ Leaks - Oil, Air _ Loose Fasteners or Lost Fasteners
Chassis	_ Sheet Metal _ Paint _ Damage	_ Grease Fittings	_ Enclosure Doors - Locks and Latches	_ Loose Fasteners or Lost Fasteners _ Welds
Hydraulic	_ Cylinder Rods	_ Hydraulic Tank _ Grease Fittings	_ Controls _ Too much Drift _ Unusual Noise	_ Leaks - Oil _ Friction or Lost Fasteners
Truck Body	_ Paint _ Damage _ Liners	_ Grease Fittings _ Body Pads _ Retention Cable	_ Body Positions	_ Welds _ Loose Fasteners or Lost Fasteners _ Damage
Cab	_ Sheet Metal _ Paint _ Glass	_ Front Window Washer _ Air Filters _ Grease Fittings _ Torque on ROPS Support	_ Disconnect Switch _ VIMS _ Hoist Control _ Horn _Seat Belts _ Seat Adjustments _ All Switches and Controls _ Doors and Windows _ Locks and Latches _ Mirrors Adjustment _ Front Window Wipers _ Front Window Washers _ Heater _ Air Conditioner/Pressurizer Lights - Outside and Cab _ Gauges _ Unusual Noise _ Steering Column Adjustment	_ Operation Guide _ Maintenance Guide _ Parts Book _ Seat Cover _ Steps and Grab Irons _ Loose Fasteners or Lost Fasteners _ Loose Wire Connections _ Leaks - Water
Misc. and Attachments	_ Special Assembly Parts _ S/N Plates _ Correct Attachments _ Hand Tools _ Paint	_ Attachment Fluid Levels _ Charge on Fire Suppression System _ Grease Fittings _ Automatic Lubrication System	_ Attachments _ Engine Shutdown Switch _ Fire Suppression Test Switch	_ Warning Plates _ Decals _ Leaks _ Loose Fasteners or Lost Fasteners

(1)	If the machine was in storage, the engine needs pressure lubrication. Pressure lubrication must occur before the engine is started.
(2)	For cold-weather operation, refer to Special Publication, SEBU5898.

Mandatory Reporting for T4 Machines

In the cases where the aftertreatment (CEM and PETU) are not applied to the engine in the engine manufacturing assembly facility, the dealer/distributor who completes the assembly must meet the respective regulatory requirements (EPA- 40 C.F.R. § 1068.260) which are also included in the AFTERTREATMENT ASSEMBLY AGREEMENT established between the dealer/distributor and Caterpillar. The dealer/distributor obligations include adherence to the provided assembly and testing instructions, and the return (to Caterpillar) of the part and serial number relationship of the engine and applied aftertreatment (both CEM and PETU and SOFTWARE).

Completion of the activities outlined below, satisfies compliance with the required dealer/distributor obligations

1. Ensure adherence to the provided assembly and testing instructions for the engine and aftertreatment system.

2. Verify the aftertreatment system is functioning properly by completing the aftertreatment system functional test.

3. Confirm the system has no active faults.

4. Generate a product status report. Ensure all available ECMs are included.

5. Send a copy of the product status report to the following email address:

   Emissions_Compliance@cat.com