Field Procedure to Install Dampers onto Certain Off-Highway Trucks Equipped with the Sound Suppression Panel Group{1801, 7076, 7261} Caterpillar

Off-Highway Truck/Tractor:

789D XQ (S/N: SHH1-UP)

793F XQ (S/N: SND1-UP)

795F AC (S/N: ERM1-UP)

795F XQ (S/N: SNT1-UP)

797F XQ (S/N: WSP1-UP)

Introduction

ReferenceOperation and Maintenance Manual, SEBU8242, "789D and 789D XQ Off-Highway Truck", "Use of Wheel Chocks"

ReferenceOperation and Maintenance Manual, SEBU8406, "793F and 793F XQ Off-Highway Truck", "Prepare the Machine for Maintenance"

ReferenceOperation and Maintenance Manual, SEBU8349, "795F and 795F XQ Off-Highway Truck", "Prepare the Machine for Maintenance"

ReferenceOperation and Maintenance Manual, SEBU8417, "797F and 797F XQ Off-Highway Truck", "Prepare the Machine for Maintenance"

This special instruction provides the required parts and the correct procedure to install the 463-2285 Damper onto machines equipped with the sound suppression panel group. The dampers will help control the descent of the access panels near the belly guard. The installation of the dampers will improve the service life of the 383-2240 Struts on the access panels.

This special instruction is adaptable to the following machines: SHH1-319, SND1-131, ERM199,206-208,211-215,218-220, SNT1-101 and WSP1-129.

Important Safety Infromation

Do not perfrom any procedure in this special instruction until you have read this special instruction and you understand this infromation. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perfrom these functions properly.

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

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

Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures.

Required Parts

Prepare the Machine for Maintenance

Prepare the machine for maintenance. For the correct procedure, refer to the infromation listed at the beginning of the document for your machine. For the 789D Off-Highway Truck, perfrom the following procedure.

1. Permit only one operator on the machine. Either keep other personnel away from the machine, or keep other personnel in the sight of the operator.

2. Move the machine to a smooth horizontal location. Move the machine away from any machines that are working and any personnel. The surface must be solid enough to support the weight of the machine and any tooling that is used to support the machine.

3. Move the transmission control to the NEUTRAL position.

4. Move the parking brake switch to the ON position in order to engage the parking brakes. Turn the engine start switch to the OFF position in order to stop the engine.

5. Turn the battery disconnect switch to the OFF position. Remove the key.

6. Place chocks in front of the wheels and behind the wheels. Refer to Operation and Maintenance Manual, SEBU8242, "Use of Wheel Chocks" for more infromation.

7. When the use wheel chocks are not possible, ensure that the machine is unable to roll. Turning the wheels into a suitable bank, or place the wheels in a suitable ditch.

Rework Procedure

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Illustration 1	g03773066
A view of the front of a typical machine looking up from the bottom. (A) Front, right access panel (B) Front, left access panel

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Illustration 2	g03772484

1. Open the access panel (A). Remove the two nuts and washers (C) from strut (D). Remove the strut from the machine. Save the two nuts, the washers, and the strut.

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Illustration 3	g03772485

2. Remove the two bolts (E), and two washers (F) from plate assembly (G). Remove the plate assembly from the machine. Save the bolts and the washers. Discard the plate assembly.

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Illustration 4	g03772837

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Illustration 5	g03772841

3. Remove the two bolts (H) ), and two washers (J) from plate assembly (K). Remove the plate assembly from the machine. Save the bolts and washers. Discard the plate assembly.

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Illustration 6	g03772864

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Illustration 7	g03772871

4. Use the two bolts (H) and the two washers (J) from the previous step to assemble one plate assembly (1) onto the machine. The two holes on the plate assembly should point toward the outside of the machine.

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Illustration 8	g03772936

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Illustration 9	g03772941

5. Use the two bolts (E) and two washers (F) from Step (2) to assemble one plate assembly (2) onto the machine. Position the plate assembly so the two holes point upward when the access panel is in the closed position. The two holes should point toward the outside of the machine when the access panel is in the open position.

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Illustration 10	g03772999

6. Nuts and washer (C), and strut (D) were saved in Step (1). Retrieve the parts. Use the nuts and washers to assemble the strut onto the bottom holes in the two new plate assemblies.

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Illustration 11	g03773006

7. Use two nuts (3), and two washers (4) to assemble one damper (5) onto the top holes in the two new plate assemblies.

8. Close access panel (A) .

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Illustration 12	g03774931

9. Go to the front, left side of the machine. Open access panel (B) .

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Illustration 13	g03773516

10. Remove the two nuts and washers (K) from strut (L). Remove the strut from the machine. Save the two nuts, the washers, and the strut.

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Illustration 14	g03773547

11. Remove the two bolts (M), and two washers (N) from plate assembly (P). Remove the plate assembly from the machine. Save the bolts and the washers. Discard the plate assembly.

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Illustration 15	g03773561

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Illustration 16	g03773599

12. Remove the two bolts (R) ), and two washers (S) from plate assembly (T). Remove the plate assembly from the machine. Save the bolts and washers. Discard the plate assembly.

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Illustration 17	g03773601

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Illustration 18	g03773607

13. Use the two bolts (R) and the two washers (S) from the previous step to assemble one plate assembly (1) onto the machine. The two holes on the plate assembly should point toward the outside of the machine.

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Illustration 19	g03773610

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Illustration 20	g03773616

14. Two bolts (M) and two washers (N) were saved in Step 11. Retrieve the parts. Use the two bolts and washers to assemble one plate assembly (2) onto the machine. Position the plate assembly so the two holes point upward when the access panel is in the closed position. The two holes should point toward the outside of the machine when the access panel is in the open position.

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Illustration 21	g03773618

15. Nuts and washer (K) and strut (L) were saved in Step 10. Retrieve the parts. Use the nuts and washers to assemble the strut onto the lower holes in the two new plate assemblies.

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Illustration 22	g03774084

16. Use two nuts (3), and two washers (4) to assemble one damper (5) onto the top holes in the two new plate assemblies.

17. Close access panel (B). Prepare to return the machine to service.