Instructions for Rerouting the Expansion Tank Coolant Lines on Certain 795F AC Off-Highway Trucks {1354, 1380}
- Off Highway Truck
- 795F (S/N: SNT1-UP)
- 795FAC (S/N: ERM1-UP)
Introduction
Reference: Operation and Maintenance Manual, SEBU8349, "795F XQ and 795F AC Off-Highway Truck"
The following procedure includes the required parts and instructions for rerouting the expansion tank coolant lines on certain 795F AC Off-Highway Trucks.
Safety
Before you attempt the procedures documented in this Special Instruction, make sure that you have read and understand the information in this document.
Before starting any work on the machine, ensure that the machine has properly been locked out and tagged out.
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| NOTICE |
|---|
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "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. |
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| NOTICE |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
Required Parts
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| Required Parts | ||
| Qty | Part Number | Description |
| 1 | 163-7451 | Bracket |
| 4 | 294-9072 | O-Ring Seal |
| 1 | 437-7416 | Hose As |
| 1 | 437-7417 | Hose As |
| 1 | 468-7412 | Expansion Tank As |
| 1 | 468-7416 | Baffle |
| 1 | 6G-3027 | Spacer |
| 1 | 6V-1889 | Clip |
| 2 | 6V-5063 | O-Ring Seal |
| 5 | 8T-4121 | Hard Washer |
| 1 | 8T-4172 | Bolt |
| 2 | 6V-9007 | Elbow |
| 1 | 6V-9839 | Swivel Tee |
| 1 | 8S-0948 | Clip |
| 1 | 1P-3705 | Rectangular Seal |
| 2 | 9S-4191 | Plug |
| 2 | 6V-3250 | O-Ring Seal |
| 1 | 6V-8398 | O-Ring Seal |
| 1 | 250-2343 | O-Ring Seal |
| 2 | 8T-4136 | Bolt |
| 2 | 8T-4133 | Nut |
Removal Procedure
- Remove eight bolts (A), eight hard washers (B), and grill (C). Retain grill (C), bolts (A) and hard washers (B).
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Illustration 2 g06004923 View of front of the machine
(D) Harness assembly - Disconnect harness assembly (D) from behind the grill and remove and retain harness assembly (D).
Note: Standard stairway configuration shown, reverse stairway configuration similar.
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Illustration 3 g06005017 View of front of the machine
(E) Bolt
(F) Hard washer
(G) Grill assembly - Attach a suitable lifting device to grill assembly (G). The approximate weight of grill assembly (G) is
54 kg (120 lb) . Remove 14 bolts (E) and 14 hard washers (F) that are securing grill assembly (G). Retain bolts (E), hard washers (F) and grill assembly (G).Note: There is approximately
50 mm (2.00 inch) clearance between the face of grill assembly and stairway, allowing grill assembly to be removed without removing the stairway.Show/hide table
Illustration 4 g06005055 View of hood group
(H) Handrail assembly
(J) Hood assembly - Attach a suitable lifting device to handrail assembly (H). Remove and retain handrail assembly (H) and mounting hardware.
Note: The approximate weight of handrail assembly (H) is
35 kg (77 lb) . - Open and secure hood assemblies (J) in the open position.
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Illustration 5 g06005693 View of the front left-hand side of the engine
(K) Bracket assembly
(L) Half clip
(M) Nut
(N) Bolt
(P) Bolt
(R) Hard washer
(S) Bracket assembly
(T) Half clip
(U) Bolt
(V) Bolt
(W) Hard washer
(X) Bracket assembly
(Y) Half clip
(Z) Bolt
(AB) Bolt
(AC) Hard washer - Remove and retain bracket assembly (K), two half clips (L), two nuts (M), two bolts (N), two bolts (P) and six hard washers (R).
- Remove and retain bracket assembly (S), two half clips (T), two bolts (U), four bolts (V) and six hard washers (W).
- Remove and retain bracket assembly (X), two half clips (Y), two bolts (Z), four bolts (AB) and six hard washers (AC).
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Illustration 6 g06005710 View of the front left-hand side of the engine
(AD) T-bolt clamp
(AE) T-bolt clamp
(AF) Tube assembly - Remove and retain two T-bolt clamps (AE), four T-bolt clamps (AD) and tube assembly (AF).
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Illustration 7 g06006955 View of the front right-hand side of the engine
(AG) Bracket assembly
(AH) Bolt
(AJ) Hard washer
(AK) Bolt
(AL) Hard washer
(AM) Nut
(AN) Bracket assembly
(AP) Half clip
(AR) Bolt
(AS) Bolt
(AT) Hard washer
(AU) Bracket assembly
(AV) Half clip
(AW) Bolt
(AX) Hard washer
(AY) Bolt
(AZ) Hard washer
(BA) Nut
(BB) Hard washer - Remove and retain bracket assembly (AG), two bolts (AH), two hard washers (AJ), two bolts (AK), four hard washers (AL), and two nuts (AM).
- Remove and retain bracket assembly (AN), two half clips (AP), two bolts (AR), four bolts (AS), and six hard washers (AT).
- Remove and retain bracket assembly (AU), two half clips (AV), two bolts (AW), two hard washers (AX), two bolts (AY), four hard washers (AZ), two nuts (BA), and six hard washers (BB).
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Illustration 8 g06007087 View of the right-hand side of the engine
(BC) T-bolt clamp
(BD) T-bolt clamp
(BE) Tube assembly - Remove and retain two T-bolt clamps (BC), four T-bolt clamps (BE), and tube assembly (BD).
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Illustration 9 g06007137 View of the front of the engine - Plug/cover the four hump hoses to prevent objects from entering the turbo compressor inlet.
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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, NENG2500, "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.
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Illustration 10 g06007184 View of the shunt tank on top of the cooling module
(BF) Shunt tank - Drain approximately
232 L (61 US gal) from the radiator to remove coolant from shunt tank (BF).Reference: Operation and Maintenance Manual, SEBU8349
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Illustration 11 g06016435 View behind the cooling module
(BG) Hose assembly
(BH) Hose assembly - Remove and discard hose assembly (BG), retain clipping and mounting hardware. Remove and discard hose assembly (BH), clip, and mounting hardware.
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Illustration 12 g06007579 View behind the cooling module
(BK) Tee adapter assembly
(BL) Adapter assembly - Remove and discard tee adapter assembly (BK), and adapter assembly (BL).
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Illustration 13 g06007606 View below the tank assembly
(BM) Adapter assembly
(BN) Boss
(BP) Tube assembly
(BR) Hose assembly - Disconnect hose assembly (BR) from adapter assembly (BM). Remove and discard adapter assembly (BM) from boss (BN). Disconnect tube assembly (BP) retain mounting hardware. Retain hose assembly (BR).
Note: Plug/cover tube assembly (BP).
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Illustration 14 g06007614 View of the top of the cooling module
(BS) Tank assembly
(BT) Bolt
(BU) Hard washer - Attach a suitable lifting device to tank assembly (BS) the approximate weight of tank assembly (BS) is
154 kg (340 lb) .Note: Before removing tank assembly (BS), remove the plate at the back of the tank assembly and disconnect the wire harness.
- Remove and retain eight bolts (BT), eight hard washers (BU), and remove tank assembly (BS).
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Illustration 15 g06007620 View of the cooling module
(BV) Baffle - Remove baffle (BV), retain mounting hardware ( nine plates, 18 bolts, and 18 hard washers).
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Illustration 16 g06009306 View of the thermostat on the front right side of the engine behind the pedestal
(BW) Hose assembly
(16) Plug
(17) O-ring seal - Remove and discard hose assembly (BW) and install two O-ring seals (17) and two plugs (16).
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| Illustration 1 | g06004796 |
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View of front of the machine (A) Bolt (B) Hard washer (C) Grill | |
Rework the Cowling Assembly
- Use the following Steps to rework cowling assembly (A).
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Illustration 18 g06008108 View of the cowling assembly
(B) Existing hole
(C) New hole
(AA)81 mm (3.19 inch) Diameter
(BB)1156.37 mm (45.53 inch)
(CC)320.60 mm (12.62 inch) - Use the dimensions in Illustration 18 to increase the diameter of existing hole (B) to
81 mm (3.19 inch) and to make new hole (C).
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| Illustration 17 | g06008008 |
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View of the front of the machine (A) Cowling assembly | |
Rework Procedure
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| Required Parts | |||
| Item | Qty | Part Number | Description |
| 1 | 1 | 163-7451 | Bracket |
| 2 | 4 | 294-9072 | O-Ring Seal |
| 3 | 1 | 437-7416 | Hose As |
| 4 | 1 | 437-7417 | Hose As |
| 5 | 1 | 468-7412 | Expansion Tank As |
| 6 | 1 | 468-7416 | Baffle |
| 7 | 1 | 6G-3027 | Spacer |
| 8 | 1 | 6V-1889 | Clip |
| 9 | 2 | 6V-5063 | O-Ring Seal |
| 10 | 5 | 8T-4121 | Hard Washer |
| 11 | 1 | 8T-4172 | Bolt |
| 12 | 2 | 6V-9007 | Elbow |
| 13 | 1 | 6V-9839 | Swivel Tee |
| 14 | 1 | 8S-0948 | Clip |
| 15 | 1 | 1P-3705 | Rectangular Seal |
| 16 | 2 | 9S-4191 | Plug |
| 17 | 2 | 6V-3250 | O-Ring Seal |
| 18 | 1 | 6V-8398 | O-Ring Seal |
| 19 | 1 | 250-2343 | O-Ring Seal |
| 20 | 2 | 8T-4136 | Bolt |
| 21 | 2 | 8T-4133 | Nut |
- Attach a suitable lifting device to expansion tank assembly (5), the approximate weight of the expansion tank assembly (5) is
155 kg (342 lb) . - Position expansion tank assembly (5) onto the cowling and secure using eight bolts and eight hard washers retained in Step 20 of the removal procedure.
Note: Remove panel on the back of the expansion tank and connect the harness.
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Illustration 20 g06008305 View of the cooling module
(6) Baffle - Install baffle (6) and secure into position using the mounting hardware retained in Step 21 of the removal procedure.
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Illustration 21 g06008522 View below the tank assembly
(C) Tube assembly
(2) O-ring seal
(9) O-ring seal
(12) Elbow
(13) Swivel tee
(15) Rectangular seal - Connect tube assembly (C) using new rectangular seal (15) and hardware retained in Step 18 of the removal procedure.
- Install elbow (12), O-ring seal (9), and O-ring seal (2).
Note: Install elbow (12) 5 degrees from either the inner face or outer face of the cowling assembly.
- Install elbow (12), O-ring seal (9), O-ring seal (2), swivel tee (13), and two O-ring seals (2).
Note: Install elbow (12) and swivel tee (13) 66 degrees from either the inner face or outer face of the cowling assembly.
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Illustration 22 g06009188 View below the tank assembly
(D) Hose assembly
(3) Hose assembly
(4) Hose assembly
(6) Baffle - Connect hose assembly (D) which was disconnected in Step 18 of the removal procedure.
- Install hose assembly (4) and hose assembly (3), and route each hose through baffle (6).
Note: Do not tighten the hose assemblies until each hose is routed.
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Illustration 23 g06008786 View behind the cooling module
(E) Hose assembly
(F) Mounting hardware
(3) Hose assembly
(7) Spacer
(10) Hard washer
(11) Bolt
(14) Clip
(18) O-ring seal - Route hose assembly (3) and connect to hose assembly (E) using new O-ring seal (18). Secure hose assembly (3) using new spacer (7), new clip (14), new hard washer (10), new bolt (11), and the clipping and mounting hardware (F) which was retained in Step 16 of the removal procedure.
Note: Do not tighten the hose assembly until each hose is routed.
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Illustration 24 g06009167 View behind the cooling module
(1) Bracket
(4) Hose assembly
(8) Clip
(10) Hard washer
(19) O-ring seal
(20) Bolt
(21) Nut - Connect hose assembly (4) to the turbo lines group using new O-ring seal (19). Secure hose assembly (4) using bracket (1), clip (8), bolt (20), hard washer (10), nut (21).
- Once the hose assemblies are routed and clipped into position, go back and tighten the hose assemblies.
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| Illustration 19 | g06008246 |
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View of the top of the cooling module (A) Bolt (B) Hard washer (5) Expansion tank assembly | |
Install Components
- Remove the plug/cover from the four hump hoses.
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Illustration 26 g06005710 View of the front left-hand side of the engine
(AD) T-bolt clamp
(AE) T-bolt clamp
(AF) Tube assembly - Install tube assembly (AF), two T-bolt clamps (AE), and four T-bolt clamps (AD).
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Illustration 27 g06005693 View of the front left-hand side of the engine
(K) Bracket assembly
(L) Half clip
(M) Nut
(N) Bolt
(P) Bolt
(R) Hard washer
(S) Bracket assembly
(T) Half clip
(U) Bolt
(V) Bolt
(W) Hard washer
(X) Bracket assembly
(Y) Half clip
(Z) Bolt
(AB) Bolt
(AC) Hard washer - Install bracket assembly (K), two half clips (L), two nuts (M), two bolts (N), two bolts (P) and six hard washers (R).
- Install bracket assembly (S), two half clips (T), two bolts (U), four bolts (V) and six hard washers (W).
- Install bracket assembly (X), two half clips (Y), two bolts (Z), four bolts (AB) and six hard washers (AC).
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Illustration 28 g06007087 View of the right-hand side of the engine
(BC) T-bolt clamp
(BD) T-bolt clamp
(BE) Tube assembly - Install tube assembly (BD), two T-bolt clamps (BC), and four T-bolt clamps (BE).
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Illustration 29 g06006955 View of the front right-hand side of the engine
(AG) Bracket assembly
(AH) Bolt
(AJ) Hard washer
(AK) Bolt
(AL) Hard washer
(AM) Nut
(AN) Bracket assembly
(AP) Half clip
(AR) Bolt
(AS) Bolt
(AT) Hard washer
(AU) Bracket assembly
(AV) Half clip
(AW) Bolt
(AX) Hard washer
(AY) Bolt
(AZ) Hard washer
(BA) Nut
(BB) Hard washer - Install bracket assembly (AG), two bolts (AH), two hard washers (AJ), two bolts (AK), four hard washers (AL), and two nuts (AM).
- Install bracket assembly (AN), two half clips (AP), two bolts (AR), four bolts (AS), and six hard washers (AT).
- Remove and retain bracket assembly (AU), two half clips (AV), two bolts (AW), two hard washers (AX), two bolts (AY), four hard washers (AZ), two nuts (BA), and six hard washers (BB).
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Illustration 30 g06005017 View of front of the machine
(E) Bolt
(F) Hard washer
(G) Grill assembly - Attach a suitable lifting device to grill assembly (G) the approximate weight of grill assembly (G) is
54 kg (120 lb) . Remove 14 bolts (E) and 14 hard washers (F) that are securing grill assembly (G), retain bolts (E), hard washers (F) and grill assembly (G).Show/hide table
Illustration 31 g06004923 View of front of the machine
(D) Harness assembly - Install and connect harness assembly (D).
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Illustration 32 g06004796 View of front of the machine
(A) Bolt
(B) Hard washer
(C) Grill - Install grill (C) secure into position using eight bolts (A), and eight hard washers.
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Illustration 33 g06005055 View of hood group
(H) Handrail assembly
(J) Hood assembly - Attach a suitable lifting device to handrail assembly (H). Install handrail assembly (H) and secure with mounting hardware.
Note: The approximate weight of handrail assembly (H) is
35 kg (77 lb) . - Close and secure hood assemblies (J) in the closed position.
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| Illustration 25 | g06007137 |
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