Procedure to Improve the Torque Converter Wiring Group on Certain 793F Off-Highway Trucks {1408} Caterpillar

Off-Highway Truck/Tractor

793F (S/N: SND1-133; SSP1-1170; SXP1-103; RBT1-186)

Introduction

The following procedure contains all the required parts and information needed to improve the torque converter wiring group on certain 793F Off-Highway Trucks. Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Reference: Disassembly and Assembly, UENR2257

Reference: Operation and Maintenance Manual, SEBU8406

Reference: Torque Specifications, SENR3130

Safety Section

Do not perform any procedure in this special instruction until you have read this special instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. Observe the following procedures.

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 to perform these functions properly.

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

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

Ensure that all personnel are safe when using a tool, procedure, work method, or operating technique not recommended by Caterpillar. Ensure that the product will not be damaged or the product made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Cat dealer for replacement manuals. Proper care is your responsibility.

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

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Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.

Required Parts

Machine Preparation

Note: Cleanliness is an important factor. Before the removal procedure, clean the exterior of the component thoroughly. Cleaning the exterior will help to prevent dirt from entering the internal mechanism.

1. Move the machine to a smooth horizontal location. Move to an area that is free of machines and personnel.

2. Move the transmission control to the P Position.

3. Lower the body to the frame.

4. Stop the engine.

5. Permit only one operator on the machine. Keep all personnel in the sight of the operator.

6. Make sure that all hydraulic pressure is released before any component is adjusted. Refer to Operation and Maintenance Manual, SEBU8406, "793F, 793F CMD, 793F OEM, and 793F XQ Off-Highway Truck", "Prepare the Machine for Maintenance".

Removal Procedure

Illustration 1	g06167194
Location of an Old Transmission Harness Assembly

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Illustration 2	g06167267
View of Coil

1. Disconnect the transmission harness assembly from coil (C). Remove nut (A), washer (B), and coil (C) from the valve assembly group. Discard the components. Use Illustration 2 as reference for Step 1.
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   Illustration 3	g06167294
   View of Temperature Sensor Group

2. Remove bolt assembly (J), cable strap (H), and cable tie mounting (G) from bracket assembly (F). Discard the components.

3. Remove bolt (D), washer (E), and bracket assembly (F) from the torque converter housing. Discard the components.

4. Remove temperature sensor group (P) and O-Ring seal (R) from the torque converter housing. Discard the components.

5. Remove bolt (K), washer (E), cable tie mounting (G), two cable straps (H), clip (L), hard washer (M), and bracket assembly (N) from bracket assembly (EE). Remove bolt (CC), washer (BM), and bracket assembly (EE) from the relief valve group. Retain bolt (CC) and washer (BM) for later installation. Discard the rest components. Use Illustration 3 as reference for Step 2 through Step 5.
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   Illustration 4	g06167710
   View of Harness Cable

6. Disconnect the two connectors from the harness cable. Remove bolt (BH), two clips B (K), and spacer (BL) from the engine arrangement. Discard the components.

7. Remove bolt (Y), washer (E), and spacer (T) from bracket assembly (S). Remove clip (U), clip (W), and grommet (X) from the transmission harness assembly. Remove bolt (DD) and bracket assembly (S) from the engine arrangement. Retain bolt (DD) for later installation. Discard the rest components.

8. Remove two bolt assemblies (J), two clips (U), two clips (W), and two grommets (AB) from the torque converter housing. Discard the components. Use Illustration 4 as reference for Step 6 through Step 8.
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   Illustration 5	g06167816
   View of Speed Sensor and Bypass Switch

9. Remove cable strap (H) and disconnect the speed sensor connector from the transmission harness assembly. Remove speed sensor (AK) from the engine arrangement. Remove cable strap (H) and disconnect the bypass switch connector from the transmission harness assembly. Remove bypass switch (AL) from the screen group. Discard the components.

10. Remove bolt (AC), two washers (E), clip (L), and bracket (F) from the engine arrangement. Discard the components.

11. Remove bolt (K), hard washer (M), and cable tie mounting (G) from the engine arrangement. Discard the components.

12. Remove bolt assembly (J), clip (AE), clip (AF), and grommet (AG) from bracket assembly (AD). Remove bolt (FF), bracket assembly (AD), and clip (AH) from the screen group. Discard the components. Use Illustration 5 as reference for Step 9 through Step 12.
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    Illustration 6	g06167880
    View of Grommets (AR) Bracket Assembly (Optional)

13. Remove two bolt assemblies (J), two clips (U), two clips (W), and two grommets (AM) from the torque converter housing.

14. Remove two bolts (BF), two washers (BG), and optional bracket assembly (AR) from the torque converter housing. Discard the components. Use Illustration 6 as reference for Step 13 and Step 14.
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    Illustration 7	g06167935
    View of Sensor Groups and Bracket Assembly (AP) Liquid Level Sensor Gp (Optional) (GG) Bracket (Optional)

15. Remove two cable straps (H) and disconnect two liquid level sensor group connectors from the transmission harness assembly. Remove two optional liquid level sensor groups (AP) from the torque converter housing. Discard the components.

16. Remove optional bracket (GG) from bracket assembly (AY). Discard optional bracket (GG).

17. Remove cable strap (H) and disconnect the liquid level sensor group connector from the transmission harness assembly. Remove liquid level sensor group (BD) and O-Ring seal (BE) from torque converter housing. Discard the components.

18. Remove bolt (M), washer (E), washer (AU), ladder clip (AW), cable strap (AX) , clip (AE), clip (AF), and grommet (AG) from bracket assembly (AY). Discard the components.

19. Remove bolt (D), two washers (E), clip (L), and nut (AT) from bracket assembly (AY). Discard the components.

20. Remove bolt (M), washer (E), cable tie mounting (G), and hard washer (AU) from bracket assembly (AY). Discard the components.

21. Remove bolt assembly (BC), washer (E), nut (AT), cable tie mounting (G), grommet (BA), and bracket assembly (AZ) from bracket assembly (AY). Discard the components.

22. Remove nut (AT), washer (E), clip (L), spacer (T), and stud (AS) from the bracket assembly (AY). Discard the components.

23. Remove bolt assembly (J), washer (E), and nut (AT) from bracket assembly (AY). Discard the components.

24. Remove bolt (AN), washer (E), spacer (T), and clip (L) from bracket assembly (AY). Remove bracket assembly (AY) from the torque converter housing. Discard the components. Use Illustration 7 as reference for Step 15 through Step 24.

Installation Procedure

Illustration 8	g06168094
Location of a New Transmission Harness Assembly

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Illustration 9	g06168191
View of Bracket Assembly (27) and Transmission Harness Assembly (29) ( 4) 132-5789 Clip (11) 204-2281 Cable Strap (15) 238-5081 O-Ring Seal (16) 288-7158 Stud (17) 304-6771 Boss (19) 344-5675 Nut (23) 430-9455 Liquid Level Sensor Gp (27) 513-8021 Bracket As (29) 523-7505 Transmission Harness As (34) 7G-7053 Grommet (35) 7K-1181 Cable Strap (41) 8T-4121 Hard Washer (43) 8T-4137 Bolt (AP) Liquid Level Sensor Group (Optional)

1. Install bracket assembly (27) to the torque converter housing with two hard washers (41) and two bolts (43). Tighten two bolts (43).

2. Install stud (16), clip (4) to bracket assembly (27) with hard washer (41), and nut (19). Tighten nut (19).

3. Install grommet (34) onto bracket assembly (27). Install transmission harness assembly (29) to bracket assembly (27). Secure transmission harness assembly (29) with two cable straps (11) and cable strap (35).

4. Install O-Ring seal (15) and liquid level sensor group (23) to the torque converter housing with. Connect the connector to transmission harness assembly (29). Secure the connector and liquid level sensor group (23) with two cable straps (11).

5. Install two optional liquid level sensor groups (AP) to the torque converter housing. Secure two optional liquid level sensor groups (AP) with two cable straps (11). Connect the two connectors to transmission harness assembly (29) and secure the transmission harness assembly (29) with two cable straps (11). Use Illustration 9 as reference for Step 1 through Step 5.
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   Illustration 10	g06168258
   View of Bracket Assembly (28) ( 19) 344-5675 Nut (28) 513-8094 Bracket As (41) 8T-4121 Hard Washer (43) 8T-4137 Bolt (47) 8T-4195 Bolt

6. Install bracket assembly (28) with five hard washers (41), three bolts (43), bolt (47), and nut (19). Tighten bolts (43), bolt (47), and nut (19). Use Illustration 10 as reference for Step 6.
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   Illustration 11	g06168309
   View of Grommets (31) ( 29) 523-7505 Transmission Harness As (31) 6V-0826 Grommet (39) 8T-1889 Clip (40) 8T-1890 Clip (41) 8T-4121 Hard Washer (42) 8T-4136 Bolt

7. Assemble two grommets (31), two clips (39), and two clips (40) onto transmission harness assembly (29). Install transmission harness assembly (29) to the torque converter housing with two hard washers (41) and two bolts (42) . Tighten bolts (42). Use Illustration 11 as reference for Step 7.
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   Illustration 12	g06168350
   View of Speed Sensor Group (2) ( 2) 116-6680 Speed Sensor (3) 127-9323 Bracket As (9) 198-4777 Hard Washer (11) 204-2281 Cable Strap (12) 204-8000 Cable Tie Mounting (25) 483-4287 Plate (29) 523-7505 Transmission Harness As (41) 8T-4121 Hard Washer (45) 8T-4186 Bolt (46) 8T-4191 Bolt

8. Install hard washer (9), bracket assembly (3), and cable tie mounting (12) to the engine arrangement with hard washer (41) and bolt (45). Tighten bolt (45).

9. Install speed sensor (2) into engine arrangement. Connect the speed sensor connector to transmission harness assembly (29).

10. Install plate (25) to the bracket assembly (3) with hard washer (41) and bolt (46). Tighten bolt (46).

11. Secure transmission harness cable (29) and speed sensor (2) with three cable straps (11). Use Illustration 12as reference for Step 8 through Step 11.
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    Illustration 13	g06168368
    View of Bypass Switch (21) ( 7) 136-1122 Bushing (11) 204-2281 Cable Strap (20) 353-7957 Grommet (21) 391-7125 Bypass Switch (25) 483-4287 Plate (26) 510-8204 Bracket As (29) 523-7505 Transmission Harness As (37) 8T-1887 Clip (38) 8T-1888 Clip (41) 8T-4121 Hard Washer (42) 8T-4136 Bolt (48) 8T-4223 Hard Washer (49) 7X-2551 Bolt

12. Install bracket assembly (26) to the screen group with two bushing (7), two hard washers (48), and two bolts (49). Tighten two bolts (49).

13. Install grommet (20), clip (37), clip (38), and plate (25) with hard washer (41) and bolt (42). Tighten bolt (42).

14. Install bypass switch (21) into the screen group. Connect the bypass switch connector to transmission harness assembly (29). Secure the bypass switch connector and bypass switch (21) with two cable straps (11). Use Illustration 13 as reference for Step 12 through Step 18.
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    Illustration 14	g06168724
    View of Temperature Sensor Group (6) ( 1) 091-0081 Spacer (6) 134-2252 Temperature Sensor Gp (11) 204-2281 Cable Strap (12) 204-8000 Cable Tie Mounting (13) 214-7568 O-Ring Seal (24) 444-2210 Bracket As (25) 483-4287 Plate (29) 523-7505 Transmission Harness As (41) 8T-4121 Hard Washer (45) 8T-4186 Bolt (BM) Hard Washer (CC) Bolt

15. Install hard washer (BM) and bracket assembly (24) to the relief valve group with bolt (CC). Tighten bolt (CC).

16. Install plate (25), spacer (1), and cable tie mounting (12) with hard washer (41) and bolt (45). Tighten bolt (45).

17. Install temperature sensor group (6) into the torque converter housing. Connect the temperature sensor group connector to transmission harness group (29). Secure temperature sensor group (6) and transmission harness assembly (29) with three cable straps (11). Use Illustration 14 as reference for Step 15 through Step 22.
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    Illustration 15	g06168850
    View of Bracket Assembly (3) ( 3) 127-9323 Bracket As (8) 164-2108 Washer (11) 204-2281 Cable Strap (12) 204-8000 Cable Tie Mounting (14) 218-2373 Nut (18) 311-0456 Coil (29) 523-7505 Transmission Harness As (41) 8T-4121 Hard Washer (42) 8T-4136 Bolt (43) 8T-4137 Bolt

18. Install bracket assembly (3) to torque converter housing with hard washer (41) and bolt (43). Tighten bolt (43).

19. Install cable tie mounting (12) to bracket assembly (3) with hard washer (41) and bolt (42). Tighten bolt (42).

20. Install coil (18) onto the valve assembly group with washer (8) and nut (14). Tighten nut (14) to a torque of 13 ± 0.5 N·m (115 ± 4.4 lb in).

21. Connect transmission harness assembly (29) to coil (18). Secure cable transmission harness assembly (29) with cable strap (11). Use Illustration 15 as reference for Step 18 through Step 21.
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    Illustration 16	g06168784
    View of Grommets (31) ( 29) 523-7505 Transmission Harness As (30) 6V-0826 Grommet (39) 8T-1889 Clip (40) 8T-1890 Clip (41) 8T-4121 Hard Washer (42) 8T-4136 Bolt

22. Assembly two grommets (30), two clips (39), and two clips (40) onto transmission harness assembly (29). Install the transmission harness assembly (29) to torque converter housing with two hard washers (41), and two bolts (42). Tighten two bolts (42). Use Illustration 16 as reference for Step 22.
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    Illustration 17	g06168833
    View of Bracket Assembly (22) and Plates (25) ( 5) 133-6934 Spacer (10) 1V-6645 Spacer (11) 204-2281 Cable Strap (22) 421-1172 Bracket As (25) 483-4287 Plate (29) 523-7505 Transmission Harness As (32) 6V-5839 Washer (33) 6V-5843 Bolt (36) 7V-6571 Grommet (39) 8T-1889 Clip (40) 8T-1890 Clip (41) 8T-4121 Hard Washer (44) 8T-4185 Bolt

23. Install bracket assembly (22) to the torque converter housing with bolt (DD). Tighten bolt (DD).

24. Install spacer (10), two plates (25) to the torque converter housing with hard washer (32) and bolt (33). Tighten bolt (33). Secure the transmission harness assembly connectors to two plates (25) with two cable straps (11).

25. Assemble grommet (36), clip (39), and clip (40) onto transmission harness assembly (29) . Install transmission harness assembly (29) to bracket assembly (22) with spacer (5), hard washer (41), and bolt (44). Tighten bolt (44). Use Illustration 17 as reference for Step 23 through Step 25.