797F Off-Highway Truck Field Assembly Caterpillar

Parts and Specification Information

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Note: Verify that all parts are shipped and undamaged for preparation of assembly. Missing or damaged parts can be ordered prior to assembly to avoid delays during assembly.

Installation Procedure

Start By:

1. Install the engine

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Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

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Do not attempt to assemble this machine until you read and you understand the assembly instructions. Improper assembly procedures could result in injury or death.

Note: Remove all protective shipping covers, flanges, plugs, caps, clamps, cable straps, and material.

Note: Clean mounting and contact surfaces for major component installation free of wax, dirt, debris, paint, and grease.

Note: If necessary, chase unprotected threaded holes with an appropriately sized tap to remove paint, rust, or other debris.

Note: Unless otherwise specified, all torque requirements are Standard Torque values. Refer to the "General Information" section in this document for the correct torque values.

Note: Before tightening the cable straps (mounting hardware), remove the slack from the harness assembly(s) and allow adequate strain relief.

Air lines Install

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Illustration 21	g06203674
(20) 284-2923 Tube As (28) 161-9926 Pressure Sensor Gp (31) 9X-0262 Adapter (32) 3J-7354 O-Ring Seal (T1) 5P-3975 Rubber Lubricant

1. Lubricate two O-ring seals (32) with Tooling (T1). Install two O-ring seals (32) onto one adapter (31). Install one adapter (31) and one pressure sensor group (28) onto tube assembly (20). Tighten one pressure sensor group (28) to a torque of 10 ± 2 N·m (89 ± 18 lb in)
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   Illustration 22	g06190317
   (20) 284-2923 Tube As (24) 479-2171 Bolt As (25) 376-0665 Plate (26) 204-8000 Cable Tie Mounting (27) 204-2281 Cable Strap (29) 277-7045 Sensor Harness As

2. Install one harness assembly (28), five mounts (26), five cable straps (27), one plate (25), and seven bolt assemblies (24) onto tube assembly (20).
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   Illustration 23	g06190339
   (20) 284-2923 Tube As (28) 161-9926 Pressure Sensor Gp (27) 204-2281 Cable Strap (35) 8T-4137 Bolt (34) 8T-4121 Hard Washer (36) 483-4287 Clip

3. Install one cable strap (27) onto pressure sensor group (28). Install one clip (36), one hard washer (34) and one bolt (35) onto tube assembly (20).
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   Illustration 24	g06190347
   (28) 161-9926 Pressure Sensor Gp (29) 277-7045 Sensor Harness As

4. Connect harness assembly (29) to pressure sensor group (28).

5. Repeat Step 1 though Step 4 for tube assembly (21).
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   Illustration 25	g06190358
   (22) 284-2924 Tube As (28) 161-9926 Pressure Sensor Gp (31) 9X-0262 Adapter (32) 3J-7354 O-Ring Seal (T1) 5P-3975 Rubber Lubricant

6. Lubricate two O-ring seals (32) with Tooling (T1). Install two O-ring seals (32) onto one adapter (31). Install one adapter (31) and one pressure sensor group (28) onto tube assembly (22). Tighten one pressure sensor group (28) to a torque of 10 ± 2 N·m (89 ± 18 lb in).
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   Illustration 26	g06190367
   (22) 284-2924 Tube As (24) 479-2171 Bolt As (25) 376-0665 Plate (26) 204-8000 Cable Tie Mounting (27) 204-2281 Cable Strap (30) 305-9237 Sensor Harness As

7. Install one harness assembly (30), four mounts (26), four cable straps (27), one plate (25) and seven bolt assemblies (24) onto tube assembly (22).
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   Illustration 27	g06190378
   (22) 284-2924 Tube As (28) 161-9926 Pressure Sensor Gp (27) 204-2281 Cable Strap (35) 8T-4137 Bolt (34) 8T-4121 Hard Washer (36) 483-4287 Clip

8. Install one cable strap (27) onto pressure sensor group (28). Install one clip (36), one hard washer (34), and one bolt (35) onto tube assembly (22).
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   Illustration 28	g06203689
   (28) 161-9926 Pressure Sensor Gp (30) 305-9237 Sensor Harness As

9. Connect harness assembly (30) to pressure sensor group (28).

10. Repeat Step 6 though Step 9 for tube assembly (23).
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    Illustration 29	g06203741
    (20) 284-2923 Tube As (22) 284-2924 Tube As (50) 5T-6459 Elbow (51) 251-0039 Clamp

11. Install two elbows (50) and eight T-bolt clamp assemblies (51) onto tube assembly (20) and tube assembly (22).

    Note: Do not tighten the T-bolt clamp assemblies to a final torque at this time.

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    Illustration 30	g06225170
    (20) 284-2923 Tube As (22) 284-2924 Tube As (37) 284-2986 Hose (38) 289-4013 T Bolt Clamp

12. Install two hoses (37) and eight T bolt clamps (38) onto tube assembly (20) and tube assembly (22).

    Note: Do not tighten the T-bolt clamp assemblies to a final torque at this time.

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    Illustration 31	g06204103

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    Illustration 32	g06204109
    (22) 284-2924 Tube As (38) 289-4013 T Bolt Clamp (51) 251-0039 T Bolt Clamp

13. Attach a suitable lifting device to install tube assembly (22). The weight of tube assembly (22) is approximately 30 kg (65 lb). Install tube assembly (22). Tighten four T bolt clamps (38) and four T bolt clamps (51) to a torque of 10 ± 2 N·m (89 ± 18 lb in).

    Note: The T-bolt clamps should be orientated 180° apart.

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    Illustration 33	g06204125

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    Illustration 34	g06204141
    (20) 284-2923 Tube As (38) 289-4013 T Bolt Clamp (51) 251-0039 T Bolt Clamp

14. Attach a suitable lifting device to install tube assembly (20). The weight of tube assembly (20) is approximately 30 kg (65 lb). Install tube assembly (20). Tighten four T bolt clamps (38) and four T bolt clamps (51) to a torque of 10 ± 2 N·m (89 ± 18 lb in).

    Note: The T-bolt clamps should be orientated 180° apart.

15. Repeat Step 11 though Step 14 for tube assembly (23).
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    Illustration 35	g06237833
    (39) 8T-4244 Nut (40) 8T-4223 Hard Washer (41) 2H-5832 Spacer (42) 233-6699 Rod As (43) 8T-4194 Bolt (44) 9X-6605 U-Bolt (45) 201-1378 Spacer (46) 8X-3635 Strip (47) 6V-7744 Locknut (48) 7X-7729 Washer (49) 292-5833 Bracket As

16. Install bracket assembly (49), strip (46), two U-bolts (44), four washers (48), four locknuts (47), rod assembly (42), spacer (41), washer (40), and bolt (43). Install spacer (45), two washers (40), bolt (43), and nut (39).
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    Illustration 36	g06237834
    Right-Hand Side (29) 277-7045 Sensor Harness As (30) 305-9237 Sensor Harness As

17. Connect harness assembly (29) and harness assembly (30) to the chassis harness.

18. Repeat Step 16 and Step 17 for the opposite side of the truck.

Expansion Tank Install

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Illustration 37	g06237835
(85) 7X-7729 Washer (84) 375-4079 Expansion Tank As (86) 8T-4186 Bolt (T5) 477-3139 Eyebolt As

1. Use Tooling (T5) and a suitable lifting device to install expansion tank (84) onto the radiator module. The weight of expansion tank (84) is approximately 170 kg (375 lb). Install eight hard washers (85) and eight bolts (86).
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   Illustration 38	g06238054
   (A) 8T-4191 Bolt (B) 8T-4121 Hard Washer (C) 443-0300 Cover

2. Remove four bolts (A), four hard washers (B), and one cover (C). Retain the hardware.
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   Illustration 39	g06238071
   (27) 204-2281 Cable Strap (D) 465-0619 Front Harness As (E) 111-4012 Grommet (G) 443-4613 Service Center Wiring Gp (J) 430-9449 Coolant Level Sensor Gp

3. Route harness assembly (D) through grommet (E). Connect harness connector (F) to service center wiring group (G). Connect harness connector (H) to coolant level sensor (J). Install one cable strap (17).
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   Illustration 40	g06238073
   (A) 8T-4191 Bolt (B) 8T-4121 Hard Washer (C) 443-0300 Cover

4. Install one cover (C), four hard washers (B), and four bolts (A).
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   Illustration 41	g06238082
   (K) 451-7287 Hose As or 452-6617 Hose As (27A) 1P-3709 Rectangular Seal (40) 8T-4910 Bolt (90) 8T-4223 Hard Washer (L) 367-2360 Tube As

5. Connect hose assembly (K). Install D-ring seal (27A) onto tube assembly (L). Install four hard washers (90) and four bolts (40).

Handrails Install

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Illustration 42	g06237832
(55) 445-8068 Tube As (55A) 361-0032 Tube As

1. Install handrail assembly (55) and handrail assembly (55A).
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   Illustration 43	g06238089
   (24) 479-2171 Bolt As (56) 281-6798 Handrail As

2. Use a suitable lifting device to position handrail assembly (56). The weight of handrail assembly (56) is approximately 28 kg (61 lb). Install twelve bolt assemblies (24).
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   Illustration 44	g06238090
   (24) 479-2171 Bolt As (57) 288-2534 Handrail As

3. Use a suitable lifting device to position handrail assembly (57). The weight of handrail assembly (57) is approximately 15 kg (33 lb). Install eight bolts (24).
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   Illustration 45	g06238095
   (6) 135-8578 Bolt (39) 8T-4244 Nut (40) 8T-4223 Hard Washer (65) 5P-7468 Clip (66) 8T-7087 Grommet (67) 5P-7469 Clip (68) 115-3580 Plate

4. Install two clips (65), two grommets (66), two clips (67), and one plate (68). Install two hard washers (40), two bolts (6), and two nuts (39).
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   Illustration 46	g06238106
   (19) 479-2171 Bolt As (33) 479-2172 Bolt As (52) 248-0102 U-Bolt (53) 8T-4224 Hard Washer (54) 5C-7261 Nut (57) 445-8067 Handrail As (62) 290-7167 Handrail As (94) 8T-4956 Bolt

5. Position handrail assembly (57). Install eight washers (40), and eight bolts (94). Install two U-bolts (52), four washers (53), and four nuts (54).

6. Position handrail assembly (62). Install eight bolt assemblies (19). Install two U-bolts (52), four washers (53), and four nuts (54).

7. install two bolt assemblies (33).
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   Illustration 47	g06238109
   (59) 146-3287 Special Bolt (60) 9X-2133 Hose (61) 449-5464 Gate As

8. Position gate assembly (61). Install two hoses (60) and two special bolts (59).
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   Illustration 48	g06238121
   (69) 8T-4184 Bolt (13) 5P-1076 Hard Washer (39) 8T-4244 Nut (40) 8T-4223 Hard Washer (65) 5P-7468 Clip (66) 8T-7087 Grommet (67) 5P-7469 Clip

9. Install four clips (65), four grommets (66), four clips (67). Install two washers (13), two hard washers (40), two bolts (69), and two nuts (39).
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   Illustration 49	g06238140
   (24) 479-2171 Bolt As (64) 279-9496 Handrail As

10. Use a suitable lifting device to install handrail assembly (64). The weight of handrail assembly (64) is approximately 32 kg (70 lb). Install ten bolt assemblies (24).

Aftercooler Lines Install

Note: Loosely assemble the parts. All parts should be loose from the turbocharger outlets to the after cooler. Align the tube assemblies and hoses, and install all hardware. After the overall alignment is ensured, all hardware can be tightened. The parts must be correctly installed from the turbocharges to the ATTAC. Then, apply the final torque values to the fasteners.

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Illustration 50	g06238149
(M) 342-1323 T- Bolt Clamp

1. Loosen two T- bolt clamps (M). Remove and discard two protective shipping covers (N).
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   Illustration 51	g06238388
   (7) 8T-4194 Bolt (8) 198-4778 Hard Washer (9) 329-3356 Nut (10) 329-3555 Half Clip (11) Tube As

2. Install tube assembly (11), ten clips (10), twelve bolts (7), sixteen hard washers (8), and twelve nuts (9).
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   Illustration 52	g06238402
   (11) Tube As

3. Align tube assembly (11) and the two aftercooler bellows. Tighten two two T- bolt clamps (M).

   Note: Do not tighten two T- bolt clamps (M) to a final torque at this time.

Camera Install

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Illustration 53	g06238410
(96) 336-6684 Camera Gp (P) 3T-0849 Bolt

1. Remove and retain two bolts (P) from camera group (96).
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   Illustration 54	g06238413
   (96) 336-6684 Camera Gp (98) 305-3748 Plate As (99) 9X-8256 Washer (P) 3T-0849 Bolt

2. Install camera group (96) onto plate assembly (98). Install two washers (99) and two bolts (P).
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   Illustration 55	g06238430
   (34) 8T-4121 Hard Washer (33) 479-2172 Bolt As (26) 204-8000 Cable Tie Mounting (27) 204-2281 Cable Strap (97) 8T-6466 Bolt (100) 312-4475 Bracket (101) 344-5675 Nut (R) Camera Group and Bracket Subassembly

3. Install camera group and bracket assembly (R) onto bracket (100). Install six hard washers (34), three bolts (97), and three nuts (101). Install one mount (26), hard washer (34), bolt assembly (33), and nut (101). Install cable strap (27).
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   Illustration 56	g06238436
   (34) 8T-4121 Hard Washer (24) 479-2171 Bolt (101) 344-5675 Nut (102) 348-8145 Bracket (S) Camera Group and Bracket Subassembly

4. Install camera group and bracket subassembly (S) onto bracket (102). Install four bolt assemblies (24), four hard washers (34), and four nuts (101).
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   Illustration 57	g06238443
   (T) 8T-4186 Bolt (V) 7X-7729 Washer (W) 283-0657 Cable As

5. Remove and retain one bolt (T) and one hard washer (V). Position mount and coaxial cable assembly (W) out of the way.
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   Illustration 58	g06238449
   (33) 479-2172 Bolt As (X) Camera Group and Bracket sub-assembly (T) 8T-4186 Bolt (V) 7X-7729 Washer (W) 283-0657 Cable As

6. Install camera group and bracket sub-assembly (X). Install three bolt assemblies (33). Position coaxial cable assembly (W) and the mount. Install one hard washer (V) and one bolt (T). Connect coaxial cable assembly (W) to camera group and bracket sub-assembly (X).

Front Module Install

Note: In the following procedure, the connecting hoses can be pre-assembled onto either the tubes on the front module side or the tubes on the engine side for ease of assembly.

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Illustration 59	g06238452
(Y) 8T-4195 Bolt (Z) 8T-4121 Hard Washer (AA) 308-6629 Plate (AB) 308-6625 Baffle

1. Remove and retain twelve bolts (Y), twelve hard washers (Z), two plates (AA), and one baffle (AB).
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   Illustration 60	g06238459
   (88) 135-6261 Clamp (89) 366-8500 Hose

2. Install one hose (89) and four clamps (88).

   Note: Do not tighten four clamps (88) to a final torque at this time.

3. Repeat Step 1 and Step 2 for the opposite side of the front module.
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   Illustration 61	g06238462
   (AC) 8T-4956 Bolt (AD) 8T-4223 Hard Washer (AE) 248-3104 Flange (AF) 129-1609 O-Ring Seal

4. Remove and retain four bolts (AC), four hard washers (AD), two flanges (AE), and one O-ring seal (AF).

   Note: Discard the cover.

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   Illustration 62	g06238478
   (AG) 8T-4194 Bolt (AH) 8T-4223 Hard Washer (AJ) 1P-5767 Half Flange (AK) 235-2475 Rectangular Seal

5. Remove and retain eight bolts (AG), eight hard washers (AH), four flanges (AJ), two D-ring seals (AK). Remove and discard eight nuts (AL), eight washers (AH), and two covers (AM).
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   Illustration 63	g06238917
   Right-Hand Side (34) 8T-4121 Hard Washer (35) 8T-4137 Bolt (35A) 8T-4136 Bolt (70) 352-5028 Heat Shield As (71) 372-3117 Angle As (72) 371-5839 Baffle

6. Install one angle assembly (71), four hard washers (34) and four bolts (35). Install one heat shield assembly (70), one baffle (72), three hard washers (34), and three bolts (35A).
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   Illustration 64	g06238618
   Left-Hand Side (34) 8T-4121 Hard Washer (35) 8T-4137 Bolt (35A) 8T-4136 Bolt (73) 352-5028 Heat Shield As (71) 372-3117 Angle As (74) 371-5839 Baffle

7. Install one angle assembly (71), four hard washers (34), and four bolts (35). Install one heat shield assembly (73), one baffle (74), three hard washers (34) and three bolts (35A).
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   Illustration 65	g06238928
   Right-Hand Side (34) 8T-4121 Hard Washer (35A) 8T-4136 Bolt (78) 484-0774 Plate Assembly

8. Install three plate assemblies (78), six hard washers (34), and six bolts (35A).
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   Illustration 66	g06238935
   Left-Hand Side (34) 8T-4121 Hard Washer (35A) 8T-4136 Bolt (78) 484-0774 Plate Assembly

9. Install three plate assemblies (78), six hard washers (34), and six bolts (35A).
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   Illustration 67	g06238992
   Left-Hand Side (104) 8T-4195 Bolt (75) 5P-4115 Hard Washer (76) 6V-7357 Bolt (77) 501-6480 Plate As (79) 355-6155 Plate (80) 227-5327 Clip (81) 484-0743 Baffle (82) 278-1598 Plate (83) 8T-4222 Plated Washer (101) 344-5675 Nut

10. Position baffle (81) and install plate (79), plate assembly (77), four hard washers (75), and four bolts (76). Install three plates (80), plate (82), six hard washers (83), six bolts (104). Install two plated hard washers (83), bolt (104), and nut (101).
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    Illustration 68	g06238995
    Right-Hand Side (104) 8T-4195 Bolt (75) 5P-4115 Hard Washer (76) 6V-7357 Bolt (77) 501-6480 Plate As (79) 355-6155 Plate (80) 227-5327 Clip (81) 484-0743 Baffle (82) 278-1598 Plate (83) 8T-4222 Plated Washer (101) 344-5675 Nut

11. Position baffle (81) and install plate (79), plate assembly (77), four hard washers (75), and four bolts (76). Install three plates (80), plate (82), six hard washers (83), six bolts (104). Install two plated hard washers (83), bolt (104), and nut (101).
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    Illustration 69	g06238996
    (88) 135-6261 Clamp (89) 366-8500 Hose

12. Install hose (89) and four clamps (88). Do not tighten four clamps (88) to a final torque at this time. Repeat this step for the opposite side.
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    Illustration 70	g06239000
    (AP) 127-2170 Screw (AR) 290-4689 Plate

13. Remove ten screws (AP) and one cover (AR). Repeat this step for the opposite side.
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    Illustration 71	g06239014
    (1) 285-4173 Cooling Ar (T2) 439-3941 Link Bracket As (T3) 189-0410 Shackle As (T4) 386-6034 Link Bracket As, 439-3940 Bracket As

14. Attach Tooling (T2), Tooling (T3), Tooling (T4), and a suitable lifting device onto cooling arrangement (1) at the specified lifting locations.
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    Illustration 72	g06239028
    (1) 285-4173 Cooling Ar (T2) 439-3941 Link Bracket As (T3) 189-0410 Shackle As (T4) 386-6034 Link Bracket As, 439-3940 Bracket As

15. Use Tooling (T2), Tooling (T3), Tooling (T4), and the suitable lifting device to lift and level cooling arrangement (1). Position cooling arrangement (1) onto the truck chassis. The weight of cooling arrangement (1) is approximately 6545 kg (14430 lb).
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    Illustration 73	g06014574
    Right Hand Side (4) 198-4782 Hard Washer (5) 7X-2489 Bolt

16. Install seven hard washers (4) and seven bolts (5). Tighten bolts (5) to a torque of 800 ± 100 N·m (590 ± 74 lb ft).
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    Illustration 74	g06014582
    Left Hand Side (4) 198-4782 Hard Washer (5) 7X-2489 Bolt

17. Install seven hard washers (4) and seven bolts (5). Tighten bolts (5) to a torque of 800 ± 100 N·m (590 ± 74 lb ft).
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    Illustration 75	g06239033
    Left-Hand Side (6) 135-8578 Bolt As

18. Install three bolt assemblies (6). Tighten bolt assemblies (6) to a torque of 100 ± 20 N·m (74 ± 15 lb ft).
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    Illustration 76	g06239037
    Right-Hand Side (6) 135-8578 Bolt As

19. Install three bolt assemblies (6). Tighten bolt assemblies (6) to a torque of 100 ± 20 N·m (74 ± 15 lb ft).
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    Illustration 77	g06239040
    Right Hand Side (2) 4S-8033 Secondary Bar Pin (3) 3B-4640 Cotter Pin (AS) 221-0751 Link

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    Illustration 78	g06239041
    Left Hand Side (2) 4S-8033 Secondary Bar Pin (3) 3B-4640 Cotter Pin (AT) 221-0751 Link

20. Position link assembly (AS). Install one pin (2) and one cotter pin (3).

21. Position link assembly (AT). Install one pin (2) and one cotter pin (3).

22. Adjust link assembly (AS) and link assembly (AT) as needed to align the cooling module vertically.

    Note: The link assemblies are used for aligning the front module with the hood panels.

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    Illustration 79	g06239044
    (AP) 127-2170 Screw (AR) 290-4689 Plate

23. Install one cover (AR) and ten bolts (AP) . Repeat this step for the opposite side of the front module.
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    Illustration 80	g06239057
    (40) 8T-4223 Hard Washer (93) 355-1735 Bracket (94) 8T-4956 Bolt

24. Install two brackets (93), four hard washers (40), and four bolts (94).
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    Illustration 81	g06239064
    (87) 286-5260 Tube (88) 135-6261 Clamp

25. Install tube (87). Tighten eight T bolt clamp assemblies (88) to a torque of 7.5 ± 1 N·m (66.4 ± 8.9 lb in).

    Note: The T-bolt clamps should be orientated 180° apart.

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    Illustration 82	g06239069
    (39) 8T-4244 Nut (40) 8T-4223 Hard Washer (90) 8T-4910 Bolt (91) 198-4778 Hard Washer (95) 128-2477 Spacer (92) 329-3555 Half Clip

26. Install four half clips (92), four spacers (95), four hard washers (91), four bolts (90), four hard washers (40), and four nuts (39).
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    Illustration 83	g06239076
    (Y) 8T-4195 Bolt (Z) 8T-4121 Hard Washer (AA) 308-6629 Plate (AB) 308-6625 Baffle

27. Install baffle (AB), two plates (AA), twelve hard washers (Z), twelve bolts (Y).

28. Repeat Step 24 through Step 27 for the opposite side of the front module.
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    Illustration 84	g06239086
    (AG) 8T-4194 Bolt (AH) 8T-4223 Hard Washer (AJ) 1P-5767 Half Flange (AK) 235-2475 Rectangular Seal (AV) 423-5682 Hose As (AW) 423-5683 Hose As

29. Install one rectangular seal (AK) on hose assembly (AV) and one rectangular seal (AK) on hose assembly (AW). Position hose assembly (AV) and hose assembly (AW) onto the hydraulic fan make-up valve (AX). Install four half-flanges (AJ), eight hard washers (AH), and eight bolts (AG).
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    Illustration 85	g06239091
    Right-Hand Side (AY) 338-0036 Hose As

30. Connect hose assembly (AY).
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    Illustration 86	g06239094
    Left-Hand Side (AZ) 459-2590 Hose As

31. Connect hose assembly (AZ).
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    Illustration 87	g06239100
    From Service Center (BA) 342-2790 Hose As

32. Connect hose assembly (BA) from the service center to the radiator.
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    Illustration 88	g06239105
    (115) 220-4126 Clamp (116) 444-9740 Hose (117) 232-4901 Clamp (118) 465-1317 Hose (119) 465-0338 Tube As (120) 230-3671 T Bolt Clamp (121) 217-4195 Hose

33. Install hose (116), hose (118), hose (121), four T-bolt clamps (115), four T-bolt clamps (117), and T-bolt clamps (120) onto tube assembly (119).

    Note: Do not tighten four T-bolt clamps (115), four T-bolt clamps (117), and four T-bolt clamps (120) to a final torque at this time

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    Illustration 89	g06239106
    (119) 465-0338 Tube As (AC) 8T-4956 Bolt (AD) 8T-4223 Hard Washer (AE) 248-3104 Flange (AF) 129-1609 O-Ring Seal

34. Install O-ring seal (AF) onto tube assembly (119). Install tube assembly (119), two flanges (AE), four hard washers (AD), and four bolts (AC).
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    Illustration 90	g06239108
    (115) 220-4126 Clamp (117) 232-4901 Clamp (BB) 392-5045 Hose As

35. Tighten four T-bolt clamps (115) and four T-bolt clamps (117) to a torque of 7.5 ± 1 N·m (66.4 ± 8.9 lb in). Connect hose assembly (BB).
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    Illustration 91	g06239110
    (120) 230-3671 T Bolt Clamp

36. Tigthten four T-bolt clamps (120) to a torque of 7.5 ± 1 N·m (66.4 ± 8.9 lb in).

    Note: The T-bolt clamps should be orientated 180° apart.

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    Illustration 92	g06239112
    (BC) 370-4297 Hose As

37. Connect hose assembly (BC).
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    Illustration 93	g06239115
    Thermostatic Valve Connection (113) 226-0087 T Bolt Clamp (114) 217-4192 Hose

38. Install one hose (114) and four T-bolt clamps (113). Tighten four T-bolt clamps (113) to a torque of 7.5 ± 1 N·m (66.4 ± 8.9 lb in).

    Note: The T-bolt clamps should be orientated 180° apart.

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    Illustration 94	g06239116
    (BD) 452-6617 Hose As (BE) 338-0052 Hose As

39. Connect hose assembly (BD) and hose assembly (BE) to the expansion tank.
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    Illustration 95	g06239123
    (BF) 274-4477 Cable As (BG) 500-1819 Chassis Harness As (BH) 470-1567 Hose As (BJ) 471-7944 Hose As

40. Connect one coaxial cable assembly (BF), one hose assembly (BH), one hose assembly (BJ), and one harness assembly (BG).

41. Use the following steps to install and align the upper ATTAC lines,

    Do not final tighten the bolts until after adjusting the tubes position in order to optimize lateral and axial alignment of the bellows. Once aligned, tighten all bolts to a final torque.

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    Illustration 96	g06239529

    1. Loosen six clamps (BK).
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       Illustration 97	g06239541
       (BL) 367-7967 Bolt (BM) 363-2031 Spacer

    2. Remove and retain four bolts (BL) and four spacers (BM).
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       Illustration 98	g06239548

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       Illustration 99	g06239647
       (BL) 367-7967 Bolt (BM) 363-2031 Spacer (T6) 513-0256 Fixture As

    3. Install Tooling (T6). Install four bolts (BL) and four spacers (BM). Tighten three clamps (BK) on each side of the engine in the following order.

       • 1

       • 2

       • 3

       Note: This step can be performed before the engine and the front module is installed.

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       Illustration 100	g06239652
       Top View of Front Module

    4. Loosen the brackets and clamps at the top of the front module for alignment purposes.
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       Illustration 101	g06239567
       (BN) 6V-7687 Bolt (T7) 470-1585 Tool As-Alignment (BP) 494-0134 Tube As (BR) 351-4957 Tube As (12) 135-8577 Bolt As (13) 5P-1076 Hard Washer (14) 329-3356 Nut

    5. Loosen eight nuts (BN). Install Tooling (T7), two bolts (12), four hard washers (13), and two nuts (14). Use Tooling (T7) to align tube (BP) and tube (BR) and the rigid support bracket to obtain a nominal alignment. Once the alignment is made, tighten eight nuts (BN). Remove two bolts (12), two nuts (14), four hard washers (13), and Tooling (T7).

       Note: Use a level gauge to level Tooling (T7) horizontally.

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       Illustration 102	g06239583
       (BN) 6V-7687 Bolt (T7) 470-1585 Tool As-Alignment (T6) Tool As-Alignment (BP) 494-0134 Tube As (BR) 351-4957 Tube As (12) 135-8577 Bolt As (13) 5P-1076 Hard Washer (14) 329-3356 Nut

    6. Once the alignment is made, tighten eight nuts (BN). Remove and keep two bolts (12), two nuts (14), four hard washers (13), Tooling (T7), and Tooling (T6).

    7. Repeat Step41.e and Step 41.f for the remaining rigid support brackets.
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       Illustration 103	g06239589
       (12) 135-8577 Bolt As (13) 5P-1076 Hard Washer (14) 329-3356 Nut (15) 8N-4401 V Band Clamp (16) 470-1594 Bellows As (17) 9N-1941 V Band Clamp

    8. Install two bellows assemblies (16), eight hard washers (13), four bolts (12), four nuts (14), two clamps (15), and two clamps (17). Do not tighten the V-band clamps to a final torque at this time.
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       Illustration 104	g06239651
       Tightening direction

    9. Begin tightening all hardware at the inlet bellows on the ATTAC. Continue to tighten all hardware in the direction indicated toward the engine.
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       Illustration 105	g06239849
       Inlet Bellows (M) 465-8082 Bellows

    10. Tighten two V-band clamps of inlet bellows assembly (M) at the AATAC inlet to a torque of 20 ± 3 N·m (177 ± 27 lb in).
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        Illustration 106	g06239832
        (15) 8N-4401 V Band Clamp (17) 9N-1941 V Band Clamp

    11. Tighten two V-band clamps (15) to a torque of 14 ± 3 N·m (124 ± 27 lb in). Tighten two V-band clamps (17) to a torque of 11 ± 1 N·m (97 ± 9 lb in)
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    Illustration 107	g06239859
    (18) 470-1502 Plate As (19) 479-2171 Bolt As

42. Install plate assembly (18) and fifteen bolt assemblies (19).

Installation of the Cat® Detect Object Detection

Note: The information that is contained in this Special Instruction guides the user in the installation of the Caterpillar Integrated Object Detection System for Off-Highway Trucks.

Note: Do not perform any of the procedures until you have read the information in this publication.

Note: Refer to Operation and Maintenance Manual, SEBU8454, "Cat® Integrated Object Detection System for Off-Highway Trucks" for the orientation of the radar. The radar orientation is critical for the operation of the object detection system.

Note: Do not perform any of the procedures until you have read the information in this publication.

383-2781 Sensor Mounting Gp

Note: Refer to Operation and Maintenance Manual, SEBU8454, "Cat® Integrated Object Detection System for Off-Highway Trucks" for the orientation of the radar. The radar orientation is critical for the operation of the object detection system.

1. Use the following steps if installing the 383-2781 Sensor Mounting Gp
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   Illustration 108	g06239796
   (107) 383-1162 Sensor Mount As (108) 8T-4183 Bolt (109) 198-4778 Hard Washer

   1. Install one sensor mounting group (107), four hard washers (109), and four bolts (108).
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      Illustration 109	g06239798
      (85) 7X-7729 Washer (47) 6V-7744 Locknut (86) 8T-4186 Bolt (106) 458-2204 Bracket As

   2. Install two bracket assemblies (106), sixteen hard washers (85), eight bolts (86), and eight lock nuts (47).
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      Illustration 110	g06239803
      (85) 7X-7729 Washer (103) 347-7917 Object Detection Box Gp (104) 8T-4195 Bolt (105) 380-4489 Plate (8A) 265-9596 Hard Washer

   3. Install two object detection box groups (103), two plates (105), four hard washers (8A), four hard washers (85), and four bolts (104).
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      Illustration 111	g06239808
      (33) 279-2172 Bolt As (26) 204-8000 Cable Tie Mounting

   4. Install three mounts (26) and three bolt assemblies (33).
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      Illustration 112	g06239810
      (27) 204-2281 Cable Strap (110) 380-8404 Sensor Harness As

   5. Install one harness assembly (110) and six cable straps (27).

384-5498 Sensor Mounting Gp

Note: Refer to Operation and Maintenance Manual, SEBU8454, "Cat® Integrated Object Detection System for Off-Highway Trucks" for the orientation of the radar. The radar orientation is critical for the operation of the object detection system.

1. Use the following steps if installing the 384-5498 Sensor Mounting Gp
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   Illustration 113	g06239759
   (111) 383-1162 Sensor Mount As (108) 8T-4183 Bolt (109) 198-4778 Hard Washer

   1. Install one bracket assembly (111), four hard washers (109), and four bolts (108).
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      Illustration 114	g06239769
      (85) 7X-7729 Washer (47) 6V-7744 Locknut (86) 8T-4186 Bolt (106) 458-2204 Bracket As

   2. Install two bracket assemblies (106), sixteen hard washers (85), eight bolts (86), and eight lock nuts (47).
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      Illustration 115	g06239771
      (85) 7X-7729 Washer (103) 347-7917 Object Detection Box Gp (104) 8T-4195 Bolt (105) 380-4489 Plate (8A) 265-9596 Hard Washer

   3. Install two object detection box groups (103), two plates (105), four hard washers (8A), four hard washers (85), and four bolts (104).
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      Illustration 116	g06239788
      (34) 8T-4121 Hard Washer (35A) 8T-4136 Bolt (26) 204-8000 Cable Tie Mounting (36) 130-5300 Clip (63) 8T-4195 Bolt

   4. Install five mounts (26), five hard washers (34), and five bolts (63). Install clip (36), hard washer (34), and bolt (35A).
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      Illustration 117	g06239793
      (27) 204-2281 Cable Strap (110) 380-8404 Sensor Harness As (112) 368-9816 Sensor Harness As

   5. Install one harness assembly (110), one harness assembly (112), and seven cable straps (27).

Radar and Camera adjustment and calibration

1. After the truck has been assembled and the body has been installed, the camera and radars must be adjusted and calibrated. Refer to Testing and Adjusting, UENR2507, "Cat® Detect Object Detection System", "Object Detection Sensor - Calibrate" and Testing and Adjusting, UENR2507, "Cat® Detect Object Detection System", "Object Detection Sensor - Adjust" or Testing and Adjusting, KENR8668, "Cat® Detect Object Detection System", "Object Detection Sensor - Calibrate" and Testing and Adjusting, KENR8668, "Cat® Detect Object Detection System", "Object Detection Sensor - Adjust"for the correct procedures.