Procedure to Improve the ATAAC Tubes on Certain 797 and 797B Off-Highway Trucks {1071}
- Off-Highway Truck/Tractor
- 797 (S/N: 5YW260-260)
- 797B (S/N: JSM146-147,151-152,220-225,236-237,244-244,252-252,256-256,293-293)
Introduction
This Special Instruction provides the needed procedures to improve the support of the ATAAC tubes on certain 797 and 797B Off-Highway Trucks.
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.
Safety Section
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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility. |
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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. |
Required Parts
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| Parts List | ||
| Item | Qty | Part |
| 1 | 8 | 135-6259 Clamp |
| 2 | 12 | 198-4777 Hard Washer |
| 3 | 19 | 198-4778 Hard Washer |
| 4 | 4 | 214-0584 Clamp |
| 5 | 8 | 233-8484 Clamp |
| 6 | 2 | 273-3537 Hose |
| 7 | 1 | 276-7213 Plate |
| 8 | 10 | 329-3555 Half Clip |
| 9 | 1 | 341-4743 Plate |
| 10 | 1 | 422-2398 Block |
| 11 | 1 | 512-0224 Bracket As |
| 12 | 1 | 512-0225 Bracket As |
| 13 | 1 | 512-0226 Bracket As |
| 14 | 1 | 512-0227 Bracket As |
| 15 | 1 | 512-0228 Bracket As |
| 16 | 1 | 512-0233 Bracket As |
| 17 | 1 | 512-0797 Tube As |
| 18 | 1 | 512-0803 Tube As |
| 19 | 2 | 519-2151 Elbow |
| 20 | 8 | 8T-4182 Bolt |
| 21 | 19 | 8T-4184 Bolt |
| 22 | 4 | 8T-4186 Bolt |
Installation Procedure
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| Illustration 1 | g06257454 |
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View of back of radiator (A) Before Retro fit (B) After Retro fit | |
Preparing the Machine
- Move the machine to a smooth level area with enough room around the machine to work safely.
- Park the machine and turn of the engine.
- Place chocks under the wheels to prevent movement.
- Perform Lock out /Tag out procedures to the machine controls.
Retrofit Procedure
- Remove all the necessary panels and shrouds around the radiator compartment need to access the tubes.
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Illustration 2 g06257469 View of backside of radiator group
(A) Tube
(B) Tube - Remove tubes (A) and (B) from the radiator group along with the hardware and discard.
Note: If tube (B) cannot be removed past the other tubes and structures, cut tube (B) in half.
Welding on the New Supports
- Prepare the surface to be welded on by removing paint at the weld location. Clean off any grease or other contaminants from plate.
Weld 341–4743 plate (9) into position on the cab support using the datums supplied in Illustration 3.
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Illustration 4 g06257155 View of right cab support looking towards the engine
(7)276-7213 Plate
(D3)221.98 mm (8.7 inch)
(D4)216.63 mm (8.6 inch) - Prepare the surface to be welded on by removing paint at the weld location. Clean off any grease or other contaminants from the plate.
- Weld 276–7213 plate (7) into position on the cab support using the datums supplied in Illustration 4.
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Illustration 5 g06257188 View of left front cab support
(10)422-2398 Block
(D5) 3 degrees deflection from center
(D6)193 mm (7.6 inch)
(D7)74 mm (2.9 inch) - Prepare the surface to be welded on by removing paint at the weld location. Clean off any grease or other contaminants from the block.
- Weld block (10) into position on the left front cab support pillar using the datums supplied in Illustration 5.
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| Illustration 3 | g06251652 |
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View of right front cab support looking towards the engine (9) (D1) (D2) | |
Installing the Left Side ATAAC Lines
- Assemble bracket assembly (16) to bracket assembly (15) using four hard washers (3) and four Bolts (21).
- Attach bracket (16) to block (10) with four bolts (22) and four hard washers (2).
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Illustration 7 g06258213 View of front left cab support pillar
(1)135-6259 Clamp
(3)198-4778 Hard Washer
(4)214-0584 Clamp
(5)233-8484 Clamp
(6)273-3537 Hose
(8)329-3555 Half Clip
(15)512-0228 Bracket As
(18)512-0803 Tube As
(19)519-2151 Elbow
(21)8T-4184 Bolt - Install hose (6) between the existing tube and tube assembly (18) and secure using four clamps (5).
- Attach tube assembly (18) to bracket assembly (15) with four half clips (8), four bolts (21), and four hard washers (3). Refer to Illustration 7 for orientation of tube assembly (18).
- Connect elbow (19) to tube assembly (18) and secure using two clamps (4). Connect the twin tubes of elbow (19) to the existing tubing coming from the cooling group with four clamps (1).
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| Illustration 6 | g06257575 |
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View of left front cab support pillar (10) (2) (3) (15) (16) (21) (22) | |
Installing the Right Side ATAAC Lines
- Assemble bracket (12) to bracket (13) using three bolts (21) and three hard washers (3).
- Mount brackets (12) and (13) to plate (9) with four bolts (20) and four hard washers (2).
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Illustration 10 g06258731 View of right side lower bracket assembly
(2)198-4777 Hard Washer
(3)198-4778 Hard Washer
(10)422-2398 Block
(11)512-0224 Bracket As
(14)512-0227 Bracket As
(20)8T-4182 Bolt
(21)8T-4184 Bolt - Assemble bracket assembly (11) and bracket assembly (14) together using two bolts (21) and two hard washers (3).
- Mount bracket assemblies (11) and (14) onto plate (10) with four bolts (20) and four hard washers (2).
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Illustration 11 g06258625 View of upper bracket and tube
(3)198-4778 Hard Washer
(8)329-3555 Half Clip
(17)512-0797 Tube As
(21)8T-4184 Bolt - Attach tube assembly (17) to bracket (13) using four half clips (8), four bolts (21), and four hard washers (3).
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Illustration 12 g06258685 View of right side cab support pillar
(1)135-6259 Clamp
(4)214-0584 Clamp
(17)512-0797 Tube As
(19)519-2151 Elbow - Connect elbow (19) between the existing tubes next to the right side cooling group and tube assembly (17). Secure elbow (19) in place with four clamps (1) and two clamps (4).
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Illustration 13 g06258785 View of lower right bracket assembly
(3)198-4778 Hard Washer
(8)329-3555 Half Clip
(14)512-0227 Bracket As
(17)512-0797 Tube As
(21)8T-4184 Bolt - Attach tube assembly (17) onto lower bracket (14) using two half clips (8), two bolts (21) and two hard washers (3).
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Illustration 14 g06258817 View of right side engine compartment
(5)233-8484 Clamp
(6)273-3537 Hose
(17)512-0797 Tube As - Connect hose (6) between tube (17) and the existing connection on the right side engine compartment. Use four clamps (5) to secure hose (6) in place.
- Replace any panels or shrouds that were removed for installation.
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| Illustration 8 | g06258295 |
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View of right side front face of cab support pillar (A) upper tube mount location (B) Lower tube mount location | |
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| Illustration 9 | g06258360 |
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View of right side upper bracket assembly (2) (3) (9) (12) (13) (20) (21) | |
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