798 AC Off-Highway Truck Field Assembly Caterpillar

Parts and Specification Information

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.

Pipe Cleaning Instructions

1. Prior to assembly, clean the airline pipes. Check all the new pipes for the protective caps. Inspect the new pipes to ensure that the pipes are free of rust and debris. If debris and rust are found, clean inside the pipes until free of debris and rust.
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   Illustration 1	g06332606
   Cleaning the inside of the pipe

2. Before assembly, clean inside all the pipes.

3. Obtain a length of rope (D) long enough to extend through the entire length of the longest pipe (C). Obtain a stiff pillow (A) large enough fit tightly through the pipe. Tie rope (D) around pillow (A). Cut a hole in a chunk of blanket (B) large enough to cover the pillow. Pass the rope through the hole in the blanket.

4. Spray the blanket with window cleaner. Pull the blanket through the pipe several times to clean inside the pipe. Remove all debris from inside the pipe.

Installation Procedure

Start By:

1. Install the front axle.

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Climbing equipment may be required to access this service point. Refer to the Operation and Maintenance Manual, "Mounting and Dismounting" topic for safety information.

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Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.

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Personal injury or death can occur from heavy components falling during removal or installation. Properly support the component with a suitable lifting device during removal or installation.

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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 and allow adequate strain relief.

Note: Any tooling that is used for lifting the machine or for securing the machine in the raised position should be used on a concrete surface capable of supporting the weight of the machine.

1. Use the following step to assemble fourteen hangar subassemblies (A).
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   Illustration 2	g06332268
   (1) 434-5654 Nut (2) 442-2672 Washer (3) 117-4937 Pipe As (4) 2L-6324 Bolt (5) 442-2671 Support (6) 8T-2501 Bolt (7) 3K-6060 Locknut (8) 431-5834 Support

   1. Install support (5), support (8), two bolts (6), two locknuts (7), pipe assembly (3), bolt (4), washer 2, and nut (1).

      Note: Assemble the parts loosely.

      Note: Secure bolt (4) using wire (14).

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   Illustration 3	g06424156
   (A) Hanger Sub-Assembly (9) 507-6295 Pipe or 502-7100 Tube (10) 442-2667 Pipe (11) 442-2670 Pipe

2. Install seven hanger subassemblies (A). Install pipe (9), pipe (10), and pipe (11). Repeat this step for the opposite side.

   Note: Before installation, mark the hose overlap distance on all pipes.

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   Illustration 4	g06332622
   Hose and pipe overlap (D1) 60 ± 5 mm (2.4 ± 0.2 inch)

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   Illustration 5	g06411394
   Reduced diameter hose and pipe overlaps (D2) 67 ± 5 mm (2.6 ± 0.2 inch)

3. The overlap distance for the hose on the pipe to filter assembly connections, the pipe to pipe connections, and the pipe to elbow connection is 60 ± 5 mm (2.4 ± 0.2 inch) (D1). The overlap is on both ends of the hose. Both units are the same diameter.
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   Illustration 6	g06424157

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   Illustration 7	g06411355
   VIEW A-A

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   Illustration 8	g06411369
   Typical Example (D3) 110 Degrees MIN (D4) 6.35 mm (0.25 inch) (12) 243-5606 Hose (13) 442-2673 Clamp

4. Install two hoses (12). Install four clamps (13) to dimension (D3) and (D4).

   Note: Several adjustments of the airlines tubes may be required. Final alignments and torque will be made once the platform has been installed on the chassis.

5. During the pipe installation, leave the components loose to adjust the alignment of the pipes and hoses. Misalignment of the pipes should not exceed 3.0 mm (0.12 inch).

6. Check the overlap distance marks. If the assembly is within the specifications, tighten the clamps.

   Note: Position the clamps 180 degrees apart.

7. Once the turbo connections are made, pressure check the pipe assemblies. Refer to UENR2267, Air Inlet System - Test and Inspect

8. Repeat step 1 through step 4 for the opposite side.