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.

Installation Procedure

Start By:

1. Install the battery box

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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.

Assembly Order

Note: Before installing the tires and rims, refer to Special Instruction , SEHS0003 , "Commissioning" , Purge the brake system for instruction.

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Illustration 1	g06424836
(T1) 439-3943 Bracket As. (A) 308-3083 Adapter As 292-0259 Final Drive, Brake, and Wheel Gp (B) 201-4606 Bolt (C) 217-9903 Washer (D) 308-3083 Adapter As

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NOTICE
Do not attempt to operate the machine to rotate the wheel and final drive with the rim adapters removed. The retaining bolts can shear and the final drive can fall from the wheel causing severe personal injury or death.

1. Attach Tooling (T1) and a suitable lifting device onto upper adapter assembly (A). Remove and keep twenty-four bolts (B) and twenty-four washers (C). Remove and keep adapter assembly (A).

2. Attach Tooling (T1) and a suitable lifting device onto lower adapter assembly (D). Remove and keep twenty-four bolts (B) and twenty-four washers (C). Remove and keep adapter assembly (D).
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   Illustration 2	g06424866

3. Attach a suitable lifting device on to bracket (E). The weight of bracket (E) is approximately 56 kg (124 lb). Remove and discard ten nuts (F), ten washers (G). Remove and discard bracket (E).

4. Repeat Step 1 through Step 3 for the opposite side of the truck.
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   Illustration 3	g06424873
   (T6) 9U-7489 Lift Stand (100 Ton)

5. Use two Tooling (T6) to raise the rear chassis at the specified jacking locations enough to allow the rear tires and rims to be installed. The weight of the rear chassis is approximately 45359 kg (100000 lb).
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   Illustration 4	g06424904

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   Illustration 5	g06424905

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   Illustration 6	g06424907
   (T4) 443-7801 Tool Gp, 443-7797 Tool Gp, 132-8232 Power Pack, 159-2833 Socket (H) 445-9732 Tire Valve Gp (1) Tire and Rim Gp (2) 217-9903 Washer (3) 8C-4032 Nut

6. Position tire valve group (H) out of the way. Use a suitable tire handler to install tire and rim group (1) on the inboard rear axle location. The weight of tire and rim group (1) is approximately 8570 kg (18893 lb).

   Note: The tire and rim group will have the tire valve group (H) installed. As the tire and rim group is being installed, check to ensure the extension hose of tire valve group (H) does not bind or crimp.

7. Install fifty-four nuts (3) and fifty-four hard washers (2). Use Tooling (T4) to tighten nuts (3) to a torque of 3100 ± 350 N·m (2286 ± 258 lb ft).
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   Illustration 7	g06425127
   (H) 445-9732 Tire Valve Gp (4) 9X-8257 Washer (5) 7X-2555 Bolt (6) 201-6656 Guard

8. Position tire valve (H) under guard (6). Install guard (6), four bolts (5), and four washers (4).

9. Repeat Step 6 through Step 8 for the remaining inner rear tire.
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   Illustration 8	g06424915
   (T6) 9U-7489 Lift Stand (100 Ton)

10. Use Tooling (T6) to lower the weight of the rear end of the chassis onto the tires. The weight of the rear end of the chassis is approximately 62595 kg (138000 lb).
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    Illustration 9	g06424916
    (T3) 193-5474 Shackle

11. Use Tooling (T3) and a suitable lifting device to raise the front end of the chassis. The weight of the front end of the chassis is approximately 58967 kg (130000 lb).
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    Illustration 10	g06424918

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    Illustration 11	g06424920
    (T4) 443-7801 Tool Gp, 443-7797 Tool Gp, 132-8232 Power Pack, 159-2833 Socket (1) Tire and Rim Gp (2) 146-1799 Washer (3) 8C-4032 Nut

12. use a suitable tire handler to install tire and rim assembly (1). The weight of tire and rim assembly is approximately 70000 kg (15,432 lb)

13. Install fifty nuts (3) and fifty hard washers (2). Use Tooling (T4) to tighten nuts (3) to a torque of 3100 ± 350 N·m (2286 ± 258 lb ft).

14. Repeat Step 12 through Step 13 for the remaining front tire and rim.
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    Illustration 12	g06424923
    (T3) 193-5474 Shackle

15. Use Tooling (T3) and the suitable lifting device to lower the weight of the front end of the chassis onto the tires. The weight of the front end of the chassis is approximately 76106 kg (167786 lb). Remove Tooling (T3) and the suitable lifting device.
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    Illustration 13	g06424924

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    Illustration 14	g06286271

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    Illustration 15	g06424929
    (T1) 439-3943 Bracket As. (T5) M12 bolt and washer (A) 308-3083 Adapter As (B) 201-4606 Bolt (C) 217-9903 Washer (D) 308-3083 Adapter As

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    NOTICE
    Do not attempt to operate the machine to rotate the wheel and final drive with the rim adapters removed. The retaining bolts can shear and the final drive can fall from the wheel causing severe personal injury or death.

16. Clean the mating surfaces free of wax, dirt, debris, paint, and grease.

    Note: The adapter assemblies must be oriented so that the inboard tire valve group will pass through the cutout in the adapter assemblies in a straight line.

17. Use Tooling (T1) and a suitable lifting device to install adapter assembly (D). The weight of adapter assembly (D) is approximately 224 kg (494 lb). Install twenty-four bolts (B), and twenty-four washers (C). Use Tooling (T1) and a suitable lifting device to install adapter assembly (A). The weight of adapter assembly (A) is approximately 224 kg (494 lb). twenty-four bolts (B), and twenty-four washers (C). The gaps at the ends of the adapter assemblies must be equal on each side to insure proper rim fit up. Use Tooling (T5) or similar fasteners installed through the holes in the special studs at each end of the rim adapters. Pull the adapters in tight against the wheel flange outer diameter and equalize end gaps.

18. Once the gaps are equal, use Tooling (T4) to tighten bolts (B) to a torque of 3100 ± 350 N·m (2286 ± 258 lb ft) from the center outward while insuring that the adapter assemblies are seated against the wheel flange diameter.

19. Remove Tooling (T5).

20. Repeat Step 16 through Step 19 for the remaining rear tire and rim.
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    Illustration 16	g06424932
    (T6) 9U-7489 Lift Stand (100 Ton)

21. Use two Tooling (T6) to lift the weight the rear end of the chassis enough to install the outer tires and rims. The weight of the rear end of the chassis is approximately 62595 kg (138000 lb).
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    Illustration 17	g06424935

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    Illustration 18	g06424936

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    Illustration 19	g06424938
    (T4) 443-7801 Tool Gp, 443-7797 Tool Gp, 132-8232 Power Pack, 159-2833 Socket (H) 445-9732 Tire Valve Gp (1) Tire and Rim Gp (2) 146-1799 Washer (3) 8C-4032 Nut

22. Use a suitable tire handler to install tire and rim group (1) on the outboard rear axle location. The weight of tire and rim group (1) is approximately 8570 kg (18893 lb). Check to ensure that tire valve group is guided through the rim. Attach a string or wire to guide the tire valve group.

23. Install fifty-four nuts (3) and fifty-four hard washers (6). Use Tooling (T4) to tighten nuts (3) to a torque of 3100 ± 350 N·m (2286 ± 258 lb ft).

24. Repeat Step 22 and 23 for the remaining outer rear tire and rim.
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    Illustration 20	g06424948
    (T6) 9U-7489 Lift Stand (100 Ton)

25. Lower the weight of the rear of the chassis onto the tires. The weight of the rear chassis is approximately 79638 kg (175572 lb). Remove Tooling (T6).
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    Illustration 21	g06424949

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    Illustration 22	g06425129
    (H) 445-9732 Tire Valve Gp (J) 6C-8648 Bolt (K) 198-4768 Hard Washer (L) Nut (7) 445-9730 Support

26. Remove and keep two bolts (J), two washer (K), and nut (L). Position tire valve group (AH) through support (7) and install nut (L) to secure tire valve group (H) to support (7). Apply Tooling (T7) onto two bolts (J). Install support (7), two washers (K) and two bolts (J). Tighten two bolts (J) to a torque of 320 ± 40 N·m (236 ± 30lb ft).

27. Repeat Step 26 for the opposite side.