Commissioning Procedure for the 794 AC, 796 AC, and 798 AC Off-Highway Trucks {1000, 7000, 7961} Caterpillar

Mining Truck

794 AC (S/N: HRT1-UP)

Off-Highway Truck/Tractor

794 AC (S/N: MN51-UP; MT51-UP)

796 (S/N: HRY1-UP; HRZ1-UP)

798 (S/N: ST71-UP)

Reference: Operation and Maintenance Manual, SEBU9099, "794 AC Off-Highway Truck"

Reference: Service Magazine, SEPD1178, "Switch Settings for the Payload Monitors"

Reference: Service Manual, UENR3957, "794 AC Off-Highway TruckVIMS 3G and Truck Payload Measurement System (TPMS)"

Reference: Testing and Adjusting, UENR2267, "794 AC Off-Highway Truck Machine Systems"

Reference: Troubleshooting, UENR3890, "Electrical Shutdown and Voltage Discharge"

Reference: Special Instruction, REHS5464, "Accumulator Discharging and Charging Procedures"

Reference: Testing and Adjusting, UENR4125, "Air Conditioning and Heating R134a for All Cat Machines"

Introduction

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Personal injury or death can result from air in the oil for the brake hydraulic system. Air in the system can prevent complete brake application and it is possible that the wheels on the machine can not be stopped. Air must not be in the oil for the brake hydraulic system to function properly.

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Personal injury or death can result from machine movement. Place blocks in front of and behind the wheels to make sure the machine does not move while the parking brakes are disengaged.

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Do not check for leaks with your hands. Pin hole (very small) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use cardboard or paper to locate pin hole leaks.

Illustration 1	g01962775

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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 body retaining pins. Install the body retaining pins through the ends of the retaining cables. Always use both retaining cables. Failure to properly secure the body (bed) may result in personal injury or death.

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When service or maintenance must be performed in a hazardous-voltage component enclosure, always assume that a hazardous level of voltage could be present. Qualified personnel should manually check for hazardous-voltage using electrical measuring tools that have the capacity to measure the hazardous-voltage components being checked. The level of voltage present must be confirmed to be below 50 VDC before any exposure to the hazardous-voltage components can take place. Failure to follow these instructions could result in personal injury or death.

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Working with electrical circuits is hazardous. Bodily contact with electrical potential will cause personal injury or death. Ensure that personnel are trained in proper operating procedures in order to ensure safe operation.

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The Power Train Electric Drive System will contain hazardous voltage levels during machine operation and for a short period of time after engine shutdown. Do not remove any covers that will expose energized high voltage electrical components while the engine is operating. Any type of maintenance on the following components can only be performed after the Power Train Electrical System Service Shutdown procedure has been followed: High voltage compartments in the inverter cabinet The rear axle housing that contains the electric drive traction motors The generator The retarding resistor grid, the grid blower motor and the grid system cabling The excitation field regulator The high voltage cables and connection enclosures Failure to follow these instructions could result in personal injury or death.

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In order to avoid the buildup of hazardous live voltages on the exposed surfaces, all grounding wires and grounding straps must be properly connected at all times during engine operation. Any disconnected grounding wires, including the grounding wires for all high voltage components and the grounding strap for the inverter cabinet must be properly reconnected before the engine is started. Failure to follow these instructions could result in personal injury or death.

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates.

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NOTICE
This machine is equipped with a Tier 4 Certified Engine system that is configured to meet the emissions requirements mandated by the United States Environmental Protection Agency (EPA). Care must be taken to comply with all instructions within this document to ensure that the engine, as assembled (including the exhaust piping, DEF Fluid lines, and controls), performs as designed to meet and maintain Tier 4 emissions requirements. Also, to meet the EPA regulatory requirements related to recording the combination of engine and emissions components that will be placed into service with the machine, perform the checks, and record the results as instructed in the "Emissions Compliance Report (Tier 4 Equipped Machines)" section later in this document. Complete and return the required information to the address listed in the "Emissions Compliance Report (Tier 4 Equipped Machines)" section later in the document.

This Special Instruction contains the following necessary procedures for the 794 AC Off-Highway Truck commissioning procedure.

The photographs in this publication are for illustrative purposes. Do not perform any procedures in this publication or order any parts until you understand the information that is contained in this publication.

Table 1

Dealer Information for Commissioning Procedure
Date
Serial Number
Service Meter Units
Name of the Technician
Unit Number
Engine Serial Number
Pump Electronic Tank Unit (PETU) Serial Number(1)
Clean Emissions Module (CEM) Serial Number(1)
Dealer
Dealer Code
Customer
Job Site
Right-Hand Wheel Station Serial Number
Left-Hand Wheel Station Serial Number
Rear Axle Serial Number
Body Manufacturer/Part Number
Body Serial Number
General Body Condition

(1)	If Tier 4 equipped

Table 2

Miscellaneous Checks
Take Digital Photos of Completed Truck
Missing Parts(1)
Performance Issues
Dealer Installed Attachments(2)
Dealer Comments(3)
Verify the function of all Cab Controls
Verify the function of the Engine Aftertreatment(4)
Payload Target

(1)	Develop a list of all the part numbers and the next highest part number level.
(2)	Take digital photos of all dealer installed attachments.
(3)	Record positive and negative comments.
(4)	If Tier 4 equipped

Required Tooling

Illustration 2	g02571852
Tooling (A) 198-4240 Digital Pressure Indicator Gp

Table 3

Required Tools
Tool	Item	Qty	Part No	Description
A			198-4240	Digital Pressure Indicator Gp
	A1	1	198-4234	Digital Indicator
	A2	1	198-4237	Pressure Sensor Gp (0 kPa to 3,445 kPa (0 psi to 500 psi))
	A2	1	198-4238(1)	Pressure Sensor Gp (0 kPa to 34,450 kPa (0 psi to 5,000 psi))
	A2	1	198-4239	Pressure Sensor Gp (0 kPa to 41,368 kPa (0 psi to 6,000 psi))
	A2	1	251-9600(2)	Pressure Sensor Gp (0 kPa to 68,900 kPa (0 psi to 10,000 psi))
	A3	1	198-4236	Adapter Cable As

(1)	This sensor must be purchased separately, the sensor is not included in the 198-4240 Digital Pressure Indicator Gp
(2)	This sensor can only be used on large diameter pressure taps like 6V-3965 Fitting.

Illustration 3	g02726620
Tooling (B)

Table 4

Required Tools
Tool	Item	Qty	Part No	Description
B	B1	1	8T-0862	Pressure Gauge (-100 TO 500 kPa (-15 TO 72 psi))
	B1	1	8T-0863	Pressure Gauge (0 TO 250 kPa (0 TO 36 psi))
	B1	1	8T-0853	Pressure Gauge (0 TO 400 kPa (0 TO 58 psi))
	B1	1	8T-0854	Pressure Gauge (0 TO 1,000 kPa (0 TO 144 psi))
	B1	1	8T-0855	Pressure Gauge (0 TO 4,000 kPa (0 TO 580 psi))
	B1	1	8T-0856	Pressure Gauge (0 TO 6,000 kPa (0 TO 860 psi))
	B1	1	8T-0857	Pressure Gauge (0 TO 10,000 kPa (0 TO 1,450 psi))
	B1	1	8T-0858	Pressure Gauge (0 TO 16,000 kPa (0 TO 2,300 psi))
	B1	1	8T-0859	Pressure Gauge (0 TO 25,000 kPa (0 TO 3,600 psi))
	B1	1	8T-0860	Pressure Gauge (0 TO 40,000 kPa (0 TO 5,800 psi))
	B1	1	8T-0861	Pressure Gauge (0 TO 60,000 kPa (0 TO 8,600 psi))
	B2	1	6V-3989	Fitting
	B3	2	6V-4143	Quick Connect Coupler
	B4	1	177-7860	Hose As 3.0 m (10 ft)
	B4	1	177-7861	Hose As 4.3 m (14 ft)
	B4	1	177-7862	Hose As 5.5 m (18 ft)

Illustration 4	g03334430
Tooling (C) 317-7484 Communication Adapter III

Table 5

Required Tools
Tool	Item	Qty	Part Number	Description
C		1	317-7484(1)	Communication Adapter Gp
	C1	1	370-4617	Cable As (USB PC Communication)
	C2	1	317-7485	Communication Adapter III
	C3	1	327-8981	Cable As (Data Link)

(1)	Caterpillar Electronic Technician (Cat®ET) and Software CD, NETG5057 are required when using the communication adapter.

Table 6

Required Tools
Tool	Item	Qty	Part Number	Description
T3	T3a	1	6V-9830	Cap
	T3b	1	6V-9509	Plug

Illustration 5	g06397839
Tooling (T4)

Table 7

Required Tools
Tool	Item	Qty	Part Number	Description
T4	T4a	1	214-7566	O-Ring Seal
	T4b	1	8T-2353	Adapter
	T4c	2	214-7568	O-Ring Seal
	T4d	1	6V-8076	Elbow
	T4e	1	6V-3965	Fitting
	T4f	1	6V-0852	Dust Cap

Table 8

Required Tools
Tool	Item	Qty	Part Number	Description
T5	T5a	1	238-5078	O-Ring Seal
	T5b	1	—	5/16-24 #2 STOR to 9/16-18 #6 STOR Adapter
	T5c	2	214-7568	O-Ring Seal
	T5d	1	6V-3965	Fitting
	T5e	1	6V-0852	Dust Cap

Table 9

Required Tools
Tool	Item	Qty	Part Number	Description
T6	T6a	1	238-5081	O-Ring Seal
	T6b	1	5P-1404	Adapter
	T6c	2	214-7568	O-Ring Seal
	T6d	1	6V-8076	Elbow
	T6e	1	6V-3965	Fitting
	T6f	1	6V-0852	Dust Cap

Table 10

Required Tools
Tool	Item	Qty	Part Number	Description
T7	T7a	1	214-7566	O-Ring Seal
	T7b	1	5P-4499	Adapter
	T7c	2	8C-3446	Sampling Valve
	T7d	1	8C-3451	Dust Cap

Perform the Commissioning Procedure for the Machine

Reference: Refer to Operations and Maintenance Manual, SEBU9099, "794 AC Off-Highway Truck" for additional information on the oil recommendations.

Reference: Refer to Testing and Adjusting, UENR2267, "794 AC Off-Highway Truck Machine Systems" for hydraulic check information.

Illustration 6	g01340699

Note: Ensure that the wheels are chocked before performing the commissioning procedure.

Fluid Level Checks

Reference: Refer to Operations and Maintenance Manual, SEBU9099, Capacities (Refill) for additional information on checking the fluid levels.

Table 11

Checking the Fluid Levels	Check if OK
Engine Coolant System(1)
Hydraulic Tank
Engine Crankcase
Left Rear Final Drive
Right Rear Final Drive
Grease for the Autolube
Left Front Wheel Station
Right Front Wheel Station
Window Washer Reservoir
Fuel
Diesel Exhaust Fluid (DEF)(2)

(1)	Check the Jacket Water level.
(2)	If Tier 4 Equipped

Ground Straps

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Illustration 7	g06286455
Ground strap locations

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Illustration 8	g06322401
Ground strap locations

1. Inspect ground straps. Ensure that all ground straps are present, secure, and have a good electrical connection.

   Note: Paint under a ground strap at the mounting location, can cause poor electrical connection.

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   Table 12

   Location of Ground Straps			Check if OK
   Ground Strap		Location
   G1	Generator	Right side of the generator to Right- Hand frame rail.(1)
   G2	Engine	Right rear engine mount to Right-Hand frame rail.(1)
   G3	Upper Cooler	Left-Hand side of cooler to inside of Left-Hand frame rail.(1)
   G4	Radiator Group	Left-Hand bottom of cooler to Left-Hand cooler mount.(1)
   G5	Superstructure	Left-Hand rear superstructure saddle mount to Left-Hand frame rail.(1)
   G6	Rear Axle Housing	Top of rear axle housing front center linkage to frame near cross tube.(1)
   G7	RH Drive Motor	Inside the rear axle housing.(2)
   G8	LH Drive Motor	Inside the rear axle housing.(2)
   G9	Cab	Right front corner under the cover.(2)
   G10	Upper Upright Beam	Top box to Left-Hand upright beam.(2)
   G11	Lower Upright Beam	Lower box to Left-Hand upright beam(2)
   G12	ECM Cabinet	Bottom of ECM cabinet to the deck.(2)
   G13	Retarding Grid	Inboard side of the retarding grid to the deck.(2)
   G14	Inverter Cabinet	Two cables at the Right rear of the inverter cabinet by cable entry.(2)

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   (1)	Refer to Illustration 7
   (2)	Refer to Illustration 8

Pins and Retainers

Illustration 9	g06323429
Examples of pins, retainers, and hardware

Inspect machine pins, retainers, and hardware.

Table 13

Pins, Retainers, and Hardware
Inspection Area	Left-Hand Side	Right-Hand Side
Platform Connections
Front Suspension Cylinders
Front Axle Connections
Steering Linkages
Hoist Cylinders
Rear Axle Housing Nosecone Bushing
Rear Axle Housing Rear Linkage
Rear Suspension Cylinders
Rear Dump Body Pins

High-Voltage Cabling

1. Inspect all the high-voltage cabling for the proper routing and for any interference.

   Look for issues such as the following:

   • Any area where the cabling may rub on other components or other cables

   • Improperly secured cables or loose cables

   • Bent, kinked, or twisted cables

   • Cut, nicked or damaged cables

High-Voltage System Megger Test

1. Ensure that the electrical system is discharged.

   Reference: Troubleshooting, UENR3890, "Electrical Shutdown and Voltage Discharge"

2. Turn off the main disconnect.
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   Illustration 10	g06402940

3. Remove covers (A).
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   Illustration 11	g02913001
   View of the rear side of the inverter cabinet

4. Remove cover (B).
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   Illustration 12	g06404197
   View of inverter cabinet back (C) Retarding Grid Blower Inverter

5. Remove the four internal ground wires at the bottom left-hand area of compartment behind cover (B). Isolate each of the ground wires from one another. Isolate each of the ground wires from the frame ground.

   Note: The test must hold a minimum of two meg ohms.

6. Remove "IP" and "IN" from the top of the Retarding Grid Blower Inverter (RGBI) (C) per Illustration 12.
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   Illustration 13	g02160914

7. Open the contractor compartment and connect a jumper between the "DCP" and the "DCN" bus bars.
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   Illustration 14	g02160915

8. In the contractor compartment, using the 2500 V setting, megger the "DCP" or the "DCN" to ground. Connect the positive to "DCP" or the "DCN" and connect to the negative to the location in Illustration 14.
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   Illustration 15	g02160916

9. In the contractor compartment, using the 2500 V setting, megger the "CNP" or the "CNN" to ground. Leave the ground in the previous location. The reading should be 2 megaohms or greater of resistance to ground.

   Note: "IP" and "IN" must be disconnected from RGBI (C) for correct reading.

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   Illustration 16	g02161299
   View of the motor 1 connection

10. Open the "HV" cable connection compartment. Individually megger each phase of the "motor 1" cable using the 2500 V setting . The reading should be 2 megaohms or greater of resistance to ground.

    Note: Only necessary to megger each phase, if the motor is not connected. When motor is connected one phase is enough. The connected motor makes the connection between the phases while testing.

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    Illustration 17	g02161435
    View of the generator connection

11. Individually megger each phase of the "generator" cable to ground using the 2500 V setting . The reading should be 2 megaohms or greater of resistance to ground.
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    Illustration 18	g02161331
    View of the motor 2 connection

12. Individually megger each phase of the "motor 2" cable to ground using the 2500 V setting one phase. The reading should be 2 megaohms or greater of resistance to ground.
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    Illustration 19	g06403425
    View of the three blower motor cable termination location. (C) Retarding Grid Blower Inverter

13. Access the grid blower motor AC three phase connections at there termination location at rear of inverter cabinet to the bottom of the RGBI (C) per Illustration 19. Change test setting to 1000 V. Individually megger each phase of the three blower motor cables to ground at 1000 V setting.

    Reference: Refer to Service Manual, UENR3890, "Troubleshooting 794 AC Off-Highway Truck" to troubleshoot the electrical system.

14. If the system meggers ok, remove the tool, remove the jumper wire, restore the intentional ground wire, and restore the disconnected RGBI wires.
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    Illustration 20	g06402940

15. Install covers (A) onto the inverter cabinet.
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    Illustration 21	g03788807

16. Install cover (B) onto the inverter cabinet.

Check the Configuration of the Electronic Control Modules (ECM)

1. Turn on the electrical system power
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   Illustration 22	g03741877
   (4) Battery disconnect switch

   1. Disengage the battery disconnect switch (4). The light will be OFF.

   2. In the cab, turn the key to the ON position.

      Note: The gauges should illuminate all icons and all gauges will swing from full left to full right and return to full left. Advisor should flash red, yellow, and green.

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   Illustration 23	g06285963
   (1) "VIMS" connector (2) "CAT ET" connector (3) 12 V connector

2. Connect a laptop computer to the Caterpillar Diagnostic Connector on the right-hand side of the center counsel.

3. To power the electrical system of the truck, perform the steps that follow:

4. Use your laptop computer to open Caterpillar Electronic Technician. Use the latest version of Caterpillar Electronic Technician.

   Note: The Illustrations that are shown using Caterpillar Electronic Technician are for reference only. Use the latest version of Caterpillar Electronic Technician.

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   Illustration 24	g06299836

5. Verify the machine serial number in the "Product ID" parameter under the "Monitor 794 AC" ECM.

6. Update each parameter under each ECM configuration to meet the site-specific requirements. The ECM configurations are shown in Illustration 24
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   Illustration 25	g06299907

   Note: The "Equipment ID" will need to be set up in each ECM.

7. From the toolbar, select "Service", and select "Configuration".
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   Illustration 26	g06299920

8. From the toolbar, select "Service". Then select "ECM Date/Time".
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   Illustration 27	g03868228

9. Input the correct time zone, the date, and the time.

Enable Hoist

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Illustration 28	g06299934

1. Enable the hoist under the "Chassis 794" ECM.

Set Machine Speed Correction Factor

Table 14

Speed Correction Factor
Tire Size	Manufacturer	Correction Factor
59/80 R63	Bridgstone	2.9804
55/80 R63	Bridgstone	0(1)
56/80 R63	Michelin	2.742
53/80 R63	Michelin	1.2938
59/80 R63	Goodyear	4.3584

(1)

Default

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Illustration 29	g06299956

1. Set the machine speed correction factor under the "Drivetrain 794" ECM.

Injector Code Setting and Calibration

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Illustration 30	g03868243

1. From the toolbar, click "Service". Select "Calibrations". Click "Injector Trim Calibration".

2. Confirm that all the injectors have trim files.

VIMS

Note: Refer to Service Manual, UENR3957, "794 AC Off-Highway TruckVIMS 3G and Truck Payload Measurement System (TPMS)" for additional information on warnings.

Note: Refer to Special Instruction, REHS7412, "VIMS 3GSoftware Installation Guide For Large Off-Highway Truck (LOHT) Using VIMSpc 2011A" information for installation of the VIMS 3G software using VIMSpc 2011A and Cat ET (Version 2010B-v1.0 or newer).

Note: The following screen shots in the Illustrations are for visual reference only. The file-specific information on the Illustrations may differ from the information being displayed on the machine being serviced. Always refer to SIS Web for the latest flash files for the machine being serviced and program updates for the program being used.

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Illustration 31	g06285963
(1) "VIMS" connector (2) "CAT ET" connector (3) 12 V connector

1. Using SIS Web, locate the VIMS Main flash file, VIMS Application flash file, VIMS Main configuration file, and VIMS Application file for your specific Serial Number. Save each file to a local hard drive.

2. Using SIS Web locate the VIMS Wash Configuration File (380-3140.cfg). Save this file to a local hard drive

   Note: Do not change the name of the files when saving to the local hard drive.

3. Connect the VIMSpc download cable ( 305-5528 Cable As) to the service port cable (1) in the cab port on the machine.

4. Connect the Ethernet cable portion of the VIMSpc download cable ( 305-5528 Cable As) to the back of a laptop that is equipped with VIMSpc 2011A.

   Note: The bumper port must be used on machines equipped with MineStar

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   Illustration 32	g02720794
   (1) "Connect" button

5. Launch VIMSpc 2011A from the shortcut on your desktop or through the start menu.

6. Click the "Connect" button (1) that is on the left side of the VIMSpc application screen.
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   Illustration 33	g02720798

7. Select the appropriate port where the connection is being attempted. Select "Cab" for the cab port or "Chassis" for the bumper port. Then click the "OK" button
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   Illustration 34	g02720801
   (2) "Connection Icon"

8. Verify that a connection to the VIMS has been established. The connection to the VIMSpc is established once the "Connection Icon" (2) at the bottom left hand of the screen turns from red to green.
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   Illustration 35	g02738858
   (3) Check box for "Enable resetting cumulative and histogram after download"

9. Select the "Settings" button on the left-hand menu, and check the box for "Enable resetting cumulative and histogram after download" (3).

   Note: This option is active for only one download. Restart VIMSpc to reset this feature.

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   Illustration 36	g02738956
   (4) Box at the top of the column to the left of the "Type" column (5) Checkboxes in the "Reset" column

10. Select "Download" from the left-hand menu. Select the menu item listed as "All" in the "Download Groups Section". Select the box at the top of the column to the left of the "Type" column (4). Selecting the box at the top of the column to the left of the "Type" column will then allow the selection of all the checkboxes in the "Reset" column (5).

    Note: This process will clear the stored VIMS data on the VIMS ECMs, so the database will know that the data is reset. Clearing this data will show a "reset" point in the database for this machine.

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    Illustration 37	g02753117
    (7) "Download" button

11. Select the "Download" button (7) on the bottom of the screen. The resulting files should be forwarded to the person managing the data.
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    Illustration 38	g02936096

12. From the toolbar, click "Configure Equipment" tab and verify that the serial number in the "Onboard" column matches the new serial number in the "User Specified" column.
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    Illustration 39	g02936596

13. In the "Equipment Number" field under the "User Specified" column, change the equipment number to correspond to the new customer machine number.
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    Illustration 40	g02936521

14. Enter the date and time in the "Date/Time" field under the "User Specified" column.
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    Illustration 41	g02936378

15. Click the "Update" button.

    Note: The "SMH" is not resettable.

Preliminary Set-Up Prior to Starting the Engine

Note: Refer to Operation and Maintenance Manual, SEBU9099, "794 AC" for additional information on starting the machine.

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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 body retaining pins. Install the body retaining pins through the ends of the retaining cables. Always use both retaining cables. Failure to properly secure the body (bed) may result in personal injury or death.

Pre-startup Checks

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Illustration 42	g06365743
(1) Brake Drag Front (2) Powered Stairway Down (3) Brake Oil Hot (4) Brake Drag Rear (5) Traction Control System (6) Auto Lube Malfunction (7) Engine Stop (8) Brake Pressure (9) Low Steering Pressure (10) Fuel Level (11) Electrical System Fault 2 (12) Engine Check (13) Hydraulic Oil Temperature (14) Hydraulic Oil Level (15) Retarder (Hot) (16) Electrical System Fault 1

1. Verify function of warning lights and systems.
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   Illustration 43	g06400541
   Accumulator locations (17) Brake Accumulators (18) Steering Accumulators

2. Check and charge brake accumulators (17) and steering accumulators (18). Refer to Special Instruction, REHS5464, "Accumulator Discharging and Charging Procedures".
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   Table 15

   Brake System Accumulator Pre-Charge
   Ambient Temperature	Pre-Charge Pressure
   −23.3° C (−10° F)	5135 kPa (745 psi)
   −17.8° C (−0° F)	5252 kPa (762 psi)
   −12.2° C (10° F)	5368 kPa (779 psi)
   −6.7° C (20° F)	5485 kPa (796 psi)
   −1.1° C (30° F)	5601 kPa (812 psi)
   4.4° C (40° F)	5718 kPa (829 psi)
   10° C (50° F)	5834 kPa (846 psi)
   15.6° C (60° F)	5951 kPa (863 psi)
   21.1° C (70° F)	6067 kPa (880 psi)
   26.7° C (80° F)	6184 kPa (897 psi)
   32.2° C (90° F)	6300 kPa (914 psi)
   37.8° C (100° F)	6417 kPa (931 psi)
   43.3° C (110° F)	6533 kPa (948 psi)
   48.9° C (120° F)	6650 kPa (964 psi)
   54.4° C (130° F)	6766 kPa (981 psi)
   60.0° C (140° F)	6883 kPa (998 psi)

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   Table 16

   Steering System Pressure Accumulator Pre-Charge
   Ambient Temperature	Pre-Charge Pressure
   −23.3° C (−10° F)	8764 kPa (1271 psi)
   −17.8° C (−0° F)	8961 kPa (1300 psi)
   −12.2° C (10° F)	9159 kPa (1328 psi)
   −6.7° C (20° F)	9356 kPa (1357 psi)
   −1.1° C (30° F)	9553 kPa (1386 psi)
   4.4° C (40° F)	9750 kPa (1414 psi)
   10° C (50° F)	9948 kPa (1443 psi)
   15.6° C (60° F)	10145 kPa (1471 psi)
   21.1° C (70° F)	10342 kPa (1500psi)
   26.7° C (80° F)	10539 kPa (1529 psi)
   32.2° C (90° F)	10737 kPa (1557 psi)
   37.8° C (100° F)	10934 kPa (1586 psi)
   43.3° C (110° F)	11131 kPa (1614 psi)
   48.9° C (120° F)	11328 kPa (1643 psi)
   54.4° C (130° F)	11526 kPa (1672 psi)
   60.0° C (140° F)	11723 kPa (1700 psi)

3. Purge the air from the fuel system. Refer to Operation and Maintenance Manual, SEBU9099, "Fuel System - Prime"

4. Inflate the tires to the correct pressure and record the tire specifications in Table 17.
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   Table 17

   Tire Size		Manufacturer
   Left Front
   Right Front
   Left Rear Outside
   Left Rear Inside
   Right Rear Inside
   Right Rear Outside

5. Verify that the engine cooling fan is not tied to the shroud.

Purge the brakes

1. Prepare hydraulic components

   • Open the two hydraulic tank gate valves

   • Verify that all brake line and bleeder screws are tight

   • Verify that all hydraulic line connections are installed correctly and are tight

   • Verify all pressure gauges are tight and sealed

   • Verify that all solenoids, sensors, and switches are installed and connected to the correct wiring connector

   • Leave the manual drain buttons in the open position for initial start
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   Illustration 44	g06396096
   Side view of service center

2. Use service center (A) (If Equipped) for filling the hydraulic tank to ensure that hydraulic oil is being filtered. If machine is not equipped with service center, filter oil with a 4-micron filter before filling the hydraulic tank.
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   Illustration 45	g06396171
   Top view of case drain lines

3. Fill the hydraulic tank to the upper site gage (Body Lowered) or the lower site gage (Body Raised) depending on body position. Crack open the steering case drain line (B) and fan pump case drain line (C) to ensure that any air is bled out and that the drive pump is full of hydraulic oil. Disconnect breather hose at location (BB) and cap with tool (T3).

   Note: Monitor case drain lines and capped breather port once tank is pressurized in step 6. As oil begins to escape these locations, tighten case drain lines and breather cap.

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   Illustration 46	g06396218
   View of hydraulic cabinet

4. Replace brake accumulator pressure gage in hydraulic cabinet at location (D) with elbow connector and quick disconnect test fitting Tooling (T4) per Illustration 46. Connect one end of an air purge line to test fitting and place other end of line into suitable container.

   Note: Hydraulic cabinet is equipped with factory installed gages. Gages may be replaced with pressure taps.

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   Illustration 47	g06396276
   View of hydraulic tank

5. Temporarily remove breather (E) located at the top of the hydraulic tank and cap hole. Insert an air adapter and regulator at location (F) per Illustration 47.

6. Pressurize hydraulic tank to 70 kPa (10 psi) to prime hydraulic system.Do not put additional pressure on hydraulic system. 70 kPa (10 psi) Maximum.

   Note: Do not start the engine

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   Illustration 48	g06396764
   Battery disconnect switch and emergency shut down

7. Depress emergency shutdown (H) and activate battery disconnect switch (G) to dry-start engine. Perform at least two dry-start cranks for 15 seconds maximum. Wait at least one minute between engine cranks.
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   NOTICE
   At brake accumulator pressure tap (D), the first crank may only show a small amount of oil present after 15 seconds. The second crank should show a steady stream of oil. If a steady clear oil stream is not showing, repeat until a steady clear oil stream is present. This is a critical step for filling the hydraulic cabinet to purge air from the highest location in the hydraulic circuit.

8. After air has been purged from hydraulic cabinet, remove air supply that was installed in Step 5. Reinstall hydraulic tank breather that was removed in Step 5 and drive box breather hose in location (BB) that was capped off in Step 3.

9. Remove brake accumulator air purge line that was installed in Step 4.

10. Verify hydraulic oil level in hydraulic tank and add oil as required.
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    Illustration 49	g06397888
    Steering Manifold located on inside Left-Hand frame rail.

11. Remove test fitting in location (J) and replace with elbow connector and quick disconnect test fitting Tooling (T4).

12. Connect a 34474 kPa (5000 psi) pressure gage to the steering pump test fitting (J).

13. Start engine and run at low idle. If abnormal pump noise is detected, shut engine off. Repeat Steps 5 through 10. If no abnormal pump is detected continue to Step 14.
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    Illustration 50	g06398173
    Top view of steering pump compensator valve location

14. Run engine at low idle and allow the machine system pressures to settle. Verify steering pump output pressure of 24100 ± 700 kPa (3500 ± 100 psi) at location (J). Adjust the steering pump compensator valve (K) setting if required.

15. Slowly perform steering cycles through the entire steering range. Go from stop to stop. Do not hold at full stop and immediately switch direction. Perform at least 6 cycles (3 in each direction). Re-center the front tires when steering cycles are completed.
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    Illustration 51	g06398352
    Priority Valve located on inside Left-Hand frame rail.

16. Listen to blower motor. Verify that the motor is operating at a steady rpm of 1250 ± 50 (check in Advisor menu) with engine at low idle. If the blower motor speed is unsteady, measure priority valve pressure at location (M) and lower valve pressure setting at location (N).

    • Install Test fitting Tool (T5) in location (M)

    • Clockwise turn increases pressure, counterclockwise turn decreases pressure

    • Priority valve pressure settings should not be set below 20684 kPa (3000 psi)
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    Illustration 52	g06398433
    Top view of fan pump solenoid location

17. Unplug fan pump connector (P) to bring pump to full displacement. Run the fan for at least 2 minutes. Reconnect fan pump connector (P). Verify fan rpm reduces to a slow/loping speed.

18. Operate hoist system at low idle. Raise body to full raised position. Immediately lower body by power down mode. Repeat the raise and lower cycle 5 times.

19. Shut down machine for 30 to 60 minutes to allow any air in the hydraulic system to vent out of the hydraulic tank breather (E). Verify hydraulic oil level and add oil if necessary.

20. Restart the engine and run at low idle.
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    Illustration 53	g06400470
    Brake bleed locations

21. Purge the brake system. Refer to Testing and Adjusting, UENR2267, "Brake System Air - Purge" and bleed the following systems in order.

    Note: Service brakes and parking brakes should be purged of air for a minimum of 1 minute at each wheel to ensure that a steady stream of clear oil is flowing.

    Note: Use secondary brake pedal (Red Pedal) for service brake purging.

    Note: Bleeders may need to be installed in parking brake bleeder locations. Install tooling (T6) onto park brake bleed locations as required.

    1. Service brake front slack adjuster (P1)

    2. Service brake left front wheel (P2)

    3. Service brake right front wheel (P3)

    4. Service brake rear slack adjuster (P4)

    5. Service brake left rear wheel (P5)

    6. Service brake right rear wheel (P6)

    7. Park brake relay valve in hydraulic cabinet (P7)

    8. Parking brake left front wheel (P8)

    9. Parking brake right front wheel (P9)

    10. Parking brake left rear wheel (P10)

    11. Parking brake right rear wheel (P11)
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    Illustration 54	g06400170
    SOS port location

22. Obtain hydraulic oil sample at the SOS sampling port (R) at oil cooler inlet.

    Note: If there is no SOS port in location (R), install tool (T7)

23. Check particle count.

    • Refer to Tool Operating Manual, NEHS0799, "170-8500 Analyzer Group" for proper installation and operation. Caterpillar recommends connecting the on-line particle counters directly to the SOS valve.

    • Refer to Operation and Maintenance Manual, SEBU6250, "Caterpillar Machine Fluids Recommendations" for fluid cleanliness recommendations.

24. If kidney looping is required, refer to Contamination Control Guidelines, SEBF8840, "Basic Principles of Kidney Loop Filtering Hydraulic Fluid Systems"

25. Change filter elements. Inspect filter elements for metallic particles that may be a sign of pump damage. Cut into filter pleats if deeper investigation is required.

26. Change or inspect breathers as required.

27. Recheck particle count.

Start the Engine

1. Verify that all the fluids are at an acceptable level.

   Note: Refer to the Operation and Maintenance Manual, SEBU9099, "Capacities (Refill)" for the fluid capacities.

2. Perform air inlet system test. This test must be performed prior to starting the engine. Refer to Testing and Adjusting, UENR2267, Air Inlet System - Test and Inspect.
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   Illustration 55	g06322198
   View of the battery disconnect switch

3. Move battery disconnect switch (A) to the ON position.

4. Chock the wheels.

5. Ensure that the machine is in PARK.

6. Hold the key switch to the START position to prime the engine. The engine will pre-lube until the engine builds 48 kPa (7 psi) or for 45 seconds.

   Note: Do not allow the engine to start. Do not cycle the key to override the engine pre-lube. If the engine does not crank, turn off the key for 30 seconds and repeat Step 6.

7. Start the engine and allow the engine to run for 10 seconds. After 10 seconds, turn the key switch to the OFF position.

8. Use Cat ET and hydraulic cabinet to monitor pressures and temperatures.

9. Verify all the hydraulic and engine fluid levels and adjust as needed.

10. Repeat Step 7 and Step 9 until all the fluid levels are correct.

    Note: The Advisor may instruct the operator to shut down the engine to resolve any issues. All issues must be resolved before restarting the engine.

11. Start the engine again and allow the engine to idle.

12. Perform a walk around inspection to check for leaks. Monitor all the engine and hydraulic fluid levels.

13. With the engine on, turn the steering wheel from the center position to the left. Next, turn the steering wheel back to the center position. Verify that the wheels turn in the correct direction.

    Note: To reduce excessive wear of the tires. do not turn the wheels full right or full left.

14. Turn the engine off.

Pressure Specifications

Table 18

Hoist System
Hoist Raise Pressure	20684 kPa (3000 psi)
Hoist Lower Pressure	3447 kPa (500 psi)

Table 19

Brake System
Accumulator Nitrogen Charge Pressure	6067 ± 345 kPa (880 ± 50 psi)
Service Brake Valve Pilot Pressure	0 kPa (0 psi) to 2758 kPa (400 psi)
Pressure at the brake packs (packs fully depressed)	6067 ± 345 kPa (880 ± 50 psi)

Table 20

Parking Brake
Parking Brake Release Pressure	4598 ± 345 kPa (667 ± 50 psi)
Parking Brake Pressure in PARK
Parking Brake Pressure in NEUTRAL	4598 ± 345 kPa (667 ± 50 psi)

Table 21

Steering System
Accumulator Nitrogen Charge Pressure	10342 ± 345 kPa (1500 ± 50 psi)
Steering Pump High Idle RAX Off	24100 ± 700 kPa (3500 ± 100 psi)
Accumulator Pressure Test	24100 ± 700 kPa (3500 ± 100 psi)
Steering System Load Sensing Relief	23000 ± 500 kPa (3335 ± 72 psi)

Perform the Aftertreatment System Functional Test (if Tier 4 Equipped)

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NOTICE
Confirm that the latest software vintage is flashed to the engine and aftertreatment prior to performing functional testing.

Note: All images of Cat Electronic Tecnician (ET) screens are for reference only. Use the most upto date version of ET available.

1. Use a laptop computer to open Cat Electronic Technician (ET).
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   Illustration 56	g06369745

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   Illustration 57	g06369675
   Side view of machine (1) Clean Emissions Module (CEM) (2) Pump Electronic Tank Unit (PETU)

2. Confirm correct serial numbers for the Clean Emissions Module (CEM) and Pump Electronic Tank Unit (PETU).

   1. Check the value of the "Factory Installed Aftertreatment #1 Identification Number" and ensure that the serial number is correct. If incorrect, enter the correct number.

   2. Check the value of the "Aftertreatment DEF Pump Electronics Tank Unit Identification Number" and ensure that the serial number is correct. If incorrect, enter the correct number.
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   Illustration 58	g03825970

3. From the toolbar, select "Diagnostics" then "Diagnostic Tests".
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   Illustration 59	g06369767

4. Select "Aftertreatment System Functional Test" and click "Start".
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   Illustration 60	g03825152

5. Read and understand the warning. Click "OK" to proceed to the test.
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   Illustration 61	g03825157

6. Click "Next" to proceed to the test.

Charge the A/C system with refrigerant

Illustration 62	g06345392
Air conditioning compressor location

Refer to Testing and Adjusting, UENR4125, "Air Conditioning and Heating R134a for All Cat Machines". Check and charge the Air Conditioning system.

Ground Level Controls Function

Illustration 63	g06321963
Battery disconnect switch

Illustration 64	g06321955
Lighting and engine shutdown switch

Table 22

Ground Level Controls	Check if OK
Turn the battery disconnect switch (1) to the ON position
Turn the ignition key to the ON position
Turn on the access light switch (2)
Turn on the engine compartment light switch (3)
Start the engine
Press the engine shutdown switch (4), engine should stop(1)
Pull out engine shutdown switch (4)
Start the engine
Turn the ignition key to the OFF position

(1)	Shutdown switch (4) stops fuel flow to the engine. Steering system may still be able to operate with accumulator pressure.

Cab Instrumentation and Functional Checks

Illustration 65	g06321553
(1) Flood Light (2) Engine Stop/Start Switch (3) Load Brake Button Switch (4) Power Outlet/Cigar Lighter (5) Press to Test (Lamp Check) (6) Park Brake Indicator (7) Air Conditioner Switch (8) Heater Switch (9) Fan Speed Switch (10) Accelerator Pedal (11) Hoist Control (12) Dynamic Retarder Pedal (13) Service Brake Control Pedal (14) Steering Wheel Control (15) Steering Wheel Tilt and Telescope Control (Lever) (16) Multifunction Switch (17) Delayed Engine Shutdown Switch (18) Auto Lube Manual Operation Switch (19) Auto Lube Alarm Reset (20) Throttle Lock (21) Stairway Light (22) Head/Tail Light (23) Window Wiper/Washer Switch (24) Front Fog Light Switch (If equipped) (38) Radio

Cab Doors

Table 23

Check the operation of Cab Doors	Check if OK
	LH	RH
Proper seal when door is closed
Ensure outside handle function
Ensure inside handle function
Turn the ignition key to the ON position
Fully lower and raise power window
Turn the ignition key to the OFF position

Pressurize the Cab

Table 24

Check the Operation of the Blower Motor to Pressurize the Cab(1)	Check if OK
Turn the ignition key to the ON position
Turn switch (9) to check the four blower speeds(2)
Turn the ignition key to the OFF position

(1)	Pressurizing the Cab helps to eliminate dust in the operators compartment
(2)	There should be an audible sound between the different settings

Climate Control

Illustration 66	g06288640
Heater lines location (H1) Supply heater valve (H2) Return heater valve

Table 25

Check the operation of the Heater and the Air Conditioner	Check if OK
Ensure heater lines (H1) and (H2) are open
Start the engine
Turn on the blower motor switch (9)
Turn on air conditioner switch (7)
Air from the dash vents should be cold(1)
Turn off air conditioner switch (7)
Turn on heather switch (8)
Air from the dash vents should be warm (1)
Turn the ignition key to the OFF position

(1)	When the engine is at operating temperature

Window Wipers

Table 26

Check the Operation of the Window Wiper and Washer	Check if OK
Turn the ignition key to the ON position
From the OFF position, turn the window wipers to the LOW setting
Turn the window wiper switch (23) to the HIGH setting
Press the button to activate the window washer fluid
Turn the window wiper to the first INTERMITTENT setting
Turn the window wiper to the second INTERMITTENT setting
Turn the window wiper to the third INTERMITTENT setting
Turn the window wipers to the OFF position
Turn the ignition key to the OFF position

Flood Light

Table 27

Check the operation of the Panel Lights and the Headlights(1)	Check if OK
Turn the ignition key to the OFF position
Pushing switch (1) up to the first detent turns on the Park Lights and the Taillights. Pushing switch (1) to the second detent turns on the headlights (4) , park lights, and taillights
Dimmer for the panel lights. Pressing the top of the switch makes the lights brighter and the bottom makes the lights dimmer
Use multifunction switch (3) to toggle between low beam lights (4) and high beam lights (5)
Push the bottom half of switch (1) to the OFF position to deactivate the headlights
This switch turns on the fog lights and works only when the headlights are on low
Need to verify that the park lights and tail lights are operational

(1)	The tail lights should be on any time a light switch is activated

Front Fog Light

Table 28

Check the operation of the Fog Lights	Check if OK
Turn the ignition key to the OFF position
Push the top half of switch (24) to activate fog lights (6)
Push the bottom half of switch (24) to deactivate fog lights (6)

Head/Tail Light

Table 29

Check the operation of the Head/Tail Lights	Check if OK
Turn the ignition key to the OFF position
Push the top half of switch (22) to activate Head/Tail Lights
Push the bottom half of switch (22) to Head/Tail Lights

Stairway Light

Table 30

Check the operation of the Auxiliary Lights(1)	Check if OK
Turn the ignition key to the OFF position
Push the top half of switch (9) or switch (10) to activate the access lights
If necessary, adjust the access light to provide light for the steps
Push the bottom half of switch (9) or switch (10) to deactivate the access lights

(1)	The access lights can be activated from two places on the machine. The position of one switch will determine whether the other switch is in the ON position or in the OFF position.

Turn Signal

Table 31

Check the operation of the Turn Signals	Check if OK
Turn the ignition key to the ON position
Use multi function switch (16) to activate Left turn signal
Use multi function switch (16) to activate Right turn signal

Hazard Lights

Table 32

Check the operation of the Hazard Lights	Check if OK
Turn the ignition key to the OFF position
Use multi function switch (16) to activate the Hazard Lights

Brake Lights

Table 33

Check the operation of the Brake Lights	Check if OK
Turn the ignition key to the ON position
Depress dynamic retarder pedal (12) check brake lights
Depress service brake pedal (13) check brake lights

Backup Alarm

Table 34

Check the operation of the Backup Alarm(1)	Check if OK
The engine is running
Move the shift control lever and the speed control lever to the REVERSE position
The backup alarm should sound immediately(2)

(1)	Make sure that the area behind the machine is clear of personnel and clear of obstacles
(2)	The backup alarm should sound until the shift control lever and speed control lever are moved to the NEUTRAL position or the FORWARD position.

Radio

Table 35

Check the operation of the Radio	Check if OK
Turn the ignition key to the ON position
Power on radio (38)
Check functions of radio (38)

Operators Seat

Illustration 67	g06289649
(25) Headrest (26) Armrest Angle (27) Heat/Vent Selector (If Equipped with Heated and Ventilated Seat (28) Backrest Angle (29) Ride Indicator (30) Fore/Aft Adjustment (31) Height Adjustment (32) Seat Heater/Ventilation (If Equipped with Heated or Heated and Ventilated Seat) (33) Damper (34) Seat Cushion Tilt (35) Lumbar Support (36) Seat Belt Latch (37) Shoulder Belt Adjustment

Table 36

Check for Seat Adjustability	Check if OK
Full range of the back reclining positions
Full range of the headrest positions
Full range of the arm rests positions
Full range of the seat cushion tilt
Full range of the seat suspension travel
Check the range of the light to heavy dampening for the seat
Full range of the lumbar support
Seat Heater/Ventilation function and adjustment (If Equipped)

Table 37

Check Seat Belt Latch and Seat Belt Adjustability	Check if OK
Adjust the length of the seat belt
Fasten the seat belt catch into the buckle
The seat belt must not be able to slip after adjusting
The seat belt catch should unlatch from the buckle when required

Passenger/Buddy Seat

Illustration 68	g06321914
(25) Headrest (28) Backrest Angle (29) Ride Indicator (30) Fore/Aft Adjustment (31) Height Adjustment (33) Damper (34) Seat Cushion Tilt (35) Lumbar Support (36) Seat Belt Latch

Table 38

Check for Seat Adjustability	Check if OK
Full range of the back reclining positions
Full range of the headrest positions
Full range of the seat cushion tilt
Full range of the seat suspension travel
Check the range of the light to heavy dampening for the seat
Full range of the lumbar support

Table 39

Check Seat Belt Latch and Seat Belt Adjustability	Check if OK
Adjust the length of the seat belt
Fasten the seat belt catch into the buckle
The seat belt must not be able to slip after adjusting
The seat belt catch should unlatch from the buckle when required

Speedometer Calibration

Illustration 69	g06341964

Depress buttons (A) and (B) while turning on the ignition to enter the setup menu.

Calibrate the speedometer per settings in Operation and Maintenance Manual, SEBU9099, " Monitoring System ".

Table 40

Speedometer Menu	Setting Selection
Self Test
Engine Type
Speedo Source

Autolube System

Purge the Autolube System

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NOTICE
Ensure that all the automated grease injectors are receiving a sufficient supply of grease.

1. Manually purge the autolube system.
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   Illustration 70	g03784049
   View for the front left-hand and right-hand side injectors

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   Illustration 71	g06322255
   View for the rear injectors

2. Adjust the grease injectors, as required. Refer to Testing and Adjusting, UENR2267, "Automatic Lubrication System - Adjust".

Inspect Grease Points

Inspect the grease points of the automatic lubrication system. Ensure that grease is reaching all points of lubrication.

Manually Actuate Grease System

Illustration 72	g06323336
Autolube pressure gauge (1) Manual Actuation Button

Use button (1) to manually actuate the autolube system. Ensure that the pressure builds in the system to 17237 kPa (2500 psi).

Verify Grease Alarm Function

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Illustration 73	g06341148
Autolube cycle timer location (2) Autolube Timer

1. Change setting of timer (2) from minutes to seconds.

2. Manually actuate autolube system. Autolube warning light should activate.

   Note: The changed timer setting does not allow enough time for pressure to build in the system before attempting to cycle again. The low pressure warning is normally an indication of no grease in the tank or a broken line to the injector banks.

3. Reset timer (2) to minutes.

Body Installation Inspection

Table 41

Record Body information
Body Manufacturer/Part Number
Serial Number
Condition

Body to Chassis Interference

1. When properly shimmed there should be no gaps between the body and the chassis.

2. If the truck is equipped with body heat, verify the proper adjustment of the body heat connection.

3. Check the hoses on top of the hydraulic tank, fuel tank, and the hoses between the frame rails. If necessary, adjust the grease line at the top of the hoist cylinder to prevent any damage.

Suspension Cylinder Charging

Dump body must be installed for proper suspension cylinder charging.

Rear Suspension Charge

1. Ensure that the machine is on a level surface, the wheels are chocked, and the frame and dump body are clean from dirt and debris.
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   Illustration 74	g06288171
   Typical view of a rear suspension cylinder (A) Rear Suspension Assembly (B) Measurement from Center of Pin to Pin

   Note: Rear suspension cylinders should be charged simultaneously

2. For both rear suspension cylinders (A), verify proper oil height by measuring from pin center to pin center. A pin to pin measurement (B) of 1514.6 mm (59.63 inch) indicates proper oil height prior to nitrogen charge.

   Refer to Special Instruction, M0092742, "Servicing the Suspension Cylinders for 794 AC Off-Highway Trucks" for adding oil to suspension cylinders.

3. Charge rear suspension cylinders (A) until pin to pin measurement (B) reaches 1571.75 ± 13 mm (61.88 ± 0.5 inch).

   Refer to Special Instruction, M0092742, "Servicing the Suspension Cylinders for 794 AC Off-Highway Trucks" for suspension cylinder charging procedure.

Table 42

Rear Suspension Cylinders
	Pin to Pin Oil Level		Pin to Pin Final
	Target	Actual	Target	Actual
Left Cylinder	1514.6 mm (59.63 inch)		1571.75 ± 13 mm (61.88 ± 0.5 inch)
Right Cylinder

Front Suspension Charge

1. Ensure that the machine is on a level surface, the wheels are chocked, and the frame and dump body are clean from dirt and debris.
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   Illustration 75	g06288226
   Typical view of a front suspension cylinder (C) Front Suspension Assembly (D) Measurement from Center of Pin to Pin

   Note: The front suspension can be charged individually or simultaneously.

2. For both front suspension cylinders (C), verify proper oil height by measuring from pin center to pin center. A pin to pin measurement (D) of 1593.85 mm (62.75 inch) indicates proper oil height prior to nitrogen charge.

   Refer to Special Instruction, M0092742, "Servicing the Suspension Cylinders for 794 AC Off-Highway Trucks" for adding oil to suspension cylinders.

3. Charge front suspension cylinders (C) until pin to pin measurement (D) reaches 1755 ± 13 mm (69.1 ± 0.5 inch).

   Refer to Special Instruction, M0092742, "Servicing the Suspension Cylinders for 794 AC Off-Highway Trucks" for suspension cylinder charging procedure.

Table 43

Front Suspension Cylinders
	Pin to Pin Oil Level		Pin to Pin Final
	Target	Actual	Target	Actual
Left Cylinder	1593.85 mm (62.75 inch)		1755 ± 13 mm (69.1 ± 0.5 inch)
Right Cylinder

Check the Configuration of the Electronic Control Modules (ECM)

Reference: Service Manual, UENR3957, "794 AC Off-Highway TruckVIMS 3G and Truck Payload Measurement System (TPMS)"

Reference: Refer to Service Magazine, SEPD1178, "Switch Settings for the Payload Monitors" for additional information on the switch settings for the payload monitors.

Check for Active Diagnostic Codes and Logged Diagnostic Codes

Note: The payload diagnostic codes will be active until the system is calibrated.

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Illustration 76	g03868244

1. From the toolbar, click "Diagnostic". Click "Active Diagnostic Codes".

2. Resolve any of the active diagnostic codes.
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   Illustration 77	g03868247

3. From the toolbar, click "Diagnostics". Click "Logged Diagnostic Codes".
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   Illustration 78	g03868249
   Typical view

4. Clear any logged diagnostic codes by highlighting an event. Next, click the "Clear" button that is located in the lower left corner of the screen.
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   Illustration 79	g03868330

5. From the toolbar, click "Diagnostics". Select "Events" and click "Logged Events".

6. If necessary, resolve any logged events and clear any logged events.

7. Clear the logged event by selecting an event and clicking the "Clear" button that is located in the lower left corner of the screen.

   Note: A factory assigned password may be required to clear some events that are logged on the engine "ECM".

Ground Protection

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The Power Train Electric Drive System will contain hazardous voltage levels during machine operation and for a short period of time after engine shutdown. Do not remove any covers that will expose energized high voltage electrical components while the engine is operating. Any type of maintenance on the following components can only be performed after the Power Train Electrical System Service Shutdown procedure has been followed: High voltage compartments in the inverter cabinet The rear axle housing that contains the electric drive traction motors The generator The retarding resistor grid, the grid blower motor and the grid system cabling The excitation field regulator The high voltage cables and connection enclosures Failure to follow these instructions could result in personal injury or death.

1. Prepare the machine for maintenance. Shut down and discharge the high-voltage electrical system.

   Note: Refer to Operation and Maintenance Manual, SEBU9099, "794 AC Off-Highway Truck" for additional information on the ground protection.

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   Illustration 80	g06289594

2. Open cover (1) for the retarding contactor compartment on the inverter cabinet.

3. Temporarily attach an insulated jumper wire FROM ground plate (2) TO EITHER DC positive bus bar (3) OR DC negative bus bar (4).

4. Close the cover for the retarding contactor compartment.

5. Deactivate the engine lockout control. refer to Operation and Maintenance Manual, "Engine Lockout Control" for more information.

6. Start the engine and allow the voltage for the DC power bus to climb above 500V.

   Note: The voltage for the DC power bus can be monitored on the Advisor screen or through ET.

7. Verify that a warning category 1 ground fault event is logged. The message "DC Ground Fault" can be viewed through the Advisor screen or through ET.

   Note: The message "DC Ground Fault" will take approximately 10 seconds to be logged.

8. If a warning category 1 ground fault event is not logged, troubleshoot the ground fault procedure. For more information, refer to Troubleshooting, UENR3890 or contact your Caterpillar dealer.

9. Stop the engine.

10. Perform the drive train electrical system shutdown procedure.

11. Open the cover for the retarding contactor compartment.

12. Remove the temporary jumper wire and securely close the access door.

13. Close the cover for the retarding contactor compartment.

Perform Brake Holding Tests

Refer to Operation and Maintenance Manual, SEBU9099, "Braking System - Test" and perform the braking tests.

Table 44

Brake Holding Tests	Check if OK
Service Brake Holding Ability Test
Secondary Brake Holding Ability Test
Parking Brake Holding Ability Test
Load Brake Test

Steering System Test

Reference: Testing and Adjusting, UENR2267, Steering System - Check

Note: A full right or left turn shall be made with a reasonable amount of effort.

1. Chock the wheels. Start the engine and run at high idle.

2. Turn the steering wheel to the left and hold it against the stop. Check for leaks and verify accumulator pressure.

3. Turn the steering wheel to the right and hold it against the stop. Check for leaks and verify accumulator pressure.

4. Turn the steering wheel from one stop to the other stop and count the revolutions.
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   Table 45

   Steering System Test
   Test	Actual		Check if ok
   Steering Wheel Left	No Leaks
   	Accumulator Pressure	24131 ± 690 kPa (3500 ± 100 psi)
   Steering Wheel Right	No Leaks
   	Accumulator Pressure	24131 ± 690 kPa (3500 ± 100 psi)
   Stop to Stop	6 Revolutions Max

Set Engine Radiator Maximum Speed

1. Chock the wheels.

2. Start the engine.
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   Illustration 81	g06287751
   Bottom view (1) Radiator Fan Pump

3. Unplug solenoid from pump (1) to increase pump flow to maximum output.

4. Use Cat ET or VIMS Monitor to verify fan speed per specifications in table 46.

   Note: Pump (1) adjustments may be required.

Table 46

Hydraulic Fan Speed
Actual Fan Speed At Low Idle	255 rpm at 700 Engine rpm
Actual Fan Speed At High Idle	650 rpm at 1800 Engine rpm

Set Drivetrain Cooling Fan Speed

1. Chock the wheels.

2. Start the engine.
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   Illustration 82	g06287836
   (1) Drivetrain Cooling Fan Pump

3. Unplug solenoid from pump (1) to increase pump flow to maximum output.

4. Use Cat ET or VIMS Monitor to verify fan speed per specifications in table 47.

   Note: Pump (1) adjustments may be required.

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   Illustration 83	g06365558
   (2) Rear Axle Housing Vent

5. Verify sufficient air flow out of the rear axle housing vent (2) with drivetrain cooling fan running.

Table 47

Blower Fan Speed
Engine Speed	Target Fan Speed	Actual
Below 1300 rpm	1250 ± 25 rpm
Above 1300 rpm	2800 to 3200 rpm

Grid Dry Function

Illustration 84	g03664695

Use adviser to manually activate Grid Dry function.

Refer to Operation and Maintenance Manual, SEBU9099, " Monitoring System " for more information on Grid Dry function and settings.

Table 48

Grid Dry	Check if OK
Manual Grid Dry function

Engine Performance Test

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NOTICE
Clear personnel from machine platform before performing test.

1. Refer to Engine Performance - Test, UENR2267 and perform test.

   Note: The engine should be at normal operating temperature and the shift control lever should be in the PARK position.

2. Record figures from test for a baseline.

   Note: A screen shot can be taken in ET for records.

Manual Motor Disable

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NOTICE
Clear the surrounding area around the truck. The motor disable procedure requires moving the machine.

1. Prepare the truck to be moved.
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   Illustration 85	g02207433

2. Select the "Service Settings" and press "OK".
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   Illustration 86	g02207473

3. Enable the "Service Mode". Press the "HOME" button after enabling the service mode.
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   Illustration 87	g02207494

4. Select "Settings" from the main menu. Press "OK".
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   Illustration 88	g02207515

5. Select "Drivetrain". Press "OK".
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   Illustration 89	g02207535

6. Select "Drv Mtr Disable Config". Press "OK".
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   Illustration 90	g02207554

7. Use the arrows to select the drive motor that you would like to disable. Press "OK" after you have selected the correct motor.
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   Illustration 91	g02207693

8. The following message will be displayed to show which motor has been disabled.

9. Disable drive motor one.

10. Place the shift control lever into D and move the truck forward.

    Note: Verify that the truck moves in the correct direction and that no faults were logged.

11. Place the shift control lever into R and move the truck backward.

    Note: Verify that the truck moves in the correct direction and that no faults were logged.

12. Engage drive motor one.

13. Disable drive motor two.

14. Place the shift control lever into D and move the truck forward.

    Note: Verify that the truck moves in the correct direction and that no faults were logged.

15. Place the shift control lever into R and move the truck backward.

    Note: Verify that the truck moves in the correct direction and that no faults were logged.

16. Engage drive motor two.

    Note: Verify that both drive motors are enabled.

Truck Payload - Calibrate

Dump body installation and suspension cylinder charging must be completed prior to payload calibration.

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Illustration 92	g02202273

1. Select the "Service" mode. Select "Calibration" mode.
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   Illustration 93	g02202276

2. Select "Truck Payload" mode.
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   Illustration 94	g02202278

3. Select "Truck Payload Calibration".

Emissions Compliance Report (Tier 4 Equipped Machines)

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Illustration 95	g06370761

1. From the toolbar, click "Information" and "Product Status Report".
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   Illustration 96	g03394193

2. Run the Product Status Report.

   Note: The Product Status Report will show the injector codes.

After you complete the final check, sign your name and the name of the dealer. Make copies of the check procedure, and the Product Status Report as an ".xml" file. Mail (or e-mail) the copies to the following addresses:

Note: If needing to view the ".xml" file, word-processing software can be used.

Caterpillar Inc.
Attention: Product Support Engineer
794 AC Off-Highway Trucks
97 E. Congress St
Tucson, AZ 85701

Caterpillar Inc.
P.O. Box 600
Mossville, Illinois 61552-0600
Attention: Emissions Compliance Manager

Also, email a copy of the check procedure to:

Emissions_Compliance@cat.com

Dealer:____________________

Inspector Signature:____________________

Customer:____________________

Product Identification Number:____________________

Baseline Measurements

Operate the machine for 50 hours. After the initial 50 hours of operation baseline measurements of the following procedures must be recorded. Comparing the baseline measurements to future measurements of the same procedures, helps track component wear.

Record baseline measurements of the following procedures:

Kingpin Baseline Check

Refer to Testing and Adjusting, UENR2267, Kingpin (Front) - Check for the procedure to establish Kingpin Baselines.

Table 49

Kingpin Measurement
Machine Side	Indicator Location	Baseline Measurement
Right-hand Kingpin	Upper
	Lower
Left-hand Kingpin	Upper
	Lower

Rear Axle Housing Bearing (Nosecone) Baseline Check

Refer to Testing and Adjusting, UENR2267, Rear Axle Housing Bearing - Inspect for the procedure to establish Rear Axle Housing Bearing (Nosecone) Baselines.

Table 50

Rear Axle Housing Bearing (Nosecone) Baseline
Trial Number	Vertical	Horizontal 1	Horizontal 2
Trial 1
Trial 2
Trial 3

Brakewear Indicator Baseline Check

Refer to Testing and Adjusting, UENR2267, Service Brake Discs - Check for the initial set up procedure of Front Brake Wear Indicators and the procedure to establish Rear Brake Wear Baselines.

Table 51

Initial Setting of the Front Brake Wear Indicator
Wheel	Setting Complete
RH Front Wheel
LH Front Wheel

Table 52

Rear Brake Wear Baseline
Wheel	Baseline Measurement
RH Rear Wheel
LH Rear Wheel

Worksheets

Table 53

Dealer Information for Commissioning Procedure
Date
Serial Number
Service Meter Units
Name of the Technician
Unit Number
Engine Serial Number
Pump Electronic Tank Unit (PETU) Serial Number(1)
Clean Emissions Module (CEM) Serial Number(1)
Dealer
Dealer Code
Customer
Job Site
Right-Hand Wheel Station Serial Number
Left-Hand Wheel Station Serial Number
Rear Axle Serial Number
Body Manufacturer/Part Number
Body Serial Number
General Body Condition

(1)	If Tier 4 equipped

Table 54

Miscellaneous Checks
Take Digital Photos of Completed Truck
Missing Parts(1)
Performance Issues
Dealer Installed Attachments(2)
Dealer Comments(3)
Verify the function of all Cab Controls
Verify the function of the Engine Aftertreatment(4)
Payload Target

(1)	Develop a list of all the part numbers and the next highest part number level.
(2)	Take digital photos of all dealer installed attachments.
(3)	Record positive and negative comments.
(4)	If Tier 4 equipped

Table 55

Checking the Fluid Levels	Check if OK
Engine Coolant System(1)
Hydraulic Tank
Engine Crankcase
Left Rear Final Drive
Right Rear Final Drive
Grease for the Autolube
Left Front Wheel Station
Right Front Wheel Station
Window Washer Reservoir
Fuel
Diesel Exhaust Fluid (DEF)(2)

(1)	Check the Jacket Water level.
(2)	If Tier 4 Equipped

Table 56

Location of Ground Straps			Check if OK
Ground Strap		Location
G1	Generator	Right side of the generator to Right- Hand frame rail.(1)
G2	Engine	Right rear engine mount to Right-Hand frame rail.(1)
G3	Upper Cooler	Left-Hand side of cooler to inside of Left-Hand frame rail.(1)
G4	Radiator Group	Left-Hand bottom of cooler to Left-Hand cooler mount.(1)
G5	Superstructure	Left-Hand rear superstructure saddle mount to Left-Hand frame rail.(1)
G6	Rear Axle Housing	Top of rear axle housing front center linkage to frame near cross tube.(1)
G7	RH Drive Motor	Inside the rear axle housing.(2)
G8	LH Drive Motor	Inside the rear axle housing.(2)
G9	Cab	Right front corner under the cover.(2)
G10	Upper Upright Beam	Top box to Left-Hand upright beam.(2)
G11	Lower Upright Beam	Lower box to Left-Hand upright beam(2)
G12	ECM Cabinet	Bottom of ECM cabinet to the deck.(2)
G13	Retarding Grid	Inboard side of the retarding grid to the deck.(2)
G14	Inverter Cabinet	Two cables at the Right rear of the inverter cabinet by cable entry.(2)

(1)	Refer to Illustration 7
(2)	Refer to Illustration 8

Table 57

Pins, Retainers, and Hardware
Inspection Area	Left-Hand Side	Right-Hand Side
Platform Connections
Front Suspension Cylinders
Front Axle Connections
Steering Linkages
Hoist Cylinders
Rear Axle Housing Nosecone Bushing
Rear Axle Housing Rear Linkage
Rear Suspension Cylinders
Rear Dump Body Pins

Table 58

Tire Size		Manufacturer
Left Front
Right Front
Left Rear Outside
Left Rear Inside
Right Rear Inside
Right Rear Outside

Table 59

Ground Level Controls	Check if OK
Turn the battery disconnect switch (1) to the ON position
Turn the ignition key to the ON position
Turn on the access light switch (2)
Turn on the engine compartment light switch (3)
Start the engine
Press the engine shutdown switch (4), engine should stop(1)
Pull out engine shutdown switch (4)
Start the engine
Turn the ignition key to the OFF position

(1)	Shutdown switch (4) stops fuel flow to the engine. Steering system may still be able to operate with accumulator pressure.

Table 60

Check the operation of Cab Doors	Check if OK
	LH	RH
Proper seal when door is closed
Ensure outside handle function
Ensure inside handle function
Turn the ignition key to the ON position
Fully lower and raise power window
Turn the ignition key to the OFF position

Table 61

Check the Operation of the Blower Motor to Pressurize the Cab(1)	Check if OK
Turn the ignition key to the ON position
Turn switch (9) to check the four blower speeds(2)
Turn the ignition key to the OFF position

(1)	Pressurizing the Cab helps to eliminate dust in the operators compartment
(2)	There should be an audible sound between the different settings

Table 62

Check the operation of the Heater and the Air Conditioner	Check if OK
Ensure heater lines (H1) and (H2) are open
Start the engine
Turn on the blower motor switch (9)
Turn on air conditioner switch (7)
Air from the dash vents should be cold(1)
Turn off air conditioner switch (7)
Turn on heather switch (8)
Air from the dash vents should be warm (1)
Turn the ignition key to the OFF position

(1)	When the engine is at operating temperature

Table 63

Check the Operation of the Window Wiper and Washer	Check if OK
Turn the ignition key to the ON position
From the OFF position, turn the window wipers to the LOW setting
Turn the window wiper switch (23) to the HIGH setting
Press the button to activate the window washer fluid
Turn the window wiper to the first INTERMITTENT setting
Turn the window wiper to the second INTERMITTENT setting
Turn the window wiper to the third INTERMITTENT setting
Turn the window wipers to the OFF position
Turn the ignition key to the OFF position

Table 64

Check the operation of the Panel Lights and the Headlights(1)	Check if OK
Turn the ignition key to the OFF position
Pushing switch (1) up to the first detent turns on the Park Lights and the Taillights. Pushing switch (1) to the second detent turns on the headlights (4) , park lights, and taillights
Dimmer for the panel lights. Pressing the top of the switch makes the lights brighter and the bottom makes the lights dimmer
Use multifunction switch (3) to toggle between low beam lights (4) and high beam lights (5)
Push the bottom half of switch (1) to the OFF position to deactivate the headlights
This switch turns on the fog lights and works only when the headlights are on low
Need to verify that the park lights and tail lights are operational

(1)	The tail lights should be on any time a light switch is activated

Table 65

Check the operation of the Fog Lights	Check if OK
Turn the ignition key to the OFF position
Push the top half of switch (24) to activate fog lights (6)
Push the bottom half of switch (24) to deactivate fog lights (6)

Table 66

Check the operation of the Head/Tail Lights	Check if OK
Turn the ignition key to the OFF position
Push the top half of switch (22) to activate Head/Tail Lights
Push the bottom half of switch (22) to Head/Tail Lights

Table 67

Check the operation of the Auxiliary Lights(1)	Check if OK
Turn the ignition key to the OFF position
Push the top half of switch (9) or switch (10) to activate the access lights
If necessary, adjust the access light to provide light for the steps
Push the bottom half of switch (9) or switch (10) to deactivate the access lights

(1)	The access lights can be activated from two places on the machine. The position of one switch will determine whether the other switch is in the ON position or in the OFF position.

Table 68

Check the operation of the Turn Signals	Check if OK
Turn the ignition key to the ON position
Use multi function switch (16) to activate Left turn signal
Use multi function switch (16) to activate Right turn signal

Table 69

Check the operation of the Hazard Lights	Check if OK
Turn the ignition key to the OFF position
Use multi function switch (16) to activate the Hazard Lights

Table 70

Check the operation of the Brake Lights	Check if OK
Turn the ignition key to the ON position
Depress dynamic retarder pedal (12) check brake lights
Depress service brake pedal (13) check brake lights

Table 71

Check the operation of the Backup Alarm(1)	Check if OK
The engine is running
Move the shift control lever and the speed control lever to the REVERSE position
The backup alarm should sound immediately(2)

(1)	Make sure that the area behind the machine is clear of personnel and clear of obstacles
(2)	The backup alarm should sound until the shift control lever and speed control lever are moved to the NEUTRAL position or the FORWARD position.

Table 72

Check the operation of the Radio	Check if OK
Turn the ignition key to the ON position
Power on radio (38)
Check functions of radio (38)

Table 73

Check for Seat Adjustability	Check if OK
Full range of the back reclining positions
Full range of the headrest positions
Full range of the arm rests positions
Full range of the seat cushion tilt
Full range of the seat suspension travel
Check the range of the light to heavy dampening for the seat
Full range of the lumbar support
Seat Heater/Ventilation function and adjustment (If Equipped)

Table 74

Check Seat Belt Latch and Seat Belt Adjustability	Check if OK
Adjust the length of the seat belt
Fasten the seat belt catch into the buckle
The seat belt must not be able to slip after adjusting
The seat belt catch should unlatch from the buckle when required

Table 75

Check for Seat Adjustability	Check if OK
Full range of the back reclining positions
Full range of the headrest positions
Full range of the seat cushion tilt
Full range of the seat suspension travel
Check the range of the light to heavy dampening for the seat
Full range of the lumbar support

Table 76

Check Seat Belt Latch and Seat Belt Adjustability	Check if OK
Adjust the length of the seat belt
Fasten the seat belt catch into the buckle
The seat belt must not be able to slip after adjusting
The seat belt catch should unlatch from the buckle when required

Table 77

Speedometer Menu	Setting Selection
Self Test
Engine Type
Speedo Source

Table 78

Record Body information
Body Manufacturer/Part Number
Serial Number
Condition

Table 79

Rear Suspension Cylinders
	Pin to Pin Oil Level		Pin to Pin Final
	Target	Actual	Target	Actual
Left Cylinder	1514.6 mm (59.63 inch)		1571.75 ± 13 mm (61.88 ± 0.5 inch)
Right Cylinder

Table 80

Front Suspension Cylinders
	Pin to Pin Oil Level		Pin to Pin Final
	Target	Actual	Target	Actual
Left Cylinder	1593.85 mm (62.75 inch)		1755 ± 13 mm (69.1 ± 0.5 inch)
Right Cylinder

Table 81

Brake Holding Tests	Check if OK
Service Brake Holding Ability Test
Secondary Brake Holding Ability Test
Parking Brake Holding Ability Test
Load Brake Test

Table 82

Steering System Test
Test	Actual		Check if ok
Steering Wheel Left	No Leaks
	Accumulator Pressure	24131 ± 690 kPa (3500 ± 100 psi)
Steering Wheel Right	No Leaks
	Accumulator Pressure	24131 ± 690 kPa (3500 ± 100 psi)
Stop to Stop	6 Revolutions Max

Table 83

Hydraulic Fan Speed
Actual Fan Speed At Low Idle	255 rpm at 700 Engine rpm
Actual Fan Speed At High Idle	650 rpm at 1800 Engine rpm

Table 84

Blower Fan Speed
Engine Speed	Target Fan Speed	Actual
Below 1300 rpm	1250 ± 25 rpm
Above 1300 rpm	2800 to 3200 rpm

Table 85

Grid Dry	Check if OK
Manual Grid Dry function

Table 86

Kingpin Measurement
Machine Side	Indicator Location	Baseline Measurement
Right-hand Kingpin	Upper
	Lower
Left-hand Kingpin	Upper
	Lower

Table 87

Rear Axle Housing Bearing (Nosecone) Baseline
Trial Number	Vertical	Horizontal 1	Horizontal 2
Trial 1
Trial 2
Trial 3

Table 88

Initial Setting of the Front Brake Wear Indicator
Wheel	Setting Complete
RH Front Wheel
LH Front Wheel

Table 89

Rear Brake Wear Baseline
Wheel	Baseline Measurement
RH Rear Wheel
LH Rear Wheel