794 AC Off-Highway Truck Field Assembly Caterpillar

Parts and Specification Information

Illustration 1	g03845639

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.

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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.

Installation Procedure

Note: Over the course of the installation of the air lines (turbocharger), adjust the brackets, radiator adjustment rods, and clamps as necessary. All air line connections should not be under tension, and should be as straight as possible.

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Illustration 2	g03846939
View of the left-hand side air lines.

1. Secure the air lines to the platform using the three existing brackets, eight bolts (1), and 14 hard washers (2).

2. Repeat Step 1 for the other side air lines.
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   Illustration 3	g06356794

3. Connect pipe assembly (3) to the left-most air intake line using one hose (4). Secure hose (4) in place using two clamps (5) on each end of the hose.

   Note: Orient each pair of clamps (5) 180 degrees apart.

4. Secure pipe assembly (3) to the underside of the platform using one nut (6), one washer (7), one spacer (8), one bolt (9), one support (10), one support (11), two bolts (12), and two locknuts (13). Slide nut (6) into the channel on the underside of the platform.

   Note: Secure bolt (9) using wire (28).

   Note: The rubber elbow that connects to the turbo inlet needs to be in the neutral position. Ensure that the weight of the tube is supported at the clamp bolted joint under the platform.

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   Illustration 4	g03847690

5. Install elbow (14) between pipe assembly (3) and the turbocharger intake. Secure elbow (14) to pipe assembly (3) using two clamps (15). Secure elbow (14) to the turbo charger intake using two clamps (16).

   Note: The rubber elbow that connects to the turbo inlet needs to be in the neutral position. Ensure that the weight of the tube is supported at the clamp bolted joint under the platform.

   Note: Orient each pair of clamps 180 degrees apart.

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   Illustration 5	g06356800

6. Connect pipe assembly (17) to the left-most air intake line using one hose (4). Secure hose (4) in place using two clamps (5) on each end of the hose.

   Note: Orient each pair of clamps (5) 180 degrees apart.

7. Secure pipe assembly (17) to the underside of the platform using one nut (6), one washer (7), one spacer (8), one bolt (9), one support (10), one support (11), two bolts (12), and two locknuts (13). Slide nut (6) into the channel on the underside of the platform.

   Note: Secure bolt (9) using wire (28).

8. Install elbow (14) between pipe assembly (17) and the turbocharger intake. Secure elbow (14) to pipe assembly (17) using two clamps (15). Secure elbow (14) to the turbo charger intake using two clamps (16).

   Note: Orient each pair of clamps 180 degrees apart.

9. Repeat Steps 6 to 8 for the right side intake lines.
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   Illustration 6	g03848533

10. Install one flared elbow (18), one filter adapter (19), and one pipe bushing (20) on each of the four air lines.

11. Install one hose assembly (21) to the flared elbow (18) on each of the two left side air lines. Install one hose assembly (22) to the flared elbow (18) on each of the two right side air lines.

12. Secure the two hose assemblies (22) to the platform in three places, using one bolt (23), one hard washer (24), and one clip (25) at each location.

13. Secure two hose assemblies (21) and two hose assemblies (22) to the platform using one bolt (23), one hard washer (24), and two clips (25).

14. Install one clamp (26) to the platform. Secure two hose assemblies (21) and two hose assemblies (22) to clamp (26) using one bolt (1), one hard washer (24), one spacer (27), and two clips (25).
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    Illustration 7	g03848587

15. Route the hose assemblies (21) and hose assemblies (22) into the cab and connect to the cab behind the front panel.