794 AC Off-Highway Truck Field Assembly Caterpillar

Parts and Specification Information

Illustration 1	g03850916

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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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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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

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Illustration 2	g03851253
A view of the top of the engine

1. Install one bellows assembly (1) to each of the two exhaust manifolds. Secure the bellows assembly (1) in place using one band clamp (2). Install one protection cap (3) on the end of the threads of each band clamp (2).

2. Install one exhaust pipe (4). on the end of each bellows assembly (1). Secure the exhaust pipe (4) in place using one band clamp (2). Install one protection cap (3) on the end of the threads of each band clamp (2).
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   Illustration 3	g03851370
   A view of the rear of the engine

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   Illustration 4	g03851608
   Close up view of the connector rod

3. Install exhaust pipe (5) and exhaust pipe (6), each to an exhaust pipe (4).

4. Install four brackets (7) and secure each pair with four bolts (8) and four nuts (9).

5. Install support bracket (10) with four bolts (8) and four hard washers (11). Secure exhaust pipe (5) and exhaust pipe (6) to exhaust pipes (4).

6. Secure exhaust pipe (5) and exhaust pipe (6) in place. Secure each with one clamp assembly (12). Connect each clamp assembly (12) to support bracket (10) using two connector rods (13). Install each connector rod to clamp assemblies (12) using one bolt (14), one hard washer (15), one spacer (16), one rod end (17), and one nut (9). Install each connector rod to support bracket (10) using one bolt (14), two hard washers (15), one spacer (16), one rod end (18), and one nut (9).

7. Install a full nut (19) on each connector rod (13) to adjust the height of the rod.
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   Illustration 5	g03851685
   A view of the rear of the engine

8. Install exhaust pipe assembly (20) and exhaust pipe assembly (21). Secure each to the preceding exhaust pipe using four brackets (7) eight bolts (8), and eight nuts (9).
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   Illustration 6	g03852012
   A view of the rear of the engine

9. Once all exhaust lines are positioned correctly, install bracket assembly (22) to the platform assembly using three bolts (23), six hard washers (24), and three nuts (25).

10. Install hanger (26) and hanger (27) to bracket assembly (22) using one bolt (8), two hard washers (11), and one nut (9) at the top of each hanger.

11. Install two tube supports (28) around each exhaust pipe and secure each to the bottom of a hanger using two bolts (14) and two nuts (9) on each pair of tube supports (28).
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    Illustration 7	g03852181
    A view of the rear of the engine

12. Install one exhaust blanket (29) on each exhaust line.

13. Install exhaust blanket (30) and exhaust blanket (31) on the lower exhaust line.

14. Install exhaust blanket (32) and exhaust blanket (33) on the upper exhaust line.

15. Install one exhaust blanket (34) and one heat shield (35) on each exhaust line.