Procedure to Install an Improved Antenna Assembly on Certain Off-Highway Trucks {733B} Caterpillar

OEM

CAT WDS (S/N: M6J1-125)

Off-Highway Truck/Tractor

770G (S/N: RMA1-101; TWA1-152; KDH1-372; ECM1-337,340-340; ECX1-114)

772G (S/N: LTS1-1,254-400,402-404; KEX1-1,103-272; LTX1-210)

777G (S/N: GT71-170; T5A1-123; TNM1-884,1000-1018; RDR1-385,500-505; T4Y1-210,500-500)

Quarry Truck

773G (S/N: MWH1-422; JWS1-387; T5S1-126; T5T1-106)

775G (S/N: T5F1-103; RFM1-921; MJS1-575; T5W1-112)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information. This Special Instruction covers the removal and installation of an Antenna Assembly.

Reference: Refer to Disassembly and Assembly, UENR1135, "Seat - Remove and Install on Certain 770G and 772G Off-Highway Truck Machine Systems".

Reference: Refer to Disassembly and Assembly, KENR9969, "Seat - Remove and Install on Certain 773G and 775G Off-Highway Truck Machine Systems".

Reference: Refer to Disassembly and Assembly, KENR9939, "Seat - Remove and Install on Certain 777G Off-Highway Truck Machine Systems".

Reference: Refer to Torque Specifications, SENR3130

Caterpillar Channel 1 Videos

For supplemental information on this procedure, refer to the following video. The previous training has been replaced with the video below.

Note: A CWS login is required to access Caterpillar Channel 1. Scan the QR code below with a QR enabled device or copy the link that follows.

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https://channel1.mediaspace.kaltura.com/media/Introduction+to+Visualization+Service+Procedures+%28VSP%29/1_92vjr92v

Important Safety Section

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Cat dealers have the most current information available.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If the tools, the procedure, the work method, or your actions are not recommended by Caterpillar, ensure that the tools and your actions are safe for you and for others.

Ensure that all personnel are safe when using a tool, procedure, work method, or operating technique not recommended by Caterpillar. Ensure that the product will not be damaged or the product made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Before service work is begun, park the machine on a hard level surface. Block the wheels of the machine so unexpected movement will not occur. Unexpected movement of the machine can cause personal injury or death.

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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine.

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Cat dealer for replacement manuals. Proper care is your responsibility.

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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 rear tow points. Install the rear tow point pins through the ends of the retaining cables. Failure to properly secure the body (bed) may result in personal injury or death.

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NOTICE
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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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, NENG2500, "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.

Prepare the Machine

Note: Permit only one operator on the machine. Either keep other personnel away from the machine, or keep other personnel in the sight of the operator.

Note: Cleanliness is an important factor. Before the removal procedure, clean the exterior of the component thoroughly. Cleaning the exterior will help to prevent dirt from entering the internal mechanism.

1. Park the machine on a dry, level, solid surface that is free of any debris.

   Note: The surface must be solid enough to support the weight of the machine and any tooling that is used to support the machine.

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   Illustration 2	g02331435

2. Make sure that the transmission control is in the P (Parking Brake Applied) position. Refer to Operation and Maintenance Manual, "Direction and Speed Control" for more information.

   Note: When the transmission control is in the P position, the parking brakes are automatically engaged and the transmission is not in any gear (Neutral).

3. Move the hoist control to the FLOAT position to lower the dump body. Refer to Operation and Maintenance Manual, "Operator Controls" for more information.
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   Incorrect installation of the wheel chocks may not limit machine movement resulting in serious injury or death. The machine must be parked on a suitable level surface with the park brake engaged. Use wheel chocks in pairs. The Caterpillar offered wheel chocks, if equipped, are for use on level grade only. If machine is to be chocked on a grade other than level, a field assessment is required to evaluate variables that can affect chock performance. It is the decision of each individual user to determine the best chock and chocking method for their particular application. Work site techniques need to be developed and tested to determine the acceptability of using the wheel chocks in those applications. Alternatively the machine front wheels can be turned into a suitable berm or placed in a parking ditch.

4. Install wheel chocks on the machine. Refer to Operation and Maintenance Manual, "Use of Wheel Chocks" for more information.

5. When it is not possible to use wheel chocks, ensure that the machine is unable to roll by turning the wheels into a suitable bank or placing with the wheels in a suitable ditch.
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   Illustration 3	g02331595

6. Ensure that the pressure is released from any closed system that will be opened during the maintenance procedure. Refer to Operation and Maintenance Manual, "System Pressure Release" for more information.
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   A raised body (bed) may fall unexpectedly and without warning resulting in personal injury or death. When it is necessary to work under the truck with the body (bed) raised, install the body (bed) retaining pins through the pin bores in the frame and the retaining brackets on the body.

7. For maintenance that requires the dump body to be in the raised position, install the truck body retaining pins. Refer to Operation and Maintenance Manual, "Body Retaining Pin" for more information.

8. This machine is equipped with lockout controls to suit the following types of machine maintenance:

   • Maintenance that requires the engine to be running

   • Maintenance that DOES NOT require the engine to be running

   • Maintenance that requires the electrical system to be disabled

9. For maintenance that requires the engine to be running, perform the following:

   1. Run the engine at an idle.
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      Illustration 4	g02195616

   2. Activate the machine lockout control. Refer to Operation and Maintenance Manual, "Machine Lockout Control" for more information.

10. For maintenance that DOES NOT require the engine to be running, perform the following:

    1. Move the engine start switch to the OFF position. Refer to Operation and Maintenance Manual, "Operator Controls" for more information.
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       Illustration 5	g01520019

    2. Activate the engine lockout control. Refer to Operation and Maintenance Manual, "Engine Lockout Control" for more information.

11. For maintenance that requires the electrical system to be disabled, perform the following:

    1. Move the engine start switch to the OFF position. Refer to Operation and Maintenance Manual, "Operator Controls" for more information.
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       Illustration 6	g02331433

    2. Use the battery disconnect switch to disconnect the battery from the machine electrical system. Refer to Operation and Maintenance Manual, "Battery Disconnect Switch" for the proper procedure.

Graphic Color Description

Color-coding of targeted components, or sections of a part, is used to communicate a required action.

The descriptions below illustrate the different colors and what is represented when used in a graphic.

(Blue) The primary component of focus for a particular step. Target or primary component to be installed or removed. Installation implied unless otherwise noted with a symbol.

(CAT® Yellow) Description of parts.

(Yellow) Components placed aside for access, but not removed. Highlighted areas of adjustment, inspection, or special attention.

(Cyan) Special tools or other equipment required for use in a particular step.

(Light Gray) Components used for reference.

(Magenta) Any fastener, retainer, or electrical connector used to install or remove the primary component.

Graphic Symbol Description

This section includes all the symbol graphics used throughout the Visual Service Procedure (VSP), along with a brief description of what the symbol represents.

Loosen - To make less tight. To set free. To release.

Tighten - To make nearer, to fully stretch, without slack, or to apply tension or torque.

Disconnect - To remove from an electrical circuit. To separate.

Connect - To place in an electrical circuit. To join or fasten together.

Cut - To divide or terminate. To reduce the length of an object.

Discard, Do Not Reuse - To cast aside as useless or undesirable in approved and responsible manner.

Remove - To take off.

Replace - To put back in place.

Route - To install a harness, hose, or wire along a specific course or layout along or through a product, to direct along a predefined path.

Attach - To connect together or to fasten on something.

Keep, Store - To retain for reinstallation or reuse.

Service Indicator - Refer to a Technical Manual, Warning, Caution, or Notice

Torque Specification

English (SAE) Fasteners

The following table has the recommended standard torque values.

Table 1

Nuts and Bolts
Thread Size Inch	Standard Torque
1/4	12 ± 3 N·m (9 ± 2 lb ft)
5/16	25 ± 5 N·m (18 ± 5 lb ft)
3/8	47 ± 10 N·m (35 ± 5 lb ft)
7/16	70 ± 15 N·m (50 ± 10 lb ft)
1/2	105 ± 20 N·m (75 ± 15 lb ft)
9/16	160 ± 30 N·m (120 ± 20 lb ft)
5/8	215 ± 40 N·m (160 ± 30 lb ft)
3/4	370 ± 50 N·m (275 ± 37 lb ft)
7/8	620 ± 80 N·m (460 ± 60 lb ft)
1	900 ± 100 N·m (660 ± 75 lb ft)
1 1/8	1300 ± 150 N·m (960 ± 110 lb ft)
1 1/4	1800 ± 200 N·m (1320 ± 150 lb ft)
1 3/8	2400 ± 300 N·m (1780 ± 220 lb ft)
1 1/2	3100 ± 350 N·m (2280 ± 260 lb ft)

Metric (ISO) Fasteners

The following table has the recommended standard torque values.

Table 2

Nuts and Bolts
Thread Size Metric	Standard Torque
M6	12 ± 3 N·m (9 ± 2 lb ft)
M8	30 ± 5 N·m (20 ± 5 lb ft)
M10	55 ± 10 N·m (40 ± 5 lb ft)
M12	100 ± 20 N·m (75 ± 15 lb ft)
M14	160 ± 30 N·m (120 ± 20 lb ft)
M16	240 ± 40 N·m (175 ± 30 lb ft)
M20	460 ± 60 N·m (340 ± 45 lb ft)
M24	800 ± 100 N·m (590 ± 75 lb ft)
M30	1600 ± 200 N·m (1180 ± 150 lb ft)
M36	2700 ± 300 N·m (2000 ± 220 lb ft)

Required Parts

Table 3

Parts List
Qty	New Part Number	Description
1	437-3856	Antenna As
1	241-4938	Cable As
38	7K-1181	Cable Strap

Removal Procedure

Removal of Antenna Assembly and Cable Assembly 770G and 772G

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View of Cab 770G and 772G

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Refer to Disassembly and Assembly, UENR1135, "Seat - Remove and Install".

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Removal of Antenna Assembly and Cable Assembly 773G, 775G, and 777G

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View of Cab 773G, 775G, and 777G

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For 777G, Refer to Disassembly and Assembly, KENR9939, "Seat - Remove and Install". For 773G and 775G, Refer to Disassembly and Assembly, KENR9969, "Seat - Remove and Install".

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Installation Procedure

Installation of Antenna Assembly and Cable Assembly 770G and 772G

Illustration 29	g06174614
View of Antenna Assembly and Cable Assembly

Table 4

Part List
Item	Qty	New Part Number	Description	Illustration (Sub-step) Location
1	1	437-3856	Antenna As	Illustration 30
2	1	241-4938	Cable As	Illustration 31 and 32
3	38	7K-1181	Cable Strap	Illustration 31 and 32

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Installation of Antenna Assembly and Cable Assembly 773G, 775G, and 777G

Illustration 39	g06174614
View of Antenna Assembly and Cable Assembly

Table 5

Part List
Item	Qty	New Part Number	Description	Illustration (Sub-step) Location
1	1	437-3856	Antenna As	Illustration 40
2	1	241-4938	Cable As	Illustration 41 and 42
3	38	7K-1181	Cable Strap	Illustration 41 and 42

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