21/10/2016 793FOffHighwayTruckSSP00001UP(MACHINE)POWEREDBYC17516Engine(SEBP4987137)/Bsquedabsica

Pantallaanterior
Bienvenido:cr120rxr
Producto:TRUCK
Modelo:793FTRUCKSSP
Configuracin:793FOffHighwayTruckSSP00001UP(MACHINE)
POWEREDBYC17516Engine

InstruccinEspecial
ProceduretoUpdatetheBrakeControlSystemonCertain793FOffHighwayTrucks{1365,4257,
4265,4295,5073}
NmerodemedioREHS798408 Fechadepublicacin25/11/2014 Fechadeactualizacin25/11/2014

i06005069

ProceduretoUpdatetheBrakeControlSystemonCertain793FOff
HighwayTrucks{1365,4257,4265,4295,5073}
SMCS13654257426542955073

OffHighwayTruck:
793F(S/N:SND1UPSSP1UPRBT1UP)

Introduction
ReferenceOperationandMaintenanceManual,SEBU8406,"793Fand793FXQOffHighwayTruck","Prepare
theMachineforMaintenance"

ReferenceOperationandMaintenanceManual,SEBU8406,"793Fand793FXQOffHighwayTruck","Capacities
Refill"

ReferenceOperationandMaintenanceManual,SEBU8406,"793Fand793FXQOffHighwayTruck","Welding
onMachinesandEngineswithElectronicControls"

ReferenceDisassemblyandAssembly,KENR8579,"793FOffHighwayTruck","GearPump(Brake,Hoist)
RemoveandInstall"

ReferenceSpecialInstruction,REHS1841,"GeneralWeldingProcedures"

ReferenceTestingandAdjusting,KENR8738,"793Fand793FCMDOffHighwayTruckBrakingSystem",
"BrakeSystemAirPurge"

ReferenceTestingandAdjusting,KENR8738,"793Fand793FCMDOffHighwayTruckBrakingSystem",
"BrakeAccumulatorTestandCharge"

ReferenceTestingandAdjusting,KENR8738,"793Fand793FCMDOffHighwayTruckBrakingSystem",
"BrakeSystemPressureTestandAdjust"

ReferenceTestingandAdjusting,KENR8738,"793Fand793FCMDOffHighwayTruckBrakingSystem",
"ReliefValve(Main)TestandAdjust"

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ReferenceTestingandAdjusting,KENR8738,"793Fand793FCMDOffHighwayTruckBrakingSystem",
"ServiceBrakesandRetarderSystemPressureTest"

ReferenceTestingandAdjusting,KENR8738,"793Fand793FCMDOffHighwayTruckBrakingSystem",
"ParkingBrakeReleasePressureTest"

ReferenceTestingandAdjusting,KENR8738,"793Fand793FCMDOffHighwayTruckBrakingSystem",
"BrakeCoolingPressureCheck"

ReferenceTestingandAdjusting,KENR8738,"793Fand793FCMDOffHighwayTruckBrakingSystem","Foot
BrakeControl(Service)PilotPressureTest"

ReferenceTestingandAdjusting,KENR8738,"793Fand793FCMDOffHighwayTruckBrakingSystem",
"PressureReducingValve(PilotOil)TestandAdjust"

ReferenceTestingandAdjusting,KENR8738,"793Fand793FCMDOffHighwayTruckBrakingSystem",
"Worksheets"

ReferenceSpecialInstruction,REHS9546,"ProceduretoPrimetheHydraulicSystemonCertain793FOff
HighwayTrucks"

ThisspecialinstructionprovidestheneededpartsandtheproceduretoAnewdivertervalvewithaneworifice
limitspressurespikesduringoperation.Thediameterofthesupplyhosewasincreasedtoallowalargerflowtothe
gearpumpforthebrakesystem.Thelocationofthemakeupoillinewasmovedfrombeforetheoilcoolertoafter
theoilcooler.Thenewlocationwilllowerthetemperatureoftheoilgoingintothemakeupoiltank.Anewgear
pumpisusedthatprovidesimprovedlowspeedpumpingefficiency.Anewbrakefilterisusedthatcontainsmetal
endcapsallowbettercoldoilflow.

ThisspecialinstructionisadaptabletomachinesS/N:SSP1880,andS/N:SND1131.

ImportantSafetyInformation
Donotperformanyprocedureinthisspecialinstructionuntilyouhavereadthisspecialinstructionandyou
understandthisinformation.Useonlypropertoolsandobserveallprecautionsthatpertaintotheuseofthosetools.
Failuretofollowtheseprocedurescanresultinpersonalinjury.Thefollowingproceduresshouldalsobeobserved.

Worksafely.Mostaccidentsthatinvolveproductoperation,maintenance,andrepairarecausedbyfailureto
observebasicsafetyrulesorprecautions.Anaccidentcanoftenbeavoidedbyrecognizingpotentiallyhazardous
situationsbeforeanaccidentoccurs.

Apersonmustbealerttopotentialhazards.Thispersonshouldalsohavethenecessarytraining,skills,andtoolsin
ordertoperformthesefunctionsproperly.

Safetyprecautionsandwarningsareprovidedinthisinstructionandontheproduct.Ifthesehazardwarningsare
notheeded,bodilyinjuryordeathcouldoccurtoyouortootherpersons.Caterpillarcannotanticipateevery
possiblecircumstancethatmightinvolveapotentialhazard.

Therefore,thewarningsinthispublicationandthewarningsthatareontheproductarenotallinclusive.Ifthe
tools,orprocedurearenotrecommendedbyCaterpillar,ensurethatthetoolsandyouractionsaresafefor
everyone.

Ensurethattheproductwillnotbedamagedortheproductwillbemadeunsafebytheoperation,lubrication,
maintenance,ortherepairprocedures.

RequiredParts
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Table1
PartsinSection1
Qty PartNumber Description

1 3196219(1) ElbowAs

1 6V9005 Elbow

1 2287093 ORingSeal

1 2385084 ORingSeal
1 4430065 HoseAs

2 3239259 Grommet
3 6V1572 Clips

3 6V1573 Clip

6 5P8444 Grommets
6 5P7468 Clips

6 5P7469 Clips
5 8T4186 Bolts

19 8T4121 HardWashers

5 8T4133 Nuts
12 8T4223 HardWashers

1 8T4956 Bolt
1 6V1574 Grommet

2 8T4196 Bolts

1 1223608 Clip
1 8T4136 Bolt

2 5P8182 Grommets
2 5P7470 Clips

2 5P7471 Clips
7 8T4183 Bolts

5 8T4244 Nuts
1 4211762 PlateAs
1 3978133 CheckValveGp
2 8T4178 Bolts

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1 3196220(2) ElbowAs

1 6V9008 Elbow
1 2287093 ORingSeal
1 2385084 ORingSeal

1 3309757(3) ElbowAs

1 8T1905 Elbow

1 2147568 ORingSeal
1 2287089 ORingSeal
1 4460447 HoseAs
1 3295515(4) TeeAs

1 6V8785 Tee
2 2287093 ORingSeal

1 2385084 ORingSeal
1 6V9833 CapAs
2 1833399(5) ConnectorAs

1 6V8636 Connector
1 2147568 ORingSeal

1 2287089 ORingSeal
1 4173133 PlugAs
1 3537956 Grommet

1 3P5903 Clip
1 3P5904 Clip
2 1176496 Blocks
1 9S4181 ORingPlug

1 2385084 ORingSeal
1 4287403 Plate
1 2287093 ORingSeal

1 6V8946(6) Reducer

1 2287092(6) ORingSeal

1 7I1036(6) CouplingAs

1 2385080 ORingSeal

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1 2815934(7)(6) ElbowAs

1 6V9877 Elbow
1 2287092 ORingSeal
1 2385080 ORingSeal

1 3295515(4)(6) TeeAs

1 6V8785 Tee

2 2287093 ORingSeals
1 2385084 ORingSeal
1 4161330(6) HoseAs

2 8T5005 Bolts
1 3690750 PlateAs

1 5P7703 Grommet
1 4161327(6) Plate

1 4460448 HoseAs
1 1223608 Clip
4 6V0683 Grommets
4 5P7463 Clips

4 5P7462 Clips
1 8T4184 Bolt
(1) Requiredpartsforassembling3196219ElbowAsconsistofone6V9005Elbow,one2287093ORingSeal,andone2385084
ORingSeal
(2) Requiredpartsforassembling3196220ElbowAsconsistofone6V9008Elbow,one2287093ORingSeal,andone2385084
ORingSeal
(3) Requiredpartsforassembling3309757ElbowAsconsistofone8T1905Elbow,one2147568ORingSeal,andone2287089
ORingSeal
(4) Requiredpartsforassembling3295515ElbowAsconsistofone6V8785Tee,two2287093ORingSeals,andone2385084O
RingSeal
(5) Requiredpartsforassembling1833399ConnectorAsconsistofone6V8636Connector,one2147568ORingSeal,andone
2287089ORingSeal
(6) Partisusedonlyonmachinesequippedwiththe3737667ServiceBrakeControlGpfortheEuropeanMarket.
(7) Requiredpartsforassembling2815934AdapterAsconsistofone6V9877Elbow,one2287092ORingSealandone2385080
ORingSeal

Table2
PartsinSection2
Qty PartNumber Description

1 2352478 RectangularSeal

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1 4231569 TubeAs

4 8T4194 Bolts
23 8T4223 HardWashers
1 4235018 HoseAs
2 6V1889 Clips

1 8T4191 Bolt
7 8T4121 HardWashers
1 5P1480 ORingSeal

1 1503028(1) ElbowAs

1 6V9343 Elbow

1 6V5050 ORingSeal
1 8L2779 ORingSeal
1 4235019 HoseAs

1 5P4295 Clip
1 8T4648 Bolt
1 8Y1816 Spacer
2 6V0545 Grommets

3 5P7468 Clips
3 5P7469 Clips

1 8T7529 Clip
2 8T4956 Bolts

2 8T4244 Nuts

1 3992371 PlateAs
2 8T4139 Bolts

1 3218609(2) TeeAs

1 6V9160 FaceSealTee

3 2287092 ORingSeals

1 2P1293 Locknut
1 2815933(3) ElbowAs

1 6V9853 Elbow
1 2287092 ORingSeal

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1 3992363 HoseAs

4 8T4183 Bolts
4 1P4582 HalfFlanges

1 4447013 HoseAs

1 4235020 HoseAs
1 6D4246 Clip

1 8T4136 Bolt

1 8T4133 Nut
1 6V1869 Grommet

1 6V1867 Clip
1 6V1868 Clip

1 3996643 HoseAs

1 6V4590 ORingSeal
5 2343544 ORingSeal

1 3992370 TubeAs

1 4235017 HoseAs
1 5P8444 Grommet

4 8T8919 Bolt

1 3906120 GearPumpGp
1 3992367 HoseAs

1 1912962 ORingSeal

2 1P4578 HalfFlanges
4 8T4186 Bolts

4 8T4184 Bolts

6 1P4579 HalfFlanges
1 3196211(4) AdapterAs

1 2P8421 ORingAdapter
1 2385082 ORingSeal

1 3196208(5) AdapterAs

1 5P9617 Adapter

1 2147568 ORingSeal

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1 3218649(6) FluidSamplingValveAs

1 8C3446 FluidSamplingValve
1 2147566 ORingSeal

1 6V5553 ORingSeal

4 1163719 TaperlockStuds
4 8T3282 HardWashers

4 6V7742 FullNuts

2 2343544 ORingSeals
4 8T0568 ORingSeals

8 1P4584 HalfFlanges

2 3718946(7) Hoses

8 2094575 Clamps

1 2287092 ORingSeal
1 8C3451 DustCap
(1) Requiredpartsforassembling1503028ElbowAsconsistofone6V9343Elbow,one6V5050ORingSeal,andone8L2779O
RingSeal
(2) Requiredpartsforassembling3218609TeeAsconsistofone6V9160FaceSealTee,andthree2287092ORingSeals
(3) Requiredpartsforassembling2815933ElbowAsconsistofone6V9853Elbow,andone2287092ORingSeal
(4) Requiredpartsforassembling3196211AdapterAsconsistofone2P8421ORingAdapter,andone2385082ORingSeal
(5) Requiredpartsforassembling3196208AdapterAsconsistofone5P9617Adapter,andone2147568ORingSeal
(6) Requiredpartsforassembling3218649FluidSamplingValveAsconsistofone8C3446FluidSamplingValve,andone214
7566ORingSeal
(7) Cutthehosestoalengthof178mm(7.0inch).

Table3
PartsinSection3

Qty PartNumber Description

1 4472930 TubeAs

20 8T4223 HardWashers
8 8T4184 Bolts

1 7Y2522 Plate

6 8T4139 Bolts
1 2958037 Plate

6 1P4582 HalfFlanges

3 6V4590 ORingSeals

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4 8T4183 Bolts
1 4255909 HoseAs

4 8T4194 Bolts

2 2815979(1) ElbowAs

1 6V9007 Elbows

2 2287092 ORingSeals
2 2385082 ORingSeals

1 3968352 HoseAs

1 9X2646 Clip
1 9X2647 Clip

1 6V1889 Clip

1 8T4196 Bolt
2 8T4121 HardWashers

1 8T4133 Nut
1 3893707(2) PlugAs

1 5P9436 Plug
1 2385082 ORingSeal

2 8T4244 Nuts

4 3718949(3) Hoses

1 3968346 Elbow

1 8T0568 ORingSeal
1 2443712 PlugAs

1 9S4181 ORingPlug

1 2147568 ORingSeal
1 4469478 Plate

1 4458799 PlateAs

7 8T4956 Bolts
1 6V1875 Grommet

1 5P7470 Clip

1 5P7471 Clip
4 5P1076 HardWashers

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(1) Requiredpartsforassemblingone2815979ElbowAsconsistofone6V9007Elbow,one2287092ORingSeal,andone238
5082ORingSeal
(2) Requiredpartsforassemblingone3893707PlugAsconsistofone5P9436Plug,andone2385082ORingSeal
(3) Cutthehosestoalengthof178mm(7.0inch)

Table4
PartsinSection4
Qty PartNumber Description

1 4421875 Plate

1 4158654 HoseAs
1 4212635 HoseAs

1 3196220(1) ElbowAs

1 6V9008 Elbow

1 2287093 ORingSeal
1 2385084 ORingSeal

4 8T4223 HardWashers

4 8T4183 Bolts
1 3933691 OilFilterGp

2 2352477 RectangularSeals

2 4158651 Flanges
8 8T0439 Bolts

1 1645567(2) QuickDisconnectCouplerAs

1 6V3965 Fitting

1 2147568 ORingSeal

1 6V0852 DustCap
1 3353973(3) TeeAs

1 8C6515 Tee
1 2287093 ORingSeal

1 2385084 ORingSeal

1 3295470(4) TeeAs

1 6V9840 SwivelTee

1 2287093 ORingSeal
1 4158653 HoseAs

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1 3557004 PressureIndicator

4 2287093 ORingSeals

1 8T4184 Bolt
1 2307732 CableTieMounting

2 2042281 CableStrap

1 1305301 Clip
1 2048000 CableTieMounting

1 8T4194 Bolt

1 8T4136 Bolt
1 3445675 Nut

1 3G4005 Link

1 5P8444 Grommet
1 5P7468 Clip

1 5P7469 Clip
1 6V1249 Grommet

1 5P7469 Clip

1 5P7465 Clip
2 8T4223 HardWashers

1 8T4184 Bolt

1 8T4244 Nut
(1) Requiredpartsforassemblingone3196220ElbowAsconsistofone6V9008Elbow,one2287093ORingSeal,andone238
5084ORingSeal
(2) Requiredpartsforassemblingone1645567QuickDisconnectCouplerAsconsistofone6V3965Fitting,andone2147568O
RingSeal
(3) Requiredpartsforassemblingone3353973TeeAsconsistofone8C6515Tee,andone2287093ORingSeal,andone238
5084ORingSeal
(4) Requiredpartsforassemblingone3295470TeeAsconsistofone6V9840SwivelTee,andone2287093ORingSeal

InstallationProcedure
InstallationofSection1

Table5
PartsinSection1

Item Qty PartNumber Description

1 1 3196219(1) ElbowAs

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1A 1 6V9005 Elbow
1B 1 2287093 ORingSeal

1C 1 2385084 ORingSeal

2 1 4430065 HoseAs
3 2 3239259 Grommet
4 3 6V1572 Clips

5 3 6V1573 Clip
6 6 5P8444 Grommets
7 6 5P7468 Clips

8 6 5P7469 Clips
9 5 8T4186 Bolts
10 19 8T4121 HardWashers

11 5 8T4133 Nuts
12 15 8T4223 HardWashers
13 1 8T4956 Bolt

14 1 6V1574 Grommet
15 2 8T4196 Bolts
16 1 1223608 Clip

17 1 8T4136 Bolt
18 2 5P8182 Grommets
19 2 5P7470 Clips

20 2 5P7471 Clips
21 7 8T4183 Bolts
22 5 8T4244 Nuts

23 1 4211762 PlateAs
24 1 3978133 CheckValveGp
25 2 8T4178 Bolts

26 1 3196220(2) ElbowAs

26A 1 6V9008 Elbow

26B 1 2287093 ORingSeal

26C 1 2385084 ORingSeal

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27 1 3309757(3) ElbowAs

27A 1 8T1905 Elbow

27B 1 2147568 ORingSeal
27C 1 2287089 ORingSeal

28 1 4460447 HoseAs
29 1 3295515(4) TeeAs

29A 1 6V8785 Tee

29B 2 2287093 ORingSeal
29C 1 2385084 ORingSeal

30 1 6V9833 CapAs
32 2 1833399(5) ConnectorAs

32A 1 6V8636 Connector

32B 1 2147568 ORingSeal
32C 1 2287089 ORingSeal

33 1 4173133 PlugAs
34 1 3537956 Grommet
35 1 3P5903 Clip

36 1 3P5904 Clip
37 2 1176496 Blocks
38 1 9S4181 ORingPlug

39 1 2385084 ORingSeal
40 1 4287403 Plate
41 1 2287093 ORingSeal

42 1 6V8946(6) Reducer

43 1 2287092(6) ORingSeal

44 1 7I1036(6) CouplingAs

44A 1 2385080 ORingSeal

45 1 2815934(7)(6) ElbowAs

45A 1 6V9877 Elbow

45B 1 2287092 ORingSeal
45C 1 2385080 ORingSeal

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47 1 3295515(4)(6) TeeAs

47A 1 6V8785 Tee

47B 2 2287093 ORingSeals

47C 1 2385084 ORingSeal
48 1 4161330(6) HoseAs

49 2 8T5005 Bolts
50 1 3690750 PlateAs

51 1 5P7703 Grommet
52 1 4161327(6) Plate

53 1 4460448 HoseAs
55 1 1223608 Clip
57 4 6V0683 Grommets

58 4 5P7463 Clips
59 4 5P7462 Clips
61 1 8T4184 Bolt
62 1 8T5436 Bolt
(1) Requiredpartsforassembling3196219ElbowAsconsistofone6V9005Elbow,one2287093ORingSeal,andone2385084
ORingSeal
(2) Requiredpartsforassembling3196220ElbowAsconsistofone6V9008Elbow,one2287093ORingSeal,andone2385084
ORingSeal
(3) Requiredpartsforassembling3309757ElbowAsconsistofone8T1905Elbow,one2147568ORingSeal,andone2287089
ORingSeal
(4) Requiredpartsforassembling3295515ElbowAsconsistofone6V8785Tee,two2287093ORingSeals,andone2385084O
RingSeal
(5) Requiredpartsforassembling1833399ConnectorAsconsistofone6V8636Connector,one2147568ORingSeal,andone
2287089ORingSeal
(6) Partisusedonlyonmachinesequippedwiththe3737667ServiceBrakeControlGpfortheEuropeanMarket.
(7) Requiredpartsforassembling2815934AdapterAsconsistofone6V9877Elbow,one2287092ORingSealandone2385080
ORingSeal

Note:Thefollowingfourproceduresarewrittenasindividualprocedures.Ifthefourproceduresaretobe
performedinthesamemaintenancesession,considerperformingtheremovalstepsfromallfourprocedures.All
oftheformerpartswillberemovedfromthemachine.Then,performtheinstallationproceduresforthenewparts
forthefourprocedures.

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Illustration1 g03351250
Viewofarea(A)

ThereworkofthevalvegroupinvolvestheareashowninIllustrationandIllustration1.

Personalinjuryordeathcanresultfrommachinemovement.

Placeblocksinfrontofandbehindthewheelstomakesurethemachine
doesnotmovewhiletheparkingbrakesaredisengaged.

Donotattempttoassemblethismachineuntilyoureadandyou
understandtheassemblyinstructions.

Improperassemblyprocedurescouldresultininjuryordeath.

Personalinjurycanresultfromthesuddenreleaseofhighpressureoil.
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Besuretheenginehasbeenshutoffforaminimumoffiveminutestobe
surethattheaccumulatorpressureiszero.

Theaccumulatorisfilledwithdrynitrogen.Donotloosenorremove
thevalveorcapfromthetopoftheaccumulator.Apurgescrewatthe
bottomoftheaccumulatorcanbeusedtoreleasethepressurethatisleft
inthesystem.

Hydraulicaccumulatorcontainsgasandoilunderhighpressure.
Improperremovalorrepairprocedurescouldcausesevereinjury.To
removeorrepair,instructionsintheservicemanualmustbefollowed.
Specialequipmentisrequiredfortestingandcharging.

NOTICE
Caremustbetakentoensurethatfluidsarecontainedduring
performanceofinspection,maintenance,testing,adjusting,andrepair
oftheproduct.Bepreparedtocollectthefluidwithsuitablecontainers
beforeopeninganycompartmentordisassemblinganycomponent
containingfluids.

RefertoSpecialPublication,NENG2500,"DealerServiceTool
Catalog"fortoolsandsuppliessuitabletocollectandcontainfluidson
Catproducts.

Disposeofallfluidsaccordingtolocalregulationsandmandates.

NOTICE
Donotallowanydirtorforeignmaterialtogetintothehydraulic
systemduringassembly,connectionoflines,whencomponentsare
filledwithfluid,orduringanymaintenanceoperation.

NOTICE
Maintaintheoilinthehydraulicsystematthecorrectleveltoprevent
pumpcavitation.

1.Preparethemachineformaintenance.Forthisprocedure,thetruckbodyshouldbeintheRAISEDposition
withbothtruckbodyretainingcablesinstalled.Forthecorrectprocedure,referto"PreparetheMachinefor
Maintenance"intheabovelistedOperationandMaintenanceManual.

2.Beforeweldingonthemachine,refertotheweldinginformationintheabovelistedOperationand
MaintenanceManual.

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3.Useasuitablecontainertodrainthehydraulicoilfromthebrakeactuationsectionofthehydraulictank.The
approximatecapacityofthehoistandbrakesystemis1315L(347.4USgal).

Illustration2 g03350399

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Illustration3 g03350403
Viewofarea(B)

4.Removeclips(D),grommets(E),nuts(F)washers(G),andbolts(H)fromthetubeassembly(A)andthe
hoseassembly(C).

5.Removeclips(D),grommet(E),washer(G),andbolt(H)fromthehoseassembly.

Note:Removingthebracketfromtheoilcoolermanybeeasierthanremovingtheclipsfromthebracket.
Checkthebracketfrodamage.Replacethebracketifthebracketisdamaged.

6.Removehoseassembly(C),andelbow(B)fromthetankassembly.

Note:Hoseassembly(C)willbefilledwithhydraulicoil.Drainthehydraulicoilintoasuitable
container.

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Illustration4 g03350533

Illustration5 g03350536
Viewofarea(C)

7.Removeclips(J),grommets(K),nuts(L)washers(M),andbolts(N)fromthethreelocations.

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Illustration6 g03350560

Illustration7 g03350567
Viewofarea(D)

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Illustration8 g03377898

Illustration9 g03377922

8.RefertoIllustration7.Removethethreeclips(S),grommets(T),nuts(W)washers(V),andbolts(U).

9.RefertoIllustration7.Removehoseassembly(R),andelbow(P)fromthemachine.RefertoIllustration8.
Installseal(39)onplug(38).InstalltheplugintotheportT2fromwhichelbow(P)wasremoved.

10.RefertoIllustration7.Removethesecondendofhoseassembly(R)fromplate(X).Removehoseassembly
(C)fromthemachine.

11.RefertoIllustration7.Removeplate(X),twobolts(X1)bulkheadnut(Y),andadapter(Z)fromthe
machine.RefertoIllustration8.Installtwobolts(49)toreplacethetwobolts(X1).

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Illustration10 g03441320

12.Removehoseassembly(BA)fromthemachine.Thehoseassemblyisattachedtothefittingsassembledinto
the"Hoist"portonthebrakecontrolvalvegroup.

13.Removeclipandhardware(BB),and(BC)fromthemachine.Savetheclipsandhardware.

Illustration11 g03441326

14.Removeclipandhardware(BD),and(BE)fromthemachine.Savetheclipsandhardware.

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Illustration12 g03441339

15.Removehoseassembly(BA)fromelbowassembly(BF).Removethehoseassemblyfromthemachine.
Discardthehoseassembly.Removetheelbowassemblyfromthehoistcontrolvalvegroup.Discardthe
elbowassembly.

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Illustration13 g03350622

16.Installelbowassembly(1)tothehydraulictank.

17.Attachoneendofhoseassembly(2)toelbowassembly(1).

18.Installgrommet(3),oneclip(4),andoneclip(5)aroundthetubeassembly.Installonegrommet(6),one
clip(7),andoneclip(8)aroundhoseassembly(2)nearthetubeassembly.Aligntheholesintheclips.Use
onebolt(9),twohardwashers(10),andonenut(11)tosecuretheclips.

19.RefertoIllustration13.Installonegrommet(6),oneclip(7),andoneclip(8)aroundhoseassembly(2)near
theedgeofthehydraulictank.Useonebolt(13)andonehardwasher(12)tosecurethehoseassemblyto
theplateassembly(50).

Illustration14 g03350965

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Illustration15 g03350966
Viewofarea(E)

20.Installonegrommet(14),oneclip(4),andoneclip(5)aroundtheverticalhoseassembly.Installone
grommet(6),oneclip(7),andoneclip(8)aroundhoseassembly(2)neartheverticalhoseassembly.Align
theholesintheclips.Useonebolt(15),twohardwashers(10),andonenut(11)tosecuretheclips.

21.Installoneconnectorassembly(32)intotheportonthehoistcontrolvalvegroupthatadapterassembly(BF)
wasremoved.Installthe90degreeendofhoseassembly(53)ontotheconnectorassembly.

22.Hoseassembly(2)andthehoseassemblyfromthebrakecoolingpumpmaybeclosetotouchingat(E1).If
thehosesareclosetotouching,installonegrommet(6),oneclip(7),andoneclip(8)aroundeachhose.
Aligntheholesintheclips.Useononebolt(13),twohardwashers(12)andonenut(11)tosecuretheclips.

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Illustration16 g03350698

23.Hoseassembly(53)willberoutedtothebrakecontrolvalvegroup.Youwillattachtheendofthehose
assemblytothefittingsassembledintothe"Hoist"portonthebrakecontrolvalvegroup.

24.Usetheclipsandhardwareremoved,andsavedinStep13,andStep14toholdthehoseassembly.Placethe
clipsandhardwareintheoriginalpositions.RefertoIllustration10,andIllustration11forthepositions.

25.Installonegrommet(6),oneclip(7),andoneclip(8)aroundhoseassembly(2)inthetwolocationsshown
inIllustration16.Installonegrommet(18),oneclip(19),andoneclip(20)aroundthehoseassemblyas
showninIllustration16.Installonegrommet(51),oneclip(19),andoneclip(20)aroundthehoseassembly
asshowninIllustration16.Aligntheholesintheclips.Useonebolt(21),twohardwashers(5),andonenut
(22)tosecuretheclips.InstallthepartsinthetwolocationsshowninIllustration16.Thesecondendofhose
assembly(2)willnotbeconnectedatthistime.

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Illustration17 g03350796
Positionofthetwoblocksontheinsideoftheleftframebehindthetorquetube.

Illustration18 g03350777
Viewofarea(G)

(A)195.3mm(7.69inch)

(B)231.3mm(9.11inch)

(C)84.2mm(3.32inch)

(D)198.1mm(7.80inch)

(E)44.2mm(1.74inch)

(F)39.5mm(1.56inch)

(G)36.7mm(1.45inch)

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(W1)6mm(0.24inch)filletweldonthetwolongsidesoftheblock

(W2)6mm(0.24inch)filletweldonthetwolongsidesoftheblock

26.UsethedimensionsinIllustration18topositionthetwoblocks(37).Markthepositionofthetwoblocks.
Preparetheareaforwelding.Forthecorrectprocedure,refertotheabovelistedspecialinstruction.Usethe
informationintheillustration18toweldtheblocksintoposition.

Illustration19 g03378400
Viewofarea(G)

(H)37mm(1.5inch)

(J)195mm(7.7inch)

(K)195mm(7.7inch)

(L)201mm(7.9inch)

(W3)6mm(0.24inch)filletweldonthetwolongsidesoftheblock

(W4)6mm(0.24inch)filletweldonthetwolongsidesoftheblock

27.TheinformationinIllustration19isanoptiontolocatethetwoblocks(37).Markthepositionofthetwo
blocks.Preparetheareaforwelding.Forthecorrectprocedure,refertotheabovelistedspecialinstruction.
UsetheinformationinIllustration19toweldtheblocksintoposition.

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Illustration20 g03350889

Illustration21 g03666195
Viewofarea(M)

28.Usetwobolts(9),andtwohardwashers(10)toattachplateassembly(23)tothetwoblocks(37).
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29.Usetwobolts(25),onebolt(62)andthreehardwashers(10)tosecurevalveassembly(24)toplate
assembly(23).

30.Installelbowassembly(26)totheoutletportonvalveassembly(24).Attachtheendofhoseassembly(2)to
theelbowassembly.

31.Installteeassembly(29)intotheinletportonvalveassembly(24).Installcap(30)totheendoftheteeto
theoutsideofthevalveassembly.Installthehoseassemblytothetopofthetee.

32.Installelbowassembly(27)intothepilotportonvalveassembly(24).Attachhoseassembly(28)tothe
elbowassembly.Positionthehoseassemblyasshownintheillustration.

Illustration22 g03350939

Illustration23 g03350942
Viewofarea(N)
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Viewofarea(N)

33.Installoneclip(55)ontothelargetubeassemblynearhose(28).Installonegrommet(57),oneclip(58),and
oneclip(59)ontohoseassembly(28)neartheclips.Aligntheholesintheclips.Useonebolt(15),two
washers(12),andonenut(22)tosecuretheclips.

Illustration24 g03445776
Viewofarea(N)

34.RefertoIllustration24.Gototheclipsinthetop,centeroftheillustrationthatattachesthehoseassemblyto
themachine.Removetheboltandwasherthatsecuretheclipstothemachine.Discardthebolt,andthe
washer.Installplate(40)undertheclips.Useonebolt(15),andonehardwasher(12)tosecuretheclipsto
theplate.

35.Installonegrommet(57)aroundhoseassembly(28)nearplate(40).Installoneclip(58),andoneclip(59)
aroundthegrommet.Useonebolt(27),twohardwashers(12),andonenut(11)tosecuretheclipstothe
secondholeinplate(40).

36.Gototheareawherehoseassembly(28)passesclosetohoseassembly(53).Placeonegrommet(57)around
eachhoseassembly.Placeoneclip(58),andoneclip(59)aroundeachgrommet.Aligntheholesintheclips.
Useonebolt(61),twohardwashers(12),andonenut(22)tosecuretheclips.

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Illustration25 g03444316

37.Attachtheendofhoseassembly(53)tothefittingsassembledintothe"Hoist"portonthebrakecontrol
valvegroup.

Illustration26 g03378444
Thebrakecontrolvalvegrouplookingforward

38.RefertoIllustration26.RemovetheplugfromportOR1.Installconnectorassembly(32)intoportOR1on
thebrakemanifoldvalveandconnecthoseassembly(28)toconnectorassembly(32).

39.RefertoIllustration26.RemovethecontrolvalvegroupfromportLE1onthebrakemanifoldvalve.Install
plugassembly(33)intoportLE1onthebrakemanifoldvalve.

40.InstalloneOringseal(39)ontoOringplug(38).InstalltheOringplugintoportT2onthebrakemanifold
valve.

41.Machinesthatcontainthe3737667ServiceBrakeControlGpmustperformthefollowingsteps.This
servicebrakecontrolgroupisusedintheEuropeanMarket.

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Illustration27 g03357285

42.Removehoseassembly(BA),fromfitting(BB).Movethehoseassemblyoutoftheway.

43.Removehoseassembly(BC)fromthemachine.Discardthehoseassembly.

44.Removefitting(BB)fromthemachine.Discardthepart.

45.Removethetwobolts(BD),andthetwowashers(BE)fromthemachine.Savetheparts.

46.Removethetwobolts(BH),andthetwowashers(BJ)fromthebackofplate(BK).Savetheboltsand
washers.Removetheplatefromreliefvalvegroup(BG).Discardplate(BK).

47.Movereliefvalvegroup(BG)outoftheway.

48.PerformStep28throughStep42.

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Illustration28 g03357690

49.Removecap(30)fromthevalvegroup.

Illustration29 g03357295

50.Usethetwobolts(BH),andthetwowashers(BJ)thatweresavedinStep46toattachplate(52)torelief
valvegroup(BG).

51.Installreducer(42),andOringseal(43)tothevalvegroup.

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52.Installcouplingassembly(44)toreliefvalvegroup(BG).

53.Installreliefvalvegroup(BG)toreducer(42).

54.Usebolts(BD),andwashers(BE)tofastenreliefvalvegroup(BG)toplateassembly(23).

55.Installadapterassembly(45)toreliefvalvegroup(BG).

Illustration30 g03357697
Partsremovedforclarity

56.Installteeassembly(47)intotheopenportonvalve(BL).

57.Installhoseassembly(BA)tothetopportinteeassembly(47).

58.Installhoseassembly(48)betweenadapterassembly(45),andteeassembly(47).

InstallationofSection2
Table6
PartsinSection2

Item Qty PartNumber Description

1 1 2352478 RectangularSeal

2 1 4231569 TubeAs

3 4 8T4194 Bolts
4 23 8T4223 HardWashers

5 1 4235018 HoseAs

6 2 6V1889 Clips

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7 1 8T4191 Bolt
8 7 8T4121 HardWashers
9 1 5P1480 ORingSeal

10 1 1503028(1) ElbowAs

10A 1 6V9343 Elbow

10B 1 6V5050 ORingSeal

10C 1 8L2779 ORingSeal

11 1 4235019 HoseAs
12 1 5P4295 Clip

13 1 8T4648 Bolt

14 1 8Y1816 Spacer
15 2 6V0545 Grommets

16 3 5P7468 Clips

17 3 5P7469 Clips
18 1 8T7529 Clip

19 2 8T4956 Bolts

20 2 8T4244 Nuts
21 1 3992371 PlateAs

22 2 8T4139 Bolts

23 1 3218609(2) TeeAs

23A 1 6V9160 FaceSealTee

23B 3 2287092 ORingSeals

24 1 2P1293 Locknut
25 1 2815933(3) ElbowAs

25A 1 6V9853 Elbow

25B 1 2287092 ORingSeal

26 1 3992363 HoseAs
27 4 8T4183 Bolts

28 4 1P4582 HalfFlanges

29 1 4447013 HoseAs
30 1 4235020 HoseAs

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31 1 6D4246 Clip
32 1 8T4136 Bolt

33 1 8T4133 Nut
34 1 6V1869 Grommet

35 1 6V1867 Clip

36 1 6V1868 Clip
37 1 3996643 HoseAs

38 1 6V4590 ORingSeal

39 5 2343544 ORingSeal
40 1 3992370 TubeAs

41 1 4235017 HoseAs

42 1 5P8444 Grommet
43 4 8T8919 Bolt

44 1 3906120 GearPumpGp

45 1 3992367 HoseAs
46 1 1912962 ORingSeal

47 2 1P4578 HalfFlanges

48 4 8T4186 Bolts
49 4 8T4184 Bolts

50 6 1P4579 HalfFlanges

51 1 3196211(4) AdapterAs

51A 1 2P8421 ORingAdapter

51B 1 2385082 ORingSeal

52 1 3196208(5) AdapterAs

52A 1 5P9617 Adapter

52B 1 2147568 ORingSeal

53 1 3218649(6) FluidSamplingValveAs

53A 1 8C3446 FluidSamplingValve

53B 1 2147566 ORingSeal

54 1 6V5553 ORingSeal

55 4 1163719 TaperlockStuds

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56 4 8T3282 HardWashers
57 4 6V7742 FullNuts
58 2 2343544 ORingSeals

60 4 8T0568 ORingSeals

61 8 1P4584 HalfFlanges
62 2 3718946(7) Hoses

63 8 2094575 Clamps

64 1 2287092 ORingSeal
65 1 8C3451 DustCap
(1) Requiredpartsforassembling1503028ElbowAsconsistofone6V9343Elbow,one6V5050ORingSeal,andone8L2779O
RingSeal
(2) Requiredpartsforassembling3218609TeeAsconsistofone6V9160FaceSealTee,andthree2287092ORingSeals
(3) Requiredpartsforassembling2815933ElbowAsconsistofone6V9853Elbow,andone2287092ORingSeal
(4) Requiredpartsforassembling3196211AdapterAsconsistofone2P8421ORingAdapter,andone2385082ORingSeal
(5) Requiredpartsforassembling3196208AdapterAsconsistofone5P9617Adapter,andone2147568ORingSeal
(6) Requiredpartsforassembling3218649FluidSamplingValveAsconsistofone8C3446FluidSamplingValve,andone214
7566ORingSeal
(7) Cutthehosestoalengthof178mm(7.0inch).

Illustration31 g03352894

ThereworkofthebrakehydrauliclinesinvolvestheareashowninIllustration31.

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Illustration32 g03356223

Illustration33 g03378585

1.Removegearpump(A)fromthemachine.Fortheproperprocedure,refertotheabovelistedDisassembly
andAssemblymodule.

Note:Duringtheremovalofthegearpump,examinethefour1P4579HalfFlanges(50)onthetopofthe
gearpumpforreuse.Replaceanydamagedhalfflanges.Replacethetwo2343544ORingSeals(58).Four
tubeassembliesareattachedtothebottomofthegearpump.Examinetheeight1P4584HalfFlanges(61)
thathelpsecurethetubeassemblies.Replaceanydamagedhalfflanges.Replacethefour8T0568ORing
Seals(60).Replacethetwo3718946Hoses(62)onthemachine,andtheeight1440367HoseClampswith
theeightnew2094575Clamps(63).Cutthenew3718946Hoses(62)to178mm(7.0inch).

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Illustration34 g03356227

2.InstallOringseal(54)onthepumpdrive.Usefourtaperlockstuds(55),fourhardwashers(56),andfour
fullnuts(57)toinstallgearpump(44).Torquethetaperlockstudsto17030Nm(12522lbft).Torque
thefullnutsto46060Nm(33944lbft).Fortheproperprocedure,refertotheabovelisted
DisassemblyandAssemblymodule.

Illustration35 g03352915

3.Removefourbolts(B),andfourwashers(C)fromthehydraulictank.

4.Removeclips(F),grommet(G),twowashers(H),bolt(J),andnut(K)fromthehydraulictank.

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Illustration36 g03352924

5.Removethetwonuts(U),fourwashers(W),twobolts(V),andtwoclips(X)fromhoseassembly(L).
Removethehoseassemblyfromthemachine.

6.Removethetwobolts(S),twowashers(T),threegrommets(R),andthesixclips(P)fromtubeassembly
(E)andtubeassembly(M).Removetheeightbolts,eightwashers,andtwohalfflangesfromtubeassembly
(M).Removetubeassembly(M)andseal(N)fromthemachine.

Note:Inspectthetwohalfflanges.Ifthehalfflangesaregood,reusethehalfflanges.Ifthehalfflangesare
worn,replacewithtwohalfflanges(50).

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Illustration37 g03352995

7.Gototheendoftube(E)thatisinsidethehydraulictank.Removethefourbolts(Y),fourwashers(Z),and
twohalfflanges(BA).Removetubeassembly(E),andseal(D)fromthemachine.

Illustration38 g03378633

8.Removenut(BD),bolt(BE),twowashers(BF),twogrommets(BG),andthefourclips(BH).

Illustration39 g03515076

9.Removethefourbolts,fourwashers,andtwohalfflangesfromthepumpendofhoseassembly(BB).
Removethehoseassemblyandthetwoseals(BC)fromthemachine.

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Illustration40 g03378627

10.Removenut(BK),twowashers(BL),bolt(BM),thetwoclips(BN),adapter(BP),andhoseassembly(BJ)
fromthemachine.

11.Removethefourbolts,fourwashers,andtwohalfflangesfromthetopendofhoseassembly(BR).Remove
hoseassembly(BR)andthetwoseals(BS)fromthemachine.

Note:Inspecttheflangesforreuse.Ifdamaged,replacethetwo1P4579HalfFlange(50).

Illustration41 g03589337

12.Removehoseassembly(BX)fromthemachine.

13.Removehoseassembly(BU)fromthemachine.
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14.Removebolt(BZ),andwasher(CA)thatallowsplate(BV),adaptertee(BW),andbulkheadnut(BY)tobe
removedfromthemachine.Removeplug(BT)fromthehydraulictank.

Note:Plug(BT)islocatedonthesideofthetankthatistowardthefrontofthemachinebelowthebendfor
themountingsupports.

Illustration42 g03353004

15.Installonerectangularseal(1)ontubeassembly(2).Usefourbolts(3),andfourhardwashers(4)toattach
thetubeassemblytothehydraulictank.

16.Attachhoseassembly(5)tothehydraulictank.Installoneclip(6)aroundthehoseassembly.Useonebolt
(7)andonewasher(8)tosecurethehoseassembly.

Note:Beforeinstallationofbolt(7),cleanoutthethreadedhole.

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Illustration43 g03353012

Illustration44 g03353022
Viewofarea(A)

17.RefertoIllustration43.Installoneseal(9)totubeassembly(40).Usefourbolts(27),fourhardwashers(4),
andtwohalfflanges(50)toattachthetubeassemblytothehydraulictank.

18.RefertoIllustration44.Installadapterassembly(10)intotheportthatplug(BT)filled.Attachhose
assembly(11)totheadapterassembly.

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19.RefertoIllustration44.Installonegrommet(15)aroundtheendoftubeassembly(2)asshown.Installone
clip(16)andoneclip(17)aroundthegrommet.Installoneclip(18)aroundhoseassembly(5).Alignthe
holesintheclips.Useonebolt(19),twohardwashers(4),andonenut(20)tosecurethehoseassembly.

20.RefertoIllustration44.Installonegrommet(15)aroundtheendoftubeassembly(2)nexttotheother
grommet(15).Installoneclip(16)andoneclip(17)aroundthegrommet.Installoneclip(12)aroundhose
assembly(11)asshown.Aligntheholesintheclips.Useonebolt(13),onehardwasher(4),andonespacer
(14)tosecuretubeassembly(2)tothehydraulictank.

21.RefertoIllustration44.Installonegrommet(42)aroundtubeassembly(40)inthepositionshown.Place
oneclip(16)andoneclip(17)aroundthegrommet.Useonebolt(19)andonehardwasher(4)toattachthe
tubeassemblytothehydraulictank.

Note:Theseclipsaretheonlyadditionalclipsforthetowmotor.Reusetheclipsandtheclippingstrategyof
theformertowmotorhoseassembly,the3389262HoseAs.

Illustration45 g03589730
Aviewbehindthehydraulictankundertheframewithpartsremovedforclarity

22.Usetwobolts(22),andtwohardwashers(4)toattachplateassembly(21)tothemachine.

Note:Positionthelongerlegofplateassembly(21)towardthecenterofthemachine.

23.Uselocknut(24)toattachteeassembly(23)toplateassembly(21).Attachelbowassembly(25)tothe
outsideoftheteeassemblytowardthehydraulictank.

24.Attachtheendofhoseassembly(26)withthe90degreebendtotee(23).Attachtheotherendofthehose
assemblytothemanifoldontheinsideoftherightframebythepumpdrivegroup.

25.Installoneendofhoseassembly(30)toadapterassembly(25).Attachtheotherendofthehoseassemblyto
themotorgrouponthehydraulictank.

26.Oneendofhoseassembly(5)wasinstalledinStep16.Installthesecondendofthehoseassemblytothe
openportontee(23).

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Illustration46 g03589749
Aviewbehindthehydraulictankundertheframe

27.RefertoIllustration42andIllustration46.Usefourbolts(43),fourhardwashers(4),andtwohalfflanges
(28)toattachendofhoseassembly(41)withthe67degreebendtotubeassembly(2).

28.Usefourbolts(27),fourhardwashers(4),andtwohalfflanges(28)toattachtheendofhoseassembly(41)
withthe90degreebendtopump(44).

29.Usefourbolts(49),fourhardwashers(4),andtwohalfflanges(50)toattachtheendofhoseassembly(29)
totubeassembly(40).Attachtheotherendofthehoseassemblytothetubeassemblyonthefrontsideof
thetorquetubethatisconnectedtothetankportonthebrakecontrolvalvegroup.

30.Installadapterassembly(51)intotheportintubeassembly(40).

31.Installadapterassembly(52)intoadapterassembly(51).

32.Installfluidsamplingvalveassembly(53)adapterassembly(52).Installdustcap(65)ontothefluid
samplingvalveassembly.

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Illustration47 g03353045
Viewofarea(B)

33.Installoneclip(6)onhoseassembly(26).Installoneclip(31)onhoseassembly(11).Aligntheholesinthe
clips.Useonebolt(32),twohardwashers(8),onebolt(32),andonenut(33)tosecuretheclips.

34.Installonegrommet(34)onhoseassembly(41)nearplateassembly(21).Installoneclip(35),andoneclip
(36)aroundthegrommet.Aligntheholesintheclipswiththeholeintheplateassembly.Placetheclipson
thesideoftheplateassemblytowardtheoutsideofthemachine.Useonebolt(19),twohardwashers(4),
andonenut(20)tosecuretheclips.

Illustration48 g03353046

35.Movetothetorquetubeareaoftheframe.Belowthetorquetubeisthebrakeandhoistgearpumpgroup.
Removehoseassembly(CC),theseals(CD)frombothendsofthehoseassembly,twohalfflanges(CE),the
fourbolts(CF),andthefourwashers(CG)fromthemachine.

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Illustration49 g03378958

36.InstalloneOringseal(46),andoneOringseal(64)ontohoseassembly(45).Usetwohalfflanges(47),
fourbolts(48),andfourhardwashers(7)toattachthehoseassemblytothepump.

Illustration50 g03353047
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37.Movetowardthebackofthemachine,behindthetorquetube.Removehoseassembly(CH),Oringseal
(CJ),andOringseal(CK)fromthemachine.Thehoseassemblyistheclosestofthetwohoseassembliesto
therightframe.Savethehardware.

Note:Examinetheflangesonthevalveandonthescreen.Ifdamaged,installtwonewhalfflanges(50)on
thevalve.Installtwonewhalfflanges(28)onthescreen.

Illustration51 g03353048

38.InstalloneOringseal(38),andoneOringseal(39)ontohoseassembly(37).Usethehardwarefromthe
previoussteptoinstallthehoseassemblytothemachine.

InstallationofSection3
Table7

PartsinSection3
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Item Qty PartNumber Description

2 1 4472930 TubeAs

3 20 8T4223 HardWashers

4 8 8T4184 Bolts
5 1 7Y2522 Plate

6 6 8T4139 Bolts

7 1 2958037 Plate

8 6 1P4582 HalfFlanges

9 3 6V4590 ORingSeals

10 4 8T4183 Bolts
11 1 4255909 HoseAs

12 4 8T4194 Bolts

13 2 2815979(1) ElbowAs

13A 1 6V9007 Elbows

13B 2 2287092 ORingSeals

13C 2 2385082 ORingSeals

14 1 3968352 HoseAs

15 1 9X2646 Clip

16 1 9X2647 Clip

17 1 6V1889 Clip
18 1 8T4196 Bolt

19 2 8T4121 HardWashers

20 1 8T4133 Nut

22 1 3893707(2) PlugAs

22A 1 5P9436 Plug

22B 1 2385082 ORingSeal

23 2 8T4244 Nuts

24 4 3718949(3) Hoses

25 1 3968346 Elbow

26 1 8T0568 ORingSeal

27 1 2443712 PlugAs
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PlugAs
27A 1 9S4181 ORingPlug

27B 1 2147568 ORingSeal

28 1 4469478 Plate

30 1 4458799 PlateAs

31 7 8T4956 Bolts

32 1 5P7703 Grommet
33 1 5P7470 Clip

34 1 5P7471 Clip

35 4 5P1076 HardWashers
(1) Requiredpartsforassemblingone2815979ElbowAsconsistofone6V9007Elbow,one2287092ORingSeal,andone238
5082ORingSeal
(2) Requiredpartsforassemblingone3893707PlugAsconsistofone5P9436Plug,andone2385082ORingSeal
(3) Cutthehosestoalengthof178mm(7.0inch)

Illustration52 g03354041

ThereworkareafortheoilflowfortheDuoConesealsandthemakeupoilisshowninIllustration52.
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Illustration53 g03354046

1.Removethesixbolts(E),12hardwashers(F),sixhalfclamps(G),andsixnuts(H)fromthemachine.Save
theparts.

2.Removetheeightbolts(J),eighthardwashers(K),fourhalfflanges(L),hoseassembly(N),andtwoOring
seals(M)fromthemachine.Discardtheparts.

3.Removethefourbolts(A),Fourhardwashers(B),tubeassembly(D),andrectangularseal(C).

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Illustration54 g03354143

4.Removeclips(S),threebolts(T),fourwashers(U),andnut(V).

5.Removetubeassembly(R),andelbowassembly(P).DiscardtheOringsealsfromtheelbowassembly,and
thetubeassembly.Savetheelbow.

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Illustration55 g03354144

6.Removenut(Y),twowashers(BA),bolt(Z),clips(X).Discardtheparts.

Illustration56 g03354145

7.Removenut(BE),twowashers(BF),bolt(BG),clips(BC),andgrommet(BD).Discardtheparts.

8.Removebolt(BK),washer(BJ),andbracketassembly(BH).Discardtheparts.

9.Removehoseassembly(W)fromthemachine.Discardthepart.

10.Removeconnectorassembly(BB)fromthemachine.Discardthepart.

11.Installplugassembly(22)intotheoilfiltergroup.

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Illustration57 g03354060

12.Installonerectangularseal(9)intotubeassembly(2).Installonehardwasher(3)ontofourbolts(4).Usethe
bolts,andtwohalfflanges(8)toinstallthetubeassemblytothemachine.

Note:Ifthetubeassembliesneedtobeloosenedforrework,replacethefourhoses(24).Cutthehosesto
178mm(7.0inch).

13.Installthesixbolts(E),12hardwashers(F),sixhalfclamps(G),andsixnuts(H)totubeassembly(2).The
partsweresavedinStep1.

14.Installoneelbowassembly(13)intotheportintubeassembly(2).

15.Installhoseassembly(14)toelbowassembly(13).Runthehoseassemblyalongtubeassembly(21).

16.Placeoneclip(17)onhoseassembly(14).Placeoneclip(15),andoneclip(16)aroundtubeassembly(21).
Aligntheholesintheclips.Useonebolt(18),twowashers(19),andonenut(20)tofastenthehose
assembly.

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Illustration58 g03379719

17.Gotothehydraulictank.InstalloneOringseal(13B),andoneOringseal(13C)ontotheelbow(P)that
wassavedinStep5.Installtheelbowassemblyintotheportfromwhichtheelbowassemblywasremoved.
Pointtheelbowassemblyupward.Installthesecondendofhoseassembly(14)totheelbowassembly.

Illustration59 g03380253

18.Placeonehardwasher(3)ontofourbolts(6).Usetheboltstoassembleplate(28)totheframe.

19.Assembleplugassembly(27)toelbow(25).Placeonehardwasher(35)ontofourbolts(31).Usethebolts
toassembleelbow(25)toplateassembly(28).

20.Placeoneseal(9)ononeendofhoseassembly(11).Placeonehardwasher(3)ontofourbolts(4).Usethe
fourbolts,andtwohalfflanges(8)toattachoneendofhoseassembly(11)totubeassembly(2).

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21.Placeoneseal(9)ontheotherendofhoseassembly(11).Placeonehardwasher(3)ontofourbolts(10).
Usethefourbolts,andtwohalfflanges(8)toattachtheendofhoseassembly(11)toelbow(25).

22.Placeonegrommet(32)aroundtubeassembly(2)asshown.Placeoneclip(33),andoneclip(34)around
thegrommet.Placeonehardwasher(3)onebolt(31).Aligntheholesintheclips.Usethebolttofastenthe
clipstoplateassembly(30).

23.Placeonehardwasher(3)ontwobolts(31).Placeonehardwasher(3)ontwobolts(6).Aligntheholesin
plate(7)withtheholesinplateassembly(30).Usethetwobolts(31),andtwonuts(23)tofastenplate(7)to
plate(30).Usethetwobolts(6)tofastenplate(7)toplate(5).

24.Afterthepartsareassembled,markthepositionofplate(5)onthemachine.Preparetheareaforwelding.
Fortheproperprocedure,refertotheabovelistedspecialinstruction.Assemblethepartsandtackweldthe
plateinposition.Usea6mm(0.24inch)filletweldalongthetwolongsidesoftheblocktoweldtheblock
inposition.

InstallationofSection4
Table8
PartsinSection4

Item Qty PartNumber Description

1 1 4421875 Plate
2 1 4158654 HoseAs

3 1 4212635 HoseAs

4 1 3196220(1) ElbowAs

4A 1 6V9008 Elbow
4B 1 2287093 ORingSeal

4C 1 2385084 ORingSeal

5 4 8T4223 HardWashers

6 4 8T4183 Bolts

7 1 3933691 OilFilterGp
8 2 2352477 RectangularSeals

9 2 4158651 Flanges

10 8 8T0439 Bolts

11 1 1645567(2) QuickDisconnectCouplerAs

11A 1 6V3965 Fitting

11B 1 2147568 ORingSeal

12 1 6V0852 DustCap

13 1 3353973(3) TeeAs

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13A 1 8C6515 Tee

13B 1 2287093 ORingSeal
13C 1 2385084 ORingSeal

14 1 3295470(4) TeeAs

14A 1 6V9840 SwivelTee

14B 1 2287093 ORingSeal

15 1 4158653 HoseAs

16 1 3557004 PressureIndicator

17 4 2287093 ORingSeals

18 1 8T4184 Bolt

19 1 2307732 CableTieMounting
20 2 2042281 CableStrap

21 1 1305301 Clip

22 1 2048000 CableTieMounting

27 1 8T4194 Bolt

28 1 8T4136 Bolt

29 1 3445675 Nut
30 1 3G4005 Link

31 1 5P8444 Grommet

32 1 5P7468 Clip

33 1 5P7469 Clip

34 1 6V1249 Grommet

35 1 5P7469 Clip
36 1 5P7465 Clip

37 2 8T4223 HardWashers

38 1 8T4184 Bolt

39 1 8T4244 Nut
(1) Requiredpartsforassemblingone3196220ElbowAsconsistofone6V9008Elbow,one2287093ORingSeal,andone238
5084ORingSeal
(2) Requiredpartsforassemblingone1645567QuickDisconnectCouplerAsconsistofone6V3965Fitting,andone2147568O
RingSeal
(3) Requiredpartsforassemblingone3353973TeeAsconsistofone8C6515Tee,andone2287093ORingSeal,andone238
5084ORingSeal
(4) Requiredpartsforassemblingone3295470TeeAsconsistofone6V9840SwivelTee,andone2287093ORingSeal

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Illustration60 g03354884

ThereworkareaforthebrakeoilfiltergroupisshowninIllustration60.Thebrakeoilfiltergroupislocatedonthe
leftsideoftheframebythehoistcylinder.

Illustration61 g03354888

1.Removehoseassembly(A),andhoseassembly(B).Discardthehoses.

2.Disconnectthedifferentialpressureswitchassembly(F).Removethefourbolts(C),andfourwashers(D)
fromthebrakesystemoilfiltergroup(G).Discardalloftheparts

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Illustration62 g03354892
(A)187.7mm(7.39inch)

(B)96.6mm(3.80inch)

3.UsethedimensionsinIllustration62tolocatethetwopointsontheplateontheframe.Inordertolocatethe
twopoints,placeasquareonthefueltankmountingplate.Measureoutonthefiltersupportbrackettolocate
thepoints.Drawalinebetweenthetwopoints.Cuttheplatebeyondthelinebetweenthetwopoints.Grind
thesurfacesmoothtothecutline.

Illustration63 g03354938

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4.UsetheinformationinIllustration63toweldplate(1)totheremainderoftheoriginalfiltersupport.Align
thebottomoftheplatetothebottomofthefiltersupport.

Illustration64 g03381047

5.Placeonehardwasher(5)ontotwobolts(6).Placeonehardwasher(5)ontoonebolt(18),andontoonebolt
(27).Placecabletiemounting(20)ontobolt(27).Placeclip(21),andlink(30)ontobolt(18).Usethebolts
asshowntofastenoilfiltergroup(7)toplate(1).

6.Assemblepressureindicator(16)tothecenterofoilfiltergroup(7).Usebolt(28),twohardwashers(24),
andnut(29)toassemblecabletiemounting(22)tolink(30).Onecablestrap(20)willbeusedonbothcable
tiemounts.

Note:Torquepressureindicator(16)to1005Nm(743.6lbft).

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Illustration65 g03381057

7.Installoneseal(8)ontoeachflange(9).Usefourbolts(10)tofasteneachflangetooilfiltergroup(7).

Illustration66 g03354972

Illustration67 g03354978

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Illustration68 g03381078

8.Installteeassembly(13)intotheportthatpointstowardthefrontofthemachine.Installelbowassembly(4)
intotheportthatpointtowardthebackofthemachine.

9.Installteeassembly(14)ontoteeassembly(13).InstalloneOringseal(17)ontothestraightendofhose
assembly(15).Installthe45degreeendofhoseassembly(15)ontotheportonteeassembly(14)thatpoint
towardthefrontofthemachine.Attachthesecondendofhoseassembly(15)tothetubeassemblythatis
attachedtothebrakecontrolvalve.Installquickdisconnectcoupler(11),anddustcap(12)intothebottom
portonteeassembly(13).

10.Attachthe45degreeendofhoseassembly(3)ontothetopportofteeassembly(14).Installtheendofthe
hoseassemblywiththe90degreebendontotheinlettothereliefvalve.Thereliefvalveisontheleftframe
behindthesupportforthehoistcylinders.

11.Installthe45degreeendofhoseassembly(2)ontoelbowassembly(4).InstalloneOringseal(17)ontothe
straightendofthehoseassembly.Installthesecondendofthehoseassemblytothetubeassemblyfromthe
pump.

12.Placegrommet(34)onthesmallerhoseassemblythatpassesclosethehoseassembly(3).Placeclip(35),
andclip(36)aroundthegrommet.Placegrommet(31)aroundhoseassembly(3)neartheclips.Placeclip
(32),andclip(33)aroundthegrommet.Aligntheholesinthetwoclips.Useonebolt(38),twohardwashers
(37),andonenut(39)tofastentheclips.

13.Refillthehoistandbrakesectionofthehydraulictank.RefertotheabovelistedOperationandMaintenance
Manualforthecorrectrefillquantity.

Note:PriortostartingthemachinerefertoSpecialInstruction,REHS9546,"ProceduretoPrimethe
HydraulicSystemonCertain793FOffHighwayTrucks".

Performthefollowingtestsinordertoconfirmthatthemachineisoperatingwithinspecifications.Refertothe
abovelistedreferencesforthecompletetitlesofthetests.
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TestingandAdjusting,"BrakeSystemAirPurge"

TestingandAdjusting,"BrakeAccumulatorTestandCharge"

TestingandAdjusting,"BrakeSystemPressureTestandAdjust"

TestingandAdjusting,"ReliefValve(Main)TestandAdjust"

TestingandAdjusting,"ServiceBrakesandRetarderSystemPressureTest"

TestingandAdjusting,"ParkingBrakeReleasePressureTest"

TestingandAdjusting,"BrakeCoolingPressureCheck"

TestingandAdjusting,"FootBrakeControl(Service)PilotPressureTest"

TestingandAdjusting,"PressureReducingValve(PilotOil)TestandAdjust"

TestingandAdjusting,"Worksheets"

Section5UpdatetheSoftware
Theupdatedbrakesystemrequiresanupdatetothesoftwarethatcontrolstheintegratedbrakecontrol(IBC)and
thechassissoftware.Obtainthecorrectsoftwarefromthe"ServiceSoftwareFiles"linkonthehomepageofthe
CatServiceInformationSystem"SIS".

Note:Softwarepartnumbersaresubjecttochangewithoutnotice.Alwaysusethelatestsoftwareavailable
foryourmachine.

Section6RegistertheRetrofit

Note:Usethefollowingpartnumber4465596ServiceBrakeControlGptoregistertheretrofit.

Becauseretrofitstoaprimeproductwillchangetheconfigurationoftheproduct,updatingtheconfigurationin
SIMSiandAIMSisimportant.Iftheretrofitinformationisnotprovided,Caterpillarwillnotbeabletoprovide
importantproductupdates.

Thefollowinginformationincludesinstructionsonregisteringtheupdatesandretrofits.

1.Whenperformingaretrofitinstallation,recordthevitalinformationinTable9.

Note:Iftheprocedureisperformedbythecustomer,askthecustomertorecordtheproperinformation.

Table9
RepairDate
ProductSerialNumber

ServiceHoursorServiceMeterUnits

RemovedComponentPartNumber(1)

RemovedComponentSerialNumber(1)

InstalledComponentPartNumber(2)

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InstalledComponentSerialNumber(3)
(1) Onlyappliesifacomponentisreplacedbyaretrofitcomponent.Iftheproductisanengine,andtheproductretrofitisakit
forupgradingtheengine,disregardthe"RemovedComponent"information.RefertodetailedinstructionsinSpecial
Instruction,REHS5097,"InstructionstoRegistertheRetrofit"formoreinformation.
(2) Recordthehighestlevelretrofitkit,arrangement,orgrouppartnumber.
(3) Mostretrofitswillnothaveaserialnumber.Exceptionsincludeemissionsrepowerenginesanddieselparticulatefilters.

2.UpdatetheproductconfigurationbyenteringtheinformationfromTable9intoSIMSiandAIMS.

Note:ForretrofitsthathaveaCaterpillarserialnumber,theAIMSapplicationis"JIZ11108".Forretrofits
thatdonothaveaCaterpillarserialnumber,theAIMSapplicationis"JIZ11107".

3.Fordetailedinstructionsonupdatingtheproductconfiguration,refertoSpecialInstruction,REHS5097,
"InstructionstoRegistertheRetrofit".

Copyright19932016CaterpillarInc. FriOct21201614:13:45GMT0300(HoraveranoSudamricaPacfico)
Todoslosderechosreservados.
cr120rxr
RedprivadaparalicenciadosdelSIS.

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