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Special Instruction789C Off-Highway Truck Assembly Procedure{7000, 7006, 7960}

789C Off-Highway Truck Assembly Procedure{7000, 7006, 7960}

SMCS -7000-016; 7006-016; 7960-016

Off-Highway Truck/Tractor:

789C (S/N: 2BW303-303,306-UP)

Introduction

This special instruction contains the necessary procedures for the field assembly of 789C S/N:2BW303,306-UPOff-Highway Trucks. This publication also contains the necessary commissioning procedures.

Note: The photographs in this publication are for illustrative purposes. Some photographs may not be in sequencefor illustrative purposes.

The shipping configuration consists of the rear axle housing that has the transmission and final drives that areattached. The rear axle group is not connected to the chassis.

The suggested tools and equipment should be present before assembly. If the recommended tools and equipment arenot present, assembly will be more difficult and more time will be necessary to complete the assembly.

Do not perform any procedures or order any parts until you read this publication. Do not perform any procedures ororder any parts until you understand this publication thoroughly.

All of the parts that are contained within the shipping boxes will be identified with a white label. DO NOTREMOVE THE WHITE LABELS FROM THE PARTS UNTIL THE PARTS ARE READY FORINSTALLATION.The white label identifies the part number and the group number for that particular part. Whenyou unpack the shipping containers, organize the parts by the group number or by the next level part number("N/L"). This manual is organized by the assembly of the groups.

Tighten all of the fasteners to standard torque for that particular thread. Unless otherwise specified, do not usethread lock or thread lubricant. A tightening specification is provided only when a special torque is required. Thefollowing items are examples of fasteners that require special tightening specifications:

high/low tightening specification

torque turn

thread lock

Shutdown SIS

Previous Screen

Product: TRUCKModel: 789C TRUCK 2BWConfiguration: 789C Truck 3516 Engine 2BW00001-UP (MACHINE)

Media Number -REHS0878-11 Publication Date -02/01/2011 Date Updated -02/01/2011

i04195649

Page 1 of 347789C Truck 3516 Engine 2BW00001-UP (MACHINE)(SEBP2790 - 126)/Basic Search

14/02/2011https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...


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anti-seize

After assembly is complete, prepare the machine for use. The Operations and Maintenance Manual, SEBU7174shows the preparation of the machine. Use the Parts Manual, SEBP2790 and the Service Manual, SENR1515 withthis special instruction.

ReferenceParts Manual, SEBP2790, "789C S/N:2BW1-UP" Off-Highway Trucks

ReferenceOperations and Maintenance Manual, SEBU7174, "789C S/N:2BW1-UP" Off-Highway Trucks

ReferenceService Manual, SENR1515, "789C S/N:2BW1-UP" Off-Highway Trucks

ReferenceTesting and Adjusting, SENR1502, "784C, 785C, 785D, 789C, 793C and 793D Off-HighwayTruck/Tractors Power Train Electronic Control System "

Note: After assembly of the truck is complete, the suspension cylinders must be charged. The air should be purgedfrom the brake system. This is shown in the Operations and Maintenance Manual. Use the Parts Manual and theService Manual with this special instruction.

Parts List

Do not attempt to assemble this machine until you read and youunderstand the assembly instructions.

Improper assembly procedures could result in injury or death.

The space between the body and the frame becomes a zero clearancearea when the body is lowered. Failure to install the retaining cable canresult in injury or death to personnel working in this area.

NOTICE

Do not allow any dirt or foreign material to get into the hydraulicsystem during assembly, connection of lines, when components arefilled with fluid, or during any maintenance operation.

NOTICEClean all surfaces and remove burrs from all areas where parts are tobe installed. Chase all tapped holes used for mounting purposes.Remove the paint from all contacting surfaces. Clean surfaces arenecessary for a good solid joint.




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Approximate Weights

1 5P-9297 Clip

1 3T-3048 Clip Assembly

Table 36

Parts that are Needed for Installation of 115-6488 Payload Signal Lamp Group

Qty Part Number Part Name

2 9G-9150 Clip

1 8T-4896 Hard Washer

1 5M-3062 Bolt

1 8K-1433 Grommet

Personal injury or death can result from lifting a heavy assembly.

The heavy assembly can fall if using an incorrect hoist to lift the load.

Be sure the hoist has the correct capacity to lift a heavy assembly.Approximate weight of the assembly is given below.

Personal injury or death can result from improper lifting or blocking.

When a hoist or jack is used to lift any part or component, stand clearof the area. Be sure the hoist or jack has the correct capacity to lift acomponent. Install blocks or stands before performance of any workunder a heavy component.

Approximate weights of the components are shown. Clean all surfaceswhere parts are to be installed.

Table 37

Module Weight

Air Cleaner 62 kg (137 lb)

Body pivot pin34 kg (75 lb)




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Cab Assembly 1920 kg (4250 lb)

Cab Support (front)169 kg (372 lb)

Cab Support (rear)232 kg (511 lb)

Rear Axle Housing and Transmission20200 kg (44520 lb)

Front Suspension Cylinder, Wheel, and Brake Assembly4960 kg (10920 lb)

Fuel Tank1200 kg (2640 lb)

Hoist Cylinder833 kg (1835 lb)

Top Mounting Pin for the Hoist Cylinder

15 kg (33 lb)

Mirror Guards72 kg (159 lb)

Right Side Platform Assembly761 kg (1676 lb)

Rim1600 kg (3540 lb)

Rock Ejector99 kg (218 lb)

Mounting Bracket for the Rock Ejector 38 kg (83 lb)

Safety Cable35 kg (79 lb)

Steering Arm280 kg (617 lb)

Steering Hydraulic Tank100 kg (220 lb)

Tire3178 kg (7000 lb)

Assembled Truck Body44230 kg (97500 lb)

Hinge Pin for the Truck Body41 kg (90 lb)

Truck Frame Module At Shipment39920 kg (88000 lb)




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Specifications

Torque Specifications

Tighten the 20 cab mounting bolts to a torque value of 1900 70 Nm (1397 50 lb ft).

Tighten the 25 cab support mounting bolts to a torque value of 900 100 Nm (662 75 lb ft).

Tighten the 100 nuts that mount the front wheel rim to a torque value of 1150 150 Nm (845 110 lb ft).

Tighten the six lower bolts that mount the fuel tank to a torque value of 450 50 Nm (330 35 lb ft).

Tighten the two bolts that mount the bracket to the fuel tank to a torque value of 370 50 Nm (272 35 lbft).

Tighten the four bolts for the fuel tank cap to a torque value of 450 25 Nm (330 20 lb ft).

Tighten the 114 ring nuts that mount the rear outer wheel to a torque value of 1150 150 Nm (845 110 lbft).

Tighten the 100 bolts and the 100 nuts that mount the rear outer wheel rim to a torque value of 1150 150Nm (845 110 lb ft).

Tighten the 16 bolts that mount the front support of the right side platform to a torque value of 370 50 Nm(272 35 lb ft).

Tighten the 12 bolts that mount the rear support of the right side platform to a torque value of 215 40 Nm(158 30 lb ft).

Table 38

Areas that are Measured Specifications

Empty weight130933 kg (288660 lb)

Wheel Base5690 mm (224 inch)

Length12167 mm (479 inch)

Ground to top of canopy6147 mm (242 inch)

Ground to upper edge of body5207 mm (205 inch)

Machine clearance turning circle30.2 m (99 ft)

Width of body assembly7671 mm (302 inch)

Width of truck frame at rear tires6934 mm (273 inch)




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Tighten the 16 bolts that mount the steering arm to a torque value of 1632 50 Nm (1200 35 lb ft).

Tighten the eight strut mounting bolts for the top bearings to a torque value of 900 100 Nm (661 75 lb ft).

Tighten the top 24 strut mounting bolts to a torque value of 2300 300 Nm (1691 220 lb ft).

Tighten the lower eight strut mounting bolts to a torque value of 4000 500 Nm (2941 365 lb ft).

Tighten the ball stud at the tie rod end to a torque value of 2550 100 Nm (1875 75 lb ft).

Tighten the 20 bolts that secure the axle housing to the A-frame to a torque value of 1800 250 Nm (1325 185 lb ft).

Specifications for Cables, Chains, and Lifting Devices

ReferenceService Magazine, SEPD0531 03 July, "Fabric Slings and Protective Sleeves Are Available for LiftingTruck Bodies"

Use approved cables, chains, and lifting devices in order to lift components. Refer to the literature from themanufacturer in order to determine the application when you select the items that follow: cable, chain and lifting

devices. When you lift a component, the lift angle is critical. Refer to the Illustration that follows in order to see theeffect of the lift angle on the working load limit.

Illustration 1 g00629745

Lift angles for lifting slings.

(A) The load capacity is 100 percent of the working load limit for the sling.




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Necessary Hoist Capacity

Two hoists are needed to remove the truck frame from the trailer. One hoist with a 54430 kg (120,000 lb) capacityand one hoist with a 36,290 kg (80,000 lb) is needed.

When the rear axle housing is on supports, a hoist with a 36,290 kg (80,000 lb) capacity is needed to lift the truckframe at the front lifting points.

With the front crossmember on supports, one hoist with 54,430 kg (120,000 lb) capacity is needed to lift the truckframe at the rear lifting points.

789C Assembly Tips

Note: Follow the table of contents for the assembly sequence of the truck.

1. The assembly of the 789C requires four mechanics for a total of 196 hours. Two crane operators are requiredfor a total of 24 hours until the major components are installed.

2. All of the parts that are contained within the shipping boxes will be identified with a yellow label. DO NOTREMOVE THE YELLOW LABELS FROM THE PARTS UNTIL THE PARTS ARE READY FORINSTALLATION.The yellow label identifies the part number and the group number for that particular part.When you unpack the shipping containers, organize the parts by the group number or by the next level partnumber ("N/L"). This manual is organized by the assembly of the groups.

3. Complete the assembly of components such as the cab, right side platform, and the body prior to assemblingthe components to the truck. For example, before you assemble the cab to the truck, assemble as much of thefollowing items as possible: 150-8726 Steering Lines Group, 5T-1070 Fender Group and 159-2489 RearView Mirror Group.

4. After assembly is complete, prepare the machine for use. Refer to the commissioning procedure. In order toperform the tests that are contained in the commissioning procedure, refer to the following serviceinformation: Operations and Maintenance Manual, SEBU7174, Parts Manual, SEBP2790 and ServiceManual, SENR1515.

Necessary Equipment and Supplies for Assembly

The following items are necessary for assembly:

Six 208 L (55 US gal) barrels of hoist, converter, and brake oil (TDTO, TO-4). - SAE viscosity grade 10 isrecommended. Refer to the Operation and Maintenance Manual for more details.

One 133 L (35 US gal) barrel of steering oil- The steering oil should be of one of the following types: HYDO,TDTO, DEO CF-4, API CF-4 and CE-compliant oils. Refer to the Operation and Maintenance Manual for moredetails.

Several shackles- The shackles should have a working load limit of 27,240 kg (60,053 lb).

A steel rod that is 88.9 mm (3.50 inch) in diameter - The steel rod should be at least 4191 mm (165 inch) long.

(B) The load capacity is 86 percent of the working load limit for the sling.

(C) The load capacity is 70 percent of the working load limit for the sling.

(D) The load capacity is 50 percent of the working load limit for the sling.




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mounting nuts, mounting rings for the outside rear tires, cab support mounting bolts and cab mounting bolts.

Use the 6V-6080 Torque Multiplier in order to tighten the components that follow: the bolts for the frontsuspension cylinder, steering arm mounting nuts, ball stud nuts and wheel rim mounting nuts. The 6V-6080Torque Multiplier provides an 18.5 to 1 mechanical advantage.

Use a 9U-5089 Wheel Nut Socket (57.1 mm (2.25 inch)) to assemble the bottom bolts for the mounting struts.Use a 8F-2239 Wrench to hold the bolts.

Use the 9U-6566 Socket (47.62 mm (1.875 inch)) to tighten the bolts that secure the components that follow:the ROPS, the upper front suspension and the steering arm.

Use an 0V-0455 Open End Wrench (47.62 mm (1.875 inch)) to hold the upper bolts that secure the frontsuspension cylinders.

Use the 9U-6560 Socket (38.1 mm (1.50 inch)) to tighten the ROPS cab mount bolts, mounting bolts for thebearing cap for the front suspension cylinder, and the wheel rim mounting nuts.

Use a 4C-3386 Spanner Wrench in order to assemble the ball stud for the tie rod.

Use a 5S-6084 Socket (88.9 mm (3.50 inch)) to tighten the ball stud.

Use a 8T-0447 Dial Caliper in order to determine the shims that are required in order to mount the top of thefuel tank.

Use a 162-8718 Torque Wrench in order to assemble the mounting bolts for the fuel tank and the mountingbolts for the right side platform.

Have a 5S-6076 Extension in order to assemble the mounting nuts for the wheel rim.

Use 6V-0006 Connector Pliers in order to connect the wiring harness to the TCS sensor.

Use a 6V-4040 Tire Inflation Group to inflate the tires.

Use a 4C-4911 Battery Load Tester in order to test the batteries.

Use a 8T-0900 Ammeter in order to test the batteries.

Use a 6V-7070 Digital Multimeter in order to test batteries.

Use a 175-5507Nitrogen Charging Group and a 175-7410 Auxiliary Fitting Group in order to charge thesuspension cylinders.

Have an FT-1975 Gauge Block for charging the front suspension cylinders.

Use a 9U-5617 Oil Refill Group for charging the suspension cylinders with oil.

Use a 139-4166 Data Link Cable and a 171-4400 Communication Adapter Group in the commissioningprocedure.

Use a 8T-5182 Socket (38.1 mm (1.50 inch)) to install the rim nuts.

Have a 6V-3146 Extension Handle .

Have a 6V-4170 Adapter .




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Prepare to Assemble the 789C Off-Highway Truck

1. Unload the truck frame and the shipping crates on a flat, smooth, drained area 30.5 m (100 ft) by 24.5 m (80ft). The area is needed for assembly of the truck.





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2. Set the truck frame in the center of the area. Keep the area around the truck frame free so the cranes can bepositioned for proper lifting.


789C Off-Highway Truck chassis on a truck trailer


Lifting diagram

The lifting diagram is located on the left frame rail. The left frame rail is located forward of the mounting bracket for the fuel tank.




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3. Unload the components from the trailer. Use a crane and a suitable lifting device in order to prepare the frontof the 789C chassis for removal from the truck trailer. The lifting device should have two 3.5 m (11.5 ft)chains. The lifting device must be rated at 36320 kg (80000 lb). In the shipping configuration, the chassisweighs approximately 39920 kg (88000 lb).

4. In order to prepare the rear of the 789C chassis for removal from the trailer, use the following items: a secondcrane, a steel bar and a suitable lifting device. Install the steel bar through the future location of the hingepins. Connect a two-way lifting device to each end of the steel bar. The lifting device should have two 3.5 m(11.5 ft) chains. The bar must be made of solid steel. The bar should have a 88.9 mm (3.5 inch) diameter. Thebar should be 4.2 m (165 inch) long. The lifting device must be rated at 36320 kg (80000 lb).


Typical front lifting location of the chassis

NOTICE

Failure to use a suitable two-way lifting device or lifting device withouta suitable spreader may result in damage to the front of the truckchassis.


View of the rear lifting location




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5. Use both cranes in order to lift the chassis from the trailer. Drive the trailer forward. The frame is ready to be

blocked.

6. Use hardwood blocks that are 203 mm (8 inch) by 203 mm (8 inch) to block the front of the frame. Stack thehardwood blocks alternately. Use suitable metal stands to block the rear of the chassis. Place the stands underthe lower cross-tube at the supports for the hoist cylinder.



View of the proper lifting procedure for the 789C Truck


View of the frame that is blocked




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7. Once the blocking is in place, slowly shift the weight of the chassis to the blocking. If the blocking appears tobe adequately supporting the weight of the chassis, remove the cranes.


View of the frame that is blocked






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8. Use a suitable lift truck or a suitable crane in order to unload the remaining three trucks.







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9. Position the components near the truck chassis.

10. Use a suitable crane and a lift truck in order to position the cab on suitable stands. To assemble the rightfender and air cleaner to the cab, use 121.9 cm (48 inch) stands. The cab weighs approximately 1920 kg (4250lb).

11. Once the front blocking is in place, slowly shift the weight of the cab to the stands. If stands appear to beadequately supporting the weight of the cab, remove the cranes.

12. Set four large wooden boxes of smaller components and the hardware in front of the chassis. Open the boxesin order to become familiar with the contents of each box.

13. Organize the hardware by the next group level. Do not open the bags of hardware.


View of the components that are being unloaded and positioned


NOTICE

Do not open the contents of the plastic part bags until parts are readyfor assembly. Once the bags are opened and the parts are removed, theidentity of the part number and the next group level may be lost. Bothof these numbers are necessary in order to facilitate the assembly ofthe truck.




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Note: The brake cooling ports must be oriented toward the back of the brake assembly. The weight of thecomplete assembly is 4960 kg (10920 lb).

1. Use a clevis assembly and a hoist in order to rotate the housing assembly of the front suspension cylinder.Refer to Illustration 24.

2. Use 4C-4204 Paint Remover in order to clean the shipping grease or clean the paint from the mounting flangeof the front suspension cylinder. Clean the bolt holes. Make sure that the spot faces are clean. Clean surfacesensure proper torque values.

3. Use 4C-4204 Paint Remover in order to clean the shipping grease or paint from the top bearing mount for thefront suspension cylinder.

(1) 4T-5182 Front Suspension Gp

(1) 229-2379 Front Suspension Gp





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4. Remove the straps in order to reposition the hose assemblies (B) for the service and parking brakes.Reposition the hose assemblies (B) in order to prepare for the installation of the front suspension cylinder.

5. Disconnect grease line (D) from the ball stud for the steering cylinder. Disconnect grease line (D) from theball stud for the tie rod.

6. Support the steering arm. Remove the following items: four 2D-7687 Bolts (2), four 3S-6162 Hard Washers


(2) 2D-7687 Bolt

(3) 3S-6162 Hard Washer

(4) 5T-4896 Spacer

(5) 8H-3390 Full Nut

(A) Top mounting surface for the upper bearing of the front suspension cylinder

(B) Hose assemblies for the service and parking brake

(C) Shipping bracket

(D) Grease lines

(E) Lower mounting surface for front suspension cylinder

NOTICE

Failure to disconnect grease lines (D) in the previous step beforeproceeding will result in damage to the grease lines.




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(3), four 5T-4896 Spacers (4) and four 8H-3390Nuts (5). Lower the steering arm. Save the fasteners forinstallation of the suspension cylinder.

7. Remove shipping bracket (C) from the steering arm and discard shipping bracket (C) .

8. Use 4C-4204 Paint Remover in order to clean the top mounting surface (A) and the main mounting surface(E) for the front suspension cylinder. Clean mounting surface (A) and mounting surface (E) to bright metal.Remove the four plastic plugs in the tapped holes in mounting surface (A) .

9. Use 4C-4204 Paint Remover to clean the grease and paint from the spot faces on the back of the mountingflanges on mounting surface (E). Deburr any sharp edges.

10. Install 5T-6255 Key (6) .



(6) 5T-6255 Key




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11. Install 5T-5202 Cap (2) on the end of 4T-5182 Front Suspension Gp (1) (If Equipped) or 229-2379 Front

Suspension Gp (1). Refer to the arrows.

Note: There may not be sufficient space in order to install the bearing after the suspension cylinder is boltedto the frame.




(7) 5T-5202 Cap

NOTICE

Assemble 5T-5202 Cap (2) so the retaining ring is positioned below thebearing.






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12. Use a suitable lifting strap and a crane in order to position 4T-5182 Front Suspension Gp (1) (If Equipped) or229-2379 Front Suspension Gp (1) (If Equipped). Refer to Illustration 32 for the correct position. Adjust thelifting strap until the mounting flange of the front suspension cylinder can be positioned squarely against themounting flange of the frame.

13. Position the front suspension group against the mounting flange on the frame.









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14. Use a suitable crane and a lever puller in order to align the mounting bolt holes.







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15. Install the following items: four 2D-7687 Bolts (3), four 3S-6162 Washers (4), four 5T-4896 Spacers (5) andfour 8H-3390Nuts (6). Place 5T-4896 Spacers (5) on 2D-7687 Bolts (3). Install the bolts and the spacers tothe mounting flange from the inside of the frame.

Note: Check the alignment of the mounting holes for the top bearing prior to tightening 2D-7687 Bolts (3) .

16. Install the following items: 12 5P-5769 Bolts (8), 12 4K-0684 Hard Washers (9), 12 5T-1352 Spacers (10)and 12 7H-7539 Full Nuts (11). Place 5T-1352 Spacers (10) on 5P-5769 Bolts (8). Install the bolts (8) and thespacers (10) to the mounting flange from the inside of the frame.

17. Tighten 2D-7687 Bolts (3) to a torque value of 4000 500 Nm (2940 365 lb ft). Tighten 5P-5769 Bolts (8)to a torque value of 2300 300 Nm (1690 220 lb ft).


(3) 2D-7687 Bolt

(4) 3S-6162 Hard Washer

(5) 5T-4896 Spacer

(6) 8H-3390 Full Nut

(8) 5P-5769 Bolt

(9) 4K-0684 Hard Washer

(10) 5T-1352 Spacer

(11) 7H-7539 Full Nut




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18. Align the holes for the top bearing cap. Install 117-4935 Plates (12). Install as many plates between the topbearing and the frame as possible without driving plates by force.

Note: Remove the plug for the grease line in order to fit a socket onto 1D-4639 Bolt (13) .

19. Install four 1D-4639 Bolts (13) and four 5P-8250 Washers (14) through the upper bearing housing. Tighten1D-4639 Bolts (13) to a torque value of 900 100 Nm (660 75 lb ft).

20. Connect the sensor for the front suspension group.


(12) 117-4935 Plate

NOTICE

Do not drive 117-4935 Plates (12) between bearing cap assembly andtruck frame.


(13) 1D-4639 Bolt

(14) 5P-8250 Washer





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21. Repeat Step 1 through Step 20 for the other front suspension group.

Installation of 5T-4462 Steering Link Group

1. On each suspension cylinder, remove the eight existing bolts, washers, and spacers from the mounting surfacefor the steering arm.

Table 40

Parts that are Needed for Installation of the 5T-4462 Steering Link Group

Item Qty Part Number Part Name

1 16 3R-2300 Bolt

2 16 4K-0684 Hard Washer

3 1 3J-6899 Locknut






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2. Use 4C-4204 Paint Remover in order to clean the steering arm mounting surfaces to bright metal. Removeany nicks or burrs on the mounting surfaces.

3. Use a suitable crane in order to support the right side steering arm. The steering arm assembly weighsapproximately 280 kg (617 lb).

4. Use 1U-9200 Lever Puller Hoist in order to rotate the front suspension cylinder rod. Rotate the frontsuspension cylinder rod in order to align the front spindle with the steering arm.







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5. Install eight 3R-2300 Bolts (1) and eight 4K-0684 Washers (2) .

6. Remove the crane and remove 1U-9200 Lever Puller Hoist .


(1) 3R-2300 Bolt

(2) 4K-0684 Hard Washer






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7. Tighten 3R-2300 Bolts (1) to a torque value of 1632 50 Nm (1200 37 lb ft).

8. Repeat Step 2 through Step 7 for the other side.

9. Remove paper tube (A) and cap (B) from the ball stud.

10. Use a suitable crane in order to support the tie rod.

(1) 3R-2300 Bolt

(2) 4K-0684 Washer


(A) Paper Tube

(B) Cap





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11. Use 4C-4204 Paint Remover in order to clean the ball stud. Use 4C-4204 Paint Remover in order to clean thecenter steering arm bore. Refer to the arrow in Illustration 50.

12. Apply 5P-3931 Anti-Seize Compound to the taper of the ball stud and threads. Refer to the arrows inIllustration 49.

13. Apply 5P-3931 Anti-Seize Compound to the face of 3J-6899 Locknut (3). Refer to the arrow in Illustration51.

14. Install 3J-6899 Locknut (3) .



(3) 3J-6899 Locknut




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15. Remove the retaining ring and the cap.

16. Use a 4C-3386 Spanner Wrench in order to hold the ball stud. Hold the ball stud while you tighten Locknut(3) .

17. Tighten 3J-6899 Locknut (3) to a torque value of 2550 100 Nm (1875 74 lb ft).







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Installation of 5T-4474 Rear Axle Housing Group

Refer to the 5T-4474 Rear Axle Housing .

Refer to either the 5T-4466 Rear Suspension Gp (If Equipped) or 193-6342 Rear Suspension Gp (IfEquipped).

Refer to the 5T-8543 Drive Shaft .

Refer to the 5T-1031 Drive Shaft Guard .

1. Place the axle and transmission assembly near the truck frame. Block up the transmission.

Table 41

Parts that Are Needed for Installation of Rear Axle Housing and Transmission

Item Quantity Part Number Part Name

1 1 8X-0465 (1) Slip Joint

2 8 2N-2486 (1) Bolt

3 20 2H-1618 Bolt

4 20 5T-1352 Spacer

( 1 ) Part of 5T-8543 Drive Shaft





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2. Remove the guard from the left side of the rear axle housing. Remove the guard on the right side of the rearaxle housing.

3. Remove six bolts (B), six hard washers (C), and plate (D) that retains pin (A) in the axle housing.



(A) Pin

(B) Bolts

(C) Hard Washers

(D) Plate




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4. Remove pins (A) from the axle housing. Use 4C-4204 Paint and Decal Remover to remove the paint frompins (A) .

5. Remove the shipping brackets from the A-frame.

6. Remove the paint and clean the mounting area on the A-frame.


(A) Pin






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7. Use 4C-4204 Paint and Decal Remover to remove the paint and clean the mounting areas on the rear axlehousing.

8. Remove five bolts (E) and washers (F) that secure guard (G). Clean the transmission drive shaft.



(E) Bolts

(F) Washers

(G) Guard




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Note: Hold the drive shaft with a prybar during the torque sequence.

9. Align 8X-0465 Slip Joint (1) to the transmission. Install the four 2N-2486 Bolts (2). Tighten the 2N-2486Bolts (2) to a torque of 550 20 Nm (405 15 lb ft).

10. Reinstall guard (E) with five bolts (F) and washers (G) .


(1) 8X-0465 Slip Joint

(H) Holes for 2N-2486 Bolts


(E) Bolts

(F) Washers

(G) Guard




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11. Remove shipping plate (J) on the drive shaft yoke at the transmission. Discard shipping plate (J) .

12. Use 4C-4204 Paint and Decal Remover to remove paint from pin (K) .




(K) Pin




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13. Remove bolt (L), hard washer (M), full nut (N), and two washers (P) that secure pin (K) in the rear cross-tube.


(K) Pin

(L) Bolt

(M) Hard Washer

(N) Full Nut

(P) Washers


(K) Pin




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14. Remove pin (K) from the bore.

Note: The pin secures control rod (R) to the frame.

15. Support control rod (R) with wood blocks in order to raise control rod (R) away from the rear axle assembly.

16. Lift the rear axle assembly to the frame assembly.


(R) Control Rod


(R) Control Rod





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Note: Apply anti-seize grease to the pin. Apply anti-seize grease to the bore.

17. Slide pin (K) back into position.

18. Install bolt (L), hard washer (M), full nut (N), and two washers (P) that secure pin (K). Tighten bolt (L) to atorque of 620 80 Nm (455 60 lb ft).


(K) Pin

(R) Control Rod


(L) Bolt

(M) Hard Washer

(N) Full Nut

(P) Washers




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19. Apply 9S-3263 Thread Lock Compound to the 20 2H-1618 Bolts (3). Install 20 2H-1618 Bolts (3) and 205T-1352 Spacers (4). This will secure the A-frame to the rear axle housing. Tighten the 20 2H-1618 Bolts (3)that secure the rear axle housing to the A-frame. Tighten the 20 bolts to a torque of 1800 200 Nm (1330 150 lb ft).

20. Remove the links in the chains that were used to secure the A-frame.


(3) 2H-1618 Bolts

(4) 5T-1352 Spacers





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21. Align the rear struts with the rear axle housing.

Note: Make sure that the lubrication fittings on the pins face toward the rear of the machine. The lubricationfittings should be on the horizontal center line of the bore. Refer to figure 79.

22. Install the following items: pins (A), plates (D), 12 washers (C) and 12 bolts (B). Tighten bolts (B) to a torqueof 370 50 Nm (270 35 lb ft).



(B) Bolts

(C) Washers

(D) Plates


Location of the lubrication fittings on the lower rear strut pin




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23. If the guards are removed, reinstall the guards over the pins.

24. Remove five bolts (S) and washers (T) that secure guard (U). Clean the transmission drive shaft.


Illustration 81 g01150855(S) Bolts

(T) Washers

(U) Guard




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Note: Hold the drive shaft with a prybar during the torque sequence.

25. Align 8X-0465 Slip Joint (1) to the transmission. Install four 2N-2486 Bolts (2). Tighten 2N-2486 Bolts (2) toa torque of 550 20 Nm (405 15 lb ft).

26. Reinstall guard (U) with five bolts (S) and washers (T) .

Installation of 241-7846 Service Brake Lines Gp

Refer to 241-7847 Traction Control .


(1) 8X-0465 Slip Joint

(2) 2N-2486 Bolts


(S) Bolts

(T) Washers

(U) Guard

Table 42

Parts that Are Needed for Installation of 241-7846 Service Brake Lines Gp


1 1 8W-3191 Hose

2 4 6V-9746 O-Ring Seal

3 1 8W-3723 (1) Hose

4 1 114-2891 (1) Hose

5 4 5P-7466 Clip

6 4 5P-7467 Clip

7 4 5P-8112 (1) Grommet




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1. Remove cap (A) that covers the hose connections for the master cylinders.

2. Attach the end of the 8W-3191 Hose (1) to the master cylinders.

8 2 8T-8917 (1) Bolt

9 3 8T-4223 (1) Hard Washer

10 4 5M-1932 Taperlock Stud

11 4 6V-8188 Nut

12 2 7G-3832 Grommet

13 2 7G-3833 Clip

14 2 7G-3834 Clip

15 4 5P-1076 Hard Washer

( 1 ) Part of 241-7847 Traction Control


(A) Cap on the hose connection to the master cylinder


(1) 8W-3191 Hose




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3. Remove cap (B) and cap (C) that covers the hose connections at the TCS valve.

4. Use a 6V-9746 O-Ring Seal (2) when you are connecting 8W-3723 Hose (3). Connect the end of the 8W-3723 Hose (3) to the port at the right side of the TCS valve.


(B) Cap on TCS valve

(C) Cap on TCS valve


(2) 6V-9746 O-Ring Seal

(3) 8W-3723 Hose

(4) 114-2891 Hose




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5. Use a 6V-9746 O-Ring Seal (2) when you are connecting 114-2891 Hose (4). Connect the end of the 114-

2891 Hose (4) to the port at the left side of the TCS valve.



(3) 8W-3723 Hose

(4) 114-2891 Hose


(1) 8W-3191 Hose

(3) 8W-3723 Hose

(4) 114-2891 Hose

(5) 5P-7466 Clips

(6) 5P-7467 Clips

(7) 5P-8112 Grommets

(8) 8T-8917 Bolts

(9) 8T-4223 Hard Washers

(10) 5M-1932 Taperlock Studs

(11) 6V-8188 Nuts




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6. Use the following components to secure the 114-2891 Hose (4) to the A-frame: two 5P-7466 Clips (5), two5P-7467 Clips (6), two 5P-8112 Grommets (7), two 8T-8917 Bolts (8) and two 8T-4223 Hard Washers (9) .

7. Use the components that follow to secure the 8W-3723 Hose (3) and the 8W-3191 Hose (1) to the A-frame:four 5M-1932 Taperlock Studs (10), four 5P-1076 Hard Washers (15), four 6V-8188Nuts (11), two 7G-3832Grommets (12), two 7G-3833 Clips (13) and two 7G-3834 Clips (14) .

(12) 7G-3832 Grommets

(13) 7G-3833 Clips

(14) 7G-3834 Clips

Illustration 90 g01066619(1) 8W-3191 Hose

(3) 8W-3723 Hose

(4) 114-2891 Hose

(5) 5P-7466 Clips

(6) 5P-7467 Clips

(7) 5P-8112 Grommets

(8) 8T-8917 Bolts


(10) 5M-1932 Taperlock Studs

(11) 6V-8188 Nuts

(12) 7G-3832 Grommets

(13) 7G-3833 Clips

(14) 7G-3834 Clips

(15) 5P-1076 Hard Washers




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2. Use the following components to attach the 8W-3358 Hose (1) to the transmission lubrication port: two 1P-4582 Half Flanges (2), one 4J-0527 O-Ring Seal (3), four 5P-2566 Bolts (4) and four 8T-4223 Washers (10) .

3. Use the following components to attach the 8W-3353 Hose (6) to the port of the transmission for thetransmission charge pump: two 1P-4579 Half Flanges (7), one 4J-0524 O-Ring Seal (8), four 8T-9389 Bolts(9) and four 8T-4223 Hard Washers (10) .


(1) 8W-3358 Hose

(2) 1P-4582 Half Flanges

(3) 4J-0527 O-Ring Seal

(4) 5P-2566 Bolts

(10) 8T-4223 Washers


(6) 8W-3353 Hose



(9) 8T-9389 Bolts





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4. Use the components that follow to attach the 8W-3354 Hose (11) to the port of the transmission for thetransmission cooler: two 1P-4579 Half Flanges (7), one 4J-0524 O-Ring Seal (8), four 8T-9389 Bolts (9) andfour 8T-4223 Hard Washers (10) .

5. Use the components that follow to attach the 160-4960 Hose (12) to the port of the transmission for the




(9) 8T-9389 Bolts


(11) 8W-3354 Hose



(12) 160-4960 Hose


(14) 2H-6338 O-Ring Seal

(15) 7X-0347 Bolts




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transmission scavenge pump: two 1P-4585 Half Flanges (13), one 2H-6338 O-Ring Seal (14), four 7X-0347Bolts (15) and four 8T-4122 Hard Washers (5) .

6. Use a 172-4613 Connector (16) in order to attach 4D-4791 Hose (17) to the transmission. 4D-4791 Hose (17)comes from the hydraulic tank.


(16) 172-4613 Connector

(17) 4D-4791 Hose


(18) 8W-3707 Hose




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7. Connect the 8W-3707 Hose (18) to the port at the transmission control. 8W-3707 Hose (18) comes from the

torque converter lockup clutch and synchronizing valve.

8. Connect the 8W-3708 Hose (19) to the port that is above the port for the transmission lubrication. 8W-3708Hose (19) comes from the torque converter lockup clutch and synchronizing valve.

Connect the 8X-8270 Automatic Lubrication Group at the Rear Axle


(18) 8W-3707 Hose

(19) 8W-3708 Hose


(19) 8W-3708 Hose

Table 44

Parts that Are Needed for Installation of 8X-8270 Automatic Lubrication Group at the Rear Axle


1 6 8T-9377 Bolt

2 6 6V-8801 Nut


4 1 8W-4532 Hose As

5 4 2N-1287 Flared Elbow

6 2 5N-5646 Hose

7 2 5T-5760 Hose

8 5 4K-8864 Clip

9 1 9X-8250 Clip

10 3 5M-3062 Bolt




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1. Place the lubrication injector bank in position at the rear axle housing. Use six 8T-9377 Bolts (1), six 6V-

8801Nuts (2) and 12 8T-4896 Hard Washers (14) to attach the lubrication injector bank to the rear axlehousing.

2. Install the 8W-4532 Hose (4) to the junction block. The 8W-4532 Hose (4) is the supply line for lubrication.

11 2 6K-1972 Flared Elbow

12 2 3P-1823 Pipe Adapter

13 1 5T-5760 Hose

14 13 8T-4896 Hard Washer

15 1 5T-4381 Hose


(1) 8T-9377 Bolts

(2) 6V-8801 Nuts

(3) 5P-1075 Hard Washers


(4) 8W-4532 Hose




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5. Use a 6K-1972 Flared Elbow (11) and a 3P-1823 Pipe Adapter (12) to attach one 5N-5646 Hose (6) to each

lower pin for the rear suspension cylinders.

6. Use a 4K-8864 Clip (8) and the existing bolt to secure each hose for the lower pins of the rear suspensioncylinders.


(6) 5N-5646 Hose

(11) 6K-1972 Flared Elbow

(12) 3P-1823 Pipe Adapter


(8) 4K-8864 Clip




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7. Use a 2N-1287 Flared Elbow (5) to attach a 5T-5760 Hose (13) to the control rod at the frame. Use one 4K-8864 Clip (8), one 5M-3062 Bolt (10), and one 8T-4896 Hard Washer (14) to secure the 5T-5760 Hose (13)at the opposite end of the control rod.


(5) 2N-1287 Flared Elbow

(13) 5T-5760 Hose


(8) 4K-8864 Clip

(10) 5M-3062 Bolt

(13) 5T-5760 Hose

(14) 8T-4896 Hard Washer




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8. Use a 2N-1287 Flared Elbow (5) to attach a 5T-4381 Hose (15) to the control rod at the axle housing.

Connect the Wiring Harness for the Rear Axle and TransmissionAssembly

Refer to the 186-6581 Harness .



1. Unwrap the differential oil filter and the harness for the traction control system. Route the harness along theinside of the A-frame at the right side of the machine. Connect the six pin connector and the eight pinconnector at the front chassis harness. Secure the harness with the existing bolts and clips.


(5) 2N-1287 Flared Elbow

(15) 5T-4381 Hose





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2. Remove two bolts (A) that secure guard (B) over the transmission speed sensor. Connect lead (C) from the

transmission wiring harness to the transmission speed sensor. Install guard (B). Secure lead (C) with theexisting bolt and clamp.

3. Connect lead (D) from the transmission wiring harness to the gear position switch at the transmission. Securelead (D) with the existing clip and bolt.


(A) Bolt

(B) Guard

(C) Lead


(D) Lead




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4. Connect the three leads from the transmission wiring harness to the three solenoids. The three solenoids arelocated under the step at the top of the transmission. The three leads have the following labels: upshift,downshift and lockup clutch. Refer to Illustration 112 in order to make sure that the leads are connected to theappropriate solenoids.


Cover on three solenoids on the transmission.


(E) Upshift solenoid

(F) Downshift solenoid

(G) Lockup clutch solenoid




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5. Connect the long lead (H) from the rear chassis harness for VIMS to the oil temperature sensor at the top ofthe axle housing at the left side of the machine.

Installation of 162-2634 Hydraulic Oil Cooler Lines

1. Remove the following items for each hose connection: four bolts, four washers, two split flanges, cap and O-ring seal. Refer to the arrows. Retain the hardware for installation of the hose assembly for the front oilcooler.


(H) Lead

Table 45

Parts That Are Needed for Installation of 162-2634 Hydraulic Oil Cooler Lines


1 4 165-4931 Elbow Gp

2 4 148-8339 Connector

3 4 6V-0852 Dust Cap

4 2 5T-7618 Tube Assembly

5 2 3S-7594 Hose

6 8 5P-0598 Clamp

7 2 5P-1935 Seal

8 6 7X-0325 Bolt



NOTICE

Prevent contamination of the hydraulic system when hose assemblies




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2. Repeat Step 1 for the second connection to the hose assembly to the brake oil cooler.

and components are removed from the machine. Contamination of thehydraulic system with foreign material will reduce the service life ofcomponents.


(A) Caps


(B) Hose assembly

(C) Hose assembly

(D) O-Ring seal




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3. Remove caps (A) from hose assembly (B) and hose assembly (C). Make sure that O-ring seal (D) is still in theproper position. Use the hardware that was removed in Step 1 and Step 2 in order to connect hose assembly(B) and hose assembly (C) to the front brake.

Note: Inspect O-ring seals (D) for wear or damage. If necessary, replace O-ring seals (D) with 4J-0524 O-Ring Seal . Apply 1U-6396 O-Ring Assembly Compound to O-ring seals prior to assembly.

4. Repeat Step 1 through Step 3 for the other front service brake.

5. Remove the clamp assembly. Refer to the arrow. Save the hardware for installation of the hose assembly forthe rear oil cooler.

6. Remove the cap from tube assembly (E) .



(E) Hose assembly that returns cooling oil from the rear service brake




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7. Remove the following items: three bolts, three washers, the plate and the O-ring seal.

8. Install an oil sampling fitting in each of the oil cooler tubes. Install one 165-4931 Elbow Gp (1) in each oilcooler tube assembly. Install one 148-8339 Connector (2) on each 165-4931 Elbow Gp (1). Install one 6V-0852 Dust Cap (3) on each fitting (2) .



(1) 165-4931 Elbow Gp

(2) 148-8339 Connector Assembly

(3) 6V-0852 Dust Cap




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9. Connect 5T-7618 Tube Assembly (4) to the return hose assembly for the hydraulic oil tank by using 3S-7594Hose (5) and four 5P-0598 Clamps (6). Leave 5P-0598 Clamps (6) loose until the opposite end of 5T-7618Tube Assembly (4) is connected.


(4) 5T-7618 Tube Assembly

(5) 3S-7594 Hose

(6) 5P-0598 Clamp

(F) Clamp Assembly


(7) 5P-1935 Seal

(8) 7X-0325 Bolt



Proper routing of rear cooling line for the right side of the truck




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10. Connect the remaining end of 5T-7618 Tube Assembly (4) by using the following items: 5P-1935 Seal (7),three 7X-0325 Bolts (8) and three 8T-4223 Hard Washers (9) .

Note: Inspect 5P-1935 Seal (7) for wear or damage. If necessary, replace 5P-1935 Seal (7) with a new part.Apply 1U-6396 O-Ring Assembly Compound to the seals prior to assembly.

11. Remove the tie-downs from the frame.


Proper routing of rear cooling line for the left side of the truck






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12. Remove the following items: Two half flanges, cap, O-ring seal, four washers and four bolts. Refer to thearrows. Save the hardware for installation of the hose assembly for the rear oil cooler.

13. Use the hardware that was removed in step 12 in order to connect the hose assembly.

14. Repeat step 5 through step 13 in order to install the other rear cooling oil lines.

Installation of 241-7845 Service Brake Lines Gp



Table 46

Parts that Are Needed for Installation of the 241-7845 Service Brake Lines Gp


1 4 148-8345 Connector

2 4 5T-0967 Block

3 4 5T-0968 Block

4 8 8T-2501 Bolt




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6 1 5T-9053 Plate

7 4 7X-0353 Bolt


9 1 5T-0965 Plate

10 2 3S-9175 Elbow

11 1 5J-0541 Hose

12 1 9D-0771 Hose

13 2 1S-0996 Clip

14 2 9C-4937 Breather As

15 8 7K-1181 Cable Strap




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Routing of the front brake lines

(1) 148-8345 Connector

(2) 5T-0967 Block

(3) 5T-0968 Block

(4) 8T-2501 Bolts


(6) 5T-9053 Plate

(7) 7X-0353 Bolt




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Note: Before you operate the machine, purge all air from the brake lines after the lines are installed.

Note: Refer to Systems Operation/Testing and Adjusting Air System and Brakes, "Brake System Air - Purge"for information regarding purging brake lines.

1. Remove the shipping plug from the parking brake port and the service brake port in each brake anchor. The

service brake port is marked with an "S" that is cast in the brake anchor. The parking brake port is markedwith a "P" that is cast in the brake anchor.

2. Remove the caps from the service brake line and from the parking brake line at each side of the machine.

3. Install one 148-8345 Connector (1) in the service brake port and in the parking brake port in each brakeanchor.

4. At each side of the machine, slide the existing Hose (A) through the hole in the bracket behind the ports forthe brake cooling lines. Attach the service brake line to the 148-8345 Connector (1) at each service brake port.


(9) 5T-0965 Plate

(10) 3S-9175 Elbow

(11) 5J-0541 Hose

(12) 9D-0771 Hose

(13) 1S-0996 Clip

(14) 9C-4937 Breather As



(A) Hose




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5. Use block (2), block (3), two bolts (4), and two hard washers (5) to secure the service brake line. Secure theservice brake line to the bracket at each side of the machine.

6. At each side of the machine, connect the parking brake line (B) to the 148-8345 Connector (1) at the parkingbrake port.


(2) 5T-0967 Block

(3) 5T-0968 Block

(4) 8T-2501 Bolt


(A) Brake hose



(B) Parking brake line




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7. At the right side of the machine, use two bolts (7) and two hard washers (8) to secure the plate (9) above theparking brake port.


(2) 5T-0967 Block

(3) 5T-0968 Block

(4) 8T-2501 Bolt


(7) 7X-0353 Bolt


(9) 5T-0965 Plate

(10) 3S-9175 Elbow

(12) 5J-0451 Hose

(A) Brake hose


(6) 5T-9053 Plate

(7) 7X-0353 Bolt





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8. At the left side of the machine, use two bolts (7) and two hard washers (8) to secure the plate (6) above theparking brake port.

9. Use a block (2), a block (3), two bolts (4), and two hard washers (5) to secure the parking brake line to theplate at each side of the machine.

10. Remove the shipping plug from each spindle.


(2) 5T-0967 Block

(3) 5T-0968 Block

(4) 8T-2501 Bolt






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11. Install a 3S-9175 Elbow (10) in each spindle. Apply 5P-3413 Pipe Sealant to the external threads of the 3S-9175 Elbow (10) prior to assembly.

12. At each side of the machine, attach the existing vent line from the breather to the 3S-9175 Elbow (10). The5J-0451 Hose (11) is for the right side. The 9D-0771 Hose (12) is for the left side.


(10) 3S-9175 Elbow


(10) 3S-9175 Elbow

(12) 9D-0771 Hose




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13. By using clip (13), the existing bolt, and the existing washer, attach hose (11) on the right side and hose (12)on the left side.

14. Attach 9C-4937 Breather As (14) to the end of the vent line on each side of the truck.

15. Use 7K-1181 Cable Straps (15) to secure the vent lines.

Installation of 133-3418 Fuel Tank Gp or 133-3419 Fuel Tank Gp


(12) 9D-0771 Hose

(13) 1S-0996 Clip

(14) 9C-4937 Breather As


(15) 7K-1181 Cable Straps

Table 47

Parts That Are Needed for Installation of 133-3418 Fuel Tank Gp or 133-3419 Fuel Tank Gp


1 1 150-9548 (1) Fuel Tank Assembly

1 1 151-3177 (2) Fuel Tank Assembly

2 4 8X-2232 Shim Pack

3 1 8W-3602 Mud Flap

4 5 8T-2561 Washer

5 5 4L-6454 Bolt

6 5 6V-8801 Nut

7 1 145-2817 O-Ring Face Seal Hose Assembly

8 1 9M-7958 Hose Clamp




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1. Remove either the 150-9548 Fuel Tank Assembly (1) (If Equipped) or the 151-3177 Fuel Tank As (1) (IfEquipped) from the shipping pallet.

9 1 6V-8400 O-Ring Seal

( 1 ) Part of 133-3418 Fuel Tank Gp

( 2 ) Part of 133-3419 Fuel Tank Gp

Illustration 141 g00940921(1) 150-9548 Fuel Tank Assembly (If Equipped)


(A) Front top mount for the fuel tank

(B) Rear top mount for the fuel tank

(C) Bottom mount for the fuel tank




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2. Remove two nuts (D) from bottom mount (C). Disassemble the hardware from bottom mount (C). For 151-3177 Fuel Tank As , disassemble the hardware from mounting point (E) for the fuel tank. Retain all hardware.

Note: 150-9548 Fuel Tank As (1) has two lower mounting points. 151-3177 Fuel Tank As (1) has three lowermounting points.


150-9548 Fuel Tank As (1) mounting on chassis


(D) Nuts


151-3177 Fuel Tank As (1) mounting on chassis


(D) Nuts

(E) Additional mounting point for fuel tank

NOTICE

Mating surfaces of the mounting flanges must be cleaned to brightmetal and free of nicks and burrs to produce joints with the desiredstructural properties.




99/346

3. Disassemble the upper mounts for the fuel tank on the chassis. Use 4C-4204 Paint Remover to remove theshipping grease or paint from the front fuel tank mounting (A) and rear fuel tank mounting (B). The matingsurfaces of these mounts must be cleaned to bright metal and free of nicks and burrs.

4. Reassemble the upper mounts for the fuel tank on the chassis.

5. Use 8T-0447 Dial Caliper As to measure dimension (F) at the front and rear fuel tank mounting. Record thesedimensions for use later in this procedure.

6. Remove the following parts from the front fuel tank mounting (A) : two existing bolts, two washers and cap.Repeat for the existing rear fuel tank mounting (B) .


(A) Typical front mount for the fuel tank

(B) Typical rear mount for the fuel tank

(F) Dimension





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7. Use 4C-4204 Paint Remover to remove the shipping grease or paint from the front fuel tank mounting andrear fuel tank mounting. The mating surfaces of these mounts must be cleaned to bright metal and free ofnicks and burrs.

8. Use an outside micrometer to measure dimension (G) at the front and rear fuel tank mounting.

9. Subtract dimension (G) from dimension (F) in order to calculate the maximum shim thickness. The minimumallowable shim thickness is equal to 0.12 mm (0.005 inch) less than the maximum shim thickness. Repeat thiscalculation for the remaining fuel tank mounting. Use 8X-2232 Shim Pack (3) to obtain the required shim forthe front and rear mounts.

10. Use a suitable crane to lift 150-9548 Fuel Tank Assembly (1) or 151-3177 Fuel Tank As (1). The Fuel TankAssembly weighs approximately 900 kg (1982 lb).


(G) Dimension

(H) Fuel Tank Assembly


(1) 150-9548 Fuel Tank Assembly

Page 100 of 347789C Truck 3516 Engine 2BW00001-UP (MACHINE)(SEBP2790 - 126)/Basic Sear...



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11. Position 150-9548 Fuel Tank Assembly (1) or 151-3177 Fuel Tank As (1) on the front and rear fuel tankmounting.

12. Assemble the appropriate number of 8X-2232 Shim Packs (2) that was determined in Step 9. Then, replacethe existing cap (A), two washers, and two bolts. Tighten the bolts to a torque of 450 25 Nm (331 18 lbft).

13. Assemble the appropriate number of 8X-2232 Shim Packs (2) that was determined in Step 9 and replace theexisting cap (B), two washers, and two bolts. Tighten the bolts to a torque value of 450 25 Nm (331 18 lbft).


(2) 8X-2232 Shim Pack

(A) Front mount for the fuel tank


(2) 8X-2232 Shim Pack

(B) Rear mount for the fuel tank




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14. Assemble the lower mount (C) for the fuel tank by sliding bolt (H) through the hole and tightening nut (D).

Repeat for the remaining mounts. Tighten the two bolts (I) to a torque value of 370 50 Nm (272 37 lb ft).

15. Assemble the 8W-3602 Mud Flap (3) by using five 8T-2561 Washers (4), five 4L-6454 Bolts (5), and five6V-8801Nuts (6). Tighten 4L-6454 Bolts (5) to a torque value of 47 9 Nm (35 7 lb ft).


Mount for 150-9548 Fuel Tank As

(D) Nut

(I) Bolts


(3) 8W-3602 Mud Flap

(4) 8T-2561 Washer

(5) 4L-6454 Bolt

(6) 6V-8801 Nut




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16. Use a 9M-7958 Hose Clamp (8) to secure the 145-2817 O-Ring Face Seal Hose Assembly (7) to fitting on thefuel tank.

17. Connect the 145-2817 O-Ring Face Seal Hose Assembly (7) to the Elbow by using an 6V-8400 O-Ring Seal(9) .

Installation of 170-3600 Fuel Lines Group


(7) 145-2817 O-Ring Face Seal Hose Assembly

(8) 9M-7958 Hose Clamp


(7) 145-2817 O-Ring Face Seal Hose Assembly


Table 48

Parts that are Needed for Installation of 170-3600 Fuel Lines Group


1 1 9L-5254 Elbow

2 1 030-7944 Elbow




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1. Remove the two caps from the hose assemblies. Remove the two plugs from the fuel tank.

2. Assemble 9L-5254 Elbow (1). Apply 5P-3413 Pipe Sealant to the external tapered threads of the elbow priorto installation.

3. Connect hose assembly (A) to 9L-5254 Elbow (1). Apply 5P-3413 Pipe Sealant to the external taperedthreads prior to installation.

4. Assemble 6V-8358 Ball Valve (3) to the fuel tank. Connect 030-7944 Elbow (2) to 6V-8358 Ball Valve (3).Apply 5P-3413 Pipe Sealant to the external tapered threads prior to installation.

5. Connect hose assembly (B) to 030-7944 Elbow (2). Apply 5P-3413 Pipe Sealant to the external taperedthreads prior to installation.

Installation of 5T-4463 Hydraulic Tank Mounting Group

3 1 6V-8358 Ball Valve


Rear view of the fuel tank

(1) 9L-5254 Elbow

(2) 030-7944 Elbow

(3) 6V-8358 Ball Valve

(A) Fuel return line

(B) Fuel supply to engine

Table 49

Parts that are Needed for Installation of 5T-4463 Hydraulic Tank Mounting Group


1 2 105-2200 Mud Flap

2 16 4L-6454 Bolt




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1. Remove seven bolts (A) and loosen two bolts (B) .

3 16 8T-2561 Washer

4 16 6V-8801 Nut

5 1 105-2204 Support

6 1 105-2205 Support

7 1 105-2201 Mud Flap

8 1 105-4620 Support

9 2 8T-9101 Bolt


(A) Remove the bolts prior to installation of the guards.

(B) Do not remove these bolts. Loosen the bolts approximately 8 mm (0.3 inch).


(1) 105-2200 Mud Flap

(2) 4L-6454 Bolt

(3) 8T-2561 Washer




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2. Assemble the 105-2200 Flap (1) to 105-2204 Support (5) by using the following items: four 4L-6454 Bolts

(2), four 8T-2561 Washers (3) and four 6V-8801Nuts (4). Tighten 4L-6454 Bolts (2) to a torque value of 47 9 Nm (35 7 lb ft).

3. Install the 105-2204 Support Assembly (5) and tighten two bolts (B). Tighten bolts (B) to a torque value of 47 9 Nm (35 7 lb ft).

4. Assemble the 105-2200 Flap (1) to 105-2205 Support (6) by using the following items: four 4L-6454 Bolts(2), four 8T-2561 Washers (3) and four 6V-8801Nuts (4). Tighten 4L-6454 Bolts (2) to a torque value of 47 9 Nm (35 7 lb ft).

5. Use two bolts (A) in order to secure the 105-2205 Support Assembly (6) to the hydraulic tank. Tighten bolts

(A) to a torque value of 47 9 Nm (35 7 lb ft).

(4) 6V-8801 Nut

(5) 105-2204 Support

(B) Bolts


(1) 105-2200 Mud Flap

(2) 4L-6454 Bolt

(3) 8T-2561 Washer

(4) 6V-8801 Nut

(6) 105-2205 Support

(A) Bolts




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6. Assemble the 105-2201 Flap (7) to 105-4620 Support (8) by using the following items: eight 4L-6454 Bolts(2), eight 8T-2561 Washers (3) and six 6V-8801Nuts (4). Tighten 4L-6454 Bolts (2) to a torque value of 47 9 Nm (35 7 lb ft).

7. Install the 105-4620 Support Assembly (8) by using three bolts (A). Tighten bolts (A) and two 8T-9101 Bolts(9) to a torque value of 47 9 Nm (35 7 lb ft).

Installation of 145-3418 Ladder Group


(2) 4L-6454 Bolt

(3) 8T-2561 Washer

(4) 6V-8801 Nut

(7) 105-2201 Mud Flap

(8) 105-4620 Support

(9) 8T-9101 Bolt

(A) Bolts

Table 50

Parts That Are Needed for Installation of 145-3418 Ladder Group


1 1 8W-0671 Ladder Assembly


3 8 8T-2502 Bolt


5 6 4L-6454 Bolt

6 2 5T-8218 Plate

7 2 5T-8220 Baffle

8 1 149-6884 Ladder Assembly




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1. Use eight 8T-4896 Hard Washers (2) and eight 8T-2502 Bolts (3) to assemble 8W-0671 Ladder Assembly (1)

to the truck frame.


10 4 5P-2566 Bolt

11 5 6V-8188 Nut

12 4 8T-8917 Bolt

13 1 8T-4835 Bolt

14 1 8W-2025 Brace

15 8 4L-9337 Bolt

16 8 6V-8801 Nut

17 2 9P-2950 Handhold


19 8 5P-2228 Bolt

20 2 153-1315 Handhold


(1) 8W-0671 Ladder Assembly


(3) 8T-2502 Bolt




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2. Use the following parts to assemble 5T-8220 Baffle (7) to 149-6884 Ladder As (8) : 5T-8218 Plate (6), three5P-1075 Hard Washers (4) and three 4L-6454 Bolts (5) .

3. Use a suitable crane to position the 149-6884 Ladder Assembly (8). The 149-6884 Ladder Assembly (8)

weighs approximately 36 kg (79 lb).


(4) 5P-1075 Hard Washer

(5) 4L-6454 Bolt

(6) 5T-8218 Plate

(7) 5T-8220 Baffle

(8) 149-6884 Ladder As


(8) 149-6884 Ladder Assembly




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4. Assemble 149-6884 Ladder Assembly (8) by using the following parts: four 5P-2566 Bolts (10), eight 8T-4223 Hard Washers (9) and four 6V-8188Nuts (11). Leave 5P-2566 Bolts (10) loose at this time.

5. Install three 8T-8917 Bolts (12) and three 8T-4223 Hard Washers (9) into the top of 149-6884 Ladder As (8).

8T-8917 Bolts (12) and 8T-4223 Hard Washers (9) hold 149-6884 Ladder As (8) to the frame.


(8) 149-6884 Ladder Assembly


(10) 5P-2566 Bolt

(11) 6V-8188 Nut

Illustr

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