793C XQ Off-Highway Truck and 793C Off-Highway Truck Engine Supplement Modular Front End - Install Caterpillar

Installation Procedure

Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL OR THE INSTALLATION. THIS TOOLING IS SHOWN IN ORDER TO ASSIST THE EXPERIENCED SERVICEMAN.

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Illustration 1	g00917168

1. Attach Tooling (B) to modular front end (60). Attach a suitable lifting device to Tooling (B). Attach the lifting device to a suitable crane. The weight of the complete modular front end is approximately 4826 kg (10640 lb).
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   Illustration 2	g00917169

2. Align modular front end (60) with truck frame (62).

3. Secure the modular front end to the truck frame with bolts (61).

4. Repeat Steps 2 and 3 for opposite side of the modular front end.
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   Illustration 3	g00917170

5. Align the center frame of the modular front end to truck frame (59).

6. Secure the modular front end with bolts (58).
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   Illustration 4	g00917172

7. Secure electrical box (56) to the front bumper with bolts (57).

   Note: Ensure that the harness assembly for warning light (53) is properly routed during installation. Also ensure that the harness assembly for the warning light is not damaged during installation.

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   Illustration 5	g00917174

8. Position right panel (55) and warning light (53) on the modular front end. Secure the panel with bolts (52).

9. Repeat Step 8 in order to install left panel (54) on the modular front end.
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   Personal injury can result from contact with refrigerant. This system is under pressure at all times, even if the engine is not running. Heat should never be applied to a charged system. Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury. Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant. Always use caution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, evacuate the system recovering the refrigerant before removing the fitting. Personal injury or death can result from inhaling refrigerant through a lit cigarette. Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death. Do not smoke when servicing air conditioners or wherever refrigerant gas may be present. Before any checks of the air conditioning and heating system are made, move the machine to a smooth horizontal surface. Lower all implements to the ground. Make sure the transmission is in NEUTRAL or PARK and that the parking brake is engaged. Keep all other personnel away from the machine or where they can be seen.

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   Illustration 6	g00917177

10. Connect hose assemblies (50) and (51) at the quick connect ports.

    Note: It is not necessary to recharge the air conditioning system after the installation.

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    Illustration 7	g00917179

11. Connect hose assembly (49) to tee (48).
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    Illustration 8	g00917180

12. Connect hose assembly (46) to piston pump (47).
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    Illustration 9	g00917181

13. On the left side of the truck, align top mounting flange (45) to the modular front end. Secure the top mounting flange to the radiator by installing bolts (44).
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    Illustration 10	g00917182

14. Position upper panel (42) on the truck. Secure the panel with bolts (43).

15. Install air inlet elbow (40). Position u-bolt assembly (41). Secure the inlet elbow by tightening hose clamps (39). Tighten the u-bolt.
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    Illustration 11	g00917183

16. Position and secure lower panels (37) with bolts (38).
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    Illustration 12	g00917184

17. Position and secure middle panel (36) with bolts (35).
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    Illustration 13	g00917185

18. Position bracket (34) on truck frame (32). Secure the bracket to the truck frame with bolts (33).

19. Repeat the following Steps for the opposite side of the truck: 13, 14, 15, 16, 17 and 18.
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    Illustration 14	g00917186

20. Connect hose assembly (30) to hydraulic tank filler neck (31). Secure the hose with the bolts.
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    Illustration 15	g00917188

21. Attach a suitable lifting device to catwalk assembly (29). The weight of the catwalk assembly is approximately 50 kg (110 lb).

22. Position catwalk assembly (29) on the truck frame. Secure the catwalk assembly to the truck frame with bolts (28).

23. Repeat Step 21 for the catwalk assembly on the opposite side of the truck.
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    Illustration 16	g00917189

24. Connect hose assembly (27) to the modular front end. Connect top tubes (26) to the modular front end. Tighten hose clamps (25) in order to secure top tubes.

25. Install Tooling (A) to the expansion tank, as shown. Install a suitable lifting device to Tooling (A). Attach the lifting device to a suitable crane. The combined weight of the expansion tank and hood assembly is approximately 227 kg (500 lb).
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    Illustration 17	g00917190

26. Lift expansion tank (15) and the hood assembly as a unit into the correct position.
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    Illustration 18	g00917192

27. Install the following parts in order to secure the hood assembly: bolts (20), nuts (24), washers (21), mounting (22) and spacers (23).

28. Repeat Step 27 for the opposite side of the hood assembly mounting.
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    Illustration 19	g00917210

29. Secure hood assembly (19) to the modular front end with bolts (18).
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    Illustration 20	g00917196

30. Connect hoses (17) to the expansion tank. Tighten hose clamps (16).
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    Illustration 21	g00917198

31. Connect hose assembly (14) to expansion tank (15).

32. Repeat Step 31 for the hose assembly on the opposite side of the expansion tank.
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    Illustration 22	g00917199

33. Position cover (12) on the expansion tank. Secure the cover by installing bolts (13).

34. Repeat Step 33 for the cover on the opposite side of the expansion tank.
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    Illustration 23	g00917201

35. Connect harness assembly (11) that is located on top of the radiator tanks.
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    Illustration 24	g00917203

36. Slide radiator hose (10) in order to connect tube (8) to the radiator (7). Secure the radiator hose by tightening hose clamps (6).

    Note: Ensure that drain plug (9) is tight.

37. Repeat Step 36 for the opposite radiator hose.
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    Illustration 25	g00917204

38. Connect the harness assembly for warning light (5).
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    Illustration 26	g00917206

39. Connect harness assembly (3). Secure harness assembly with cable straps (4).
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    Illustration 27	g00917208

40. With the assistance of another person, position panel (2) on the truck frame. The weight of each panel is approximately 53 kg (117 lb).

41. Secure panels (2) to the frame of the truck by installing bolts (1).

42. Repeat Step 40 for the panel on the opposite side of the truck.

43. Refill the engine cooling system to the correct level with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant (DEAC) - Change" for the correct procedures and for the correct fluid capacities. The capacity of the cooling system is 775 L (205 US gal).

End By:

1. Install the hood. Refer to Disassembly and Assembly, "Hood - Remove and Install" for the correct procedure.

2. Remove the truck body retaining cable. Lower the truck body. Refer to Disassembly and Assembly, "Truck Body Retaining Cable - Remove and Install" for the correct procedure.