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Product: TRUCK
Model: 793D TRUCK FDB
Configuration: 793D Off-Highway Truck FDB00001-UP (MACHINE)
POWERED BY 3516B Engine
Special Instruction
Assembly Procedure For the 793D Off-Highway Truck{7960}
Media Number -REHS2210-01 Publication Date -2006/10/17 Date Updated -2006/10/17
i02559962
Assembly Procedure For the 793D Off-Highway Truck{7960}

SMCS - 7960
Off-Highway Truck:
793D (S/N: FDB1-UP)
Introduction
This Special Instruction contains the following necessary procedures for the 793D (S/N: FDB1-UP)
Off-Highway Truck: field preparation, assembly and commissioning procedure.
Note: The photographs in this publication are for illustrative purposes.
The shipping configuration consists of the rear axle housing that has the transmission and final
drives that are attached. 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 are not present, assembly will be more difficult and more time will be necessary to
complete the assembly.
Do not perform any procedures in this publication or order any parts until you understand the
information that is contained in this publication.
After assembly is complete, prepare the machine for use. The Operations and Maintenance Manual
shows the preparation of the machine. Use the Parts Manual and the Service Manual with this special
instruction.
ReferenceOperation and Maintenance Manual, SEBU7792, "793D (S/N: FDB1-UP) Off-Highway

Trucks"
ReferenceParts Manual, SEBP3976, "793D (S/N: FDB1-UP) Off-Highway Trucks"
ReferenceService Magazine, SEPD0531 03 July, "Fabric Slings and Protective Sleeves Are
Available for Lifting Truck Bodies"
ReferenceSpecial Instruction, SMHS7867, "Use of 6V-4040 Inflation Group "
https://sis2001.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 06/11/2006
793D Off-Highway Truck FDB00001-UP (MACHINE) POWERED BY 3516B En...Página 2 de 289
ReferenceOperation and Maintenance Manual, SEBU5898, "Cold Weather Recommendations for

Caterpillar Machine"
ReferenceService Manual, RENR2630, "784C, 785C, 789C, 793C, 797 Off-Highway

Truck/Tractors Vital Information Management System (VIMS)"
ReferenceTesting and Adjusting, Troubleshooting, RENR2631, "Off-Highway Truck/Tractors Vital

Information Management System (VIMS)"
Do not attempt to assemble this machine until you read and you
understand the assembly instructions.
Improper assembly procedures could result in injury or death.
NOTICE
Do not allow any dirt or foreign material to get into the hydraulic
system during assembly, connection of lines, when components are
filled with fluid, or during any maintenance operation.
Note: After assembly of the truck is complete, the suspension cylinders must be charged. The air
should be purged from the brake system. Prepare the truck for use. This is shown in the Operations
and Maintenance Manual. Use the Parts Manual and the Service Manual with this special instruction.
NOTICE
Clean all surfaces and remove burrs from all areas where parts are to
be installed. Chase all tapped holes used for mounting purposes.
Remove the paint from all contacting surfaces. This is necessary for a
good solid joint.
Parts List
Table 1
Parts that are Required to Install the 193-6225 Rear Axle Housing Gp and the 191-0158
Final Drive Gp
Qty Part Number Description
24 9X-6152 Bolt
24 3S-6162 Hard Washer
1 8X-0433 Slip Joint (1)
8 2N-2486 Bolt (1)

(1) 8X-0433 Slip Joint and 2N-2486 Bolt are part of 8X-0249 Drive Shaft .
Table 2
Parts that are Required to Install the 245-0898 Hydraulic Oil Cooler Lines Gp
1 241-5837 Hose As
4 8T-4193 Bolt
4 9X-8257 Washer
2 1P-7016 Half Flange
Table 3
Parts that are Required to Install the 193-6213 Automatic Lubrication Gp

6 8T-6466 Bolt
12 8T-4121 Hard Washer
6 8T-4133 Nut
1 6V-9169 Bulkhead Nut
2 4H-6147 Connector
1 9M-8662 Coupling
1 148-8457 Union Gp
Table 4
Parts that are Required to Install the 193-6276 Hydraulic Fan Lines Gp

1 250-0555 Hose As (1)
2 1P-4582 Half Flange
4 8T-4956 Bolt
1 258-8126 Tube As (2)
4 8T-4193 Bolt
4 9X-8257 Washer
1 242-3230 Hose As (2)
1 273-1169 Hose As (1)
1 252-7156 Hose As (1)
(1) Part of 193-6296 Hydraulic Oil Lines Gp
(2) Part of 193-6276 Hydraulic Fan Lines Gp
Table 5
Parts that are required to install the 9C-4937 Breather As (Rear)

1 003-2143 Elbow
1 8D-7495 Hose As
1 9C-4937 Breather As
Table 6
Parts that are Required to Install the 193-6244 Service Brake Lines Gp (Rear)
1 213-9807 Hose As
1 8X-6161 Hose As
2 8T-4956 Bolt
1 7G-3833 Clip
1 7G-3834 Clip
1 7G-3832 Grommet
1 8X-6169 Hose As
Table 7
Parts that are Required to Install the 240-4803 Power Train Oil Lines Gp
1 138-0580 Hose As
1 125-9460 Hose As
1 125-9461 Hose As
1 128-0928 Hose As
1 258-6652 Hose As
4 131-5525 Hose As
Table 8
Parts that are Required to Install the 236-5234 Rear Axle Oil Cooler Gp (If Equipped)

1 248-1583 Hose As
1 248-1584 Hose As
1 164-5641 Tee As
Table 9
Parts that are Required to Install the 240-2792 Power Train Cooler Lines Gp

1 113-6365 Hose As
1 164-5641 Tee As
1 271-4905 Hose As
1 271-4906 Hose As
1 148-8444 Tee As
1 150-4043 Connector As
1 243-1293 Hose As
1 206-4137 Hose As
2 6V-9877 Elbow
1 271-4904 Hose As
1 6V-9872 Connector
Table 10
Parts that are Required to Install the 8X-2837 Walkway

2 215-1463 Platform
2 248-2221 (1) Handhold As

2 248-2218 (1) Handhold As
8 8T-4196 Bolt
8 8T-4133 Nut
4 114-1243 (2) Belt Assembly
4 114-1244 (2) Plate
6 223-4472 (2) Step Assembly
24 8T-4223 (2) Washer
24 1K-6872 (2) Locknut
24 1D-4691 (2) Bolt
12 4V-9804 (2) Plate
(1) This part is assembled to 215-1463 Platform at the factory.
(2) These parts are preassembled at the factory in order to make the step assembly.
Table 11
Parts that are Required to Install the 193-6282 Handhold Gp or the 193-6278 Handhold Gp

1 241-6990 Handhold As
133 8T-4136 Bolt (1)
133 8T-4121 Hard Washer (1)
2 8T-7087 Grommet
2 5P-7468 Clip
2 5P-7469 Clip
1 8T-4194 Bolt
1 8T-4244 Nut
1 242-9547 Handhold As (2)
1 242-9538 Handhold As (3)
1 242-9815 Handhold As (4)

4 8T-4956 Bolt
1 8X-9874 Chain
1 5P-0765 Hose
1 8C-8451 Bolt
1 5C-2890 Nut
1 6B-8085 Chain Snap
(1) Part of 193-6251 Handhold Fastener Gp
(2) Wide body only
(3) Standard body only
(4) Optional rear access only
Table 12
Parts that are Required to Install the 290-0057 Rear View Mirror
1 250-7605 Bracket As (1)
8 8T-4182 Bolt (1)
1 134-0987 Bracket As
2 134-0989 Block
4 8T-4186 Bolt
1 290-0057 Rear View Mirror (3)
3 8T-4136 Bolt
(1) Use on wide body
(2) Use additional hard washers (3) if there is a gap between mirror (7) and bracket assembly (4) .
(3) Part of 193-6277 Rear View Mirror Gp
Table 13
Parts that are Required to Install the 193-6310 Fender Gp

1 237-9098 Fender As
10 8T-4195 Bolt
1 8X-4284 Brace
4 8T-4139 Bolt
4 8T-4244 Nut
1 8X-4295 Guard
3 8X-4294 Strip
71 8T-0722 Bolt
38 8T-4133 Nut
1 8W-7899 Guard
1 8X-4296 Strip
2 251-7661 Deflector
2 8X-4089 Plate
2 8X-3822 Bracket
2 8X-4029 Plate
1 8X-4285 Plate As (1)
1 275-5111 Guard
1 8X-4293 Strip
1 275-5110 Guard
1 275-8089 Strip
1 8X-4289 Plate
(1) Part of 240-4794 Handhold Gp
Table 14
Parts that are Required to Install the 240-4794 Handhold Gp

20 8T-4136 Bolt
Table 15
Parts that are Required to Install the 8X-2808 Suspension Mounting Gp (Front)
2 5T-5202 Bearing Cap (1)
2 5T-6255 Key
20 8T-6624 Bolt
20 5T-1352 Spacer
20 9X-8399 Washer
20 8T-1583 Nut
12 9X-6626 Bolt
12 5T-4896 Spacer
12 9X-8259 Washer
12 8C-4032 Nut
16 117-4935 Plate
8 6V-8132 Bolt
8 6V-8237 Hard Washer
(1) One 6V-3249 Bearing and two 6V-0836 retaining rings for each cap
Table 16
Parts that are Required to Install the Supply and Return 193-6305 Hydraulic Oil Cooler
Lines Gp

16 8T-4944 Bolt
2 265-0975 Tube As
2 241-5766 Hose
8 9X-2201 Hose Clamp
2 156-5744 Half Clamp
18 8T-4183 Bolt
2 8T-4244 Nut
4 242-0361 Hose As
793D Off-Highway Truck FDB00001-UP (MACHINE) POWERED BY 3516B ... Página 10 de 289
2 265-0975 Tube As
1 226-5576 Plate (1)
1 226-5575 Plate (2)
2 8C-5172 Rectangular Seal
1 202-8652 Tube As (1)
1 203-2429 Tube As (2)
16 8T-7338 Bolt
16 9X-8257 Washer
(1) LH side only
(2) RH side only
Table 17
Parts that are Required to Install the 8X-0259 Steering Cylinder and Mounting Gp and the
245-0905 Steering Link
4 3J-6899 Locknut (1)
1 3J-6899 Locknut (2)
(1) Use with 793D Standard Wheel and Brake Group configuration
(2) Use with 793D Extended Life, Wheel and Brake Group configuration
Table 18
Parts that are Required to Install the 131-3541 Service Brake Lines Gp (Front)
4 8X-6137 Block
4 5T-0968 Block
8 8T-4185 Bolt
2 148-8358 Elbow
1 185-1449 Bracket (LH)
1 185-1450 Bracket (RH)
2 7X-0871 Tee
2 6V-0852 Dust Cap
2 164-5567 Fitting Gp
2 148-8345 Connector Gp
4 0S-1627 Bolt
4 5P-8248 Hard Washer
6 7K-1181 Cable Strap
2 5J-0451 Hose As
2 6D-6489 Pipe Connector
2 9C-4937 Breather As
2 1S-0996 Clip
Table 19
Parts that are Required to Install the 216-1735 Fuel Tank Fastener Gp
4 7X-2489 Bolt
4 8T-4167 Washer
2 8X-2575 Cap
1 216-2976 Plate Assembly
2 7X-2564 Bolt
8 8T-5439 Washer
2 8T-4131 Nut
4 8N-1214 Mount Assembly
2 7N-5656 Sleeve
2 7X-2488 Bolt
2 6V-7688 Locknut
4 8X-2576 Shim Pack
2 8T-5005 Bolt
Table 20
Parts that are Required to Install the 8X-2829 Steering Arm Fastener Group
20 8T-0283 Bolt
20 9X-8399 Washer
20 8G-1694 Spacer
1 3J-6899 Locknut
Table 21
Parts that are Required to Install the 230-1086 Fuel Filter Lines Gp
1 231-7582 Adapter (1)
1 5H-6734 O-Ring Seal (1)
6 8T-2501 Bolt (1)
1 6V-9852 Elbow
1 8X-5311 Check Valve As
1 230-1097 Hose As
1 251-3248 Hose As
2 8T-4195 Bolt
1 7E-6719 Primary Fuel Filter Gp
1 285-5634 Hose As
1 159-4724 Ball Valve
1 6V-9182 Elbow
1 113-9339 Hose As
4 8T-4139 Bolt (1)
1 4J-0527 O-Ring Seal (2)
(1) Part of 264-7554 Service Center Gp
Table 22
Parts that are Required to Install the 8X-0193 Fuel Heater Group (If Equipped)
1 114-8701 Plate
2 7X-2568 Bolt (1)
1 7W-5300 Fuel Heater

4 8T-4194 Bolt
2 6B-9081 Reducing Bushing
2 8C-6874 Connector
4 6V-9746 O-Ring Seal
1 6V-9852 Swivel Elbow
4 7J-9108 O-Ring Seal
2 8C-6873 Connector
2 061-9593 Reducer Bushing
1 8T-8899 Elbow
1 107-8163 Hose As
1 8W-5428 Hose As
(1) These bolts replace the bolts that are included in the Fuel Tank Fastener Gp .
Table 23
Parts that are Required to Install the 151-8730 Steering Lines Gp

1 6V-9200 Elbow
1 3J-7354 O-Ring Seal
1 150-8710 Tube As
2 6V-8639 Connector
4 3K-0360 O-Ring Seal
2 6V-8625 Elbow
1 150-8709 Tube
1 150-8723 Tube As
1 150-8708 Tube As
1 150-8713 Tube As
2 5T-6867 Clip
3 5M-3062 Bolt
1 9S-1350 Clip
1 150-9037 Bar
4 8T-4136 Bolt
1 8X-5968 Bracket Assembly
1 6G-8532 Guard Assembly
Table 24
Parts that are Required to Install the 163-7226 Cab Mounting

40 163-0042 Mount
8 163-3127 Sleeve
1 8X-0436 Support
6 164-4411 Sleeve
1 244-3102 Support
9 8T-0283 Bolt
21 5T-1352 Spacer
6 9X-6618 Bolt
6 8C-3236 Bolt
6 163-0364 Sleeve
4 5T-9894 Shim (1)
20 5T-5807 Retainer
6 1K-9420 Bolt
6 6B-0388 Bolt
8 6V-2624 Bolt
4 5T-9893 Shim (1)
1 9M-8406 Clip
1 8T-4137 Bolt
(1) Use the shims to obtain a flatness within 0.75 mm (0.03 inch) with the cab.
Table 25
Parts that are required to install the 240-4798 Walkway Gp

1 244-1688 Walkway As
12 8T-4139 Bolt (1)
Table 26
Parts that are Required to Install the 240-2780 Muffler Gp

1 5T-7824 Clamp Assembly
2 6V-3668 Bolt
2 6V-8149 Nut
1 8X-3142 Extension Pipe
1 6N-9298 Clamp
2 6V-3823 Bolt
2 6V-7687 Locknut
1 242-8869 Extension Pipe
3 6V-6317 Bolt
3 2Y-5829 Nut
6 6V-5839 Washer
Table 27
Parts that are Required to Install the 294-0849 Muffler Gp (If Equipped)
2 6V-3823 Bolt
2 6V-7687 Locknut
2 6N-9298 Clamp
2 290-8576 Extension Pipe
Table 28
Parts that are Required to Install the 193-6252 Platform Mounting Gp

2 8X-2053 Plate
1 8X-2052 Plate
2 8X-1991 Plate
1 241-4233 Plate
1 8X-1990 Strip
1 242-7006 Plate
3 8T-6430 Bolt
3 8T-4123 Washer
4 8T-4139 Bolt
5 5P-1076 Washer
4 7X-0344 Bolt
1 8T-4183 Bolt
1 8T-4244 Nut
Table 29
Parts that are Required to Install the 8X-4180 Hood Latch Gp

2 5S-7379 Bolt
1 2G-9399 Rod
1 6F-8499 Spring
1 8X-4425 Bracket Assembly

1 3B-4615 Cotter Pin
1 0T-0883 Washer
1 8X-4428 Plate Assembly
8 8T-4136 Bolt
1 101-0368 Prop Assembly
Table 30
Parts that are Required to Install the 240-2784 Air Cleaner Gp

2 9Y-8930 Air Cleaner Gp
12 7X-0344 Bolt
4 7N-5008 Hose
16 230-2535 Clamp
2 251-2151 Tube As
4 285-6593 U-Bolt
8 6V-7687 Locknut
1 8T-4910 Bolt
2 8T-4244 Nut
4 233-8485 Hose Clamp
1 7D-8586 Nonslip Tread
Table 31
Parts that are Required to Install the 193-6262 Rim Mounting Gp

6 8W-0338 O-Ring Seal
6 5T-9790 Tire Valve

2 8W-0331 Swivel Connector
564 7X-0851 Nut
564 6V-8237 Washer
2 190-6095 Ring
2 251-6360 Extension
2 207-6030 Plate (1)
2 220-8202 Hose As (1)
4 1S-1015 Clip (1)
32 8T-4139 Bolt
8 8T-4244 Nut
4 229-9387 Plate (1)
4 8T-5092 Bolt (1)
2 280-7372 Plate (2)
2 280-9835 Plate (2)
4 6J-0427 Spacer
2 7I-5931 Bracket
4 8T-6868 Bolt
2 5T-9796 Connector
1 281-0569 Hose As (2)
12 137-3615 Bracket (3)
4 3V-8340 Bracket (3)
8 136-9459 Plate As (3)
(1) Use with 793D Extended Life, Wheel and Brake Group configuration only
(2) Use with 793D Standard Wheel and Brake Group configuration only
(3) Part of 208-8789 Rim Guard Gp
Table 32
Parts that are Required to Install the Odometer (If equipped)

141-1513 (1)
155-6138 (2)
1 Odometer Assembly
5T-8673 (3)
141-1514 (4)
1 122-1478 Plate As
2 5B-5839 Spacer
2 8T-4184 Bolt
(1) The 141-1513 Odometer Assembly is part of 143-2253 Odometer .
(3) The 5T-8673 Odometer Assembly is part of 188-3648 Odometer Gp .
(4) The 141-1514 Odometer Assembly is part of 188-3649 Odometer Gp .
Table 33
Parts that are Required to Install the 240-4782 Exhaust Pipe Gp

1 272-5460 Tube As
6 7E-8452 Clamp
2 242-0799 Bellows As
8 8T-4183 Bolt
4 8T-4244 Nut
1 272-5466 Tube As
2 242-0811 Clamp
2 5G-3845 Boss
2 7X-7729 Washer
2 8T-4172 Bolt
2 251-6357 Heat Shield
1 272-5463 Tube As
1 7E-8452 Clamp (1)
(1) Part of 240-2780 Muffler Gp
Table 34
Parts that are Required to Install the 293-5905 Exhaust Pipe Gp (If Equipped)
1 272-5460 Tube As
7 7E-8452 Clamp
2 242-0799 Bellows As
8 8T-4183 Bolt
4 8T-4244 Nut
1 290-8577 Tube As
2 242-0811 Clamp
2 5G-3845 Boss
2 7X-7729 Washer
2 8T-4172 Bolt
2 251-6357 Heat Shield
1 290-8578 Tube As
Table 35
Parts that are Required to Install the 126-1358 Hydraulic Tank Guard Gp
1 119-8732 Cover
1 270-8622 Cover
Table 36
Parts that are Required to Install the 168-9897 Ladder Lighting

1 153-2073 Flood Lamp Gp
1 5C-7261 Nut
1 8T-6869 Bolt
1 140-1088 Bracket Assembly
1 5L-4241 Hard Washer
1 8T-4196 Bolt
Table 37
Parts that are Required to Install the 284-4927 Truck Body Mounting Gp
4 5T-7255 Plate
73 8T-4196 Bolt
73 8T-4133 Nut
2 8X-5063 Deflector
4 5T-7352 Strip
2 5T-7274 Mud Flap
1 105-4727 Mud Flap
1 8X-5421 Plate
1 6G-9703 Cable
1 105-0314 Coupler
2 8T-4649 Bolt
2 6V-7676 Nut
1 8W-0109 Plate
1 2B-0974 Clevis Pin

2 7I-5517 Pin As
1 8W-2896 Washer
2 6G-9697 Washer
10 8T-4184 Bolt
2 8W-8677 Plate
30 8X-3046 Shim
30 7D-1649 Hard Washer
24 8T-4910 Bolt
24 8T-4244 Nut
10 219-7595 Pad As
16 8T-4137 Bolt
16 4K-8864 Clip
2 233-1880 Bracket As (1)
2 227-5875 Ejector
2 6G-7773 Pin
2 3D-0404 Washer
4 205-4178 Pad
4 205-4179 Shackle
2 205-4181 Chain
(1) Part of 260-9120 Body and Canopy As
Table 38
Parts that are Required to Install the 8X-3380 Cylinder Mounting Gp

2 237-0417 Pin As
4 8X-4043 Spacer
2 8X-4044 Plate
10 8T-4183 Bolt
Table 39
Parts that are Required to Install the 251-4831 Film Gp

1 100-5615 Film
1 100-9984 Film (1)
1 131-5415 Film
1 251-4832 Film
1 251-4833 Film
1 251-4834 Film
(1) LH side only
Approximate Weights
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 clear
of the area. Be sure the hoist or jack has the correct capacity to lift a
component. Install blocks or stands before performance of any work
under a heavy component.
Approximate weights of the components are shown. Clean all surfaces

where parts are to be installed.
Table 40
Module Weight
Truck frame module without rear axle housing (1)

43545 kg (96000 lb)
Rear axle housing with final drives

24494 kg (54000 lb)
Truck frame module and rear axle housing with final drives (1)
68038 kg (150000 lb)
Front suspension cylinder, wheel and brake assembly

6504 kg (14340 lb)
Tire
3500 kg (7800 lb)
Rim
1583 kg (3490 lb)
Body pivot pin

41 kg (90 lb)
Fuel tank (2)

1597 kg (3521 lb)
Right side platform assembly

1130 kg (2490 lb)
Body (center)
12160 kg (26800 lb)
Body (center) with liners

18430 kg (40620 lb)
Body (2 sides)
6530 kg (14400 lb)
Canopy
4170 kg (9200 lb)
Liners (3)
3500 kg (7710 lb)
Tail extension assembly

304 kg (670 lb)
Sideboard assembly
118 kg (260 lb)
Cab with catwalks and handholds

2132 kg (4700 lb)
Completed body without liners (4)

45359 kg (100000 lb)
(1) The weight of the truck frame is distributed equally between the front and back lifting points.
(2) Tank capacity 4921 L (1300 US gal)
(3) Some liner packages can weigh as much as 18144 kg (40000 lb)
(4) A completed body with liners can weigh as much as 63503 kg (140000 lb). When lifting a completed body, use a
suitable lifting device.
Specifications
Table 41
Item Specifications
Wheel base
5900 mm (232 inch)
Length
12866 mm (506.5 inch)
Ground to top of canopy

6604 mm (260 inch)
Ground to upper edge of body

5865 mm (230.9 inch)
Turning radius
32.40 m (106.3 ft)
Width of body assembly

7411 mm (291.8 inch)
Width of truck frame at rear tires

7406 mm (291.5 inch)
Torque Specifications
z Tighten the 24 rear axle housing bolts to a torque of 2700 ± 300 N·m (1991 ± 221 lb ft).
z Tighten the 72 bolts that mount the rear wheel rim to a torque of 900 ± 100 N·m (664 ± 74 lb
ft).
z Tighten the 70 bolts that mount the front wheel rim to a torque of 1000 ± 125 N·m (738 ± 92
lb ft).
z Tighten the lower 12 bolts and nuts that mount the front suspension cylinder to a torque of
1500 ± 150 N·m (1106 ± 110 lb ft) plus 60 ± 5 degrees.
z Tighten the upper 20 bolts that mount the front suspension cylinder to a torque of 1000 ± 100
N·m (738 ± 74 lb ft) plus 60 ± 5 degrees.
z Tighten the eight bolts that mount the cap for the front suspension cylinder to a torque of 800
± 100 N·m (590 ± 74 lb ft).
z Tighten one nut (or four nuts if equipped) that mounts the ball stud to a torque of 2550 ± 100
N·m (1881 ± 74 lb ft).
z Tighten the 20 cab mounting bolts to a torque of 1904 ± 68 N·m (1405 ± 50 lb ft).
z Tighten the 21 cab support mounting bolts to a torque of 1600 ± 200 N·m (1180 ± 148 lb ft).
z Tighten the bolts for the fuel tank to a torque of 460 ± 60 N·m (339 ± 44 lb ft).
z Tighten the fuel tank caps to a torque of 800 ± 100 N·m (590 ± 74 lb ft).
z Tighten the bolts for the platform assembly to a torque of 460 ± 60 N·m (339 ± 44 lb ft).
Specifications for Cables, Chains, and Lifting Devices

Use approved cables, chains, and lifting devices in order to lift components. Refer to the
manufacturer's literature 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 the effect 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.
(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.
Necessary Lifting Capacity

A lifting device with a capacity of 54430 kg (120000 lb) and a lifting device with a capacity of
36290 kg (80000 lb) are required in order to remove the truck frame from the trailer.
With the rear axle on supports, a hoist with a 36290 kg (80000 lb) capacity is needed in order to lift
the truck frame at the front lifting points.
With the front crossmember on supports, one hoist with 54430 kg (120000 lb) capacity is needed to
lift the truck frame at the rear lifting points.
793D Off-Highway Truck Assembly Tips

Note: Follow the table of contents for the assembly sequence of the truck.
1. The assembly of the 793D Off-Highway Truck requires four mechanics for approximately 250
hours. The rear axle and the transmission are shipped together. Two crane operators are
required for a total of 24 hours until the major components are installed.
2. The cab needs to be a minimum of 1270 mm (50 inch) from the ground when the fender and
the catwalk railing are added.
Necessary Equipment and Supplies for Assembly

The following supplies and equipment are used for the assembly procedure:
z Obtain six 208 L (55 US gal) barrels of hoist, converter, and brake oil (TDTO, TO-4).
z Obtain 227 L (60 US gal) of transmission/drive train oil (TDTO). Ambient temperatures that
are extreme may require a different oil viscosity. Refer to Service Manual, SEBU6250,
"Caterpillar Machine Lubricant Recommendations".
z Obtain 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.
z Obtain one crane or a suitable lifting device with a 54430 kg (120000 lb) lifting capacity.
Obtain one crane or a suitable lifting device with a 36287 kg (80000 lb) lifting capacity.
z Obtain cables, lifting straps, and chains that have adequate lifting capacity.
z Obtain several shackles. The shackles should have a working load limit of 27240 kg (60053
lb).
z Obtain one portable air compressor. The air compressor should have enough capacity in order
to operate two 25.4 mm (1 inch) impact wrenches. The air compressor should have a minimum
capacity of 3 CM (100 CFM).
z Obtain 40 hardwood blocks that are 203 mm (8.0 inches) tall. The blocks should be 203 mm
(8.0 inches) wide. The blocks should be 914 mm (36.0 inches) long.
z Obtain one stepladder that is 1.8 m (6 ft) tall. Have two stepladders that are 3.6 m (12 ft) tall.
z Obtain at least 94 m (308 ft) of rope that is 19 mm (0.75 inch) in diameter. When you install
the body on the chassis, use the rope in order to guide the body into position.
z Obtain 20 nitrogen bottles that are T-size in order to inflate the tires and charge the suspension
cylinders.
z Obtain one lift truck that can lift 6810 kg (15000 lb).
z Obtain two 7X-1062 Ether Cylinders .
z Obtain a paint spray gun.
z Obtain three 138-7573 Link Brackets and three 138-7574 Link Brackets .
z Four metal stands. The metal stands support the truck body before the truck body is installed
to the truck frame.
z Obtain 4C-4188 Paint Remover . The solvent cleans the parts on the truck.
z Obtain 9S-3263 Thread Sealant for the platform bolts.
Required Tools
z Use a 5P-3520 Spanner Wrench to torque the ball studs for the steering system.
z Use a 5S-6084 Socket to tighten the ball studs for the steering system.
z Use a 6V-6080 Torque Multiplier in order to tighten the components that follow: the bolts for
the front suspension cylinder, steering arm mounting nuts, ball stud nuts and wheel rim
mounting nuts.
z Use a 2P-2336 Socket to tighten the ROPS cab mount bolts.
z Use a 9U-5089 Socket to tighten the wheel rim mounting nuts.
z Use a 8T-9293 Torque Wrench to torque the ROPS cab mounting bolts.
z Use a 6V-4170 Adapter for the mounting group for the front suspension.
z Use a 6V-4154 Box Wrench for the mounting group for the front suspension.
z Use a 6V-3146 Extension for the mounting group for the front suspension.
z Use a 2P-8261 Adapter (3/4 inch to 1.0 inch) for the mounting group for the front suspension.
z Use a 4C-6724 Socket for the rear axle housing, the mount for the front cylinder, and the cab
support.
z Use a 5S-6076 Extension with the 2P-2336 Socket and with the 2P-2338 Socket .
z Use a 175-5507 Charging Group for the front suspension cylinders.
z Use a 9U-5617 Oil Refill Pump for charging the suspension cylinders with oil.
z Use a 6V-4040 Inflation Group in order to inflate the tires.
z Use a 8T-5230 Torque Wrench Gp (300 N·m (221 lb ft)).
z Use a 8T-5183 Extension for the torque wrench.
z Use a 8T-3196 Wrench for the mounting nuts on the front suspension cylinder.
z Use a pair of 6V-0006 Pliers to install the connector for the AETA.
z When you are instructed, apply 4C-5593 Anti-Seize Thread Lubricant to threads.
z When you are instructed, apply 4C-5599 High Temperature Anti-Seize Compound to threads.
Site for the Assembly of the Truck
Illustration 2 g
This is a typical view of the layout for the 793DOff-Highway Truck.
View of the 793D chassis
View of the 793D skids with some right side components and skids for the front strut
View of the 793D skid with the cab, rims, fuel tank and handrail
View of the rear axle assembly from the 793D Extended Life, Wheel and Brake Group configuration
View of the 793D lifting points
1. The work area for the truck chassis and the components should be flat, smooth and well
drained. An area 30.5 m (100 ft) by 24.5 m (80 ft) is needed for the assembly of the truck.
2. The truck chassis should be located in the center of the assembly area. Keep the area around
the truck chassis clear. Space needs to be left unobstructed for the crane for proper lifting.
3. Attach a suitable cable or a strap at four places on the chassis.
Note: Straps and clevises are used in order to lift the front and the rear of the chassis.
View of typical use of alternate lifting devices on a similar chassis
Note: A spreader bar and cables can be used in order to lift the rear of the chassis. The
spreader bar is a steel rod that is 89 mm (3.5 inch) in diameter and 4191 mm (165 inch) in
length. Cables and clevises are used to lift the front of the chassis.
4. Use two cranes in order to lift the 793D chassis from the trailer. The chassis weighs
approximately 43545 kg (96000 lb).
Typical front view of a similar chassis that is blocked
5. Carefully lower the chassis onto support blocks.
Note: The wood blocks are 203 mm (8.0 inch) by 203 mm (8 inch). The wood blocks are
stacked alternately. A suitable metal stand can be used under the rear of the frame.
Note: 1320 mm (52 inch) is the height that is required to install the rear tires.
Note: 1600 mm (63 inch) is the height that is required to install the front tires.
Typical view of a similar chassis on metal stands
Typical view of a similar chassis that is blocked
6. Illustration 14 shows an alternate blocking position that is under the front frame and the rear
rail that uses steel plates and stands.
View of rear axle assembly from the 793D Extended Life, Wheel and Brake Group configuration
7. Attach a clevis to each existing lifting bracket. Attach suitable lifting devices in order to lift
the rear axle assembly and final drives from the trailer. The weight of the rear axle assembly
and final drives is approximately 24494 kg (54000 lb).
View of rear axle assembly from the 793D Extended Life, Wheel and Brake Group configuration
8. Place the rear axle assembly behind the frame .
Note: Refer to Illustration 2 for placement of the components.
View of the skid with the components for the right platform
View of the front strut assembly for the left side from the 793D Extended Life, Wheel and Brake Group
configuration
View of the cab
View of the fuel tank
9. Use a suitable lifting device to unload the remaining components. Place the components away
from the crane. Refer to Illustration 2 for placement of the components.
10. Set the wooden boxes of smaller components out of the way. Open the boxes and check the
components that are in each box.
Note: Do not open the bags of hardware. The bags are well marked for easy identification.
Place the hardware with the correct components. Refer to the photos in this special instruction.
The photos will help to position the components.
Install the 193-6225 Rear Axle Housing Gp and the 191-0158

Final Drive Gp
Table 42
Parts that are Required to Install the 193-6225 Rear Axle Housing Gp and the 191-0158
Final Drive Gp
Item Qty Part Number Description
1 24 9X-6152 Bolt
2 24 3S-6162 Hard Washer
3 1 8X-0433 Slip Joint (1)
4 8 2N-2486 Bolt (1)
(1) 8X-0433 Slip Joint and 2N-2486 Bolt are part of 8X-0249 Drive Shaft .
1. Use 4C-4204 Paint Remover in order to prepare the frame mounting surface.
View of rear frame
2. Remove three bolts (A) in order to remove the wood block.
3. Repeat step 2 for the left side of the frame.
View of rear frame rail
4. Remove bar (B) .
Note: Do not remove the chains.
5. Remove twelve bolts (1) and twelve washers (2) from the rear axle housing.
Note: Keep bolts (1) and washers (2) for installation.
6. Repeat step 5 for the other side of the rear axle housing.
View of left side of the rear axle housing
7. Use 4C-4204 Paint Remover in order to remove paint from the left side of the rear axle
housing.
8. Repeat step 7 for the right side of the rear axle housing assembly.
9. Remove two bolts and the cover from the front of the transmission on the rear axle housing
assembly.
10. Prepare the transmission yoke in order to install the drive shaft slip joint.
11. Remove the wire ties and bolts (4) from drive shaft slip joint (3) .
12. Clean the surface of the drive shaft slip joint.
Note: Rear struts (C) are lifted in order to position the rear axle housing and the final drives.
Use a suitable lifting device to raise each rear strut. The weight of each rear strut is
13. Position the rear axle housing and the final drives to the frame.
14. Apply 4C-5593 Anti-Seize Thread Lubricant to twelve bolts (1) and twelve washers (2) that
were removed in step 5.
View of the right side of rear axle housing and final drive
15. Install twelve bolts (1) and twelve washers (2) in order to secure the rear axle housing.
Note: Use an impact wrench in order to tighten bolts (1). Do not torque bolts (1) yet.
16. Repeat steps 14 and 15 for the left side.
17. Remove two bolts (D) and two washers (E) in order to remove retainer (F) and pin (G) .
Note: The weight of the pin is 16.7 kg (37 lb).
18. Prepare pin (G) by removing paint and dirt.
19. Use 4C-4204 Paint Remover in order to remove paint from pin bores. Apply 4C-5593 Anti-
Seize Thread Lubricant to pin (G) and the bores.
20. Use a suitable lifting device in order to lift lateral control rod (H) into position. The weight of
the lateral control rod is 146 kg (322 lb).
21. Install pin (G). Install retainer (F), two bolts (D), and two washers (E) that were removed in
Step 17. Tighten bolts (D) to a torque value of 475 N·m (350 lb ft).
View of lower strut mount
22. Remove top bolt (J) and washer (K) and loosen bottom bolt (J) in order to position the guard
for pin removal. Keep top bolt (J) and washer (K) .
View of right rear mount
23. Remove six bolts (M), six washers (N) and retainer (L) .
24. Remove pin (P) .
Note: The weight of the pin is 28.59 kg (63 lb).
25. Remove paint from pin (P).
View of the lower right strut
26. Remove the cap from the elbow.
View of lower strut
27. Attach lubrication line (R) to the elbow.
28. Repeat Step 26 and Step 27 for the other side of the machine.
29. Apply 4C-5593 Anti-Seize Thread Lubricant to pin (P), the frame bore and the bore in the
strut.
View of right rear mount
30. Position rear strut (C) in order to install pin (P) .
Note: The location of grease port on pin (P) is indicated by an arrow.
31. Install washer (L), six bolts (M) and six washers (N) that were removed in Step 23 in order to
secure pin (P). Tighten bolts (M) to a torque value of 475 N·m (350 lb ft).
View of grease port for the left strut
32. Repeat Step 22 through Step 31 for the other side.
View of the rear axle assembly from the 793D Extended Life, Wheel and Brake Group configuration
33. Place wood blocks under the rear axle housing and the final drives in order to support the
assembly.
34. Remove nine bolts and washers in order to remove drive shaft guard (R) .
35. Apply 4C-5593 Anti-Seize Thread Lubricant to bolts (4) .
36. Use a suitable lifting device in order to position drive shaft slip joint (3) to the transmission.
Note: The weight of the slip joint is 127.1 kg (280 lb).
37. Install bolts (4). Tighten bolts (4) to a torque value of 550 ± 20 N·m (406 ± 15 lb ft).
38. Install nine bolts and nine washers that were removed in Step 34 in order to secure drive shaft
guard (R).
39. Tighten twelve bolts (1) to a torque value of 2700 ± 300 N·m (1991 ± 221 lb ft).
40. Repeat step 39 for the other side.
Install the Rear Supply 245-0898 Hydraulic Oil Cooler Lines

Gp
Table 43
Parts that are Required to Install the 245-0898 Hydraulic Oil Cooler Lines Gp
1 1 241-5837 Hose As
2 4 8T-4193 Bolt
3 4 9X-8257 Washer
4 2 1P-7016 Half Flange
View of hose (1) and shipping strap
1. Remove four bolts (2) and four washers (3). Remove two flange halves (4). Discard cover
(A) .
2. Discard four bolts (B), four washers (C) and four nuts (D) from hose assembly (1). Discard
two flange halves (E) and cover (F) .
3. Position flange halves (4) on each side of hose (1). Install four bolts (2) and four washers (3)
in order to secure hose assembly (1) .
Install the 193-6213 Automatic Lubrication Gp

Table 44
Parts that are Required to Install the 193-6213 Automatic Lubrication Gp

1 6 8T-6466 Bolt
2 12 8T-4121 Hard Washer
3 6 8T-4133 Nut
4 1 6V-9169 Bulkhead Nut

5 2 4H-6147 Connector
6 1 9M-8662 Coupling
7 1 148-8457 Union Gp
1. Use six bolts (1), twelve hard washers (2), and six nuts (3) in order to secure lubrication
injector bank (A) to the rear axle housing.
2. Remove cap (B) from hose assembly (C) . Remove cap (D) from lubrication injector bank (A).
Attach hose (C) to lubrication injector bank (A) .
3. Secure hose (C) with existing clips and hardware that is provided. The clips and hardware are
located on the top, and left hand side of the rear axle housing.
View of the left lower pin and strut
4. Remove cap (G) from elbow (H) .
5. Attach lubrication line (J) to elbow (H) .
6. Position guard (K). Install two bolts and two washers that are provided in order to secure the
guard.
View of the right side lower rear strut and lubrication line that is installed
7. Repeat Step 6 through Step 6 for the other side.
View of the left rear upper chassis
8. Attach lubrication line (L) to the body pin bore.
View of the right rear upper chassis
9. Repeat step 8 for the other side.
View of the lateral control rod at the rear axle housing
10. Remove cap (M) from elbow (N) on the rod.
11. Attach lubrication hose (P) to elbow (N) .
12. Locate the opposite end of the lateral control rod and remove cap (R) from elbow (S) .
13. Attach lubrication hose (T) to elbow (S) .
View of the lubrication hoses on the right platform
14. Use the following items in order to connect the hoses from the lubrication pump to the hood
mount : 6V-9169 Bulkhead Nut (4), two 4H-6147 Connectors (5), 9M-8662 Coupling (6) and
148-8457 Union Gp (7) .
15. Attach the lubrication hoses.
Install the 193-6276 Hydraulic Fan Lines Gp

Table 45
Parts that are Required to Install the 193-6276 Hydraulic Fan Lines Gp

1 1 250-0555 Hose As (1)
2 2 1P-4582 Half Flange
3 4 8T-4956 Bolt
5 1 258-8126 Tube As (2)
6 4 8T-4193 Bolt
7 4 9X-8257 Washer
8 1 242-3230 Hose As (2)
9 1 273-1169 Hose As (1)
10 1 252-7156 Hose As (1)
(1) Part of 193-6296 Hydraulic Oil Lines Gp

(2) Part of 193-6276 Hydraulic Fan Lines Gp
1. Remove shipping covers (A) and (B). Discard the covers and the hardware.
2. Position hose assembly (1) to the tank.
3. Position two flange halves (2) around hose assembly (1). Install four bolts (3) and four
washers (4) in order to secure the hose to the tank.
4. Position hose assembly (5) to the tank.
5. Install four bolts (6) and four washers (7) in order to secure the hose to the tank.
6. Attach hose assembly (8) to existing fitting (C) .
7. Attach hose assembly (9) to existing fitting (D) .
8. Attach hose assembly (10) to existing fitting (E) .
Install the 9C-4937 Breather As (Rear)

Table 46
Parts that are required to install the 9C-4937 Breather As (Rear)

1 1 003-2143 Elbow
2 1 8D-7495 Hose As
3 1 9C-4937 Breather As
1. Remove plug (A) from the rear axle housing.
2. Install elbow (1) and hose assembly (2) .
3. Attach breather (3) onto hose (2). Use clamp (B), bolt (C), and washer (D) to secure the
breather.
Install the 193-6244 Service Brake Lines Gp (Rear)

Table 47
Parts that are Required to Install the 193-6244 Service Brake Lines Gp (Rear)
1 1 213-9807 Hose As
2 1 8X-6161 Hose As
3 2 8T-4956 Bolt
5 1 7G-3833 Clip
6 1 7G-3834 Clip
7 1 7G-3832 Grommet
8 1 8X-6169 Hose As
1. Remove caps (A) from hose (1) and hose (2) .
View of the traction control valve that is located on the right inside frame rail
2. Attach hose (1) and hose (2) to traction control valve (B) .
3. Remove the following hardware and retain the following hardware. Two bolts (3), two
washers (4), one top clip (5), one bottom clip (6) and one grommet (7) .
4. Install two bolts (3), two washers (4), one clip (5), one clip (6), and one grommet (7) in order
to secure hose (1) and hose (2) .
5. Remove cap (C) from slack adjuster (D) .
6. Attach hose (8) to slack adjuster (D) .
View of hose (8) that is installed
7. Use existing hardware to secure hose (8) .
Install the 240-4803 Power Train Oil Lines Gp

Table 48
Parts that are Required to Install the 240-4803 Power Train Oil Lines Gp

1 1 138-0580 Hose As
2 1 125-9460 Hose As
3 1 125-9461 Hose As
4 1 128-0928 Hose As
5 1 258-6652 Hose As
6 4 131-5525 Hose As
Note: Remove the caps from the hoses for installation.
Side view of transmission
1. Remove four bolts (A) and four washers (B) in order to remove two flange halves (C). Discard
cover (D) .
2. Remove four bolts (E), four washers (F), and four nuts (G) from hose (1). Discard the
hardware. Discard cover (H) .
3. Install four bolts (A), four washers (B) and two flange halves (C) that were removed in Step 1
in order to secure hose (1) .
Right side view of transmission
4. Remove shipping caps (J) from the transmission.
5. Attach hoses (2), (3), (4) and (5) to the transmission.
6. Remove four bolts (K), four washers (L), and two flange halves (M). Retain the hardware.
Discard cover (N).
7. Remove four bolts (P), four washers (R), four nuts (S) and cover (T) from hose (6). Discard
the hardware.
8. Install four bolts (K), four washers (L) and two flange halves (M) that were removed in Step 6
in order to secure hose (6) .
Illustration 99
Left side view of the lines group
9. Use existing clamps and hardware to secure hoses.
Install the 236-5234 Rear Axle Oil Cooler Gp (If Equipped)

Table 49
Parts that are Required to Install the 236-5234 Rear Axle Oil Cooler Gp

1 1 248-1583 Hose As
2 1 248-1584 Hose As
3 1 164-5641 Tee As

View of top rear axle assembly
1. Remove caps (A) and (C) from manifold (B) .
2. Remove cap (D) from hose (1) .
3. Connect hose (1) to manifold (B) .
4. Remove the cap from hose (2). Connect hose (2) to manifold (B) .
Install the 240-2792 Power Train Cooler Lines Gp (If

Equipped)
Note: This procedure is for trucks that are equipped with 236-5234 Rear Axle Oil Cooler Gp .
Table 50
Parts that are Required to Install the 240-2792 Power Train Cooler Lines Gp

1 1 113-6365 Hose As
2 1 164-5641 Tee As
3 1 271-4905 Hose As
4 1 271-4906 Hose As
5 1 150-4043 Connector As
6 1 148-8444 Tee As
7 1 243-1293 Hose As
8 1 206-4137 Hose As
9 2 6V-9877 Elbow
10 1 271-4904 Hose As
11 1 6V-9872 Connector
Illustration 104
Location of rear axle oil pump assembly (B)
1. Remove cap (A) from rear axle oil pump assembly (B) .
2. Connect hose (1) to rear axle oil pump assembly (B) .

Bottom view of pump (B)
3. Install tee (2) into rear axle oil pump assembly (B). Connect hose (3) and connect hose (4) to
tee (2) .
4. Install connector assembly (5) into rear axle oil pump assembly (B). Install tee (6) to the
connector assembly.
5. Connect hose (7) and connect hose (8) to tee (6) .

View of housing (D) for the pump motor and fan that is above the rear rail of the chassis

View of pump motor (E) for the fan that is located in housing (D)
6. Install elbow (9) into pump motor (E). Connect hose (10) to elbow (9) .
7. Install elbow (9) into pump motor (E). Connect hose (2) to elbow (9) .
8. Install fitting (11) into pump motor (E). Connect hose (8) to fitting (11) .
9. Connect harness (F) to solenoid (G) .
Install the Electrical Connectors

View of the plug that is located near the drive shaft guard
1. Connect transmission harness (A) .

View of the rear frame and the rear axle assembly
2. Connect chassis harness (B) to rear chassis harness (C) in two places.
3. Connect the electrical connectors that are located on the right side of the frame assembly.
4. Secure the rear electrical harness with the bolts, washers, and clamps that are provided.
Install the 8X-2837 Walkway Gp

Table 51
Parts that are Required to Install the 8X-2837 Walkway

1 2 215-1463 Platform
2 2 248-2221 (1) Handhold As
3 2 248-2218 (1) Handhold As
4 8 8T-4196 Bolt
6 8 8T-4133 Nut
7 4 114-1243 (2) Belt Assembly
8 4 114-1244 (2) Plate
9 6 223-4472 (2) Step Assembly
10 24 8T-4223 (2) Washer
11 24 1K-6872 (2) Locknut
12 24 1D-4691 (2) Bolt
13 12 4V-9804 (2) Plate

(1) This part is assembled to 215-1463 Platform at the factory.
(2) These parts are preassembled at the factory in order to make the step assembly.

View of the mounting area for the RH platform
1. Remove six bolts (A) and six washers (B). Retain the hardware.

View of right side platform and handhold
2. Use a suitable lifting device (C) to position platform (1), handhold (2) and handhold (3). The
approximate weight of platform (1), handhold (2), and handhold (3) is 51 kg (112 lb).

View of left side of platform
3. Install three bolts (A) and three washers (B) that were removed in Step 1. Install bolts (A).
Torque the bolts to a value of 100 ± 20 N·m (74 ± 15 lb ft).
4. Repeat Step 3 for the right side of platform (1) .
5. Position step assembly (4) to platform (1) .
Note: Refer to table 10 for parts that make up step assembly (4) .
6. Install four bolts (5), eight washers (6) and four nuts (7) in order to secure step assembly (4) to
platform (1).
7. Repeat Step 1 through Step 6 for the left side platform.
Install the 193-6282 Handhold Gp or Install the 193-6278

Handhold Gp
Note: Parts of the handhold group can be installed at ground level.
Table 52
Parts that are Required to Install the 193-6282 Handhold Gp or the 193-6278 Handhold Gp

1 1 241-6990 Handhold As
2 133 8T-4136 Bolt (1)
3 133 8T-4121 Hard Washer (1)
5 2 8T-7087 Grommet
6 2 5P-7468 Clip
7 2 5P-7469 Clip
8 1 8T-4194 Bolt
9 1 8T-4244 Nut
11 1 242-9547 Handhold As (2)
12 1 242-9538 Handhold As (3)

13 1 242-9815 Handhold As (4)
14 4 8T-4956 Bolt
17 1 8X-9874 Chain
18 1 5P-0765 Hose
19 1 8C-8451 Bolt
21 1 5C-2890 Nut
22 1 6B-8085 Chain Snap
(2) Wide body only
(3) Standard body only
(4) Optional rear access only
1. Use a suitable lifting device to position handhold (1). The weight of handhold (1) is
2. Install sixteen bolts (2) and sixteen washers (3) in order to secure handhold (1) .
4. Install twelve bolts (2) and twelve washers (3) in order to secure handhold (4) .
5. Position two grommets (5), two clips (6) and two clips (7) around handhold (4) and handhold
(A).
Note: Handhold (A) is part of the right platform arrangement.
6. Use bolt (8) and nut (9) in order to secure two grommets (5), two clips (6) and two clips (7) .

View of the LH side of the machine

View of the cab with wide mount handhold (11) and optional rear access handhold (13)
9. Step 10 through Step 11 can be completed before the cab is installed to the truck frame.
Note: For the trucks that are not equipped with the optional rear access handhold, use the 240-
4794 Handhold Gp .
NOTICE
The 793D (S/N: FDB1-UP) Off-Highway Trucks with the wide body
use the 242-9547 Rail (11) . The 793D (S/N: FDB1-UP) Off-Highway
Trucks with bodies of standard width use the 242-9538 Handhold As
(12)
10. Position the appropriate rail assembly to the catwalk. Install sixteen bolts (2) and sixteen
washers (3) in order to secure handhold (11). Install four bolts (14) and four washers (15) in
order to secure handhold (11) .
12. Install four bolts (2) and four washers (3) in order to connect handhold (11) and handhold
(13) .
13. Position handhold (16) to chassis. Install six bolts (2) and six washers (3) in order to secure
handhold (16) .
Note: Handhold (16) weighs approximately 7 kg (15 lb).
14. Install bolt (19), washer (20) and nut (21) in order to secure chain (17) and hose (18) to
handhold (11). Secure chain snap (22) to chain (17) .
Install the 290-0057 Rear View Mirror

Table 53
Parts that are Required to Install the 290-0057 Rear View Mirror
1 1 250-7605 Bracket As (1)
2 8 8T-4182 Bolt
3 18 8T-4121 Hard Washer (2)
4 1 134-0987 Bracket As
5 2 134-0989 Block
6 4 8T-4186 Bolt
7 1 290-0057 Mirror As (3)
8 3 8T-4136 Bolt
(1) Use with the wide body
(2) Use additional hard washers (3) if there is a gap between mirror (7) and bracket assembly (4) .
(3) Part of 193-6277 Rear View Mirror Gp

Left side view of bracket (1) for wide body
1. Use eight bolts (2) and eight washers (3) in order to secure bracket (1) to handhold (A) .
2. Install four washers (3) and four bolts (6) in order to secure bracket (4) and blocks (5) to
bracket (1) .
3. Install three washers (3) and three bolts (8) in order to secure mirror assembly (7) to bracket
(4) .
Install the 193-6310 Fender Gp

Table 54
Parts that are Required to Install the 193-6310 Fender Gp

1 1 237-9098 Fender As
2 10 8T-4195 Bolt
4 1 8X-4284 Brace
5 4 8T-4139 Bolt
7 4 8T-4244 Nut
8 1 8X-4295 Guard
9 3 8X-4294 Strip
10 71 8T-0722 Bolt
11 38 8T-4133 Nut
12 1 8W-7899 Guard
13 1 8X-4296 Strip
14 2 251-7661 Deflector
15 2 8X-4089 Plate
16 2 8X-3822 Bracket
17 2 8X-4029 Plate
18 1 8X-4285 Plate As (1)
19 1 275-5111 Guard
20 1 8X-4293 Strip
21 1 275-5110 Guard
22 1 275-8089 Strip
23 1 8X-4289 Plate
(1) Part of 240-4794 Handhold Gp

View of LH side of cab
1. Position fender (1) to the mounting location on catwalk (A). Use nine bolts (2) and nine
washers (3) in order to secure fender (1) .
Note: The weight of fender (1) is approximately 51 kg (113 lb).
793D Off-Highway Truck FDB00001-UP (MACHINE) POWERED BY 3516... Página 100 de 289

Bottom view of LH catwalk
2. Position brace (4). Install two bolts (5), two washers (6) and two nuts (7) in order to secure
brace (4) .

View of left side of cab
3. Position guard (8) and three strips (9). Install twelve bolts (10), twelve washers (3) and twelve
nuts (11) in order to secure guard (4) .

View of RH platform and guard that is installed

Bottom view of the guard that is installed on the RH platform
4. Position guard (12) to the right platform. Install nine washers (3), nine bolts (10) and nine nuts
(11) in order to secure guard (12) .

View of LH deflector that is installed
5. Position deflector (14) and plate (15) to the fender. Install eight washers (3) and eight bolts
(10) in order to secure deflector (14) to the fender.

View of LH bracket and plate (17) that secures deflector
6. Position bracket (16). Install four washers (3) and four bolts (10) in order to secure bracket
(16) to the platform.
7. Install five washers (3) and five bolts (10) in order to secure plate (17) and the bottom of
deflector (14) to the platform.
8. Repeat Step 5 through Step 7 for the right hand side.

Bottom view of plate and guards that are installed at the rear of the cab
9. Install four bolts (10), eight washers (3) and four nuts (11) in order to secure plate (18) .

Top view of the plate and guards that are located at the rear of the cab
10. Position guard (19) and strip (20) to plate (18). Install five bolts (10), ten washers (3) and five
nuts (11) in order to secure guard (19) .
11. Position guard (21) and strip (22) to plate (18). Install seven bolts (10), fourteen washers (3)
and ten nuts (11) in order to secure guard (21) .
12. Install two bolts (5), four washers (6) and four nuts (7) in order to secure plate (23) to plate
(18) .
Install the 8X-2808 Suspension Mounting Gp

Table 55
Parts that are Required to Install the 8X-2808 Suspension Mounting Gp (Front)
1 2 5T-5202 Bearing Cap (1)
2 2 5T-6255 Key
3 20 8T-6624 Bolt
4 20 5T-1352 Spacer
5 20 9X-8399 Washer
6 20 8T-1583 Nut
7 12 9X-6626 Bolt
8 12 5T-4896 Spacer
9 12 9X-8259 Washer
10 12 8C-4032 Nut
11 16 117-4935 Plate
12 8 6V-8132 Bolt
13 8 6V-8237 Hard Washer
(1) One 6V-3249 Bearing and two 6V-0836 retaining rings for each cap
Table 56
Tools that are Required to Install the 8X-2808 Suspension Mounting Gp (Front)

A 1 6V-6080 Torque Multiplier Gp
B 1 6V-4170 Adapter
C 1 4C-6724 Socket
D 1 5S-6076 Extension
E 1 8T-3196 Wrench
Note: The weight of the suspension cylinder group is 6504 kg (14340 lb).

View of mounting area for the bearing cap
1. Remove all dirt and shipping grease from the top of the suspension cylinder group.
2. Apply 4C-5593 Anti-Seize Thread Lubricant to the mounting area for the bearing cap.
3. Clean all mating surfaces of bearing cap (1). Position bearing cap (1) onto the top of the
suspension cylinder group.
4. Remove the paint from the suspension cylinder group.

View of LH suspension cylinder group from the 793D Extended Life, Wheel and Brake Group configuration
5. Use a suitable lifting device in order to raise the suspension cylinder group and bearing cap
(1). Use a pallet to support the bottom of the suspension cylinder group. The weight of the
suspension cylinder group is approximately 6504 kg (14340 lb).
6. Remove all paint, dirt and grease from the mounting area and the keyway.
Note: The keyway must be clean and free of nicks or burrs.

View of LH strut mounts
7. Prepare the surfaces on the chassis by removing all paint, dirt and grease. Remove any nicks or
burrs from the mounting surfaces.
8. Remove dirt or grease from key (2). Install key (2) into the mounting area on the chassis.
Note: Remove any nicks or burrs from the key before installation.
9. Position the suspension cylinder group to the chassis.
10. Apply 4C-5593 Anti-Seize Thread Lubricant to the threads of six bolts (7) and ten bolts (3).
Apply 4C-5593 Anti-Seize Thread Lubricant to both sides of six washers (9) and ten washers
(5) .

View of LH side hardware for the suspension cylinder group
11. Install the following items to each side of the left hand suspension cylinder group: five bolts
(3), five spacers (4), five washers (5) and five nuts (6) .
Note: The bolts are installed from the inside.
12. Install the following items to each side of the left hand suspension cylinder group: three bolts
(7), three spacers (8), three washers (9) and three nuts (10) .
Note: The bolts are installed from the inside.
13. Tighten the upper ten nuts (6) to a torque value of 1000 ± 100 N·m (738 ± 74 lb ft). After
torque, turn an additional 60 degrees.
14. Tighten the lower six nuts (10) to a torque value of 1500 ± 150 N·m (1106 ± 111 lb ft). After
torque, turn an additional 60 degrees.

View of plates that can be used behind cap (1)
15. Install four bolts (12) and four washers (13) in order to secure cap (1). Plates (11) can be used
to fill the gap between the chassis and cap (1). Tighten bolts (12) to a torque value of 800 ±
100 N·m (590 ± 74 lb ft).
16. Repeat Step 1 through Step 15 for the other side of the machine.
Install the Supply and Return 193-6305 Hydraulic Oil Cooler

Lines Gp
Table 57
Parts that are Required to Install the Supply and Return 193-6305 Hydraulic Oil Cooler
Lines Gp

1 16 8T-4944 Bolt
2 2 265-0975 Tube As
3 2 241-5766 Hose
4 8 9X-2201 Hose Clamp
5 2 156-5744 Half Clamp
6 18 8T-4183 Bolt
8 2 8T-4244 Nut
9 4 242-0361 Hose As
10 2 265-0975 Tube As
11 1 226-5576 Plate (1)
12 1 226-5575 Plate (2)
13 2 8C-5172 Rectangular Seal
14 1 202-8652 Tube As (1)
15 1 203-2429 Tube As (2)
16 16 8T-7338 Bolt
17 16 9X-8257 Washer
(1) LH side only
(2) RH side only

View of RH final drive
1. Remove cover (A) from the final drive. Discard the cover.

View of outside right rear frame rail
2. Remove the plug from return tube assembly (B). Discard the plug.
3. Install hose (3) onto tube assembly (2). Connect hose (3) to existing tube assembly (B) .
4. Install four bolts (1) in order to secure tube assembly (2) to the final drive.
5. Install four hose clamps (4) around hose (3) in order to secure the connection between tube
assembly (2) and tube assembly (B) .
6. Install half clamp (5) around tube assembly (2). Install two bolts (6), four washers (7) and two
nuts (8) .
7. Remove cover (C) from hose (9). Discard the cover.
8. Repeat Step 7 for three other hoses (9) .

View of lower LH front mounting suspension group
9. Remove eight bolts (D), eight washers (E) and two covers (F). Discard the hardware.
10. Install O-Ring (13) into plate (11) .
Note: Plate (11) must be clean and free of nicks or burrs before installing the O-Ring.

View of LH front mounting suspension group
11. Install four bolts (1) in order to secure plate (11) and O-Ring (13) to mounting area (G) .
Note: Mounting area (G) must be clean and flat.

12. Install eight bolts (16) and eight washers (17) in order to install tube assembly (14) .

13. Install four bolts (5) and four washers (6) in order to secure hose (9) .

14. Repeat Step 13 for the other hose.

View of front RH cooler lines that are installed
15. Repeat Step1 through Step 14 for the other side.
Install the 8X-2829 Steering Arm Fastener Group

Extended Life, Wheel and Brake Group Configuration Equipped Truck.
Table 58
Parts that are Required to Install the 8X-0259 Steering Cylinder and Mounting Gp and the
1 4 3J-6899 Locknut
Table 59
Tools that are Required to Install the 8X-0259 Steering Cylinder and Mounting Gp and the
AA 1 5P-3520 Spanner Wrench
BB 2 5S-6084 Socket
1. Remove two nuts (1) and two protective sleeves (C) from ball studs on steering link (B) and
steering cylinder (A) .

View of LH steering arm and steering link
View of LH steering arm
2. Remove dirt and grease from ball stud (D) .
Note: Ball stud (D) must be free of nicks and burrs.
3. Remove dirt and grease from tapered bore (E) of steering arm (F) .
Note: Tapered bore (E) must be free of nicks and burrs.
4. Install ball stud (D) of steering link (B) into steering arm (F). Remove retaining ring (G) and
cover (H) .
Note: Apply 5P-3931 High Temperature Thread Compound to the threads, the washer face,
and the nut.

View of LH steering link (B) that is installed
5. Use spanner wrench (AA) in order to hold ball stud (D) for tightening. Use socket (BB) to
tighten nut (1) to a torque of 2550 ± 100 N·m (1881 ± 74 lb ft).
6. Reinstall retaining ring (G) and cover (H) that was removed in Step 4.
7. Repeat Step 2 through Step 5 for steering cylinder end (A) .
8. Repeat Step 2 through Step 7 for the right side.
Standard Equipped Truck
Table 60
Parts that are Required to Install the 8X-2829 Steering Arm Fastener Group
1 20 8T-0283 Bolt
2 20 9X-8399 Washer
3 1 3J-6899 Locknut
1. Check the surfaces for cleanliness and metal burrs.
2. Use a chain and a lever puller to support steering arm (A). Position the steering arm to the left
side of the front suspension cylinder.
3. Install ten bolts (1) and ten washers (2) in order to secure left steering arm (A) to the left front
suspension cylinder.
Note: Tighten the bolts to a torque value of 1600 ± 200 N·m (1180 ± 148 lb ft).
4. Use a chain and a lever puller to support right steering arm (B). Align right steering arm (B) to
center steering arm (C) .
5. Remove dirt and grease from the tapered bore of center steering arm (C) .
6. Install right steering arm (B) to center steering arm (C) .

View of a tie rod that is installed
7. Install locknut (3) to the pin. Use a 5P-3520 Spanner Wrench to hold the pin. Use a 5S-6084
Socket to tighten the nut.
Note: Apply 5P-3931 High Temperature Thread Compound to the threads, the washer face,
and the nut.
Note: Tighten the nut to a torque of 2550 ± 100 N·m (1881 ± 74 lb ft).
8. Repeat Step 1 through Step 3 for the installation of the right steering arm to the right
suspension cylinder.
Install the 131-3541 Service Brake Lines Gp (Front)

Table 61
Parts that are Required to Install the 131-3541 Service Brake Lines Gp (Front)
1 4 8X-6137 Block
2 4 5T-0968 Block
3 8 8T-4185 Bolt
5 2 148-8358 Elbow
6 1 185-1449 Bracket (LH)
7 1 185-1450 Bracket (RH)
8 2 7X-0871 Tee
9 2 6V-0852 Dust Cap
10 2 164-5567 Fitting Gp
11 2 148-8345 Connector Gp
12 4 0S-1627 Bolt
13 4 5P-8248 Hard Washer
14 6 7K-1181 Cable Strap
15 2 5J-0451 Hose As
16 2 6D-6489 Pipe Connector
17 2 9C-4937 Breather As
18 2 1S-0996 Clip
1. Install one elbow (5) to the front brake. Attach the existing hose to elbow (5). Use the
following items in order to secure the hose to the bracket: one block (1), one block (2), two
bolts (3) and two washers (4) .
2. Install bracket (6) to the front brake. Use two bolts (12) and two washers (13) .
Note: Bracket (6) is for the left hand side of the machine. Bracket (7) is for the right hand side
of the machine.
3. Install one connector (11) to the front brake. Install tee (8) to connector (11). Install dust cap
(9) and fitting (10) to tee (8) .
4. Attach existing hose to tee (8). Secure hose with the following items: one block (1), one block
(2), two bolts (3) and two washers (4) .
5. Install one connector (16) to the front brake. Attach one end of hose assembly (15) to
connector (16) .
6. Use cable straps (14) to secure hose assembly (15) to the existing hose.
7. Attach one breather (17) to the other end of hose assembly (15). Use one clip (18) and the
existing hardware in order to secure hose assembly (15) to the mount for the front strut.
8. Repeat Step 1 through Step 7 for the right hand side of the machine.

Right side view
Install the 216-1735 Fuel Tank Fastener Gp

Note: The 216-1735 Fuel Tank Fastener Gp is for use with the 240-4806 Fuel Tank and Filter
Arrangement . The 240-4806 Fuel Tank Gp has a capacity of 4353 L (1150 US gal).
ReferenceRefer to ""Install the 8X-0193 Fuel Heater Group " " if the machine is equipped with a
heater for the fuel tank.
Table 62
Parts that are Required to Install the 216-1735 Fuel Tank Fastener Gp
1 4 7X-2489 Bolt
2 4 8T-4167 Washer
3 2 8X-2575 Cap
4 1 216-2976 Plate Assembly
5 2 7X-2564 Bolt
6 8 8T-5439 Washer
7 2 8T-4131 Nut
8 4 8N-1214 Mount Assembly
9 2 7N-5656 Sleeve
10 2 7X-2488 Bolt
11 2 6V-7688 Locknut
12 4 8X-2576 Shim Pack
13 2 8T-5005 Bolt

View of the LH frame rail
1. Remove the strap for fuel tank harness (A) .

View of LH side
2. Remove four bolts (1), four washers (2) and two caps (3). Retain the hardware.
3.
4. Remove paint and dirt from two fuel tank supports (B) .
5. Remove paint and dirt from two caps (3) .
6. Position cap (3) to fuel tank support (B). Install two bolts (1) and two washers (2) from Step 2
in order to secure the cap. Tighten the bolts to a torque of 800 ± 100 N·m (590 ± 74 lb ft).

View of fuel tank support (B) and cap (3) .
7. Measure and record inside diameter (AA) .
8. Repeat Step 6 and Step 7 for the other side.
9. Remove paint and dirt from mounting pin (C) on the fuel tank.

View of pin (C)
10. Measure and record outside diameter (BB) .
12. Record the difference between measurement (AA) and measurement (BB) for both sides.
Note: The difference will determine the amount of shim (12) that is required for the final
installation.
13. Repeat Step 2.
14. Remove paint and dirt from mounting location (D) and plate assembly (4) .

View of LH chassis
15. Install two bolts (5), four washers (6) and two nuts (7) in order to secure plate assembly (4).

View of 240-4800 Fuel Tank Gp
16. Use a suitable lifting device to lift the fuel tank to the frame. Position mounting pins (C) to
supports (B).
Note: The weight of the fuel tank is 1597 kg (3520 lb).
Note: Steps 17 and 18 are for machines that have a fuel tank capacity of 4467 L (1180 US
gal).

View of side of fuel tank
17. Install two mounts (8) and two sleeves (9) between plate assembly (4) and the bracket.
18. Install two mounts (8), two bolts (10), two washers (6) and two nuts (11) in order to secure the
fuel tank to plate assembly (4) .
Note: Tighten bolts (10) to a torque value of 460 ± 60 N·m (339 ± 44 lb ft)
19. Position shim (12) that is equal to the last recorded value in Step 12 to fuel tank support (B) .
Note: Shim both sides of support (B) equally.
20. Install two bolts (1), two washers (2) and cap (3). Tighten the bolts to a torque of 800 ± 100
N·m (590 ± 74 lb ft).
22. Use clamps (E) that are provided in order to secure the hose in two places.

View of the vent assembly that is installed
23. Install two bolts (13) and two washers (14) in order to secure vent assembly (D) .
Note: Vent assembly (D) is already provided.

View of bottom of the fuel tank
24. Remove six bolts (F) and six washers (G) in order to remove cover (H). Retain hardware.
25. Connect harness (A) to the electrical connections for the fuel tank sensor.
26. Install the hardware that was removed in Step 24 in order to secure cover (H) .
Install the 230-1086 Fuel Filter Lines Gp (If Equipped)

Table 63
Parts that are Required to Install the 230-1086 Fuel Filter Lines Gp
1 1 231-7582 Adapter (1)
2 1 5H-6734 O-Ring Seal (1)
3 6 8T-2501 Bolt (1)
4 6 8T-4896 Hard Washer (1)

5 1 6V-9852 Elbow
6 1 8X-5311 Check Valve As
7 1 230-1097 Hose As
8 1 251-3248 Hose As
9 2 8T-4195 Bolt
11 1 7E-6719 Primary Fuel Filter Gp
12 1 285-5634 Hose As (1)
13 1 159-4724 Ball Valve
14 1 6V-9182 Elbow
15 1 113-9339 Hose As
16 4 8T-4139 Bolt (1)
17 4 8T-4223 Hard Washer (1)
18 1 4J-0527 O-Ring Seal (2)
(1) Part of 264-7554 Service Center Gp

View of back of the fuel tank that faces the frame
1. Remove six bolts (A) in order to remove cover (B). Discard the hardware.
2. Position adapter (1) and O-Ring (2) to the fuel tank. Install six bolts (3) and six washers (4).
Install check valve (6). Install elbow (5) onto check valve (6) .
ReferenceView illustration 216 in order to position existing tapped holes in adapter (1) to
fitting (6) .
3. Connect existing hose (7) to elbow (5). Install two bolts (9) and two washers (10) in order to
secure filter assembly (11). Connect existing hose (8) to filter assembly (11) .
4. Remove four bolts (D), four washers (E) and four nuts (F). Discard hardware. Remove cover
(C) from hose (12). Discard the cover.
Note: Retain flange halves.

View of components that are installed
5. Install ball valve (13) and elbow (14). Connect existing hose (15) from the filter assembly to
elbow (14). Install four bolts (16) and four washers (17) in order to secure flange halves from
Step 4, hose (12) and O-Ring (18) .
Install the 8X-0193 Fuel Heater Group (If Equipped)

ReferenceRefer to "" 216-1735 Fuel Tank Fastener Gp " ".
Table 64
Parts that are Required to Install the 8X-0193 Fuel Heater Group
1 1 114-8701 Plate
2 2 7X-2568 Bolt (1)
3 1 7W-5300 Fuel Heater

4 4 8T-4194 Bolt
6 2 6B-9081 Reducing Bushing
7 2 8C-6874 Connector
8 4 6V-9746 O-Ring Seal
9 1 6V-9852 Swivel Elbow
10 4 7J-9108 O-Ring Seal
11 2 8C-6873 Connector
12 2 061-9593 Reducer Bushing
13 1 8T-8899 Elbow
14 1 107-8163 Hose As
15 1 8W-5428 Hose As
(1) These bolts replace the bolts that are included in the Fuel Tank Fastener Gp .

View of the rear of the fuel tank
Note: Refer to ""Fuel Tank Fastener Gp" " for some of the hardware that is used.
1. Use two bolts (2) and the existing hardware from the Fuel Tank Fastener Gp in order to install
plate (1) .
Note: Tighten the bolts to a torque of 460 ± 60 N·m (339 ± 44 lb ft).
2. Install fuel heater (3) to plate (1). Use four bolts (4) and four washers (5) .
3. Install bushing (6) to fuel Heater (3). Install connector (7) and O-Ring seal (8) to bushing (6) .
4. Install bushing (12) to fuel Heater (3). Install connector (11) and O-Ring seal (10) to bushing
(12). Install elbow (9) and O-Ring Seal (10) to Connector (11) .
5. Install elbow (13) to connector (7). Install hose (14) and O-Ring Seal (8) to elbow (13) .
6. Install bushing (12) to fuel Heater (3). Install one connector (11) to bushing (12). Install hose
(15) and O-Ring Seal (10) to connector (11) .
7. Install bushing (6) to fuel Heater (3). Install connector (7) and O-Ring Seal (8) to bushing (6).
Connect existing hose to connector (7) .

Typical view of installed components
8. Connect the other end of hose (14). Connect the other end of hose (15) .
9. Connect existing hoses.
Install the 151-8730 Steering Lines Gp

Table 65
Parts that are Required to Install the 151-8730 Steering Lines Gp

1 1 6V-9200 Elbow
2 1 3J-7354 O-Ring Seal
3 1 150-8710 Tube As
5 2 6V-8639 Connector
6 4 3K-0360 O-Ring Seal
7 2 6V-8625 Elbow
8 1 150-8709 Tube
10 1 150-8723 Tube As
11 1 150-8708 Tube As
12 1 150-8713 Tube As
13 2 5T-6867 Clip
15 3 5M-3062 Bolt
16 1 9S-1350 Clip
17 1 150-9037 Bar
18 4 8T-4136 Bolt
19 1 8X-5968 Bracket Assembly
20 1 6G-8532 Guard Assembly
Note: The parts that are shown in Table 23 are located under the hood or in the cab.
Note: Steps 1 through 10 should be completed while the cab is located at ground level.

Parts are located under the hood.
1. Remove the four plastic caps.
2. Remove the shipping plug. Install elbow (1) and one O-Ring Seal (2) .
3. Clean the surface of the steering assembly. Install tube assembly (3). Use one O-Ring Seal
(4) .
4. Install two connectors (5). Use two O-Ring Seals (6) in the back two orifices.
5. Install two elbows (7). Use two O-Ring Seals (6) in the front two orifices.
6. Install tube assembly (8). Use one O-Ring Seal (9) .
Note: Tube assembly (8) is the pump oil supply.
Note: Tube assembly (10) is the pilot oil line for right turns.
Note: Tube assembly (11) is the return oil line.
9. Install a tube assembly (12). Use one O-Ring Seal (9) .
Note: Tube assembly (12) is the pilot oil line for left turns.
10. Fasten the five steering lines to bar (17). Use the following parts to fasten the steering lines:
two clips (13), one Clip (16), three bolts (15) and three washers (14) .
Note: Torque the bolts to 47 ± 9 N·m (35 ± 7 lb ft).
Note: The rest of this assembly procedure is completed after the cab is installed to the frame
assembly.

View of the identification tags on the tube assemblies
11. Connect the tube assemblies to the hose connections from the frame assembly. Install the tube
assemblies and the hose connections. Use the identification tags that are installed on the tube
assemblies.
The following list matches the identification tags to the tube assemblies:
{ (T) 1V-6277 Identification Tag to the 150-8708 Tube As
{ (P) 8R-4853 Identification Tag to the 150-8709 Tube As
{ (R) 1V-6274 Identification Tag to the 150-8723 Tube As
{ (LS) 4J-6311 Identification Tag to the 150-8710 Tube As
{ (L) 1V-6276 Identification Tag to the 150-8713 Tube As

View of the clamps that secure the steering hoses and the air line under the cab
12. Install guard (20) and bracket (19). Use four bolts (18) and four washers (14) .
Note: Torque the bolts to 55 ± 10 N·m (41 ± 7 lb ft).
Install the 193-6349 Cab Mounting

Table 66
Parts that are Required to Install the 163-7226 Cab Mounting

1 40 163-0042 Mount
2 8 163-3127 Sleeve
3 1 8X-0436 Support
4 6 164-4411 Sleeve
5 1 244-3102 Support
6 9 8T-0283 Bolt
7 21 5T-1352 Spacer
8 6 9X-6618 Bolt
9 6 8C-3236 Bolt
10 6 163-0364 Sleeve
11 4 5T-9894 Shim (1)
12 20 5T-5807 Retainer
13 6 1K-9420 Bolt
14 6 6B-0388 Bolt
15 8 6V-2624 Bolt
16 4 5T-9893 Shim (1)
17 1 9M-8406 Clip
18 1 8T-4137 Bolt
(1) Use the shims to obtain a flatness within 0.75 mm (0.03 inch) with the cab.
Note: Mating surfaces must be free of paint and grease prior to assembly.
1. Remove lifting bracket (A) from the left side of the frame.
2. Clean paint from mounting surface (B) with 4C-4204 Paint Remover . Ensure that the
mounting surface is clean.

View of the LH front cab mounts that are installed
3. Install four mounts (1) into the top of the four bores that are provided. Install four mounts (1)
and four sleeves (2) into the bottom of the four bores that are provided.

View of support (3)
4. Use 4C-4204 Paint Remover in order to clean paint from the mounting surface of support (3).
Ensure that the mounting surface is clean.
5. Use 4C-4204 Paint Remover in order to clean paint from four seats (C) of support (3) .

View of left side of frame
6. Clean paint from mounting surface (D) with 4C-4204 Paint Remover . Ensure that the
mounting surface is clean.

View of LH rear cab mounts that are installed
7. Install six mounts (1) into six bores that are provided. Install six mounts (1) and six sleeves (4)
into six bores that are provided.

View of support (5)
8. Use 4C-4204 Paint Remover in order to clean paint from the mounting surface of support (5).
Ensure that the mounting surface is clean.

View of support (5)
9. Use 4C-4204 Paint Remover in order to clean paint from six seats (E) of support (5) .
10. Use a suitable lifting device in order to lift support (3) to the truck frame. The weight of
support (3) is approximately 182 kg (401 lb).
11. Install nine bolts (6) and nine spacers (7) in order to secure support (3). Tighten bolts (6) to a
torque of 1600 ± 200 N·m (1180 ± 148 lb ft).
12. Install eight mounts (1) and four sleeves (2) into support (3) .
13. Use a suitable lifting device in order to lift support (5) to the truck frame. The weight of
support (5) is approximately 240 kg (529 lb).
Note: The mounts can be installed before the cab supports are installed on the truck.
14. Install six bolts (8) and six spacers (7) into the top six holes of support (5). Install six bolts (9)
and six washers (7) into the bottom six holes of support (5) .
15. Install twelve mounts (1) and six sleeves (10) into support (5) .

View of supports (5) and (3) that are installed
16.
17. Use a suitable lifting device in order to position the cab assembly to support (3) and support
(5) .
Note: The weight of the cab assembly, catwalks and the handrail is approximately 2132 kg
(4700 lb).
18. Install six bolts (13) and six retainers (12). Install shims (11) in order to level the cab
assembly. A flatness of 0.75 mm (0.03 inch) is required.
Note: Apply 9S-3263 Thread Lock Compound to the bolts.
Note: Tighten the cab mounting bolts to a torque of 1904 ± 68 N·m (1405 ± 50 lb ft).

The cab is indicated by the arrow.
19. Install six bolts (14) and six retainers (12).
20. Install eight retainers (11) and eight bolts (15) .
Note: Install shim (16) in order to level the cab. A flatness of 0.75 mm (0.03 inch) is required.
21. Connect cab harness (F) to chassis harness (G). Install clip (17), bolt (18), and washer (19) in
order to secure the harness.
Install the 240-4798 Walkway Gp (If Equipped)

Table 67
Parts that are required to install the 240-4798 Walkway Gp

1 1 244-1688 Walkway As
2 12 8T-4139 Bolt (1)
3 12 8T-4223 Hard Washer (1)

View of walkway
Top view of walkway that is in position
1. Position the walkway to the mounting area behind cab (A) .
Note: The weight of the walkway is approximately 42 kg (93 lb).

View of hardware that is underneath of the walkway
2. Install four bolts (2) and four washers (3) in order to secure the walkway to the cab support.
3. Install eight bolts (2) and eight washers (3) in order to secure the walkway.
Install the 244-2233 Handhold As
Table 68
Parts that are required to install the 244-2233 Handhold As

1 1 244-2233 Handhold As (1)
2 2 139-1649 Pin (1)
3 2 140-4784 Cotter Pin (1)
4 1 1P-7403 Eyebolt (1)
6 2 9S-8752 Full Nut (1)
7 1 4F-2943 Spring (1)
8 1 6F-8499 Spring (1)
10 1 3B-4615 Cotter Pin (1)
11 1 244-2638 Rod (1)
1. Position handhold (1) to walkway (A) .
Note: The weight of the handhold is approximately 14.5 kg (32 lb).
2. Install pin (2) and cotter (3) in two places in order for handhold (1) to pivot.
Illustration 268
The handhold is shown in the forward position.
3. Position eyebolt (4) to the platform. Install two washers (5) and two nuts (6) in order to secure
the eyebolt.
Note: Do not tighten the nuts.
4. With handhold (1) in the upright position, insert one end of spring (7) to existing hole (B) in
the handhold.
5. Insert the opposite end of spring (7) to eyebolt (4) .
6. Adjust the tension of spring (7) in order for the handhold to move freely. Tighten two nuts (6)
in order to lock the eyebolt in place.
7. Install spring (8), washer (9) and cotter (10) onto rod (11) .
8. Position rod (11) in hand rail (1) .
Note: See illustration 268.
Install the Air Hoses and Install the Electrical Connection for
the Cab
View of the hose and electrical connections at right rear of cab
1. Remove the tape and the plugs from the cab assembly.
View of the hose and electrical connections for the cab assembly
(1) Main air supply and the line for the air compressor governor
(2) Air supply to air start control valve
(3) Air line for the parking brake control valve
(4) Air line for the service brake control valve
(5) Air line for the brake diverter valve
(6) Unconnected
(7) Air line for the automatic lubrication system
(A) Transmission
(B) Battery
(C) Chassis 1
(D) Chassis 2
(E) Engine
2. Match each hose to the fitting with the same number that is indicated on the side of the cab.
Note: Each air hose has an identification tag with a number.
3. Match and install the electrical connectors to the side of the cab.
4. Use tie straps to secure the hoses and cab wiring.

View of the heater hoses that are underneath of the cab
5. Install heater hose assembly (A) and heater hose assembly (B) from the cab assembly. Use the
four clamps and the two spacers that are already provided.
Note: It may be necessary to cut the hoses to the proper length before installation.
NOTICE
Open the heater valves on the engine after the installation of the heater
hoses.

View of the connection for the horn
6. Connect the air horn hose assembly to the connection in the cab. Secure the hose with a clip on
the frame.
View of the air conditioner lines that are installed
7. Connect air conditioner hose assembly (C) and air conditioner hose assembly (D) .
Install the 240-4782 Exhaust Pipe Gp

Note: The right side platform needs to be installed prior to installing the 240-4782 Exhaust Pipe Gp .
Table 69
Parts that are Required to Install the 240-4782 Exhaust Pipe Gp

1 1 272-5460 Tube As
2 6 7E-8452 Clamp
3 2 242-0799 Bellows As
4 1 269-3301 Bracket As
5 8 8T-4183 Bolt
7 4 8T-4244 Nut
8 1 272-5466 Tube As
9 2 242-0811 Clamp
10 2 5G-3845 Boss
11 2 7X-7729 Washer
12 2 8T-4172 Bolt
13 2 251-6357 Heat Shield
14 1 242-0801 Bracket As
16 1 272-5463 Tube As
17 1 7E-8452 Clamp (1)
(1) Part of 240-2780 Muffler Gp
1. Position tube assembly (1) onto the left side manifold (A). Install clamp (2) in order to hold
the tube to the manifold.
Note: Do not tighten clamp (2). Alignment of the tube assembly may be required before the
final tightening of the clamp.

View of right side manifold and bellows
2. Position bellows (3) onto the right side manifold (B). Install clamp (2) in order to secure the
bellows to the manifold.
3. Position bracket assembly (4) to mounting area (C) on the platform. Install bolt (5), washer (6)
and nut (7) in four places in order to secure the bracket.

View of right side manifold
4. Position tube assembly (8) into bellows (3). Install clamp (2) in order to hold the assemblies
together.
final tightening of the clamps.
5. Position tube assembly (8) into bracket assembly (4) .
6. Clamps (2) can now be tightened.

Side view for reference only
7. Position clamp (9) to bracket assembly (4). See illustration 284. Install boss (10), washer (11)
and bolt (12) in order to secure the clamp to tube assembly (8) .
8. Install heat shield (13) over bellows (3) .
Illustration 288
9. Position bracket assembly (14) to mounting location (D). Install bolt (5) and washer (15) in
four places in order to secure the bracket.

View of left side bellows
10. Position bellows (3) between tube assembly (16) and tube assembly (1) .
11. Install tube (16) in bracket assembly (14) .
12. Tighten two clamps (2) in order to secure the tube assemblies.
Note: Tighten all clamps (2) to a torque of 12.5 ± 1 N·m (111 ± 9 lb in). Lightly tap the clamp
and then tighten the clamp to 12.5 ± 1 N·m (111 ± 9 lb in). The minimum torque before the
engine starts is 9 N·m (80 lb in).

Side view of the two clamps around the tube assembly
Install the 293-5905 Exhaust Pipe Gp (If Equipped)

Note: The right side platform needs to be installed prior to installing the 293-5905 Exhaust Pipe Gp .
Table 70
Parts that are Required to Install the 293-5905 Exhaust Pipe Gp (If Equipped)
1 1 272-5460 Tube As
2 7 7E-8452 Clamp
3 2 242-0799 Bellows As
4 1 292-1009 Bracket As
5 8 8T-4183 Bolt
7 4 8T-4244 Nut
8 1 290-8577 Tube As
9 2 242-0811 Clamp
10 2 5G-3845 Boss
11 2 7X-7729 Washer
12 2 8T-4172 Bolt
13 2 251-6357 Heat Shield
14 1 292-1008 Bracket As

16 1 290-8578 Tube As
1. Position tube assembly (1) onto the left side manifold (A). Install clamp (2) in order to hold
the tube to the manifold.
final tightening of the clamp.

View of right side manifold and bellows
2. Position bellows (3) onto the right side manifold (B). Install clamp (2) in order to secure the
bellows to the manifold.
3. Position bracket assembly (4) to mounting area (C) on the platform. Install bolt (5), washer (6)
and nut (7) in four places in order to secure the bracket.

View of right side manifold
4. Position tube assembly (8) into bellows (3). Install clamp (2) in order to hold the assemblies
together.
final tightening of the clamps.
5. Position tube assembly (8) into bracket assembly (4) .
6. Clamps (2) can now be tightened.

Side view for reference only
Illustration 303
View of the exhaust pipe gp for the 793D Extra Quiet model
9. Position bracket assembly (14) to mounting location (D). Install bolt (5) and washer (15) in
four places in order to secure the bracket.

View of left side bellows
10. Position bellows (3) between tube assembly (16) and tube assembly (1) .
11. Install tube (16) in bracket assembly (14) .
12. Tighten two clamps (2) in order to secure the tube assemblies.
Note: Tighten all clamps (2) to a torque of 12.5 ± 1 N·m (111 ± 9 lb in). Lightly tap the clamp
and then tighten the clamp to 12.5 ± 1 N·m (111 ± 9 lb in). The minimum torque before the
engine starts is 9 N·m (80 lb in).

Side view of the two clamps around the tube assembly
Install the 240-2780 Muffler Gp

Note: Some hardware is installed onto the platform before the platform is installed on the chassis.
Table 71
Parts that are Required to Install the 240-2780 Muffler Gp

1 1 5T-7824 Clamp Assembly
2 2 6V-3668 Bolt
4 2 6V-8149 Nut
5 1 8X-3142 Extension Pipe
6 1 6N-9298 Clamp
7 2 6V-3823 Bolt
8 2 6V-7687 Locknut
9 1 242-8869 Extension Pipe
10 3 6V-6317 Bolt
11 3 2Y-5829 Nut
12 6 6V-5839 Washer
1. Remove the tape and protective covers from mufflers (A) and (B) .
Note: Mufflers (A) and (B) are factory installed on the right side platform.

View of muffler (A)
2. Position clamp assembly (1) to the platform assembly. Install two bolts (2), four washers (3),
and two nuts (4) in order to secure the clamp.
3. Slide pipe extension (5) through clamp assembly (1). Slide clamp (6) onto pipe extension (5).
4. Slide pipe extension (5) onto muffler (A). Install one bolt (7) and one locknut (8) in two places
in order to secure pipe extension (5). See illustration 311.
Note: Apply 4C-5598 High Temperature Anti-Seize to the exhaust pipe joint.
Note: Lubricate the clamp bolt threads. Lubricate the clamp surface before installation.
5. Position pipe extension (9) onto muffler (B). Install bolt (10), nut (11) and two washers (12) in
three places in order to secure the pipe to the muffler. Tighten bolts (10) to a torque of 30 ± 7
N·m (22 ± 5 lb ft).
Note: Apply 4C-5598 High Temperature Anti-Seize to the male end of the muffler before
installation.
Note: Lubricate the bolt threads before installation.
Install the 294-0849 Muffler Gp (If Equipped)

Note: Some hardware is installed onto the platform before the platform is installed on the chassis.
Table 72
Parts that are Required to Install the 294-0849 Muffler Gp (If Equipped)
1 2 6V-3823 Bolt
2 2 6V-7687 Locknut
3 2 6N-9298 Clamp
4 2 290-8576 Extension Pipe

View of the muffler gp for the 793D Extra Quiet model
1. Remove the tape and protective covers from mufflers (A) and (B) .
Note: Mufflers (A) and (B) are factory installed on the right side platform.

View of mufflers (A) and (B)
2. Slide one pipe extension (4) through one clamp assembly (3). Slide pipe extension (4) onto
muffler (A). Install one bolt (1) and one locknut (2) into clamp assembly (3) in order to secure
pipe extension (4) onto muffler (A) .
Note: Apply 4C-5598 High Temperature Anti-Seize to the male end of the mufflers before
installation of the pipe extensions.
Note: Lubricate the bolt threads and the clamp surfaces before installation of the clamp
assemblies.
3. Slide the other pipe extension (4) through the other clamp assembly (3). Slide pipe extension
(4) onto muffler (B). Install the other bolt (1) and the other locknut (2) into clamp assembly (3)
in order to secure pipe extension (4) onto muffler (B) .
Install the 193-6252 Platform Mounting Gp
Table 73
Parts that are Required to Install the 193-6252 Platform Mounting Gp

1 2 8X-2053 Plate
2 1 8X-2052 Plate
3 2 8X-1991 Plate
4 1 241-4233 Plate
5 1 8X-1990 Strip
6 1 242-7006 Plate
7 3 8T-6430 Bolt
8 3 8T-4123 Washer
9 1 241-4197 Bracket As
10 4 8T-4139 Bolt
11 5 5P-1076 Washer
12 4 7X-0344 Bolt
14 1 8T-4183 Bolt
15 1 8T-4244 Nut
Note: The right side air cleaner is factory installed to the right side platform.
1. Prepare plates (1), (2), (3), (4), (5) and (6) for welding by removing the paint from the edges.

View of paint that is removed from the platform assembly
2. Remove the paint from the area on the edge of the platform assembly and from the bottom of
the platform assembly. The weight of the right side platform assembly is 1130 kg (2491 lb).
3. Remove four bolts (A) and four washers (B) in order to remove plate (6) from the platform.
Retain the hardware for future use.
4. Prepare the area on the platform for welding by removing paint.

RH view of the truck
5. Remove paint from the area on the right side of the frame.
6. Remove paint from top of frame for welding. Remove the paint from the mounting area of the
platform.

View of the two existing lifting points
View of existing rear lifting point
7. Use the lifting points that are provided for the positioning of the platform.

View of the platform assembly that is being positioned to the frame
8. Use a suitable lifting device to position the platform to the chassis.

View of bolt (7) and washer (8)

View of bolt (7) and washer (8) underneath the platform

Top view of bolt (7) and washer (8)
9. Position the platform assembly. Install bolt (7) and washer (8) in three places in order to
secure the platform.

View of the accumulators that are covered
10. Cover the accumulators in order to protect the accumulator against the weld splatter.
Illustration 331
Welding requirements
Note: Do not weld area (AA) .
11. Weld the platform in place. Refer to Illustration 331, Table 74, and Table 75.
Table 74
Dimensions for Illustration 331

Item Dimension
A
10 ± 1.50 mm (0.40 ± 0.06 inch)
B
16.1 ± 1.5 mm (0.634 ± 0.059 inch)
Table 75
Weld Tolerances for Illustration 331

Weld Tolerances
W1 6 mm (0.24 inch) fillet weld with a

1.50 mm (0.06 inch) penetration
W2
3 mm (0.12 inch) square groove weld
12. Weld plate (2) to the frame and the platform assembly.
13. Weld two Plates (1) to the frame assembly and the platform assembly.
14. Weld plate (4) to the frame assembly and the platform assembly.
15. Weld two plates (3) to the frame assembly, the platform assembly, and plate (4).
16. Weld plate (5) to the frame assembly and the platform assembly.
17. Position plate (6). Install four bolts (A) and four washers (B) from Step 3. Weld plate (6) to the
frame assembly and the platform assembly.
18. Paint the welded areas.
19. Position bracket assembly (9) to the frame assembly and to the platform assembly. Install four
bolts (10) and four hard washers (11) in order to secure the bracket assembly to the frame
assembly.
20. Install four bolts (12) and four washers (13) in order to secure bracket assembly (10) to the
platform assembly.
21. Position existing brace (C). Install bolt (14), washer (11) and nut (15) in order to secure the
brace.
Note: Do not weld area (AA) .
Note: Tighten bolt (14) and existing bolt (D) to a torque value of 100 ± 20 N·m (74 ± 15 lb ft).

View of the electrical connections under the right side of the platform assembly
22. Connect the electrical lines for the oil cooler to the platform with clips, bolts, and washers.
23. Connect the load indicator wiring to the platform. Use clips, bolts, and washers.
Install the 8X-4180 Hood Latch Gp

Table 76
Parts that are Required to Install the 8X-4180 Hood Latch Gp

1 2 5S-7379 Bolt
3 1 2G-9399 Rod
4 1 6F-8499 Spring
5 1 8X-4425 Bracket Assembly

6 1 3B-4615 Cotter Pin
7 1 0T-0883 Washer
8 1 8X-4428 Plate Assembly
9 8 8T-4136 Bolt
12 1 101-0368 Prop Assembly
Note: Do not install the hood latch when the hood assembly is open.
1. Position bracket assembly (5) to the side of the cab. Install two bolts (1) and two washers (2)
in order to secure the bracket.
2. Install rod (3), spring (4) , cotter pin (6), and washer (7) to bracket assembly (5) .
3. Position plate assembly (8) to the platform. Install eight bolts (9) and eight hard washers (2) in
order to secure the plate assembly.
4. Install prop assembly (12) to the hood assembly by using hard washer (10) and cotter (11) .
Install the 240-2784 Air Cleaner Gp

Table 77
Parts that are Required to Install the 240-2784 Air Cleaner Gp

1 2 9Y-8930 Air Cleaner Gp
2 12 7X-0344 Bolt
4 4 7N-5008 Hose
5 16 230-2535 Clamp
6 2 251-2151 Tube As
7 4 285-6593 U-Bolt
9 8 6V-7687 Locknut
10 1 8T-4910 Bolt
12 2 8T-4244 Nut
13 4 233-8485 Hose Clamp
14 1 7D-8586 Nonslip Tread

View of the left side air cleaner group
1. Use two eyebolts (A) and a suitable lifting device in order to remove air cleaner group (1)
from the pallet.
Note: Air cleaner group (1) is shipped upside-down. Air cleaner group (1) weighs

View of the front left fender and air cleaner assembly
2. Use lifting eyes (B) that are provided and a suitable lifting device in order to position air
cleaner group (1) to the assembly.
3. Install four bolts (2) and four washers (3) in order to secure existing bracket (C) to the chassis.
4. Remove two shipping covers (D) from the air cleaner group. Discard the covers.
5. Remove covers (E) and (F) from tube assembly (6). Discard the covers.
Note: Two tube assemblies (6) are shipped from the factory with the right side platform.
6. Position tube assembly (6), two hoses (4) and eight clamps (5) to the air cleaner group.
Note: Apply 207-1601 Rubber Lubricant immediately before the assembly of hose (4) to the
mating part. Position the parts quickly and complete the assembly as the lubricant will
evaporate quickly. It may be necessary to reapply the lubricant.

View of left side tube and hoses
7. Install one bolt (7), two washers (8) and two locknuts (9) in two places in order to secure the
tube assembly to mount (G) .
Note: Tighten the locknuts to a torque of 30 ± 7 N·m (22 ± 5 lb ft).
8. Rotate each pair of clamps (5) until the t-bolts are located 180° from each other. Tighten the
clamps to a torque value of 7.5 ± 1 N·m (66 ± 9 lb in).

View of left side
9. Position existing braces (F) and (G). Install bolt (10), two washers (11) and nut (12) in order to
secure the braces.
Note: Tighten bolt (12) to a torque value of 100 ± 20 N·m (74 ± 15 lb ft).
10. Tighten two bolts (H) to a torque value of 100 ± 20 N·m (74 ± 15 lb ft).
Illustration 353
Top view of left side and tube assembly (6)

View of area (A)

Bottom view of area (A)
11. Align hose (J) to tube (6). Tighten two clamps (13) to a torque value of 7.5 ± 1 N·m (66 ± 9 lb
in) in order to secure the hose to the tube.
Note: Apply 207-1601 Rubber Lubricant immediately before the assembly of hose (J) to tube
assembly (6). Position the parts quickly and complete the assembly as the lubricant will
evaporate quickly. It may be necessary to reapply the lubricant.
12. Rotate each pair of clamps (13) until the t-bolts are located 180° from each other. Tighten the
clamps to a torque value of 7.5 ± 1 N·m (66 ± 9 lb in).

View of the left side and wiring that is installed
13. Install the wiring group. Use existing clips, bolts, and washers.
14. Repeat Step 4 through Step 13 for the right side.
15. Install nonslip tread (14) to the top of the air cleaner on the left hand side.
Install the 193-6262 Rim Mounting Gp

Table 78
Parts that are Required to Install the 193-6262 Rim Mounting Gp

1 6 8W-0338 O-Ring Seal
2 6 5T-9790 Tire Valve
3 2 8W-0331 Swivel Connector
4 564 7X-0851 Nut
5 564 6V-8237 Washer
6 2 190-6095 Ring
7 2 251-6360 Extension
8 2 207-6030 Plate (1)
9 2 220-8202 Hose As (1)
10 4 1S-1015 Clip (1)
11 32 8T-4139 Bolt
13 8 8T-4244 Nut
14 4 229-9387 Plate (1)
15 4 8T-5092 Bolt (1)
16 2 280-7372 Plate (2)
17 2 280-9835 Plate (2)
18 4 6J-0427 Spacer
19 2 7I-5931 Bracket
20 4 8T-6868 Bolt
22 2 5T-9796 Connector
23 1 281-0569 Hose As (2)
24 12 137-3615 Bracket (3)
25 4 3V-8340 Bracket (3)
26 8 136-9459 Plate As (3)
(1) Use with 793D Extended Life, Wheel and Brake Group configuration only
(2) Use with 793D Standard Wheel and Brake Group configuration only
(3) Part of 208-8789 Rim Guard Gp
Servicing and changing tires and rims can be dangerous and should be
done only by trained personnel using proper tools and procedures.
Do not attempt to assemble this machine until you read and you
understand the assembly instructions.
Improper assembly procedures could result in injury or death.
Note: Ensure that the pattern of the tread is oriented to the desired position. Inflate the tire with dry
nitrogen to operating pressure. Refer to Operation and Maintenance Manual, SEBU7174, "Tire
Inflation Information".
Note: When the tire is inflated in an area that is 20 °C (68 °F) and the tire operates in freezing
temperatures, the tire is underinflated. Low tire pressure shortens tire life. Refer to Operation and
Maintenance Manual, SEBU5898, "Cold Weather Recommendations for Caterpillar machines" for
cold weather conditions.
Note: Use a 6V-4040 Inflation Group to inflate the tire from a nitrogen cylinder. Refer to Special
Instruction, SMHS7867 for the tire inflation instructions.
Install the Front Tires
1. Remove the grease and the metal burrs from the wheel and the mounting area. Use cleaning
solvent and 4C-4188 Paint Remover to clean the parts. Failure to clean the parts will result in a
poor joint.

View of the front lifting points and lifting straps
2. Install clevis assemblies and lifting straps to the frame assembly.
Note: Inspect the locations of the straps. Metal will tear the straps.
3. Use a suitable lifting device in order to raise the front of the truck.
Note: Keep the hoist attached to the truck, until the front tires and rims are installed.
4. Use a tire handler in order to position the left tire and rim to the hub.
Note: The valve stem must face the outside.
Note: The weight of the rim is 1583 kg (3490 lb). The weight of the typical tire is 3500 kg
(7800 lb).
5. Install seventy nuts (4) and seventy washers (5) in order to secure the rim and tire assembly.
Secure the nuts with an impact wrench. Do not final torque the nuts.
Note: Position the washer so the part number is visible during installation.
6. Repeat Step 1 through Step 5 for the right tire.
Install the Rear Tires
Illustration 362
Use with 793D Extended Life, Wheel and Brake Group configuration only
Illustration 363
Use with 793D Standard Wheel and Brake Group configuration only
Note: The shop or a tire servicing person installs the rim assembly.
1. Use the following parts in order to assemble the rims to the rear tires: four O-Ring seal (1) ,
four tire valve (2) , two connectors (22) for the inside tires and two extensions (7) for the
outside tires. Before continuing, ensure that the thread pattern is oriented to the desired
position. Inflate the tire with dry nitrogen to operating pressure. Refer to Operation and
Maintenance Manual, SEBU7174, "Tire Inflation Information".
2. Attach a suitable lifting device in order to lift ring (6) .
Note: The weight of ring (6) is approximately 175 kg (386 lb).
3. Remove nuts (E) and washers (F) from the rear wheel assembly.
4. Remove ring (6) from the final drive.
Note: Ring (6) will be used later to install the outside rim and tire assembly.

View of the ring that is removed from the final drive
5. Clean the mounting area of the rim of metal burrs and paint.

View of front wheel that is blocked

View of the frame assembly that is lifted
6. Block the front wheels. Raise the rear of the truck in order to install the rear rims and
tires.35939 kg (79231.8382 lb)
Note: Keep the hoist attached to the truck, until the rear rims and tires are installed.
7. Mark the wheel assembly with chalk at the four bolt holes. The four holes are located at the
guard side of the valve stem extension. The mark allows you to align the tires and rims on the
wheel with more ease.
8. Use a tire handler to install an inside tire. The valve stem and hose assembly face outward.
9. Install 70 nuts (4) and 70 washers (5) to the rear inside wheel.
Note: The part number on the washer must face away from the machine. The part number on
the washer may prevent the proper torque from being obtained.

View of the nuts that are tightened with an impact wrench
10. Tighten the nuts with an impact wrench.
11. Repeat Step 1 through Step 10 on the other rim and the other tire.
12. Tighten the nuts on the two front tires and the two inside rear tires to a torque of 1000 ± 125
N·m (738 ± 92 lb ft).
13. Attach one end of hose assembly (9) or (23) to connector (22) .
Note: Hose (9) is for the 793D Extended Life, Wheel and Brake Group configuration.
Note: Hose (23) is for the 793D Standard Wheel and Brake Group configuration.
Note: Refer to illustration 362 and 363.
14. Position six brackets (24) and two brackets (25) to the wheel assembly. Position four plate
assemblies (26) to the brackets. Install fourteen bolts (11) and fourteen washers (21) in order
to secure plates (26). Tighten bolts (11) to a torque value of 55 ± 10 N·m (41 ± 7 lb ft).
Note: Position the valve stem in the correct position before the installation of the plates.
Note: Step 14 only applies to machines with mud guards for the rim on standard wheel
assemblies.
15. Repeat Step 14 for the other side.
16. Position two clips (10) around hose assembly (9). Install two bolts (11), two washers (12) and
two nuts (13) in order to secure hose assembly (9) to plate (8). See illustration 362.

View of the 793D Extended Life, Wheel and Brake Group configuration
17. Position plate (8) to the final drive assembly. Position two plates (14). Install two bolts (15),
four washers (12) and two nuts (13) in order to secure plate (8) and plates (14) to the final
drive assembly.
Note: Step 16 and Step 17 is for the 793D Extended Life, Wheel and Brake Group
configuration.
19. Position plate (16) and plate (17) around hose assembly (23). Install two bolts (11) and two
washers (12) in order to secure the plates.
Note: Reference illustration 363.
Note: Step 19 is for the 793D Standard Wheel and Brake Group configuration.
20. Repeat Step 19 for the other side.

View of the rings for assembly to the rear wheels

View of ring that is attached to the wheel before installation
21. Position ring (6) to the rim group. The ring goes on the opposite side of the valve stem of the
rim. Align the "U" notch in the ring with the valve stem assembly.
Note: Both valves should be free before the installation of the ring.
22. Install 70 nuts (4) and 70 washers (5) in order to secure ring (6) to the rim group.
Note: The part number on the washer must face away from the machine. The part number on
the washer may prevent the proper torque from being obtained.
Note: Do not use any lubrication on the nuts or washers. The mating surfaces are clean and
dry.
23. Secure the nuts with an impact wrench.
24. Tighten the outside nuts to a torque value of 1000 ± 125 N·m (738 ± 92 lb ft).
Note: Do not use oil on the threads.
25. Repeat Step 21 through Step 23 on the other outside wheel.

View of wheel and tire that is being installed
26. Use a tire handler to position the left outside rear wheel to ring (6) on the final drive.
27. Install the bolts and washers that were removed from step 3.
Note: Use the wire to pull the valve stem of the inside tire through the opening in the retaining
ring.
28. Tighten the bolts that secure ring (6) to the final drive. Tighten the bolts to a torque value of
900 ± 100 N·m (664 ± 74 lb ft).
29. Position bracket (19) to the rear wheel assembly. Install two bolts (20), two hard washers (12)
and two spacers (18) in order to secure the bracket.
30. Repeat Steps 26 through 29 on the other side of the machine.
Install the Odometer (If Equipped)

Table 79
Parts that are Required to Install the Odometer

141-1513 (1)
155-6138 (2)
1 1 Odometer Assembly
5T-8673 (3)
141-1514 (4)
2 1 122-1478 Plate As
3 2 5B-5839 Spacer
4 2 8T-4184 Bolt
(3) The 5T-8673 Odometer Assembly is part of 188-3648 Odometer Gp .
(4) The 141-1514 Odometer Assembly is part of 188-3649 Odometer Gp .
1. Use the existing fastener in order to attach the appropriate odometer assembly (1) to plate
assembly (2) .
2. Position two spacers (3) between plate assembly (2) and the rear wheel assembly.
3. Install two bolts (4) and two hard washers (5) in order to secure plate assembly (2) to the rear
wheel assembly.
Install the 126-1358 Hydraulic Tank Guard Gp

Table 80
Parts that are Required to Install the 126-1358 Hydraulic Tank Guard Gp
1 1 119-8732 Cover
2 1 270-8622 Cover

View of the hydraulic tank
1. Remove four bolts (B) and two bolts (C) from hydraulic tank (A). Retain the bolts.

View of area (AA)
2. Position cover (1) to hydraulic tank (A). Install two bolts (B) that were removed in Step 1 in
order to secure the cover.
3. Position cover (2) to hydraulic tank (A). Install two bolts (C) that were removed in Step 1 in
order to secure the cover.
Install the Ether Cylinder

View of the ether cylinder
1. Install two 7X-1062 Ether Cylinders .
Install the 168-9897 Ladder Lighting

Table 81
Parts that are Required to Install the 168-9897 Ladder Lighting

1 1 153-2073 Flood Lamp Gp
2 1 5C-7261 Nut
4 1 8T-6869 Bolt
5 1 140-1088 Bracket Assembly
6 1 5L-4241 Hard Washer
8 1 8T-4196 Bolt

View of flood lamp (1) that is installed
1. Position bracket assembly (5) to the right side radiator cowling. Install bolt (8), hard washer
(7), and spacer (6) in order to secure the bracket.
Note: Spacer (6) should be placed between bracket assembly (5) and the top of the welded
bracket.
2. Position flood lamp (1) onto Bracket Assembly (5). Install bolt (4), two hard washers (3), and
Nut (2) in order to secure the lamp.
3. Connect the wiring harness connector to flood lamp (1) .
4. Adjust the lamp to the requirements that are needed.
Install the 284-4927 Truck Body Mounting Gp

Note: Be sure to remove all lifting eyes prior to the installation of the body and canopy to the
chassis.
Table 82
Parts that are Required to Install the 284-4927 Truck Body Mounting Gp
1 4 5T-7255 Plate
2 73 8T-4196 Bolt
4 73 8T-4133 Nut
5 2 8X-5063 Deflector
6 4 5T-7352 Strip
7 2 5T-7274 Mud Flap
8 1 105-4727 Mud Flap
9 1 8X-5421 Plate
10 1 6G-9703 Cable
11 1 105-0314 Coupler
12 2 8T-4649 Bolt
14 2 6V-7676 Nut
13 1 8W-0109 Plate
14 1 2B-0974 Clevis Pin
19 2 7I-5517 Pin As
20 1 8W-2896 Washer
21 2 6G-9697 Washer
22 10 8T-4184 Bolt
24 2 8W-8677 Plate
25 30 8X-3046 Shim
26 30 7D-1649 Hard Washer
27 24 8T-4910 Bolt
28 24 8T-4244 Nut
29 10 219-7595 Pad As
30 16 8T-4137 Bolt
31 16 4K-8864 Clip
32 2 233-1880 Bracket As (1)
33 2 227-5875 Ejector
34 2 6G-7773 Pin
35 2 3D-0404 Washer
37 4 205-4178 Pad
38 4 205-4179 Shackle
39 2 205-4181 Chain
(1) Part of 260-9120 Body and Canopy As

View of the right side front deflector that is installed
1. Position the truck body onto suitable supports.
Note: The weight of the completed truck body with the liners is approximately 63503 kg
(140000 lb).
2. Position plate (1) to the body. Install five bolts (2), five washers (3) and five nuts (4) in order
to secure the plate to the body.
3. Position deflector (5) and strip (6) to plate (1). Install twelve bolts (2) and twelve nuts (4) in
order to secure the strip and the deflector to the plate.

View of right side rear deflector that is installed
4. Position plate (1) to the body. Install five bolts (2), five washers (3) and five nuts (4) in order
to secure the plate to the body.
5. Position deflector (7) and strip (6) to plate (1). Install twelve bolts (2) and twelve nuts (4) in
order to secure the strip and the deflector to the plate.

View of mud flap that is installed
7. Position mud flap (8) and plate (9) to the body. Install five bolts (2), five washers (3) and five
nuts (4) in order to secure the mud flap and the plate.
8. Position cable (10) to existing bracket (A) on the body. Position coupler (11) through the end
of cable (10 ). Install two bolts (12), two washers (13) and two locknuts (14) in order to secure
the coupler to the bracket.
9. Position cable (10) over existing bracket (B). Position plate (15) to bracket (B). Install pin
(16), washer (17) and cotter (18) to secure plate (15) and cable (10) to the body.
10. Remove paint and dirt from four bores in the body and two bores in the chassis.
11. Remove dirt and grease from two pin assemblies (19) .
Note: The weight of one pin assembly is 42 kg (93 lb).

View of two pins that are used to lift body

View of lifting pins and straps that are attached to the body
12. Position lifting pins (C) through existing lifting holes in the body.
13. Repeat Step 12 for the other side of the body.
14. Use a suitable lifting device in order to position the body to the chassis.
Note: The weight of the completed truck body is 45359 kg (100000 lb).

View of right side pin assembly that is being installed
15. Install pin assembly (19) .

View of left side pin assembly and washers that are installed
16. Install washer (20) and washer (21).
Note: Washer (20) is 6 mm (0.24 inch) thick.
Note: Washer (21) is 10 mm (0.40 inch)thick.
17. Position plate (22) to the body. Install two bolts (23) and two hard washers (24) in order to
secure the plate.

View of the left hoist cylinder that is secured with a cable
19. Secure the hoist cylinder with a chain or cable in order to prevent any movement of the hoist
cylinder.

View of the left hoist cylinder that is secured

View of shipping bracket that is being removed
20. Use a torch in order to remove the shipping bracket and the retaining bolt.
21. Repeat Step 19 and Step 20 for the other side of the machine.

View of the truck body that is lowered onto two wood blocks
Note: Refer to ""Install the 8X-3380 Cylinder Mounting Gp " " for the installation of the hoist
cylinders to the body assembly.
Note: Position the truck on a level surface. The body and cylinder installation must be
completed in order to proceed to the following steps:
22.
23. Raise or lower the body in order to bring the body and frame rails parallel to each other. The
distance between the body rail and the frame rail is 42 mm (1.65 inch).
24. Measure the distance between the body rail and the frame rail. Place the pad assemblies on top
of the frame rail. Use shims to produce a zero clearance between the rails. Finish the
installation of the eight pad assemblies and shims to the body.
25. Install the two pad assemblies to the top of the main crossbeam. Align the slipper pads to the
body supports. Measure the distance between the pads. Use shims to produce 1.5 mm (0.059
inch) compression at the two locations. The nominal distance between the slipper and the body
is 42 mm (1.65 inch).

View of four pad assemblies that are installed
26. Install shims (25), eight pads (26), twenty-four bolts (27), twenty-four washers (28), and
twenty-four nuts (29) .
Note: Block the body in position when you install the shims and pads.
27. Install shims (25) under pad assembly (26) in order to achieve the correct thickness. Install
three bolts (23) and three washers (30) in order to secure the pad. Repeat for the other side.
Note: Refer to Step 24. This determines the number of shims (25) that are required.
28. Attach arm (D) of the body position sensor to the truck body. Secure arm (D) with existing
bolt (E) .
Note: Adjust the length of the arm in order for the body position sensor to automatically
calibrate. After the arm is installed and the body assembly is lowered to the frame rails, type in
code 724. Press the "gauge" key on the VIMS keypad module in the cab. This parameter
number displays the angle of the body. The display shows the current angle of the body. If the
angle of the body is greater than 7 degrees, adjust the length of the arm. The display should
show an angle less than 7 degrees. When the angle of the body is less than 7 degrees, the body
position sensor will automatically calibrate. Press "OK" on the VIMS keypad module in order
to return to the standard display.
29. Position the grease line for the hoist cylinder to the bottom of the body assembly. Install
sixteen bolts (30), sixteen washers (3), and sixteen clips (31) in order to secure the grease
lines.

View of the lubrication line for the cylinder
30. Install the grease line to the hoist cylinders.
31. Position rock ejector bracket (32) .
NOTICE
The rock ejector brackets should be installed after the body has been
installed.

Side view of rock ejector bracket that is tack welded

Rear view of rock ejector bracket that is centered between rear tires
32. Attach a string and a plumb bob to the center of the bracket for the mounting pin in the rock
ejector bracket. Position the rock ejector bracket on the bottom of the truck body. The string is
centered in the middle of the two tires. Check the distance that separates the string and the
wheel group assembly in order to prevent the rock ejectors from striking the wheels. The rock
ejectors that are installed should be centered in the forward position, in the rear position, and
in the side position.
33. Prepare the surface for welding by removing paint and dirt from the body in order to install
bracket (32).
Table 83
Weld Tolerances
Weld Description
W5 10 mm (0.40 inch) with a

1.50 mm (0.06 inch) penetration (2 Places)
W6 8 mm (0.31 inch) with a

W7 6 mm (0.23 inch)with a
Note: Reference this table for weld specifications.

Bottom view of the bracket for the ejector
Illustration 420
Bottom view of the body
34. Weld bracket (32) to the body.
Note: Refer to illustration 419 and illustration 420.
Note: Refer to Table 83 for welding requirements.
35. Use a suitable lifting device to position ejector (33) to bracket (32) .
Note: The ejector weighs approximately 115 kg (254 lb).
36. Install pin (34) and slowly lower the rock ejector between the rear tires.
37. Check the clearance on both sides of the rock ejector to the rear tires.
38. Install washer (35) and two cotter pins (36) in order to secure the ejector to the bracket.
Illustration 423
39. Remove paint and dirt from the body and ejector (33) in order to prepare the surfaces to weld
two pads (37) .
40. Weld one pad (37) to the body and weld one pad (37) to ejector (33) .
Note: Refer to illustration 420 and illustration 423.
Note: Refer to table 83 for weld specifications.
41. Install two shackles (38) and chain (39) .
Install the 8X-3380 Cylinder Mounting Gp

Table 84
Parts that are Required to Install the 8X-3380 Cylinder Mounting Gp

1 2 237-0417 Pin As
2 4 8X-4043 Spacer
3 2 8X-4044 Plate
4 10 8T-4183 Bolt
1. Clean the paint from the mounting surfaces of the hoist cylinder.
2. Position the lift cylinder to the body pin bore.
3. Install one pin (1) and two spacers (2) .
4. Position plate (3) to the body.
5. Install bolt (4) and washer (5) in order to secure plate (3) .
6. Repeat Step 1 through 5 for the other side of the machine.
7. Remove the bracket that holds the cylinder .
Install the 251-4831 Film Gp

Table 85
Parts that are Required to Install the 251-4831 Film Gp

1 1 100-5615 Film
2 1 100-9984 Film (1)
3 4 131-5415 Film
4 2 251-4832 Film
5 1 251-4833 Film
6 1 251-4834 Film
(1) Left side only
Note: The film on the right side platform is installed at the factory.
Illustration 429
1. Clean the area.
2. Position film (4) to the fender. Apply tape only at the top in order to hold film (4) in place.
Note: Do not remove the backing from the film.
3. Raise film (4) in order to spray a solution on the fender.
Note: Do not lower the film.
4. Remove the backing from film (4) .
5. Position film (4) to the fender.
6. Use a heat gun and a plastic straight edge in order to dry and smooth film (4) .
Note: The straight edge is used to remove any air bubbles.
7. Remove the protective paper from the face of film (4) .

View of film (4) that is installed
8. Repeat Step 1 through Step 7 for the remaining film.
Purge the Brakes
Personal injury could result from improperly coupled attachments. Be

certain latches are fully engaged on both sides before transporting or
pulling the attachment.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Dealer Service

Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
ReferenceTesting and Adjusting, RENR8330, "Brake System Air - Purge"
Align the Front Wheels
ReferenceTesting and Adjusting, RENR8330, "Front Wheel - Align"
The Parking Brake
While the engine is running, actuate the parking brake switch five times. This will purge the air from
the lines. Actuate the brake in one minute intervals. The parking brake will release after the air has
been purged.
Final Check
With full air pressure, inspect the lines, connections, and fittings for leaks.
Apply the service brakes when the engine is stopped. The air pressure should be between 760 kPa
(110 psi) and 840 kPa (122 psi). Monitor the system air pressure. There should be no noticeable drop
within two minutes, while the brakes are applied.
Field Test for the 793D Truck That is Fully Built

1. Set the toe-out to 48.20 mm (1.90 inch). The front suspension cylinders should be fully
extended.
2. The steering system accumulators should be charged to 6550 kPa (950 psi).
3. Check for nitrogen leaks at the suspension cylinders.
4. The engine is OFF. The oil level of the steering hydraulic tank should be at the top of the sight
glass.
5. At HIGH IDLE, turn the steering wheel against full left turn stop. Hold the wheel while you
check for cracks and for leaks.
6. At HIGH IDLE, turn the steering wheel against full right turn stop. Hold the wheel while you
check for cracks and for leaks.
7. At HIGH IDLE, the steering wheel should go from stop to stop in 3 to 5 seconds.
8. Steering wheel should have a tight feel from proper retaining nut torque and bearing fit.
9. Check the tilt of the wheel.
10. This following information is for the test of the steering system. The steering system should be
fully charged and the truck should be off. The accumulators should discharge and the steering
pressure should drop to zero in 20 seconds. The steering system should be fully charged. Stop
the engine from the ground level shutdown switch. The steering pressure must NOT drop.
Release the brake and steer from stop to stop two times. This test will check the secondary
steering system. The level 3 warning must activate.
11. Check for air leaks. Run the truck, until the air pressure is at 827 kPa (120 psi). The air dryer
should exhaust at pressures above 827 kPa (120 psi). Shut off the engine and apply all three
brakes. Apply each brake for two minutes. Listen for leaks, while you are watching the air
gauge. The air system must not leak over 3.40 kPa (0.50 psi) per minute.
12. Park the truck on a slight grade. Shut off the engine. Purge the air out of the brakes, until low
air pressure locks the springs in the brakes. Turn on the towing switch. The truck should roll.
This indicates that the towing switch has overcome the spring pressure. When the brakes lock
up, the brake light comes on.
13. Park the truck on level ground. Put the truck in first gear. Check the brake holding ability with
the engine at 1300 RPM. Check the foot brake, the retarder, and the secondary brake
separately. The truck should barely move or the truck should not move at all. Apply all three
of the brakes. The truck should not move at all.
14. Check the Automatic Electronic Traction Aid (AETA). Turn on the AETA Switch. Drive to
the right in a tight circleat LOW IDLE. Drive in a tight circle to the left. The turning radius for
both circles should be similar.
Note: The steering system should be adjusted properly for the test accuracy.
15. Check the transmission neutralizer. Back up the truck, while you raise the body assembly. The
transmission should shift into NEUTRAL. If the shifter is in REVERSE and the hoist lever is
moved to the power down position, the transmission should shift to NEUTRAL.
16. Check the tire pressure.
{ The Goodyear bias ply tire holds 723 kPa (105 psi) of air pressure.
{ The Goodyear radial tire holds 758 kPa (110 psi) of air pressure.
{ The Michelin radial tire holds 689 kPa (100 psi) of air pressure.
{ The Bridgestone radial tire holds 703 kPa (102 psi) of air pressure.
Perform the Commissioning Procedure for the Machine

Check all fluid levels. The fluids should be properly filled before the commissioning procedures
begin.
z The engine crankcase contains 307 L (81 US gal) of 5P-2586 Oil . The oil is a SAE 10W30
oil.
z The coolant system contains 681 L (180 US gal) of 119-5148 Coolant . Refer to the
Operations and Maintenance Manual for the proper mixture of coolant and water for certain
applications.
z The hydraulic tank for the transmission and the torque converter contain 224 L (59 US gal) of
2P-9869 Oil . The oil is a SAE 30W oil and the oil contains a red dye.
z The hydraulic tank for the hoist and brakes contains 909 L (240 US gal) of 3P-0659 Oil . The
oil is a SAE 10W oil.
z The steering hydraulic tank has a capacity of 129 L (34 US gal) of 2P-9063 Hydraulic Fluid .
The hydraulic fluid is a SAE 10W oil. DO NOT attempt to fill this tank while the engine is
running. Fill the steering hydraulic tank when the engine is OFF. The fluid should appear in
the middle of the upper sight glass. Refer to the Operations and Maintenance Manual for the
Diagnostic Pressure Ports for the truck.
z Air pressure can be taken from the line or the air start tank.
z The steering pressure tap is for standby pressure that is on the right side of the inside of the
frame. This is close to the rear engine mount.
z The steering pressure tap is located on the left side of the steering valve. The steering valve is
located on the right side of the inside of the frame near the rear engine mount. The steering
pressure tap is for the standby cut-in pressure and the cut out pressure.
z The torque converter outlet pressure tap is located on the converter valve body that is below
the lockup.
z The torque converter lockup switch is located on the lockup valve on the rear of the converter
housing.
z The transmission pump pressure tap is located on the right side of the transfer gear housing on
the transmission.
z The transmission lube oil pressure tap is on the right side of the engine transfer gear housing
that is located on the transmission.
z The hoist pressure tap is located on the hoist pump on the inside of the right hand frame.
z The two AETA taps are located on the AETA valve. The valve is located on the right side of
the frame. The right hand wheel is located on the rear port.
z The towing motor tap is located on the top left side of the differential housing.
z The brake retracting motor contains the same tap as the towing motor.
z Look for parts that are damaged or parts that are missing.
z Look for loose connections, loose fasteners, and joints.
z Look for leaks underneath the truck.
z Use the Service Manual to correct any problems.
Check the Configuration of the Electronic Control Modules

(ECM)
ReferenceService Manual, RENR2630, "784C, 785C, 789C, 793C, 797 Off-Highway
Truck/Tractors Vital Information Management System (VIMS)"
ReferenceTesting and Adjusting, Troubleshooting, RENR2631, "Off-Highway Truck/Tractors Vital

Information Management System (VIMS)"
This section contains assembly checks and functional checks of systems. Perform the checks before
you deliver the machine to a customer.
1. Connect a laptop computer to the Caterpillar Diagnostic Connector on the fuse panel behind
the operator seat. The laptop computer should have 139-4166 Cable , 7X-1700
Communication Adapter , 7X-1425 Cable , and a NEXG4523 Service Program Module.
2. In order to power the electrical system of the truck, perform the steps that follow:
a. Connect the batteries.
b. Turn the battery disconnect switch ON.
c. Turn the manual engine shutdown switch OFF.
d. Turn the key of the machine ON.
e. DO NOT START THE TRUCK.
Note: When the key is in the "ON" position, the VIMS will perform a four to six second self
test. Disregard the VIMS self test at this time.
3. Start the Electronic Technician (ET). The Electronic Technician (ET) lists all of the electronic
control modules for the machine. There will be at least an "ENGINE CONTROL", "POWER
TRAIN CONTROL" and a "BRAKE CONTROL". If the truck has the Automatic Retarder
Control (ARC), the ET screen should show the features.
4. The Electronic Technician (ET) should display the truck model for each control. Make sure
that the model is correct for each control.
5. Choose the "ENGINE CONTROL". Next, choose "CONFIGURATION".
6. Change the EQUIPMENT ID NUMBER in order to correspond to the PIN of the truck. If you
select a new setting, select "ENTER". This confirms the change.
7. Check the "ENGINE SERIAL NUMBER". The "ENGINE SERIAL NUMBER" must match
the engine serial number on the engine. If you select a new setting, select "ENTER". This
confirms the change.
8. Adjust the "FUEL RATIO CONTROL", if necessary. The air/fuel ratio is adjustable. The
range is -25 to 25. The factory default is 0. If you select a new setting, select "ENTER". This
9. Check the "ETHER CONTROL" setting. Set the "ETHER CONTROL" to the "ON" position.
If you select a new setting, select "ENTER". This confirms the change.
10. On a truck that is equipped with the oil renewal attachment, the "OIL RENEWAL
CONTROL" must be set to "ON". After you set the engine oil renewal solenoid to "ON", the
"OIL TO FUEL" ratio must be set to "ON". After you set the engine oil renewal solenoid to
"ON", the "OIL TO FUEL" ratio should be set. The "OIL TO FUEL" is adjustable in a range
from -50 to 50. The factory default is 10. If you select a new setting, select "ENTER". This
11. Check the "ENGINE OIL PRE-LUBE" setting. On a truck that is equipped with the engine
pre-lube attachment, "ENGINE OIL PRE-LUBE" must be ON. If you select a new setting,
select "ENTER". This confirms the change.
12. Check the "COOL CYLINDER CUT-OUT". If you select a new setting, select "ENTER".
This confirms the change.
13. Check the "SHUTTER CONTROL" setting. On a truck that is equipped with an attachment
shutter, "SHUTTER CONTROL" must be ON.
14. Return to the engine control screen. Select "ACTIVE CODES". Select the "INCLUDE ALL
ECM'S" button. The button is at the bottom of the screen. If "NO ACTIVE CODES" appears,
then continue. Refer to Service Manual, RENR2630, "Vital Information Management System
(VIMS)". This will help to resolve the active faults.
Note: A factory assigned password clears events that are logged on the engine ECM. This is
the only way to clear the events from the engine ECM.
15. Return to the engine control screen and select "LOGGED CODES". Select the button at the
bottom of the screen "INCLUDE ALL ECM'S". Clear all codes that are logged. Refer to
Service Manual, RENR2630, "Vital Information Management System (VIMS)".
16. Return to the engine control screen and select "DIAGNOSTICS" and "EVENTS". Select the
button at the bottom of the screen "INCLUDE ALL ECM'S". Clear all of the codes that are
logged. Refer to Service Manual, RENR2630, "Vital Information Management System
(VIMS)".
Note: A factory assigned password clears events that are logged on the engine ECM. This is
the only way to clear the events from the engine ECM.
17. Return to the engine control screen and select "SERVICE", "CALIBRATIONS", and
"INJECTOR CODES CALIBRATION". Select "PRINT" at the bottom of the screen. Select a
print destination.
Note: Step 21 provides a record of the injector code for each cylinder. The codes may
accidentally change. The injector codes are stamped on the injector. If an injector is changed,
the new injector code must be updated in the engine ECM.
18. The engine prelube and the ether control can be tested without starting the engine. The engine
prelube and the ether control can be tested.
a. Return to the engine control screen and select "DIAGNOSTICS" and "OVERRIDE
PARAMETERS". Select "START AID" and "CHANGE". The ether solenoids will
energize. Select "CHANGE" again. Turn the feature "OFF".
b. Return to the engine control screen and select "DIAGNOSTICS" and "OVERRIDE
PARAMETERS". Select "ENGINE PRELUBE" and "CHANGE". The prelube motor
will energize. Select "CHANGE" again. The prelube motor will de-energize.
19. Return to the ET menu. Select "DATA LINK", "SELECT ECM", "POWER TRAIN
CONTROL", and "CONFIGURATION". On the configuration screen, check and adjust the
following parameters. Refer to Testing and Adjusting, Troubleshooting, RENR2631, "Off-
Highway Truck/Tractors Vital Information Management System (VIMS)".
a. The "EQUIPMENT NUMBER" and the customer number should match. Make the
changes to the numbers, as needed. If you select a new setting, select "ENTER". This
b. Check the "TRANSMISSION SERIAL NUMBER". "TRANSMISSION SERIAL

NUMBER" should match the transmission serial number on the transmission. If you
c. Check the "TRANSMISSION MAXIMUM GEAR" setting. The transmission maximum

gear setting is adjustable from four to six. If you select a new setting, select "ENTER".
This confirms the change.
d. Check the "BODY UP GEAR LIMIT" setting. The body up gear limit is adjustable from
one to four. If you select a new setting, select "ENTER". This confirms the change.
20. Return to the Electronic Technician screen. Select "DATA LINK", "SELECT ECM",
"BRAKES", "AUTO RETARDER", and" CONFIGURATION". From the configuration
screen, check and adjust the following parameters. Refer to Testing and Adjusting,
Troubleshooting, RENR2631, "Off-Highway Truck/Tractors Vital Information Management
System (VIMS)".
b. Check the "TRANSMISSION SERIAL NUMBER". The "TRANSMISSION SERIAL

NUMBER" should match the transmission serial number on the transmission. If you
c. Check the "TRANSMISSION MAXIMUM GEAR" setting. The maximum transmission

gear selection is adjustable from four to six. If you select a new setting, select
"ENTER". This confirms the change.
d. Check the "BODY UP GEAR LIMIT" setting. The body up gear limit is adjustable from
one to four. If you select a new setting, select "ENTER". This confirms the change.
21. Return to the Electronic Technician screen. Select "DATA LINK", "SELECT ECM",
"BRAKES", "AUTO RETARDER", and "CONFIGURATION". From the configuration
screen, check and adjust the following parameters. Refer to Testing and Adjusting,
Troubleshooting, RENR2631, "Off-Highway Truck/Tractors Vital Information Management
System (VIMS)".
b. Check the "DESIRED ENGINE AUTO RETARDER SPEED". The engine automatic
retarder speed that is desired is adjustable from 1850 RPM to 1950 RPM. If you select a
new setting, select "ENTER". This confirms the change.
c. Use the VIMS keypad module. Enter "8378" and press "OK". This will initiate the
"VIMS SELF TEST". Refer to "VIMS Self Test" in the Operations and Maintenance
Manual.
d. With the laptop computer that is connected to the diagnostic port, continue to the next
step. Use the laptop computer again after the engine has been started.
Prepare to Start the Engine
1. Verify that the fluid levels are at a safe level.
2. Disable the engine at ground level. The engine should be shut off, so the engine will not start.
3. Prime the pump drive housing and the hoist pump with 3P-0659 Oil or crank the engine.
Crank the engine over two times for 15 seconds, while the engine is locked out. This will fill
the compartments with oil.
4. Start the engine. Verify that the pressures are safe for operation. Run the engine until normal
operation temperatures are reached. All the fluid levels should be adjusted, as required. Run
the engine for 5 seconds for the first two starts. Check and fill the hydraulic transmission, the
steering, the radiator, and the engine, as needed. Restart the engine and check for leaks. Run
the engine for 30 seconds and then run the engine for 60 seconds. Check the ground for leaks.
5. Refer to Service Manual, RENR2630, "Vital Information Management System (VIMS)" for
additional information. There are three levels of warnings. Level 1 is one red light. Level 2 is
two red lights ON. Level 3 is two red lights ON and the alarm sounds.
{ The coolant temperature is 2.
{ The coolant flow is 3.
{ The engine oil pressure is 3.
{ The brake air pressure is 3.
{ The transmission oil filter is 2.
{ The converter or return oil temperature is 2.
{ The brake ON is 1 or 3.
{ The alternator is 1.
{ The fuel level is 1 with a 10 second delay.
{ The steering is 3.
6. Disconnect the cable, the adapter, and the module that is running the Electronic Technician
(ET) from the laptop computer. Connect a 127-9797 Cable to the RS-232 port on the laptop
computer. Connect the other end of the 127-9797 Cable to the diagnostic port in the panel
behind the operator's seat. Observe the gauges, the warning lights, and the service lights with
the laptop computer during the truck operation.
7. The low brake pressure indicator causes the alert indicator to flash. The VIMS Message Center
should provide the following instruction: "Do Not Move Machine". This message is on display
until the starting and service reservoir is charged to one-half of the maximum operating
pressure. Do not turn off the parking brake switch before the pressure is attained. The warning
horn will sound.
8. Take notes on all of the events that are recorded on the message center. Resolve the events
before you proceed.
9. Start VIMS-PC software. Use VIMS-PC software to clear all faults that are logged on VIMS
memory.
Note: The logged events cannot be cleared when you are using the VIMS Keypad module.
10. Select "VIMS-PC COMMUNICATE" from the "VIMS-PC" group. Refer to Service Manual,
RENR2630, "Vital Information Management System (VIMS)", "Downloading Data From The
Machine".
11. Select "DATA" and "DOWNLOAD DATA". Choose a destination and select "STANDARD
DATA". Then select "OK".
Note: Remove faults that are logged on the VIMS memory.
12. The yellow light should activate when the retarder is engaged.
13. The engine should be at normal operation temperature and the transmission should be in
neutral. Check the "HIGH" idle speeds (1960 ± 40 RPM) and the LOW idle speeds (700 ± 15
RPM). The RPM ranges cannot be changed.
Note: After the engine has been started, the automatic elevated low idle will activate in ten
minutes. The low idle comes up gradually at the rate of 33 RPM per second. The transmission
should be in "NEUTRAL" and the parking brake should be ON. Do NOT depress the pedal for
engagement.
Note: After the activation of the elevated idle speed, the operator may reset the 10 minute
delay by tapping the throttle pedal to more than 25% of the pedal's travel. If the coolant
temperature rises above 70 °C (158 °F) engine speed returns to low idle.
14. Push the ground level shutdown switch. This shuts down the engine. The steering accumulator
tanks will not drain. Wait for 5 seconds. Turn the key to the off position. Listen for the tanks to
drain. The steering accumulator pressure drops to zero before you start the truck.
At operating temperature, the steering oil is hot and under pressure.

Hot oil can cause burns.
To prevent possible personal injury, release the pressure in the steering

system before the lines are disconnected or removed.
15. Bring the air pressure governor to the proper level for a maximum pressure of 827 ± 34 kPa
(120 ± 5 psi). Purge the air pressure to 455 kPa (66 psi). A Level III warning should occur at a
pressure of 455 kPa (66 psi).
16. Check the air dryer. The air dryer should expel air at 827 kPa (120 psi).
17. The dryer should have 24 Volts or more.
18. The hoist pressure for the 793C (S/N: ATY1-UP) is 20,720 ± 350 kPa (3005 ± 51 psi).
Note: The power down pressure for the 793C (S/N: ATY1-UP) is 3625 ± 175 kPa (525 ± 25
psi) at high idle. The system should recover to full pressure within 1 second.
19. Check the hoist pressure. Hoist pressure occurs when the system powers up and when the
system powers down. When the system is in the middle detent the system pressure is zero.
20. The transmission does not shift into reverse with the hoist lever that is raised. The truck must
be shifted to the forward gears with the hoist lever that is raised.
21. The cut-in pressure is 19200 ± 200 kPa (2785 ± 29 psi).
22. The cut out pressure is 21400 ± 200 kPa (3104 ± 29 psi).
23. The maximum standby pressure is 3600 kPa (522 psi).
24. The lube oil pressure for the transmission in NEUTRAL at LOW idle is 5 kPa (0.73 psi) to 65
kPa (9 psi). The lube oil pressure for the transmission in NEUTRAL at HIGH idle is 115 kPa
(17 psi) to 210 kPa (30 psi).
25. The minimum charge oil pressure for the transmission in LOW idle is 2480 kPa (360 psi). The
maximum charge oil pressure for the transmission in HIGH idle is 3203 kPa (465 psi).
26. The torque converter pressure at lockup is 2136 ± 69 kPa (310 ± 10 psi) at 1300 RPM.
27. The maximum pressure for the torque converter outlet is 551 kPa (80 psi) at high idle.
28. As the shift cane moves through each gear, the indicator will flash the correct gear. As the
gears shift the engine speed increases. This indicates that the throttle control shifting chip is
programmed.
29. Properly control the throttle shifting through all of the gears. As you shift up and down the
brakes must be off.
30. Check the downshift inhibitor. At HIGH idle, shift the transmission from sixth gear through all
of the gears to first gear. The transmission should not downshift.
31. Check the reverse shift inhibitor. With the transmission in first gear and travel speed at 10
mph, shift the shift cane into reverse. The transmission will shift into NEUTRAL. The
transmission will shift into reverse at 3 mph.
32. Check the transmission neutralizer switch. The engine will start in neutral only. Try to start the
engine in first gear and reverse.
33. With the engine that is turned off, shut the cab doors and windows. Engage the retarder and
apply the secondary brake and the foot brake. Listen for air leaks. Watch the air gauge for a
drop after the initial drop from the brake engagements. The pressure should remain at 3.5 kPa
(0.51 psi) per minute. Hold the engagement for 3 minutes. The maximum drop in air pressure
is 10 kPa (1.45 psi).
34. Test the air system overnight. Leave the truck shut down overnight. The air tank should
contain 827 kPa (120 psi). The air tank should contain enough air. The engine should start the
next morning. The truck requires 518 kPa (75 psi) to start the engine.
35. Check the pressure for the AETA control. There should be 2482 kPa (360 psi) to 4895 kPa
(710 psi).
Note: When both the retarder and the AETA switch are on, the pressure drops off. The
pressure drops off first on the left. The pressure then drops off on the right.
36. The parking brake indicator must flash when the parking brake is engaged.
37. A Level iii warning will activate when all of the following conditions are true.
{ The engine is running.
{ The transmission is in forward or reverse.
{ The parking brake is ON.
Note: Trucks that are operating with a VIMS system need ground speed to activate the
warning.
38. The parking brake warning light flashes when the secondary brake is engaged. A Level iii
warning will activate when the following conditions are true:
{ The engine is running.
{ The transmission is in forward or reverse.
{ The parking brake is ON.
Note: Trucks that are operating with a VIMS system need ground speed to activate the
warning.
39. Check the towing motor. The motor should have a minimum of 3790 kPa (550 psi).
40. The current draw of the towing motor should be 12 to 22 amperes at high pressure.
41. The brake retract pressure is 4685 ± 207 kPa (680 ± 30 psi).
Activate the Body Hoist Controls
The truck might appear to have a problem with the body hoist controls. The 184-4671 Software
Group will set the parameters for the hoist system.
Note: ET Software must be used to set these parameters on all trucks.
Note: On the 2.4 ET Software, when the parameters are not visible or accessible on the configuration
screen, disconnect the connection and reconnect the connection. This establishes the communication
to the transmission control, until the parameters appear.
Note: On the 3.0 ET Software, the parameters appear clearly on the configuration screen.
Note: On the 3.1 ET Software, the figures will appear on the configuration.
Adjustment of the Hoist Lower Valve
Lowering the hoist is adjustable. This compensates for the differences in valves. The adjustment
range is -5 to +5 with zero as the default. A positive adjustment factor will increase the lower valve
command. This causes the body to come down harder. A negative adjustment factor will decrease
the lower valve command. This causes the body to come down softer.
The adjustment of the Hoist Lower Valve may not be available on earlier ECM systems. The
adjustment range may be from 0 to 10 with 5 as the default on some early ECM systems.
Note: When the Hoist Lower Valve is adjusted too high, too much oil can be diverted to the hoist
system. If the hoist system is in the float mode, the brake oil heats up faster. Retarding capability is
also decreased. To set the Hoist Lower Valve, follow the procedure below.
1. Raise the truck body. Place the pins of the body.
2. Place a 6V-7830 Tetragauge or place a 3.45 MPa (500 psi) gauge with a hose extension on the
outlet port of the hoist pump.
Note: Remove the body pins and lower the body to the frame.
3. While the body is down, place the hoist lever in hold.
4. Enter the configure parameter screen through the service menu in the Electronic Technician.
5. Adjust the Hoist Lower Valve to a desired setting. The procedure begins at 0. Adjust the
settings in increments of 1 in the positive position or in the negative position.
Note: If you are using a 3.45 MPa (500 psi) gauge, remove the gauge from the extension.
6. Raise the body to the middle position.
7. Lower the body to the frame.
8. If a 6V-7830 Tetragauge is not installed, shut off the engine and install a 3.45 MPa (500 psi)
gauge. Start the engine and run the engine to high idle. Cycle the hoist lever to the body float
position and the hold position. Do not power down or raise the bed if you are using a 3.45
MPa (500 psi) gauge. Damage may occur to the gauge.
9. With the engine that is running, place the hoist lever in the body float position.
10. Run the engine to high idle. Verify that the pressure at the hoist outlet port is less than 1723
kPa (250 psi).
Note: When the pressure is greater than 1724 kPa (250 psi), the adjustment is set too high. This
causes too much oil to be diverted to the hoist valve. This causes the brake oil to overheat when the
body is in the body float position. Lower the adjustment of the Hoist Lower Valve. Repeat Step 1
through Step 3. This lowers the pressure below 1724 kPa (250 psi).
Note: The pressure can be checked after each resetting of the adjustment in ET. Cycle the hoist lever
from the hold position to the body float position. If you change the adjustment setting and there is no
corresponding pressure setting, cycle the lever again. A change will occur in the settings between 2
and 5.
Enable the Hoist System
The Hoist Enable Parameter is set to 2 on all trucks with the 184-4671 Software Group . Parameter
Value 2 is a test mode. Parameter Value 2 will prevent the hoist cylinders from being activated by
accident. After the body is installed, change the Parameter Value to 1. The hoist system should
function properly. When the hoist system does not work, check the items below.
1. Verify that the hoist system is enabled in the Configurable Parameters Screen through the
service menu in the Electronic Technician.
Table 86
Parameter Settings of the Hoist

Parameter
Description
Value
The hoist system is not installed.
0 a hoist lever that will not function
No diagnostics will be logged on the hoist lever or on the solenoids.
1 The hoist system is installed and enabled.
The hoist system is installed but disabled.
2 The solenoids and the hoist lever have diagnostics, but the hoist lever is
ignored. The solenoids are kept in hold.
2. Disconnect the ET. Reconnect the line when the Hoist Enable Status does not appear on the
configuration screen. The hoist enable parameter flexes with the 3.0 ET Software when the
parameter connects. Occasionally, the ET will miss the flexed parameters when the connection
is made.
Note: This parameter is standard on the configuration screen with 3.1 ET Software.
3. If the Hoist Enable Status does not change, check the following conditions:
{ The engine should not be running.
{ The truck should not be moving.
{ Zero the TOS in order to change the parameter.
{ The engine causes the TOS signal to fluctuate. This keeps the parameter from changing.
Note: Press the "F5" button in order to go directly to the configuration screen.
Body Down Snub Function
The body down snub function cushions the shock when the body hits the bed of the truck. When the
body is lowered, the body up switch detects the position of the body. When the body is close to the
rail of the truck, the ECM will go into snub mode.
When the operator's request is less than the snub mode, the ECM will use the operator's request. This
ensures that the snub function will never cause the body to go down faster than the hoist lever
modulation (operator's request).
The body snub function will be cancelled as the operator moves the hoist lever out of the body float
position or the body lower position. The body snub function will not start, until the body goes above
the body up switch activation level.
Seat Controls
1. Check the following adjustments:
{ The distance from the front of the seat to the rear of the seat is 150 mm (6 inch).
{ The height is 75 mm (3 inch).
{ Adjust the weight for the suspension to the correct ride position.
{ The seat cushion has two positions.
{ The back cushion has three positions.
Seat Belt
1. Adjust the seat belt to the proper length.
2. Fasten the seat belt buckle around the lap. The length of the belt may not slip.
3. The belt should unlatch.
Instrument Panel
1. Turn the ignition key to ON. This supplies the power to the electrical circuits in the cab. The
dome lights and the windshield wipers can be checked.
1. Turn the key to START. This activates the starting motor. The diesel engine starts. After the
engine starts, release the key. The key will return to ON.
2. Turn the ignition switch to OFF. The engine should stop. The electrical circuits in the cab
should de-energize. The instrument panel lights, the headlights, and the taillights remain on.
Climate Control
1. To pressurize the cab, complete the following steps:
{ Turn the ignition key to ON.
{ Turn the switch for the blower to LOW.
{ Turn the blower switch to HIGH.
{ There should be an audible sound.
2. Check the heater:
{ Start the engine.
{ The lines for the heater valves should be open.
{ Turn on the heat control. The air should be warm.
3. To check for air flow, perform the following steps:
{ Turn the fan control switch to LOW or to HIGH.
{ Check for air flow from the dash assembly and from the seat supports.
Windshield Wipers
1. Turn the ignition key to ON. Turn the wiper switch to the three positions. The three positions
are OFF, LOW, and HIGH. The front wipers and the rear wipers must operate in both modes.
2. Depress the wiper switches. This will activate the windshield washers.
3. Turn the switches to OFF. The front wiper arms and the rear wiper arms should return to the
proper position.
Running Lights
1. The ignition switch should be OFF. Push the three position switch from OFF to the middle
position. The instrument panel lights and the taillights should be on.
2. Push the switch to the up position. The front headlights should be on.
Flood Lights
1. Turn the ignition key to ON.
2. Push the switch from OFF to ON. The floodlights should be on.
Flood Lights (Auxiliary)
1. Turn the ignition key to the OFF position. Push the switch for the access ladder to the opposite
direction. The lamps for the access ladder should be on.
Check the switches in the cab and at ground level.
2. Push the switch for the engine compartment at ground level. The switch is in the bumper
assembly. The lamps in the engine compartment should be on.
Dome Lights
2. Turn the switch for the dome light ON and OFF.
Cigar Lighter
2. Push the cigar lighter inward. The cigar lighter should pop out.
Machine Horns
The ignition switch should be in the OFF position. Press the horn. The horn should sound.
Machine Operation
1. Operate the machine for a minimum of 15 minutes. Operate the machine in all gears and
perform steering maneuvers. Perform braking operations. Operate the implement systems
while you are operating the truck.
2. Correct any problems:
{ Harsh Braking
{ Jerky steering
{ Unusual noises
Parking Brake Release Oil Filter
The truck comes from the factory with a 132-8875 Oil Filter Element Assembly . The 132-8875 Oil
Filter Element Assembly is located on the inside of the 8E-0769 Oil Filter . The 8E-0769 Oil Filter
is located in front of the hydraulic tank on the right hand side of the machine. Install a 1R-0773 Oil
Filter Element Assembly after the clean up period.
Front Brake Cooling Oil Filters
The truck comes from the factory with four 132-8876 Oil Filter Element Assemblies . The 132-8876
Oil Filter Element Assemblies are located on the inside of the 125-6712 Oil Filters . The 125-6712
Oil Filters are located in front of the fuel tank on the left hand side of the machine. Install four 1R-
0778 Oil Filter Element Assemblies after the clean up period.
Rear Axle Oil Filter
The truck comes from the factory with a 1R-0773 Oil Filter Element Assembly . The 1R-0773 Oil
Filter Element Assembly is located on the inside of the 132-2820 Oil Filter . The 132-2820 Oil Filter
is mounted on the rear differential. Install a 1R-0773 Oil Filter Element Assembly after the clean up
period.
Torque Converter Oil Filter
The truck comes from the factory with two 132-8876 Oil Filter Element Assemblies . The 132-8876
Oil Filter Element Assemblies are located on the inside of the 196-6957 Oil Filter . The 196-6957
Oil Filter is located in front of the hydraulic tank on the right hand side of the machine. Install two
new 132-8876 Oil Filter Element Assemblies after the clean up period.
Transmission Oil Filter
The truck comes from the factory with two 132-8876 Oil Filter Element Assemblies . The 132-8876
Oil Filter Element Assemblies are located on the inside of the 199-3389 Oil Filter . The 199-3389
Oil Filter is located behind the fuel tank and left of the torque converter. Install two new 132-8876
Oil Filter Element Assemblies after the clean up period.
Steering System Oil Filter
The truck comes from the factory with 139-1536 Oil Filter Element Assembly . The 139-1536 Oil
Filter Element Assembly is located on the inside of the 132-6285 Steering Tank and Filter . The 132-
6285 Steering Tank and Filter is on the right hand platform. Install 1R-0774 Oil Filter Element
Assembly after the clean up period.
Steering Pump Case Drain Filter
The truck comes from the factory with 4T-6915 Oil Filter . The 4T-6915 Oil Filter is located on the
inside of the 6E-2575 Oil Filter . The 6E-2575 Oil Filter is mounted to the front of the steering
hydraulic tank. The steering hydraulic tank is located on the right hand platform. Install a new 4T-
6915 Oil Filter after the clean up period.
Checks Before the Delivery of the 793D Off-Highway Truck
The page that is following is a list of assembly checks and systems checks that are recommended. Do
this checklist before the truck is delivered to the customer. Do all of the checks and verify that the
systems function properly.
Refer to the Air System and Brakes Testing and Adjusting, "Service Brake Discs – Check". Also,
refer to Guideline for Reusable Parts and Salvage, SEBF8095, "Service Brakes for Off-Highway
Trucks and Tractors" in order to determine the service intervals. Record all data in the Air System
and Brakes Testing and Adjusting, "Worksheets".
Use the Service Manual and use the Operation and Maintenance Manual in order to correct any
system problems before you deliver the truck.
After you complete the final check, please sign your name and the name of the dealer.
Make copies of the check procedure. Mail the copies to the following address:
Caterpillar Inc.
Attention: MCE Product Support
793C Off-Highway Truck
N. 27th and Pershing Road
Decatur, IL 62525
Dealer:____________________
Customer:____________________
Product Identification Number:____________________
1. Before you start the engine, make sure that all fluid compartments are full. Also, make sure
that all pump case drains are full.
2. Check that the system pressures are set correctly.
{ Pump
{ YES ____ NO ____
{ Brake
{ YES ____ NO ____
{ Steering Pressure
{ YES ____ NO ____
{ Transmission
{ YES ____ NO ____
{ Torque Converter
{ YES ____ NO ____
{ Differential
{ YES ____ NO ____
3. Check the machine lights.
{ Operational
{ YES ____ NO ____
{ Cab and Dash
{ YES ____ NO ____
4. Check the controls in the cab.
{ Check if the cab door opens. Check if the cab door closes.
{ YES ____ NO ____
{ Check if the Operation and Maintenance Manual is in the literature pouch on the back of
the operator's seat.
{ YES ____ NO ____
{ Check if the horn functions.
{ YES ____ NO ____
{ Check if the windshield wipers and washers function.
{ YES ____ NO ____
{ Check if the seat belts operate.
{ YES ____ NO ____
{ Check if the fan switch operates.
{ YES ____ NO ____
{ Check if the heater functions.
{ YES ____ NO ____
{ Check if the air conditioner functions.
{ YES ____ NO ____
{ Check the test light. The test light is for the EMS.
{ YES ____ NO____
{ Check if the hour meter operates.
{ YES ____ NO ____
{ Check if the implements operate:
{ Hoist
{ YES ____ NO ____
{ Steering Action
{ YES ____ NO ____
{ Check if the steering column functions.
{ YES ____ NO ____
{ Check if the parking brake functions.
{ YES ____ NO ____
5. Check if all fluid levels are full.
{ YES ____ NO ____
6. Correct any unusual noises or unusual leaks.
{ YES ____ NO ____
7. Check if all lubrication lines are filled with grease.
{ YES ____ NO ____
8. Check if all quality requirements are fulfilled. Check if all variances have been corrected.
{ YES ____ NO ____
9. Check if the backup alarms function.
{ YES ____ NO ____
10. Check if the machine is repainted to the factory specifications.
{ YES ____ NO ____
11. Check if there was damage to the machine from shipment.
{ YES ____ NO ____
12. Check if all required parts were shipped with the machine.
{ YES ____ NO ____
13. Sign your name in the space below.
{ Hydraulic
{
{ Electrical
{
{ Structural
{
{ Other
14. Comments
Predelivery Worksheet
Table 87
Date Personal Identification Model Serial Number Hours Inspector Name

Number
Note: All safety product improvement programs (PIP) must be completed.
Table 88
Visual Service Points and

Operation Engine Off
Inspection Fluid Levels
_ Air Cleaner
_ Oil Indicator
_ Coolant _ V-Belt Tension
_ Fuel _ Priming Pump
_ Two Batteries _ Governor _ Oil, Air, Fuel,
_ Air Filters Control or Coolant Leaks
_ Paint _ Drain the water _ Air Compressor _ Friction on
Engine (1) (2) _ Outside from the fuel tank. Hoses
Damage _ Drain the Water _ Color of _ Friction on
from the Separator. Exhaust Wires
_ Open the Coolant _ Unusual Noise _ Loose Wire
conditioner Valves. Connections
_ Fasteners that
_ Grease Fittings are Loose or
Missing
_ Transmission
_ Differential _ Each Gear in
_ Final Drives the Transmission
_ Tire Pressure _ Neutral Start
_ Paint _ Oil Leaks
_ Grease Fittings _ Transmission
_ Outside _ Fasteners that
_ Bolt Torques for Lever Lock
Damage are Loose or
Power Train the Front and Rear _ Back Up Alarm
_ Cuts or Missing
Axle
Gouges in _ Cuts or Gouges
_ Torques for the _ Neutralizer
Tires in the Tires
Front and Rear Valve
Universal Joints _ Unusual Noise
_ Torques for the
Wheel to Rim
_ Steering
_ Retarder _ Oil or Air
_ Brake Fluid
_ Paint _ Service Brakes Leaks
Steering and _ Moisture in the
_ Outside _ Parking Brakes _ Fasteners that
Brakes Air Tank
Damage _ Air Dryer are Loose or
_ Grease Fittings
_ Unusual Noise Missing
_ Fasteners that
_ Sheet Metal _ Locks and
are Loose or
Chassis _ Paint _ Grease Fittings Latches on Doors
Missing
_ Damage
_ Welds
_ Controls
_ Too much Drift _ Oil Leaks
_ Friction or Lost
_ Cylinder _ Hydraulic Tank
Hydraulic _ Unusual Noise Fasteners
Rods _ Grease Fittings
_ Welds
_ Grease Fittings
_ Paint _ Fasteners that
_ Body Pads _ Positions of the
Truck Body _ Damage are Loose or
_ Retention for the Body
_ Liners Missing
Cable
_ Damage
_ Disconnect
Switch
_ VIMS
_ Hoist Control
_ Horn
_Seat Belts
_ Seat
Adjustments
_ Controls and all
_ Operation
Switches
Guide
_ Doors and
_ Maintenance
Windows
Guide
_ Locks and
_ Windshield _ Parts Book
Latches
Washer _ Seat Cover
_ Sheet Metal _ Adjustment of
_ Air Filters _ Handrail and
Cab _ Paint the Mirrors
_ Grease Fittings Steps
_ Glass _ windshield
_ Torque on ROPS _ Fasteners that
Wipers
are Loose or
_ Windshield
Missing
Washers
_ Loose Wire
_ Heater
Connections
_ Pressure of Air
_ Water Leaks
Conditioner
System
Outside Lights
and Cab Lights
_ Gauges
_ Unusual Noise
_ Steering
Column
Adjustment
_ Special Parts _ Fluid Level
_ Attachments
for Assembly Attachments _ Warning Plates
_ Engine
_ Serial _ Fire Suppression _ Decals
Shutdown Switch
Miscellaneous Number Plates System _ Leaks
Attachments _ Correct _ Grease Fittings _ Fasteners that
_ Switch for the
Attachments _ Automatic are Loose or
Fire Suppression
_ Hand Tools Lubrication System missing
_ Paint
(1) Machines that are in storage need pressurized lubrication in the engine before starting.
(2) For cold weather operation, refer to Operation and Maintenance Manual, 5338.
Copyright 1993 - 2006 Caterpillar Inc. Mon Nov 6 10:44:15 UTC-0400 2006
All Rights Reserved.
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793D Off-Highway Truck FDB00001-UP (MACHINE) POWERED BY 3516B En...

Assembly Procedure For the 793D Off-Highway Truck{7960}

Note: The photographs in this publication are for illustrative purposes.

ReferenceOperation and Maintenance Manual, SEBU7792, "793D (S/N: FDB1-UP) Off-Highway

ReferenceParts Manual, SEBP3976, "793D (S/N: FDB1-UP) Off-Highway Trucks"

ReferenceSpecial Instruction, SMHS7867, "Use of 6V-4040 Inflation Group "

ReferenceOperation and Maintenance Manual, SEBU5898, "Cold Weather Recommendations for

ReferenceService Manual, RENR2630, "784C, 785C, 789C, 793C, 797 Off-Highway

ReferenceTesting and Adjusting, Troubleshooting, RENR2631, "Off-Highway Truck/Tractors Vital

Improper assembly procedures could result in injury or death.

8 2N-2486 Bolt (1)

Parts that are Required to Install the 193-6213 Automatic Lubrication Gp

Qty Part Number Description

Parts that are required to install the 9C-4937 Breather As (Rear)

Qty Part Number Description

Qty Part Number Description

Qty Part Number Description

Parts that are Required to Install the 8X-2837 Walkway

2 248-2221 (1) Handhold As

Qty Part Number Description

1 242-9538 Handhold As (3)

1 242-9815 Handhold As (4)

Parts that are Required to Install the 193-6310 Fender Gp

Parts that are Required to Install the 240-4794 Handhold Gp

Qty Part Number Description

Qty Part Number Description

1 7W-5300 Fuel Heater

Parts that are Required to Install the 151-8730 Steering Lines Gp

Parts that are Required to Install the 163-7226 Cab Mounting

Parts that are required to install the 240-4798 Walkway Gp

Parts that are Required to Install the 240-2780 Muffler Gp

Parts that are Required to Install the 193-6252 Platform Mounting Gp

Parts that are Required to Install the 8X-4180 Hood Latch Gp

1 8X-4425 Bracket Assembly

Parts that are Required to Install the 240-2784 Air Cleaner Gp

Parts that are Required to Install the 193-6262 Rim Mounting Gp

6 5T-9790 Tire Valve

Parts that are Required to Install the Odometer (If equipped)

Qty Part Number Description

Parts that are Required to Install the 240-4782 Exhaust Pipe Gp

Parts that are Required to Install the 168-9897 Ladder Lighting

1 8T-4122 Hard Washer

Parts that are Required to Install the 8X-3380 Cylinder Mounting Gp

Parts that are Required to Install the 251-4831 Film Gp

Qty Part Number Description

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

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

Approximate weights of the components are shown. Clean all surfaces

Truck frame module without rear axle housing (1)

Rear axle housing with final drives

Front suspension cylinder, wheel and brake assembly

Body pivot pin

Fuel tank (2)

Right side platform assembly

Body (center) with liners

Tail extension assembly

Cab with catwalks and handholds

Completed body without liners (4)

Ground to top of canopy

Ground to upper edge of body

Width of body assembly

Width of truck frame at rear tires

Specifications for Cables, Chains, and Lifting Devices

Lift angles for lifting slings.