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2021/06/09 Assembly Procedure For The 793D Off-Highway Truck {7000, 7006, 7960} (REHS2210-22)
Revision History:
Revision Summary of Changes
22 Changes have been made to "Install the Truck Body" section.
21 Changes have been made to "Install the Air Hoses and Install the Electrical Connection for the Cab" section.
Table 1
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.
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.
Reference: Operation and Maintenance Manual, SEBU7792, "793D (S/N: FDB1-UP) Off-Highway Trucks"
Reference: Service Magazine, SEPD0531, 3, July 2000, "Fabric Slings and Protective Sleeves Are Available for Lifting Truck Bodies"
Reference: Operation and Maintenance Manual, SEBU5898, "Cold-Weather Recommendations for Caterpillar Machine"
Reference: Service Manual, RENR2630, "784C, 785C, 789C, 793C, 797 Off-Highway Truck/Tractors Vital Information Management System
(VIMS)"
Reference: Testing and Adjusting, Troubleshooting, RENR2631, "Off-Highway Truck/Tractors Vital Information Management System (VIMS)"
Reference: Testing and Adjusting, SENR1502, "784C, 785C, 785D, 789C, 793C, and 793D Off-Highway Truck/Tractors Power Train Electronic
Control System"
Do not attempt to assemble this machine until you read and you
understand the assembly instructions.
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. Preparation is shown in the Operations and Maintenance Manual. Use the Parts Manual and the Service Manual with
this special instruction.
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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 for a
good solid joint.
Parts List
Reference: Service Parts, PECP9067, "One Safe Source"
Table 2
(1)
(2) Part of 384-0740 Axle Housing Support Gp
(3) 8X-0433 Slip Joint and 2N-2486 Bolt are part of 8X-0249 Drive Shaft.
Part of 246-6747 Rear Suspension Gp
Parts that are Required to Connect the Rear Supply Oil Cooler Lines Group
Qty Part Number Description
1 241-5837 Hose As
4 8T-4193 Bolt
4 9X-8257 Washer
2 1P-7016 Half Flange
1 3E-6773 O-Ring Seal
Table 3
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Table 4
Table 5
Parts that are Required to Hydraulic Lines to the Tank on the Right-Hand Platform
Qty Part Number Description
1 250-0555 Hose As(1)
2 1P-4582 Half Flange
4 8T-4956 Bolt
4 8T-4223 Hard Washer
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(2)
1 252-7156 Hose As(2)
Table 6
(1)
(2) Part of 193-6296 Hydraulic Oil Lines Gp
Part of 193-6276 Hydraulic Fan Lines Gp
Parts that are Required to Connect the Brake Lines Groups to the Rear Axle Housing
Qty Part Number Description
1 213-9807 Hose As
1 8X-6161 Hose As
2 8T-4956 Bolt
2 8T-4223 Hard Washer
1 7G-3833 Clip
1 7G-3834 Clip
1 7G-3832 Grommet
1 8X-6169 Hose As
Table 7
Parts that are Required to Connect the Power Train Oil Lines Group
Qty Part Number Description
1 8X-4094 Block
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4 6M-9149 Bolt
4 7X-0591 Hard Washer
1 124-1859 O-Ring Seal
2 1P-4584 Half Flange
8 8T-4223 Hard Washer
4 8T-4184 Bolt
1 8T-0568 O-Ring Seal
1 128-0931 Adapter
1 6V-4590 O-Ring Seal
4 6J-2515 Bolt
2 197-3295 Half Flange
4 8T-4183 Bolt
1 191-2962 O-Ring Seal
Table 8
Parts that are Required to Install the Rear Axle Oil Cooler Group
Qty Part Number Description
1 320-1516 Hose As
1 320-1541 Hose As
Table 9
Parts that are Required to Install the Power Train Cooler Lines Group
Qty Part Number Description
1 113-6365 Hose As
1 8X-8886(1) Hose As
1 243-1293 Hose As
1 371-0572 Hose As
1 271-4905 Hose As
1 284-7705 Hose As
2 319-6226 Elbow As
1 319-6242 Elbow As
1 332-8558 Tee As
1 153-6270 Tee
2 228-7090 O-Ring Seal
1 214-7568 O-Ring Seal
Table 10
(1)
Part of the 379-4937 Fan Drive Lines Gp
Table 11
(1)
Part of the 344-2424 Stairway Gp
Parts that are Required to Install the 354-0520 Stairway Ar (Powered Access)
Table 12
Parts that are Required to Install the 193-6282 Handhold Gp or the 193-6278 Handhold Gp(1)
Qty Part Number Description
1 241-6990 Handhold As
133 8T-4136 Bolt(2)
133 8T-4121 Hard Washer (2)
1 241-6981 Handhold As
2 8T-7087 Grommet
2 5P-7468 Clip
2 5P-7469 Clip
1 8T-4194 Bolt
1 8T-4244 Nut
1 241-6986 Handhold As
1 242-9547 Handhold As (3)
1 242-9538 Handhold As(4)
1 242-9815 Handhold As(5)
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4 8T-4956 Bolt
4 8T-4223 Hard Washer
1 290-6591 Brace
6 5S-7382 Bolt
6 5P-1075 Hard Washer
1 285-3218 Handhold As
1 8X-9874 Chain
1 5P-0765 Hose
1 8C-8451 Bolt
1 8T-4205 Hard Washer
1 5C-2890 Nut
1 6B-8085 Chain Snap
Table 13
(1)
(2) Some required parts may be part of the 193-6251 Handrail Fastener Gp
(3) Partof 193-6251 Handhold Fastener Gp
(4) Wide body only
(5) Standard body only
Optional rear access only
Table 14
(1)
(2) Part of 240-4784 Rear View Mirror Gp
Part of 240-4794 Handhold Gp
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2 134-0989 Block(1)
2 303-8300 Block(3)
4 8T-4186 Bolt(1)
4 8T-4910 Bolt(3)
4 198-4778 Hard Washer(3)
1 290-0057 Mirror As(4)
3 8T-4136 Bolt
Table 15
(1)
(2) Wide body only
(3) Additional hard washers (3) can be used if there is a gap between mirror (11) and bracket assembly (4).
(4) Standard body only
193-6277 Rear View Mirror Gp
Table 16
(1)
One 6V-3249 Bearing and one 6V-0836 Retaining Ring for each cap
Parts that are Required to Install the Brake Cooling Lines Group
Qty Part Number Description
8 8T-4944 Bolt
2 265-0975 Tube As
2 241-5766 Hose
8 209-4589 Clamp
4 156-5744 Half Clamp
18 8T-4183 Bolt
20 8T-4223 Hard Washer
2 8T-4244 Nut
16 9X-8257 Washer
8 7X-2556 Bolt
8 8T-4175 Bolt
Table 17
Parts that are Required to Install the Service Brake Lines Group to the Front Wheels
Qty Part Number Description
4 8X-6137 Block
4 5T-0968 Block
8 8T-4185 Bolt
8 8T-4121 Hard Washer
2 148-8358 Elbow
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Table 18
Parts that are Required to Connect the Steering Links and Steering Cylinders to the Wheel Groups
Table 19
Table 20
Parts that are Required to Install the 238-2848 Fuel Filter Lines Gp
Qty Part Number Description
1 159-4724 Ball Valve
2 7M-8485 O-Ring Seal
1 6V-9182 Elbow
1 8X-5311 Check Valve As
1 2M-9780 O-Ring Seal
1 6V-9852 Elbow
2 7J-9108 O-Ring Seal
1 6V-9746 O-Ring Seal
1 5P-6994 Clip
1 8T-4192 Bolt
1 8T-4223 Hard Washer
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Table 21
Parts that are Required to Install the 230-1086 Fuel Filter Lines Gp
Qty Part Number Description
1 159-4724 Ball Valve
2 7M-8485 O-Ring Seal
1 6V-9182 Elbow
1 8X-5311 Check Valve As
1 2M-9780 O-Ring Seal
1 6V-9852 Elbow
2 7J-9108 O-Ring Seal
1 7E-6719 Primary Fuel Filter Gp
2 8T-4195 Bolt
2 8T-4121 Hard Washer
2 6V-9007 Elbow
2 3D-2824 O-Ring Seal
1 113-9339 Hose As
3 6V-9746 O-Ring Seal
1 5P-6994 Clip
1 8T-4192 Bolt
1 8T-4223 Hard Washer
Table 22
Parts that are Required to Install the 8X-0193 Fuel Heater Group
Qty Part Number Description
1 114-8701 Plate
2 7X-2568 Bolt (1)
1 7W-5300 Fuel Heater
4 8T-4194 Bolt
4 8T-4223 Hard Washer
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
Table 23
(1)
These bolts replace the bolts that are included in the Fuel Tank Fastener Gp.
Parts that are Required to Install the 264-7554 Service Center Gp
Qty Part Number Description
1 231-7582 Adapter
1 5H-6734 O-Ring Seal
6 8T-2501 Bolt
6 8T-4896 Hard Washer
2 1P-4582 Half Flange
1 4J-0527 O-Ring Seal
5 8T-4183 Bolt
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Table 24
Parts that are Required to Install the Cab Steering Lines Group
Table 25
Parts that are Required to Install the 247-5876 Cab Mounting Gp
Qty Part Number Description
1 304-2711 Support As
9 7X-2582 Bolt
23 5T-1352 Spacer
1 296-7866 Support As
1 298-3859 Walkway As(1)
6 130-0099 Bolt
8 107-3953 Bolt
Table 26
(1)
Part of 240-4787 Walkway Gp
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Table 27
(1)
(2) Use the shims to obtain a flatness within 0.75 mm (0.03 inch).
Part of the 144-4181 Air Horn Gp
Parts that are Required to Install the Handrail Assembly for the Rear Access Arrangement
Qty Part Number Description
1 456-0270 Handrail As
2 8T-5005 Bolt
2 1F-7854 Spacer
6 8T-4121 Hard Washer
2 8T-0389 Locknut
1 296-5446 Spring
1 5L-3946 Rod End
2 8T-4896 Hard Washer
1 9S-8752 Full Nut
1 431-6297 Bracket As
2 8T-4195 Bolt
1 5G-0817 Conical Bumper
1 6V-8186 Full Nut
1 8T-4224 Hard Washer
4 6V-1874 Grommet
4 5P-7468 Clip
4 5P-7469 Clip
4 8T-4956 Bolt
8 8T-4223 Hard Washer
4 329-3356 Nut
1 438-9871 Plate
1 456-0271 Plate
1 172-8125 Pin
1 160-9925 Lanyard
1 5C-9553 Bolt
1 9X-8256 Washer
1 344-5673 Nut
Table 28
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2 242-0811 Clamp(2)
1 272-5466 Tube As(3)
1 269-3301 Bracket As(3)
4 8T-4183 Bolt(3)
4 5P-1076 Hard Washer(3)
4 8T-4244 Nut(3)
Table 29
(1)
(2) Part of tube assembly 1
(3) Part of tube assembly 1 and tube assembly 2
Part of tube assembly 2
Parts that are Required to Install the 293-5905 Exhaust Pipe Gp (If Equipped)
Qty Part Number Description
1 272-5460 Tube As
7 7E-8452 Clamp
2 242-0799 Bellows As
1 292-1009 Bracket As
8 8T-4183 Bolt
8 5P-1076 Hard Washer
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
1 292-1008 Bracket As
4 8T-4223 Hard Washer
1 290-8578 Tube As
Table 30
Table 31
Parts that are Required to Install the 294-0849 Muffler Gp (If Equipped)
Table 32
Parts that are Required to Install the 8X-4180 Hood Latch Gp
1 2G-9399 Rod
1 6F-8499 Spring
1 8X-4425 Bracket Assembly
1 3B-4615 Cotter Pin
1 0T-0883 Washer
1 276-7617 Plate As
8 8T-4136 Bolt
1 8T-4223 Hard Washer
1 3B-4627 Cotter Pin
1 101-0368 Prop Assembly
Table 33
Parts that are Required to Install the 240-2784 Air Cleaner Gp
Qty Part Number Description
1 9Y-8930 Air Cleaner Gp
1 241-4197 Bracket As
4 7X-0344 Bolt
4 8T-4122 Hard Washer
4 8T-4139 Bolt
10 5P-1076 Hard Washer
6 8T-4194 Bolt
4 198-4778 Hard Washer
1 351-9112 Rod As
2 8T-4244 Nut
2 202-6473 Bolt
3 2S-5658 Hard Washer
1 8T-4132 Nut
1 351-9110 Rod As
1 251-2151 Tube As
2 251-6235 Hose
8 230-2535 Clamp
1 7E-7790 Hose
4 233-8485 Clamp
2 285-6593 U-Bolt
2 285-7524 Strip
4 8T-4223 Hard Washer
4 129-3180 Locknut
1 9X-0262 Adapter
2 6V-5048 O-Ring Seal
1 161-9926 Pressure Sensor Gp
1 7K-1181 Cable Strap
1 7D-8586 Nonslip Tread
Table 34
Table 35
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Table 36
Parts that are Required to Install the 193-6262 Rim Mounting Gp
Qty Part Number Description
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
16 8T-4223 Hard Washer
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
32 5P-1076 Hard Washer
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)
Table 37
(1)
(2) Use with 793D Extended Life, Wheel, and Brake Group configuration only
(3) Use with 793D Standard Wheel and Brake Group configuration only
Part of 208-8789 Rim Guard Gp
Table 38
(1)
(2) The 141-1513 Odometer Assembly is part of 143-2253 Odometer.
(3) The 155-6138 Odometer Assembly is part of 143-2256 Odometer.
(4) The 5T-8673 Odometer Assembly is part of 188-3648 Odometer Gp.
The 141-1514 Odometer Assembly is part of 188-3649 Odometer Gp.
Parts that are Required to Install the 126-1358 Hydraulic Tank Guard Gp
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Table 39
Parts that are Required to Install the 284-4927 Truck Body Mounting Gp
Qty Part Number Description
2 8X-5063 Deflector
1 105-4727 Mud Flap
1 6G-9703 Cable
1 105-0314 Coupler
2 8T-4649 Bolt
2 8T-4167 Hard Washer
2 6V-7676 Nut
1 8W-0109 Plate
1 2B-0974 Clevis Pin
1 8T-4122 Hard Washer
1 3B-4617 Cotter Pin
2 7I-5517 Pin As
1 8W-2896 Washer
2 6G-9697 Washer
2 8W-8677 Plate
4 5P-1076 Hard Washer
4 8T-4184 Bolt
10 219-7595 Pad As
30 8X-3046 Shim
2 8X-3044 Plate (1)
24 8T-4910 Bolt
30 7D-1649 Hard Washer
24 8T-4244 Nut
16 8T-4137 Bolt
16 8T-4121 Hard Washer
16 4K-8864 Clip
2 233-1880 Bracket As(2)
2 227-5875 Ejector
2 6G-7773 Pin
2 3D-0404 Washer
4 3B-4647 Cotter Pin
4 205-4178 Pad
4 205-4179 Shackle
2 205-4181 Chain
Table 40
(1)
(2) A 8X-3044 Plate that has a thickness of 8 mm (0.3150 inch) should be used in place of four 8X-3046 Shims that have a thickness of 2 mm (0.0787 inch) each
Part of 260-9120 Body and Canopy As
Parts that are Required to Install the 8X-3380 Cylinder Mounting Gp
Table 41
Table 42
Approximate Weights
The heavy assembly can fall if using an incorrect hoist to lift the
load.
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) 1150 kg (2525 lb)
Fuel tank (3) 1700 kg (3725 lb)
Fuel tank (4) 2020 kg (4455 lb)
Right side platform assembly 1130 kg (2490 lb)
Body (center) 12160 kg (26800 lb)
Body (center) with liners 18430 kg (40620 lb)
Body (two sides) 6530 kg (14400 lb)
Canopy 4170 kg (9200 lb)
Liners(5) 3500 kg (7710 lb)
Tail extension assembly 304 kg (670 lb)
Sideboard assembly 118 kg (260 lb)
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Table 43
(1)
(2) The weight of the truck frame is distributed equally between the front and back lifting points.
(3) Tank capacity 2839 L (750 US gal)
(4) Tank capacity 4353 L (1150 US gal)
(5) Tank capacity 4921 L (1300 US gal)
(6) The total weight of the liners can weigh as much as 18144 kg (40000 lb).
A completed body with liners can weigh as much as 63503 kg (140000 lb). When you lift a completed body, use a suitable lifting device.
Specifications
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)
Table 44
Torque Specifications
Tighten the 24 rear axle housing bolts to a torque of 2800 ± 350 N·m (2065 ± 260 lb ft).
Tighten the 72 bolts that mount the rear wheel rim to a torque of 900 ± 100N·m (664 ± 74 lb ft).
Tighten the 70 nuts that mount the front wheel rim to a torque of 1000 ± 125 N·m (738 ± 92 lb ft).
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.
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.
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).
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).
Tighten the 20 cab mounting bolts to a torque of 1904 ± 68 N·m (1405 ± 50 lb ft).
Tighten the 21 cab support mounting bolts to a torque of 1600 ± 200 N·m (1180 ± 148 lb ft).
Tighten the bolts for the fuel tank to a torque of 460 ± 60 N·m (339 ± 44 lb ft).
Tighten the fuel tank caps to a torque of 800 ± 100 N·m (590 ± 74 lb ft).
Tighten the bolts for the platform assembly to a torque of 460 ± 60 N·m (339 ± 44 lb ft).
Use approved cables, chains, and lifting devices to lift components. Refer to the manufacturer's literature 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
to see the effect of the lift angle on the working load limit.
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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.
With the rear axle on supports, a hoist with a 36290 kg (80000 lb) capacity is needed 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.
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 approximately 24 total 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.
Obtain six 208 L (55 US gal) barrels of hoist, converter, and brake oil (TDTO, TO-4).
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".
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.
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.
Obtain cables, lifting straps, and chains that have adequate lifting capacity.
Obtain several shackles. The shackles should have a working load limit of 27240 kg (60053 lb).
Obtain one portable air compressor. The air compressor should have enough capacity to operate two 25.4 mm (1 inch) impact wrenches. The
air compressor should have a minimum capacity of 3 CM (100 CFM).
Obtain 40 hardwood blocks that are 203 mm (8.0 inch) tall. The blocks should be 203 mm (8.0 inch) wide. The blocks should be 914 mm
(36.0 inch) long.
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Obtain one stepladder that is 1.8 m (6 ft) tall. Have two stepladders that are 3.6 m (12 ft) tall.
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 to guide the
body into position.
Obtain 20 nitrogen bottles that are T-size to inflate the tires and charge the suspension cylinders.
Obtain one lift truck that can lift 6810 kg (15000 lb).
Obtain three 138-7573 Link Brackets and three 138-7574 Link Brackets.
Four metal stands. The metal stands support the truck body before the truck body is installed to the truck frame.
Obtain 4C-4188 Paint Remover. The solvent cleans the parts on the truck.
Obtain Loctite 242 Blue Threadlocker for the cab mounting bolts.
Required Tools
Use a 5P-3520 Spanner Wrench to torque the ball studs for the steering system.
Use a 5S-6084 Socket to tighten the ball studs for the steering system.
Use a 6V-6080 Torque Multiplier 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.
Use a 8T-9293 Torque Wrench to torque the ROPS cab mounting bolts.
Use a 6V-4170 Adapter for the mounting group for the front suspension.
Use a 6V-4154 Box Wrench for the mounting group for the front suspension.
Use a 6V-3146 Extension for the mounting group for the front suspension.
Use a 2P-8261 Adapter (3/4 inch to 1.0 inch) for the mounting group for the front suspension.
Use a 9U-5089 Socket for the rear axle housing, the mount for the front cylinder, and the cab support.
Use a 5S-6076 Extension with the 2P-2336 Socket and with the 2P-2338 Socket.
Use a 9U-5617 Oil Refill Pump for charging the suspension cylinders with oil.
Use a 8T-3196 Wrench for the mounting nuts on the front suspension cylinder.
Use a pair of 6V-0006 Pliers to install the connector for the AETA.
When you are instructed, apply 4C-5593 Anti-Seize Thread Lubricant to threads.
When you are instructed, apply 4C-5599 High Temperature Anti-Seize Compound to threads.
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Illustration 2 g01266425
Typical view of the layout for the 793D Off-Highway Truck.
Illustration 3 g01224956
Typical view of the 793D chassis
Illustration 4 g01224989
Typical view of the 793D components
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Illustration 5 g01225040
Typical view of the 793D skid with the cab, rims, fuel tank, and handrail
Illustration 6 g01225052
Typical view of the 793D Extended Life, Wheel, and Brake Group rear axle assembly
Illustration 7 g01382054
Typical view of the standard rear axle assembly for the 793D
Illustration 8 g01225126
Typical view of the 793D lifting points
1. The work area for the truck chassis and the components should be flat, smooth, and well draining. 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 assembly area around the truck chassis clear. Also, the
assembly area must be left unobstructed in order for the crane to lift the components properly.
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Illustration 9 g01225174
Illustration 10 g00678780
Typical view of the alternate lifting devices on a similar chassis
Note: A spreader bar and cables can be used 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.
Illustration 11 g01225102
Typical view
4. Use two cranes to lift the 793D chassis from the trailer. The chassis weighs approximately 43545 kg (96000 lb).
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Illustration 12 g00679038
Typical front view of a similar chassis that is blocked
Illustration 13 g01225422
Typical view
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.
Illustration 14 g00812964
Typical view of a similar chassis on metal stands
Illustration 15 g00678801
Typical view of a similar chassis that is blocked
6. Illustration 14 shows an alternate blocking method using steel plates and steel stands.
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Illustration 16 g01225541
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 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).
Illustration 17 g01225669
View of rear axle assembly from the 793D Extended Life, Wheel, and Brake Group configuration
Illustration 18 g01225649
Typical view
View of the skid with the components for the right platform
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Illustration 19 g01372356
Typical view
View of the LH
front strut assembly, outrigger, and hardware for a standard truck
Illustration 20 g01381488
Typical view
View of the RH
front strut assembly
The rear outrigger is shown with the
optional rear access for a standard truck.
Illustration 21 g01225656
View of the front strut assembly for the left side from the 793D Extended Life, Wheel, and Brake Group configuration
Illustration 22 g01225685
View of the cab
Illustration 23 g01225683
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.
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Note: Do not open the bags of hardware. The bags are 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.
Illustration 24 g02127076
Typical view
Illustration 25 g02127079
(A) 15 ± 2 mm (0.59 ± 0.0787 inch)
NOTICE
Do not grind through the weld or the parent material of the
frame.
1. Use a torch to remove the tie-down eyes from the frame. Leave the weld and the parent material to dimension (A).
2. Clean all the areas that were affected in Step 1. Paint the areas to inhibit rust.
Table 45
(1)
(2) Part of 384-0740 Axle Housing Support Gp
(3) 8X-0433 Slip Joint and 2N-2486 Bolt are part of 8X-0249 Drive Shaft.
Part of 246-6747 Rear Suspension Gp
Illustration 26 g01225812
Illustration 27 g01225916
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2. Remove three bolts (A) to remove the wood block. Discard the hardware.
Illustration 28 g01225802
View of rear frame rail
Illustration 29 g01225882
View of left side of the rear axle housing
5. Use 4C-4204 Paint Remover to remove paint from the left side of the rear axle housing.
6. Repeat step 5 for the right side of the rear axle housing assembly.
Illustration 30 g01226427
7. Remove two bolts and the cover from the front of the transmission on the rear axle housing assembly. Discard the bolts.
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Illustration 31 g01226433
8. Prepare the transmission yoke to install the drive shaft slip joint.
Inspect the universal joints and mating yokes for damage to the key, keyway, threaded holes, and pilot diameters.
Note: If damage is present in any of the areas, replace the universal joint or yoke accordingly.
Clean the mating surface of the yoke assembly, including the threaded holes and universal joint assembly. Ensure that the yoke assembly is
free of wax, dirt, debris, paint, and grease.
Illustration 32 g01372372
9. Remove the cable straps and bolts (F) from drive shaft slip joint (E).
Illustration 33 g01226464
10. Inspect the universal joints and mating yokes for damage to the key, keyway, threaded holes, and pilot diameters.
Note: If damage is present in any of the areas, replace the universal joint or yoke accordingly.
Clean the mating surface of the slip joint. Ensure that the slip joint is free of wax, dirt, debris, paint, and grease. Repeat for opposite side.
Illustration 34 g01372383
View of the sensor at the LH strut
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NOTICE
Before raising the rear struts, disconnect both of the rear strut
sensors. Failure to disconnect the sensors may result in
damage to the electrical connection of the sensor.
Illustration 35 g01372377
11. Use a suitable lifting device to raise rear struts (G). The weight of each rear strut is approximately 601 kg (1325 lb).
Illustration 36 g01225957
Illustration 37 g01225972
12. Use a suitable lifting device to position the rear axle housing and the final drives to the frame.
Note: The weight of the rear axle assembly and final drives is approximately 24494 kg (54000 lb).
Illustration 38 g01372423
View of the right side of rear axle housing and final drive
13. Install 12 bolts (C) and 12 washers (D) to secure the rear axle housing.
Note: Use an impact wrench to tighten bolts (C). Do not torque bolts (C) yet.
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Illustration 39 g01372450
14. Remove two bolts (H) and two washers (J) to remove retainer (K) and pin (L).
Note: The weight of the pin is 16.7 kg (37 lb).
Illustration 40 g01372455
Illustration 41 g01226157
16. Use 4C-4204 Paint Remover to remove paint from pin bores. Apply 4C-5593 Anti-Seize Thread Lubricant to pin (L) and the bores.
Illustration 42 g01372458
17. Use a suitable lifting device to lift lateral control rod (M) into position. The weight of the lateral control rod is 146 kg (322 lb).
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Illustration 43 g01372460
18. Install pin (L). Install retainer (K), two bolts (H), and two washers (J) that were removed in Step 14. Tighten bolts (H) to a torque value of
475 N·m (350 lb ft).
Illustration 44 g01372464
View of lower strut mount
19. Remove top bolt (N) and washer (P). Retain the hardware. Loosen bottom bolt (N) to position the guard for the pin removal. Keep top bolt (J)
and washer (K).
Illustration 45 g01372476
View of the lower right strut
Illustration 46 g01372478
View of lower strut
22. Repeat Step 20 and Step 21 for the other side of the machine.
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Illustration 47 g01372484
23. Apply 4C-5593 Anti-Seize Thread Lubricant to pin (U), the frame bore, and the bore in strut (G). Grease line (V) that is attached to the elbow
faces the front of the machine.
Illustration 48 g01372498
View of right rear mount
Illustration 49 g01372502
25. Install washer (R), six bolts (S), and six washers (T) that were removed in Step 22 to secure pin (U). Tighten bolts (S) to a torque value of
475 N·m (350 lb ft).
Illustration 50 g01226583
View of grease port for the left strut
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Illustration 51 g01372383
View of the LH strut and sensor
Illustration 52 g01226399
View of the rear axle assembly from the 793D Extended Life, Wheel, and Brake Group configuration
28. Place wood blocks under the rear axle housing and the final drives to support the assembly.
Illustration 53 g01372580
29. Remove drive shaft guard (W). Retain guard (W) and all mounting hardware.
Illustration 54 g01372589
30. Make sure that torque converter and transmission yokes are aligned and in phase.
Use a suitable lifting device to position drive shaft slip joint (E) to the transmission.
31. Ensure that the universal joints are fully seated prior to tightening the bolts. There are two methods:
A - Use a suitable rubber or wood hammer to seat the universal joints in the yoke.
B - Use designated run-down bolts tocompletely seat the universal joints in the yoke. Refer to Step 31a and Step 31b.
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b. Remove the designated "run-down" bolts and replace with new 2N-2486 Bolts
Note: Ensure that the universal joints are fully seated prior to tightening the bolts.
32. Insert new 2N-2486 Bolts (F) and torque to 550 ± 20 N·m (406 ± 15 lb ft) in a sequential alternating "X" pattern.
Static check 2N-2486 Bolts (F) and ensure that the bolts are tightened to a minimum of 530 N·m (391 lb ft) to maximum of 570 N·m
(420 lb ft).
33. Perform a static check on the 2N-2486 Bolts (F) 250 hours after the driveshaft has been installed.
NOTICE
Do not separate the drive shaft. Drive shafts are assembled with
the universal joints in phase for balancing purposes. If the drive
shaft must be separated, use a paint pen to make aligning
marks on both sides of the slip joint. When assembling the drive
shaft, make sure the aligning marks match to ensure proper
universal joint phasing and balance performance.
Illustration 55 g01372591
Illustration 56 g03740554
View of the drive shaft after the center tube
(1) 398-7352 Guard As
a. Position guard assembly (1) to the center tube. Secure the top of the guard assembly with three bolts (2) and three plated washers (3).
Secure each side of the guard assembly with three bolts (2) and three plated washers (3).
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Illustration 57 g03740678
View of the drive shaft after the center tube
(1) 398-7352 Guard As
b. Install plate assembly (4) to guard assembly (1) with nine bolts (2) and nine plated washers (3).
Illustration 58 g03740941
View of the drive shaft after the center tube
(3) 8T-4222 Plated Washer
c. Install guard (5) to plate assembly (4) with eight bolts (6) and eight plated washers (3).
Illustration 59 g03740954
View of the drive shaft after the center tube, from below
(1) 398-7352 Guard As
d. Install guard (7) to guard assembly (1) with two plates (8), using four bolts (9), and four plated washers (3).
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Illustration 60 g01372599
35. Tighten 12 bolts (C) to a torque value of 2800 ± 350 N·m (2065 ± 260 lb ft).
The
Parts that are Required to Connect the Rear Supply Oil Cooler Lines Group
Item Qty Part Number Description
1 1 241-5837 Hose As
2 4 8T-4193 Bolt
3 4 9X-8257 Washer
4 2 1P-7016 Half Flange
5 1 3E-6773 O-Ring Seal
Table 46
Illustration 61 g01229506
View of hose (1) and shipping strap
Illustration 62 g01372671
1. Remove four bolts (2) and four washers (3). Remove two flange halves (4). Discard cover (A).
Note: Make sure that seal (5) is in the housing.
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Illustration 63 g01228200
2. Discard four bolts (B), four washers (C), and four nuts (D) from hose assembly (1). Discard two flange halves (E) and cover (F).
Illustration 64 g01372690
3. Position flange halves (4) on each side of hose (1). Install four bolts (2) and four washers (3) to secure hose assembly (1) and O-Ring Seal
(5).
Table 47
Illustration 65 g01228339
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1. Use six bolts (1), 12 hard washers (2), and six nuts (3) to secure lubrication injector bank (A) to the rear axle housing.
Illustration 66 g01228423
Illustration 67 g01228420
2. Remove cap (B) from hose assembly (C) . Remove cap (D) from lubrication injector bank (A). Attach hose (C) to lubrication injector bank (A).
Illustration 68 g00818724
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.
Illustration 69 g01228501
View of the left lower pin and strut
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Illustration 70 g01228505
Illustration 71 g01228520
6. Position guard (K). Install two bolts and two washers that are provided to secure the guard.
Illustration 72 g01228526
View of the right side lower rear strut and lubrication line that is installed
Illustration 73 g01228537
View of the left rear upper chassis
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Illustration 74 g01228781
View of the right rear upper chassis
Illustration 75 g01228627
View of the lateral control rod at the rear axle housing
Illustration 76 g01228633
Illustration 77 g01228717
12. Locate the opposite end of the lateral control rod and remove cap (R) from elbow (S).
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Illustration 78 g01228644
Illustration 79 g00818726
View of the lubrication hoses on the right platform
Illustration 80 g00818727
Illustration 81 g00818730
14. Use the following items 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).
16. Use the clips and the fasteners that are provided to secure the lubrication lines.
The required parts to install the right-hand platform are part of the 193-6252 Platform Mounting Gp.
Note: The right side air cleaner is factory installed to the right side platform.
Table 48
Illustration 82 g06099556
Typical view of the right-hand platform mounting plates
1. Prepare the right-hand platform mounting plates for welding by removing the paint from the edges.
2. Remove the paint from the area on the edge of the platform assembly and from the bottom of the platform assembly. The approximate weight
of the right side platform assembly is 1130 kg (2491 lb).
Illustration 83 g06099887
View of the rear of the right-hand platform as shipped
(9) 242-7006 Plate
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Illustration 84 g06099898
(9) 242-7006 Plate
3. Remove the four bolts and four washers that secure plate (9) from the platform. Retain the bolts, the washers, and plate (9) for future use.
Prepare plate (9) for welding by removing the paint from the edges.
Illustration 85 g01237757
Illustration 86 g01379624
Typical RH view of the truck
Illustration 87 g01237776
5. Remove paint from the area on the right side of the frame.
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Illustration 88 g01237806
6. Remove paint from top of frame for welding. Remove the paint from the mounting area of the platform.
Illustration 89 g01237785
View of the two existing lifting points
Illustration 90 g01237790
View of existing rear lifting point
Illustration 91 g01237796
7. Use the lifting points that are provided for the positioning of the platform.
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Illustration 92 g01237805
View of the platform assembly that is being positioned to the frame
Illustration 93 g06099909
View from the top of the left-hand side of the right-hand platform
(11) 8T-6430 Bolt
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Illustration 94 g06099920
View from the bottom front of the right-hand platform
(11) 8T-6430 Bolt
9. Position the platform assembly. Secure the platform in three locations by using three bolts (11) and three washers (12).
Note: Tighten the bolts to a torque of 460 ± 60 N·m (339 ± 44 lb ft).
Illustration 95 g06099946
View of the rear of the right-hand fender and air cleaner
(7) 241-4197 Bracket As
10. Install four bolts (13) and four hard washers (14) to hold bracket assembly (7) to the frame assembly. Do not tighten four bolts (13) at this
time.
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Illustration 96 g01379640
View of the gap between the RH platform and the radiator support
11. The platform must be level before finish welding can begin. If necessary, use a suitable lifting device to adjustment the platform.
Note: The lifting device for the RH platform must remain in place until the platform is welded completely.
Illustration 97 g00693245
View of the accumulators that are covered
12. Cover the accumulators to protect the accumulator against the weld splatter.
Illustration 98 g06099518
View from under the rear of the right-hand platform
(1) 8X-1991 Plate
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Illustration 99 g06099533
View from under the front of the right-hand platform
(1) 8X-1991 Plate
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(W1) 6 mm (0.236 inch) fillet weld with 1.5 mm (0.059 inch) penetration
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(W2) 6 mm (0.236 inch) fillet weld with 1.5 mm (0.059 inch) penetration
(W3) 6 mm (0.236 inch) fillet weld with 1.5 mm (0.059 inch) penetration (two plates (1))
(W4) 6 mm (0.236 inch) fillet weld with 1.5 mm (0.059 inch) penetration (two places)
(W5) 6 mm (0.236 inch) fillet weld with 1.5 mm (0.059 inch) penetration
(W6) 6 mm (0.236 inch) fillet weld with 1.5 mm (0.059 inch) penetration (two places)
(W7) Four 6 mm (0.236 inch) fillet welds around plate (4). No weld 25 mm (0.984 inch) from the corners and on the curve.
(W8) 3 mm (0.118 inch) Flare bevel weld the entire length of plate assembly (5)
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(W9) 3 mm (0.118 inch) Fillet weld the entire length of plate assembly (5)
( W10) Four 6 mm (0.236 inch) fillet welds around plate (8). No weld 25 mm (0.984 inch) from the corners and on the curve.
(W11) 3 mm (0.118 inch) Bevel weld at the base of plate assembly (5)
( W12) Two 6 mm (0.236 inch) fillet welds on both sides of the two plates (6). No weld 25 mm (0.984 inch) from the corners and on the curve.
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13. Weld the platform in place. Refer to Illustration 98, Illustration 99, and Illustration 100for the locations of the components. Refer to Illustration
101, Illustration 102, Illustration 103, Illustration 104, and Illustration 105 for the welding and dimension information.
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14. Position plate (9). Install the bolts and washers from Step 3. Weld plate (9) to the frame assembly and the platform assembly.
16. Final tighten bolts (13) that secure bracket assembly (7).
17. Connect the electrical lines for the oil cooler to the platform with clips, bolts, and washers.
18. Connect the load indicator wiring to the platform. Use clips, bolts, and washers that are provided to secure the wiring.
Parts that are Required to Hydraulic Lines to the Tank on the Right-Hand Platform
Item Qty Part Number Description
1 1 250-0555 Hose As(1)
2 2 1P-4582 Half Flange
3 4 8T-4956 Bolt
4 4 8T-4223 Hard Washer
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)
Table 49
(1)
(2) Part of 193-6296 Hydraulic Oil Lines Gp
Part of 193-6276 Hydraulic Fan Lines Gp
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1. Remove shipping covers (A) and (B). Discard the covers and the hardware.
3. Position two flange halves (2) around hose assembly (1). Install four bolts (3) and four washers (4) to secure the hose to the tank.
5. Install four bolts (6) and four washers (7) to secure the hose to the tank.
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Parts that are Required to Connect the Brake Lines Groups to the Rear Axle Housing
Item Qty Part Number Description
1 1 213-9807 Hose As
2 1 8X-6161 Hose As
3 2 8T-4956 Bolt
4 2 8T-4223 Hard Washer
5 1 7G-3833 Clip
6 1 7G-3834 Clip
7 1 7G-3832 Grommet
8 1 8X-6169 Hose As
Table 50
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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) to secure hose (1) and hose (2).
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Parts that are Required to Connect the Power Train Oil Lines Group
Item Qty Part Number Description
1 1 8X-4094 Block
2 4 6M-9149 Bolt
3 4 7X-0591 Hard Washer
4 1 124-1859 O-Ring Seal
5 2 1P-4584 Half Flange
6 8 8T-4223 Hard Washer
7 4 8T-4184 Bolt
8 1 8T-0568 O-Ring Seal
9 1 128-0931 Adapter
10 1 6V-4590 O-Ring Seal
11 4 6J-2515 Bolt
12 2 197-3295 Half Flange
13 4 8T-4183 Bolt
14 1 191-2962 O-Ring Seal
Table 51
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Seal
1. Secure hose assembly (A) and hose assembly (B) to the transmission.
Hose assembly (A) requires the following hardware:
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2. Secure hose assembly (C), hose assembly (D), hose assembly (E), and hose assembly (F) to the side of the transmission.
Table 52
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4. Remove the cap from hose (2). Connect hose (2) to manifold (B).
Parts that are Required to Install the Power Train Cooler Lines Group
Item Qty Part Number Description
1 1 113-6365 Hose As
2 1 8X-8886(1) Hose As
3 1 243-1293 Hose As
4 1 371-0572 Hose As
5 1 271-4905 Hose As
6 1 284-7705 Hose As
7 2 319-6226 Elbow As
8 1 319-6242 Elbow As
9 1 332-8558 Tee As
10 1 153-6270 Tee
11 2 228-7090 O-Ring Seal
12 1 214-7568 O-Ring Seal
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Table 53
(1)
Part of the 379-4937 Fan Drive Lines Gp
NOTICE
Some hydraulic hose connections require the removal of the
protective shipping plug assembly from the hose and/or the
fitting. Some protective shipping plug assemblies contain an O-
ring. Keep all hydraulic connections clean and dry during the
assembly procedure.
1. If not already installed, install elbow assembly (7), elbow assembly (8), tee assembly (9), and tee (10).
Connect hose assembly (1), hose assembly (2), hose assembly (3), hose assembly (4), hose assembly (5), and hose assembly (6) to the
appropriate connectors.
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2. Connect chassis harness (B) to rear chassis harness (C) in two places.
3. Connect the electrical connectors that are on the right side of the frame assembly.
4. Secure the rear electrical harness with the bolts, washers, and clamps that are provided.
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Table 54
(1)
Part of the 344-2424 Stairway Gp
1. Remove six bolts (A) and six washers (B). Retain the hardware.
2. Use a suitable lifting device (C) to position the platform assembly. The approximate weight of the platform assembly is 63 kg (139 lb).
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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).
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Table 55
1. Secure plate assembly (1) to the right-hand side of the bumper assembly by using eight bolts (2) and eight hard washers (3).
(B) Bolt
(C) Washer
(4) 328-1150
Platform Gp
2. Remove tread plate (A) from the top of platform group (1) by removing bolts (B) and washers (C).
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Secure platform group (4) to plate assembly (1) by using eight bolts (2) and eight hard washers (3).
After platform group (4) has been secured, resecure tread plate (A) that was removed in Step 2.
4. Secure pipe assembly (5) to platform group (4) by using eight bolts (7) and eight hard washers (8).
Secure pipe assembly (6) to platform group (4) by using eight bolts (7) and eight hard washers (8).
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Secure stairway assembly (9) to platform group (4) by using two hubs (10), 16 bolts (11), 16 hard washers (12), and two plug buttons (13).
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6. Secure handrail group (14) to stairway assembly (9) by using four bolts (7) and four hard washers (8).
Secure handrail group (15) to stairway assembly (9) by using four bolts (7) and four hard washers (8).
7. Secure two pipe assemblies (16) between handrail group (14) and pipe assembly (5) by using four screws (18), four plated washers (19),
eight bushings (20), and eight quad ring seals (21).
Secure two pipe assemblies (17) between handrail group (15) and pipe assembly (6) by using four screws (18), four plated washers (19),
eight bushings (20), and eight quad ring seals (21).
8. Remove cover (D) from the rear of the platform group. Retain cover (D) and all mounting hardware.
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9. Secure cable assembly (E), cable assembly (F), and harness assembly (G) to platform group (4) by using taperlock stud (22), spacer (23),
hard washer (24), nut (25), and the following clipping:
Clip (28), clip (27), and grommet (26) for cable assembly (F)
10. Secure cable assembly (E) to platform group (4) by using bolt (32) and hard washer (33).
11. Secure cable assembly (F) and harness assembly (G) to platform group (4) by using bolt (31) and hard washer (24) and the following
clipping:
Clip (28), clip (27), and grommet (26) for cable assembly (F)
Cable tie mounting (34) and cable strap (35) for harness assembly (G)
12. Secure cable assembly (F) to platform group (4) by using bolt (32) and hard washer (33).
14. Secure cover (D) that was previously removed by using the retained hardware.
Parts that are Required to Install the 193-6282 Handhold Gp or the 193-6278 Handhold Gp(1)
Item Qty Part Number Description
1 1 241-6990 Handhold As
2 133 8T-4136 Bolt(2)
3 133 8T-4121 Hard Washer (2)
4 1 241-6981 Handhold As
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
10 1 241-6986 Handhold As
11 1 242-9547 Handhold As (3)
12 1 242-9538 Handhold As(4)
13 1 242-9815 Handhold As(5)
14 4 8T-4956 Bolt
15 4 8T-4223 Hard Washer
16 1 290-6591 Brace
17 4 4L-6459 Bolt
18 4 346-3713 Spacer
19 1 285-3218 Handhold As
20 1 8X-9874 Chain
21 1 5P-0765 Hose
22 1 8C-8451 Bolt
23 1 8T-4205 Hard Washer
24 1 5C-2890 Nut
25 1 6B-8085 Chain Snap
Table 56
(1)
(2) Some required parts may be part of the 193-6251 Handrail Fastener Gp
(3) Part of 193-6251 Handhold Fastener Gp
(4) Wide body only
(5) Standard body only
Optional rear access only
1. Use a suitable lifting device to position handhold (1). The weight of handhold (1) is approximately 48 kg (106 lb).
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3. Use a suitable lifting device to position handhold (4). The weight of handhold (4) is approximately 28 kg (62 lb).
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) to secure two grommets (5), two clips (6) and two clips (7).
7. Use a suitable lifting device to position handhold (10). The weight of handhold (10) is approximately 18 kg (40 lb).
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9. Step 10 through Step 15 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 16 bolts (2) and 16 washers (3) to secure handhold (11). Install four bolts (14)
and four washers (15) to secure handhold (11).
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11. Remove six bolts (A) and six washers (B) in preparation for installation of brace (16).
12. Position brace (16) to the mounting location that is located next to the front outrigger.
13. Secure brace (16) to the bottom of the left-hand catwalk by using four bolts (17) and four spacers (18).
14. Position handhold (13) to the mounting location. The weight of the handhold is approximately 28.5 kg (63 lb).
15. Install 12 bolts (2) and 12 washers (3) to secure handhold (13).
Note: Refer to Illustration 152.
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16. Install four bolts (2) and four washers (3) to connect handhold (11) and handhold (13).
17. Position handhold (19) to chassis. Install six bolts (2) and six washers (3) to secure handhold (19).
Note: Handhold (19) weighs approximately 7 kg (15 lb).
18. Install bolt (22), washer (23), and nut (24) to secure chain (20) and hose (21) to handhold (11). Secure chain snap (25) to chain (20).
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Table 57
(1)
(2) Part of 240-4784 Rear View Mirror Gp
Part of 240-4794 Handhold Gp
1. Position fender (1) to the mounting location on catwalk (A). Use nine bolts (2) and nine washers (3) to secure fender (1).
Note: The weight of fender (1) is approximately 51 kg (113 lb).
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2. Install four bolts (5) and four washers (6) to secure brace (4) to the handhold assembly.
3. Position guard (10) and three strips (11) to the catwalk. Install 12 bolts (12), 24 washers (3), and 12 nuts (13) to secure the guard.
4. Position guard (14) and strip (15) to the right platform. Install nine bolts (12), 18 washers (3), and nine nuts (13) to secure the guard.
5. Remove 13 bolts (D) and 13 washers (E) to remove two strips (C). Retain the hardware.
6. Position deflector (16) and two strips (C). Install 13 bolts (D) and 13 washers (E) to secure the deflector.
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8. Position plate assembly (17) to the rear outrigger. Install four bolts (12), eight washers (3), and four nuts (13) to secure the plate assembly.
Note: Position tab (F) of plate assembly (17) to the outside of the catwalk. Refer to Illustration 167.
9. Position guard (18) and strip (19) to plate (17). Install seven bolts (12), 14 washers (3), and seven nuts (13) to secure the guard.
Note: Refer to Illustration 166.
10. Position plate (20) to plate (17) and the rear catwalk. Install two bolts (7), four washers (8) and two nuts (9) to secure the plate.
11. Install one bolt (2), two washers (3) and one nut (13) to secure tab (F) of plate assembly (17) to the left-hand side of the rear catwalk.
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12. Position guard (21) and strip (22) to plate (17). Install five bolts (12), ten washers (3), and five nuts (13) to secure the guard.
Each mirror group can use the following mirror mounting groups:
Note: This procedure contains information to install a 290-0057 Mirror As on a machine that is equipped with a standard body or a wide body. If
your machine is equipped with a standard body, then refer to Step 4.
Table 58
(1)
(2) Wide body only
(3) Additional hard washers (3) can be used if there is a gap between mirror (11) and bracket assembly (4).
(4) Standard body only
193-6277 Rear View Mirror Gp
1. Use eight bolts (2) and eight washers (3) to secure bracket (1) to handhold (A).
2. Install four washers (3) and four bolts (8) to secure bracket (4) and blocks (6) to bracket (1).
3. Install three washers (3) and three bolts (12) to secure mirror assembly (11) to the bracket.
4. Install four washers (10) and four bolts (9) to secure bracket (5) and blocks (7) to handhold (B).
5. Repeat Step 3.
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Table 59
(1)
One 6V-3249 Bearing and one 6V-0836 Retaining Ring for each cap
Tools that are Required to Install the 8X-2808 Suspension Mounting Gp (Front)
Item Qty Part Number Description
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
Table 60
Note: The weight of the suspension cylinder group is 6504 kg (14340 lb).
1. Remove all dirt and shipping grease from the top of the suspension cylinder group.
NOTICE
To install the bearing cap correctly, the retaining ring must face
towards the strut when installed. An incorrectly installed
bearing cap may result in cap bearing failure and/or front strut
failure.
2. Clean all mating surfaces of the bearing cap. Position the bearing cap onto the top of the suspension cylinder group.
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4. Use a suitable lifting device 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).
5. 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.
6. Prepare the surfaces on the chassis by removing all paint, dirt, and grease. Remove any nicks or burrs from the mounting surfaces.
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7. 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. 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).
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10. 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.
11. 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.
12. 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.
13. 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.
14. Install four bolts (12) and four washers (13) 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).
Note: Plates (11) should be installed to fill the gap.
15. Repeat Step 1 through Step 14 for the other side of the machine.
Parts that are Required to Install the Brake Cooling Lines Group
Item Qty Part Number Description
1 8 8T-4944 Bolt
2 2 265-0975 Tube As
3 2 241-5766 Hose
4 8 209-4589 Clamp
5 4 156-5744 Half Clamp
6 18 8T-4183 Bolt
7 20 8T-4223 Hard Washer
8 2 8T-4244 Nut
9 16 9X-8257 Washer
10 8 7X-2556 Bolt
11 8 8T-4175 Bolt
Table 61
1. Remove cover (A) from the final drive. Discard the cover.
2. Remove the plug from return tube assembly (B). Discard the plug.
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3. Install hose (3) onto tube assembly (2). Connect hose (3) to existing tube assembly (B).
4. Install four bolts (1) to secure tube assembly (2) to the final drive.
5. Install four hose clamps (4) around hose (3) 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 the covers from the cooling hose assemblies. Discard the cover.
Secure the hose assemblies by using bolts (9), bolts (10), and washers (11).
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Connect the Steering Links and Steering Cylinders to the Wheel Groups
Required parts to connect the steering links and steering cylinders to the wheel groups are from the following groups:
Table 62
Tools that are Required to Connect the Steering Links and Steering Cylinders to the Wheel Groups
Item Qty Part Number Description
AA 1 5P-3520 Spanner Wrench
BB 2 5S-6084 Socket
Table 63
1. Remove two nuts (1) and two protective sleeves (C) from ball studs on steering link (B) and steering cylinder (A).
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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 taper of the ball stud, the threads, and the washer face of the nut.
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5. Use spanner wrench (AA) 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.
Table 64
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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) 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).
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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.
The 245-0896 Service Brake Lines Gp is part of the standard 245-0906 Final Drive and Brake Wheel Ar or the standard 454-9776 Final Drive
and Brake Wheel Ar
The 193-6243 Service Brake Lines Gp is part of the extended life 240-4767 Final Drive and Brake Wheel Ar or the extended life 454-9778
Final Drive and Brake Wheel Ar
Parts that are Required to Install the Service Brake Lines Group to the Front Wheels
Item Qty Part Number Description
1 4 8X-6137 Block
2 4 5T-0968 Block
3 8 8T-4185 Bolt
4 8 8T-4121 Hard Washer
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
Table 65
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1. Install one elbow (5) to the front brake. Attach the existing hose to elbow (5). Use the following items 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 to secure hose assembly (15) to
the mount for the front strut.
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8. Repeat Step 1 through Step 7 for the right-hand side of the machine.
The 240-4806 Fuel Tank and Filter Ar and the 359-7705 Fuel Tank and Filter Ar have a capacity of 4353 L (1150 US gal)
The 240-4799 Fuel Tank and Filter Ar and the 359-7710 Fuel Tank and Filter Ar have a capacity of 4921 L (1300 US gal)
Note: The 216-1735 Fuel Tank Fastener Gp is for use with all fuel tank sizes.
Reference: Refer to "Install the 8X-0193 Fuel Heater Group (If Equipped)" if the machine is equipped with a heater for the fuel tank.
Table 66
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2. Remove four bolts (1), four washers (2), and two caps (3). Retain the hardware.
3. Remove paint and dirt from two fuel tank supports (B).
5. Position cap (3) to fuel tank support (B). Install two bolts (1) and two washers (2) from Step 2 to secure the cap. Tighten the bolts to a torque
of 800 ± 100 N·m (590 ± 74 lb ft).
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8. Remove paint and dirt from mounting pin (C) on the fuel tank.
11. 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.
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13. Remove paint and dirt from mounting location (D) and plate assembly (4).
14. Install two bolts (5), four washers (6) and two nuts (7) to secure plate assembly (4).
15. 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).
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Note: Steps 16 and 17 are for machines that have a fuel tank capacity of 4467 L (1180 US gal).
16. Install two mounts (8) and two sleeves (9) between plate assembly (4) and the bracket.
17. Install two mounts (8), two bolts (10), two washers (6) and two nuts (11) 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)
18. Position shim (12) that is equal to the last recorded value in Step 11 to fuel tank support (B).
Note: Shim both sides of support (B) equally.
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19. 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).
21. Use clamps (E) that are provided to secure the hose in two places to the fuel tank.
22. Install two bolts (13) and two washers (14) to secure vent assembly (D) to the truck frame.
Note: Vent assembly (D) is already provided.
23. Remove six bolts (F) and six washers (G) to remove cover (H). Retain hardware.
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24. Connect harness (A) to the electrical connections for the fuel tank sensor.
25. Install the hardware that was removed in Step 23 to secure cover (H).
Install the 238-2848 Water Separator and Fuel Filter Gp (If Equipped)
Parts that are Required to Install the 238-2848 Fuel Filter Lines Gp
Item Qty Part Number Description
1 1 159-4724 Ball Valve
2 2 7M-8485 O-Ring Seal
3 1 6V-9182 Elbow
4 1 8X-5311 Check Valve As
5 1 2M-9780 O-Ring Seal
6 1 6V-9852 Elbow
7 2 7J-9108 O-Ring Seal
8 1 6V-9746 O-Ring Seal
9 1 5P-6994 Clip
10 1 8T-4192 Bolt
11 1 8T-4223 Hard Washer
Table 67
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1. Remove cap assembly (A) and O-ring (B) from the fuel tank. Discard the hardware.
Remove cap assembly (C) and O-ring (D) from the fuel tank. Discard the hardware.
2. Secure ball valve (1) to the fuel tank with O-ring seal (2). Secure elbow (3) to ball valve (1) with O-ring seal (2).
Secure check valve assembly (4) to the fuel tank with O-ring seal (5). Secure elbow (6) to check valve assembly (4) with O-ring seal (7).
3. Remove the caps for shipping from hose assembly (E) and hose assembly (F).
Connect hose assembly (E) with O-ring seal (8) to elbow (3).
Connect hose assembly (F) with O-ring seal (7) to elbow (6).
4. Secure hose assembly (E) and hose assembly (F) to the frame by using clip (9), bolt (10), and hard washer (11).
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Table 68
1. Remove cap assembly (A) and O-ring (B) from the fuel tank. Discard the hardware.
Remove cap assembly (C) and O-ring (D) from the fuel tank. Discard the hardware.
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2. Secure ball valve (1) to the fuel tank with O-ring seal (2). Secure elbow (3) to ball valve (1) with O-ring seal (2).
Secure check valve assembly (4) to the fuel tank with O-ring seal (5). Secure elbow (6) to check valve assembly (4) with O-ring seal (7).
Secure primary fuel filter group (8) to the fuel tank by using two bolts (9) and two hard washers (10).
Secure two elbows (11) with two O-ring seals (12) to primary fuel filter group (8).
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3. Remove the caps for shipping from hose assembly (E) and hose assembly (F).
Connect hose assembly (E) with O-ring seal (7) to elbow (3).
Connect hose assembly (F) with O-ring seal (14) to elbow (11).
4. Secure one end of hose assembly (13) with O-ring seal (14) to elbow (3). Secure the other end of hose assembly (13) with O-ring seal (14) to
elbow (11).
5. Secure hose assembly (E) and hose assembly (F) to the frame by using clip (15), bolt (16), and hard washer (17).
Parts that are Required to Install the 8X-0193 Fuel Heater Group
Item Qty Part Number Description
1 1 114-8701 Plate
2 2 7X-2568 Bolt (1)
3 1 7W-5300 Fuel Heater
4 4 8T-4194 Bolt
5 4 8T-4223 Hard Washer
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
Table 69
(1)
These bolts replace the bolts that are included in the Fuel Tank Fastener Gp.
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1. Use two bolts (2) and the existing hardware from the Fuel Tank Fastener Gp 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).
Note: Tighten the bolts to a torque of 100 ± 20 N·m (73 ± 14 lb ft).
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).
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8. Connect the other end of hose (14). Connect the other end of hose (15).
Table 70
1. Remove six bolts (A) to remove cover (B). Discard the hardware.
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2. Secure adapter (1) with O-ring seal (2) to the fuel tank by using six bolts (3) and six hard washers (4).
3. Remove the shipping cover from hose assembly (A). Discard the shipping cover and the associated mounting hardware.
Secure hose assembly (A) with O-ring seal (6) to adapter (1) by using two half flanges (5), four bolts (7), and four hard washers (8).
Secure plate (9) to the fuel tank by using two bolts (10) and two hard washers (11).
Secure hose assembly (A) to plate (9) by using clip (12), clip (13), grommet (14), bolt (7), two hard washers (8), and nut (15).
Parts that are Required to Install the Cab Steering Lines Group
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Table 71
Note: Steps 1 through3should be completed while the cab is located at ground level.
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2. Secure two connectors (1) with two O-ring seals (3) to the steering valve group.
Secure two elbows (2) with two O-ring seals (3) to the steering valve group.
Secure elbow (4) with O-ring seal (5) to the steering valve group.
3. Secure tube assembly (6) with O-ring seal (11) to the upper left connector (1).
Secure tube assembly (7) with O-ring seal (11) to the upper right connector (1).
Secure tube assembly (8) with O-ring seal (11) to the lower left elbow (2).
Secure tube assembly (9) with O-ring seal (11) to the lower right elbow (2).
Secure tube assembly (10) with O-ring seal (12) to the elbow (4).
Note: The following step may need to be completed after the cab is installed on the machine.
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As
4. Secure tube assembly (7) and tube assembly (9) to the machine by using clamp (13), bolt (14), and hard washer (15).
Secure tube assembly (6) and tube assembly (8) to the machine by using clamp (13), bolt (14), and hard washer (15).
Secure tube assembly (10) to the machine by using clip (16), bolt (14), and hard washer (15).
Secure bracket assembly (17) to the machine by using bolt (18) and hard washer (15).
The following list matches the identification tags to the tube assemblies:
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5. Secure guard assembly (19) to the bottom of the cab by using three bolts (18) and three hard washers (15).
Table 72
(1)
Part of 240-4787 Walkway Gp
Note: When you install the support assemblies, ensure that all mating surfaces are free of paint and grease. 4C-4204 Paint and Decal Remover
can be used to remove paint during this procedure.
Note: Before the support assemblies are attached to the truck, the cab mounting surfaces for the cab can be prepared. Also, the cab mounts can
be installed.
1. Remove four bolts and four washers to remove lifting eye (A). Discard the hardware. Prepare the mounting surface (B) of the frame by
removing all paint and grease.
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2. Remove all paint and grease from the mating surface of front support assembly (1).
3. Use a suitable lifting device to position support assembly (1) to mounting surface (B).
Note: The approximate weight of the support assembly is 173.5 kg (383 lb).
4. Install nine bolts (2) and nine spacers (3) to secure support assembly (1). Tighten bolts (2) to a torque value of 1600 ± 200 N·m
(1180 ± 148 lb ft).
5. Prepare the mounting surface for rear support assembly (C) by removing all paint and grease.
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6. Prepare the mounting surface for rear support assembly (4) by removing all paint and grease.
Note: Optional walkway assembly (5) may already be attached to rear support assembly (4).
7. Use a suitable lifting device to position rear support (4) and walkway assembly (5) to mounting surface (C). The approximate weight of rear
support (4) is 300 kg (661 lb). The approximate weight of optional walkway (5) is 42 kg (93 lb).
8. Install six bolts (6) and six spacers (3) into the top holes of support assembly (4). Install eight bolts (7) and eight spacers (3) into the bottom
holes of support assembly (4). Tighten the bolts to a torque value of 1600 ± 200 N·m (1180 ± 148 lb ft) to secure rear support assembly (4).
Table 73
(1)
(2) Use the shims to obtain a flatness within 0.75 mm (0.03 inch).
Part of the 144-4181 Air Horn Gp
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1. Use 4C-4204 Paint Remover or a suitable device to clean the paint from four seats (A) and the cab mounting area of front support (B).
2. Install four mounts (1) into the top of the bores of support assembly (B). Install four mounts (1) and four sleeves (2) into the bottom bores of
support assembly (B).
3. Use 4C-4204 Paint Remover or a suitable device to clean the paint from the four seats and cab mounting area (C) of the frame.
4. Install four mounts (1) into the top bores of the frame. Install four mounts (1) and four sleeves (2) into the bottom bores of the frame.
5. Use 4C-4204 Paint Remover or a suitable device to clean the paint from six seats (D) and the cab mounting area of rear support (E).
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6. Install six mounts (1) into the top bores of support assembly (E). Install six mounts (1) and six sleeves (3) into the bottom bores of support
assembly (E).
7. Use 4C-4204 Paint Remover or a suitable device to clean paint from the six seats and cab mounting area (F) of the frame.
8. Install six mounts (1) into the top bores of the frame. Install six mounts (1) and six sleeves (4) into the bottom bores of the frame.
9. Use a suitable lifting device to position the cab assembly to support assembly (B) and support assembly (E). The weight of the cab assembly,
catwalks, and the handrail is approximately 2300 kg (5071 lb).
Note: The mating surfaces of the cab assembly must be clean. Also, the mating surfaces must be smooth.
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10. Apply 9S-3263 Thread Lock Compound to the threads of eight bolts (6). Install four retainers (5) and four bolts (6) in two places into the cab
assembly.
Note: Partially install bolts (6) to allow movement of the cab assembly for the installation of the rear bolts.
11. Apply 9S-32639S-3263 Thread Lock Compound to the threads of six bolts (7) and six bolts (8). Install six retainers (5) and six bolts (7). Install
six retainers (5) and six bolts (8).
12. If necessary, install shims (9) and (10) to achieve a flatness within 0.75 mm (0.03 inch) with the cab.
13. Tighten all the cab mounting bolts to a torque value of 1904 ± 68 N·m (1405 ± 50 lb ft).
14. Connect cab harness (F) to chassis harness (G). Install clip (11), bolt (12), and washer (13) to secure the harness.
Install the Handrail Assembly for the Rear Access Arrangement (If
Equipped)
The 456-0270 Handrail As and the required installation parts are part of the 240-4797 Handrail Fastener Gp.
Parts that are Required to Install the Handrail Assembly for the Rear Access Arrangement
Item Qty Part Number Description
1 1 456-0270 Handrail As
2 2 8T-5005 Bolt
3 2 1F-7854 Spacer
4 6 8T-4121 Hard Washer
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5 2 8T-0389 Locknut
6 1 296-5446 Spring
7 1 5L-3946 Rod End
8 2 8T-4896 Hard Washer
9 1 9S-8752 Full Nut
10 1 431-6297 Bracket As
11 2 8T-4195 Bolt
12 1 5G-0817 Conical Bumper
13 1 6V-8186 Full Nut
14 1 8T-4224 Hard Washer
15 4 6V-1874 Grommet
16 4 5P-7468 Clip
17 4 5P-7469 Clip
18 4 8T-4956 Bolt
19 8 8T-4223 Hard Washer
20 4 329-3356 Nut
21 1 438-9871 Plate
22 1 456-0271 Plate
23 1 172-8125 Pin
24 1 160-9925 Lanyard
25 1 5C-9553 Bolt
26 1 9X-8256 Washer
27 1 344-5673 Nut
Table 74
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2. Secure handrail assembly (1) to the walkway assembly by using bolt (2), spacer (3), two hard washers (4), and nut (5).
3. Secure rod end (7) to the bottom of the walkway assembly by using two hard washers (8) and two nuts (9).
Note: Do not tighten the nuts.
Secure rod end (7) to handrail assembly (1) by using spring (6).
Note: Adjust rod end (7) as needed to adjust the spring tension. Handrail assembly (1) should move freely.
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4. Secure bracket assembly (10) to the side of the walkway assembly by using two bolts (11) and two hard washers (4).
Secure conical bumper (12) to bracket assembly (10) by using full nut (13) and hard washer (14).
5. Secure plate (21) to the back of the existing handrail assembly by using two grommets (15), two clips (16), two clips (17), two bolts (18), four
hard washers (19), and two nuts (20).
Secure plate (22) to the existing handrail assembly by using two grommets (15), two clips (16), two clips (17), two bolts (18), four hard
washers (19), and two nuts (20).
Secure pin (23) and lanyard (24) to the handrail assembly by using bolt (25), washer (26), and nut (27).
Install the Air Hoses and Install the Electrical Connection for the Cab
The following groups connect to the side of the cab:
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1. Remove the tape and the plugs from the cab assembly.
(2) 7D-4242 Hose As, Air supply to air start control valve, Tag Number 2
(3) 279-0486 Hose As, Air line for the parking brake control valve, Tag Number 3
(4) 4S-7570 Hose As, Air line for the service brake control valve, Tag Number 4
(5) 7D-2984 Hose As, Air line for the brake diverter valve, Tag Number 5
(6) Unconnected
(7) 4S-7570 Hose As, Air line for the automatic lubrication system, Tag Number 7
(A) Transmission
(B) Battery
(C) Chassis 1
(D) Chassis 2
(E) Engine
Note: Verify the hose function and match the hose assembly tag number with the corresponding tag number fitting on the cab.
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3. Insert the four video cables into the 348-9226 Grommet Assembly (1) and secure the grommet into the second hole drilled in the plate that is
located at the right rear corner of the cab. Torque the nut of the 348-9226 Grommet Assembly to 20 ± 2 N·m (15 lb ft ± 1 lb ft). Pass the
excess video cable into the electronics bay.
4. Connect the four video cables from the cameras to the four video cables from the display.
Video Cables to Display Video Cables to Camera Cable Color
1 Front Red
2 Right Blue
3 Rear Green
4 Left Yellow
Table 75
5. Secure the harnesses in the electronics bay with the 3S-2093 Cable Strap.
6. 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.
Note: The 3D-7587 Elbow, that is to be installed for the cabs main air supply, can be found in a shipping bag behind the cab seat.
7. Match and install the electrical connectors to the side of the cab.
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9. 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: The hoses may require cutting to the proper length before installation.
NOTICE
Open the heater valves on the engine after the installation of the
heater hoses.
10. Connect the air horn hose assembly to the connection in the cab. Secure the hose with a clip on the frame.
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11. Connect air conditioner hose assembly (C) and air conditioner hose assembly (D).
Note: The right-hand platform must be installed prior to installing the exhaust pipe group.
Table 76
(1)
(2) Part of tube assembly 1
(3) Part of tube assembly 1 and tube assembly 2
Part of tube assembly 2
1. Remove the shipping strap to lift tube assembly (1) from the pallet.
Note: The weight of tube assembly (1) and bracket assemblies (C) and (D) is approximately 44.5 kg (98 lb).
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2. Use a suitable lifting device to position tube assembly (1) to the rear of the RH platform. Remove bracket assemblies (C) and (D) from tube
assembly (1). Retain the hardware.
Note: Remove the shipping covers from the ends of tube assembly (1). Also, remove the shipping covers from mufflers (F) and (G). Discard
the covers.
3. Remove the shipping covers from manifold assembly (K) and manifold assembly (L). Discard the covers.
4. Install four bolts (H) and four washers (J) that are provided to secure bracket assembly (D) to the rear of the RH platform.
5. Use a suitable lifting device to position tube assembly (1) to bracket assembly (D).
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6. Position bracket assembly (C) over tube assembly (1). Use the hardware that was retained in Step 2 to secure tube assembly (1).
Note: Do not tighten the bolt that secures bracket (C). Alignment of the tube assembly may be required before the final tightening of the
clamps.
7. Install band clamp (A) that is provided to secure tube assembly (1) to manifold assembly (L).
Note: Do not finish tightening clamp (A). Alignment of the tube assembly may be required before the final tightening of the clamps.
8. Position band clamp (E) that is provided to secure tube assembly (1) to muffler (G). Position the top of the band clamp at the top of the
captured slot. Finish tightening band clamp (E) to a torque value of 68 ± 12 N·m (50 ± 9 lb ft).
9. Finish tightening band clamp (A) to a torque value of 12.5 ± 1 N·m (9 ± 1 lb ft).
Note: Refer to Illustration 294.
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Shield
11. Use a suitable lifting device to position tube assembly (2) to the rear of the RH platform. Loosen clamp assembly (N).
Note: The weight of tube assembly (2) and bracket assemblies (N) and (P) is approximately 26.5 kg (59 lb).
12. Position tube assembly (2) next to tube assembly (1). Remove the shipping covers from the ends of tube assembly (2). Discard the shipping
covers.
13. Remove four bolts (R), four washers (S), and four nuts (T) from bracket assembly (P). Retain the hardware.
14. Position bracket assembly (P) to the mounting location. Install four bolts (R), four washers (S), and four nuts (T) to secure the bracket.
15. Position band clamp (M) that is provided to secure tube assembly (2) to muffler (F). Position the top of band clamp (M) at the top of the
captured slot.
Note: Do not finish tightening band clamp (M) or clamp (N). Alignment of the tube assembly may be required before the final tightening of the
clamps.
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16. Remove heat shield (U) from tube assembly (2). Position tube assembly (2) to manifold (K). Install clamp (V) that is provided to secure tube
assembly (2) to manifold assembly (K).
17. Finish tightening band clamp (V) to a torque value of 12.5 ± 1 N·m (9 ± 1 lb ft). Finish tightening clamp (N).
18. Finish tightening band clamp (M) to a torque value of 68 ± 12 N·m (50 ± 9 lb ft). (2) can now be tightened. Finish tightening clamp (N).
Note: Refer to Illustration 298.
19. Install heat shield (U) over the bellows for tube assembly (2).
Parts that are Required to Install the 293-5905 Exhaust Pipe Gp (If Equipped)
Item Qty Part Number Description
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
6 8 5P-1076 Hard Washer
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
15 4 8T-4223 Hard Washer
16 1 290-8578 Tube As
Table 77
1. Position tube assembly (1) onto the left side manifold (A). Install clamp (2) to hold the tube to the manifold.
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Note: Do not tighten clamp (2). Alignment of the tube assembly may be required before the final tightening of the clamp.
2. Position bellows (3) onto the right side manifold (B). Install clamp (2) 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 to secure the
bracket.
4. Position tube assembly (8) into bellows (3). Install clamp (2) to hold the assemblies together.
Note: Do not tighten clamp (2). Alignment of the tube assembly may be required before the final tightening of the clamps.
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7. Position clamp (9) to bracket assembly (4). See illustration 306. Install boss (10), washer (11), and bolt (12) to secure the clamp to tube
assembly (8).
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9. Position bracket assembly (14) to mounting location (D). Install bolt (5) and washer (15) in four places to secure the bracket.
10. Position bellows (3) between tube assembly (16) and tube assembly (1).
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13. Position clamp (9) to bracket assembly (14). See illustration 313. Install boss (10), washer (11), and bolt (12) to secure the clamp to tube
assembly (16).
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5 6 6V-5839 Washer
Table 78
1. Remove clamp (G) from muffler (A). Retain the clamp. Remove the protective cover from muffler (A).
Note: Mufflers (A) and (B) are factory installed on the right side platform.
2. Loosen bolt (D), washers (E), and nut (F). Slide extension pipe (1) through clamp assembly (C). Slide clamp (G) onto extension pipe (1).
3. Slide extension pipe (1) onto muffler (A). Use the hardware that is provided on clamp (G) to secure extension pipe (1) to the muffler. Tighten
bolt (D) to secure extension pipe (1) to the platform.
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.
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5. Position extension pipe (2) onto muffler (B). Install bolt (3), nut (3), and two washers (5) in three places to secure extension pipe (2) to the
muffler. Tighten bolts (3) to a torque value 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.
Parts that are Required to Install the 294-0849 Muffler Gp (If Equipped)
Table 79
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.
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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) 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) to secure pipe extension (4) onto muffler (B).
Table 80
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1. Position bracket assembly (5) to the side of the cab. Install two bolts (1) and two washers (2) to secure the bracket.
Note: Tighten the bolts to a torque of 47 ± 9 N·m (35 ± 7 lb ft).
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) to secure the plate assembly.
4. Install prop assembly (12) to the hood assembly by using hard washer (10) and cotter (11).
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Table 81
1. Use a suitable lifting device to remove the air cleaner group from the shipping pallet. The approximate weight of the air cleaner group is
191 kg (421 lb).
NOTICE
When positioning the air cleaner group for installation,
removing precleaner cup assemblies may be required to avoid
any damage.
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3. Secure air cleaner group (1) to the machine by using bracket assembly (2), four bolts (3), four hard washers (4), four bolts (5), and four hard
washers (6).
Note: Do not remove the lifting device from the air cleaner assembly.
4. Secure the plate assembly attached to the rear of the air cleaner group to the front of the front cab outrigger by using four bolts (7) and four
washers (8). Do not finish tightening bolts (7).
Note: Do not remove the lifting device from the air cleaner assembly.
5. Secure rod assembly (9) to the bottom of the front cab outrigger by using bolt (7), two hard washers (6), and nut (10). Secure the other end of
rod assembly (9) to the plate assembly on the rear of the air cleaner group by using bolt (11), two hard washers (12), and nut (13).
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6. Secure rod assembly (14) to the front of the front cab outrigger by using bolt (11) and hard washer (12). Secure the other end of rod assembly
(14) to the top of the plate assembly on the rear of the air cleaner group by using bolt (6), two hard washers (7), and nut (10).
7. Remove the clamps and the shipping covers in three places from tube assembly (15). Discard the covers, retain the clamps and the other
hardware.
8. Remove the two shipping covers from the rear of the air cleaner group. Discard the covers.
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9. Remove the shipping cover from the tube at the front of the engine. Discard the cover.
10. Secure tube assembly (15) tube on the front of the engine by using hose (18) and four clamps (19). Secure tube assembly (15) to the rear of
the air cleaner group by using two hoses (16) and eight clamps (17).
Rotate each pair of clamps until the T-bolts are located 180 degrees from each other. Tighten the clamps to a torque value of 7.5 ± 1 N·m
(66 ± 9 lb in).
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(B) Plate
11. Secure tube assembly (15) to bracket assembly (A) and to plate (B) by using two U-bolts (20), two strips (21), four hard washers (22), and
four locknuts (23).
Note: Tighten the locknuts to a torque of 30 ± 7 N·m (22 ± 5 lb ft).
12. Secure adapter (24) with O-ring seal (25) to the top of tube assembly (15). Secure pressure sensor group (26) to adapter (24) with O-ring
seal (25).
Connect pressure sensor group (26) to the existing harness assembly (C).
Note: Tighten sensor (26) to a torque value of 10 ± 2 N·m (7.3 ± 1.5 lb ft)
Secure the loose slack of pressure sensor group (26) with cable strap (27).
Note: The adapter and pressure sensor can be installed onto the tube assembly prior to the installation of the tube assembly.
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13. Install the wiring group. Use existing clips, bolts, and washers.
Note: Tighten the bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
14. Reinstall the three precleaner cup assemblies. Each precleaner cup assembly consists of one 2W-9069 Precleaner Cup Assembly and one
2M-0879 O-Ring Seal.
15. Prior to positioning the RH tube assembly, locate battery cables (R) under the RH platform.
16. Secure battery cables (R) with the clips and bolts that are provided.
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18. Install nonslip tread (28) to the top of the air cleaner on the left-hand side.
Table 82
1. Install one precleaner cup assembly (16) and one O-ring seal (17) in three places to the bottom of the RH air cleaner assembly.
Table 83
1. Locate two batteries (A) that are installed into the top of the RH platform.
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2. To charge the batteries or fill the batteries, refer to Special Instruction, REHS0458, "Activation of 101-4000 Batteries, 115-2421 Batteries, and
9X-9730 Batteries That Are Shipped Without Electrolyte".
Install the Tires with the Rim Mounting Group 193-6262 Rim Mounting Gp
There are four rim mounting group options:
The following instructions are specific for the 193-6262 Rim Mounting Gp.
Instructions to install the 208-8789 Rim Guard Gp are also included in the following sections.
Parts that are Required to Install the 193-6262 Rim Mounting Gp
Item Qty Part Number Description
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
12 16 8T-4223 Hard Washer
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
21 32 5P-1076 Hard Washer
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)
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Table 84
(1)
(2) Use with 793D Extended Life, Wheel, and Brake Group configuration only
(3) Use with 793D Standard Wheel and Brake Group configuration only
Part of 208-8789 Rim Guard Gp
Do not attempt to assemble this machine until you read and you
understand the assembly instructions.
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.
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.
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Note: Inspect the locations of the straps. Metal will tear the straps.
4. Use a tire handler 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 70 nuts (4) and 70 washers (5) 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.
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Note: The shop or a tire servicing person installs the rim assembly.
1. Use the following parts to assemble the rims to the rear tires: four O-Ring seals (1) , four tire valves (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".
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3. Remove nuts (E) and washers (F) from the rear wheel assembly.
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5. Clean the mounting area of the rim of metal burrs and paint.
6. Block the front wheels. Raise the rear of the truck 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.
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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.
11. Repeat Step 1 through Step 10 on the other rim and the other tire.
NOTICE
If the truck is to be moved with only the inner rear wheel and tire
installed, then nuts (G) must be installed to secure the final
drive assembly to the rear axle assembly.
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.
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14. Position six brackets (24) and two brackets (25) to the wheel assembly. Position four plate assemblies (26) to the brackets. Install 14 bolts
(11) and 14 washers (21) 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.
16. Position two clips (10) around hose assembly (9). Install two bolts (11), two washers (12) and two nuts (13) to secure hose assembly (9) to
plate (8). See illustration 349.
17. Position plate (8) to the final drive assembly. Position two plates (14). Install two bolts (15), four washers (12) and two nuts (13) to secure
plate (8) and plates (14) to the final drive assembly.
Note: Step 16 and Step 17 are 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) to secure the plates.
Note: Reference illustration 350.
Note: Step 19 is for the 793D Standard Wheel and Brake Group configuration.
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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) 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.
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.
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) to secure the bracket.
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Table 85
(1)
(2) The 141-1513 Odometer Assembly is part of 143-2253 Odometer.
(3) The 155-6138 Odometer Assembly is part of 143-2256 Odometer.
(4) The 5T-8673 Odometer Assembly is part of 188-3648 Odometer Gp.
The 141-1514 Odometer Assembly is part of 188-3649 Odometer Gp.
1. Use the existing fastener 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) to secure plate assembly (2) to the rear wheel assembly.
Table 86
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1. Remove four bolts (B) and two bolts (C) from hydraulic tank (A). Retain the bolts.
2. Positioncover (1) to hydraulic tank (A). Install two bolts (B) that were removed in Step 1 to secure the cover.
Note: Tighten the bolts to a torque of 30 ± 7 N·m (22 ± 5 lb ft).
3. Positioncover (2) to hydraulic tank (A). Install two bolts (C) that were removed in Step 1 to secure the cover.
Note: Tighten the bolts to a torque of 30 ± 7 N·m (22 ± 5 lb ft).
261-8621 Truck Body Mounting Gp for use on 793D dual slope body.
284-4927 Truck Body Mounting Gp for use on all 793D bodies, except dual slope.
Reference: Service Magazine, SEPD0531, 3, July 2000, "Fabric Slings and Protective Sleeves Are Available for Lifting Truck Bodies"
Note: Be sure to remove all lifting eyes prior to the installation of the body and canopy to the chassis.
NOTICE
Failure to use a 8X-3044 Plate that has a thickness of 8 mm
(0.3150 inch) in place of four 8X-3046 Shims that have a
thickness of 2 mm (0.0787 inch) each can result in failure of the
body pad retention bolts.
Parts that are Required to Install the 284-4927 Truck Body Mounting Gp
Item Qty Part Number Description
1 2 8X-5063 Deflector
2 1 105-4727 Mud Flap
3 1 6G-9703 Cable
4 1 105-0314 Coupler
5 2 8T-4649 Bolt
6 2 8T-4167 Hard Washer
7 2 6V-7676 Nut
8 1 8W-0109 Plate
9 1 2B-0974 Clevis Pin
10 1 8T-4122 Hard Washer
11 1 3B-4617 Cotter Pin
12 2 7I-5517 Pin As
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Table 87
(1)
(2) A 8X-3044 Plate that has a thickness of 8 mm (0.3150 inch) should be used in place of four 8X-3046 Shims that have a thickness of 2 mm (0.0787 inch) each
Part of 260-9120 Body and Canopy As
1. Use a suitable lifting device to 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 deflector assembly (1) to the body. Install five bolts (A), five washers (B), and five nuts (C) that are provided to secure the deflector
assembly to the body.
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4. Position mud flap assembly (2) to the body. Install five bolts (D), five washers (E), and five nuts (F) to secure the mud flap assembly.
5. Position cable (3) to existing bracket (G) on the body. Position coupler (4) through the end of cable (3). Install two bolts (5), two washers (6)
and two locknuts (7) to secure the coupler to the bracket.
Note: Tighten the bolts to a torque of 800 ± 100 N·m (590 ± 74 lb ft).
6. Position cable (3) over existing bracket (H). Position plate (8) to bracket (H). Install pin (9), washer (10), and cotter (11) to secure plate (8) and
cable (3) to the body.
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7. Remove paint and dirt from four bores in the body and two bores in the chassis.
Note: The 376-4554 Pin As should be used to assist in lifting the truck body.
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12. Position plate (15) to the body. Install two hard washers (16) and two bolts (17) to secure the plate.
Note: Tighten the bolts to a torque of 100 ± 20 N·m (74 ± 15 lb ft).
13. Repeat Step 10 through Step 12 for the other side of the machine.
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14. Secure the hoist cylinder with a chain or cable to prevent any movement of the hoist cylinder.
15. Use a torch to remove the shipping bracket and the retaining bolt.
16. Repeat Step 14 and Step 15 for the other side of the machine.
Note: Refer to "Install the 8X-3380 Cylinder Mounting Gp" for the installation of the hoist cylinders to the body assembly.
17. If necessary, position the truck on a level surface. The body and cylinder installation must be completed to proceed to the following steps.
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(J) Rockers
19. Lower the body slowly. If the body contacts both of the factory installed rocker pads on rockers (J) at the same time, then go to Step 24. If the
body does not contact both rocker pads (18) at the same time, shims (19) are required under the rocker pad that must be raised. Refer to
Step 20 to install the shims.
Note: If the rocker pad needs to be raised more than 8 mm (0.315 inch), then plate (20) should be used. Refer to Service Magazine,
SEPD0861-00, "A New Plate for the Assembly of the Truck Body Is Available".
20. Raise the dump body and install the proper safety device to secure the dump body in the RAISE position.
21. Remove bolt (21) and washer (22) in three places. Retain the hardware. Add required shims (19) and/or plate (20) between the top of rocker
(J) and rocker pad (18).
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22. Install hardware that was retained from Step 21 to secure rocker pad (18), shim (19) and/or plate (20).
Note: Tighten the bolts to a torque of 100 ± 20 N·m (74 ± 15 lb ft).
23. Remove the safety device. Repeat Step 18 through Step 22 until both of the rocker pads come into contact with the body at the same time.
24. Raise or lower the body to bring the body and frame rails parallel to each other.
25. Measure the distance between body rail (K) and frame rail (L) at the front of the body and at the rear of the body. Ensure that the distance is
the same at the front of the body and at the rear of the body.
26. Install one pad (18) and the required shims (19) and/or plates (20) in four places. Install three bolts (21), three washers (22), and three nuts
(23) in four places to secure the pads and shims. Evenly tighten bolts (21) to a torque of 105 ± 20 N·m (80 ± 15 lb ft).
Note: Block the body in position when you install the shims and pads.
28. Remove the block and lower the body to the DOWN position.
29. Measure the gap between the rocker pads (18) and the body. Add equal amounts of shim (19) and/or plates (20) to each side to take up the
gap. Refer to Step 19 for the proper procedure to add shims (19) or plates (20).
30. Raise and lower the body to make sure that all mounted pads have even contact with the frame.
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31. Attach arm (M) of the body position sensor to the truck body. Secure arm (M) with existing bolt (N).
Note: The body position sensor will be calibrated later in the assembly procedure.
32. Position the grease line for the hoist cylinder to the bottom of the body assembly. Install 16 bolts (24), 16 washers (25), and 16 clips (26) to
secure the grease lines.
NOTICE
The rock ejector brackets should be installed after the body has
been installed.
34. Attach a string and a plumb bob to the center of bracket (27). Position bracket (27) to the body. Check the distance that separates the string
and the wheel group assembly. The string must be centered in the middle of the two tires. Bracket (27) that is installed should be centered in
the forward position, in the rear position, and in the side position. Refer to Illustration 402.
35. After the position of bracket (27) has been determined, prepare the surface for welding by removing paint and dirt from the body.
Note: Reference this table for weld specifications.
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36. Position rock ejector bracket (27) to the bottom of the body. The approximate weight of the bracket is 64 kg (141 lb).
Weld Tolerances
Weld Description
W5 10 mm (0.40 inch) with a 1.50 mm (0.06 inch) penetration (two Places)
W6 8 mm (0.31 inch) with a 1.50 mm (0.06 inch) penetration (two Places)
W7 6 mm (0.23 inch)with a 2.5 mm (0.098 inch) penetration (two Places)
Table 88
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38. Use a suitable lifting device to position ejector (28) to bracket (27).
Note: The ejector weighs approximately 115 kg (254 lb).
39. Install pin (29) and slowly lower the rock ejector between the rear tires.
40. Check the clearance on both sides of the rock ejector to the rear tires.
41. Install washer (30) and two cotter pins (31) to secure ejector (28) to the bracket.
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42. Remove paint and dirt from the body and ejector (28) to prepare the surfaces to weld two pads (32).
43. Weld one pad (32) to the body and weld one pad (32) to ejector (28).
Note: Refer to table 88 for weld specifications.
45. Repeat Step 34 through Step 44 for the other side of the machine.
Table 89
1. Clean the paint from the mounting surfaces of the hoist cylinder.
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3 1 311-3586 Film
4 1 311-3587 Film
5 1 311-3591 Film
6 2 311-3595 Film
Table 90
Note: The film on the right side platform is installed at the factory.
(AA) 1650 ± 5 mm
(64.960 ± 0.197 inch)
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2. Position the film to the fender. Apply tape only at the top to hold film in place.
Note: Do not remove the backing from the film.
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6. Use a heat gun and a plastic straight edge to dry and smooth the film.
Note: The straight edge is used to remove any air bubbles.
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NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting, and
repair of the product. Be prepared to collect the fluid with
suitable containers before opening any compartment or
disassembling any component containing fluids.
Do not perform any of the procedures until you have read the information in this publication.
Reference: Special Instruction, REHS1841, "General Welding Procedures" for additional welding instructions.
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Reference: Refer to Operation and Maintenance Manual, SEBU8454, "Cat® Integrated Object Detection System for Off-Highway Trucks" for the
orientation of the radar. The radar orientation is critical for the operation of the object detection system.
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or
precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.
A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions
properly.
Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death
could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure that any tool, procedure, work
method, or operating technique you use that is not recommended by Caterpillar is safe.
Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or repair
procedures used.
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(2) Cable
1. Raise the truck body and install retaining cable (2) for the truck body.
3. Turn the key start switch and the disconnect switch to the OFF position.
Table 91
(1)
Part of the 336-6684 Camera Gp
Table 92
(1)
Each object detection box group includes a 365-1271 Object Detection Sensor Gp
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Table 93
(1)
(2) With379-8133 Plate As
(3) Assembled in "Assemble the Radar Boxes to the Brackets"
Assembled in "Assemble the Front Camera to the Brackets"
Table 94
(1)
(2) With378-6997 Bracket As
(3) Assembled in "Assemble the Radar Boxes to the Brackets"
Assembled in "Assembly the Side Cameras to the Brackets"
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1 - Camera Assembly(3)
1 363-7065 Plate As
6 8T-4195 Bolt
4 7W-9094 Spacer
1 378-7007 Plate As
4 8T-4183 Bolt
4 198-4778 Hard Washer
2 7X-7729 Washer
1 372-9143 Plate
4 8T-4189 Bolt
4 5P-4116 Hard Washer
6 8T-4137 Bolt
6 8T-4121 Hard Washer
1 219-6485 Flood Lamp Gp
4 7N-3718 Clip
2 4D-7794 Clip
1 6D-4246 Clip
1 124-3019 Bracket As
1 217-4590 Bracket As
Table 95
(1)
(2) With378-6997 Bracket As
(3) Assembled in "Assemble the Radar Boxes to the Brackets"
Assembled in "Assembly the Side Cameras to the Brackets"
Table 96
(1)
(2) With 379-8133 Plate As
(3) Assembled in "Assemble the Radar Boxes to the Brackets"
(4) With 372-9144 Bracket As
Assembled in "Assemble the Radar Boxes to the Brackets"
(5)
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(5)
Assembled in "Assemble the Camera Components"
Table 97
(1)
Part of the 336-6684 Camera Gp
Note: An arrow is at the top of the camera lens which indicates the up direction of the camera. The camera that is going to be installed on the rear
of the truck needs to have this arrow installed facing up.
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(2) Bolt
(3) Camera
(4) Bolt
(5) Nut
(6) Nut
1. Assemble the four cameras with the parts that are supplied with the cameras.
Refer to Illustration 427.
Note: Do not tighten the nuts (6). The nuts will be used in the following procedure to attach the camera to the brackets for the camera.
2. Route the camera harness and the connector through the hole that is provided in plate assembly (7) and plate assembly (9). Place the
grommet that is provided on the harness for the camera through the hole. Repeat this procedure for all the cameras.
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(6) Nut
(6) Nut
3. Use bolts (4) and nuts (6) to secure the 336-6684 Camera Groups to the plate assemblies.
1. Secure plate assembly (7) to bracket (13) by using three bolts (10), six hard washers (11), and three nuts (12).
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2. Secure bracket (13) to bracket (14) by using four bolts (15), eight washers (16), and four nuts (12).
3. Secure camera harness (A) to bracket (13) by using one clip (17), one bolt (15), two hard washers (11), and one nut (12).
1. For the two side cameras, mount the camera groups and plate assemblies (7) to plate assembly (18) by using six bolts (10), 12 hard washers
(11), and six nuts (12).
NOTICE
The 365-1271 Object Detection Sensor Groups must be
handled gently.
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Table 98
(1)
Each object detection box group includes a 365-1271 Object Detection Sensor Gp
Note: Mounting location is important. Each radar box must be mounted in the designated location that is labeled on the harness connector for each
box.
The boxes for the Object Detection System are assembled before shipping. Use the following procedure to assemble the mounting brackets to the
radar boxes.
Note: Inspect the grommet on the bottom of the radar box to ensure that the sealant has not been disturbed during shipment. If the seal is not
intact, use silicone sealant to seal the grommet.
Reference: Refer to Operation and Maintenance Manual, SEBU8454, "Cat® Integrated Object Detection System for Off-Highway Trucks" for the
orientation of the radar. The radar orientation is critical for the operation of the object detection system.
1. Locate four object detection box groups (1) and four plate assemblies (2).
2. Secure four box groups (1) to four plate assemblies (2) by using 16 bolts (3), four plates (4), and eight hard washers (5).
Note: The four box groups assembled in Step 2 are for the front two locations and the two lower rear locations.
Note: Ensure that each box group is assembled with two hard washers (5) and one plate (4). Plates (4) should be on the outside facing
section of each box group.
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3. Locate two object detection box groups (1) and two bracket assemblies (7).
4. Secure two box groups (1) to two bracket assemblies (7) by using eight bolts (6), two plates (4), eight hard washers (8), and four hard
washers (5).
Note: The two box groups assembled in Step 4 are for the upper two rear locations.
Note: Hard washers (8) are located between box group (1) and bracket assembly (7).
Note: Ensure that each box group is assembled with two hard washers (5) and one plate (4). Plates (4) should be on the side of the box
group that faces the right side of the machine.
5. Locate two object detection box groups (1) and two brackets (9).
6. Secure two box groups (1) to two brackets (9) by using eight bolts (6), two plates (4), eight hard washers (8), and four washers (5).
Note: The two box groups assembled in Step 6 are for the two side locations.
Note: Hard washers (8) are located between box group (1) and bracket (9).
Table 99
(1)
(2) With 379-8133 Plate As
(3) Previously assembled in "Assemble the Radar Boxes to the Brackets"
Previously assembled in "Assemble the Front Camera to the Brackets"
Reference: Refer to Operation and Maintenance Manual, SEBU8454, "Cat® Integrated Object Detection System for Off-Highway Trucks" for the
orientation of the radar. The radar orientation is critical for the operation of the object detection system.
Each radar box has a specific mounting location. The radar sensors have individual part numbers on the harnesses at the bottom of the box.
1. Secure two plate assemblies (1) to plate assembly (2) by using four bolts (3) and four washers (4).
2. Secure the two assembled radar box groups to plate assembly (2) by using eight bolts (5), 16 washers (4), and eight locknuts (6).
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4. Secure sensor harness assembly (11) to plate assembly (2) and one plate assembly (1) by using three bolts (7), three hard washers (8), two
clips (9), and one clip (10).
5. Secure the two plate assemblies (1) to the front of the bumper by using four bolts (12) and four hard washers (13).
6. Connect sensor harness assembly (11) to existing wiring harness assembly (A).
7. Secure sensor harness assembly (11) to the top of the front bumper by using one clip (14), one bolt (15), and one hard washer (16).
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8. Secure two brackets (17) onto the bracket assemblies for the radar boxes by using four bolts (18) and four washers (19).
Note: Brackets (17) must be installed to help ensure that the radars are oriented in the proper location.
1. Secure the front camera that was previously assembled to the front of the platform assembly at the top of the stairway by using four bolts (3)
and four washers (4).
2. Connect existing harness assembly (B) to the harness assembly for the camera assembly.
Table 100
(1)
(2) With 378-6997 Bracket As
(3) Previously assembled in "Assemble the Radar Boxes to the Brackets"
Previously assembled in "Assembly the Side Cameras to the Brackets"
Reference: Refer to Operation and Maintenance Manual, SEBU8454, "Cat® Integrated Object Detection System for Off-Highway Trucks" for the
orientation of the radar. The radar orientation is critical for the operation of the object detection system.
Installation of the Radar Box Group for the Object Detection (Left-Hand Side)
1. Secure plate assembly (1) to the side of the left-hand walkway by using four bolts (2) and four spacers (3).
2. Secure one plate assembly (4) to plate assembly (1) by using four bolts (5) and four hard washers (6).
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3. Secure one side radar group that was previously assembled to plate assembly (4) by using two bolts (2) and two washers (7).
4. Secure one plate (8) to the top of the radar group by using four bolts (9) and four hard washers (10).
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1. Secure one camera assembly that was previously assembled to the left-hand walkway by using four bolts (11) and four hard washers (12).
1. Secure one flood lamp group (13) to the side of the camera assembly bracket. Use the hardware provided with flood lamp group (13) to
secure lamp group (13).
Note: Tighten nut (A) to a maximum torque of 20 N·m (177 lb in).
1. Connect the existing harness assembly to the flood lamp group, the camera assembly, and the radar assembly.
2. Secure the harness assembly by using two bolts (11), four hard washers (12), two clips (14), two clips (15), one bracket assembly (16), one
clip (17), one bolt (18), and one nut (19).
One clip (14) must be secured between the bracket for the camera assembly and the flood lamp group.
Secure both clips (15) with the existing hardware that secures the bracket for the camera assembly to the side of the walkway assembly.
Table 101
(1)
(2) With 378-6997 Bracket As
(3) Previously assembled in "Assemble the Radar Boxes to the Brackets"
Previously assembled in "Assembly the Side Cameras to the Brackets"
Reference: Refer to Operation and Maintenance Manual, SEBU8454, "Cat® Integrated Object Detection System for Off-Highway Trucks" for the
orientation of the radar. The radar orientation is critical for the operation of the object detection system.
Installation of the Radar Box Group for the Object Detection (Right-Hand Side)
1. Secure plate assembly (1) to the right side of the right-hand platform by using four bolts (2) and four spacers (3).
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2. Secure plate assembly (4) to plate assembly (1) by using four bolts (5) and four hard washers (6).
3. Secure one side radar group that was previously assembled to plate assembly (4) by using two bolts (2) and two washers (7).
4. Secure one plate (8) to the top of the radar group by using four bolts (9) and four hard washers (10).
1. Secure one camera assembly that was previously assembled to the right-hand platform by using four bolts (11) and four hard washers (12).
1. Secure one flood lamp group (13) to the side of the camera assembly bracket. Use the hardware provided with flood lamp group (13) to
secure lamp group (13).
Note: Tighten nut (A) to a maximum torque of 20 N·m (177 lb in).
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1. Connect the existing harness assembly to the flood lamp group, the camera assembly, and the radar assembly.
2. Secure the harness assembly by using two bolts (11), two hard washers (12), four clips (14), two clips (15), one clip (16), one bracket
assembly (17) and one bracket assembly (18).
Clips (14) and bracket assembly (17) must be secured using the existing hardware for mounting the radar box assembly.
Bracket assembly (18) must be secured between the bracket for the camera assembly and the flood lamp group.
Table 102
(1)
(2) With 379-8133 Plate As
(3) Previously assembled in "Assemble the Radar Boxes to the Brackets"
(4) With 372-9144 Bracket As
(5) Previously assembled in "Assemble the Radar Boxes to the Brackets"
Previously assembled in "Assemble the Camera Components"
Reference: Refer to Operation and Maintenance Manual, SEBU8454, "Cat® Integrated Object Detection System for Off-Highway Trucks" for the
orientation of the radar. The radar orientation is critical for the operation of the object detection system.
Installation of the Radar Box Groups for the Object Detection (Rear)
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1. Secure two plate assemblies (1) to the frame at the rear of the machine by using eight bolts (2) and eight washers (3).
2. Secure two brackets (4) to plate assemblies (1) by using four bolts (5) and four washers (3).
3. Secure two brackets (4) to the frame at the rear of the machine by using four bolts (6) and four washers (3).
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4. Secure two radar boxes (A) to two upper brackets (4) and two radar boxes (B) to two lower brackets (4) by using 16 bolts (6), 32 washers (3),
and 16 locknuts (7).
5. Secure four brackets (8) onto the bracket assemblies for the radar boxes by using eight bolts (9) and eight washers (10).
Note: Brackets (8) must be installed to help ensure that the radars are oriented in the proper location.
1. Secure the rear camera group to the rear of the frame by using two bolts (2) and two washers (3).
2. Connect the harness for the camera assembly to existing harness assembly (C).
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2. Secure harness assembly (11) to the frame by using two clips (12) and three clips (13).
Note: Two clips (12) and three clips (13) shown in Illustration 461 must be secured by using existing bolts and studs.
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3. Connect sensor harness assembly (11) to the four radar box assemblies.
4. Secure sensor harness assembly (11) by using one clip (13), four clips (14), one clip (15), one clip (16), one bolt (17), one hard washer (18),
one clip (19), and one clip (20). Refer to Illustration 462 and Illustration 463 for the location of the hardware.
Note: Except for clip (19) and clips (20), all clips use existing hardware to secure harness assembly (11).
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1. Install monitor display group (1) to bracket assembly (2) with two bolts (3) and two washers (4).
2. Install bracket assembly (2) to the cab with two screws (5).
3. Connect the three 319-6830 Sensor Harness As 12-pin connectors to the corresponding connectors on the back of the display. The video
cable connects to the green connector. The 12-pin connector with two wires connects to the black connector and the 12-pin connector with
five wires connects to the gray connector.
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4. Connect the 19-pin bulkhead connector (6) of the 359-7645 Cab Harness As.
Required Material
Caterpillar Electronic Technician CAT (ET)
Communication Adapter
Software
System Part Number Description Notes
387-3090 Caterpillar Integrated Object Detection System Radar and Camera
8 Radar System
393-0420 Caterpillar Integrated Object Detection System Cameras only
393-0419 Caterpillar Integrated Object Detection System Radar and Camera
12 Radar System
393-0420 Caterpillar Integrated Object Detection System (Vision Only) Cameras only
Table 103
Perform the following procedure to flash program the ECM. The ECM is flashed to upgrade the software. Flash programming of the ECM must be
done if the ECM has been replaced. Caterpillar Electronic Technician (Cat ET) contains the program WinFlash. WinFlash is used to load the
software into the ECM. The following procedure is used to flash the software into the display.
Procedure
1. Ensure that the key start switch and the disconnect switch are in the OFF position.
3. Connect the 345-7489 Monitor Harness As between the system harness for the display and the center connector on the display.
4. Connect the 7X-1425 Data Link Cable As between the 7X-1700 Communication Adapter Gp and Cat ET.
5. Connect the 139-4166 Data Link Cable As between the 7X-1700 Communication Adapter Gp and the diagnostic connector of the 345-7489
Monitor Harness As.
8. Disconnect the 345-7489 Monitor Harness As from the system harness for the display and the center connector on the display.
9. Connect the 12-pin connector of the system harness to the center connector of the display.
10. Turn the disconnect switch and the key start switch to the ON position.
11. Verify that the display turns on and the Caterpillar Integrated Object Detection system starts.
Note: Refer to Special Instruction, REHS5191 regarding information for the CIODS.
793D Front and Rear Radar Angles (As Measured with Angle Finder)
Front Radar Rear Radar
Radar
Azimuth (deg) Elevation (deg) Azimuth (deg) Elevation (deg)
Left Upper N/A N/A 15 right of center 8 down
Right Upper N/A N/A 15 left of center 8 down
Left Lower 25 left of center 1 Down 20 right of center 9 down
Right Lower 25 right of center 1 Down 20 left of center 9 down
Table 104
Table 105
793D Front and Rear Radar Angles (As Measured with Degree Marks on Bracket)
Front Radar Rear Radar
Radar
Azimuth (deg) Elevation (deg) Azimuth (deg) Elevation (deg)
Left Upper N/A N/A 15 right of center -2 down
Right Upper N/A N/A 15 left of center -2 down
Left Lower 0 left of center 1 down 20 right of center -1 down
Right Lower 0 right of center 1 down 20 left of center -1 down
Table 106
Table 107
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Table 108
Table 109
Required Tools
13mm Wrench 1
Protractor 1
Table 110
1. Loosen the four azimuth adjustment bolts on the brackets for the radars.
2. Use a protractor to set the proper azimuth angle that is listed in Table 108 or adjust the angle to fine-tune the system.
3. Carefully tighten the four azimuth adjustment bolts on the brackets for the radars.
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4. Check the angle again to verify that the bracket is set to the proper angle.
6. Check the angle again to verify that the bracket is set to the proper angle.
Table 111
1. Loosen the four adjustment bolts on the bracket for the radar.
2. Use an inclinometer or a digital level to set the proper elevation angle that is listed in Table 108 or adjust the angle to fine-tune the system.
3. Carefully tighten the four azimuth adjustment bolts on the brackets for the radars.
4. Check the angle again to verify that the bracket is set to the proper angle.
6. Check the angle again to verify that the bracket is set to the proper angle.
7. Perform the Operation and Maintenance Manual, SEBU8454, "Cat® Integrated Object Detection System for Off-Highway Trucks".
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Table 112
Table 113
(1)
Check the After Cooler level and the Jacket Water level.
VIMS Self-Test
Turn the ignition switch key from the OFF position to the ON position to activate the VIMS self-test. Do not start the truck.
Check for the Illumination of the Lights in the instrument panel(1) Check if OK
Body indicator position
Action Indicator
Retarder Indicator
TCS Indicator
Alert Indicator
Table 114
(1)
All the indicator lights will illuminate at the same time for several seconds and then turn off.
Reference: Testing and Adjusting, Troubleshooting, RENR2631, "784C, 785B, 785C, 789B, 789C, 793B, 793C, 793D, 797, 797BOff-Highway
Truck/Tractors Vital Information Management System (VIMS)"
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1. Connect a laptop computer to the Caterpillar Diagnostic Connector on the fuse panel behind the operator seat.
2. to power the electrical system of the truck, perform the steps that follow:
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Note: When the key is in the "ON" position, the VIMS will perform a 4 to 6 second self test. Disregard the VIMS self test at this time.
5. The Electronic Technician (ET) Selector screen should display the truck model for each control. Make sure that the model is correct for each
of the controls.
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11. Check the "Engine Serial Number". The "Engine Serial Number" must match the engine serial number on the engine.
12. Adjust the "Fuel Ratio Control Offset", if necessary. The "Fuel Ratio Control Offset" has an adjustable range of -25 to 25. The normal setting
for the "Fuel Ratio Control Offset" is 0.
Note: Refer to Testing and Adjusting, SENR1123, "Fuel Ratio Control"
13. Verify the "Ether Control" setting. Set the "Ether Control" setting as desired to the "Enabled" or the "Disabled" position.
14. If equipped, verify that the "Oil Renewal Rate" control is set as desired. The "Oil Renewal Rate" has an adjustable range from -50 to 50.
Note: Refer to Systems Operation, RENR2223, "Oil Renewal System".
15. If equipped, verify the "Engine Pre-Lube" setting. A truck that is equipped with the engine prelube attachment can be "Enabled".
16. Verify the "Cold Clylinder Cut-Out" setting. "Enable" or "Disable" the "Cold Clylinder Cut-Out" as desired.
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4. Select the "INCLUDE ALL ECMs" at the bottom right of the screen.
5. At the bottom left of the screen, click the clear button to clear the codes.
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7. Clear any logged diagnostic codes by highlighting an event. Next, click the "Clear" button that is located in the lower left corner of the screen.
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10. Clear the logged event by selecting an event and clicking the "Clear" button that is located in the lower left corner of the screen.
Note: Depending on the event, a factory assigned password is required to clear some of the events that are logged on the engine "ECM".
1. Click "Service". Select "Calibrations". Select and click "Injector Codes Calibration".
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2. Illustration 489 is a typical view of the injector trim codes and is for reference only.
3. Record all the injector trim codes for your machine in the table that is provided below.
Engine Injector Trim Code(1)
Injector Trim Code Injector Trim Code
1 9
2 10
3 11
4 12
5 13
6 14
7 15
8 16
Table 115
(1)
Default is 1100
Note: An Injector trim code is stamped on each injector. If an injector is changed, the new injector trim code must be updated in the engine
"ECM".
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1. Click "Diagnostics". Select "Diagnostic Tests". Select and click "Override Parameters".
2. To test the ether control operation, select "Ether Injection". Click the "Change" button that is located in the lower left corner of the screen.
3. Click the drop-down for the "New Value:" and toggle the value from "Off" to "On". Click "OK".
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5. If the ether control test is acceptable, select "Ether Injection Override" to return the mode to normal.
1. If equipped, select "Engine Pre-Lube". Click the "Change" button that is located in the lower left corner of the screen.
2. Click the drop-down for the "New Value:" and toggle the value from "Off" to "On". Click "OK".
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4. When the engine pre-lube test is completed, select "Disable Override" to return the mode to normal.
2. To test the oil renewal setting, select "Oil Renewal". Click the "Change" button that is located in the lower left corner of the screen.
3. Click the drop-down for the "New Value:" and toggle the value from "Off" to "On". Click "OK".
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5. When the oil renewal test is completed, click "Disable Override" to return the mode to normal.
6. Click "Service". Select and click "Configuration" to go back to the main configuration screen.
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1. Select and click "Configuration Group 1" under the heading "Transmission 793".
Note: Do not adjust the "Hoist System Enable Status" or the "Hoist Lower Valve Adjustment Status" at this time.
2. If the truck is equipped with the oil renewal attachment, verify that the control is set as desired.
3. Adjust all the values as required by the machine configuration. Also, adjust the values required by the mine.
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7. Set the "Desired Engine Retard Speed" between 1850 RPM and 1950 RPM.
9. If a differential cooler is installed on the machine, change the value to "Installed". If a differential cooler is not installed on the machine,
change the value to "Not Installed".
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11. The "Engine Cooling Fan Configuration" value should be set to "Additional Cooling"
Note: For all merchandising arrangements, the "Engine Cooling Fan Configuration" should be set to "Additional Cooling".
12. The "Brake Cooling Pump Configuration" value should be set to "Standard Cooling" for all machines except the "Extra Retarding Truck" and
the "High Altitude Arrangement Truck".
14. Verify the product "I.D." matches the machine serial number.
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17. The Electronic Technician (ET) portion of the commissioning procedure is complete.
VIMS
1. Connect a 127-9797 Cable As to the "RS-232" port on the laptop computer. Connect the other end of the 127-9797 Cable As to the
diagnostic port in the panel behind the operators seat. Observe the gauges, warning lights, and service lights when using the laptop computer
during the operation of the truck.
Note: The key is in the ON position.
3. 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.
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5. After the connection is completed, click "Data". Select and click "Download".
6. In the "Download Data" box, select all the boxes under "Download".
7. In the "Download Data" box, select everything under "Reset After Download".
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10. In the "Assign Serial/Equipment Number" box, change the serial number to match the new truck serial number.
11. In the "Assign Serial/Equipment Number" box, change the "Equipment" number to correspond to the new customer machine number. Click
OK.
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5. Prime the pump drive housing and the hoist pump with the recommended oil or crank the engine. Crank the engine over two times for 15
seconds to fill the compartments with oil.
Engine Start Up
NOTICE
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Engine
Brake/Hoist
10. With the engine operating, turn the steering wheel from the center position three rotations to the left. Next, turn the steering wheel back to the
center position.
11. With the engine operating, turn the steering wheel from the center position three rotations to the right. Next, turn the steering wheel back to
the center position.
12. Turn off the engine. Disable the engine at ground level and check all fluid levels. Check for leaks.
13. Restart the engine and operate the engine for 60 seconds.
14. Turn off the engine. Disable the engine at ground level and check for leaks.
15. Restart the engine. Operate the engine until normal operation temperatures are reached. Check for leaks.
NOTICE
A procedure is required to purge any air that may be in the
(ARC) system. Purge air from the (ARC) system if the following
events have occurred:
Any hoses that supply oil to the automatic retarder control valve have been disconnected
Any hoses that supply the oil from the automatic retarder control valve to the brakes have been disconnected
Autolube
NOTICE
Before sending the machine to work, set the "Lube Cycle Time"
to an interval of 60 minutes. Set the "Lube Cycle Time" to a
duration of 75 seconds. Be satisfied that all the automated
grease injectors are receiving a sufficient supply of grease.
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3. Using the "VIMS" key pad, enter the code 582738 to verify the lubrication settings.
4. Press OK.
6. If necessary, use the left arrow or the right arrow to set the correct interval.
7. Press OK.
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4. After the engine has started, the automatic elevated low idle will activate in 10 minutes. When activated, the automatic elevated low idle
increases the idle RPM gradually at a rate of 33 RPM per second.
5. After the activation of the elevated idle speed, or if the coolant temperature rises above 70 °C (158 °F), the operator may reset the 10 minute
delay. Tapping the accelerator pedal to more than 25 percent of the pedals total travel will reset the 10 minute delay and return the engine to
low idle.
6. The air dryer should expel air at 827 ± 34 kPa (120 ± 5 psi).
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7. The air pressure at the VIMS screen should read 827 kPa (120 psi). For adjustment of the air pressure Refer to Testing and Adjusting, "793D
Off-Highway Truck Air System and Brakes"
4. The air pressure should not drop more than 1 PSI in 2 minutes
11. Raise the air pressure governor to the maximum pressure of 827 ± 34 kPa (120 ± 5 psi)
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12. Open the valve to purge the air and reduce the air pressure to 455 kPa (66 psi)
13. A pressure of 455 kPa (66 psi) should produce a level "I" warning on the VIMS screen.
Note: If the truck is in gear, then a level "III" warning would be produced.
14. Perform an air system integrity test. The air system integrity test will check the entire air system of the truck.
Truck should remain shutdown and undisturbed for 5-6 hours (recommended).
Air system pressure drop should not exceed 138 kPa (20 psi).
If the air system pressure drop exceeds 138 kPa (20 psi), refer to Troubleshooting Compressed Air System Components and
Performance, REHS1428 for troubleshooting instructions.
Note: The truck requires 518 kPa (75 psi) to start the engine, if equipped with air start.
1. Locate the air dryer near the left front wheel of the machine.
2. Check the amount of heater voltage at the electrical connection of the dryer.
Table 116
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3. Under the heading "Transmission 793" select "Configuration Group 1". Select and click "Hoist System Enable Status".
5. Use the drop-down to change the "Hoist System Enable Status" to "Enabled". Click "OK". Select "OK" in the verification box.
1. With the engine running, record the pressures in the table provided.
Steering Pressure Test(1)
Test Actual
Test the pressure setting for the (Priority Valve) Solenoid Valve and Manifold (Rear Axle Fan, Brake Cooling, Drive
Motor, Lubrication, and Steering)
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Test the steering cycle time at high idle. With all the brakes released, turn the steering wheel from left to right and 2.________________
Avg.______________
Left to Right
1.________________
Test the steering wheel turns from stop to stop at high idle. With all the brakes released, turn the steering wheel at 1
2.________________
Avg.______________
Right to Left
1.________________
Test the steering wheel turns from stop to stop at high idle. With all the brakes released, turn the steering wheel at 1
2.________________
Avg.______________
Table 117
(1)
(2) Steering oil temperature during tests 90.5° ± 30.5°C (195° ± 55°F)
(3) The first of two accumulators
The second of two accumulators
1. Use the table below to record the performance of the torque converter.
Note: Engine speed is reduced to 1600 rpm when the transmission is in reverse and the body is in the raised position. The torque converter
stall test must be performed when the transmission is in the first forward gear and the body is in the lowered position.
Test Actual
Torque Converter Oil Temperature (during tests) > 80 °C (176 °F) < 121 °C (250 °F)
Low Idle
Stall
Low Idle
NEUTRAL/DIRECT DRIVE(2)
Table 118
(1)
(2) Maximum pressure at high idle with cold oil.
At 1300 RPM
Transmission Test
Reference: Testing and Adjusting, "793D Off-Highway Truck Power Train"
1. Use the table below to record the transmission and torque converter pressures.
Table 119
(1)
(2) Adjust with the Transmission Relief Valve
Result of setting Direct Drive Pump Pressure
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1. Operate the engine at low idle and record the pressure in the table provided.
2. Operate the engine at high idle and record the pressure in the table provided.
Right Side
Right Side
Table 120
1. Install a 8T-0857 Pressure Gauge ( 0 to 10000 kPa (0 to 1450 psi)) to the pressure taps for the parking brake release pressure.
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6. Record the pressure for the left side and right side in the table provided.
Towing Motor Pressure
Side Actual
Left
Right
Table 121
This test will show if the parking brake release pump section is working properly. This test will also show if the relief valve for the parking brake
release system is set correctly.
1. Record the results of the pressure test in the table that is provided.
Parking Brake Pressure
Setting Actual
Relief Valve
Table 122
Brake Wear
Piston Travel Front Brake Front Brake Percent of wear Rear Brake Rear Brake Percent of wear
Baseline
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Rebuild 1
Rebuild 2
Rebuild 3
Rebuild 4
Rebuild 5
Rebuild 6
Rebuild 7
Table 123
3. When the transmission neutralizer switch activated, indicator light (2) should be on.
6. Use the table below to record the results of Step 4 and Step 5.
Transmission Neutralizer Switch
Gear Switch Activated Engine does not start. Check if OK
First
Reverse
Table 124
7. Complete the operations below and record the results in the table provided.
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With the gear selector in REVERSE, put the hoist lever in the raised position. The transmission should shift into NEUTRAL.
With the gear selector in REVERSE, put the hoist lever in the lower position. The transmission should shift into NEUTRAL.
While traveling in sixth gear at full throttle, shift the transmission from SIXTH gear-down to FIRST gear. The transmission should not
downshift. When safe, the transmission will downshift. (2)
While traveling at a speed of 7 mph in FIRST gear, shift the transmission to REVERSE. The transmission should shift into NEUTRAL
then shift into reverse at 3.2 km/h (2 mph)(3)
Table 125
(1)
(2) Produces a level 1 VIMS warning
(3) Checks the downshift inhibitor
Checks the reverse shift inhibitor.
Replace the 343-4465 Oil Filter Element with a 343-4465 Oil Filter Element or a 1R-0741 Oil Filter Element Assembly.
Note: The 343-4465 Oil Filter Element is recommended for replacement, however the 1R-0741 Oil Filter Element Assembly is also an acceptable
replacement.
Note: The 343-4465 Oil Filter Element is for power train use only and not approved for hydraulic applications.
Contamination is one of the major causes of transmission control system failure. Some power train oil systems were cleaned with fine cleanout
filters, which frequently caused oil to bypass the filter. The use of cleanout filters in power train oil systems is no longer recommended. A new line
of advanced efficiencyCaterpillartransmission filters have been introduced for use in power train application.
Note: Sound the horn for the all clear before starting the engine.
3. With the TCS switch activated and the engine at low idle, drive the machine to the right in a tight circle.
Note: The rear wheels should lock and unlock.
4. With the TCS switch activated and the engine at low idle, drive the machine to the left in a tight circle.
Note: The rear wheels should lock and unlock.
2. Start the engine and allow the air pressure to reach the cutout pressure.
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4. Move the parking brake control to the OFF position. Do not depress the secondary brake control.
6. With the brake pedal depressed, increase the engine speed to 1300 rpm. The machine should not move.
7. If the machine moves, inspect the brake system for wear or for damage. Correct the air pressure. See the Systems Operation/Testing And
Adjusting, "Braking System Troubleshooting".
2. Start the engine and allow the air pressure to reach the cutout pressure.
4. Move the parking brake control to the OFF position. If the machine moves, see Systems Operation/Testing And Adjusting, "Braking System
Troubleshooting".
6. Increase engine speed to 1300 rpm. The machine should not move.
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7. If the machine moves, inspect the brake system for wear or for damage. Correct the air pressure. See Systems Operation/Testing And
Adjusting, "Braking System Troubleshooting".
Note: The secondary brake air control valve activates all the wheel brakes. The wheel brakes are applied by spring pressure and the wheel brakes
are released by oil pressure.
1. Start the engine. Allow the pressure to reach the cutout pressure.
7. Increase engine speed to 1300 rpm. The machine should not move.
8. If the machine moves, inspect the brake system for wear or for damage. Correct the air pressure. See the Systems Operation/Testing And
Adjusting, "Braking System Troubleshooting".
Suspension Cylinders
The VIMS Truck Payload System will not operate until a successful payload calibration has been completed.
Security
Note: This service program code only functions while the service tool "VIMSpc" is connected.
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The following information describes the service program code 729225 (PAYCAL). The PAYCAL service program code uses the following procedure
to calibrate the VIMS Truck Payload System:
1. Ensure that the truck body is empty. Carryback weight will affect the payload measurement.
4. Operate the truck to a minimum ground speed of 6.4 km/h (4 mph) on hard level ground.
5. Move the transmission gear selector to the neutral position and allow the truck to coast. DO NOT use the service brakes or the retarder.
7. After the "PAYLOAD CALIBRATED" is shown on the message screen, go to the VIMS screen.
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Table 126
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The seat belt catch should unlatch from the buckle when required
Table 127
Engine Start
Check the Ignition Switch, Horn, and Engine Start Check if OK
Turn the ignition key to the ON position(1)
Sound the horn for all clear
Turn the key to the START position to activate the starting motor.
After the diesel engine starts, release the key. The key should return to the ON position
Turn the ignition key to the OFF position. The engine should stop
Table 128
(1)
The key in the ON position enables the electrical circuits in the cab and activates the VIMS self-test
Table 129
(1)
(2) Pressurizing the Cab helps to eliminate dust in the operators compartment
There should be an audible sound between the different settings
Climate Control
Check the operation of the Heater and the Air Conditioner Check if OK
Sound the horn for all clear
Start the engine
Turn the climate control to cool
Push the top of the A/C switch to activate
Air from the dash vents should be cold(1)
Push the top of the A/C switch to deactivate
Turn the climate control to warm
The lines for the heater valves should be open(2)
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Table 130
(1)
(2) When the engine is at operating temperature
Refer to illustration 550
Window Wipers
Check the Operation of the window Wiper and Washer Check if OK
Turn the ignition key to the ON position
From the OFF position, turn the window wipers to the LOW setting
Turn the window wiper to the HIGH setting
Press the button to activate the window washer fluid
Turn the window wiper to the first INTERMITTENT setting
Turn the window wiper to the second INTERMITTENT setting
Turn the window wiper to the third INTERMITTENT setting
Turn the window wipers to the OFF position
Turn the ignition key to the OFF position
Table 131
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Check the operation of the Panel Lights and the Headlights(1) Check if OK
Turn the ignition key to the OFF position
Push the top half of switch (1) to the first detent to activate the instrument panel lights, marker lights, and the tail lights
Push the top half of switch (1) to the second detent to activate low beam headlights (3) and driving lights (5)
Use multifunction switch (2)(2) to toggle between lights (3), lights (5), and high beam lights (4)(3)
Push the bottom half of switch (1) to the OFF position to deactivate the headlights
Table 132
(1)
(2) The tail lights should be on any time a light switch is activated
(3) Refer to illustration 552
Refer to illustration 553
Hazard Lights
Table 133
Fog Lights
Check the operation of the Fog Lights Check if OK
Turn the ignition key to the OFF position
Push the top half of switch (8) to activate fog lights (6)(1)
Push the bottom half of switch (8) to deactivate fog lights (6)(1)
Table 134
(1)
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(1)
Refer to Illustration 554 for the location of the switch
Reverse Lights
Check the operation of the Reverse Lights Check if OK
Turn the ignition key to the ON position
Push the top half of switch (9) to activate the reverse lights(1)
Push the bottom half of switch (9) to deactivate the reverse lights(1)
Table 135
(1)
Refer to Illustration 554 for the location of the switch
Auxiliary Lights
Table 136
(1)
The auxiliary lights can be activated from two places on the machine. The position of one switch will determine whether the other switch is in the ON position or in the OFF
(2) position.
(3) Refer to Illustration 554 for the location of the switch
Refer to Illustration 555 for the location of the switch
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Table 137
(1)
Refer to Illustration 555 for the location of the switch
Table 138
(1)
The dome light and switch are located above the operator in the cab
Cigar Lighter
Check the operation of the Cigar Lighter(1) Check if OK
Turn the ignition key to the ON position
Push the lighter inward and release the lighter
When the lighter is ready to use, the lighter will move outward.
Table 139
(1)
The lighter can also be used as a 12 V power receptacle
Backup Alarm
Check the operation of the backup alarm(1) Check if OK
Turn the ignition key to the ON position
Move the transmission direction and the speed control lever to the REVERSE position
The back-up alarm should sound immediately(2)
Table 140
(1)
(2) Make sure that the area behind the machine is clear of personnel and clear of obstacles
The backup alarm should sound until the transmission direction and speed control lever are moved to the NEUTRAL position or the FORWARD
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.
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3. Connect a 6V-7830 Tetragauge to one of the outlet ports on the hoist pump.
5. With the engine that is running, place the hoist lever in the body float position.
6. With the engine operating at high idle and the body in the snub position, record the pressure.
Note: If the pressure at the hoist outlet port is more than 1723 kPa (250 psi), then proceed to Step 7 and Step 8.
8. 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.
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11. Insert the new value in the "Hoist Lower Valve Adjustment Status" box. Click "OK". Select "Yes" in the verification box.
12. Repeat Step 5 through Step 11 until the pressure is below 1724 kPa (250 psi).
Note: When the pressure is greater than 1724 kPa (250 psi), the adjustment is set too high. Pressure too high causes too much oil to be diverted
to the hoist valve. Too much oil diverted to the hoist valve causes the brake oil to overheat when the body is in the body float position. Reduce the
Hoist Lower Valve Adjustment in ET. Repeat Step 1 through Step 6 to lower the pressure below 1724 kPa (250 psi).
Note: The body down snub function cushions the shock when the body hits the bed of the truck. When the body is lowered, the body position
sensor 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 operators
request is less than the snub mode, the ECM will use the operators request. When the ECM uses the operators request, the ECM ensures that the
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snub function will never cause the body to go down faster than the hoist lever modulation. The body snub function will be Canceled 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 is raised above
the body position sensor activation point.
Suspension Charge
If needed, refer to Special Instruction, SEHS9411, "Servicing the Suspension Cylinders for Off-Highway Trucks".
1. Measure the visible chrome on the four struts to verify the charge.
Table 141
Body Installation
Record Body information
Body Manufacturer/Part Number
Serial Number
Condition
Table 142
2. If the truck is equipped with body heat, verify the proper adjustment of the body heat connection.
3. Check the hoses on top of the hydraulic tank, fuel tank, and the hoses between the frame rails. If necessary, adjust the grease line at the top
of the hoist cylinder to prevent any damage.
Tire Specifications
1. Record the tire specifications in the table provided.
Tire Size Manufacturer
Left Front
Right Front
Left Rear Outside
Left Rear Inside
Right Rear Inside
Right Rear Outside
Table 143
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Miscellaneous Checks
If needed, refer to Operation and Maintenance Manual, SEBU7792, "793D Off-Highway Truck"
1. Perform the following checks and record your results in the table provided.
Miscellaneous Checks
Take Digital Photos of Completed Truck
Missing Parts(1)
Assembly Issues
Performance Issues
Dealer Installed Attachments(2)
Dealer Comments(3)
Verify the function of all Cab Controls
Payload Target
Table 144
(1)
(2) Develop a list of all the part numbers and the next highest part number level.
(3) Take digital photos of all dealer installed attachments.
Record positive and negative comments.
PIP-10853253
2022/05/19
17:42:02-03:00
i02449739
Caterpillar:
Confidential Green
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