793C Armado

2015/12/11 Assembly Procedure For The 793C Off-Highway Truck {7000, 7960} (SEHS9980)
SMCS - 7000,7960 i06558755

Truck
793C (S/N: 4AR1-UP; ATY1-215; 4GZ1-UP)
Introduction PIP
-11
This special instruction contains the necessary procedures for the field preparation, the field assembly, and the commissioning
202 008
procedure of the 793C (S/N: 4AR1-UP; 4GZ1-UP; ATY1-215) Off-Highway Truck.
1 / 6
Note: The photographs in this publication are for illustrative purposes. The differences in the machines are noted in the assembly
15: 0 92
8
procedures.
56: /22
The suggested tools and equipment should be present before assembly. If the recommended tools and equipment are not
SEH 48-
present, assembly will be more difficult and more time will be necessary to complete the assembly.
03:
Do not perform any procedures or order any parts until this publication is read thoroughly.
© 2 998S 00
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.
02 0
1C
Reference: Parts Manual, SEBP2503, "793C (S/N: 4AR1-UP) Off-Highway Trucks"
Cat
erp ater
Reference: Testing and Adjusting, SENR1502, "784C, 785C, 785D, 789C, 793C and 793D Off-Highway Truck/Tractors Power Train
Electronic Control System"
Con illa pill

Reference: Service Manual, SENR1440, "793C (S/N: 4AR1-UP)Off-Highway Trucks"
fide r: ar I
Reference: Operation and Maintenance Manual, SEBU6995, "793C (S/N: 4AR1-UP)Off-Highway Trucks"
nc.
ntia
Reference: Parts Manual, SEBP2791, "793C (S/N: 4GZ1-UP) Off-Highway Trucks"
lG
Reference: Service Manual, SENR1540, "793C (S/N: 4AR1-UP)Off-Highway Trucks"
ree
Reference: Operation and Maintenance Manual, SEBU7175, "793C (S/N: 4GZ1-UP; ATY1-215) Off-Highway Trucks"
n
Reference: Parts Manual, SEBP3022, "793C (S/N: ATY1-UP) Off-Highway Trucks"
Do not attempt to assemble this machine until you read and you
understand the assembly instructions.
Improper assembly procedures could result in injury or death.
NOTICE
Do not allow any dirt or foreign material to get into the
hydraulic system during assembly, connection of lines, when
components are filled with fluid, or during any maintenance
operation.
:
Note: After assembly of the truck is complete, the suspension cylinders must be charged. The air should be purged from the
brake system. Prepare the truck for use. This is shown in the Operations and Maintenance Manual. Use the Parts Manual and the
Service Manual with this special instruction.
NOTICE
Clean all surfaces and remove burrs from all areas where parts
are to be installed. Chase all tapped holes used for mounting
purposes. Remove the paint from all contacting surfaces. This is
necessary for a good solid joint.
Parts List
PIP
Parts That are Required to Install the 8X-2837 Walkway Gp
Qty Part Number

-11
Description
2 114-1238
202 008
Platform Assembly
4 114-1244 Plate
15: 1 /0 6 92
6
12
4V-9810
8T-4139
56: /228
Step Assembly
Bolt
12 5P-1076
SEH 48-
Hard Washer
8 8T-4196 Bolt
S 03:
16 8T-4121
© 2 998
Hard Washer
00
8 8T-4133
0
Nut
2 0
24 1D-4691
Cat 1C
Round Head Bolt
erp ater
24 8T-4223 Hard Washer
24 1K-6872 Locknut
4 114-1243
Con illa
Belt
pill
8 4V-9804
fide r:
Plate
ar I
nc.
Table 1
ntia
lG
ree
Parts That are Required to Install the 8X-0223 Walkway Gp for 793C (S/N: 4AR1-UP)
n
Qty Part Number Description
1 8X-7101 Walkway As
16 2H-3855 Bolt
16 5P-8245 Hard Washer
18 5S-7379 Bolt
5 8T-2502 Bolt
3 6V-8801 Nut
:
1 101-1545 Walkway As
1 124-8213 Cab (1)
Table 2
(1)
The 124-8213 Cab Assembly is not a part of the 8X-0223 Catwalk.
Parts That are Required to Install 152-4784 Walkway Gp for 793C (S/N: 4GZ1-UP; ATY1-215)
16 2H-3855 Bolt
16 5P-8245 (Hard Washer)
18 5S-7379 Bolt
5 8T-2502 Bolt
3 6V-8801 Nut
PIP
1 137-0003 ROPS Cab (1)
-11
Table 3
(1)
202 008
The 137-0003 Cab Assembly is not part of the 152-4784 Catwalk.
15: 1 /0 6
Parts That are Required to Install the 8X-4453 Handhold Fastener Gp
92
Qty Part Number
5P-0765 8
Description
56: /22
Hose
SEH 48-
149 8T-4136 Bolt
03:
1
8X-3838
6B-8085 © 2 998S
Chain
Chain Snap 00
1 8X-9874
02 Chain
0
5 8C-8451
Cat 1C
Bolt
18 8T-4205
erp ater
Hard Washer
5 5C-2890
Con illa Nut
pill
4 8T-4956
fide r:
Bolt
ar I
nc.
ntia
2 2G-9399 Rod
2 2G-2345
lG
Bracket
2 6F-8499 Spring
ree
2
2
0T-0883
3B-4615
Washer
Cotter Pin
n
:
ree
n
4 5K-4549 U-Bolt
8 6V-8185 Nut
1 8X-4303 Rail As (1)
1 8X-4304 Rail As (3)
1 155-6730 Handhold As (1)
1 8X-5545 Handhold As (1)
2 144-9447 Handhold As (1)
2 144-9449 Handhold As (1)
1 138-6709 Handhold As (1)
1 8X-3835 Cab Side Rail Assembly (1)
1 101-1546 Cab Rail Assembly (1) (2)
1 145-2814 Handhold As (1) (3)
1 152-7016 Cab Rail Assembly (1) (4)
1 159-2037 Rail As (1) (5)
Table 4
(1)
(2)
The 8X-4303 Rail Assembly is not a part of the 8X-4453 Fastener Group.
(3)
The rail assembly is for the 793C (S/N: 4AR1-UP) with a body that is standard width.
(4)
The rail assembly is for a 793C (S/N: 4AR1-UP) with a wide body.
(5)
The rail assembly is for a 793C (S/N: 4GZ1-UP; ATY1-UP)with a body that is standard width.
The rail assembly is for a 793C (S/N: 4GZ1-UP; ATY1-UP) with a wide body.
Parts That are Required to Install the 8X-9330 Lighting Group for 793C (S/N: 4AR1-UP)
1 9X-1439 Flood Lamp Gp
1 5L-4241
PIP Spacer
1 8T-4121
-11 Hard Washer
1
202
8T-4133
008 Nut
Table 5
15: 1 /0 6 92
56: /228
Parts That are Required to Install The 168-9897 Ladder Lighting for 793C (S/N: 4GZ1-UP; ATY1-UP)
SEH 48-
03:
1 153-2073 Flood Lamp Gp
1
© 2 998S
5L-4241
8T-4121 00
Hard Washer
Hard Washer
1
025C-7261
0 Nut
1
Cat 1C
8T-4196 Bolt
1
erp ater
8T-4224 Hard Washer
2
Con illa8T-6869
pill Bolt
fide r: ar I
1 140-1088 Bracket
Table 6
ntia nc.
lG
ree
n
:
Con rpilla erpill
fide r: ar I
nc.
ntia
Table 6
lG
Parts That are Required to Install The 8X-0262 Rear View Mirror Gp and 157-8393 Rear View Mirror Gp
Qty
ree
Part Number Description
1
8X-5411
8T-2287
n Pipe (1)
Mirror
1 8Y-6989 Mirror As
1 5P-6873 Mirror
1 8X-5410 Bracket
2 7D-9969 Support
2 3B-4605 Cotter Pin
2 8T-6868 Bolt (2)
5 8T-4136 Bolt
1 134-0987 Bracket Assembly
1 7K-5707 U-Bolt
2 6V-8801 Nut
2 8T-4137 Bolt
2 134-0989 Block
4 8T-4186 Bolt
2 8T-4176 Bolt (3)
1 137-2122 Tube As (4)
1 137-2129 Bracket (5)
Table 7
(1)
(2)
The pipe assembly is for use on a body that is standard width.
(3)
The bolt is for use on 793C (S/N: 4AR1-UP).
(4)
The bolt is for use on 793C (S/N: 4GZ1-UP; ATY1-UP) .
(5)
The tube assembly is for use on a wide body.
PIP
The bracket assembly is for use on a wide body.
-11
Parts That are Required for the Installation of 143-0343 Fender Gp
202 008
1 8X-4285 Plate Assembly
2 145-2815
15: 1 /0
Mud Flap
6 92
1
1
8X-4284
8X-4289
56: /228
Brace
Plate
1 8X-4290
SEH 48- Guard
1 8X-4291
S 03:
Strip
1 8X-4292
© 2 998 Guard
00
1 8X-4293
02 0
Strip
Cat 1C
erp ater
il p
:
EH 8-0
© 2 S998 3:00
02 0
3 8X-4294
Cat 1C Strip
1 8X-4295
erp aterGuard
Con illa pill

1 8W-7899 Guard
fide r: ar I
1 8X-4296 Strip
2 8X-4089 Plate
2 8X-4029
ntia Plate
nc.
2 8X-3822
lG Bracket
4 8T-4139
ree
Bolt
4
8T-4223
8T-4244 n
Hard Washer
Nut
9 8T-4195 Bolt
48 6V-7732 Bolt
35 8T-4133 Nut
2 8T-4136 Bolt
21 8T-0722 Bolt
1 8X-4283 Fender As
1 131-3936 Film (1)
1 100-9984 Film (1)
Table 8
(1)
The film is not a part of the 143-0343 Fender Gp.
Parts That are Required for the Installation of 8X-2808 Suspension Mounting Gp
2 6V-3249 Bearing
2 5T-5202 Bearing Cap
2 6V-0836 Retaining Ring
2 5T-6255 Key
8 6V-8132 Bolt
8 6V-8237 Hard Washer
2 5M-6214 Plug
20 8T-6624 Bolt
20 9X-8399 Washer
20 5T-1352 Spacer
PIP
20 8T-1583 Nut
-11
12 9X-6626 Bolt
202 008
1 6
12 9X-8259 Washer
12 5T-4896 Spacer
15: /0 8 92
56: /22
48-
0
:
-11
202 008
15: 1 /0 6 92
12 8C-4032
56: /228
Nut
SEH 48-
16 117-4935 Plate
2 9T-8910 Front Suspension Gp (1)
S 03:
© 2 998 00
Table 9
(1)
The 9T-8910 Front Suspension Gp is not a part of the 8X-2808 Suspension Mounting Gp.
02 0
Cat 1C
Parts That are Required for the Installation of 8X-2809 Suspension Group
ater
2 8X-6304
erp
Guard Assembly
2 8X-5532
Con illa
Plate Assembly
pill
2 8X-5527
fide r:
Plate
ar I
nc.
82 129-3175 Bolt
ntia
lG
6 9X-6618 Bolt
ree
6 8C-3236 Bolt
n
94 9X-8399 Washer
6 8X-6305 Boss
2 9M-8406 Clip
2 8T-4195 Bolt
2 8T-4133 Nut
2 5P-0562 Wire Lock
2 7X-4801 O-Ring Seal
8 8T-4956 Bolt
2 159-0038 Final Drive, Brake, and Wheel Gp (1)
Table 10
(1)
The 159-0038 Final Drive, Brake, and Wheel Gp is not a part of the 8X-2809 Rear Wheel Fastener Group. The 159-0038 Final Drive, Brake, and Wheel Gp is
effective with the 793C (S/N: 4GZ1-UP), 793C (S/N: ATY1-215), and 793C (S/N: 4AR1-UP). The 141-0208 Final Drive, Brake, and Wheel Gp was effective with
793C (S/N: 4AR138-312; ATY1-UP). The 135-7121 Final Drive, Brake, and Wheel Gp was effective with 793C (S/N: 4AR80-137). The 125-6508 Final Drive,
Brake, and Wheel Gp was effective with 793C (S/N: 4AR1-79).
Parts That are Required for the Installation of 8X-0250 Axle and Mounting
1 8X-0496 Axle Shaft (RH)
1 8X-0497 Axle Shaft (LH)
2 1V-6659 Retaining Ring
2 7I-5093 Clamp
4 1T-0284 Bolt
Table 11
:
Parts That are Required for the Installation of 8X-2829 Steering Arm Fastener Group
Qty Part Number

PIP Description
20 8T-0283
-11 Bolt
20 9X-8399
202 008 Washer
1 3J-6899
15: 1 /0 6 92
Self-Locking Nut
Table 12
56: /228
SEH 48-
Parts That are Required for the Installation of 8X-3380 Cylinder Mounting Gp
03:
4
8X-4040
8X-4043
© 2 998S 00
Pin Assembly
Spacer
2 8X-4044
02 0 Plate
10
Cat
8T-4183
1C Bolt
10 8T-4223
erp ater Hard Washer
2
Con illa
8X-2787
pill
Cover
fide r: ar I
2 2A-6662 Plate
2
8C-3222
5P-9560
ntia
Bolt
Union nc.
4 3D-2824
lG O-Ring Seal
2 6V-3480
ree
Nipple Assembly
2
6V-3482
121-2071
n
Cap Assembly
Hoist Cylinder Gp (1)
Table 13
(1)
The 121-2071 Hoist Cylinder Gp is not a part of the 8X-3380 Cylinder Mounting Gp.
Parts That are Required for the Installation of 115-9178 Sensor and Mounting
1 124-9325 Sensor
1 6V-5051 O-Ring Seal
4 8T-4185 Bolt
1 3E-7753 Float
1 116-2041 Guard
6 8T-4136 Bolt
1 131-7956 Fuel Tank Gp (1)
Table 14
(1)
The fuel tank is not part of the 115-9178 Sensor and Mounting.
Parts That are Required for the Installation of 115-7665 Fuel Tank Fastener Gp
:
1 8W-3602 Mud Flap
4 8X-2576 Shim Pack
4 8T-4170 Bolt
8 9D-9438 Washer
8 8X-5299 Mounting
4 6V-7688
PIP Nut
-11
8 8T-5439 Washer
202 008
5 8T-4195 Bolt
1
15:
8T-4133
/0 Nut
6 92
2
2
7X-2564
8T-4131 56: /228 Bolt
Nut
1
SEH 48-
115-7664 Plate Assembly
5 8T-4121
S 03:
Washer
2
© 2 998
8X-2575
00
Cap
4 7X-2489
02 0 Bolt
4
Cat
8T-4167
1C Washer
Table 15
erp ater
Con illa pill
fide r: ar I
Parts That are Required to Install 8X-2812 Cab Mounting for 793C (S/N: 4AR1-UP)
nc.
8 6H-1628
ntia Bolt
8 5T-5804
lG Sleeve
40 5T-5803
ree
Mount
20
6
5T-5807
1K-9418 n
Retainer
Bolt
6 5T-5805 Sleeve
6 8C-3236 Bolt
21 5T-1352 Spacer
9 8T-0283 Bolt
6 9X-6618 Bolt
6 1D-4649 Bolt
6 5T-5806 Sleeve
4 5T-9894 Shim
4 5T-9893 Shim
2 9G-9154 Clip
:
1 9M-8406 Clip
1 8T-4137 Bolt
1 5M-3062 Bolt
1 8X-0469 Support Assembly
1 8X-0436 Support Assembly
Table 16
Parts That are Required to Install 163-7226 Cab Mounting Gp for 793C (S/N: 4GZ1-UP; ATY1-UP)
8 6V-2624 Bolt
8
PIP
163-3127 Sleeve
40 163-0042
-11 Mount
20
202
5T-5807
008 Retainer
1 6
6 1K-9420 Bolt
15:
163-0364
/0 8 92 Sleeve
56: /22
6 8C-3236 Bolt
SEH 48-
21 5T-1352 Spacer
9 8T-0283 Bolt
6
S
9X-6618
03: Bolt
6
© 2 998
6B-0388
00 Bolt
6
02
164-4411
0 Sleeve
4
Cat 1C
5T-9894 Shim
4
erp
5T-9893
ater Shim
1
Con illa
9M-8406
pill Clip
fide r: ar I
1 8T-4137 Bolt
nc.
1
ntia
8X-0469 Support Assembly
1 8X-0436
lG Support Assembly
Table 17
ree
n
Parts That Are Required for Installation of 8X-4180 Hood Latch Gp
1 101-0368 Prop Assembly
8 8T-4136 Bolt

:
2 5S-7379 Bolt
1 2G-9399 Rod
1 6F-8499 Spring
1 8X-4425 Bracket Assembly
1 0T-0883 Washer
Table 18
Parts That Are Required for Installation of 142-4027 Platform Mounting Gp
4 8T-4139 Bolt
2 8X-2053 Plate
1 8X-2052 Plate
2 8X-1991 Plate
1 159-9886 Bar
PIP
1 8X-1990 Strip
1 8X-1989 Plate
1 138-1258
-11 Bracket Assembly
3 8T-6430
202 008Bolt
3 8T-4123
15: 1 /0 6 92
Washer
7
8T-4136
7X-7729
56: /228 Bolt
Washer
4 5P-1076
SEH 48- Washer
Table 19
S 03:
© 2 998 00
0
Parts that are Required for Installation of 8X-2835 Steering Lines Gp for 793C (S/N: 4AR1-UP)
Qty
Cat 02 1C
ater
1 8W-0500 Tube Assembly
1
erp
8W-0499 Tube Assembly
1
Con illa
8W-0498
pill Tube Assembly
1
fide r:
8W-0502
ar I Tube Assembly
nc.
ntia
1 8W-0501 Tube Assembly
lG
1 5T-6852 Bar
ree
1 8X-5968 Bracket Assembly
n
1 6G-8532 Guard Assembly
2 6V-8639 Connector
:
al G
ree
n
4 3K-0360 O-Ring Seal
2 6V-8625 Elbow
1 6V-9200 Elbow
1 3J-7354 O-Ring Seal
2 5T-6867 Clip
3 5M-3062 Bolt
1 9S-1350 Clip
4 8T-4136 Bolt
1 1V-6277 Tag (1)
1 8R-4853 Tag (1)
1 1V-6274 Tag (1)
1 1V-6276 Tag (1)
1 4J-6311 Tag (1)
Table 20
(1)
The tag can be installed on the tube assembly.
Parts that are Required for Installation of 151-8730 Steering Lines Gp for 793C (S/N: 4GZ1-UP; ATY1-UP)
1 150-8708 Tube Assembly
1
PIP
150-8713 Tube Assembly
-11
202 008
1 150-9037 Bar
15: 1 /0
8X-5968
6 92 Bracket Assembly
2
56: /22
6G-8532
6V-8639
8 Guard Assembly
Connector
4
SEH 48-
3K-0360 O-Ring Seal
8
S
6V-8398
03: Connector
2
© 2 9986V-8625
00 Elbow
2
02
6V-8397
0 O-Ring Seal
1
Cat 1C
6V-9200 Elbow
1
erp ater
3J-7354 O-Ring Seal
2
Con illa 5T-6867
pill
Clip
fide r: ar I
3 5M-3062 Bolt
ntia nc.
lG
:
Cat 1C
erp ater
Con illa pill
fide r: ar I
nc.
1
ntia
9S-1350 Clip
lG
4 8T-4136 Bolt
ree
n
1 1V-6277 Tag (1)
1 8R-4853 Tag(1)
1 1V-6274 Tag (1)
1 1V-6276 Tag (1)
1 4J-6311 Tag (1)
Table 21
(1)
The tag may be already installed on the tube assembly.
Parts That are Required for the Installation of 142-4044 Air Cleaner Gp
2 9Y-8930 Air Cleaner
1 139-0478 Plate Assembly
2 8X-3629 Plate
2 8X-3624 Plate
1 2G-0548 Brace
2 8X-3623 Brace
4 7E-7791 Hose
4 8T-4139 Bolt
2 7E-7790 Hose
2 7E-7786 Tube Assembly
2 8X-3635 Strip
20 7X-0344 Bolt
PIP
-11
2 4M-7470 Grommet
202
2 7W-0629 Filter Adapter Assembly
7 8T-4136 Bolt 008

11 7X-7729
1
Hard Washer
15: /0 6 92
4
11
8T-4183
5P-1076
Bolt
56: /22
Hard Washer
8
1 8T-4910
SEH 48-
Bolt
2 8T-4244 Nut
S 03:
© 2 998 00
021 0
Ca
:
56:
SEH 48-
S 03:
16 5P-0600
© 2 998
Hose Clamp
00
2 5K-5068
02 0
Pipe Nipple
2 7W-7417
Cat 1C
Indicator
4 5P-4423
erpElbow
ater
6 5P-9085
Con illa
Clip
pill
fide r: ar I
4 6V-4372 Hose Clamp
nc.
2 9X-6605 U-Bolt
4 6V-7744
ntia
Locknut
1 7D-8586
lG
Nonslip Tread
-- 5P-0756 Tube
ree
1
1
138-1264
138-1267
n
Bracket Assembly
Bracket Assembly
Table 22
Parts That are Required to Install 131-3541 Service Brake Lines Gp
6 6V-8624 Elbow
10 2M-9780 O-Ring Seal
2 6V-8638 Connector
1 8X-6139 Bracket (RH)
8 8T-4185 Bolt
4 5T-0968 Block
4 8X-6137 Block
4 0S-1627 Bolt
1 8X-6140 Bracket As (LH)
1 131-3425 Hose Assembly (1)
2 6V-8721 Elbow
1 8W-3192 Hose Assembly (2)
1 8X-8172 Hose Assembly (3)
1 8X-8173 Hose Assembly (4)
4 9X-8250 Clip
PIP
2 8T-4195 Bolt
2 8T-4133 Nut
2 5D-7464 Hose Assembly

-11
2 4H-6147 Connector
202 008
15: 1 /0 6 92
56: /228
:
PIP
-11
202 008
2 6B-5072
15: 1 /0 6 92
Reducing Bushing
2
9M-8662
7J-8611
56: /228
Coupling
Elbow
2 4H-6112
SEH 48- Breather
2 3D-7587
S 03:
Elbow
2 4D-2847
© 2 998 00
Hose Assembly
2 7X-0871
02 0
Tee
2 6V-3965
Cat 1C Nipple Assembly
erp ater
2 3J-1907 Seal
Con illa pill

2 6V-0852 Dust Cap
fide r:
2 5J-0451 Hose Assembly (5)
2 6D-6489
ar I
Pipe Connector (5)
2 9C-4937
ntia Breather (5)
nc.
lG
2 1S-0996 Clip (5)
ree
6 7K-1181 Cable Strap (5)
Table 23
(1)
n
The hose assembly is for 793C (S/N: 4GZ1-UP; ATY1-UP) trucks with the Michelin low profile tire attachment. Substitute the 8X-6431 Hose Assembly with the
(2) 173-7217 Service Brake Lines Gp.
The hose assembly is for 793C (S/N: 4GZ1-UP; ATY1-UP) trucks with the Michelin low profile tire attachment. Substitute the 115-8427 Hose Assembly with the
The hose assembly is for 793C (S/N: 4GZ1-UP; ATY1-UP) trucks with the Michelin low profile tire attachment. Substitute the 9R-4084 Hose Assembly with the
The hose assembly is for 793C (S/N: 4GZ1-UP; ATY1-UP) trucks with the Michelin low profile tire attachment. Substitute the 103-1846 Hose Assembly with the
Parts for 793C (S/N: 4GZ1-UP; ATY1-UP) Trucks
Parts That are Required for the Installation of 124-8210 Hydraulic Oil Cooler Lines Gp
1 8X-4616 Tube Assembly (1)
1 125-5083 Tube Assembly (2)
2 125-5084 Tube Assembly (3)
1 8X-4636 Tube Assembly
2 2S-2317 Hose
1 8X-4618 Elbow
1 8X-4620 Plate
2 6V-3965 Nipple Assembly
2 6V-0852 Dust Cap
6 9S-4191 O-Ring Plug

:
5 5P-1935 Seal
4 006-8352 O-Ring Seal
6 7X-0325
PIP Bolt
-11
6 8T-8919 Bolt
202 008
6 8T-9389 Bolt
4 8T-4122
15: 1 /0 6 92 Hard Washer
2
8T-6675
8T-4139
56: /228 Clamp
Bolt
4
SEH 48-
8T-4183 Bolt
4 8T-4244
S 03: Nut
4
© 2 998
9X-6400
00 Clip
2
0
6V-8521
2 0 Half Clip
4
Cat
8X-6439
1C Spacer
4
erp
7X-2475
ater Bolt
Con illa pill

4 6F-8146 O-Ring Seal
fide r: ar I
4 6V-4432 Bolt
nc.
2 8T-4835 Bolt
4 7X-0568
ntia Hard Washer
2 1P-4584
lG Half Flange
4 8T-4184
ree Bolt
8
7I-5529
4J-0527 n Hose Assembly
O-Ring Seal
16 8T-4194 Bolt
8 1P-4582 Half Flange
1 8X-6498 Plate
1 8X-4619 Elbow
4 8T-4910 Bolt
1 8X-4637 Tube Assembly
Table 24
(1)
The tube assembly is for 793C (S/N: 4GZ1-UP; ATY1-UP) trucks with the Michelin low profile tire attachment. Substitute the 160-6311 Tube Assembly from the
(2)
173-7216 Hydraulic Oil Cooler Lines Gp.
(3) 173-7216 Hydraulic Oil Cooler Lines Gp.
Parts That are Required for the Installation of the 8X-2642 Rim Mounting for the 793C (S/N: 4AR1-79)
2 104-7783 Clamp Assembly

:
2 103-5931 Plate
4 103-5932 Plate
2 8X-6125 Extension
2 8X-6127 Hose Assembly
4 8T-6868 Bolt
12 8T-4139 Bolt
20 8T-4195 Bolt
6
PIP
5T-9790 Tire Valve Gp
4 6J-0427
-11 Spacer
2
202
5T-9767
008 Connector
15: 1
8W-0338
/0 6 92
O-Ring Seal
2
7I-5931
56: /22
8W-0331 8 Bracket
Connector
SEH 48-
420 7X-0851 Nut
03:
20
© 2 998S
8M-7145
00
Washer
0
Table 25
Cat 02 1C
Parts That are Required for the Installation of the 137-3614 Rim Mounting Gp for the 793C (S/N: 4AR80-UP; 4GZ1-UP;
erp ater ATY1-UP)
Con illa pill

fide r: ar I
2 104-7783 Clamp Assembly
nc.
8 136-9459 Plate Assembly
12
ntia
137-3615 Bracket
2
lG
8X-6125 Extension
2 8X-6127
ree Hose Assembly
36
8T-6868
8T-4139 n Bolt
Bolt
4 3V-8340 Bracket
6 5T-9790 Tire Valve Gp
4 6J-0427 Spacer
2 5T-9796 Connector
6 8W-0338 O-Ring Seal
2 7I-5931 Bracket
2 8W-0331 Connector
420 7X-0851 Nut

:
6 8X-0247 Demountable Rim Gp (1)
6 137-9855 Demountable Rim Gp (2)
6 -- Tire
Table 26
(1)
The 8X-0247 Rim Group is effective with 793C (S/N: 4AR1-102). The 8X-0247 Rim Group is for a reference. The 8X-0247 Rim Group is not a part of the
(2)
137-3614 Rim Mounting Gp.
The 137-9855 Rim Group is effective with the 793C (S/N: 4AR103-UP; 4GZ1-UP; ATY1-UP). The 137-9855 Rim Group is for reference. The 137-9855 Rim
Group is not a part of the 137-3614 Rim Mounting Gp.
Parts That are Required to Install the 126-1358 Guard Group
1 105-2205 Support
1 105-2204 Support
2 105-2200 Mud Flap
8 8T-4136
PIP Bolt
-11
202 008
8 8T-4133 Nut
1 6
Table 27
15: /0 8 92
56: /22
Parts That are Required to Install the 9Y-8888 Exhaust Pipe Gp
2 7E-8452
SEH 48- Clamp
1 7E-7861
S 03:
Elbow
Table 28
© 2 998 00
02 0
Cat 1C
Parts That are Required for the 8X-2851 Exhaust Pipe Gp
Qty Part Number
erp ater
Description
Con illa pill

fide r:
8 6V-4429 Bolt
ar I
20 5P-8247
ntia
Hard Washer
nc.
2 5T-3367 Elbow
lG
ree
8 8C-0623 Taperlock Stud
n
12 7K-1270 Washer
8 8T-1757 Nut
2 5T-2762 Spring
2 6G-7038 O-Ring Seal
2 8X-3233 Piston
:
6 8X-3253 Lock
12 6V-6317 Bolt
25 8T-4121 Washer
1 6G-7031 Elbow
4 8T-0375 Bolt
2 092-5524 Bolt
4 6V-8149 Nut
1 8X-3256 Guard Assembly
4 8T-4137 Bolt
2 8T-4179 Bolt
1 8T-4133 Nut
1 5T-7826 Brace
2 6V-3668 Bolt
1 8T-4222 Plated Washer
1 5T-6643 Plate
1 105-1134 Plate
1 8X-2852 Exhaust Pipe Gp (1)
9 8T-4195 Bolt
4 5P-8245
PIP
Washer
Table 29
-11
202 008
(1)
The 8X-2852 Exhaust Pipe Gp is not a part of the 8X-2851 Exhaust Pipe Gp.
1 /0
Parts That are Required to Install the 9Y-8917 Muffler Gp
15: 6 92
Qty
1
Part Number
8X-3135
56: /228
Description
Plate As
1 7E-8452
SEH 48-Clamp
3 8X-3132
S
Bracket
03:
3 8X-3128
© 2 998 Strap
00
1 6N-9298
02
Clamp
0
1 8X-3142
Cat 1C
Extension Pipe
erp ater
1 5T-7824 Clamp As
Con illa
1 8X-2990 Extension Pipe
12 8T-4139 Bolt
pill
12 8T-4223
fide r:Hard Washer
ar I
nc.
12 6V-5843
ntia
Bolt
lG
3 2Y-5829 Nut
ree
2 6V-3823 Bolt
n
:
den Inc
tial .
G ree
2
30
6V-8149
6V-5839
Nut
Washer n
2 6V-3668 Bolt
4 8T-0375 Bolt
4 2V-8169 Plate
3 6V-6317 Bolt
2 7E-6811 Muffler
12 6V-7744 Locknut
2 6V-7687 Locknut
Table 30
Parts That are Required to Install the 8X-2813 Truck Body Mounting Gp for 793C (S/N: 4AR1-UP)
1 6G-9703 Cable (1)
4 5T-7255 Plate
1 8X-5064 Mud Flap
4 5T-7352 Strip
1 8X-5063 Mud Flap
1 5T-7275 Mud Flap
1 5T-7274 Mud Flap
2 3D-0404 Washer
10 8X-3045 Pad Assembly
30 8X-3046 Shim
2 7I-5517 Pin Assembly
1 105-0314
PIP Coupler
1 8X-5421
-11 Plate
1
202
5G-7820
008 Magnet Assembly
1 102-9552
15: 1 /0 6 92
Bracket
68
102-9549
8T-4196
56: /228 Plate Assembly
Bolt
43
SEH 48-
8T-4121 Hard Washer
68 8T-4133
S 03: Nut
© 2 998 00
2 6G-7773 Pin
0
4 3B-4647 Cotter
10
30
Cat 02
8T-4184
7D-16491C
Bolt
Washer
2
erp
6G-9697
ater Washer
Con illa pill

fide r: ar I
nc.
n
:
202
Cat 1C
erp ater
1
Con illa
8W-2896
pill Washer
4
fide r:
5P-1076
ar I
nc.
Hard Washer
ntia
2 8W-8677 Plate
24 8T-4910 Bolt
24 8T-4244
lG Nut
2 8T-4136
ree Bolt
2
8T-4649
8T-4167
n Bolt
Washer
2 6V-7676 Self-Locking Nut
1 8W-0109 Plate
1 2B-0974 Clevis Pin
1 3B-4617 Cotter
16 8T-4137 Bolt
16 4K-8864 Clip
2 8T-7547 Bolt
2 5C-7261 Nut
5 8T-4195 Bolt
1 105-4727 Mud Flap
2 112-6213 Ejector
Table 31
(1)
The 6G-9703 Cable is for use with dual slope bodies. Use the 145-9033 Cable with the flat floor bodies.
Parts That are Required to Install the 154-3758 Truck Body Mounting Gp for 793C (S/N: 4AR1-UP)
1 6G-9703 Cable Assembly (1)
4 5T-7255 Plate
1 8X-5064 Mud Flap
4 5T-7352 Strip
PIP
1 8X-5063 Mud Flap
1 5T-7275 Mud Flap
1 5T-7274
-11 Mud Flap
2 3D-0404
202 008 Washer
10 8X-3045
15: 1 /0 6 92
Pad Assembly
30
2
8X-3046
7I-5517
56: /228 Shim
Pin Assembly
1 105-0314
SEH 48- Coupler
S99 03:00
80
:
15: 08/2 92
56: 2
SEH 48-
1
S
8X-5421
03: Plate
68
© 2 998
8T-4196
00 Bolt
41
0
8T-4121
2 0 Hard Washer
68
Cat 1C
8T-4133 Nut
erp ater
2 6G-7773 Pin
Con illa
4 3B-4647 Cotter
pill
fide r:
10 8T-4184 Bolt
30 7D-1649
ar I Washer
2
ntia
6G-9697
nc. Washer
lG
1 8W-2896 Washer
ree
n
2 8W-8677 Plate
24 8T-4910 Bolt
24 8T-4244 Nut
2 8T-4649 Bolt
2 8T-4167 Washer
2 6V-7676 Self-Locking Nut
1 8W-0109 Plate
1 2B-0974 Clevis Pin
1 3B-4617 Cotter
16 8T-4137 Bolt
16 4K-8864 Clip
5 8T-4195 Bolt
1 105-4727 Mud Flap
2 112-6213 Ejector
Table 32
(1)
The 6G-9703 Cable Assembly is for use with dual slope bodies. Use the 145-9033 Cable Assembly with the flat floor bodies.
Approximate Weights
Personal injury or death can result from lifting a heavy assembly.
The heavy assembly can fall if using an incorrect hoist to lift the
load.
Be sure the hoist has the correct capacity to lift a heavy

assembly. Approximate weight of the assembly is given below.
PIP
-11
202 008
1/0 692
8/
:
PIP
-11
202 008
15: 1 /0 6 92
Personal injury or death can result from improper lifting or
8
blocking.
56: /22
When a hoist or jack is used to lift any part or component, stand
SEH 48-
clear of the area. Be sure the hoist or jack has the correct
capacity to lift a component. Install blocks or stands before
03:
performance of any work under a heavy component.
S
© 2 998 00
Approximate weights of the components are shown. Clean all
surfaces where parts are to be installed.
02 0
Cat 1C
erp ater
Module Weight
Truck frame module without the rear axle housing (1) 42640 kg (94000 lb)
Con illa
Truck frame module with rear axle housing (2)
pill 67135 kg (148000 lb)
fide r:
Rear axle housing with final drives
ar I
nc.
24500 kg (54000 lb)
ntia
Front suspension cylinder, wheel, and brake assembly 5350 kg (11800 lb)
lG
Final Drive, wheel and brake assembly 7180 kg (15830 lb)
ree
Tire 3500 kg (7800 lb)
n
Rim 1480 kg (3260 lb)
Hoist cylinder 1150 kg (2540 lb)
Axle 290 kg (640 lb)
Body pivot pin 41 kg (90 lb)
Fuel tank 1110 kg (2450 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 3500 kg (7710 lb)
Tail extension assembly 304 kg (670 lb)
Sideboard assembly 118 kg (260 lb)
Miscellaneous parts 990 kg (2190 lb)
Completed body 44230 kg (97500 lb)
Table 33
(1)
(2) The weight of the truck frame is distributed equally between the front and back lifting points.
The weight of the truck frame is distributed equally between the front and back lifting points.
Specifications
Areas Specifications
:
Empty weight 158600 kg (350000 lb)
Wheel base 5900 mm (232 inch)
Length 12866 mm (506.53 inch)
Ground to top of canopy 6604 mm (260 inch)
PIP
Ground to upper edge of body 5865 mm (230.90 inch)
Turning radius
-11 32.40 m (106.30 ft)
202
Width of body assembly
008
7411 mm (291.80 inch)
1 /
Width of truck frame at rear tires
15: 0 6 92
7406 mm (291.57 inch)
Table 34
5 8 /22
SEH :48-
Torque Specifications 6
S 03:
Tighten the 94 rear axle mounting bolts to a torque of 1800 ± 200 N·m (1327 ± 147 lb ft).
© 2 998 00
Tighten the 12 rear axle housing bolts to a torque of 100 ± 20 N·m (75 ± 15 lb ft).
0 2 0
Tighten the 72 bolts that mount the rear wheel rim to a torque of 1000 ± 125 N·m (738 ± 92 lb ft).
Cat 1C
ater
Tighten the 70 bolts that mount the front wheel rim to a torque of 1000 ± 125 N·m (738 ± 92 lb ft).
erp
Con illa
Tighten the 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.
pill
fide r: ar I
Tighten the 12 bolts that mount the front suspension cylinder mounting bolts to 1000 ± 100 N·m (738 ± 74 lb ft) plus 60 ± 5
nc.
ntia
degrees.
lG
Tighten the 8 front suspension cylinder cap mounting bolts to a torque of 800 ± 100 N·m (590 ± 74 lb ft).
ree
Tighten the 20 bolts that mount the front steering arm to a torque of 1600 ± 200 N·m (1180 ± 148 lb ft).
n
Tighten the 4 steering cylinder mounting bolts to 2250 ± 100 N·m (1660 ± 74 lb ft).
Tighten the 4 ball stud mounting bolts to a torque of 2250 ± 100 N·m (1660 ± 74 lb ft).
Tighten the 20 cab mounting bolts to a torque of 1800 ± 200 N·m (1328 ± 148 lb ft).
Tighten the 21 cab support mounting bolts to a torque of 1600 ± 200 N·m (1180 ± 148 lb ft).
Tighten the 2 hoist cylinder bolts to a torque of 1770 ± 50 N·m (1305 ± 37 lb ft).
Tighten the fuel tank bolts to a torque of 460 ± 60 N·m (339 ± 44 lb ft).
Tighten the fuel tank caps to 800 ± 100 N·m (590 ± 74 lb ft).
Tighten the right side platform assembly to 460 ± 60 N·m (339 ± 44 lb ft).
Specifications for Cables, Chains, and Lifting Devices

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.
:
PIP
-11
202 008
15: 1 /0 6 92
Illustration 1
56: /22 8 g00629745
SEH 48-
Lift angles for lifting slings.
(A) The load capacity is 100% of the working load limit for the sling.
03:
(B) The load capacity is 86% of the working load limit for the sling.
S
(C) The load capacity is 70% of the working load limit for the sling.
© 2 998 00
(D) The load capacity is 50% of the working load limit for the sling.
Necessary Hoist Capacity

0 2 0
Cat 1C
Two hoists are needed to remove the truck frame from the trailer. One hoist with a 54430 kg (120,000 lb) capacity and one hoist
erp ater
with a 36,290 kg (80,000 lb) is needed.
Con illa pill

When the differentials are on supports, a hoist with a 36,290 kg (80,000 lb) capacity is needed to lift the truck frame at the front
lifting points.
fide r: ar I
With the front crossmember on supports, one hoist with 54,430 kg (120,000 lb) capacity is needed to lift the truck frame at the
n
n c.
rear lifting points.
793C Assembly Tips tial

Gre
Note: Follow the table of contents for the assembly sequence of the truck.
en
1. The assembly of the 793C requires four mechanics for a total of 196 hours. The final drives are not attached to the rear axle
housing in this assembly. Two crane operators are required for a total of 24 hours until the major components are installed.
2. The cab needs to be a minimum of 1270 mm (50 inch) from the ground when the fender and the catwalk railing is added.
Necessary Equipment and Supplies for Assembly

The following supplies and equipment are used for the assembly:
Obtain 4 barrels of oil for the final drive. Each barrel should have a capacity of 208 L (55 US gal). Caterpillar's FDAO oil or
Caterpillar TDTO is the final drive oil that is recommended. SAE viscosity grade 50 is recommended. Refer to the Operation
and Maintenance Manual.
Obtain 6 barrels of TDTO or TO-4 hoist, converter, and brake oil. Each barrel should have a capacity of 208 L (55 US gal).
:
Obtain 1 barrel of transmission/drive train oil (TDTO). The barrel should have a capacity of 208 L (55 US gal). Ambient
temperatures that are extreme may require a different oil viscosity. Refer to Service Manual, SEBU6250, "Caterpillar Machine
Lubricant Recommendations".
One 133 L (35 US gal) barrel of steering oil such as HYDO, TDTO, DEO CF4, API CF4, OR CE
One crane with a 54,430 kg (120,000 lb) capacity
One crane with a 36,287 kg (80,000 lb) capacity
Cables, straps, and chains that have adequate capacity
Obtain several shackles. Shackles should have a working load limit of 27,240 kg (60,053 lb).
Obtain one portable air compressor. The air compressor should have enough capacity to operate two 25.4 mm (1 inch)
impact air guns. 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.
One stepladder that is 1.8 m (6 ft) tall
Two stepladders that are 3.6 m (12 ft) tall
PIP
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
-11
rope to guide the body into position.
202 008
Obtain 20 nitrogen bottles that are T-size to inflate the tires and charge the suspension cylinders.
15: 1 / 0 6 92
One lift truck that can lift 6810 kg (15,000 lb)
56: /22
Four 7X-1062 Ether Cylinders
A paint spray gun

8
SEH 48-
03:
Two 1U-9204 Lever Pullers
© 2 998 S 00
Three 138-7573 Link Brackets, three 5P-9736 Link Brackets, and three 6V-2157 Link Brackets
0 0
Obtain four metal stands. The metal stands support the truck body before the truck body is installed to the truck frame.
Cat 2 1C
Obtain one container of 4C-4188 Paint Remover. The solvent cleans the parts on the truck.
erp
5P-0960 Molybdenum Grease
ater
C o nfid illa p illa
9S-3263 Thread Sealant for the platform bolts.
Required Tools r: r In
ent c.
ial
Use a 1U-8848 Axle Installation Tool to install the axles.
Gre
Use a 5P-3520 Spanner Wrench to torque the steering cylinder ball studs.
en
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 5S-6084 Socket to tighten the steering tie rod ball studs.
Use a 2P-2336 Socket to tighten the ROPS cab mount bolts.

:
Use a 6V-7820 Torque Multiplier to tighten the rear axle housing nuts.
Use a 9U-5089 Socket to tighten the wheel rim mounting nuts.
Use a 6V-7915 Torque Wrench with the torque multipliers.
Use a 8T-9293 Torque Wrench to torque the ROPS cab mounting bolts.
Use a 6V-4154 Box Wrench.
Use a 6V-3146 Extension.
Use a 6V-4170 Adapter.
Use a 2P-8261 Adapter.
Use 4C-6724 Socket for the rear axle housing, front cylinder mount, and the cab support.
Use a 5S-6067 Extension with the 2P-2336 Socket and with the 2P-2338 Socket.
Use a 175-5507 Charging Group for the front suspension cylinders.
Use a 9U-5617 Oil Refill Pump for charging the suspension cylinders with oil.
Use a 6V-4040 Inflation Group to inflate the tires.
Use a 8T-5230 Torque Wrench with a capacity of 300 N·m (221 lb ft).
Use a 8T-5183 Extension for the torque wrench.
Use a 8T-3196 Wrench for the front suspension cylinder mounting nuts.
Use two 30 mm (1.20 inch) metric guide pins to remove the head from the 8T-6624 Bolts.
1 1/4 × 7 Thread Tap

PIP
-11
Use a pair of 6V-0006 Pliers to install the aeta connector.
202 008
When you are instructed, apply 4C-5593 Anti-Seize Lubricant to threads.
1 /0 6 9
1 5:5Truck /22 2
When you are instructed, apply 4C-5599 High Temperature Anti-Seize Compound to threads.
Site for the Assembly of the 8

SEH 6:48-
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
fide r: ar I
nc.
ntia
lG
ree
n
:
onf
ide ar: llar
In
ntia c.
lG
ree
n
Illustration 2 g00684122
This is a typical view of the layout for the 793C Truck with the final drives that are detached.
Unload the truck frame and shipping crates on a flat, smooth, drained area 30.5 m (100 ft) by 24.5 m (80 ft). The area is needed
for the assembly of the truck.
PIP
Set the truck frame in the center of the assembly area.
-11
Keep the area around the truck frame clear. Space needs to be left open for the crane for proper lifting.
202 008
Unload the components from the trailer. Place the components away from the crane. Refer to Illustration 2 or Illustration 6 for
placement of the components.
15: 1 /0 6 92
Set the large wooden boxes of smaller components out of the way. Open the boxes and check the components that are in each
box.
56: /22 8
Do not open the bags of hardware. The bags are marked for easy identification. Place the hardware with the correct components.
SEH 48-
Refer to the photos in this special instruction. The photos will help to position the components.
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
illa pill
r: ar
:
© 2 S998 3:00
0 2 0
Cat 1C
erp ater
Con illa pill
fide r: ar I
nc.
ntia
lG
ree
Illustration 3
This is a view of the components on a trailer.
n
g00678709
View of the frame on the trailer
View of the cables that are used to lift the frame
PIP
-11
202 008
15: 1 /0 6 92
8
56: /22
View of the spreader bar that is used to lift the frame
SEH 48-
S99 03:00
:
021 086
15: /08/2 92
56: 2
SEH 48-
Two ways to lift the frame assembly are shown. View 5 shows the cables that are used to lift the frame. View 6 shows the spreader
bar that is used to lift the frame. The spreader bar is a steel rod that is 89 mm (3.5 inch) in diameter and 4191 mm (165 inch) in
S 03:
length. Two clevises and cables are attached to the front of the frame. Lift the front of the frame and lift the rear of the frame.
© 2 998 00
Drive the trailer forward. The frame is ready to be blocked.
0 2 0
Cat 1C
erp ater
Con illa pill
fide r: ar I
nc.
ntia
lG
ree
n
View of the frame that is blocked
The wood blocks are 203 mm (8 inch) by 203 mm (8 inch). The wood blocks are stacked alternately. A metal stand is used under
the rear of the frame. The height of the wood blocks is 1320 mm (52 inch) high.
Note: An alternate blocking position is under the front frame and the bumper.
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 rear tires.
Use the photos as a reference to place the hardware. The correct placement of the hardware saves time and the risk of losing
hardware. Not all of the components are identified in the following photos.
PIP
-11
008
6
:
PIP
-11
202 008
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
© 2 998 00
View of catwalk platform, mud flaps, plate assembly, and the fuel tank plate
0 2 0
Cat 1C
erp ater
Con illa pill
fide r: ar I
nc.
ntia
lG
ree
View of brake lines, brackets, and the rear brake hose
View of mud flap, oil hose assembly, front brake tube, and bracket
View of the front strut and boxes
:
PIP
-11
Illustration 14
202 008g00679025
View of the platform assembly
15: 1 /0 6 92
56: /22 8
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
Illustration 15
erp ater g00679033
illaHousing Gp
Con Rear Axle pill
View of the front fender and rail
Install the 124-7721

fide r: ar I
nc.
ntia
Parts that are Required to Install the 124-7721 Rear Axle Housing Gp
Item Qty Part Number Description
1 24 lG 9X-6152 Bolt
2 24
ree
3S-6162 Hard Washer
Table 35 n
1. Align the rear axle group with the frame assembly. Block up the transmission.
:
PIP
-11
202 008
15: 1 /0 6 92
Illustration 18
56: /228
g00817881
SEH 48-
2. Remove the shipping covers from the suspension a-frame. The 24 9X-6152 Bolts and the 24 3S-6162 Hard Washers are
03:
located in boxes. The boxes are located in the a-frame.
© 2 998S 00
0 2 0
Cat 1C
erp ater
Con illa pill
fide r: ar I
nc.
Illustration 19
ntia g00811461
lG
3. Use 4C-4204 Paint Remover to remove the paint from the rear axle group. Clean the mounting areas on the rear axle group.
ree
n
:
4. Chase the holes for the mounting bolts.
5. Clean the mounting area on the a-frame.
PIP
-11
Illustration 22 202 008
g00679540
15: 1 /0 6 92
6. Use 4C-4204 Paint Remover to clean the mounting area on the transmission yoke.
56: /228
Inspect the yoke for damage to the key, keyway, threaded holes, and pilot diameters.
Note: If damage is present in any of the areas, replace the yoke accordingly.
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
Illustration 23
fide r: g00817824
ar I
nc.
ntia
7. Remove the guard from the left side of the rear axle housing.
lG
ree
n
:
ree
n
8. Remove the guard on the right side of the rear axle housing.
9. Remove the following items that hold the pin: six bolts, six washers and a plate.
PIP
-11
202 008
15: 1 /0 6 92
Illustration 26
56: /228
g00817829
SEH 48-
10. Use 4C-4204 Paint Remover to remove the paint from the pins.
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
fide r: ar I
nc.
ntia
lG
ree
:
Con rpilla terpill
fide r: ar I
nc.
Illustration 27
ntia g00817830
11. Remove both of the pins.

lG
ree
n
12. Remove the guard assembly, 18 bolts, and 18 washers that secure the guard assembly. Remove the plastic cover. Clean the
transmission drive shaft.
Inspect the universal joint 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 accordingly.
13. Remove the blocks and shipping hardware.
PIP
-11
202 008
15: 1 /0 6 92
Illustration 30
56: /228
g00817833
SEH 48-
14. Lift the rear axle assembly to the frame assembly.
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
i p
:
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
fide r: ar I
nc.
ntia
lG
ree
n
15. Align the rear struts with the rear axle housing.
16. Remove two bolts and washers that secure the pin. Remove the retainer from the pin. Slide the pin from the bore.
Note: The pin secures the control rod to the frame.
17. Lift the control rod. Slide the pin back into the original position.
PIP
-11
202 008
15: 1 /0 6 92
56: /228
48-
0
:
-11
202 008
15: 1 /0 6 92
Illustration 34
56: /228
g00817844
SEH 48-
18. Install the retainer, two bolts, and two washers into the pin.
Note: Tighten the bolts to a torque of 475 N·m (350 lb ft).
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
fide r: ar I
nc.
Illustration 35
ntia g00817834
lG
19. Install 24 9X-6152 Bolts (1) and 24 3S-6162 Washers (2). This will secure the a-frame to the rear axle housing.
ree
Note: Tighten 9X-6152 Bolts (1) with an impact wrench. Do not torque 9X-6152 Bolts (1) yet.
20. Install the pins.
Note: The port for the lubrication line for the LH rear strut must be in the 3 o'clock position.
:
PIP
-11
202 008
15: 1 /0 6 92
56: /228
SEH 48-
03:
Note: The port for the lubrication line for the RH rear strut must be in the 9 o'clock position.
S
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
fide r: ar I
nc.
Illustration 39 ntia g00817840
lG
21. Install the plates, the bolts, and the washers to the pin.
ree
Note: Tighten the bolts to a torque of 475 N·m (350 lb ft).
22. Tighten the 24 9X-6152 Bolts (1) that secure the rear axle housing to the a-frame.
Note: Tighten the bolts to a torque of 2700 ± 300 N·m (1991 ± 221 lb ft).
:
23. Remove the cables that are used to position the a-frame.
Note: There is no need to remove the tie-downs.
PIP
-11
202 008
15: 1 /0 6 92
Illustration 42
56: /228
g00817845
SEH 48-
24. Clean the mating surface of the yoke assembly, including the threaded holes and the universal joint assembly. Ensure that
03:
the yoke assembly is free of wax, dirt, debris, paint, and grease.
© 2 998S
Clean the mating surface of the clip joint. Ensure that the slip joint is free of wax, dirt, debris, paint, and grease.
00
25. Make sure that the torque converter and transmission yokes are aligned and in phase.
0 2 0
1C
26. Ensure that the universal joints are fully seated prior to tightening the bolts. There are two methods:
Cat
erp ater
A - Use a suitable rubber or wood hammer to seat the universal joints in the yoke.
Con illa pill

B - Use designated run-down bolts to completely seat the universal joints in the yoke. Refer to Step 26.a and Step
26.b.
fide r: ar I
a. Torque the designated "run-down" bolts in a sequential alternating "X" pattern.
nc.
ntia
b. Remove the designated "run-down" bolts and replace with new 2N-2486 Bolts
lG
Note: Ensure that the universal joints are fully seated prior to tightening the bolts.
ree
27. Insert new 2N-2486 Bolts and torque to 550 ± 20 N·m (406 ± 15 lb ft) in a sequential alternating "X" pattern.
n
28. Static check 2N-2486 Bolts 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).
29. Perform a static check on the 2N-2486 Bolts 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.
:
30. Use 18 bolts and 18 washers to install the guard assembly.
Install the 8X-2837 Walkway Gp

Parts That Are Required to Install 8X-2837 Walkway Gp
Item Qty Part Number

PIPDescription
1 2 114-1238
-11
Platform Assembly
2 4 114-1244
202 Plate
008
1 6
3 6 4V-9810 Step Assembly
4 12 8T-4139
15: /0
Bolt
8 92
56: /22
5 12 5P-1076 Hard Washer
SEH 48-
6 8 8T-4196 Bolt
7 16 8T-4121 Hard Washer
8 8 8T-4133
S Nut
03:
9 24 1D-4691
© 2 998 00
Round Head Bolt
10 24 8T-4223
0 2 0
Hard Washer
11 24 1K-6872
Cat 1CLocknut
12 4 114-1243
erp ater
Belt
13 8 4V-9804
Con illa Plate
pill
fide r: ar I
Table 36
ntia nc.
lG
ree
n
This is a view of the service platform for the air cleaner on the right side of the truck.
:
1. Install the 114-1238 Platform Assembly (1) to the truck frame with six 8T-4139 Bolts (4) and six 5P-1076 Hard Washers (5).
Install the platform on the right side of the truck.
This is a view of the service platform for the air cleaner on the left side of the truck.
2. Install the 114-1238 Platform Assembly (1) to the truck frame. Use six 8T-4139 Bolts (4) and six 5P-1076 Hard Washers (5).
Install the platform assembly to the left side of the truck.
3. Tighten bolts (4) to a torque of 100 ± 20 N·m (74 ± 15 lb ft).
PIP
-11
202 008
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
© 2 998 00
View of step assembly on the right side
0 2 0
Cat 1C
erp ater
Con illa pill
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Illustration 47
reeg00684422
n
View of step assembly on left side
Note: Step 4 is not necessary if the step was previously assembled.
:
al G
ree
n
4. Assemble the four 4V-9804 Plates (13), the two 114-1243 Belt (12), and the two 4V-9810 Step Assembly (3). Use eight 8T-
4223 Hard Washers (10), eight 1K-6872 Locknut (11), and eight 1D-4691 Bolts (9).
6. Install the step assembly that was assembled to the 114-1238 Platform Assembly (1). Use two 114-1244 Plates (2), four 8T-
4196 Bolts (6), eight 8T-4121 Hard Washers (7), and four 8T-4133 Nuts (8).
8. Repeat Step 4 and Step 6 for the step assembly on the left side.
Note: The length of the step assembly is increased by additional belts.
Install the 8X-0223 Walkway Gp for the 793C (S/N: 4AR1-UP)

and Install the 152-4784 Walkway Gp for the 793C (S/N: 4GZ1-
UP; ATY1-UP)
Parts That are Required to Install the 8X-0223 Walkway Gp for 793C (S/N: 4AR1-UP)
1 1 8X-7101 Walkway As (Front)
2 16 2H-3855 Bolt
5 18 5S-7379 Bolt
6 5 8T-2502 Bolt
8 3 6V-8801 Nut
9 1 101-1545 Walkway As (Side)
10 1
PIP
124-8213 Cab (1)
Table 37
-11
202 008
(1)
The 124-8213 Cab is not a part of the 8X-0223 Walkway Gp.
15: 1 /0 6 92
Parts That are Required to Install the 152-4784 Catwalk for 793C (S/N: 4GZ1-UP; ATY1-UP)
Item
1
Qty
1
56: /228
Part Number
152-7005
Description
Walkway As (Front)
2 16
SEH 48- 2H-3855 Bolt
3 16
S 03:
5P-8245 Hard Washer
© 2 998 00
0
5 18 5S-7379 Bolt
7
5
6
Cat 0 2 1C
8T-2502
8T-4896
Bolt
Hard Washer
8 3
erp ater
6V-8801 Nut
9 1
Con illa 152-7006
pill Walkway As (Rear)
fide r: ar I
nc.
(1)
ntia
lG
:
Cat 1C
erp ater
Con illa pill
10 1
fide r: 137-0003
ar I
nc.
ROPS Cab (1)
Table 38
(1)
ntia
lG
The 137-0003 ROPS Cab is not part of the 152-4784 Walkway Gp.
ree
Note: Install the four 2V-3216 Clips, four 4M-5283 Bolts, and four 8T-4205 Washers on the frame before the cab is set on
n
the truck frame. After the cab is mounted, there is no room between the cab and the frame.
This is a view of the fork lift that is lifting the Cab Assembly (10).
1. Use a fork lift and a crane to lift the cab (10). The 124-8213 Cab (10) is used on the 793C (S/N: 4AR1-UP) Off-Highway
Trucks. The 137-0003 ROPS Cab (10) is used on 793C (S/N: 4GZ1-UP; ATY1-UP) Off-Highway Trucks. Use three lifting eyes
and a chain to support the cab. Use the fork lift to remove the skid. The weight of the cab is 1705 kg (3760 lb).
View of the three lifting eyes and the chains that are used to lift the cab assembly (10)
2. The chains are the same length. This will keep the cab parallel to the ground.
PIP
-11
202 008
15: 1 /0 6 92
56: /22 8
Illustration 50
SEH 48-
g00684625
S
View of the cab (10) on hardwood blocks and supports
03:
© 2 998 00
021 0
C
:
:56 22
SEH :48-
S 03:
© 2 998 00
3. Set cab (10) on the appropriate stands. Hardwood blocks properly balance the cab on the stands. The height of the cab
0 0
floor should be 1270 mm (50 inch) from the ground. This eases the installation of the front fender and rails.
2
Cat 1C
erp ater
Con illa pill
fide r: ar I
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View of catwalk assembly that is used on the front of the cab
Note: The 101-1545 Walkway As (Side) (9) is used on the 793C (S/N: 4AR1-UP) Off-Highway Trucks. The 152-7006 Walkway
As (Rear) (9) is used on the 793C (S/N: 4GZ1-UP; ATY1-UP)Off-Highway Trucks.
4. Use a hoist and chain to support 152-7006 Walkway As (Rear) (9). Position the 152-7006 Walkway As (Rear) (9) to the cab.
View of the Side Catwalk Assembly (9)
5. Use one 5S-7379 Bolt (5) and one 5P-1075 Washer (4) to position 152-7006 Walkway As (Rear) (9) to the cab.
PIP
-11
202 008
1/0 692
8/2
2
:
PIP
-11
202 008
Illustration 53
15: 1 /0 6 92
g00684662
56: /228
6. Lift 152-7006 Walkway As (Rear) (9). Align the catwalk with the cab. Install the 17 5S-7379 Bolts (5) and the 17 5P-1075
Washers (4).
SEH 48-
Note: Apply 5P-3931 Anti-Seize Compound to the bolt threads.
S 03:
Note: Tighten the bolts to a torque of 47 ± 9 N·m (35 ± 6.64 lb ft).
© 2 998 00
Note: The first two bottom 8T-2502 Bolts (6) are longer than the rest of the 5S-7379 Bolts (5).
0 2 0
Cat 1C
erp ater
Con illa pill
fide r: ar I
nc.
ntia
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ree
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View of 152-7006 Walkway As (Rear) (9)
Note: The 8X-7101 Walkway As (Front) is used on 793C (S/N: 4AR1-UP) Off-Highway Trucks. The 152-7005 Walkway As
(Front) is used on 793C (S/N: 4GZ1-UP; ATY1-UP).
7. Fasten a link bracket to 152-7006 Walkway As (Rear) (9).
:
PIP
-11
202 008
15: 1 /0 6 92
Illustration 56
56: /22
View of the catwalk assembly8 g00688812
SEH 48-
8. Align the 152-7006 Walkway As (Rear) (9) to the cab. Use 16 2H-3855 Bolts (2) and 16 5P-8245 Hard Washers (3).
03:
Note: Tighten the bolts to a torque of 105 ± 20 N·m (77.44 ± 14.75 lb ft).
© 2 998 S 00
9. Use three 8T-2502 Bolts (6), six 8T-4896 Hard Washers (7), and three 6V-8801 Nuts (8) to secure the Front Walkway As to the
Rear Walkway As.
0 2 0
Note: Apply 5P-3931 Anti-Seize Compound to the bolts.
Cat 1C
Note: Tighten the bolts to a torque of 47 ± 9 N·m (34.66 ± 6.64 lb ft).
aterGp
erp Fastener
Install the 8X-4453 Handhold
Con illa pill
fide r: ar I
Parts That are Required to Install the 8X-4453 Fastener Group
nc.
1 178
ntia
5P-0765 Hose
2 149
lG
8T-4136 Bolt
3 149 8T-4121
reeHard Washer
5
2
1
8X-3838
6B-8085
n
Chain
Chain Snap
6 1 8X-9874 Chain
7 5 8C-8451 Bolt
9 5 5C-2890 Nut
10 4 8T-4956 Bolt
12 2 2G-9399 Rod
13 2 2G-2345 Bracket
14 2 6F-8499 Spring
15 2 0T-0883 Washer
16 2 3B-4615 Cotter Pin
17 4 5K-4549 U-Bolt
18 8 6V-8185 Nut
19 1 8X-4303 Rail Assembly (1)
(1)
:
20 1 8X-4304 Rail Assembly (1)
21 1 155-6730 Handhold (1)
22 1 8X-5545 Handhold (1)
23 2 144-9447 Handhold (1)
24 2 144-9449 Handhold (1)
25 1 138-6709 Handhold (1)
26 1 8X-3835 Handhold (1)
27 1 101-1546 Cab Rail Assembly (1) (2)
28 1 145-2814
PIP Rail Assembly (1) (3)
29 1 152-7016
-11
Rail Assembly (1) (4)
30 1 159-2037
202 008
Rail Assembly (1) (5)
Table 39
15: 1 /0 6 92
8
(1)
(2) The 8X-4303 Rail Assembly is not a part of the 8X-4453 Fastener Group.
56: /22
(3)
The rail assembly is for the 793C (S/N: 4AR1-UP) with a body that is standard width.
(4) The rail assembly is for a 793C (S/N: 4AR1-UP) with a wide body.
SEH 48-
(5)
The rail assembly is for a 793C (S/N: 4GZ1-UP; ATY1-UP) with a body that is standard width.
The rail assembly is for a 793C (S/N: 4GZ1-UP; ATY1-UP) with a wide body.
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
fide r: ar I
nc.
Illustration 57
ntia g00685037
lG
View of the handhold assembly on the right side of the truck
ree
1. Install the 144-9449 Handhold Assembly (24) on the right side. Use 12 8T-4136 Bolts (2) and 12 8T-4121 Hard Washers (3).
n
:
PIP
-11
202 008
15: 1 /0 6 92
Illustration 59
56: /228
g00685076
SEH 48-
View of the handhold assembly
03:
3. Use a suitable lifting device to position the 138-6709 Handhold Assembly (25). The weight of the 138-6709 Handhold
© 2 998S
Assembly (25) is 55 ± 10 N·m (41 ± 7 lb ft).
00
4. Install the 138-6709 Handhold Assembly (25) with 16 8T-4136 Bolts (2) and 16 8T-4121 Hard Washers (3).
0 2 0
1C
Cat
erp ater
Con illa pill
fide r: ar I
nc.
ntia
lG
ree
n
6. Install the 144-9447 Handhold Assembly (23) on the left side of the machine. Use 12 8T-4136 Bolts (2) and 12 8T-4121 Hard
:
Washers (3). The weight of the 144-9447 Handhold Assembly (23) is 85 kg (187 lb).
8. Install the 144-9447 Handhold Assembly (23) on the right side of the machine. Use 12 8T-4136 Bolts (2) and 12 8T-4121
Hard Washers (3). The weight of the 144-9447 Handhold Assembly (23) is 149 kg (328 lb).
PIP
-11
202 008
1 6
View of the handhold
15: /0 8 92
56: /22
10. Install the 144-9449 Handhold Assembly (24) on the left side of the machine. Use 12 8T-4136 Bolts (2) and 12 8T-4121 Hard
Washers (3). The weight of the 114-1231 Handhold Assembly is 14 kg (31 lb).
SEH 48-
S 03:
12. Use a fork lift to position the 8X-4304 Rail Assembly (20) and the 8X-4303 Rail Assembly (19) to the top of the machine. The
© 2 998 00
weight of the 8X-4304 Rail Assembly (20) is 18 kg (40 lb). The weight of the 8X-4303 Rail Assembly (19) is 28 kg (62 lb).
0 2 0
Cat 1C
erp ater
Con illa pill
fide r: ar I
nc.
ntia
lG
ree
n
:
den Inc
tial .
G ree
n
This is a view of the rail assembly.
13. Install the 8X-4304 Rail Assembly (20). Use 12 8T-4136 Bolts (2) and 12 8T-4121 Hard Washers (3). Install the 8X-4303 Rail
Assembly (19) with 13 8T-4136 Bolts (2) and 13 8T-4121 Hard Washers (3).

Note: Step 15 through Step 21 should be completed before the cab is installed onto the truck frame.
View of the rail assembly on the left side of the truck
15. Position the 8X-3835 Rail Assembly (26) to both of the catwalks. The weight of the 8X-3835 Rail Assembly (26) is 35 kg
(77 lb).
PIP
-11
202 008
15: 1 /0 6 92
56: /228
SEH 48-
Illustration 66
S 03:
g00685128
© 2 998 00
16. Install the 8X-3835 Rail Assembly (26) to both of the catwalks. Use 12 8T-4136 Bolts (2) and 12 8T-4121 Hard Washers (3).
0 2 0
Cat 1C
erp ater
Con illa pill
fide r: ar I
nc
n
:
202 80
Cat 1C
erp ater
Con illa pill
fide r: ar I
nc.
ntia
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ree
Illustration 67
ng00685142
18. The 793C (S/N: 4AR1-UP) that has the standard wide body uses the 101-1546 Cab Rail Assembly (27). Attach the 101-1546
Rail Assembly (27) to the catwalk. The weight of the 101-1546 Rail Assembly (27) is 45 kg (99 lb).
The 793C (S/N: 4AR1-UP) with the wide body uses the 145-2814 Rail Assembly (28).
The 793C (S/N: 4GZ1-UP; ATY1-UP) with the standard wide body use the 152-7016 Rail Assembly (29).
The 793C (S/N: 4GZ1-UP; ATY1-UP)with the wide body use the 159-2037 Rail Assembly (30).
19. Install the appropriate rail assembly to the catwalk. Use 16 8T-4136 Bolts (2) and 16 8T-4121 Hard Washers (3). Use four 8T-
4956 Bolts (10) and four 8T-4223 Hard Washers (11) to secure the larger rail assembly. This is the location of the mirror.
20. Tighten bolts (2) to torque of 55 ± 10 N·m (41 ± 7 lb ft).
View of the chains and hose with fasteners
22. Fasten the two 8X-3838 Chains (4) with the 5P-0765 Hose Assembly (1). Use four 8C-8451 Bolts (7), eight 8T-4205 Washers
(8), and four 5C-2890 Nuts (9).
23. Tighten nuts (9) to a torque of 12 ± 3 N·m (9 ± 2 lb ft).
PIP
24. Fasten one 8X-9874 Chain (6) and one 6B-8085 Chain Snap (5). Use one 8C-8451 Bolt (7), two 8T-4205 Washers (8) and
-11
one 5C-2890 Nut (9) on the front of the catwalk (not shown).
202
008
15: 1 /0 6 92
56: /228
SEH 48-
S99 03:00
80
:
15: /08/2 92
56: 2
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
fide r: ar I
nc.
ntia
lG
ree
26. Install the 2G-2345 Bracket (13) to the 155-6730 Handhold Assembly (21) with two 5K-4549 U-Bolt (17), four 8T-4205
Washers (8), four 6V-8185 Nuts (18), and one 0T-0083 Washer (15).
Note: Leave the 2G-2345 Bracket (13) loose until the right side platform is installed to the truck frame. After the battery
compartment cover is installed, the bracket can be properly positioned.
28. Insert the 2G-9399 Rod (12) into the 6F-8499 Spring (14). Secure the 2G-9399 Rod (12) with a 3B-4615 Cotter Pin (16).
29. Repeat Step 26 and Step 28 on the other handhold assembly.
30. Position the 155-6730 Rail Assembly (21) to the right side platform with 24 8T-4136 Bolts (2) and 24 8T-4121 Hard Washers
(3).
PIP
-11
202 008
1/0 692
8
:
PIP
-11
202 008
15: 1 / 0 6 92
56: /22 8
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
Illustration 71
erp ater g00685184
Con illa pill

32. Install the 8X-5545 Handhold Assembly (22) to the rear of the truck frame. Use eight 8T-4136 Bolts (2) and eight 8T-4121
fide r: ar I
Hard Washers (3). The weight of the 8X-5545 Handhold Assembly (22) is 7 kg (15 lb).
nc.4AR1-
Install the 8X-9330 Laddern tial Lighting for the 793C (S/N:
Lighting for the 793C (S/N:
UP) and Install the 168-9897 LadderG ree
4GZ1-UP; ATY1-UP)
n
Parts That are Required to Install 8X-9330 Ladder Lighting for 793C (S/N: 4AR1-UP)
1 1 9X-1439 Flood Lamp Gp
2 1 5L-4241 Spacer
4 1 8T-4133 Nut
Table 40
Parts that are Required to Install 168-9897 Ladder Lighting for 793C (S/N: 4GZ1-UP; ATY1-UP)
1 1 153-2073 Flood Lamp
2 1 5L-4241 Hard Washer
4 1 5C-7261 Nut
5 1 8T-4196 Bolt
7 2 8T-6869 Bolt
8 1 140-1088 Bracket Assembly
Table 41
:
PIP
-11
202 008
1 1 /0 6 9 2
8
5 / 22(S/N: 4AR1-UP)
View of the 8X-9330 Lighting Group
:56for the 793C

Install the 8X-9330 Ladder Lighting
SEH :48-
03:
1. Install the 9X-1439 Flood Lamp Gp (1) to the right side of the radiator cowling assembly. Use one 8T-4133 Nut (4), one 8T-
© 2 998 S
4121 Washer (3), and one 5L-4241 Spacer (2).
00
2. Tighten nut (4) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
0 2 0
1C
3. Install two electrical connectors to the screws on the rear of the lamp.
Cat
ater
4. Use the clips and hardware to secure the wiring harness to the right side platform assembly.
erp
CoLadder i p
5. Adjust the lamp to the requirements that are needed.
Install the 168-9897

n lla
Lighting
r i
for the 793Cllar
(S/N: 4GZ1-UP; ATY1-
UP) fide : Inc
ntia .
lG
ree
n
View of the 168-9897 Ladder Lighting
1. Install the 140-1088 Bracket (8) to the right side radiator cowling. Use one 8T-4196 Bolt (5), 8T-4121 Hard Washer (3), and a
5L-4241 Spacer (2).
Note: The 5L-4241 Spacer (2) should be placed between the 140-1088 Bracket (8) and the top of the welded bracket.
2. Install the 153-2073 Flood Lamp Gp (1) onto the 140-1088 Bracket (8). Use a 8T-6869 Bolt (7), two 8T-4224 Hard Washers
(6), and a 5C-7261 Nut (4).
3. Connect the wiring harness connector to the 153-2073 Flood Lamp Gp (1).
4. Adjust the lamp to the requirements that are needed.

:
Install the 8X-0262 Rear View Mirror Gp
Note: The two rear view mirror groups that are located on the right side platform assembly can be installed at ground level. Install
the rear view mirrors when the battery cover latch is installed on the 8X-2040 Handhold Assembly. Refer to "Install the 8X-4453
Handhold Fastener Gp" for additional information.
Note: The rear view mirror group that is located on the left side of the truck can be installed at ground level. Install the rear view
mirrors when the 101-1546 Rail Assembly is installed to the catwalk platform. Refer to "Install the 8X-4453 Handhold Fastener
Gp" for additional information.
Parts That are Required for the Installation of 8X-0262 Mirror and 157-8393 Mirror
PIP
1 1 8X-5411 Pipe (1)
2 1 8T-2287 Mirror
3 1
-11
8Y-6989 Mirror As
4 1
2025P-6873
008 Mirror
5 1
15: 1 /0
8X-5410
6 92
Bracket
7
2
2
56: /22
7D-9969
3B-4605
8 Support
Cotter Pin
8 2
SEH 48-
8T-6868 Bolt (2)
9 4
S
5P-1076
03: Hard Washer
10 5
© 2 9988T-4136
00 Bolt
11 14
0 2
8T-4121
0 Hard Washer
12 1
Cat 1C
134-0987 Bracket Assembly
erp ater
13 1 7K-5707 U-Bolt
Con illa pill

14 2 6V-8801 Nut
fide r:
15 2 8T-4137 Bolt
16 2 134-0989
ar I
Block
17 4
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8T-4186
nc.
Bolt
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18 2 8T-4176 Bolt (3)
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19 1 137-2122 Tube As (4)
n
20 1 137-2129 Bracket (5)
Table 42
(1)
(2) The pipe is for use on a body that is standard width.

(3) The bolt is for use on 793C (S/N: 4AR1-UP).
(4) The bolt is for use on 793C (S/N: 4GZ1-UP; ATY1-UP).

(5) The tube assembly is for use on a wide body.
The bracket assembly is for use on a wide body.
:
PIP
-11
202 008
15: 1 /0 6 92
8
56: /22
View of the rear view mirror on the right side platform assembly
1. Fasten the 8X-5411 Pipe (1) to the 155-6730 Handhold Assembly. Use two 7D-9969 Supports (6), two 3B-4605 Cotters (7),
SEH 48-
four 5P-1076 Hard Washers (9), and two 8T-6868 Bolts (8).
03:
Note: For a wide body, substitute the 137-2122 Tube Assembly (19) in place of the 8X-5411 Pipe (1).
© 2 998S 00
Note: Substitute 8T-4176 Bolts (18) in place of 8T-6868 Bolts (8) for the 793C (S/N: 4GZ1-UP; ATY1-UP).
0 0
2
Cat 1C
3. Install the 8T-2287 Mirror (2) to the 8X-5411 Pipe (1). Use two 8T-4121 Washers (11) and two 8T-4137 Bolts (15).
erp ater
4. Tighten bolts (15) to a torque of 55 ± 10 N·m (41 ± 7 lb ft). Adjust the mirror to the operator's specifications.
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:
5. Install the 8X-5410 Bracket (5). Use a 7K-5707 U-Bolt (13), two 8T-4121 Hard Washers (11), and two 6V-8801 Nuts (14).
7. Install the 5P-6873 Mirror (4) to the 8X-5410 Bracket (5).

Note: Tighten nut (14) on the 5P-6873 Mirror (4) to 25 ± 5 N·m (18 ± 4 lb ft).
Note: Adjust the mirror to the operator's specifications.
This is a view of the bracket and the mirror that is installed.
8. Fasten the 134-0987 Bracket (12) to the left side rail. Use four 8T-4186 Bolts (17), four 8T-4121 Hard Washers (11), and two
134-0989 Blocks (16).

Note: For a wide body, install the 137-2129 Bracket (20) to the left side rail. Use eight 8T-4137 Bolts (15) and eight 8T-4121
Hard Washers (11). Install the 134-0987 Bracket (12) to the 137-2129 Bracket (20).
10. Install the 8Y-6989 Mirror (3). Use three 8T-4136 Bolts (10) and three 8T-4121 Hard Washers (11).
PIP
11. Tighten bolts (10) to a torque of 55 ± 10 N·m (41 ± 7 lb ft). Adjust the mirror to the operator's specifications.
-1the
Note: Use extra 8T-4121 Hard Washers (10) when there is a gap between the mirror and the bracket assembly.
202 10Mud
Use 8X-0229 Fender Gp and Install
0 guard
869
15: 08/21 / 2
Parts That are Required for the Installation of 143-0343 Fender Gp
1 1
56: 2
8X-4285 Plate Assembly
2
SEH 48-
2 145-2815 Mud Flap
3 1
S 03:
8X-4284 Brace
4
© 2 998
1
00
8X-4289 Plate
5 1
0 2 08X-4290 Guard
6
Cat 1
1C 8X-4291 Strip
7 1
erp ater8X-4292 Guard
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8 1 8X-4293 Strip
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9 3 8X-4294 Strip
nc.
10 1 8X-4295 Guard
11 1
ntia 8W-7899 Guard
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:
onf lar: illa
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12 1 8X-4296 Strip
l Gre
en
13 2 8X-4089 Plate
14 2 8X-4029 Plate
15 2 8X-3822 Bracket
16 4 8T-4139 Bolt
18 4 8T-4244 Nut
19 9 8T-4195 Bolt
21 48 6V-7732 Bolt
22 35 8T-4133 Nut
23 2 8T-4136 Bolt
24 21 8T-0722 Bolt
25 1 8X-4283 Fender Assembly
26 1 131-3936 Film (1)
27 1 100-9984 Film (1)
Table 43
(1)
The 131-3936 Film is not a part of the 143-0343 Fender Gp.
Illustration 78
PIP g00685794
-11
202 008
15: 1 /0 6 92
56: /22 8
SEH 48-
S 03:
© 2 998 00
0
View of the fender assembly
Cat 0 2 1C
erp ater
illa pill
r: a
:
© 2 S998 3:00
0 2 0
Cat 1C
erp ater
1. Install one 131-3936 Film (26) and one 100-9984 Film (27) to the 8X-4283 Fender Assembly (25). Install the films while the
fender is on the ground.
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View of fender assembly
2. Install the 8X-4283 Fender Assembly (25) with nine 8T-4195 Bolts (19) and nine 8T-4121 Washers (20).
3. Tighten bolts (19) to a torque of 55 ± 10 N·m (41± 7 lb ft).
View of a mud flap that is installed on the cab
4. Fasten the 8X-4295 Guard (10) to the catwalk. Use three 8X-4294 Strips (9), 12 8T-0722 Bolts (24), and 24 8T-4121 Washers
(20).
PIP
-11
202 008
15: 1 /0 6 92
56: /228
SEH 48-
S9 03:0
:
202 008
15: 1 /0 6 92
56: /228
SEH 48-
View of the mud flap that is installed on the fender assembly
S 03:
6. Install the 8W-7899 Guard (11) and the 8X-4296 Strip (12) with nine 8T-0722 Locking Bolt (24), 16 8T-4121 Washers (20),
© 2 998 00
and nine 8T-4133 Nuts (22).
0 0
2
Cat 1C
erp ater
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View of the bracket assembly
8. Install one 8X-3822 Bracket (15) on the right side of the machine. Use four 6V-7732 Bolts (21) and four 8T-4121 Washers
(20).
9. Install one 8X-3822 Bracket (15) on the left side of the truck. Use four 6V-7732 Bolts (21) and four 8T-4121 Washers (20).

Note: The following installation procedures will be referred to by other topics. The assembly procedures for the fender and
the mud flap are spread apart in different sections of the assembly manual.
11. Install the 8X-4284 Brace (3). Use two 8T-4139 Bolts (16), four 8T-4223 Washers (17), and two 8T-4244 Nuts (18).
Note: Tighten the bolts to 55 ± 10 N·m (41 ± 7 lb ft).
12. Install the upper part of the 145-2815 Mud Flap (2). Use a 8X-4089 Plate (13), eight 6V-7732 Bolts (21), and eight 8T-4121
Washers (20).
13. Install the lower part of the 145-2815 Mud Flap (2). Use a 8X-4029 Plate (14), five 6V-7732 Bolts (21), and five 8T-4121
PIP
-11
008
:
Washers (20).
PIP
-11
202 008
15. Repeat Step 8 and Step 9 for the right mud flap.
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
Illustration 85
fide r: g00685850
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nc.
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View of plate assembly
lG
16. Install the 8X-4285 Plate Assembly (1) with two 8T-4136 Bolts (23) and two 8T-4121 Washers (20) on the front cab support.
ree
:
PIP
-11
202 008
15: 1 /0 6 92
Illustration 87
56: /22 8
View of the mud flap that is installed
g00685864
SEH 48-
18. Install the 8X-4289 Plate (4). Use two 8T-4139 Bolts (16), four 8T-4223 Washers (17), and two 8T-4244 Nuts (18).
S 03:
© 2 998 00
0 2 0
1C
21. Install the 8X-4290 Guard (5) with a 8X-4291 Strip (6), five 8T-4133 Nuts (22), ten 8T-4121 Washers (20), and five 6V-7732
Bolts (21).
Cat
erp ater
Con illa pill

23. Install the 8X-4290 Guard (7) with a 8X-4291 Strip (6), five 8T-4133 Nuts (22), ten 8T-4121 Washers (20), and five 6V-7732
fide r: ar I
Bolts (21).
n n c.
tiaMounting
Install the 8X-2808 Suspension
lG Gp
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Parts That are Required for the Installation of 8X-2808 Suspension Mounting Gp
Item
1
Qty
2
n
Part Number
6V-3249
Description
Bearing
2 2 5T-5202 Bearing Cap
3 2 6V-0836 Retaining Ring
4 2 5T-6255 Key
5 8 6V-8132 Bolt
6 8 6V-8237 Hard Washer
7 2 5M-6214 Plug
8 20 8T-6624 Bolt
9 20 9X-8399 Washer
10 20 5T-1352 Spacer
11 20 8T-1583 Nut
12 12 9X-6626 Bolt
:
13 12 9X-8259 Washer
14 12 5T-4896 Spacer
15 12 8C-4032 Nut
16 16 117-4935 Plate
17 2 9T-8910 Front Suspension Gp (1)
Table 44
(1)
The 9T-8910 Front Suspension Gp is not a part of the 8X-2808 Suspension Mounting Gp.
PIP
-11
202 008
15: 1 /0 6 92
Illustration 88
56: /228g00685951
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
fide r:
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Note: The front brake group and the suspension wheel group have a right and left side. Locate the air purge valve and the
nc.
parking brake port on the top of the truck to determine the correct suspension cylinder. The weight of the suspension
cylinder is 5350 kg (11,795 lb).
ntia
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1. Remove the plastic caps from the studs. Clean the shipping grease from the mounting surface of the front suspension
ree
groups.
n
2. Clean the shipping grease from the rim mounting surface on the front suspension groups.
:
3. Clean the shipping grease from the bottom mounting surface of the front suspension group. Clean the paint from the holes
and face for better contact.
PIP
-11
202 008
Illustration 92
15: 1 /0 6 92
g00686033
56: /228
View of the shipping brackets for the steering arms
4. Support the steering arms before you remove the shipping bracket.
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
Illustration 93
fide r: ar I
g00686042
nc.
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:
Gre
en
5. Remove the shipping covers and remove the caps from the grease lines.
6. Clean the shipping grease from the mating surfaces. Remove any burrs from the mounting surfaces.
PIP
-11
202 008
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
© 2 998 00
0 2 0
Illustration 96
Cat 1C g00686074
erp ater
7. Insert the 5T-6255 Key (4) into the keyway. Clean the mating surface. Align the bolt hole of the key and the support bracket.
Con illa pill

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:
erp ater
Con illa pill
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8. Install the 6V-3249 Bearing (1) into the 5T-5202 Bearing Cap (2). Install the 6V-0836 Ring (3). The bearing may already be
assembled.
Note: Check the lock ring when you install the bearing and bearing cap. The lock ring should be down.
Illustration 99
PIP g00686150
View of the lift procedure for the front suspension cylinders
-11
9. Use a lever puller and a lifting bracket to prevent movement of the front suspension cylinder.
202 008
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
:
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
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Illustration 100
n
g00686396
10. Use chains, a lifting link, and a clevis to align the front suspension group.
11. Remove the plastic caps and remove the paint from the suspension cylinder. Deburr the countersunk bolt holes before the
installation of the truck frame.

View of the bolts on the front of the suspension cylinders
PIP
12. Align the holes of the 5T-6255 Key (4) and the keyway in the truck frame.
-11
202 008
15: 1 /0 6 92
56: /228
48-
:
P-1
202 1008
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
View of the suspension cylinder that is attached to the truck frame
Con illa pill

13. Install the 9T-8910 Front Suspension Group (17) with six 9X-6626 Bolts (12), six 9X-8259 Washers (13), six 5T-4896 Spacers
fide r: ar I
(14), and six 8C-4032 Nuts (15) for the lower six holes. Secure the bolts with an air gun.
ntia nc.
14. Install ten 8T-6624 Bolts (8), ten 9X-8399 Washers (9), ten 5T-1352 Spacers (10), and ten 8T-1583 Nuts (11) for the upper ten
holes. Secure the bolts with an air gun. Install the grease line to the truck frame.
lG
Note: The nuts face the outside of the truck frame. The rear washers are thicker than the front washers.
ree
Note: Lubricate the faces of the washers and the threads of the bolts with 5P-3932 High Temperature Anti-Seize.
n
15. Use a 6V-6080 Torque Multiplier, 6V-7915 Torque Wrench, 6V-4170 Adapter, 4C-6724 Socket, 5S-6076 Extension, and a
8T-3196 Wrench.
16. Tighten the lower six 8C-4032 Nuts (15) to a torque of 1500 ± 150 N·m (1106 ± 111 lb ft).
Note: Turn 8C-4032 Nuts (15) by an additional 60 ± 5 degrees.
17. Tighten the upper ten 8T-1583 Nuts (11) to a torque of 1000 ± 100 N·m (738 ± 74 lb ft).
Note: Turn the 8T-1583 Nuts (11) by an additional 60 ± 5 degrees.

View of the shim pack
18. Install the bearing assembly with 6V-8132 Bolts (5) and 6V-8237 Washers (6). Install the 117-4935 Plates (16) for the correct
gap.
:
PIP
-11
202 008
15: 1 /0 6 92
56: /228
SEH 48-
View of the plug for the grease line
S 03:
20. Remove the 5M-6214 Plug (7). Install the grease line to the front of the bearing cap.
© 2 998 00
21. Secure the grease line with clamps. This secures the grease line to the frame assembly.
0 2 0
Cat 1C
erp ater
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Illustration 106
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g00686449
n
View of the payload measurement control connector
22. Connect the wiring to the payload monitoring system pressure sensor.

View of the grease line for the front suspension cylinder
23. Connect the grease lines to the 9T-8910 Front Suspension Gp (17).
Note: Connect the auto lube grease line and a manual grease fitting to one side of the suspension cylinder. Install a purging
off screw on the other side of the suspension cylinder.
Install the 8X-2809 Rear Wheel Fastener Group

Parts that are Required for Installation of 8X-2809 Rear Wheel Fastener Group

:
1 2 8X-6304 Guard Assembly
2 2 8X-5532 Plate Assembly
3 2 8X-5527 Plate
4 82 129-3175 Bolt
5 6 9X-6618 Bolt
6 6 8C-3236 Bolt
7 94 9X-8399 Washer
8 6 8X-6305
PIP Boss
9 2 9M-8406
-11
Clip
10 2 8T-4195
202 Bolt
008
11 2 8T-4133
15: 1 /
Nut
0 6 92
12
13
4
2
8T-4121
5P-0562
56: /228
Hard Washer
Wire Lock
14 2 7X-4801
SEH 48- O-Ring Seal
15 8 8T-4956
S
Bolt
03:
© 2 998 00
0
17 2 159-0038 Final Drive, Brake, and Wheel Gp (1)
Table 45
(1)
Cat 0 2 1C
erp ater
The 159-0038 Final Drive, Brake, and Wheel Gp is not a part of the 8X-2809 Rear Wheel Fastener Group. The 159-0038 Final Drive, Brake, and Wheel Gp is
effective with the 793C (S/N: 4GZ1-UP), 793C (S/N: ATY1-215), and 793C (S/N: 4AR313-UP). The 141-0208 Final Drive, Brake, and Wheel Gp was effective
Con illa pill

with 793C (S/N: 4AR138-312). The 135-7121 Final Drive, Brake, and Wheel Gp was effective with 793C (S/N: 4AR80-137). The 125-6508 Final Drive, Brake,
and Wheel Gp was effective with 793C (S/N: 4AR1-79).
fide r: ar I
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View of the shipping cover on the rear axle housing
1. Use a lifting device to support the shipping cover. Loosen ten bolts. Remove nine bolts. Leave one of the bolts loose until
the lifting device is attached. Once the lifting device is attached, remove the shipping cover.
:
This is a view of the rear axle housing after the cover has been removed.
2. Deburr the surface area of the axle housing before you begin assembly.
3. Clean the inside of the axle housing.
PIP
-11
202 008
15: 1 /0 6 92
56: /228
Illustration 110
SEH 48- g00686788
View of the metric guide pins
S 03:
© 2 998 00
4. Install the two metric guide pins to the rear axle housing. The weight of the final drive is 7180 kg (15,829 lb).
0 2 0
Cat 1C
erp ater
Con illa pill
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Illustration 111
ng00686803
View of the final drive cover that is attached
:
View of the shipping cover that is removed
5. Use a lifting device to support the shipping cover. Loosen ten bolts. Remove nine bolts. Leave one of the bolts loose until
the lifting device is attached. Once the lifting device is attached, remove the shipping cover.
6. Deburr the surface area of the final drive.
PIP
-11
202 008
15: 1 /0 6 92
56: /228
SEH 48-
Illustration 113
S 03:
g00686809
© 2 998
View of the O-Ring seal that is installed
00
0 0
7. Install the 7X-4801 O-Ring Seal (14) to the 159-0038 Final Drive, Brake, and Wheel Gp (17).
2
Cat 1C
Note: Refer to Table 45 for other part numbers.
erp ater
Note: Apply 1U-6396 O-Ring Compound to the 7X-4801 O-Ring Seal (14) before installation.
Con illa pill

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:
ial
G ree
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This is a view of the shipping cables.
8. Remove the cables from the final drive.

View of the brackets and chains that are installed on the final drive
PIP
-11
202 008
15: 1 /0 6 92
56: /228
Illustration 116
SEH 48- g00686894
03:
This is a view of the AETA sensor that is positioned.
S
© 2 998 00
9. Install the 6V-2156 Link Brackets and a lifting device to the final drive. Move the 159-0038 Final Drive, Brake, and Wheel
0
Gp (17) to the axle housing for installation.
the machine.
Cat 0 2
Note: Position the wheel assembly with the Automatic Electronic Traction Aid (AETA) Speed Sensor that is facing the rear of
1C
erp ater
Con illa pill
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:
Cat 1C
erp ater
Con illa pill
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This is a view of the final drive that is positioned to the rear axle housing.
10. Position the final drive onto the metric guide pins.
11. Install 41 129-3175 Bolts (4) and 41 9X-8399 Washers (7).

Note: Leave the bolts loose until the speed sensor guard and the mud scraper plate are assembled to the final drive.
Note: After the mud scraper plate and the speed sensor guard are installed tighten the 41 129-3175 Bolts (4) to a torque of
1800 ± 200 N·m (1328 ± 148 lb ft).
12. Install the 5P-0562 Lockwire (13) to the AETA switch. Lock the wire to the hole of the endbell assembly. Use 6V-0006 Pliers
to tighten the nut.
13. Install the 8X-6304 Guard Assembly (1) to the final drive. Use three 8C-3236 Bolts (6), three 8X-6305 Bosses (8), and three
9X-8399 Washers (7). Use the 6V-6820 Torque Multiplier to secure the final drive to the rear axle housing.
PIP
Note: Tighten 8C-3236 Bolts (6) to a torque of 1800 ± 200 N·m (1328 ± 148 lb ft).
-11
14. Install 9M-8406 Clip (9) to the 8X-6304 Guard Assembly (1). Use one 8T-4195 Bolt (10), two 8T-4121 Washers (12), and one
8T-4133 Nut (11).
202 008
1 / 6
15: 0 92
56: /22 8
16. Install an 8X-5532 Plate Assembly (2) to the 8X-5527 Plate (3). Use three 9X-6618 Bolts (5), and three 9X-8399 Washers (7).
SEH 48-
18. Repeat Step 1 through Step 17 for the installation of the final drive on the other side.
S 03:
© 2 998 00
021 0
C
:
:56 22
SEH :48-
0
Install the 8X-0250© S 998 3:00
Axle and Mounting
202 0
1C
Parts That are Required for the Installation of 8X-0250 Axle and Mounting
Item
Cat
1
erp
1
ater 8X-0496 Axle Shaft (RH)
2
Con illa
1
pill8X-0497 Axle Shaft (LH)
3
fide r:
2
ar I
1V-6659
nc.
Retaining Ring
ntia
4 2 7I-5093 Clamp
5 4 1T-0284 Bolt
lG
ree
Table 46

This is a view of the parking brake release that is using hydraulic pressure.
Note: To ease the installation of the rear axles, apply 4134 kPa (600 psi) of nitrogen or hydraulic pressure to the system. This
releases the rear wheels to turn the wheels. Turn the wheels to help with the alignment of the axles.
PIP
-11
202 008
1/0 692
8/2
2
:
PIP
-11
202 008
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Illustration 121
Con illa pill
g00687154
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View of the final drive cover that is removed
1. Loosen ten bolts on the final drive cover. Remove nine bolts. Leave one of the bolts loose until the lifting device is attached.
2. Attach a 6V-2156 Link Bracket to the lifting holes on the final drive cover. Remove the cover.

:
PIP
-11
202 008
15: 1 /0 6 92
Illustration 124
56: /228 g00687174

View of the outer sun gear that is removed from the final drive
SEH 48-
3. Thread the 1U-8848 Axle Installation Tool onto the axle. Slide the outer sun gear out of the final drive. Position a strap
around the sun gear.
S 03:
© 2 998 00
4. Remove the outer sun gear. Reposition the outer sun gear for a later assembly.
0 2 0
Cat 1C
erp ater
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Illustration 125
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g00687177
n
View of the inner sun gear
5. Remove the retaining ring. Slide the inner sun gear from the final drive. Reposition the inner sun gear for a later assembly.

:
PIP
6. Remove the thrust bearing from the final drive. Reposition the thrust bearing for a later assembly.
-11
202 008
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SEH 48-
S 03:
Illustration 128
© 2 998 00
g00687304
0 0
View of the axle shaft that is shipped from the factory
2
Cat 1C
7. Remove the 8X-0497 Axle Shaft (LH) (2) from the shipping crate.
erp ater
Note: The shorter 8X-0496 Axle Shaft (RH) (1) is for the right side. The longer 8X-0497 Axle Shaft (LH) (2) is for the left side.
The weight of the axle shaft is 290 kg (640 lb).
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:
View of the ends of the axle shaft that are covered with grease
8. Clean the grease from the two axle shafts.
PIP
-11
202 008
15: 1 /0 6 92
8
56: /22
View of the AETA drive clamp that is measured
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
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Con illa pill
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View of the AETA drive clamp that is installed
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:
9. Install 7I-5093 Clamp (4) to 8X-0497 Shaft (2). Apply 7M-7456 Bearing Mount Compound to the threads of two 1T-0284
Bolts (5). Position 7I-5093 Clamp (4) away from the outboard end of 8X-0497 Shaft (2) and secure using two 1T-0284 Bolts
(5).
Note: 7I-5093 Clamp (4) should be a distance of 1735 ± 5 mm (68.30 ± 0.20 inch) away from the outboard end of 8X-0497
Shaft (2).
PIP
-11
Note: The LH and RH axles are different lengths. The different lengths do not affect Dimension (A).
202 008
10. Tighten bolts (5) to a torque of 30 ± 4 N·m (22 ± 3 lb ft). Stake the bolts.
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
© 2 998 00
0 2 0
Illustration 134
Cat 1C g00687342
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:
den Inc
tial .
G ree
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View of the AETA drive clamp that is aligned to the timing gear
11. Use a 1U-8848 Axle Installation Tool to lift the 8X-0497 Axle Shaft (LH) (2). Slide the end that is not threaded into the final
drive housing up to the timing gear.
12. Align the 7I-5093 Clamp (4) on the axle with the notches in the timing gear before the axle is installed. Rotate one of the
splines on the 7I-5093 Clamp (4) to a one o'clock position.

View of the bearing, the sun gear, and the retaining ring
13. Thread the 1U-8848 Axle Installation Tool onto the 8X-0497 Axle Shaft (LH) (2). Slide the 8X-0497 Axle Shaft (LH) (2) into
the timing gear until the axle shaft spline is seated in the differential.
14. Slide the bearing, the inner sun gear, and the retaining ring onto the axle installation tool.
PIP
Note: Support the weight of the axle installation tool with a sling. Keep the axle shaft parallel with the final drive.
-11
202 008
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SEH 48-
S 03:
Illustration 137
© 2 998 00
g00687370
0 0
View of the inner sun gear that is installed
Cat 2 1C
15. Install the thrust bearing onto the 8X-0497 Axle Shaft (LH) (2).
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202 80
Cat 1C
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Illustration 138
n g00687382
View of the inner sun gear that is installed in the final drive
16. Install the inner sun gear over the axle shaft.

View of the retaining ring that is installed
17. Install the 1V-6659 Retaining Ring (3) to the axle shaft.

View of the inner sun gear that is installed in the final drive
PIP
18. Install the outer sun gear over the axle shaft.
-11
202 008
15: 1 /0 6 92
56: /228
SEH 48-
S99 03:00
80
:
15: 1/08/2 692
56: 2
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
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This is an illustration that is showing the distance between the sun gear and the planetary carrier.
19. Measure the distance between the outer sun gear and the planetary carrier. Dimension (B) should be within tolerance before
the final drive cover is installed. Dimension (B) has a value of 29 ± 2 mm (1.14 ± 0.08 inch).

View of the final drive cover that is installed
20. Install the final drive cover.
PIP
Note: Check the final drive cover for proper installation. The final drive level/fill plug is 90 degrees counterclockwise from
-11
the drain plug.
202 008
1/0 692
8
:
PIP
-11
21. Repeat Step 7 through Step 20 on the right side. Use the 8X-0496 Axle Shaft (RH) (1).
202 008
22. When both sides are completed remove the final drive level/fill plug. Fill the axle housing to the proper level. Refer to the
1 /0 6 92
Operations and Maintenance Manual for the correct information.
15: Arm Fastener

Install the 8X-2829 Steering
56: /228 Group
SEH 48-
Parts that are Required for the Installation of 8X-2829 Steering Arm Fastener Group
Item Qty
S 03:
© 2 998 00
1 20 8T-0283 Bolt
0
2 20 9X-8399 Washer
Cat
1
0 2 1C
3J-6899 Locknut
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Table 47
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1. Check the surfaces for cleanliness and metal burrs.
2. Use a chain and a lever puller to support the steering arm. Align the steering arm to the left side of the front suspension
cylinder.
3. Use ten 8T-0283 Bolts (1) and ten 9X-8399 Washers (2) to mount the left steering arm to the left front suspension cylinder.
:
PIP
-11
202 008
Illustration 145
15: 1 /0
g00688060
6 92
56: /228
5. Use a chain and a lever puller to support the steering arm. Align the right steering arm to the center steering arm.
SEH 48-
6. Install the right steering arm to the center steering arm.
S 03:
© 2 998 00
0 2 0
Cat 1C
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Illustration 146
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g00688065
n
View of a tie rod that is installed
7. Install a 3J-6899 Self-Locking Nut (3) to the pin. Use a 5P-3520 Spanner Wrench to hold the nut. 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.
8. Tighten nut (3) to a torque of 2550 ± 100 N·m (1881 ± 74 lb ft).
9. Repeat Step 1 through Step 3 for the installation of the right steering arm to the right suspension cylinder.
Install the 8X-3380 Cylinder Mounting Gp

Parts That Are Required to Install 8X-3380 Cylinder Mounting Gp
1 2 8X-4040 Pin As
2 4 8X-4043 Spacer
3 2 8X-4044 Plate
4 10 8T-4183 Bolt

:
6 2 8X-2787 Cover
7 2 2A-6662 Plate
8 2 8C-3222 Bolt
9 2 5P-9560 Union
10 4 3D-2824 O-Ring Seal
11 2 6V-3480 Fitting As
12 2 6V-3482 Cap As
13 2 121-2071 Hoist Cylinder Gp (1)
Table 48
(1)
PIP
The 121-2071 Hoist Cylinder Gp is not a part of the 8X-3380 Cylinder Mounting Gp.
-11
Note: Install the hoist cylinder on the left side of the machine before the fuel tank is installed.
202 008
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
© 2 998 00
Illustration 147
0 2 0
g00688066
1C
View of two hoist cylinders
Cat
ater
1. Cut the straps. Clean the grease from the four bearings on the hoist cylinders. The weight of the hoist cylinder is 1150 kg
(2535 lb).
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:
2. Use a suitable lifting device to install the 121-2071 Hoist Cylinder Gp (13) to the truck frame. The weight of the 121-2071
Hoist Cylinder Gp (13) is 1150 kg (2535 lb).
PIP
-11
202 008
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56: /228
SEH 48-
S 03:
Illustration 150
© 2 998 00
g00688077
0 2 0
Cat 1C
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View of the bolt and spacer that is securing the hoist cylinder to the truck frame
:
3. Install one 2A-6662 Plate (7). Use one 8C-3222 Bolt (8) to install the hoist cylinder to the truck frame.
Note: Tighten two 8C-3222 Bolts (8) to a torque of 1770 ± 50 N·m (1305 ± 37 lb ft).
4. Remove the shipping plates for the hydraulic lines on the hoist cylinders and the two hydraulic hoses.
PIP
View of the grease line and cover for the right hoist cylinder
-11
5. Remove the tie straps. Remove the cap from the grease line.
6. Install the grease line.

202 008
15: 1 /0 6
7. Install two hydraulic lines to the hoist cylinder.
92
56: /228
8. Install the 8X-2787 Cover (6). Use three 8T-4183 Bolts (4) and three 8T-4223 Hard Washers (5). Repeat Step 2 through Step
8 on the other side of the machine.
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
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en

View of the hoist cylinder that is installed
10. Secure the 121-2071 Hoist Cylinder Gp (13) with a chain. This prevents the hoist cylinders from moving during the
installation of the truck body.
Note: The hoist cylinders are identical, but it is necessary to complete Step 11 on the left cylinder.
Note: The quick disconnect fittings are only installed on the left side of the truck. The ports enable the truck to dump a load
when the truck is disabled.
11. Remove two plugs. Install two 3D-2824 Seals (10) to two 5P-9560 Unions (9). Install two 6V-3480 Nipple Assemblies (11) to
two 3D-2824 Seals (10) and two 5P-9560 Unions (9). Install two 6V-3482 Cap Assemblies (12) to two 6V-3480 Nipple
Assemblies (11) that are assembled.
Note: Step 12 and Step 13 are for the installation of the upper hoist cylinder bearing mount.
PIP
-11
202 008
15: 1 /0 6 92
56: /22 8
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
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r a
:
HS
© 2 998 3:00
0 2 0
Cat 1C
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View of the hoist cylinder that is positioned to the truck body
12. Clean the paint from the mounting surfaces of the hoist cylinder.
13. Install the 121-2071 Hoist Cylinder Gp (13) to the truck body. Use two 8X-4040 Pin Assemblies (1), four 8T-4183 Bolts (4),
four 8T-4223 Hard Washers (5), two 8X-4044 Plates (3), and four 8X-4043 Spacers (2).
Install the 115-9178 Sensor and Mounting

Parts That Are Required for Installation of 115-9178 Sensor and Mounting
1 1 124-9325 Fuel Level Sensor
2 1 6V-5051 O-Ring Seal
3 4 8T-4185 Bolt
5 1 3E-7753 Float
6 1 116-2041 Guard
7 6 8T-4136 Bolt
PIP
8 1 131-7956 Fuel Tank Gp (1)
-11
Table 49
(1)
202 008
The fuel tank is not a part of the 115-9178 Sensor and Mounting.
15: 1 /0 6 92
56: /228
SEH 48-
S9 03:0
:
202 008
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
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Illustration 158
View of the fuel tank
Con illa g00688567
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1. Remove the cover, the seal, and the four bolts from the bottom of the 131-7956 Fuel Tank Gp (8).
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PIP
-11
008
:
PIP
-11
202 008
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
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Illustration 161
View of the fuel tank sensor
n g00688616
2. Insert the 3E-7753 Float (5) into the tube assembly.

Note: The metallic surface of the 3E-7753 Float (5) contacts the VIMS Fuel Sensor.
3. Install the 6V-5051 O-Ring Seal (2) onto the 124-9325 Fuel Level Sensor (1).
4. Install the 124-9325 Fuel Level Sensor Gp (1). Use four 8T-4185 Bolts (3) and four 8T-4121 Washers (4).
Note: The 124-9325 Fuel Level Sensor Gp wiring harness will be connected to the main wiring harness in the "Install the
115-7665 Fuel Tank Fastener Gp".

View of the guard
5. Install the 116-2041 Guard (6). Use six 8T-4136 Bolts (7) and six 8T-4121 Washers (4).
:
Install the 115-7665 Fuel Tank Fastener Gp

Parts That Are Required to Install 115-7665 Fuel Tank Fastener Gp
1 1 8W-3602 Mud Flap
2 4 8X-2576
PIP Shim Pack
3 4 8T-4170
-11 Bolt
4 8
202
9D-9438
008 Washer
5 8 8X-5299
15: 1 /0 6 92
Mounting
7
4
8
6V-7688
8T-5439
56: /228 Nut
Washer
8 5
SEH 48-
8T-4195 Bolt
9 5 8T-2561
S 03: Hard Washer
© 2 998 00
10 5 8T-4133 Nut
0
11 2 7X-2564 Bolt
12 2
Cat 0 2
8T-4131
1C
Nut
ater
13 1 115-7664 Plate Assembly
14 5
erp
8T-4121 Washer
15 2
Con illa
8X-2575
pill Cap
16 4
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7X-2489
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Bolt
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17 4 8T-4167 Washer
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Table 50
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View of the wiring harness for the fuel tank
1. Cut the tie straps. Remove the tape from the end of the fuel tank sensor wiring harness.
:
View of the fuel lines with the shipping plugs that are installed
2. Remove the tie straps. Remove the plugs from the fuel lines for the installation to the fuel tank.
PIP
-11
202 008
15: 1 /0 6 92
56: /228
Illustration 165
SEH 48- g00689431
03:
View of the fuel tank support that is installed
S
© 2 998 00
3. Remove the paint from the areas that are machined on both sides of the fuel tank.
0 0
4. Install the 115-7664 Plate Assembly (13). Use eight 8X-5299 Mountings (5), eight 9D-9438 Washers (4), four 8T-4170 Bolts
2
Cat 1C
(3), four 8T-5439 Washers (7), and four 6V-7688 Nuts (6).
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View of the fuel tank with a lever puller and a chain
6. Remove the cables. Rotate the fuel tank to the correct position. The fuel tank weighs 1110 kg (2447 lb).
:
Note: Do not damage the fuel tank guard on the bottom of the fuel tank.

View of the fuel tank reinforcing plate that is installed on the truck frame
7. Use two 7X-2564 Bolts (11), four 8T-5439 Washers (7), and two 8T-4131 Nuts (12) to install the 115-7664 Plate Assembly
(13) to the truck frame.
PIP
-11
202 008
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
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Illustration 169
View of the fuel tank mounting
n
g00689457
:
Gre
en
9. Remove the 8X-2575 Caps (15), four 7X-2489 Bolts (16), and four 8T-4167 Washers (17). Use the hardware that is provided.
Use the four 8X-2576 Shim Packs (2) to assemble the fuel tank cap assembly.
Note: Remove the paint from the surfaces of the caps and brackets on the truck frame.
Bolt the cap to the frame bracket. Torque the bolts to 800 ± 100 N·m (590 ± 74 lb ft).
Measure the vertical diameter.
Measure the diameter of the pipe assembly.
Subtract the first diameter from the second diameter. This calculation will indicate the amount of gap that is present.
Install enough shims to fill the gap and add an additional shim at each bolt. The additional shim should be
0.06 ± 0.06 mm (0.0025 ± 0.0025 inch).
Shim both of the sides equally. Torque the bolts to 800 ± 100 N·m (590 ± 74 lb ft).
Repeat these steps on the other side of the fuel tank cap assembly.
10. Install the electrical connections from the fuel tank sensor to the wiring connections on the truck frame.
PIP
-11
202 008
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
© 2 998
00
0 2 0
Cat 1C
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:
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View of the primary fuel filter
11. Remove the two plugs that are for shipping purposes.
12. Install the hose assembly to the elbow on the primary fuel filter.
13. Install the hose assembly to the swivel elbow on the fuel tank.
Note: The machine that was photographed for this special instruction was not equipped with the optional fuel heater. Refer
to the Parts Manual for further information.

View of the fuel tank that is installed
14. Install the 8W-3602 Mud Flap (1). Use five 8T-4195 Bolts (8), five 8T-2561 Hard Washers (9), and five 8T-4133 Nuts (10).
PIP
Note: Install the hoist cylinders before the fuel tank. This eases both of the procedures.
Install the 8X-2812 Cab Mounting-Gp11for

2
UP)and Install the 163-72260Cab
2 008Gp for the 793C
Mounting
the 793C (S/N: 4AR1-
15: 1 /0 6 92
(S/N: 4GZ1-UP; ATY1-UP)
56: /22 8
Parts That Are Required to Install 8X-2812 Cab Mounting Gp for 793C (S/N: 4AR1-UP)
Item
SEH 48-
1 8
S 03: 6H-1628 Bolt
2
© 2 998
8
00 5T-5804 Sleeve
0 2 0
Cat 1C
erp ater
:
SEH 48-
S 03:
© 2 998 00
3 40
0 2
5T-5803
0 Mount
4 20
Cat 1C
5T-5807 Retainer
5 6
erp ater
1K-9418 Bolt
6 6
Con illa5T-5805
pill Sleeve
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7 6 8C-3236 Bolt
nc.
8 21 5T-1352 Spacer
9 9
ntia
8T-0283 Bolt
10 6
lG
9X-6618 Bolt
11 6 1D-4649
ree Bolt
12
13
6
4
5T-5806
5T-9894
n Sleeve
Shim
14 4 5T-9893 Shim
15 2 9G-9154 Clip
16 1 9M-8406 Clip
17 1 8T-4137 Bolt
19 1 5M-3062 Bolt
21 1 8X-0469 Support
22 1 8X-0436 Support
Table 51
Parts That Are Required to Install 163-7226 Cab Mounting Gp for 793C (S/N: 4GZ1-UP; ATY1-UP)
1 8 6V-2624 Bolt
2 8 163-3127 Sleeve
3 40 163-0042 Mount
4 20 5T-5807 Retainer
5 6 1K-9420 Bolt
6 6 163-0364 Sleeve
7 6 8C-3236 Bolt
8 21 5T-1352 Spacer
9 9 8T-0283 Bolt
PIP
10 6 9X-6618 (Bolt)
11 6 6B-0388 Bolt
12 6 164-4411
-11 Sleeve
13 4
202
5T-9894
008 Shim
14 4
1
5T-9893
15: /0 6 92
Shim
56: /228
48-
:
P-1
202 1008
15: 1 /0 6 92
15
16
1
1
56: /228 9M-8406
8T-4137
Clip
Bolt
17 1
SEH 48- 8T-4121 Hard Washer
18 1
S 03: 8X-0469 Support
19 1
© 2 998 00
8X-0436 Support
Table 52
0 2 0
Note: Clean the thread on the cab.
Cat 1C
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View of the lifting bracket
1. Remove the lifting bracket from the left side of the frame.

View of the cab support assemblies
:
2. Clean the grease from the mounting surfaces on the 8X-0469 Support Assembly (21) and the 8X-0436 Support Assembly
PIP
(22).
-11
3. Remove the straps from the support assemblies on the shipping crate.
202 008
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
© 2 998 00
Illustration 177
0 2 0 g00690045
1C
View of the installation alignment for the rear cab mounts
Cat
4. For the 793C (S/N: 4AR1-UP) trucks, install four 5T-5803 Mounts (3) to the front mount area. Install six 5T-5803 Mounts (3) to
erp
the rear mount area. Refer to Table 51.
ater
Con illa pill
For the 793C (S/N: 4GZ1-UP; ATY1-UP) trucks, install four 163-0042 Mounts (3) to the front mount area. Install six 163-0042
Mounts (3) to the rear mount area. Refer to Table 52.
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View of the grommets and the mounting bracket
5. Clean the grease from the 8X-0469 Support Assembly. For the 793C (S/N: 4AR1-UP) Trucks, install 12 5T-5803 Mounts (3) to
the machined surface.
For the 793C (S/N: 4GZ1-UP; ATY1-UP) trucks, install 12 163-0042 Mounts (3) to the machined surface.
Note: Install the mounts before the cab supports are installed on the truck.
:
PIP
-11
202 008
Illustration 179
15: 1 /0 6 92
g00690079
8
View of the support assembly
56: /22
6. Lift the support assembly to the truck frame. The weight of the 8X-0469 Support Assembly (21) is 170 kg (375 lb).
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
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View of the mounts that are installed to the rear cab mount holes
ntia nc.
7. For the 793C (S/N: 4AR1-UP) Trucks, install six 5T-5803 Mounts (3) to the lower cab mount holes. For the 793C (S/N: 4GZ1-
lG
UP; ATY1-UP), install six 163-0042 Mounts (3) to the lower cab mount holes.
ree
n

View of the mounts that are installed to the lower front cab mount
8. For the 793C (S/N: 4AR1-UP) Trucks, install four 5T-5803 Mounts (3) to the lower front cab mounts.
For the 793C (S/N: 4GZ1-UP; ATY1-UP), install four 163-0042 Mounts (3) to the front cab mounts.
:
View of the mounting location for the rear support
9. Remove the cover, the plastic plugs, and the grease from the truck frame.
Note: Clean the mating surfaces before assembly. Complete the procedures that are required to prepare the truck frame
that is machined for the installation procedure.
PIP
-11
202 008
15: 1 /0 6 92
56: /228
Illustration 183
SEH 48- g00690740
S 03:
© 2 998 00
0 2 0
Cat 1C
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Illustration 184
ntia g00690783
View of the rear support assembly that is installed
lG
10. Install the 8X-0469 Support Assembly (21). Use six 8C-3236 Bolts (7) and six 5T-1352 Spacers (8) on the bottom six holes.
ree
Install six 9X-6618 Bolts (10) and six 5T-1352 Spacers (8) on the top six holes.
n
:
View of the support assembly that is lifted
12. For the 793C (S/N: 4AR1-UP) Trucks, install eight 5T-5803 Mounts (3) to the 8X-0436 Support Assembly (22). Install four 5T-
5803 Mounts (3) on the top and four on the bottom.
For the 793C (S/N: 4GZ1-UP; ATY1-UP) Trucks, install eight 163-0042 Mounts (3) to the 8X-0436 Support Assembly (22).
Install four 163-0042 Mounts (3) to the 8X-0436 Support Assembly (22). Install four 163-0042 Mounts (3) on the top and
four on the bottom.
Note: Install the mounts before you install the support to the frame.
13. Lift the support assembly. Install the support assembly to the frame. The weight of the 8X-0436 Support Assembly (22) is
127 kg (280 lb).
PIP
-11
202 008
15: 1 /0 6 92
Illustration 186
56: /228 g00690835
SEH 48-
View of the mounting area for the mounting bracket
S 03:
14. Remove the shipping cover, the plastic plugs, and grease from the truck.
© 2 998 00
Note: Clean the paint and grease from the mating surface.
0 2 0
Cat 1C
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Illustration 187
lG g00690903
View of the front support assembly
ree
n
15. Install the 8X-0436 Support Assembly (22). Use four 5T-1352 Spacers (8) on the top four holes. Use five 8T-0283 Bolts (9)
:
tial
G ree
and five 5T-1352 Spacers (9) on the bottom five holes. n
17. Remove the tie straps from the cab lines.
PIP
-11
Illustration 189
202 008
g00690950
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
View of the rear mounts in position
Con illa pill

18. For the 793C (S/N: 4AR1-UP) Trucks, install the cab assembly onto the 20 5T-5803 Mounts (3).
fide r: ar I
nc.
ntia
l
:
Cat 21 C
erp ater
Con illa pill
fide r: ar I
For the 793C (S/N: 4GZ1-UP; ATY1-UP) Trucks, install the cab assembly onto the 20 163-0042 Mounts (3).
ntia nc.
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View of the sleeves that are installed to the rear cab mounts

View of the sleeves that are installed to the rear cab mounts

View of the cab assembly that is installed to the rear mounts
PIP
19. For the 793C (S/N: 4AR1-UP) Trucks, install six 5T-5806 Sleeves (12) to the rear cab mounts. Use six 5T-5807 Retainers (4)
-11
and six 1D-4649 Bolts (11) to install the cab assembly to the rear cab mounts.
202 008
For the 793C (S/N: 4GZ1-UP; ATY1-UP) Trucks, install six 164-4411 Sleeves (12) to the rear cab mounts. Install the cab
assembly to the rear frame.
1 /0 6 92
20. For the 793C (S/N: 4AR1-UP) Trucks, install six 5T-5805 Sleeves (6) onto the rear cab mounts. Install the cab assembly to the
15:
56: /22 8
rear cab mounts. Use six 5T-5807 Retainers (4) and six 1K-9418 Bolts (5).
For the 793C (S/N: 4GZ1-UP; ATY1-UP) Trucks, install six 163-0364 Sleeves (6) to the rear cab mounts. Use six 1K-9420
SEH 48-
Bolts (11) and six 5T-5807 Retainers (4) to install the cab assembly.
S 03:
© 2 998 00
021 0
C
:
5:5 /22
SEH :48-6
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
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Illustration 194
ntia g00692305
View of the sleeves that are installed to the front cab mounts
lG
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View of the sleeves that are installed to the front cab mounts

View of the cab assembly that is to the front mounts
21. For the 793C (S/N: 4AR1-UP) Trucks, install six 5T-5804 Sleeves (2) to the front cab mounts. Install the cab assembly to the
cab mounts. Use four 5T-5807 Retainers (4) and four 6H-1268 Bolts (1).
For the 793C (S/N: 4GZ1-UP; ATY1-UP) Trucks, install four 163-3127 Sleeves (2) to the rear cab mounts. Install the cab
assembly to the cab mounts. Use four 5T-5807 Retainers (4) and four 6V-2624 Bolts (1).
Note: Use 5T-9893 Shims (14) to level the cab assembly. A flatness of 0.75 mm (0.03 inch) is required.
Note: Apply 9S-3236 Thread Lock Compound to the bolts.
22. Tighten the cab mounting bolts to a torque of 1800 ± 200 N·m (1328 ± 148 lb ft).
PIP
-11
202 008
1/0 692
8/2
2
:
PIP
-11
202 008
15: 1 /0 6 92
56: /22 8
SEH 48-
S 03:
© 2 998 00
Illustration 197
0 2 0 g00692356
Cat 1C
View of the area below the cab
erp ater
23. Install the wiring harness to the support assembly. Use a 9M-8406 Clip (16), a 8T-4121 Bolt (17), and the 8T-4121 Hard
Washer (18).
Con illa pill

fide r: ar I
nc.
25. For 793C (S/N: 4AR1-UP) Trucks, install the hose assembly to the support assembly. Use a 5M-3062 Bolt (19), two 9G-9154
ntia
Clips (15), and 8T-4896 Hard Washer (20).
l
Install the 8X-4180 Hood Latch GpGre
en
Parts That Are Required for Installation of 8X-4180 Hood Latch Gp
2 1 101-0368 Prop Assembly
3 8 8T-4136 Bolt
5 2 5S-7379 Bolt
8 1 2G-9399 Rod
9 1 6F-8499 Spring
10 1 8X-4425 Bracket Assembly
11 1 0T-0883 Washer
Table 53
:
PIP
-11
202 008
15: 1 /0 6 92
Illustration 198
56: /22
View of the hood latch that is installed 8
g00693448
Note: Do not install the hood latch when the hood assembly is open. The hood support should be installed or the hood
SEH 48-
latch will be removed to close the hood assembly.
S 03:
1. Install the 8X-4425 Bracket Assembly (10). Use two 5S-7379 Bolts (5) and two 8T-4121 Washers (4).
© 2 998 00
0 2 0
3. Install one 2G-9399 Rod (8), one 6F-8499 Spring (9), one 3B-4615 Cotter Pin (12), and one 0T-0833 Washer (11) to the 8X-
4428 Plate Assembly (1).
Cat 1C
erp ater
4. Install the 8X-4428 Plate Assembly (1). Use eight 8T-4136 Bolts (3) and eight 8T-4121 Hard Washers (4).
Con illa pill

5. Install one end of the 101-0368 Prop Assembly (2) to the hood assembly. Use 8T-4223 Hard Washer (6) and the 3B-4627
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Cotter (7).
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n
:
PIP
-11
202 008
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
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View of the hood support for the hood assembly
(A) right-hand Platform
(B) Hood Assembly
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:
View of the hood latch that is installed
6. The illustrations above show the hood latch.
Install the Air Hoses and Install the Electrical Connection for the Cab
PIP
-11
202 008
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
Illustration 202
© 2 998 00
g00692470
0
View of the tape and plastic caps that are removed
Cat 0 2 1C
1. Remove the tape and plugs from the cab assembly.
erp ater
Con illa pill
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Illustration 203
View of the cab's electrical connections
n
g00692475
:
View of the wires and hoses in tie straps and tape
2. Remove the tie straps and tape from the wiring and hoses.

View of the wiring for the cab assembly
PIP
3. Each air hose has an identification tag with a number. Connect each air hose to the opening with the same number on the
-11
plate.
202 008
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
© 2 998 00
Illustration 206
0 2 0 g00692497
Cat 1C
erp ater
Con illa pill
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:
ide r In
n tial c.
G ree
n
4. Install the wind shield washer hose elbow. Connect the window washer hose with a clamp on the 793C (S/N: 4AR1-UP).

This is the view of the windshield washer hose on the 793C (S/N: 4AR1-UP).
PIP
-11
Illustration 209
202 008 g00692610
1 6
View of the air line connections for the 793C (S/N: 4AR1-UP) cab assembly
/0 92
(1) Main air supply and the line for the air compressor governor
15: 8
(2) Air supply to air start control valve
56: /22
(3) Air line for the parking brake control valve
(4) Air line for the service brake control valve
(5) Air line for the automatic lubrication supply valve
SEH 48-
(6) Governor control chamber to the line for the governor control valve
(7) Air supply for the window washer
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
fide r: ar I
n
:
©2 980
0
Cat 21 C
erp ater
Con illa pill
fide r: ar I
nc.
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View of the electrical connections for the 793C (S/N: 4GZ1-UP; ATY1-UP) cab assembly
(1) Main air supply and the line for the air compressor governor
(2) Air supply to air start control valve
(3) Air line for the parking brake control valve
(4) Air line for the service brake control valve
(5) Air line for the Diverter control valve
(6) Air line for the automatic Retarder control valve
(7) Air line for the automatic lubrication supply valve
(A) Transmission
(B) Battery
(C) Chassis 1
(D) Chassis 2
(E) Engine
Illustration 211
PIP
g00692658
-11
View of the tie straps on the 793C (S/N: 4AR1-UP)
202 008
15: 1 /0 6 92
56: /228
SEH 48-
S99 03:00
80
:
1
15: /08/2 692
56: 2
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
fide r: ar I
nc.
View of the tie straps on the 793C (S/N: 4GZ1-UP; ATY1-UP) cab assembly
ntia
5. Use tie straps to secure the cab wiring.
lG
ree
n

View of the heater hoses
6. Install the two heater hoses from the cab assembly. Use four 5D-1026 Clamps and two 6P-8855 Spacers.
Note: Cut the hoses to the proper length before installation.
Note: Open the heater valves on the engine after the installation of the heater hoses.

View of the connection for the horn
7. Connect the air horn hose assembly to the connection in the cab. Secure the hose with a clip on the frame.
PIP
-11
202 008
1/0 692
:
PIP
-11
202 008
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
Illustration 215
© 2 998 00
g00692731
0
View of the air conditioner lines
0 2 1C
8. Connect the two air conditioner lines.
Cat
erp ater
Con illa pill
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ree
Illustration 216
n
g00692739

View of the electrical connections under the right side of the platform assembly
9. Connect the electrical lines of the oil cooler to the platform with clips, bolts, and washers.
10. Connect the electrical wiring of the load indicator to the platform by using: clips, bolts and washers.
Install the 142-4027 Platform Mounting Gp

Parts That Are Required for Installation of 142-4027 Platform Mounting Gp
1 4 8T-4139 Bolt
2 2 8X-2053 Plate
3 1 8X-2052 Plate
:
4 2 8X-1991 Plate
5 1 159-9886 Bar
6 1 8X-1990 Strip
7 1 8X-1989 Plate
8 1
PIP
138-1258 Bracket
-11
9 3 8T-6430 Bolt
202 008
10 3 8T-4123 Washer
1
11 7 8T-4136 Bolt
12 7
15: /0
7X-7729
6 92 Washer
13 4
56: /22
5P-1076
8 Washer
SEH 48-
Table 54
S 03:
Note: Install the right side platform assembly before you install the right side filter assembly.
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
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Illustration 218
n
g00692898
View of paint that is removed from the platform assembly
1. Remove the paint from the welding area that is on the edge of the platform assembly. The weight of the right side platform
assembly is 1130 kg (2491 lb).
:
View of the paint that is removed from the rear edge of the platform assembly
2. Remove the paint from the welding area that is on the rear edge of the platform assembly.
PIP
-11
202 008
15: 1 /0 6 92
Illustration 220
56: /228 g00693204
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Illustration 221
Con illa pill
g00694897
fide r: ar I
3. Remove paint from the welding areas that is on the right side of the frame.
nc.
ntia
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:
PIP
-11
202 008
15: 1 /0 6 92
56: /228
Illustration 224
SEH 48- g00693119
S 03:
View of the lever puller, the link brackets, and the three hook chain
© 2 998 00
4. Install a lever puller, a three hook chain, and three 138-7573 Link Brackets. Use the equipment to lift the platform assembly
0
to the frame assembly.
Cat 0 2 1C
erp ater
Con illa pill
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ntia
lG
Illustration 225
ree g00693129
n
View of the platform assembly that is positioned to the frame
5. Position the platform assembly to the frame assembly.

:
PIP
-11
202 008
15: 1 /0 6 92
8
56: /22
View of the mounting location for the platform assembly
6. Install the platform assembly. Use three 8T-6430 Bolts (9) and three 8T-4123 Washers (10).
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
fide r: ar I
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Illustration 229
ntia g00693245
lG
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:
Con llar pill
fide : ar I
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View of the accumulators that are covered
l Gre
8. Cover the accumulators. Protect the accumulator against the weld splatter.
en
PIP
9. Weld the platform in place. Refer to Illustration 230, Table 55, and Table 56.
-11
Weld Dimensions for Illustration 230
202
Item Dimension
A 10 ± 1.50 mm (0.40 ± 0.06 inch) 008

B 170 ± 5 mm (7 ± 0.20 inch)
15: 1 /0 6 92
C
Table 55 56: /22

12.5 ± 1.50 mm (0.50 ± 0.06 inch)
8
SEH 48-
S 03:
Weld Tolerances for Illustration 230
Weld
© 2 998 00
Tolerances
W1
0 0
6 mm (0.24 inch) fillet weld with a 1.50 mm (0.06 inch) penetration
2
Cat 1C
erp ater
illa pill
r
:
HS 03:
© 2 998 00
0 2 0
W2
Cat 1C
3 mm (0.12 inch) square groove weld
W3
erp ater
W4
Con illa pill
W5
fide r: ar I
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ntia
W6 6 mm (0.24 inch) fillet weld with a 1.50 mm (0.06 inch) penetration
W7 6 mm (0.24 inch) fillet weld with a 1.50 mm (0.06 inch) penetration
Table 56 lG
ree
n

View of the plates that are welded to the frame assembly and the platform assembly
10. Weld the 8X-2052 Plate (3) to the frame assembly. Refer to Illustration 230, Table 55, and Table 56.
11. Weld the two 8X-2053 Plates (2) to the frame assembly. Refer to Illustration 230, Table 55, and Table 56.

View of the plates that are welded to the platform assembly and the frame assembly
12. Weld the 159-9886 Bar (5) to the frame assembly and the platform assembly.
13. Weld two 8X-1991 Plates (4) to the frame assembly and the platform assembly.
PIP
-11
202 008
15: 1 /0 6 92
56: /228
SEH 48-
S9 03:0
:
202 1008
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
View of the plates that are welded to the frame assembly and the platform assembly
fide r: ar I
14. Weld the 8X-1989 Plate (7) to the frame assembly and the platform assembly.
nc.
ntia
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n
View of the plate that is welded to the platform assembly and the frame assembly
15. Weld the 8X-1990 Plate (6) to the frame assembly and the platform assembly.
PIP
-11
00
:
Illustration 235
PIP
View of the 138-1258 Bracket (8)
g00775623
-11
202 008
16. Install the 138-1258 Bracket (8) to the frame assembly and the platform assembly.
1
17. Use four 5P-1076 Hard Washers (13) and four 8T-4139 Bolts (1) to mount the 138-1258 Bracket Assembly (8) to the frame
assembly.
15: /0 6 92
56: /22 8
18. Use seven 7X-7729 Washers (12) and seven 8T-4136 Bolts (11) to mount the 138-1258 Bracket (8) to the platform assembly.
SEH Lines4Gp8-for the 793C (S/N: 4AR1-

19. Clean the welding areas. Paint the areas, as needed.
Install the 8X-2835 Steering

S 03Gp:
4GZ1-UP; ATY1-UP) 2
© 9
UP) or Install the 151-8730 Steering
980 Lines 0 for the 793C (S/N:
0
Cat 21 C0
Parts That Are Required for the Installation of the 8X-2835 Steering Lines Gp for 793C (S/N: 4AR1-UP)
Item
erp
Qty
ater Part Number Description
1
Con illa 1
pill 8W-0500 Tube As
fide r: ar I
2 1 8W-0499 Tube As
4
1
1
ntia nc.
8W-0498
8W-0502
Tube As
Tube As
5 1
lG 8W-0501 Tube As
6 1
ree 5T-6852 Bar
8
1
1
n 8X-5968
6G-8532
Bracket
Guard As
9 2 6V-8639 Connector
10 4 3K-0360 O-Ring Seal
12 2 6V-8625 Elbow
14 1 6V-9200 Elbow
15 1 3J-7354 O-Ring Seal
16 2 5T-6867 Clip
17 3 5M-3062 Bolt
18 1 9S-1350 Clip
19 4 8T-4136 Bolt
21 1 1V-6277 Tag (1)
22 1 8R-4853 Tag (1)
23 1 1V-6274 Tag (1)
24 1 1V-6276 Tag (1)
(1)
:
25 1 4J-6311 Tag (1)
Table 57
(1)
The tag could be installed on the tube assembly.
Parts that are Required for Installation of 151-8730 Steering Lines Gp for 793C (S/N: 4GZ1-UP; ATY1-UP)
1 1
PIP 150-8708 Tube As
2 1
-11 150-8709 Tube As
3 1
202 008
150-8713 Tube As
1 6
4 1 150-8723 Tube As
5 1
15: /0 8 92150-8710 Tube As
56: /22
6 1 150-9037 Bar
SEH 48-
7 1 8X-5968 Bracket
8 1 6G-8532 Guard As
9 2
S 03: 6V-8639 Connector
10 4
© 2 998 00 3K-0360 O-Ring Seal
11 8
0 2 0 6V-8698 Connector
12 2
Cat 1C 6V-8625 Elbow
13 2
erp ater 6V-8397 O-Ring Seal
14 1
Con illa pill 6V-9200 Elbow
fide r: ar I
nc.
16 2 5T-6867 Clip
17 3
ntia 5M-3062 Bolt
18 1
lG 9S-1350 Clip
19 4
ree 8T-4136 Bolt
20
21
7
1
n 8T-4121
1V-6277
Hard Washer
Tag (1)
22 1 8R-4853 Tag (1)
23 1 1V-6274 Tag (1)
24 1 1V-6276 Tag (1)
25 1 4J-6311 Tag (1)
Table 58
(1)
The tag may be already installed on the tube assembly.
:
View of the cab panel for 793C (S/N: 4AR1-UP)
1. Remove ten bolts and washers. Remove the panel from the left side of the cab.
PIP
-11
202 008
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
© 2 998 00
Illustration 237
0 2 0 g00694279
1C
View of the 793C (S/N: 4GZ1-UP; ATY1-UP)
Cat
erp ater
Con illa pill
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Illustration 238
View of the plastic caps that are removed n
g00694281
2. Remove four plastic screw caps.

:
View of the shipping plug that is removed for the installation of the elbow and seal
PIP
-11
202 008
15: 1 /0 6 92
56: /228
SEH 48-
View of the tube assembly and seals that are installed
S 03:
3. Install the 6V-9200 Elbow (14) and the 3J-7354 Seal (15).
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
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ree
Illustration 241
View of the tube assembly that is installed
n
g00694300
:
Gre
en
4. Clean the surface of the steering assembly. For 793C (S/N: 4AR1-UP), install a 8W-0501 Tube Assembly (5). Use two 6V-
8397 Seals (13).
For 793C (S/N: 4GZ1-UP; ATY1-UP), install the 150-8710 Tube Assembly (5). Use two 6V-8397 Seals (13).

View of the elbows and connectors for the steering assembly
5. Install two 6V-8639 Connectors (9). Use two 3K-0360 Seals (10) in the back two orifices.
6. Install two 6V-8625 Elbows (12). Use two 3K-0360 Seals (10) in the front two orifices.
Illustration 243
PIP g00694316
-11
202 008
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
Illustration 244
© 2 998 00
g00694379
0 0
View of the tube assembly for the steering assembly
Cat
7. Install the following parts:
2 1C
erp ater
For 793C (S/N: 4AR1-UP), install a 8W-0499 Tube Assembly (Pump oil supply).
Con illa pill

For 793C (S/N: 4GZ1-UP; ATY1-UP), install a 150-8709 Tube Assembly (2). Use two 6V-8398 Seals (11) (Pump oil
fide r:
supply).
ar I
ntia nc.
lG
re
:
terp ater
Con illa pill
fide r: ar I
nc.
ntia
For 793C (S/N: 4AR1-UP), install a 8W-0498 Tube Assembly (3)(right-hand threads on the nut). Use two 6V-8398 Seals
(11).
lG
For 793C (S/N: 4GZ1-UP; ATY1-UP), install a 150-8713 Tube Assembly (3) (right-hand threads on the nut). Use two 6V-
8398 Seals (11).
ree
n
For 793C (S/N: 4AR1-UP), install a 8W-0500 Tube Assembly (1) (Return oil line). Use two 6V-8398 Seals (11).
For 793C (S/N: 4GZ1-UP; ATY1-UP), install a 150-8708 Tube Assembly (1) (Return oil line). Use two 6V-8398 Seals (11).
For 793C (S/N: 4AR1-UP), install a 8W-0502 Tube Assembly (4) (left-hand threads on the nut). Use two 6V-8398 Seals
(11).
For 793C (S/N: 4GZ1-UP; ATY1-UP), install a 150-8723 Tube Assembly (4) (left-hand threads on the nut). Use two 6V-
8398 Seals (11).
PIP
View of the tube assemblies that are secured with clips under the cab
8. For 793C (S/N: 4AR1-UP), fasten the five steering lines to the 5T-6852 Bar (6). Use two 5T-6867 Clips (16) and one 9S-1350
-11
Clip (18) with three 5M-3062 Bolts (17) and three 8T-4121 Washers (20).
202 008
For 793C (S/N: 4GZ1-UP; ATY1-UP), fasten the five steering lines to the 150-9037 Bar (6). Use two 5T-6867 Clips (16) and
one 9S-1350 18 with three 5M-3062 Bolts (17) and three 8T-4121 Washers (20).
15: 1 /0 6 92
8
56: /22
Note: The rest of this assembly procedure is completed after the cab is installed to the frame assembly.
SEH 48-
S 03:
© 2 998 00
021 0
Cat
e
:
SEH :48-
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
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ntia
Illustration 247
lG g00694554
ree
View of the tube assemblies under the cab

View of the identification tags on the tube assemblies
10. Connect the tube assemblies to the hose connections from the frame assembly. Install the tube assemblies and the hose
connections. Use the identification tags that are installed on the tube assemblies.
Identification tags that match up to the tube assemblies on the 793C (S/N: 4AR1-UP):
(A) 1V-6277 Tag to the 8W-0500 Tube As
(B) 8R-4853 Tag to the 8W-0499 Tube As
(C) 1V-6274 Tag to the 8W-0498 Tube As
(D) 4J-6311 Tag to the 8W-0501 Tube As
(E) 1V-6276 Tag to the 8W-0502 Tube As

Identification tags that are matched up to the tube assemblies on the 793C (S/N: 4GZ1-UP; ATY1-UP):
(A) 1V-6277 Tag to the 150-8708 Tube As
(B) 8R-4853 Tag to the 150-8709 Tube As
(C) 1V-6274 Tag to the 150-8713 Tube As
(D) 4J-6311 Tag to the 150-8710 Tube As
(E) 1V-6276 Tag to the 150-8723 Tube As
PIP
-11
202 008
15: 1 /0 6 92
56: /228
48
:
P-1
202 1008
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
© 2 998 00
0 2 0
Illustration 249
Cat 1C g00694589
erp ater
View of the clamps that secure the steering hoses and the air line under the cab
Con illa pill

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View of the guard assembly under the cab
11. Install the 6G-8532 Guard Assembly (8) and the 8X-5968 Bracket Assembly (7). Use four 8T-4136 Bolts (19) and four 8T-
4121 Washers (20).

Note: Operate the truck and complete a leak test before assembling the 6G-8532 Guard Assembly (8) and the 8X-5968
Bracket Assembly (7).
Install the 142-4044 Air Cleaner Gp

Parts That are Required for the Installation of 142-4044 Air Cleaner Gp
1 2 9Y-8930 Air Cleaner Gp
2 1 139-0478 Plate As
3 3 8X-3620 Plate As
4 2 8X-3629 Plate
5 2 8X-3624 Plate
6 1 2G-0548 Brace
7 2 8X-3623 Brace
8 4 7E-7791 Hose
9 1 8X-3622 Plate As
10 4 8T-4139 Bolt
11 2 7E-7790 Hose
:
12 2 7E-7786 Tube As
13 2
PIP
8X-3635 Strip
14 1 8X-3626
-11 Plate As
15 20
202
7X-0344
008 Bolt
1 6
17 2
15:
4M-7470
/0 8 92 Grommet
56: /22
18 2 7W-0629 Filter Adapter
SEH 48-
19 7 8T-4136 Bolt
20 11 7X-7729 Hard Washer
21 4
S
8T-4183
03: Bolt
22 11
© 2 998
5P-1076
00 Hard Washer
23 1
0 2
8T-4910
0 Bolt
24 2
Cat
8T-4244
1C Nut
25 16
erp
5P-0600
ater Hose Clamp
26 2
Con illa
5K-5068
pill Fitting
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27 2 7W-7417 Service Indicator
nc.
28 4 5P-4423 Elbow
29 6
ntia
5P-9085 Clip
30 4 6V-4372
lG Hose Clamp
31 2 9X-6605
ree U-Bolt
32
33
4
1
6V-7744
7D-8586
n Locknut
Nonslip Tread
34 -- 5P-0756 Tube
35 1 138-1264 Bracket
36 1 138-1267 Bracket
Table 59

View of the air cleaners in the shipping containers
Note: You can install the air cleaner after the platform is installed or before the platform is installed.
:
1. Open the shipping container with the two 9Y-8930 Air Cleaner Group (1).
PIP
-11
202 008
15: 1 /0 6 92
Illustration 252
View of the air cleaner group
56: /228 g00694791
SEH 48-
2. Remove the plastic cover. Position the 9Y-8930 Air Cleaner Gp (1) for later installation.
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© 2 998 00
0 2 0
Cat 1C
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View of the mounting position for the air cleaner

View of the plastic cover and the battery cables
3. Cut the tie straps. Remove the tape from the battery cables. Remove the shipping cover and the clamp from the air intake
:
pipe. Save the material for later assembly.

View of the air cleaner group that is supported by a hoist and chain
4. Remove the plastic covers. Use a hoist and suitable chains to lift the air cleaner group. Position the 9Y-8930 Air Cleaner
Group (1) to the platform assembly.
PIP
-11
202 008
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
© 2 998 00
0 2 0
Illustration 256
Cat 1C g00694847
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Illustration 257
View of the air cleaner group that is installed
n g00694857
5. Install the 9Y-8930 Air Cleaner Gp (1). Use ten 7X-0344 Bolts (15), ten 8T-4122 Hard Washers (16), one 8X-3629 Plate (4),
and one 8X-3620 Plate Assembly (3).

:
7. Position two 7E-7791 Hoses (8) and one 7E-7790 Hose (11).
Note: Heat the hoses for a proper fit.
8. Connect the parking and turn signal wiring harness that is located to the inside of the rubber hose. Connect the harness to
the wiring harness on the truck frame.

9. Position four 5P-0600 Clamps (25) on each 7E-7791 Hose (8). Position two 6V-4372 Clamps (30) to the 7E-7790 Hose (11).
Install the 7E-7786 Tube Assembly (12).
PIP
-11
202 008
15: 1 /0 6 92
Illustration 259
56: /228 g00694966
SEH 48-
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© 2 998 00
0 2 0
Cat 1C
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View of the tube assembly and the brace
10. Align the hoses and clamps. Tighten the clamps to a torque of 16 ± 4 N·m (12 ± 3 lb ft).
11. Install a 9X-6605 Clamp (31) and a 8X-3635 Strip (13). Use two 6V-7744 Locknuts (32) and two 7X-7729 Hard Washers (20).
12. Install the 8X-3623 Brace (7). Use two 8T-4183 Bolts (21), three 5P-1076 Washers (22), and one 8T-4244 Nuts (24).
14. Install the 7W-0629 Adapter Assembly (18), the 4M-7470 Grommet (17), and the 5P-0756 Tube Assembly (34).
Note: Cut the 5P-0756 Tube Assembly (34) to 1000 ± 20 mm (39 ± 0.80 inch).
PIP
-11
Illustration 262
202 008
g00694979
15: 1
View of the service indicator of the air cleaner
/0 6 92
56: /228
15. Install the 8X-3622 Plate Assembly (9). Use the two bolts and the two washers that were previously used.
16. Install a 5P-0756 Tube Assembly (34) through the 4M-7470 Grommet (17). Use the three bolts and three washers to install
SEH 48-
the tube assembly to the three 5P-9085 Clips (29).
03:
17. Install two 5P-4423 Elbows (28), one 5K-5068 Nipple (26), and one 7W-7417 Indicator (27).
S
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
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:
Cat 21 C
erp ater
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View of the air cleaner that is installed on the right side

View of the air cleaner group for the left side
18. Remove the protective covering. Position the 9Y-8930 Air Cleaner Group (1) for a later installation.
PIP
-11
View of the mounting position for the air cleaner group on the left side
202 008
19. Cut the tie straps. Remove the plastic covers and clamps from the tube assembly. Save the clamps for later assembly.
15: 1 /0 6 92
20. Install the 138-1264 Bracket (35) to the bottom of the cross brace that is coming from the left frame pedestal. Secure the
56: /22 8
bracket. Use two 8T-4139 Bolts (10) and two 5P-1076 Washers (22). Install the 138-1267 Bracket (36) to the top of the cross
brace. Secure the bracket with two 8T-4139 Bolts (10) and two 5P-1076 Washers (22).
SEH 48-
Note: The 138-1264 Bracket (35) and the 138-1267 Bracket (36) secure the air cleaner group to the truck frame.
S 03:
© 2 998 00
021 0
:
5:5 /2 2
SEH 48- 6 :
S 03:
© 2 998 00
0 2 0
Cat 1C
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View of the plate that is installed
21. Install the hoist and the chains to the air cleaner group. Position the 139-0478 Plate (2) to the 9Y-8930 Air Cleaner Gp (1).
Remove the two plastic covers.

View of the air cleaner group that is supported by a hoist
22. Install a 139-0478 Plate (2) to the 9Y-8930 Air Cleaner Gp (1). Use two 8X-3624 Plates (5), two 8X-3620 Plate Assemblies
(3), an 8X-3629 Plate (4), ten 7X-0344 Bolts (15), and ten 8T-4122 Hard Washers (16).
24. Install the 7E-7786 Tube Assembly (12) and an 8X-3635 Strip (13). Use two 7E-7791 Hoses (8) and eight 5P-0600 Clamps
(25).
25. Install the 9X-6605 U-Bolt (31). Use two 6V-7744 Locknuts (32) and two 7X-7729 Washers (20).
PIP
-11
202 008
1/0 692
8/2
2
:
PIP
-11
202 008
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Illustration 268
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g00695060
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View of the air cleaner group that is supported by a hoist and chain
26. Use a hoist and chains to position the 9Y-8930 Air Cleaner Gp (1) to the left side of the main frame.
27. Install the air cleaner assembly. Use seven 8T-4136 Bolts (19) and seven 7X-7729 Washers (20).
29. Install the two clamps and two 6V-4372 Clamps (30) to the 7E-7790 Hose (11).
30. Install the 7W-0629 Filter Adapter (18), the 4M-7470 Grommet (17), and the 5P-0756 Tube As (34).
Note: Cut the 5P-0756 Tube As (34) to a length of 1000 ± 20 mm (39 ± 0.80 inch).
:
View of the indicator of the air cleaner
31. Install the 8X-3626 Plate As (14). Use two bolts and two washers.
PIP
32. Install the 5P-0756 Tube As (34) and the 4M-7470 Grommet (17). Use three bolts and three washers to install the 5P-0756
Tube As (34) to three 5P-9085 Clips (29).
-11
202 008
33. Install two 5P-4423 Elbows (28), one 5K-5068 Nipple (26), and one 7W-7417 Service Indicator (27).
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
View of the wiring that is installed
Con illa pill

34. Install the wiring group. Use three clips, three bolts, and three washers.
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View of the braces that are installed
36. Install the 2G-0548 Brace (6). Use one 8T-4910 Bolt (23), two 5P-1076 Washers (22), and one 8T-4244 Locknut (24).
38. Install the 8X-3623 Brace (7). Use two 8T-4183 Bolts (21) and two 5P-1076 Washers (22).

:
View of the tread plate
PIP
40. Install the 7D-8586 Nonslip Tread (33) to the top of the air cleaner group.
Install the 131-3541 Service Brake-Lines

1
202 1 Gp
008
1 6
Note:
15: /0 8 92
56: /22
Parts That are Required to Install the 131-3541 Service Brake Lines Gp
1 6
SEH 48- 6V-8624 Elbow
2 10
S
2M-9780
03: O-Ring Seal
© 2 998 00
0
4 2 6V-8638 Connector
5 1
Cat 0 2 1C
8X-6139 Bracket
ater
6 8 8T-4185 Bolt
7 12
erp 8T-4121 Hard Washer
8
Con illa
4 5T-0968
pill Block
9 4
fide r: 8X-6137
ar I
Block
nc.
ntia
10 4 0S-1627 Bolt
lG
12 1 8X-6140 Bracket
ree Hose As (1)
n
13 1 131-3425
14 2 6V-8721 Elbow
15 1 8W-3192 Hose As (2)
16 1 8X-8172 Hose As (3)
17 1 8X-8173 Hose As (4)
18 4 9X-8250 Clip
19 2 8T-4195 Bolt
20 2 8T-4133 Nut
21 2 5D-7464 Hose As
22 2 4H-6147 Connector
23 2 6B-5072 Terminal Bushing

:
24 2 9M-8662 Coupling
25 2 7J-8611 Elbow
26 2 4H-6112 Breather
27 2 3D-7587 Elbow
28 2 4D-2847 Hose As
29 2 7X-0871 Tee
30 2 6V-3965 Fitting
31 2 3J-1907 Seal
32 2 6V-0852 Dust Cap
33 2 5J-0451 Hose As (5)
34 2 6D-6489 Pipe Connector (5)
35 2 9C-4937 Breather (5)
36 2 1S-0996 Clip (5)
37 6 7K-1181 Cable Strap (5)
Table 60 PIP
(1)
-11
202
Substitute the 8X-6431 Hose As with the 173-7217 Service Brake Lines Gp when you assemble the 793C (S/N: 4GZ1-UP; ATY1-UP) Off-Highway Truck with
(2)
the Michelin low profile tire attachment.
008
Substitute the 115-8427 Hose As with the 173-7217 Service Brake Lines Gpwhen you assemble 793C (S/N: 4GZ1-UP; ATY1-UP) Off-Highway Trucks with the
(3)
Michelin Low Profile Tire attachment.
15: 1 /0 6 92
8
Substitute the 9R-4084 Hose As with the 173-7217 Service Brake Lines Gpwhen you assemble 793C (S/N: 4GZ1-UP; ATY1-UP) Off-Highway Trucks with the
56: /22
(4)
Substitute the 103-1846 Hose As with the 173-7217 Service Brake Lines Gpwhen you assemble 793C (S/N: 4GZ1-UP; ATY1-UP) Off-Highway Trucks with the
SEH 48-
(5)
The parts are used to assemble the 793C (S/N: 4GZ137-UP; ATY1-UP) Truck.
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
Illustration 274 fide r: g00695680 ar I
nc.
View of the plugs for the rear brake lines
ntia
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1. Remove two shipping plugs from the rear brake line. Remove the tie straps and prepare the rear service brake lines for
ree
assembly.
n
:
PIP
View of the service brake lines that are installed
-11
2. Install the hose assembly that is shown in Illustration 275. Use one 6V-8624 Elbow (1), one 2M-9780 O-Ring Seal (2), and
202 008
one 6V-8398 O-Ring Seal (3).
Note: Apply 1U-6396 O-Ring Compound to the O-ring seals before installation.
1 /0 6 92
3. Install the 8X-8173 Hose As (17). Use one 6V-8721 Elbow (14), one 2M-9780 O-Ring Seal (2), and one 6V-8398 O-Ring Seal
15:
(3).
56: /228
4. Install 131-3425 Hose As (13). Use one 6V-8764 Elbow (1), one 2M-9780 O-Ring Seal (2), and one 6V-8398 O-Ring Seal (3).
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
Illustration 277
fide r: ar I
g00695781
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View of the clips for the hose assembly
5. The illustration above shows the location of the hose assembly and the 8X-8173 Hose As (17) are secured. Use two 9X-
lG
8250 Clips (18), one 8T-4195 Bolt (19), one 8T-4133 Nut (20), and two 8T-4121 Hard Washers (7).
ree
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:
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7. Repeat Step 1 through 5 on the other side of the truck. Use the same hardware with the following exceptions:
The 8W-3192 Hose As (15) is substituted for the 8X-8173 Hose As (17).
The 8X-8172 Hose As (16) is substituted for the 131-3425 Hose As (13).
PIP
View of a pressure port that is located on the front brake service line
-11
8. Install the front brake service line. Use one 6V-8624 Elbow (1), one 2M-9780 Seal (2), and one 6V-8398 O-Ring Seal (3).
202 008
9. Install the front brake service line to the brake oil cooler bracket. Use one 8X-6137 Block (9), one 5T-0968 Block (8), two 8T-
1
4185 Bolts (6), and two 8T-4121 Washers (7).
15: /0 6 92
8
56: /22
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
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©2 980
0
Cat 21 C
erp ater
Illustration 280
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g00695937
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The Front brake line routing for the 793C (S/N: 4AR1-UP; 4GZ1-136) Trucks
11. For 793C (S/N: 4AR1-UP; 4GZ1-136) Trucks, install one end of the 5D-7464 Hose Assembly (21). Use one 4H-6147
Connector (22) and one 6B-5072 Reducing Bushing (23) to the front wheel assembly.
For 793C (S/N: 4GZ137-UP; ATY1-UP) Trucks, install 5J-0451 Hose Assembly (33) to each front wheel assembly. Use one 6D-
6489 Pipe Connector (34). Install one 9C-4937 Breather (35) to the other end of each 5J-0451 Hose Assembly (33). Secure
each 9C-4937 Breather (35) to the truck frame with a 1S-0996 Clip (36). Secure each hose assembly with three 7K-1181
Cable Straps (37).
12. Install the 8X-6140 Bracket (12). Use two 0S-1627 Bolts (10) and two 5P-8248 Washers (11).
14. Install one 6V-8638 Connector (4) and one 7X-0871 Tee (29) into the top of the wheel assembly. Use a 2M-9780 O-Ring
Seal (2) and a 6V-8398 O-Ring Seal (3).
15. Install the front brake service line to the top of the 7X-0871 Tee (29). Install the 6V-3965 Nipple Assembly (30) into the 7X-
0871 Tee (29). Use a 3J-1907 O-Ring Seal (31). Install a 6V-0852 Dust Cap (32) onto the 6V-3965 Fitting (30).
16. Secure the front brake service line to the 8X-6140 Bracket (12). Use one 8X-6137 Block (9), one 5T-0968 Block (8), two 8T-
4185 Bolts (6) and two 8T-4121 Washers (7).
PIP
-11
202 008
18. For 793C (S/N: 4AR1-UP; 4AR1-136) Trucks, install a 4H-6112 Breather (26). Use a 3D-7587 Elbow (27), a 7J-8611 Elbow
1
(25), and a 9M-8662 Coupling (24).
15: /0 6 92
8
19. For the 793C (S/N: 4AR1-UP; 4AR1-136) Trucks, install the other end of the 5D-7464 Hose As (21) onto the breather.
20. Repeat Step 8 through Step 19.

56: /22
SEH 48-
The 8X-6139 Bracket (5) is substituted for the 8X-6140 Bracket (12).
S99 03:00
80
:
15: 1 /0 6 92
56: /22 8
SEH 48-
21. For 793C (S/N: 4AR1-UP; 4AR1-136) Trucks, the 4D-2847 Hose As (28) is substituted for the 5D-7464 Hose As (21).
S
Install the 124-8210 Hydraulic 03Lines
Oil Cooler
: Gp
©2 9 980 0 0
0
Parts That are Required for the Installation of 124-8210 Hydraulic Oil Cooler Lines Gp
Item
Cat 21 C
1 1
erp ater
8X-4616 Tube As (1)
Con illa pill

2 1 125-5083 Tube As (2)
fide r:
3 1 125-5085 Tube As
4 2 125-5084
ar I Tube As (3)
5 1
ntia 8X-4636
nc. Tube As
6 2
lG 2S-2317 Hose
ree
7 1 8X-4618 Elbow
9
1
2 n
8X-4620
6J-2680
Plate
O-Ring Seal
10 2 6V-3965 Fitting
11 2 6V-0852 Dust Cap
12 6 9S-4191 O-Ring Plug
14 5 5P-1935 Seal
15 4 006-8352 O-Ring Seal
16 6 7X-0325 Bolt
17 6 8T-8919 Bolt
18 6 8T-9389 Bolt
21 8 8T-6675 Clamp
22 2 8T-4139 Bolt
23 4 8T-4183 Bolt
24 4 8T-4244 Nut
25 4 9X-6400 Half Clip
26 2 6V-8521 Half Clip
27 4 8X-6439 Spacer
28 4 7X-2475 Bolt
29 4 6F-8146 O-Ring Seal
30 4 6V-4432 Bolt
31 2 8T-4835 Bolt
32 4 7X-0568 Hard Washer
33 2 1P-4584
PIP Half Flange
-11
202 008
1/0 69
:
PIP
34 4
-11 8T-4184 Bolt
35
202
4
008 7I-5529 Hose As
36
15:
8
1 /0 6 92
4J-0527 O-Ring Seal
37
38 8
56: /22
16
8 8T-4194
1P-4582
Bolt
Half Flange
39
SEH 48-1 8X-6498 Plate
40 1
S 03: 8X-4619 Elbow
© 2 998 00
41 4 8T-4910 Bolt
0
42 1 8X-4637 Tube As
Table 61
(1)
Cat 0 2 1C
erp ater
The tube assembly is for 793C (S/N: 4GZ1-UP; ATY1-UP) trucks with the Michelin low profile tire attachment. Substitute the 160-6311 Tube As from the
(2)
Con illa pill

The hose assembly is for 793C (S/N: 4GZ1-UP; ATY1-UP) trucks with the Michelin low profile tire attachment. Substitute the 160-6313 Tube As from the
r
(3)
f : a
The hose assembly is for 793C (S/N: 4GZ1-UP; ATY1-UP) trucks with the Michelin low profile tire attachment. Substitute the 160-6313 Tube As from the
id
ent r In
Rear Oil Cooler Lines
ial c.
Gre
en

View of the rear oil cooler tube assembly
1. Remove the plastic cap from the oil cooler tube.

2. Install one end of the 125-5084 Tube Assembly (4) to the right rear oil cooler tube. Use two 9X-6400 Half Clips (25), two 8T-
4183 Bolts (23), two 8T-4244 Nuts (24), four 8T-4223 Hard Washers (19), one 2S-2317 Hose (6), and four 8T-6675 Clamps
:
(21).
4. Remove the shipping cover from the right rear wheel group assembly. Remove the covers from the block on top of the rear
axle housing. Save the hardware for later installation of hardware.
PIP
-11
202 008
15: 1 /0 6 92
56: /228
SEH 48-
Illustration 284
S 03:g00696156
© 2 998 00
View of the nipple assembly that is installed
0 0
5. Install the 6V-3965 Nipple Assembly (10), the 3J-1907 O-Ring Seal (13), and the 6V-0852 Dust Cap (11) to the 125-5084
2 1C
Tube Assembly (4).
Cat
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Con illa pill
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Illustration 285
n g00696162
View of the tube assembly that is installed onto the final drive
Note: Install the pressure tap plugs to the tubes before you install the tubes.
6. Install one 5P-1935 O-Ring Seal (14) into the 125-5084 Tube Assembly (4). Install the 125-5084 Tube Assembly (4) to the
right rear final drive. Use three 8T-9389 Bolts (18) and three 8T-4223 Washers (19).
8. Repeat Step 5 for the 125-5083 Tube Assembly (2).

:
9. Install one 5P-1935 O-Ring Seal (14) into the 125-5083 Tube Assembly (2). Install 125-5083 Tube Assembly (2) to the right
rear final drive. Use three 7X-0325 Bolts (16) and three 8T-4223 Washers (19).
11. Install one 5P-1935 O-Ring Seal (14) into the end of the 125-5083 Tube Assembly (2). Install the end of the 125-5083 Tube
Assembly (2) to the block that is located on top of the axle housing. Use four 8T-4910 Bolts (41) and four 7X-0568 Washers
(32) from the shipping cover that was removed.
12. Repeat Step 1 through Step 11 for the left rear oil cooler lines.
13. Install the 9S-4191 Plug (12) and the 3J-1907 O-Ring Seal (13) to the 125-5084 Tube Assembly (4).
PIP
14. Repeat Step 9 for the left rear oil cooler lines.
-11
15. Install the 9S-4191 Plug (12) and the 3J-1907 O-Ring Seal (13) to the 8X-4616 Tube Assembly (1).
202 008
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
© 2 998 00
Illustration 287
0 2 0 g00696324
Cat 1C
View of tube assembly that is installed on the left side
erp ater
16. Install one 5P-1935 O-Ring Seal (14) to the 8X-4616 Tube Assembly (1). Install the 8X-4616 Tube Assembly (1) to the left
rear final drive. Use three 8T-4223 Hard Washers (19) and three 7X-0325 Bolts (16).
Con illa pill

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View of the half clips that are installed
18. Install two 6V-8521 Half Clips (26) to the 8X-4616 Tube As (1). Use two 8T-4139 Bolts (22) and two 8T-4223 Washers (19).

:
View of the hose assembly that is installed to the tube assembly
PIP
Illustration 290
-11 g00696368
202 008
View of the hose assembly that is installed to the block
15: 1 /0 6 92
56: /228
SEH 48-
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© 2 998 00
0 2 0
Cat
Illustration 291
1C
View of the hose assembly that is installed
g00696371
erp ater
20. Install one 6J-2680 Seal (9) to each end of the 125-5085 Hose Assembly (3). Install one end of the 8X-4616 Tube Assembly
Con illa pill

(1). Use two 1P-4584 Half Flanges (33), four 8T-4184 Bolts (34), and four 8T-4223 Washers (19).
fide r: ar I
21. Install the end of the 125-5085 Hose Assembly (3) to the block. The block is on the top right side of the rear axle housing.
nc.
Use the hardware from the shipping cover for the installation.
ntia
Front Oil Cooler Lines lG

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1. Remove the shipping cover from the right front strut.
:
en

View of the elbow that is installed to the right front strut
2. Install one 9S-4191 Plug (12) and one 006-8352 Seal (15) into the ends of the 8X-4618 Elbow (7). Install the 8X-4618 Elbow
(7) onto the right front strut. Use two 6V-4432 Bolts (30), one 8T-4835 Bolt (31), and three 8T-4223 Washers (19).

View of the tube that is installed to the front strut
3. Install one 9S-4191 Plug (12) and one 3J-1907 O-Ring Seal (13) onto the ends of the 8X-4636 Tube Assembly (5). Use three
PIP
8T-8919 Bolts (17) and three 8T-4223 Washers (19).
-11
202 008
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
Illustration 294
© 2 998 00 g00696409
0 0
View of the shipping covers on the outlets of the oil cooler line
Cat 2 1C
erp ater
Con illa pill
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:
Con illa pill
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View of the shipping covers that are removed
4. Remove the shipping covers from the frame. Clean the surfaces.

View of plate that is installed to the front strut
5. Install the 8X-4620 Plate (8) to the right front strut. Use two 8X-6439 Spacers (27), two 7X-2475 Bolts (28), and two 8T-4122
Washers (20).
PIP
-11
202 008
Illustration 297
15: 1 /0 6
g00775657
92
56: /22
View of the hoses that are installed to the plate
8
7. Install two 4J-0527 Seals (36) to the end of the two 7I-5529 Hose Assemblies (35). Install one 6F-8146 O-Ring Seal (29) to
SEH 48-
the end of the 8X-4636 Tube Assembly (5). Align the holes in the 8X-4618 Elbow (7) and the 8X-4636 Tube Assembly (5) to
the holes in the 8X-4620 Plate (8). Install two 7I-5529 Hose Assemblies (35) to the 8X-4620 Plate (8). Use two 1P-4582
S 03:
Flanges (38), four 8T-4194 Bolts (37), and four 8T-4223 Washers (19).
© 2 998 00
0 2 0
Cat 1C
erp ater
illa pill
:
HS 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
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lG
Illustration 298
ree g00775658
n
View of the front oil cooler lines that are installed to the frame

View of the front oil cooler lines that are installed
9. Install two 4J-0527 Seals (36) to the ends of the 7I-5529 Hose Assemblies (35). Use two 1P-4582 Flanges (38), four 8T-4194
Bolts (37), and four 8T-4223 Washers (19).
11. Repeat Step 2 through Step 9.

The 8X-6498 Plate (39) is substituted for the 8X-4620 Plate (8).
The 8X-4619 Elbow (40) is substituted for the 8X-4636 Tube Assembly (5).
The 8X-4637 Tube Assembly (42) is substituted for the 8X-4618 Elbow (7).
Install the 8X-2642 Rim Mounting Gp for the 793C (S/N: 4AR1-
79) and Install the 137-3614 Rim Mounting Gp for the 793C
(S/N: 4GZ80-UP; ATY1-UP)
Parts That are Required for the Installation of the 8X-2642 Rim Mounting for the 793C (S/N: 4AR1-79)
1 2 104-7783 Clamp Assembly
2 2 103-5931
PIP Plate
3 4 103-5932
-11 Plate
4 2
202
8X-6125
008
Extension
5 2 8X-6127
15: 1 /0 6 92
Hose Assembly
6 4 8T-6868
56: /228 Bolt
48-
03:
:
202 1008
15: 1 /0 6 92
56: /228
SEH 48-
7 12 8T-4139 Bolt
03:
8 20 8T-4195 Bolt
10
16
6
© 2 998S 8T-4223
5T-979000
Hard Washer
Valve Group
11 4
0 2 0
6J-0427 Spacer
12 2
Cat 1C 5T-9767 Connector
13 6
erp ater
8W-0338 O-Ring Seal
14 2
Con illa pill
7I-5931 Bracket
fide r: ar I
15 2 8W-0331 Connector
nc.
16 420 7X-0851 Nut
17 420
ntia 6V-8237 Hard Washer
18 20
lG
8M-7145 Washer
Table 62
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n
Parts That are Required for the Installation of the 137-3614 Rim Mounting Gp for the 793C (S/N: 4AR80-UP; 4GZ1-UP;
ATY1-UP)
1 2 104-7783 Clamp Assembly
2 8 136-9459 Plate Assembly
3 12 137-3615 Bracket
4 2 8X-6125 Extension
5 2 8X-6127 Hose Assembly
6 4 8T-6868 Bolt
7 36 8T-4139 Bolt
8 4 3V-8340 Bracket
10 6 5T-9790 Valve Group
11 4 6J-0427 Spacer
12 2 5T-9796 Connector
13 6 8W-0338 O-Ring Seal
14 2 7I-5931 Bracket
15 2 8W-0331 Connector
16 420 7X-0851 Nut
17 420 6V-8237 Hard Washer
18 6 8X-0247 Rim Group (1)
19 6 137-9855 Rim Group (2)
20 6 -- Tire
PIP
Table 63
-11
00
:
PIP
Table 63
(1)
The 8X-0247 Rim Group is effective with 793C (S/N: 4AR1-102). The 8X-0247 Rim Group is for a reference. The 8X-0247 Rim Group is not a part of the
(2)
137-3614 Rim Mounting.
-11
202 008
The 137-9855 Rim Group is effective with the 793C (S/N: 4AR103-UP; 4GZ1-UP; ATY1-UP). The 137-9855 Rim Group is for reference. The 137-9855 Rim
Group is not a part of the 137-3614 Rim Mounting.
15: 1 /0 6 92
Note: The shop or a tire servicing person installs the rim assembly. Move the six 5T-9790 Valve Groups (10), the two 8W-0331
8
Connectors (15), the two 5T-9796 Connectors (12), the two 8X-6125 Extensions (4), the six 8W-0338 O-Ring Seals (13), the six tire
56: /22
and rim assemblies to the job site surface. The weight of the rim is 1480 kg (3262 lb). The weight of the tire is 3500 kg (7716 lb).
SEH 48-
Note: 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 may cause damage to the wheel.
Install the Front Tires

S 03:
© 2 998 00
0 2 0
Cat 1C
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View of the clevis and protective cover on the front bumper

View of the front strap that is lifting the truck
1. Install six clevis assemblies and lifting straps to the frame assembly.
Note: Inspect the locations of the straps. Metal will tear the straps.
2. Raise the front of the truck for the installation of the tires and rims.
3. Keep the hoist attached to the truck, until the front tires and rims are installed.
:
PIP
Illustration 302
-11 g00699225
202 008
15: 1 /0 6 92
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SEH 48-
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© 2 998 00
0 2 0
Cat 1C
erp ater
Illustration 303
Con illa pillg00699308
fide r: ar I
View of the left front tire that is installed by the tire handler
nc.
4. Use a tire handler to install the left tires and rims with the valve stem to the outside.
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View of the installation of the front tire
Note: The part number on the washers faces out. The part number on the washer may prevent the proper torque from
being obtained.
5. Install 70 7X-0851 Nuts (16) and 70 6V-8237 Hard Washer (17). Secure the nuts with an air gun. Torque the nuts later in this
procedure.
:
PIP
-11
202 008
15: 1 /0 6 92
Illustration 306
56: /228 g00699341

View of the front tire that is installed with a tire handler
SEH 48-
6. Repeat Step 4 through Step 5 for the right tire.
Toe Out Adjustment Procedure

S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
fide r: ar I
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Illustration 307
n g00928716
Typical top view of the steering linkage
(A) Distance between the front tires at the front
(B) Clamps on left side tie bar
(C) Clamps on right side tie bar
(D) Distance between the front tires at the back
1. While the strut rods in the suspension cylinders are fully extended, move the wheels to a straight ahead position.
2. Measure the distance between the front wheels at location (A).

:
3. Mark location (A) at each tire. Rotate the tires by 180 degrees.
4. Measure the distance at location (D) between the same marks.
5. Distance (D) is at the back of the tires. Distance (A) is at the front of the tires. The difference between Distance (D) and
Distance (A) should be 48.20 mm (1.90 inch).
6. Adjust the tie rods for the correct toe-out. Loosen the clamps on the tie rod. Turn each tie rod. Use the same number of
turns on each side to get the correct measurement. The tie rods should be the same length.
PIP
-11
202 008
15: 1 /0 6 92
Illustration 308
View A-A
(E) Tie rod
56: /228 g00928723
(F) Clamp assembly
SEH 48-
(G) 6.350 ± 1.530 mm (0.25 ± 0.06 inch)
S 03:
© 2 998 00
7. Position clamp assembly (F) on tie rod (E).
0 2 0
Cat 1C
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Con illa pill
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:
Gre
en

(E) Tie rod
(F) Clamp assembly
(H) Nut
8. Align the open portion of clamp assembly (F) with one of the slots in tie rod (E).
9. Tighten nut (H) to a torque value of 583 ± 27 N·m (430 ± 20 lb ft).

Note: When the adjustment is correct, there will be a front wheel toe-in when the truck is in normal operation with correctly
charged suspension cylinders.
Reference: Refer to Specifications, "Steering Linkage and Cylinder Mounting" for additional information.
Install the Rear Tires PIP

-11
202 008
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
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Con illa pill
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:
ater Cat
Con pilla erpill
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View of the ring that is removed from the final drive
1. Remove the bolts and the ring from the rear wheel assembly.
Note: Use the ring later on the installation of the outside rim and tire assembly.
PIP
-11
202 008
15: 1 /0 6 92
56: /22 8
SEH 48-
S 03:
© 2 998 00
021 0
Cat
e
:
SEH 6:48-
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
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Illustration 312 n
g00699441
View of the area that is machined on the final drive
2. Clean the mounting area of metal burrs and paint.

View of the frame assembly that is lifted
3. Raise the rear of the truck for the installation of the tires and rims.
4. Keep the hoist attached to the truck, until the rear tires and rims are installed.
5. 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.
PIP
-11
202 008
15: 1 /0 6 92
56: /228
48
:
IP-
202 1008 1
15: 1 /0 6 92
56: /22 8
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
fide r: ar I
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View of the rear tire that is installed
6. Use a tire handler to install the left inside tire. The valve stem and hose assembly face outward.

:
PIP
-11
202 008
15: 1 /0 6 92
Illustration 317
56: /228 g00699505
SEH 48-
View of the nuts that are installed to the rear inside wheel
being obtained.
S 03:
© 2 998 00
7. Install 70 7X-0851 Nuts (16) and 70 6V-8237 Washers (17) to the rear inside wheel.
0
Tire Inflation Pressure
2 0
Size
Cat
Ply Rating
1C kPa Psi
erp ater
40-57 (1)
68 723 105
Con illa pill

40-R57 Michelin Two Star 689 100
fide r:
40-57R Goodyear Two Star 758 110
40-57R Bridgestone Two Star 703 102

ar I
Table 64
ntia nc.
lG
(1)
This is the standard tire, the ply rating, and the inflation pressure.
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Note: The tire's radial construction is the “R” in tire size.
Note: Install the valve stem connections and the extensionswhen the tire is mounted.
8. Fill the tires with nitrogen. Use a 6V-4040 Inflation Group to inflate the tire from a nitrogen cylinder. Refer to Special
Instruction, SMHS7867 for the tire inflation instructions.
Note: Use the same tire pressures for nitrogen inflation and air inflation. Refer to Table 64 or consult the tire dealer for the
tire operating pressures.
9. A tire is under inflated when the tire is inflated in an area that is 20 °C (68 °F) and the tire operates in freezing temperatures.
Low tire pressure shortens tire life. Refer to the Operations and Maintenance Manual, SEBU5898, "Cold Weather
Recommendations for Caterpillar Machines" for the cold weather conditions.
:
Servicing and changing tires and rims can be dangerous and
should be done only by trained personnel using proper tools and
procedures.
PIP
Do not attempt to assemble this machine until you read and you
understand the assembly instructions.
-11
202
Improper assembly procedures could result in injury or death.
008
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
Illustration 319
erp ater g00699541
Con illa pill

View of the nuts that are tightened with an air gun
fide r: ar I
10. Tighten the nuts with an air gun.
11. Repeat for the other rim and the other tire.
ntia nc.
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).
lG
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View of the rear wheel with the plates that are installed
13. Install four 136-9459 Plate Assemblies (2) to the inside wheel and the final drive on the 793C (S/N: 4AR80-UP; 4GZ1-UP;
ATY1-UP). Use six 137-3615 Brackets (3), 12 8T-4139 Bolts (7), and 12 8T-4223 Washers (9).
On 793C (S/N: 4AR1-79), install one 103-5931 Plate (2) and two 103-5932 Plate (3). Use ten 8T-4195 Bolts (8) and ten 8M-
7145 Bolts (18).
:
14. Tighten bolts (8) and (18) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
Note: Position the valve stem in the correct position before the installation of the plates.
NOTICE
If the truck is to be operatied without the outside rear tire,
install the ring and torque the bolts 8T-0669 Bolts to hold the
final drive to the wheel.
PIP
-11
202 008
1
/0
View of the clamp assembly that is installed
15: 6 92
56: /228
15. Install the 104-7783 Clamp Assembly (1) over the hose assembly. Use six 8T-4139 Bolts (7), six 8T-4223 Washers (9), and two
3V-8340 Brackets (8).
SEH 48-
03:
Note: The two 3V-8340 Brackets (8) are not required on the 793C (S/N: 4GZ1-UP; ATY1-UP).
S
© 2 998 00
Note: Attach a wire to the valve. Pull the valve through the openings.
0 0
17. Repeat for the other inside wheel on the other side of the machine.
2
Cat 1C
18. Install a ring to the rim group. The ring goes on the opposite side of the valve stem of the rim. Align the “U” notch in the
erp ater
ring with the valve stem assembly.
Con illa pill

fide r: ar I
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Illustration 322
n
g00699576
View of the rings for assembly to the rear wheels
Note: Both valves should be free before the installation of the ring.
19. Install 70 7X-0851 Nuts (16) and 70 6V-8237 Washers (17).

:
being obtained.
Note: Do not use any lubrication on the nuts or washers. The mating surfaces are clean and dry.
20. Secure the nuts with an air gun.
21. Repeat for the outside wheel on the other side of the machine.
22. Torque the outside nuts on the two outside rear tires to 1000 ± 125 N·m (738 ± 92 lb ft).
23. Use a tire handler to position the left outside rear wheel to the final drive.
24. Install the bolts and washers that were removed. Use the hardware from the ring that was taken from the final drive.
Note: Use the wire to pull the valve stem of the inside tire through the opening in the retaining ring.
25. Tighten the bolts that secure the ring to the final drive. Torque the bolts to 1000 ± 125 N·m (738 ± 92 lb ft).
Illustration 323
PIP g00699580
-11
View of the tire valve and the mounting block
202 008
26. Install two 5T-9790 Valve Groups (10). Use a 7I-5931 Bracket (14), two 8T-6868 Bolts (6), and two 6J-0427 Spacers (11).
15: 1 /0 6 92
8 /2
28. Repeat on the other side of the machine.
56Tank Guard2Gp
SEH :48-
Install the 126-1358 Hydraulic
03:
Parts that are Required to Install 126-1358 Hydraulic Tank Guard Gp
S
Item
© 2 998
Qty
00
0 0
1 1 105-2205 Support
Cat
1
2 1C
105-2204 Support
ater
3 2 105-2200 Mud Flap
4 8
erp 8T-4136 Bolt
5
Con illa
8
pill
8T-2561 Hard Washer
6 8
fide r: 8T-4133
ar I
nc.
Nut
Table 65
ntia
lG
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:
ntia c.
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View of the hydraulic tank covers
1. Install the 105-2205 Support (1).
2. Install the 105-2204 Support (2).
3. Install two 105-2200 Mud Flaps (3). Use eight 8T-4136 Bolts (4), eight 8T-2561 Hard Washers (5), and eight 8T-4133 Nuts
(8).
Miscellaneous Installations of Components
PIP
-11
202 008
1 6
/0 92
View of the battery cables that are taped
15: 8
56: /22
1. Remove the tape from the battery cables.
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
fide r: ar I
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:
Cat 021 C
erp ater
Con illa pill
fide r: ar I
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2. Install the battery connection.
ntia
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3. Install the filter to the block. Remove the plastic cover from the filter.
Installation of the Ether Cylinder
PIP
-11
202 008
15: 1 /0 6 92
8
56: /22
View of the ether cylinder
1. Install two 7X-1062 Ether Cylinders.
SEH System
Install the Automatic Lubrication 48-
S 03:
© 2 998 00
021 0
:
15: 8
56: /22
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
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Con illa pill
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View of the automatic lubrication system
1. Install connections to the automatic lubrication system.
Install the 9Y-8917 Muffler Gp

Note: The 793C is equipped with dual body mufflers or dual body heat.
Note: Some hardware is installed onto the platform before the platform is installed.
Parts that are Required to Install 9Y-8917 Muffler Gp
2 1 7E-8452 Clamp
3 3 8X-3132 Bracket Assembly
4 3 8X-3128 Strap
5 1 6N-9298 Clamp
6 1 8X-3142 Extension Pipe
7 1 5T-7824 Clamp Assembly
8 1 8X-2990 Extension Pipe
9 12 8T-4139 Bolt

PIP
-11
11 12 6V-5843 Bolt
202 008
12 3 2Y-5829 Nut
1/0 692
8/2
2
:
PIP
-11
202 008
1 6
13 2 6V-3823 Bolt
14 2 6V-8149
15:
Nut
/0 8 92
56: /22
15 30 6V-5839 Washer
SEH 48-
16 2 6V-3668 Bolt
18 4 8T-0375
SBolt 03:
19 4 2V-8169
© 2 998 Plate
00
20 3 6V-6317
0 2
Bolt
0
21 2 7E-6811
Cat 1C
Muffler
22 12 6V-7744
erp ater
Locknut
23 2 6V-7687
Con illa Locknut
pill
Table 66
fide r: ar I
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View of the bracket assembly that is installed
1. Install three 8X-3132 Bracket Assembly (3) to the right side platform. Use 12 8T-4139 Bolts (9) and 12 8T-4223 Washers (10).

View of the cover on the muffler
2. Remove the tape and protective covers from the 7E-6811 Muffler Assembly (21).
:
PIP
-11
202 008
15: 1 /0 6 92
Illustration 334
56: /228 g00702318

View of the pipe that is installed to the muffler
SEH 48-
3. Install 5T-7824 Clamp Assembly (7) to the platform assembly. Use two 6V-3668 Bolts (16), four 5P-8245 Washers (17), and
03:
two 6V-8149 Nuts (14).
© 2 998S 00
4. Slide the 8X-3142 Pipe (6) through the 5T-7824 Clamp Assembly (7). Install 6N-9298 Clamp (5) to the 8X-3142 Pipe (6). Use
one 6V-3823 Bolt (13) and one 6V-7687 Locknut (23). Do not fasten the clamp onto the pipe until the pipe is installed onto
the muffler.
0 2 0
Cat 1C
5. Install the 8X-3142 Pipe (6) to the muffler. Use a 6N-9298 Clamp (5), one 6V-3823 Bolt (13), and one 6V-7687 Locknut (23).
erp ater
Fasten the 5T-7824 Clamp Assembly (7) to the 8X-3142 Pipe (6). Use one 6V-3823 Bolt (13), and one 6V-7687 Locknut (23).
Note: Lubricate the clamp bolt threads. Lubricate the clamp surface before installation.
Con illa pill

fide r: ar I
Note: Apply 4C-5598 High Temperature Anti-Seize to the exhaust pipe joint.
nc.
Note: Torque the bolts to 50 ± 10 N·m (37 ± 7 lb ft).
ntia
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View of the muffler assembly that is installed with brackets
6. Install the 7E-6811 Muffler Assembly (21) to the 8X-3135 Plate Assembly (1). Use one 7E-8452 Clamp (2). Do not fasten the
clamp screw completely, until the muffler assembly is installed.
Note: Apply 4C-5598 High Temperature Anti-Seize to the male end of the muffler before installation.
7. Install 8X-2990 Pipe (8) to the muffler. Use three 6V-6317 Bolts (20), six 6V-5839 Washers (15), and three 2Y-5829 Nuts (12).
Note: Apply 4C-5598 High Temperature Anti-Seize to the male end of the muffler before installation.
Note: Lubricate the bolt threads before installation.
Note: Torque the bolts to 30 ± 7 N·m (22 ± 5 lb ft).
8. Install the 7E-6811 Muffler Assembly (21) to the 8X-3132 Bracket Assemblies (3). Use three 8X-3128 Straps (4), 12 6V-5843
Bolts (11), 24 6V-5839 Washers (15), and 12 6V-7744 Locknuts (22). Loosely tighten the strap bolts for support of the muffler
:
to the beam assembly.
Note: Lubricate the bolt threads before installation.
Note: Do not tighten the fasteners to the straps until the muffler assembly is installed.
PIP
-11
Illustration 336
202 008 g00702328
1
View of muffler assembly that is installed
15: /0 6 92
8
9. Install the muffler assembly to the beam assembly. Use four 2V-8169 Plates (19) and four 8T-0375 Bolts (18). Torque the
56: /22
strap bolts and clamp bolts.
Note: Torque the 8T-0375 Bolts (18) bolts to 240 ± 40 N·m (177 ± 29 lb ft).
SEH 48-
Note: Torque the 6V-5843 Bolts (11) to 30 ± 7 N·m (22 ± 5 lb ft).
S 03:
Note: Torque the 7E-8452 Clamp (2) to 16 ± 4 N·m (11 ± 3 lb ft). Lightly tap the clamp and then tighten the clamp to
© 9 9 0 0
16 ± 4 N·m (11 ± 3 lb ft). The minimum torque before the engine starts is 9 N·m (6 lb ft).
202Pipe Gp80
Install the 9Y-8888 Exhaust
Cat 1C
ater
Parts That are Required to Install the 9Y-8888 Exhaust Pipe Gp
Item Qty
erp Part Number Description
1
Con illa
2
pill
7E-8452 Clamp
2 1
fide r: 7E-7861
ar I
nc.
Elbow Assembly
Table 67
ntia
lG
1. Remove the tape and the shipping cover from the muffler assembly.
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View of the elbow assembly on the turbocharger exhaust
2. Remove the tape and the shipping cover from the turbocharger exhaust.
:
View of the clamp and elbow assembly
3. Install the 7E-7861 Elbow Assembly (2). Use two 7E-8452 Clamps (1).
Note: Torque the clamp bolts to 16 ± 4 N·m (11 ± 3 lb ft). Lightly tap the clamp and then tighten the clamp to 16 ± 4 N·m
(11 ± 3 lb ft).
Install the 8X-2851 Exhaust Pipe Gp (Dual Exhaust) for the 793C
(S/N: 4AR1-UP; 4GZ1-UP)
PIP
Parts That are Required for the 8X-2851 Exhaust Pipe Gp
Item Qty Part Number

-11
Description
1 1 8X-3218
202 008
Plate Assembly
2 1 8X-3227
15: 1 /0 6 92
Plate Assembly
4
8
20
6V-4429
5P-8247
56: /228
Bolt
Hard Washer
5 2 5T-3367
SEH 48- Elbow
6 8 8C-0623
S 03:
Taperlock Stud
7 12
© 2 998
7K-1270 Washer
00
8 8 8T-1757
0 2 0
Nut
9 2
Cat
5T-2762
1C Spring
erp ater
10 2 6G-7038 O-Ring Seal
Con illa
11 2 8X-3233 Piston
12 6 8X-3253 Lock
pill
13 12 6V-6317
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14 25 8T-4121
ntia Washer
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15 1 6G-7031 Elbow
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16 4 8T-0375 Bolt
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17 2 092-5524 Bolt
18 4 6V-8149 Nut
19 1 8X-3256 Guard Assembly
20 4 8T-4137 Bolt
21 2 8T-4179 Bolt
:
22 1 8T-4133 Nut
23 1 5T-7826 Brace
24 2 6V-3668 Bolt
25 1 8T-4222 Plated Washer
26 1 5T-6643 Plate
27 1 105-1134 Plate
28 1 8X-2852 Exhaust Pipe Gp (1)
29 9 8T-4195 Bolt
31 4 5P-8245 Washer
Table 68
(1)
This is not a part of the 8X-2851 Exhaust Pipe Gp.
PIP
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202 008
15: 1 /0 6 92
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SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
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Illustration of the dual body heat group
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1. Assemble the exhaust system from the engine to the platform.
2. Remove the shipping plate from the beam assembly.

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3. Install the 6G-7031 Elbow (15) to the frame. Use four 5P-8247 Hard Washers (4), four 7K-1270 Washers (7), and four 8T-
0375 Bolts (16).
Note: Apply 4C-5598 Anti-Seize Compound to the bolt threads and washers.
Note: Tighten the bolts. Do not torque the bolts yet.
4. Use a 6 mm (0.24 inch) fillet weld to secure the 105-1134 Plate (27) in position below the beam. Install two 092-5524 Bolts
(17) and two 6V-8149 Nuts (18) on the 105-1134 Plate (27).
5. After the 6G-7031 Elbow (15) is adjusted, torque the nuts to 100 ± 20 N·m (74 ± 15 lb ft).
6. Fasten the 8X-3256 guard Assembly (19) to the platform assembly. Use two 8T-4137 Bolts (20) and two 8T-4121 Washers
(14) on the inside. Fasten the guard assembly with four 8T-4179 Bolts (21) and four 5P-1076 Washers (30).
8. Fasten the 8X-3256 Guard Assembly (19) to the beam assembly with the 5T-6643 Plate (26). Use one 8T-4195 Bolt (29), one
8T-4222 Washer (25), one 8T-4121 Washer (14), and one 8T-4133 Nut (22).
9. Tighten bolt (29) to a torque of 100 ± 20 N·m (74 ± 15 lb ft).
10. Install the 5T-7826 Brace (23) to the exhaust group and the guard assembly. Use two 6V-3668 Bolts (24), four 5P-8245
Washers (31), and two 6V-8149 Nuts (18).
PIP
-11
202 008
15: 1 /0 6 92
Illustration 340
56: /228 g00707958
SEH 48-
Illustration of the exhaust pipe assembly
S 03:
12. Install the 8X-2852 Exhaust Pipe Gp (28) to the platform. Use eight 8T-4195 Bolts (29) and eight 8T-4121 Washers (14).
© 2 998 00
Fasten the tube to the exhaust system.
Note: Loosen the four bolts that secure the elbow to the end of the 8X-2852 Exhaust Pipe Gp (28). Tighten the bolts, but
do not torque the bolts yet.
0 2 0
Cat 1C
13. Torque the 8T-4195 Bolts (29) to 100 ± 20 N·m (74 ± 15 lb ft).
erp ater
Con illa pill
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© 2 998 00
0 2 0
Cat 1C
erp ater
14. Assemble the exhaust pipe extension assemblies on each 5T-3367 Elbow (5). Install one 8X-3233 Piston (11), one 6G-7038
Con illa pill

Ring (10), one 5T-2762 Spring (9), three 8X-3253 Locks (12), three 6V-6317 Bolts (13), and three 8T-4121 Washers (14).
fide r: ar I
Note: The piston should travel freely over the entire surface.
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16. Remove the covers from the exhaust ports on the body.
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17. Install the 8X-3218 Plate Assembly (1) and the 8X-3227 Plate Assembly (2) to the truck body. Use eight 6V-4429 Bolts (3)
and eight 5P-8247 Washers (4).
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19. Install the exhaust pipe extension assemblies. Attach the 5T-3367 Elbows (5) to the 8X-3218 Plate Assembly (1) and the 8X-
3227 Plate Assembly. Use eight 8C-0623 Studs (6), eight 7K-1270 Washers (7), eight 5P-8247 Washers (4), and eight 8T-
1757 Nuts (8).

Illustration of the exhaust pipes
(A) Body
(B) Beam
20. The body should be in the down position. Use the screws under the 6G-7031 Elbow (15) and under the 8X-2852 Exhaust
PIP
Pipe Gp (28). Adjust the length that is compressed on the 5T-2762 Springs (9) to 89 mm (3.50 inch).
Note: Tighten the bolts that are holding the 6G-7031 Elbow (15). Tighten the four bolts that are holding the 8X-2852
-11
Exhaust Pipe Gp (28). Torque the bolts to 240 ± 40 N·m (177 ± 30 lb ft).
202 008
Properly adjust the 6G-7031 Elbow (15) and the 8X-2852 Exhaust Pipe Gp. Tighten the screws to 100 ± 20 N·m
1
(74 ± 15 lb ft).
15: /0 6 92
56: /228
SEH 48-
S99 03:00
8
:
21/ 869
15: 08/2 2
56: 2
SEH
Install the 8X-2813 Truck 48- Gp (Dual Slope) for
Body Mounting
the 793C (S/N: 4AR1-UP) and S 03154-3758
Install the
: Truck Body
Mounting Gp (Dual© 99793C
Slope) for the
8 0
(S/N: 0
4GZ1-UP; ATY1-
UP) 202 0
1 C Gp (Dual Slope) for 793C (S/N:
Cat Body Mounting
Install the 8X-2813 Truck
erp ater
4AR1-UP)
Con illa pill
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Parts that are Required to Install 8X-2813 Truck Body Mounting Gp (Dual Slope) for 793C (S/N: 4AR1-UP)
nc.
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1 1 6G-9703 Cable (1)
2 4
lG 5T-7255 Plate
3 1
ree
8X-5064 Mud Flap
5
4
1
5T-7352
8X-5063
n Strip
Mud Flap
6 1 5T-7275 Mud Flap
7 1 5T-7274 Mud Flap
8 2 3D-0404 Washer
9 10 8X-3045 Pad As
10 30 8X-3046 Shim
12 2 7I-5517 Pin Assembly
13 1 105-0314 Coupler
14 1 8X-5421 Plate
15 1 5G-7820 Magnet Assembly
16 1 102-9552 Bracket
17 1 102-9549 Plate As
18 68 8T-4196 Bolt
20 68 8T-4133 Nut
21 2 6G-7773 Pin
22 4 3B-4647 Cotter
23 10 8T-4184 Bolt
24 30 7D-1649 Washer
25 2 6G-9697 Washer
26 1 8W-2896 Washer
28 2 8W-8677 Plate
29 24 8T-4910
PIP Bolt
-11
008
69
:
PIP
30 24
-11 8T-4244 Nut
31 2
202 0088T-4136 Bolt
32 2
15: 1 /0 6 92
8T-4649 Bolt
33
34
2
2
56: /228 8T-4167
6V-7676
Washer
Nut
35 1
SEH 48- 8W-0109 Plate
36 1
S 03:2B-0974 Clevis Pin
37 1
© 2 998 00
8T-4122 Hard Washer
38 1
0 2 0 3B-4617 Cotter
Cat 1C
39 16 8T-4137 Bolt
ater
40 16 4K-8864 Clip
41 2 erp 8T-7547 Bolt
42 2
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5C-7261 Nut
43 4
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8T-4224
nc.
Hard Washer
44 5
ntia 8T-4195 Bolt
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45 1 105-4727 Mud Flap
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46 2 112-6213 Ejector
Table 69
(1)
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PIP
-11
Illustration 343
202 008 g00704538
1 / 6
View of the rear and the front of the truck body on supports
15: 0 92
56: /228
1. Position the truck body onto four supports. The weight of the truck body is 45,000 kg (99,200 lb).
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Illustration 344
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g00704606
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View of the mud flaps that are assembled
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4196 Bolts (18) and 12 8T-4133 Nuts (20). nc.
2. Assemble one 5T-7255 Plate (2), one 8X-5064 Mud Flap (3), one 5T-7352 Strip (4), and one 5T-7352 Strip (4). Use 12 8T-
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4. Install the 5T-7255 Plate (2) to the bottom of the truck body. Use five 8T-4196 Bolts (18), five 8T-4121 Hard Washers (19),
and five 8T-4133 Nuts (20).
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6. Assemble one 5T-7255 Plate (2), one 8X-5063 Mud Flap (5), and one 5T-7352 Strip (4). Use 12 8T-4196 Bolts (18) and 12 8T-
4133 Nuts (20).
10. Assemble one 5T-7255 Plate (2), one 5T-7274 Mud Flap (7), and one 5T-7352 Strip (4). Use 12 8T-4196 Bolts (18) and 12 8T-
4133 Nuts (20).
:
4133 Nuts (20).
PIP
-11
202 008
15: 1 /0 6 92
Illustration 345
56: /228
g00704613
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
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View of the cable assembly
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18. Install 105-0314 Coupler (13) to the end of the cable assembly. Use two 8T-4649 Bolts (32), two 8T-4167 Washers (33), and
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two 6V-7676 Nuts (34).
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20. Install one 8W-0109 Plate (35) to the other end of the cable assembly. Use one 2B-0974 Clevis Pin (36), one 8T-4122 Hard
Washer (37), and one 3B-4617 Cotter (38).
:
Illustration 347 PIP g00704934
(A) Body assembly
-11
202 008
(B) Grease line
(C) Body in position that is raised
(D) Frame assembly
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SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
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21. Install the 105-4727 Mud Flap (45) and the 8X-5421 Plate (14). Use five 8T-4195 Bolts (44) and five 8T-4121 Washers (19).

:
en

View of the truck that is ready for the body assembly
23. Remove the bar from the rear of the frame.
PIP
-11
202 008
15: 1 /0 6 92
Illustration 351
56: /228 g00705098
SEH 48-
View of the clevis and strap that is attached to the rear of the body assembly
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
Illustration 352
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g00705434
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View of the clevis and strap that is attached to the front of the body assembly
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Con pilla rpil
lar
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View of the body assembly before installation to the truck frame
24. Install two 7I-5517 Pin (12) through the body pin bore. Repeat on the other side of the body assembly.
Illustration 355
PIP g00705114
-11
202 008
15: 1 /0 6 92
56: /22 8
SEH 48-
S 03:
© 2 998 00
0
0 2
View of the body assembly that is lowered onto the frame
Cat 1C
erp ater
illa pil
:
EH -03
S
© 2 998 :00
0 2 0
Cat 1C
erp ater
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View of the 7I-5517 Pin (12) that is inserted through the bore
25. Install two 7I-5517 Pin (12) into the truck body.

View of the washers for the body assembly
26. Install the two 6G-9697 Washers (25). The 6G-9697 Washers (25) are 10 mm (0.40 inch) thick. Use the 8W-2896 Washer (26),
if the 6G-9697 Washers (25) do not fit. The 8W-2896 Washers (26) are 6 mm (0.24 inch).

PIP
View of the pin that is inserted through the bore
-11
202 008
27. One person drives the 7I-5517 Pin (12) through the bore. One person checks for pin alignment through the hole for
installation of the mounting blocks and bolts.
15: 1 /0 6 92
56: /228
48-
03
:
202 11008
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
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Con illa pill
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View of the mounting block and bolts that are installed
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28. Install one 8W-8677 Plate (28). Use two 8T-4184 Bolts (23) and two 5P-1076 Hard Washers (27).
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Note: Remove the paint from the mounting area.
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View of the truck body that is lowered onto two wood blocks
PIP
-11
00
:
PIP
32. Secure the hoist cylinders with a chain. This prevents any movement of the hoist cylinders.
Note: Refer to "Install the 8X-3380 Cylinder Mounting Gp" for the installation of the hoist cylinders to the body assembly.
-11
Note: The truck needs to be on a level surface. The body needs to be completely installed to the frame.
202 008
33. Raise or lower the body assembly. The body assembly and the frame rail need to be parallel. The distance between the
1 /0 6
body rail and the frame rail is 42 mm (1.65 inch).
15: 92
56: /228
34. Measure the distance between the body rail and the frame rail. Place the pad assemblies on top of the frame rail. Use shims
to produce a zero clearance between the rails. Finish the installation of the eight pad assemblies and shims to the body.
SEH 48-
35. Install the two pad assemblies to the top of the main crossbeam. Align the slipper pads to the body supports. Measure the
03:
distance between the pads. Use shims to produce 38.10 mm (1.50 inch) compression at the two locations.
S
© 2 998 00
0 2 0
Cat 1C
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View of the pads that are installed to the front of the body assembly
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36. Install the 8X-3046 Shims (10), eight 8X-3045 Pad (10), 24 8T-4910 Bolts (29), 24 7D-1649 Washers (24), and 24 8T-4244
Nuts (30).
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Note: Block the body in position when you install the shims and pads.

View of the guides that are installed
38. Install the 8X-3046 Shims (10) and two 8X-3045 Pad Assemblies (9). Use six 8T-4184 Bolts (23) and six 7D-1649 Washers
(24).
Note: Refer to Illustration 368. This determines the number of 8X-3046 Shims (10) that are required.
:
PIP
-11
202 008
15: 1 /0 6 92
56: /228
SEH 48-
View of the magnet assembly and the mounting hardware
S 03:
© 2 998 00
0 2 0
Cat 1C
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This is an illustration of the magnet assembly.
(L) Body assembly
(M) Frame assembly
(N) 8 ± 2 mm (0.32 ± 0.08 inch)
Note: The location of the plate assembly will be determined in the field, when the body down switch is adjusted.
40. Install the 5G-7820 Magnet Assembly (15) to the 102-9552 Bracket (16). Use two 8T-7547 Bolts (41), four 8T-4224 Washers
(43), and two 5C-7261 Nuts (42).

Note: Clean the paint from the mounting area for the plate assembly.
42. Weld the 102-9549 Plate Assembly (17) to the truck frame. Refer to Table 70 and Table 71.
:
43. Install the 5G-7820 Magnet Assembly (15) and the 102-9552 Bracket (16) to the 102-9549 Plate Assembly (17). Use two 8T-
4136 Bolts (31) and two 8T-4121 Washers (19).

Note: Adjust the bracket until the gap is 8 ± 2 mm (0.32 ± 0.08 inch).
Illustration 367 PIP g00705260
-11
View of the underside of the body assembly
202 008
45. Install the hoist cylinder grease lines to the bottom of the body assembly. Use 16 8T-4137 Bolts (39), 16 8T-4121 Washers
1 6
(19), and 4K-8864 Clips (40).
15: /0 8 92
56: /22
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
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Illustration 368
Con illa pill
g00705269
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47. Install the grease line to the hoist cylinder.
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:
View of the rock ejector that is installed
48. Use a fork lift to position the 112-6213 Ejector (46) to the body assembly.
49. Install the 6G-7773 Pin (21). Use two 3B-4647 Cotters (22) and one 3D-0404 Washer (8). Bend the cotters with pliers. This
keeps the pin in place.
PIP
-11
202 008
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
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Con illa pill
Illustration 371
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g00705316
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Illustration of the rock ejector that is installed
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50. Lower the rock ejector between the tires. Check the clearance on both sides of the rock ejector.
Welding Dimensions
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Item Dimension
P 1310.50 ± 3 mm (52 ± 0.12 inch)

:
Gre
en
Table 70
Weld Tolerances
Weld Description
W5 10 mm (0.40 inch) with a 1.50 mm (0.06 inch) penetration (4 Places)
W6 12 mm (0.47 inch) bevel groove weld (2 Places)
Table 71
Note: The rock ejector brackets should be installed after the body has been installed.
51. Attach a string and a plumb bob to the center of the bracket mounting pin in the Rock Ejector Bracket (30). Position the
Rock Ejector Bracket (30) on the bottom of the truck body. The string is centered in the middle of the two tires. Check the
distance that separates the string and the wheel group assembly to prevent the rock ejectors from striking the wheels. The
rock ejectors that are installed should be centered in the forward position, in the rear position, and in the side position.
52. Repeat Step 48 through Step 51 on the other side of the machine.
Install the 154-3758 Truck Body Mounting Gp (Dual Slope) for the 793C
(S/N: 4GZ1-UP; ATY1-215)
Parts that are Required to Install 154-3758 Truck Body Mounting Gp (Dual Slope) for 793C (S/N: 4AR1-UP)
1 1 6G-9703 Cable (1)
2 4 5T-7255 Plate
3 1 8X-5064 Mud Flap
4 4 5T-7352 Strip
5 1 8X-5063 Mud Flap
6 1
PIP 5T-7275 Mud Flap
7 1
-11 5T-7274 Mud Flap
8 2
202 008
3D-0404 Washer
1 6
9 10 8X-3045 Pad Assembly
10 30
15: /0 8 92
8X-3046 Shim
56: /22
11 2 7I-5517 Pin
SEH 48-
12 1 105-0314 Coupler
13 1 8X-5421 Plate
14 68
S 03:
8T-4196 Bolt
15 41
© 2 998 00
8T-4121 Hard Washer
16 68
0 2 0 8T-4133 Nut
17 2
Cat 1C 6G-7773 Pin
18 4
erp ater 3B-4647 Cotter
19 10
Con illa pill
8T-4184 Bolt
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20 30 7D-1649 Washer
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:
ater Cat
Con pilla erpill
21 2 fide r: ar I
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6G-9697 Washer
22 1
ntia 8W-2896 Washer
23 4
lG 5P-1076 Hard Washer
24 2
ree 8W-8677 Plate
25
26
24
24
n 8T-4910
8T-4244
Bolt
Nut
27 2 8T-4649 Bolt
28 2 8T-4167 Washer
29 2 6V-7676 Nut
30 1 8W-0109 Plate
31 1 2B-0974 Clevis Pin
33 1 3B-4617 Cotter
34 16 8T-4137 Bolt
35 16 4K-8864 Clip
36 5 8T-4195 Bolt
37 1 105-4727 Mud Flap
38 2 112-6213 Ejector
Table 72
(1)
PIP
-11
202 008
Illustration 372
15: 1 /
g00704525
0 6 92
56: /22 8
SEH 48-
S 03:
© 2 998 00
021 0
Cat
:
SEH 6:48-
S 03:
© 2 998 00
0 2 0
Cat 1C
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View of the rear and the front of the truck body on supports
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1. Position the truck body onto four supports. The weight of the truck body is 45,000 kg (99,200 lb).

View of the mud flaps that are assembled
2. Assemble one 5T-7255 Plate (2), one 8X-5064 Mud Flap (3), one 5T-7352 Strip (4), and one 5T-7352 Strip (4). Use 12 8T-
4196 Bolts (14) and 12 8T-4133 Nuts (16).
6. Assemble one 5T-7255 Plate (2), one 8X-5063 Mud Flap (5), and one 5T-7352 Strip (4). Use 12 8T-4196 Bolts (14) and 12 8T-
4133 Nuts (16).
4133 Nuts (16).
PIP
-11
202 008
15: 1 /0 6 92
56: /228
4
:
PIP
-11
202 008
15: 1 /0 6 92
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4133 Nuts (16).
SEH 48-
03:
© 2 998S 00
0 2 0
Cat 1C
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Illustration 375
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g00706888

View of the cable assembly
18. Install 105-0314 Coupler (12) to the end of the cable assembly. Use two 8T-4649 Bolts (27), two 8T-4167 Washers (28), and
two 6V-7676 Self-Locking Nuts (29).
20. Install one 8W-0109 Plate (30) to the other end of the cable assembly. Use one 2B-0974 Clevis Pin (31), one 8T-4122 Hard
Washer (32), and one 3B-4617 Cotter (33).
:
PIP
-11
202 008
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
Illustration 377
(A) Body assembly fide r: ar I
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g00704934
(B) Grease line

(C) Body in position that is raised
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(D) Frame assembly
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Illustration of the mud flaps
21. Install the 105-4727 Mud Flap (37) and the 8X-5421 Plate (13). Use five 8T-4195 Bolts (36) and five 8T-4121 Washers (15).

:
Illustration 379
PIP g00704993
-11
202 008
15: 1 /0 6 92
56: /228
SEH 48-
S 03:
Illustration 380
© 2 998 00
g00705002
0 0
View of the truck that is ready for the body assembly
2
Cat 1C
23. Remove the bar from the rear of the frame.
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Illustration 381 n g00705098
View of the clevis and strap that is attached to the rear of the body assembly

:
View of the clevis and strap that is attached to the front of the body assembly
PIP
-11
202 008
15: 1 /0 6 92
Illustration 384
56: /228 g00706930

View of the body assembly before installation to the truck frame
SEH 48-
24. Install two 7I-5517 Pin (11) through the body pin bore. Repeat on the other side of the body assembly.
S 03:
© 2 998 00
0 2 0
Cat 1C
erp ater
Con illa pill
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:
View of the body assembly that is lowered onto the frame
25. Install two 7I-5517 Pin (12) into the truck body.
PIP
-11
View of the washers for the body assembly
202 008
26. Install the two 6G-9697 Washers (21). The 6G-9697 Washers (21) are 10 mm (0.40 inch) thick. Use the 8W-2896 Washer (22),
15: 1 /0 6 92
if the 6G-9697 Washers (21) do not fit. The 8W-2896 Washer (22) are 6 mm (0.24 inch).
56: /228
SEH 48-
S 03:
© 2 998 00
0 2 0
Cat 1C
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Con illa pill
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View of the pin that is inserted through the bore
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27. One person drives the 7I-5517 Pin Assembly (11) through the bore. One person checks for pin alignment through the hole
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for installation of the mounting blocks and bolts.
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Cat 1C
Illustration 392
erp ater g00705193

View of the truck body that is lowered onto two wood blocks
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Cat 021 C
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32. Secure the hoist cylinders with a chain. This prevents any movement of the hoist cylinders.
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Note: Refer to "Install the 8X-3380 Cylinder Mounting Gp" for the installation of the hoist cylinders to the body assembly.
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Note: The truck needs to be on a level surface. The body needs to be completely installed to the frame.
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33. Raise or lower the body assembly. The body assembly and the frame rail need to be parallel. The distance between the
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body rail and the frame rail is 42 mm (1.65 inch).
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34. Measure the distance between the body rail and the frame rail. Place the pad assemblies on top of the frame rail. Use shims
to produce a zero clearance between the rails. Finish the installation of the eight pad assemblies and shims to the body.
35. Install the two pad assemblies to the top of the main crossbeam. Align the slipper pads to the body supports. Measure the
distance between the pads. Use shims to produce 38.10 mm (1.50 inch) compression at the two locations.

View of the pads that are installed to the front of the body assembly
36. Install the 8X-3046 Shims (10), eight 8X-3045 Pads (9), 24 8T-4910 Bolts (25), 24 7D-1649 Washers (20), and 24 8T-4244
Nuts (26).
Note: Block the body in position when you install the shims and pads.
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Illustration 394
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g00705231
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8
View of the guides that are installed
56: /22
38. Install the 8X-3046 Shims (10) and two 8X-3045 Pad Assemblies (9). Use six 8T-4184 Bolts (19) and six 7D-1649 Washers
(20).
SEH 48-
Note: Refer to Illustration 368. This determines the number of 8X-3046 Shims (10) that are required.
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021 0
:
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© 2 998
00
40. Attach the arm of the body position sensor to the truck body with an 0S-1591 Bolt.
0 2 0
Note: The body position sensor will be calibrated later in the assembly procedure.
Cat 1C
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Illustration 395
ng00705260
41. Install the hoist cylinder grease lines to the bottom of the body assembly. Use 16 8T-4137 Bolts (34), 16 8T-4121 Washers
(15), and 4K-8864 Clips (35).

43. Install the grease line to the hoist cylinder.
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Cat 1C
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View of the rock ejector that is installed
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44. Use a fork lift to position the 112-6213 Ejector (38) to the body assembly.
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45. Install the 6G-7773 Pin (17). Use two 3B-4647 Cotters (18) and one 3D-0404 Washer (8). Bend the cotters with pliers. This
keeps the pin in place.
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Illustration of the rock ejector that is installed
46. Lower the rock ejector between the tires. Check the clearance on both sides of the rock ejector.
Welding Dimensions
Item Dimension
P 1310.50 ± 3 mm (52 ± 0.12 inch)

:
Table 73
Weld Tolerances
PIP
Weld Description
W5 10 mm (0.40 inch) with a 1.50 mm (0.06 inch) penetration (4 Places)
W6
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12 mm (0.47 inch) bevel groove weld (2 Places)
Table 74 202 008

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Note: Refer to Illustration 399 if the rock ejector has not been installed.
Note: The rock ejector brackets should be installed after the body has been installed.
SEH 48-
47. Attach a string and a plumb bob to the center of the bracket mounting pin in the Rock Ejector Bracket (30). Position the
03:
Rock Ejector Bracket (30) on the bottom of the truck body. The string is centered in the middle of the two tires. Check the
S
© 2 998 00
distance that separates the string and the wheel group assembly to prevent the rock ejectors from striking the wheels. The
rock ejectors that are installed should be centered in the forward position, in the rear position, and in the side position.
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48. Repeat Step 44 through Step 47 on the other side of the machine.
Purge the BrakeC

ater 1 Cat
Lines
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Personal injury could result from improperly coupled
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attachments. Be certain latches are fully engaged on both sides
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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.
Refer to Special Publication, NENG2500, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain
fluids on Cat® products.
Dispose of all fluids according to local regulations and mandates.
The make up tank and the hydraulic system should run on the same oil. Run the engine on high idle for five minutes. The air
system must have 550 kPa (80 psi).
The Front Brakes

:
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Illustration 400
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g00708302
View of the right front brake line
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0 2 0
Illustration 401
Cat 1C
g00708298
ater
View of the tool that is made
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1. Build a tool that is shown in Illustration 401. The tool is used to purge the brake valves. Connect the tool to the nipple at the
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brake line that is located on the right wheel assembly. Place the drain line in a suitable container.
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Note: The tool consists of a coupler, a gate valve, and a drain line. The pieces are assembled together with the appropriate
fittings.
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2. Open the gate valve on the tool while the engine is running. Apply the brake pedal. Ensure that there is enough air
pressure.
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Note: The tool may not be needed if the machine has a brake purge valve. If there is a brake purge valve, attach a hose to
the valve. Use a wrench to open and close the valve.
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Note: The machine is equipped with a master cylinder overstroke indicator. The indicator is located on the dash. When the
indicator comes ON and the parking brake is OFF, there is a low fluid level, air in the hydraulic circuit, or leakage in the fluid
lines.
Note: When the indicator light is ON, the switch must be manually reset before the indicator light goes out. The switch is
located on the rotochamber. Do not operate the machine until the cause is corrected.
3. Close the gate valve on the tool. Release the foot brake pedal. Ten seconds are needed for the brake oil to refill the system.
Note: Ensure that the make up tank is full. Running the engine at high idle for 20 seconds should fill the tank.
4. Repeat Step 2 and Step 3 until the brake oil is released with no air bubbles.
5. Disconnect the tool.

:
6. Repeat Step 1 through Step 4 on the left front wheel assembly.
The Rear Brakes
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Illustration of the rear brake lines
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1. Attach a drain line to the air purge valve on the right rear brake line. Place the drain line in a suitable container.
Cat 1C
Note: The tool that was used to drain the front brakes is not required for the rear brakes.
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2. Use a wrench to open the brake purge valve that is located on the rear axle housing, while the machine is running. Ensure
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that there is enough air pressure. Apply the foot brake pedal.
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lines.
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3. Open the gate valve on the tool while the engine is running. Apply the brake pedal. Ensure that there is enough air
pressure.
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Note: The tool may not be needed if the machine has a brake purge valve. If there is a brake purge valve, attach a hose to
the valve. Use a wrench to open and close the valve.
:
lines.
4. Close the brake purge valve and release the brake pedal. Ten seconds are needed for the brake oil to refill the system.
Note: Ensure that the make up tank is full. Running the engine at high idle for 20 seconds should fill the tank.
5. Repeat Step 3 and Step 8 until the brake oil is released with no air bubbles.
6. Disconnect the drain line.
7. Repeat Step 4 through Step 2 on the left front wheel assembly.
The Parking Brake

While the engine is running, actuate the parking brake switch five times. This will purge the air from the lines. Actuate the brake in
one minute intervals. The parking brake will release after the air has been purged.
Measure and Record Front and Rear Brake Baseline Measurements

Reference: Testing and Adjusting, SENR1592, "793C and 793C XQ Off-Highway Truck Air System and Brakes", "Service Brake
Discs - Check"
Brake Wear
Piston Travel Front Brake Front Brake Percent of wear Rear Brake Rear Brake Percent of wear
Baseline
Rebuild 1
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Rebuild 2
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Rebuild 3
Rebuild 4
Rebuild 5
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Rebuild 6
Rebuild 7
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Table 75
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Final Check
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With full air pressure, inspect the lines, connections, and fittings for leaks.
2
Cat 1C
Apply the service brakes when the engine is stopped. The air pressure should be between 760 kPa (110 psi) and 840 kPa
e p ThataistFully
(122 psi). Monitor the system air pressure. There should be no noticeable drop within two minutes, while the brakes are applied.
Field Test for the 793C rTruck

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1. Set the toe-out to 48.20 mm (1.90 inch). The front suspension cylinders should be fully extended.
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2. The steering system accumulators should be charged to 6550 kPa (950 psi).
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3. Check for nitrogen leaks at the suspension cylinders.
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4. The engine is OFF. The oil level of the steering hydraulic tank should be full to the top of the sight glass.
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5. At HIGH IDLE, turn the steering wheel against full left turn stop. Hold the wheel while you check for cracks and for leaks.
Repeat against the right-hand stop.
6. At HIGH IDLE, the steering wheel should go from stop to stop in 3 to 5 seconds.
7. Steering wheel should have a tight feel from proper retaining nut torque and bearing fit.
8. Check the tilt steering wheel.
9. This following information is for the test of the steering system. The steering system should be fully charged and the truck
should be off. The accumulators should discharge and the steering pressure should drop to zero in 20 seconds. The steering
system should be fully charged. Stop the engine from the ground level shutdown switch. The steering pressure must NOT
drop. Release the brake and steer from stop to stop two times. This test will check the secondary steering system. The level
3 warning must activate.
10. Check for air leaks. Run the truck, until the air pressure is at 827 kPa (120 psi). The air dryer should exhaust at pressures
above 827 kPa (120 psi). Shut off the engine and apply all three brakes. Apply each brake for two minutes. Listen for leaks,
while you are watching the air gauge. The air system must not leak over 3.40 kPa (0.50 psi) per minute.
11. Park the truck on a slight grade. Shut off the engine. Purge the air out of the brakes, until low air pressure locks the springs
in the brakes. Turn on the towing switch. The truck should roll. This indicates that the towing switch has overcome the spring
pressure. When the brakes lock up, the brake light comes on.
12. Park the truck on level ground. Put the truck in first gear. Check the brake holding ability with the engine at 1300 RPM.
Check the foot brake, the retarder, and the secondary brake separately. The truck should barely move or the truck should
not move at all. Apply all three of the brakes. The truck should not move at all.
13. While the truck is in LOW IDLE and in NEUTRAL, engage the parking brake and depress the ELEVATED LOW IDLE switch
behind the operator's seat. The engine speed should automatically increase to 1300 ± 100 N·m (959 ± 75 lb ft). If the
engine speed does not increase, adjust the valve. Depress the throttle foot pedal and release the throttle foot pedal. The
engine speed should return to standard LOW IDLE. Release the parking brake. The engine speed should return to standard
LOW IDLE.
14. Check the Automatic Electronic Traction Aid (AETA). Turn on the AETA Switch. Drive to the right in a tight circleat LOW
IDLE. Drive in a tight circle to the left. The turning radius for both circles should be similar.
Note: The steering system should be adjusted properly for the test accuracy.
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15. Check the transmission neutralizer. Back up the truck, while you raise the body assembly. The transmission should shift into
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NEUTRAL. If the shifter is in REVERSE and the hoist lever is moved to the power down position, the transmission should shift
to NEUTRAL.
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16. Check the tire pressure. 008
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8
The Goodyear bias ply tire holds 723 kPa (105 psi) of air pressure.
56: /22
The Goodyear radial tire holds 758 kPa (110 psi) of air pressure.
SEH 48-
The Michelin radial tire holds 689 kPa (100 psi) of air pressure.
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The Bridgestone radial tire holds 703 kPa (102 psi) of air pressure.
© 2 Procedure
Perform the Commissioning 998 for the00Machine
0 2 0
1C
Check all fluid levels. The fluids should be properly filled before the commissioning procedures begin.
Cat
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0 2 0
Cat 1C
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The engine crankcase contains 307 L (81 US gal) of 5P-2586 Oil. The oil is a SAE 10W30 oil.
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The coolant system contains 568 L (150 US gal) of 2P-9868 Coolant for the 793C (S/N: 4AR1-UP) and 681 L (180 US gal) of
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119-5148 Coolant for the 793C (S/N: 4GZ1-UP; ATY1-UP). Refer to the Operations and Maintenance Manual for the proper
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mixture of coolant and water for certain applications.
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The hydraulic tank for the transmission and the torque converter contain 224 L (59 US gal) of 2P-9869 Oil. The oil is a SAE
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30W oil and the oil contains a red dye.
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The hydraulic tank for the hoist and brakes contains 909 L (240 US gal) of 3P-0659 Oil. The oil is a SAE10W.
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The steering hydraulic tank has a capacity of 129 L (34 US gal) of 2P-9063 Hydraulic Fluid. The hydraulic fluid is a SAE 10W
oil. DO NOT attempt to fill this tank while the engine is running. Fill the steering hydraulic tank when the engine is OFF. The
fluid should appear in the middle of the upper sight glass. Refer to the Operations and Maintenance Manual for the
Diagnostic Pressure Ports for the truck.
Air pressure can be taken from the line for the air start tank.
The steering pressure tap is for standby pressure that is on the right side of the inside of the frame. This is close to the rear
engine mount.
The steering pressure tap for standby cut-in pressure and the cut out pressure is on the left side on the bottom of the
steering valve.
The torque converter outlet pressure tap is located on the converter valve body that is below the lockup.
The torque converter lockup switch is located on the lockup valve on the rear of the converter housing.
The transmission pump pressure tap is located on the right side of the transfer gear housing on the transmission.
The transmission lube oil pressure tap is on the right side of the engine transfer gear housing that is located on the
transmission.
The hoist pressure tap is located on the hoist pump on the inside of the right-hand frame.
The two AETA taps are located on the AETA valve. The valve is located on the right side of the frame. The right-hand wheel
is located on the rear port.
The towing motor tap is located on the top left side of the differential housing.
The brake retracting motor contains the same tap as the towing motor.
Look for parts that are damaged or parts that are missing.
Look for loose connections, loose fasteners, and joints.
Look for leaks underneath the truck.
Use the Service Manual to correct any problems.
PIP
Check the Configuration of the Electronic Control Modules
(ECM) -11
202 008
1 6
Reference: Service Manual, SENR9122, "Electronic Programmable Transmission Control (EPTCII)"Service Manual, SENR1503,
/0 92
"769D, 771D, 773D, 775D, 784C, 785C, 789C, and 793C Off-Highway Truck/Tractors Brake Electronic Control System"Service
15: 8
56: /22
Manual, SENR6059, "Vital Information Management System (VIMS)"
SEH 48-
S99 03:00
8
:
21/ 869
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56: 2
SEH 48-
This section contains assembly checks and functional checks of systems. Perform the checks before you deliver the machine to a
customer.
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© 2 998 00
1. Connect a laptop computer to the Caterpillar Diagnostic Connector on the fuse panel behind the operator seat. The laptop
0
computer should have 139-4166 Cable, 7X-1700 Communication Adapter, 7X-1425 Cable, and a NEXG4523 Service
Program Module.
Cat 0 2 1C
2. To power the electrical system of the truck, perform the steps that follow:
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a. Connect the batteries. ater
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b. Turn the battery disconnect switch ON.
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c. Turn the manual engine shutdown switch OFF.
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d. Turn the key of the machine ON.
e. DO NOT START THE TRUCK.

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Note: When the key is in the ON VIMS will perform a four to six second self test. Disregard the VIMS self test at this time.
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3. Start the Electronic Technician (ET). The Electronic Technician (ET) lists all of the electronic control modules of the machine.
There will be at least an "ENGINE CONTROL", "POWER TRAIN CONTROL" and a "BRAKE CONTROL". If the truck has the
Automatic Retarder Control (ARC), the ET screen should show the features.
4. The Electronic Technician (ET) should display the truck model for each control. Make sure that the model is correct for each
control.
5. Choose the "ENGINE CONTROL". Next, choose "CONFIGURATION".
6. Change the EQUIPMENT IDENTIFICATION NUMBER to correspond to the PIN of the truck. If you select a new setting,
select "ENTER". This confirms the change.
7. Check the "ENGINE SERIAL NUMBER". The "ENGINE SERIAL NUMBER" must match the engine serial number on the
engine. If you select a new setting, select "ENTER". This confirms the change.
8. Adjust the "FUEL RATIO CONTROL", if necessary. The air/fuel ratio is adjustable. The range is -25 to 25. The factory default
is 0. If you select a new setting, select "ENTER". This confirms the change.
9. Check the "FAN CONTROL" setting. On a truck that is equipped with the variable speed fan, the "FAN CONTROL" must
be ON. On a truck that is equipped with a fixed speed fan, the "FAN CONTROL" should be OFF. If you select a new
setting, select "ENTER". This confirms the change.
10. Check the "ETHER CONTROL" setting. Set the "ETHER CONTROL" to the "ON" position. If you select a new setting,
select "ENTER". This confirms the change.
11. On 793C (S/N: 4AR1-UP) Off-Highway Trucks, check the "OIL RENEWAL CONTROL" setting. On a truck that is equipped
with the oil renewal attachment, the "OIL RENEWAL CONTROL" must be set to "ON". After you set the engine oil renewal
solenoid to "ON", the "OIL TO FUEL" ratio must be set to "ON". After you set the engine oil renewal solenoid to "ON",
the "OIL TO FUEL" ratio should be set. The "OIL TO FUEL" is adjustable in a range from -50 to 50. The factory default is 10.
If you select a new setting, select "ENTER". This confirms the change.
12. Check the "ENGINE OIL PRE-LUBE" setting. On a truck that is equipped with the engine pre-lube attachment, "ENGINE
OIL PRE-LUBE" must be ON. If you select a new setting, select "ENTER". This confirms the change.
13. Check the "COOL CYLINDER CUT-OUT". If you select a new setting, select "ENTER". This confirms the change.
14. Check the "SHUTTER CONTROL" setting. On a truck that is equipped with an attachment shutter, "SHUTTER CONTROL"
must be ON.
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15. Return to the engine control screen. Select "ACTIVE CODES". Select the "INCLUDE ALL ECM'S" button. The button is at
202 008
the bottom of the screen. If "NO ACTIVE CODES" appears , then continue. Refer to Service Manual, SENR6059, "Vital
Information Management System (VIMS)". This will help to resolve the active faults.
15:
events from the engine ECM. 1 0 6
Note: A factory assigned password clears events that are logged on the engine ECM. This is the only way to clear the
/ 92
56: /228
16. Return to the engine control screen and select "LOGGED CODES". Select the button at the bottom of the screen
"INCLUDE ALL ECM'S". Clear all codes that are logged. Refer to Service Manual, SENR6059, "Vital Information
SEH 48-
Management System (VIMS)".
S 03:
17. Return to the engine control screen and select "DIAGNOSTICS" and "EVENTS". Select the button at the bottom of the
© 2 998 00
screen "INCLUDE ALL ECM'S". Clear all of the codes that are logged. Refer to Service Manual, SENR6059, "Vital
Information Management System (VIMS)".
0 2 0
Note: A factory assigned password clears events that are logged on the engine ECM. This is the only way to clear the
Cat
events from the engine ECM.
1C
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18. Return to the engine control screen and select "SERVICE", "CALIBRATIONS", and "INJECTOR CODES CALIBRATION".
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Select "PRINT" at the bottom of the screen. Select a print destination.
Note: Step 22 provides a record of the injector code for each cylinder. The codes may accidentally change. The injector
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codes are stamped on the injector. If an injector is changed, the new injector code must be updated in the engine ECM.
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19. The engine prelube and the ether control can be tested without starting the engine. The engine prelube and the ether
control can be tested.
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a. Return to the engine control screen and select "DIAGNOSTICS" and "OVERRIDE PARAMETERS". Select "START AID"
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and "CHANGE". The ether solenoids will energize. Select "CHANGE" again. Turn the feature "OFF".
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b. Return to the engine control screen and select "DIAGNOSTICS" and "OVERRIDE PARAMETERS". Select "ENGINE
PRELUBE" and "CHANGE". The prelube motor will energize. Select "CHANGE" again. The prelube motor will de-
energize.
20. Return to the ET menu. Select "DATA LINK", "SELECT ECM", "POWER TRAIN CONTROL", and "CONFIGURATION". On
the configuration screen, check and adjust the following parameters. Refer to Service Manual, SENR9122, "Electronic
Programmable Transmission Control (EPTCII)".
a. The "EQUIPMENT NUMBER" and the customer number should match. Make the changes to the numbers, as needed.
b. Check the "TRANSMISSION SERIAL NUMBER". "TRANSMISSION SERIAL NUMBER" should match the transmission
serial number on the transmission. If you select a new setting, select "ENTER". This confirms the change.
c. Check the "TRANSMISSION MAXIMUM GEAR" setting. The transmission maximum gear setting is adjustable from
four to six. If you select a new setting, select "ENTER". This confirms the change.
d. Check the "BODY UP GEAR LIMIT" setting. The body up gear limit is adjustable from one to four. If you select a new
21. Return to the Electronic Technician screen. Select "DATA LINK", "SELECT ECM", "BRAKES", "AUTO RETARDER", and
"CONFIGURATION". From the configuration screen, check and adjust the following parameters. Refer to Service Manual,
SENR1503, "769D, 771D, 773D, 775D, 784C, 785C, 789C, and 793C Off-Highway Truck/Tractors Brake Electronic Control
System".
b. Check the "TRANSMISSION SERIAL NUMBER". The "TRANSMISSION SERIAL NUMBER" should match the
:
transmission serial number on the transmission. If you select a new setting, select "ENTER". This confirms the change.
c. Check the "TRANSMISSION MAXIMUM GEAR" setting. The maximum transmission gear selection is adjustable from
four to six. If you select a new setting, select "ENTER". This confirms the change.
d. Check the "BODY UP GEAR LIMIT" setting. The body up gear limit is adjustable from one to four. If you select a new
PIP
22. Return to the Electronic Technician screen. Select "DATA LINK", "SELECT ECM", "BRAKES", "AUTO RETARDER", and
-11
"CONFIGURATION". From the configuration screen, check and adjust the following parameters. Refer to Service Manual,
202 008
SENR1503, "769D, 771D, 773D, 775D, 784C, 785C, 789C, and 793C Off-Highway Truck/Tractors Brake Electronic Control
System".
15: 1 /0 6 92
56: /228
b. Check the "DESIRED ENGINE AUTO RETARDER SPEED". The engine automatic retarder speed that is desired is
SEH 48-
adjustable from 1850 RPM to 1950 RPM. If you select a new setting, select "ENTER". This confirms the change.
S 03:
c. Use the VIMS keypad module. Enter "8378" and press "OK". This will initiate the "VIMS SELF TEST". Refer to "VIMS
© 2 998 00
Self Test" in the Operations and Maintenance Manual.
0 0
d. With the laptop computer that is connected to the diagnostic port, continue to the next step. Use the laptop computer
2
ater 1 Cat
CEngine
again after the engine has been started.
Prepare to Start the
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1. Verify that the fluid levels are at a safe level.
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2. Disable the engine at ground level. The engine should be shut off, so the engine will not start.
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3. Prime the pump drive housing and the hoist pump with 3P-0659 Oil or crank the engine. Crank the engine over two times
for 15 seconds, while the engine is locked out. This will fill the compartments with oil.
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4. Start the engine. Verify that the pressures are safe for operation. Run the engine until normal operation temperatures are
reached. All the fluid levels should be adjusted, as required. Run the engine for 5 seconds for the first two starts. Check and
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fill the hydraulic transmission, the steering, the radiator, and the engine, as needed. Restart the engine and check for leaks.
Run the engine for 30 seconds and then run the engine for 60 seconds. Check the ground for leaks.
5. Refer to Service Manual, SENR6059, "Vital Information Management System (VIMS)" for additional information. There are
three levels of warnings. Level 1 is one red light. Level 2 is two read lights "ON". Level 3 is two red lights "ON" and the
alarm sounds.
The coolant temperature is 2.
The coolant flow is 3.
The engine oil pressure is 3.
The brake air pressure is 3.
The transmission oil filter is 2.
The converter or return oil temperature is 2.
The brake ON is 1 or 3.
The alternator is 1.
:
The fuel level is 1 with a 10 second delay.
The steering is 3.
6. Disconnect the cable, the adapter, and the module that is running the Electronic Technician (ET) from the laptop computer.
Connect a 127-9797 Cable to the RS-232 port on the laptop computer. Connect the other end of the 127-9797 Cable to
the diagnostic port in the panel behind the operator's seat. Observe the gauges, the warning lights, and the service lights
with the laptop computer during the truck operation.
7. The low brake pressure indicator causes the alert indicator to flash. The VIMS Message Center should provide the following
instruction: "Do Not Move Machine". This message is on display until the starting and service reservoir is charged to one-
half of the maximum operating pressure. Do not turn off the parking brake switch until the correct pressure is obtained. The
warning horn will sound.
8. Take notes on all of the events that are recorded on the message center. Resolve the events before you proceed.
PIP
9. Start VIMS-PC software. Use VIMS-PC software to clear all faults that are logged on VIMS memory.
-11
Note: The logged events cannot be cleared when you are using the VIMS Keypad module.
202 008
10. Select "VIMS-PC COMMUNICATE" from the "VIMS-PC" group. Refer to Service Manual, SENR6059, "Vital Information
1
Management System (VIMS)", "Downloading Data From The Machine".
15: /0 6 92
8
11. Select "DATA" and "DOWNLOAD DATA". Choose a destination and select "STANDARD DATA". Then select "OK".
56: /22
Note: Remove faults that are logged on the VIMS memory.
SEH 48-
12. The yellow light should activate when the retarder is engaged.
03:
13. The engine should be at normal operation temperature and the transmission should be in neutral. Check the "HIGH" idle
© 2 998S
speeds (1960 ± 40 RPM) and the LOW idle speeds (700 ± 15 RPM). The RPM ranges cannot be changed.
00
Note: After the engine has been started, the automatic elevated low idle will activate in ten minutes. The low idle comes up
0 0
gradually at the rate of 33 RPM per second. The transmission should be in "NEUTRAL" and the parking brake should be
Cat 2
ON. Do NOT depress the pedal for engagement.
1C
Note: After the activation of the elevated idle speed, the operator may reset the 10 minute delay by tapping the throttle
erp ater
pedal to more than 25% of the pedal's travel. If the coolant temperature rises above 70 °C (158 °F) engine speed returns to
low idle.
Con illa pill
fide r: ar I
14. Push the ground level shutdown switch. This shuts down the engine. The steering accumulator tanks will not drain. Wait for 5
seconds. Turn the key to the off position. Listen for the tanks to drain. The steering accumulator pressure drops to zero
before you start the truck.
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At operating temperature, the steering oil is hot and under
n
pressure. Hot oil can cause burns.
To prevent possible personal injury, release the pressure in the

steering system before the lines are disconnected or removed.
15. Bring the air pressure governor to the proper level for a maximum pressure of 827 ± 34 kPa (120 ± 5 psi). Purge the air
pressure to 455 kPa (66 psi). A Level 3 warning should occur at a pressure of 455 kPa (66 psi).
16. Check the air dryer. The air dryer should expel air at 827 kPa (120 psi).
17. The dryer should have 24 Volts or more.

:
18. The hoist pressure for the 793C (S/N: 4AR1-UP) is 20,670 ± 345 kPa (3000 ± 50 psi). The hoist pressure for the 793C (S/N:
4GZ1-UP; ATY1-215) is 20,720 ± 350 kPa (3005 ± 51 psi).
Note: The power down pressure for the 793C (S/N: 4AR1-UP)is 3445 ± 345 kPa (500 ± 50 psi) at high idle. The power down
pressure for the 793C (S/N: 4GZ1-UP; ATY1-215) is 3625 ± 175 kPa (525 ± 25 psi) at high idle. The system should recover to
full pressure within 1 second.
19. Check the hoist pressure. Hoist pressure occurs when the system powers up and when the system powers down. When the
system is in the middle detent the system pressure is zero.
20. The transmission does not shift into reverse with the hoist lever that is raised. The truck must be shifted to the forward gears
with the hoist lever that is raised.
21. The cut-in pressure is 19,200 ± 200 kPa (2785 ± 29 psi).
22. The cut out pressure is 21,400 ± 200 kPa (3100 ± 29 psi).
23. The maximum standby pressure is 3600 kPa (522 psi).
24. The lube oil pressure for the transmission in NEUTRAL at LOW idle is 5 kPa (0.73 psi) to 65 kPa (9 psi). The lube oil pressure
for the transmission in NEUTRAL at HIGH idle is 115 kPa (17 psi) to 210 kPa (30 psi).
25. The minimum charge oil pressure for the transmission in LOW idle is 2480 kPa (360 psi). The maximum charge oil pressure
for the transmission in HIGH idle is 3203 kPa (465 psi).
PIP
26. The torque converter pressure at lockup is 2136 ± 69 kPa (310 ± 10 psi) at 1300 RPM.
-11
27. The maximum pressure for the torque converter outlet is 551 kPa (80 psi) at high idle.
202 008
28. As the shift cane moves through each gear, the indicator will flash the correct gear. As the gears shift the engine speed
1
increases. This indicates that the throttle control shifting chip is programmed.
15: /0 6 92
8
29. Properly control the throttle shifting through all of the gears. As you shift up and down the brakes must be off.
56: /22
30. Check the downshift inhibitor. At HIGH idle, shift the transmission from sixth gear through all of the gears to first gear. The
SEH 48-
transmission should not downshift.
03:
31. Check the reverse shift inhibitor. With the transmission in first gear and travel speed at 10 mph, shift the shift cane into
© 2 998S
reverse. The transmission will shift into NEUTRAL. The transmission will shift into reverse at 3 mph.
00
32. Check the transmission neutralizer switch. The engine will start in neutral only. Try to start the engine in first gear and
reverse.
0 2 0
Cat 1C
33. With the engine that is turned off, shut the cab doors and windows. Engage the retarder and apply the secondary brake and
erp ater
the foot brake. Listen for air leaks. Watch the air gauge for a drop after the initial drop from the brake engagements. The
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pressure should remain at 3.5 kPa (0.51 psi) per minute. Hold the engagement for 3 minutes. The maximum drop in air
pressure is 10 kPa (1.45 psi).
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34. Test the air system overnight. Leave the truck shut down overnight. The air tank should contain 827 kPa (120 psi). The air
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tank should contain enough air. The engine should start the next morning. The truck requires 518 kPa (75 psi) to start the
engine.
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35. Check the pressure for the AETA control. There should be 2482 kPa (360 psi) to 4895 kPa (710 psi).
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Note: When both the retarder and the AETA switch are on, the pressure drops off. The pressure first drops off on the left
n
side. The pressure then drops off on the right side.
36. The parking brake indicator must flash when the parking brake is engaged.
37. A Level 3 warning will activate when all the following conditions occur:
:
een
The engine is running.
The transmission is in forward or reverse.
The parking brake is ON.

Note: Trucks that are operating with a VIMS system need ground speed to activate the warning.
38. The parking brake warning light flashes when the secondary brake is engaged. A Level 3 warning will activate when the
following conditions are true:
The engine is running.
The transmission is in forward or reverse.
The parking brake is ON.

Note: Trucks that are operating with a VIMS system need ground speed to activate the warning.
39. Check the towing motor. The motor should have a minimum of 3790 kPa (550 psi).
40. The current draw of the towing motor should be 12 to 22 amperes at high pressure.
41. The brake retract pressure is 4685 ± 207 kPa (680 ± 30 psi).
Activate the Body Hoist Controls

The truck might appear to have a problem with the body hoist controls. The 184-4671 Software Group will set the parameters for
the hoist system.
Note: ET Software must be used to set these parameters on all trucks.
Note: On the 2.4 ET Software, when the parameters are not visible or accessible on the configuration screen, disconnect the
connection and reconnect the connection. This establishes the communication to the transmission control, until the parameters
appear.
PIP
Note: On the 3.0 ET Software, the parameters appear clearly on the configuration screen.
- 110
Note: On the 3.1 ET Software, the figures will appear on the configuration.
20Valve
Adjustment of the Hoist Lower
21/ 0869
15: 08/2
The valve control for lowering the hoist is adjustable. This compensates for the differences between the valves. The adjustment
2
range is -5 to +5 with zero as the default. A positive adjustment factor will increase the lower valve command. This causes the
56: 2
body to come down harder. A negative adjustment factor will decrease the lower valve command. This causes the body to come
down softer.
SEH 48-
03:
The Valve Adjustment for the Lower Hoist may not be available on earlier ECM systems. The adjustment range may be from 0 to
S
10 with 5 as the default on some early ECM systems.
© 2 998 00
Note: When the Valve Adjustment for the Lower Hoist is set too high, too much oil can be diverted to the hoist system while the
0 0
hoist system is in float mode. This causes the brake oil to heat up faster. Retarding capability is also decreased. To set the Valve
2
Cat 1C
Adjustment for the Lower Hoist, follow the procedure below.
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1. Raise the body of the truck and place the body pins.
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2. Place a 6V-7830 Tetragauge or place a 3.45 MPa (500 psi) gauge with a hose extension on the outlet port of the hoist
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pump.
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Note: Remove the body pins and lower the body to the frame.
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3. While the body is down, place the hoist lever in hold.
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4. Enter the configure parameter screen through the service menu in the Electronic Technician.
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5. Change the Hoist Lower Valve to a desired setting from -5 to 5. 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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Note: If you are using a 3.45 MPa (500 psi) gauge, remove the gauge from the extension.
6. Raise the body to the middle position.
7. Lower the body to the frame.
8. If a 6V-7830 Tetragauge is not installed, shut off the engine and install a 3.45 MPa (500 psi) gauge. Start the engine and run
the engine to high idle. Cycle the hoist lever to the BODY FLOAT position and the HOLD position. Do not power down or
raise the bed if you are using a 3.45 MPa (500 psi) gauge. Damage may occur to the gauge.
9. With the engine that is running, place the hoist lever in the BODY FLOAT position.
10. Run the engine to high idle. Verify that the pressure at the hoist outlet port is less than 1723 kPa (250 psi).
Note: When the pressure is greater than 1724 kPa (250 psi), the adjustment is set too high. This causes too much oil to be
diverted to the hoist valve. This causes the brake oil to overheat when the body is in the BODY FLOAT position. Lower the
adjustment of the Hoist Lower Valve. Repeat Step 1 through Step 3. This lowers the pressure below 1724 kPa (250 psi).
Note: The pressure can be checked after each resetting of the adjustment in ET. Cycle the hoist lever from the HOLD position to
the BODY FLOAT position. If you change the adjustment setting and there is no corresponding pressure setting, cycle the lever
again. A change will occur in the settings between 2 and 5.
Enable the Hoist System

The Hoist Enable Parameter is set to 2 for all trucks with the 184-4671 Software Group. Parameter Value 2 is a test mode.
Parameter Value 2 will prevent the hoist cylinders from being activated by accident. After the body is installed, change the
Parameter Value to 1. The hoist system should function properly. When the hoist system does not work, check the items below.
1. Verify that the hoist system is enabled in the Configurable Parameters Screen through the service menu in the Electronic
Technician.
Parameter Setting for the Hoist
Parameter
Description
Value
The hoist system is not installed.

0 a hoist lever that will not function
No diagnostics will be logged on the hoist lever or the solenoids.
1
PIP The hoist system is installed and enabled.
-11 The hoist system is installed but disabled.

2
202 008
The solenoids and the hoist lever have diagnostics, but the hoist lever is ignored. The solenoids are kept
in hold.
Table 76
15: 1 /0 6 92
56: /22 8
2. Disconnect ET and then reconnect the line when the Hoist Enable Status does not appear on the configuration screen. The
SEH 48-
hoist enable parameter flexes with the 3.0 ET Software when the parameter connects. On certain occasions, the flexed
parameters are missed by the ET at the times of connection.
03:
Note: This parameter is standard on the configuration screen with3.1 ET Software.
S
© 2 998 00
3. If the Hoist Enable Status does not change, check the following condition:
0 2
The engine should not be running.
0
Cat 1C
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:
EH -03
© 2 998 :00S
0 2 0
Cat 1C
The truck should not be moving.
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Zero the TOS to change the parameter.
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The engine causes the TOS signal to fluctuate. This keeps the parameter from changing.
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Note: Press the F5 button to go directly to the configuration screen.
fidSensor
Calibrate the Body Position
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ial
Refer to Testing and Adjusting, SENR1502, "784C, 785C, 785D, 789C, 793C and 793D Off-Highway Truck/Tractors Power Train
Gre
Electronic Control System" for instructions on calibrating the body position sensor.
Body Down Snub Function

en
The body down snub function cushions the shock when the body hits the bed of the truck. When the body is lowered, the body
up switch detects the position of the body. When the body is close to the rail of the truck The ECM will go into snub mode.
When the operator's request is less than the snub mode, the ECM will use the operator's request. This ensures that the snub
function will never cause the body to go down faster than the hoist lever modulation (operator's request).
The body down snub function will be cancelled as the operator moves the hoist lever out of the body float position or the body
lower position. The body down snub function will not start, until the body goes above the body up switch activation level.
Seat Controls
1. Check the following adjustments:
The distance from the front of the seat to the rear of the seat is 150 mm (6 inch).
The height is 75 mm (3 inch).
Adjust the weight for the suspension to the correct ride position.
The seat cushion has two positions.
The back cushion has three positions.
Seat Belt
1. Adjust the seat belt to the proper length.
2. Fasten the seat belt buckle around the lap. The length of the belt may not slip.
3. The belt should unlatch.
Instrument Panel
1. Turn the ignition key to the "ON" position. This supplies the power to the electrical circuits in the cab. The dome lights and
the windshield wipers can be checked.
1. Turn the key to the "START" position. This activates the starting motor. The diesel engine starts. After the engine starts,
release the key to the "ON" position.
PIP
-11
2. Turn the ignition switch to the "OFF" position. The engine should stop. The electrical circuits in the cab should de-energize.
202 008
The instrument panel lights, the headlights, and the taillights remain on.
Climate Control
15: 1 /0 6 92
56: /228
48-
03
:
202 11008
15: 1 /0 6 92
56: /228
1. To pressurize the cab, complete the following steps:
SEH 48-
Turn the ignition key to the "ON" position.
S 03:
Turn the switch for the blower to the "LOW" position.
© 2 998 00
Turn the blower switch to the "HIGH" position.
0 2 0
There should be an audible sound.
Cat
2. Check the heater:
1C
erp
Start the engine. ater
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The lines for the heater valves should be open.
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Turn on the heat control. The air should be warm.
3. Check for air flow:

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Turn the fan control switch to the "LOW" position or the "HIGH" position.
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Check for air flow from the dash assembly and from the seat supports.
Windshield Wipers
1. Turn the ignition key to the "ON" position. Turn the wiper switch to the three positions. The three positions are "OFF",
"LOW", and "HIGH". The front wipers and the rear wipers must operate in both modes.
2. Depress the wiper switches. This will activate the windshield washers.
3. Turn the switches to the "OFF" position. The front wiper arms and the rear wiper arms should return to the proper position.
Running Lights
1. The ignition switch should be in the "OFF" position. Push the three position switch from the "OFF" position to the middle
position. The instrument panel lights and the taillights should be on.
2. Push the switch to the up position. The front headlights should be on.
Flood Lights
1. Turn the ignition key to the "ON" position.
2. Push the switch from the "OFF" position to the "ON" position. The flood lights should be on.
Secondary Flood Lights

1. Turn the ignition key to the "OFF" position. Push the switch for the access ladder to the opposite direction. The lamps for
the access ladder should be on.
Check the switches in the cab and at ground level.
2. Push the switch for the engine compartment at ground level. The switch is in the bumper assembly. The lamps in the engine
compartment should be on.
Dome Lights
:
PIP
2. Turn the switch for the dome light "ON" and "OFF".
Cigar Lighter
-11
202 008
15: 1 /0 6 92
2. Push the cigar lighter inward. The cigar lighter should pop out.
Machine Horns
56: /22 8
The ignition switch should be in the "OFF" position. Press the horn. The horn should sound.
Machine Operation SEH 48-

S 03:
© 2 998 00
1. Operate the machine for a minimum of 15 minutes. Operate the machine in all gears and perform steering maneuvers.
0
Perform braking operations. Operate the implement systems while you are operating the truck.
Cat
2. Correct any problems: 0 2 1C
Harsh Braking
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Jerky steering
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Unusual noises
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The Rear Axle Filtration Filter
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the Lubrication Filter nc.
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The truck comes from the factory with a 6 micron filter element for the rear axle lubrication and the filtration system. The filter
element is inside of the 132-2820 Oil Filter. The filter is mounted on the rear differential. Operate the truck for 8 hours with the 6
r een
micron filter element. Install a 1R-0773 Filter Element after the clean up period. The filter element is a 20 micron filter element.
Transmission and Torque Converter Filters

The filter elements for the 133-1294 Transmission Charge Filter and the 6E-5927 Torque Converter Charge Filter should be
changed after 8 hours of operation. Install the 1R-0741 Filter Element in the 133-1294 Transmission Charge Filter. Install the 1R-
0741 Filter Element into the 6E-5927 Torque Converter Charge Filter. Install the 126-7840 Oil Filter.
Brake Cooling Oil Filters

The filter elements for the 125-6712 Front Oil Cooler Filters should be changed after 8 hours of operation. Install the 1R-0741
Filter Element in the 125-6712 Front Oil Cooler Filters. The filter is mounted on the left-hand frame behind the front wheel.
Parking Brake Release Oil Filter

The filter elements for the 8E-0764 Parking Brake Release Oil Filter should be changed after 8 hours of operation. Install the 1R-
0741 Filter Element in the 8E-0764 Parking Brake Release Oil Filter. The filter is located in front of the hydraulic tank on the right-
hand side of the machine.
Checks Before the Delivery of the 793C Truck

The page that is following is a list of assembly checks and systems checks that are recommended. Do this checklist before the
truck is delivered to the customer. Do all of the checks and verify that the systems function properly.
Use the Service Manual and use the Operation and Maintenance Manual to correct any system problems before you deliver the
truck.
After you complete the final check, please sign your name and the name of the dealer.
:
Make copies of the check procedure. Mail the copies to the following address:
Caterpillar Inc.
Attention: CMT Product Support
777D Truck and 776D Tractor
N. 27th and Pershing Road
Decatur, IL 62525
Dealer:____________________
Customer:____________________ PIP
-11
202 008
Product Identification Number:____________________
1
1. Before you start the engine, make sure that all hydraulic systems are full. Also, make sure that all pump case drains are full.
15: /0 6 92
8
2. Check that the system pressures are set correctly.
Pump
56: /22
YES ____NO ____
SEH 48-
Brake
S 03:
YES ____NO ____
© 2 998 00
Steering Pressure
0 2 0
Cat 1C
ater
YES ____NO ____
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Transmission
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YES ____NO ____
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Torque Converter
YES ____NO ____ ntia

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Differential
YES ____NO ____
3. Check the machine lights.

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Operational
YES ____NO ____
Cab and Dash
YES ____NO ____
4. Check the controls in the cab.
Check if the cab door opens. Check if the cab door closes.
YES ____NO ____
Check if the Operation and Maintenance Manual is in the literature pouch on the back of the operator's seat.
YES ____NO ____

:
Check if the horn functions.
YES ____NO ____
Check if the windshield wipers and washers function.
YES ____NO ____
Check if the seat belts operate.
YES ____NO ____
Check if the fan switch operates.
YES ____NO ____
Check if the heater functions.
YES ____NO ____
PIP
Check if the air conditioner functions.
-11
202
YES ____NO ____
008
1
Check the test light. The test light is for the EMS.
15: /0 6 92
8
YES ____NO____
56: /22
Check if the hour meter operates.
YES ____NO ____

SEH 48-
S
Check if the implements operate:
03:
Hoist
© 2 998 00
YES ____NO ____
0 2 0
Cat 1C
ater
Steering Action
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YES ____NO ____
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Check if the steering column functions.
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YES ____NO ____
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Check if the parking brake functions.
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YES ____NO ____
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5. Check if all fluid levels are full.
YES ____NO ____
6. Correct any unusual noises or unusual leaks.
YES ____NO ____
7. Check if all lubrication lines are filled with grease.
YES ____NO ____

:
8. Check if all quality requirements are fulfilled. Check if all variances have been corrected.
YES ____NO ____
9. Check if the backup alarms function.
YES ____NO ____
10. Check if the machine is repainted to the factory specifications.
YES ____NO ____
11. Check if there was damage to the machine from shipment.
YES ____NO ____
12. Check if all required parts were shipped with the machine.
YES ____NO ____
13. Check if a baseline measurement has been taken for both the front and rear brakes.
YES ____NO ____
14. Sign your name in the space below.
Hydraulic ________________
PIP
Electrical ________________
Structural ________________
-11
Other ________________
202 008
15. Comments
15: 1 /0 6 92
PIP-11008692
2021/08/22
56: /22 8
15:56:26-03:00
SEH 48-
03:
i01289464
© 2021 Caterpillar Inc.
Caterpillar:
© 2 998S 00
0 0
Confidential Green
Cat 2 1C
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nc.
:

793C Armado

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793C Armado

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2015/12/11 Assembly Procedure For The 793C Off-Highway Truck {7000, 7960} (SEHS9980)

SMCS - 7000,7960 i06558755

Con illa pill

Improper assembly procedures could result in injury or death.

Qty Part Number

16 5P-8245 Hard Washer

20 5P-1075 Hard Washer

6 8T-4896 Hard Washer

1 124-8213 Cab (1)

Qty Part Number Description

16 5P-8245 (Hard Washer)

20 5P-1075 Hard Washer

6 8T-4896 Hard Washer

1 8X-4303 Rail As (1)

1 8X-4304 Rail As (3)

1 155-6730 Handhold As (1)

1 8X-5545 Handhold As (1)

2 144-9447 Handhold As (1)

2 144-9449 Handhold As (1)

1 138-6709 Handhold As (1)

1 8X-3835 Cab Side Rail Assembly (1)

1 101-1546 Cab Rail Assembly (1) (2)

1 145-2814 Handhold As (1) (3)

1 152-7016 Cab Rail Assembly (1) (4)

1 159-2037 Rail As (1) (5)

Qty Part Number Description

1 9X-1439 Flood Lamp Gp

2 3B-4605 Cotter Pin

2 8T-6868 Bolt (2)

4 5P-1076 Hard Washer

14 8T-4121 Hard Washer

1 134-0987 Bracket Assembly

2 8T-4176 Bolt (3)

1 137-2122 Tube As (4)

1 137-2129 Bracket (5)

1 8X-4285 Plate Assembly

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115 8T-4121 Hard Washer

1 131-3936 Film (1)

1 100-9984 Film (1)

Qty Part Number Description

2 5T-5202 Bearing Cap

2 6V-0836 Retaining Ring

8 6V-8237 Hard Washer

2 9T-8910 Front Suspension Gp (1)

4 8T-4121 Hard Washer

2 5P-0562 Wire Lock

2 7X-4801 O-Ring Seal

8 5P-1076 Hard Washer

2 159-0038 Final Drive, Brake, and Wheel Gp (1)

Qty Part Number Description

1 8X-0496 Axle Shaft (RH)

1 8X-0497 Axle Shaft (LH)

2 1V-6659 Retaining Ring

Qty Part Number

Hoist Cylinder Gp (1)

Qty Part Number Description

1 6V-5051 O-Ring Seal

11 8T-4121 Hard Washer

1 131-7956 Fuel Tank Gp (1)

1 8W-3602 Mud Flap

4 8X-2576 Shim Pack

8T-4131 56: /228 Bolt

1 8T-4121 Hard Washer