Media Search - REHS2210 - Assembly Procedure For The 793D Off-Highway Truck (7000, 7006, 7960)

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Special Instruction
Assembly Procedure For the 793D Off-Highway Truck {7000, 7006, 7960}
Media Number -REHS2210-20 Publication Date -12/08/2015 Date Updated -25/06/2018
i07432211
Assembly Procedure For the 793D Off-Highway Truck {7000, 7006,

7960}
SMCS - 7000-016; 7006-016; 7960
Off-Highway Truck/Tractor
793D (S/N: FDB1-UP)
Introduction
This Special Instruction contains the following necessary procedures for the 793D (S/N: FDB1-UP) Off-Highway
Truck: field preparation, assembly, and commissioning procedure.
Note: The photographs in this publication are for illustrative purposes.
The shipping configuration consists of the rear axle housing that has the transmission and final drives that are
attached. The rear axle group is not connected to the chassis.
The suggested tools and equipment should be present before assembly. If the recommended tools and equipment
are not present, assembly will be more difficult and more time will be necessary to complete the assembly.
Do not perform any procedures in this publication or order any parts until you understand the information that is
contained in this publication.
After assembly is complete, prepare the machine for use. The Operations and Maintenance Manual shows the
preparation of the machine. Use the Parts Manual and the Service Manual with this special instruction.
Reference: Operation and Maintenance Manual, SEBU7792, "793D (S/N: FDB1-UP) Off-Highway Trucks"
Reference: Parts Manual, SEBP3976, "793D (S/N: FDB1-UP) Off-Highway Trucks"
Reference: Service Magazine, SEPD0531, 3, July 2000, "Fabric Slings and Protective Sleeves Are Available for
Lifting Truck Bodies"
Reference: Special Instruction, SMHS7867, "Use of 6V-4040 Inflation Group"
Reference: Operation and Maintenance Manual, SEBU5898, "Cold-Weather Recommendations for Caterpillar
Machine"
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Reference: Service Manual, RENR2630, "784C, 785C, 789C, 793C, 797 Off-Highway Truck/Tractors Vital
Information Management System (VIMS)"
Reference: Testing and Adjusting, Troubleshooting, RENR2631, "Off-Highway Truck/Tractors Vital Information
Management System (VIMS)"
Reference: Testing and Adjusting, SENR1502, "784C, 785C, 785D, 789C, 793C, and 793D Off-Highway
Truck/Tractors Power Train Electronic Control System"
Do not attempt to assemble this machine until you read and you
understand the assembly instructions.
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. Preparation 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 for a good solid joint.
Parts List
Reference: Service Parts, PECP9067, "One Safe Source"
Table 1
Parts that are Required to Install the Rear Axle
Qty Part Number Description
24 9X-6152 Bolt(1)
24 3S-6162 Hard Washer(1)

1 8X-0433 Slip Joint(2)
8 2N-2486 Bolt(2)
2 150-3981 Plate(3)
12 7Y-5217 Bolt(3)
18 8T-3282 Hard Washer(3)
2 150-3772 Pin(3)
2 150-3982 Plate(3)
6 6V-3532 Bolt(3)
1 398-7352 Guard As
18 8T-4136 Bolt
30 8T-4222 Plated Washer

1 431-6277 Plate As
1 431-6300 Guard
8 8T-4137 Bolt
1 456-0303 Guard
2 368-6204 Plate
4 8T-4195 Bolt
(1) Part of 384-0740 Axle Housing Support Gp
(2) 8X-0433 Slip Joint and 2N-2486 Bolt are part of 8X-0249 Drive Shaft.
(3) Part of 246-6747 Rear Suspension Gp
Table 2
Parts that are Required to Connect the Rear Supply Oil Cooler Lines Group

1 241-5837 Hose As
4 8T-4193 Bolt
4 9X-8257 Washer
2 1P-7016 Half Flange

1 3E-6773 O-Ring Seal
Table 3
Parts that are Required to Connect the Automatic Lubrication Group
6 8T-6466 Bolt
12 8T-4121 Hard Washer
6 8T-4133 Nut
1 6V-9169 Bulkhead Nut
2 4H-6147 Connector
1 9M-8662 Coupling
1 148-8457 Union Gp
Table 4
Parts that are Required to Install the Right-Hand Platform

2 8X-1991 Plate
1 352-0455 Plate
2 352-0456 Plate
1 350-6681 Plate
1 350-6680 Plate As
2 350-6683 Plate
1 241-4197 Bracket As
1 350-6682 Plate
1 242-7006 Plate
1 8X-1990 Strip
3 8T-6430 Bolt
3 8T-4123 Washer
4 8T-4139 Bolt
4 5P-1076 Hard Washer
Table 5
Parts that are Required to Hydraulic Lines to the Tank on the Right-Hand Platform
1 250-0555 Hose As(1)

4 8T-4956 Bolt
1 258-8126 Tube As(2)
4 8T-4193 Bolt
4 9X-8257 Washer
1 242-3230 Hose As(2)
1 273-1169 Hose As(2)

1 252-7156 Hose As(2)
(1) Part of 193-6296 Hydraulic Oil Lines Gp
(2) Part of 193-6276 Hydraulic Fan Lines Gp
Table 6
Parts that are Required to Connect the Brake Lines Groups to the Rear Axle Housing
1 213-9807 Hose As
1 8X-6161 Hose As
2 8T-4956 Bolt
1 7G-3833 Clip
1 7G-3834 Clip
1 7G-3832 Grommet
1 8X-6169 Hose As
Table 7
Parts that are Required to Connect the Power Train Oil Lines Group
1 8X-4094 Block
4 6M-9149 Bolt
4 7X-0591 Hard Washer

1 124-1859 O-Ring Seal
4 8T-4184 Bolt
1 8T-0568 O-Ring Seal
1 128-0931 Adapter
1 6V-4590 O-Ring Seal
4 6J-2515 Bolt
2 197-3295 Half Flange
4 8T-4183 Bolt
Table 8
Parts that are Required to Install the Rear Axle Oil Cooler Group
1 320-1516 Hose As
1 320-1541 Hose As
Table 9
Parts that are Required to Install the Power Train Cooler Lines Group
1 113-6365 Hose As
1 8X-8886(1) Hose As
1 243-1293 Hose As
1 371-0572 Hose As
1 271-4905 Hose As
1 284-7705 Hose As
2 319-6226 Elbow As
1 319-6242 Elbow As
1 332-8558 Tee As
1 153-6270 Tee

(1) Part of the 379-4937 Fan Drive Lines Gp
Table 10
Parts that are Required to Install the 364-8158 Stairway Ar (Standard)
2 344-2424 Stairway Gp
12 8T-4184 Bolt(1)
12 198-4778 Hard Washer(1)
(1) Part of the 344-2424 Stairway Gp
Table 11
Parts that are Required to Install the 354-0520 Stairway Ar (Powered Access)
1 354-0522 Plate As
16 8T-7338 Bolt
16 198-4780 Hard Washer
1 328-1150 Platform Gp
1 480-1147 Pipe As
1 481-2825 Pipe As
24 8T-4195 Bolt
1 328-1141 Stairway As
2 328-1178 Hub
16 8T-4182 Bolt
2 5A-4885 Plug Button
1 480-1153 Handrail Gp
1 480-1162 Handrail Gp
2 480-1157 Pipe As
2 480-1165 Pipe As
8 9X-2041 Screw
8 8T-4222 Plated Washer

16 457-0270 Bushing
16 4W-0435 Quad Ring Seal
1 309-1905 Taperlock Stud
1 9C-5344 Spacer
1 344-5675 Nut
2 177-4562 Grommet
2 8T-1889 Clip
2 8T-1890 Clip
1 2V-1771 Grommet
1 6D-4246 Clip
1 8T-6466 Bolt
2 8T-4179 Bolt
1 204-8000 Cable Tie Mounting
1 204-2281 Cable Strap

1 8T-4137 Bolt
1 8M-2770 Clip
1 9M-8406 Clip
Table 12
Parts that are Required to Install the 193-6282 Handhold Gp or the 193-6278 Handhold Gp(1)
1 241-6990 Handhold As
133 8T-4136 Bolt(2)
133 8T-4121 Hard Washer (2)

2 8T-7087 Grommet
2 5P-7468 Clip
2 5P-7469 Clip
1 8T-4194 Bolt
1 8T-4244 Nut
1 242-9547 Handhold As (3)

1 242-9538 Handhold As(4)
1 242-9815 Handhold As(5)
4 8T-4956 Bolt
1 290-6591 Brace
6 5S-7382 Bolt
1 8X-9874 Chain
1 5P-0765 Hose
1 8C-8451 Bolt
1 5C-2890 Nut
1 6B-8085 Chain Snap

(1) Some required parts may be part of the 193-6251 Handrail Fastener Gp
(2) Part of 193-6251 Handhold Fastener Gp
(3) Wide body only
(4) Standard body only
(5) Optional rear access only
Table 13
Parts that are Required to Install the 193-6310 Fender Gp
1 290-9011 Fender As
10 8T-4195 Bolt
1 290-6591 Brace(1)
4 8T-4194 Bolt
2 8T-4139 Bolt
2 8T-4244 Nut
1 8X-4295 Guard
3 8X-4294 Strip
37 8T-0722 Bolt
38 8T-4133 Nut
1 8W-7899 Guard
1 8X-4296 Strip
2 251-7661 Deflector
1 8X-4285 Plate As(2)
1 275-5111 Guard
1 8X-4293 Strip
1 8X-4289 Plate
1 275-5110 Guard
1 275-8089 Strip
(1) Part of 240-4784 Rear View Mirror Gp
(2) Part of 240-4794 Handhold Gp
Table 14
Parts that are Required to Install the Mirror Group
1 250-7605 Bracket As(1)

8 8T-4185 Bolt(1)
1 134-0987 Bracket As(1)
1 303-8298 Bracket As(3)
2 134-0989 Block(1)
2 303-8300 Block(3)
4 8T-4186 Bolt(1)
4 8T-4910 Bolt(3)
4 198-4778 Hard Washer(3)
1 290-0057 Mirror As(4)
3 8T-4136 Bolt
(1) Wide body only
(2) Additional hard washers (3) can be used if there is a gap between mirror (11) and bracket assembly (4).
(4) 193-6277 Rear View Mirror Gp
Table 15
Parts that are Required to Install the Front Suspension
2 5T-5202 Bearing Cap(1)
2 5T-6255 Key
20 8T-6624 Bolt
20 5T-1352 Spacer
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20 9X-8399 Washer
20 8T-1583 Nut
12 9X-6626 Bolt
12 5T-4896 Spacer
12 8C-4032 Nut
16 117-4935 Plate
8 8T-0669 Bolt

(1) One 6V-3249 Bearing and one 6V-0836 Retaining Ring for each cap
Table 16
Parts that are Required to Install the Brake Cooling Lines Group
8 8T-4944 Bolt
2 265-0975 Tube As
2 241-5766 Hose
8 209-4589 Clamp
4 156-5744 Half Clamp

18 8T-4183 Bolt
2 8T-4244 Nut
16 9X-8257 Washer
8 7X-2556 Bolt
8 8T-4175 Bolt
Table 17
Parts that are Required to Install the Service Brake Lines Group to the Front Wheels
4 8X-6137 Block
4 5T-0968 Block
8 8T-4185 Bolt
2 148-8358 Elbow
1 185-1449 Bracket (LH)
1 185-1450 Bracket (RH)
2 7X-0871 Tee
2 6V-0852 Dust Cap
2 164-5567 Fitting Gp
2 148-8345 Connector Gp
4 0S-1627 Bolt
6 7K-1181 Cable Strap

2 5J-0451 Hose As
2 6D-6489 Pipe Connector

2 9C-4937 Breather As
2 1S-0996 Clip
Table 18
Parts that are Required to Connect the Steering Links and Steering Cylinders to the Wheel Groups

4 3J-6899 Locknut
Table 19
Parts that are Required to Install the Fuel Tank
4 7X-2489 Bolt
4 8T-4167 Washer
2 8X-2575 Cap
1 216-2976 Plate Assembly

2 7X-2564 Bolt
8 8T-5439 Washer
2 8T-4131 Nut
4 8N-1214 Mount Assembly

2 7N-5656 Sleeve
2 7X-2488 Bolt
2 6V-7688 Locknut
4 8X-2576 Shim Pack
2 8T-5005 Bolt
Table 20
Parts that are Required to Install the 238-2848 Fuel Filter Lines Gp
1 159-4724 Ball Valve

2 7M-8485 O-Ring Seal
1 6V-9182 Elbow
1 8X-5311 Check Valve As

1 6V-9852 Elbow
2 7J-9108 O-Ring Seal

1 5P-6994 Clip
1 8T-4192 Bolt
Table 21
1 159-4724 Ball Valve

1 6V-9182 Elbow
1 8X-5311 Check Valve As
1 6V-9852 Elbow
1 7E-6719 Primary Fuel Filter Gp

2 8T-4195 Bolt

2 6V-9007 Elbow
2 3D-2824 O-Ring Seal
1 113-9339 Hose As
1 5P-6994 Clip
1 8T-4192 Bolt
Table 22
Parts that are Required to Install the 8X-0193 Fuel Heater Group

1 114-8701 Plate
2 7X-2568 Bolt (1)

1 7W-5300 Fuel Heater
4 8T-4194 Bolt
2 6B-9081 Reducing Bushing

2 8C-6874 Connector

1 6V-9852 Swivel Elbow

2 8C-6873 Connector
2 061-9593 Reducer Bushing
1 8T-8899 Elbow
1 107-8163 Hose As
1 8W-5428 Hose As
(1) These bolts replace the bolts that are included in the Fuel Tank Fastener Gp.
Table 23
Parts that are Required to Install the 264-7554 Service Center Gp

1 231-7582 Adapter
1 5H-6734 O-Ring Seal

6 8T-2501 Bolt

5 8T-4183 Bolt
1 285-5336 Plate
2 8T-4137 Bolt

1 6V-1867 Clip
1 6V-1868 Clip
1 6V-1869 Grommet
1 8T-4244 Nut
Table 24
Parts that are Required to Install the Cab Steering Lines Group
2 6V-8639 Connector
2 6V-8625 Elbow
4 3K-0360 O-Ring Seal

1 6V-9200 Elbow

1 150-8708 Tube As
1 150-8713 Tube As
1 150-8709 Tube As
1 150-8723 Tube As
1 150-8710 Tube As

2 5T-6867 Clamp
3 5M-3062 Bolt

1 9S-1350 Clip
1 8X-5968 Bracket As
3 8T-4136 Bolt
1 6G-8532 Guard As
Table 25
Parts that are Required to Install the 247-5876 Cab Mounting Gp

1 304-2711 Support As
9 7X-2582 Bolt
23 5T-1352 Spacer
1 296-7866 Support As
1 298-3859 Walkway As(1)
6 130-0099 Bolt
8 107-3953 Bolt
(1) Part of 240-4787 Walkway Gp
Table 26
Parts that are Required to Install the Cab Group
40 163-0042 Mount
8 163-3127 Sleeve
6 164-4411 Sleeve
6 163-0364 Sleeve
20 5T-5807 Retainer
8 6V-2624 Bolt
6 6B-0388 Bolt
6 1K-9420 Bolt
4 5T-9893 Shim (1)
4 5T-9894 Shim(1)
1 9M-8406 Clip(2)
1 8T-4137 Bolt(2)

(1) Use the shims to obtain a flatness within 0.75 mm (0.03 inch).
(2) Part of the 144-4181 Air Horn Gp
Table 27
Parts that are Required to Install the Handrail Assembly for the Rear Access Arrangement
1 456-0270 Handrail As
2 8T-5005 Bolt
2 1F-7854 Spacer

2 8T-0389 Locknut
1 296-5446 Spring
1 5L-3946 Rod End

1 9S-8752 Full Nut
2 8T-4195 Bolt
1 5G-0817 Conical Bumper
1 6V-8186 Full Nut

4 6V-1874 Grommet
4 5P-7468 Clip
4 5P-7469 Clip
4 8T-4956 Bolt
4 329-3356 Nut
1 438-9871 Plate
1 456-0271 Plate
1 172-8125 Pin
1 160-9925 Lanyard
1 5C-9553 Bolt
1 9X-8256 Washer
1 344-5673 Nut
Table 28
Parts that are Required to Install the Exhaust Pipe Group
1 272-5460 Tube As(1)
4 302-8136 Band Clamp(2)
2 251-6357 Heat Shield(2)
2 242-0799 Bellows As(2)
1 272-5463 Tube As(1)
2 242-0811 Clamp(2)
1 272-5466 Tube As(3)
1 269-3301 Bracket As(3)
4 8T-4183 Bolt(3)
4 5P-1076 Hard Washer(3)
4 8T-4244 Nut(3)
(1) Part of tube assembly 1
(2) Part of tube assembly 1 and tube assembly 2
Table 29
Parts that are Required to Install the 293-5905 Exhaust Pipe Gp (If Equipped)
1 272-5460 Tube As
7 7E-8452 Clamp
2 242-0799 Bellows As
8 8T-4183 Bolt

4 8T-4244 Nut
1 290-8577 Tube As
2 242-0811 Clamp
2 5G-3845 Boss
2 7X-7729 Washer
2 8T-4172 Bolt
2 251-6357 Heat Shield

1 290-8578 Tube As
Table 30
Parts that are Required to Install the 240-2780 Muffler Gp

1 8X-3142 Extension Pipe
1 242-8869 Extension Pipe

3 6V-6317 Bolt
3 2Y-5829 Nut
6 6V-5839 Washer
Table 31
Parts that are Required to Install the 294-0849 Muffler Gp (If Equipped)
2 6V-3823 Bolt
2 6V-7687 Locknut
2 6N-9298 Clamp
2 290-8576 Extension Pipe
Table 32
Parts that are Required to Install the 8X-4180 Hood Latch Gp

2 5S-7379 Bolt

1 2G-9399 Rod
1 6F-8499 Spring
1 8X-4425 Bracket Assembly
1 3B-4615 Cotter Pin

1 0T-0883 Washer
1 276-7617 Plate As
8 8T-4136 Bolt

1 101-0368 Prop Assembly
Table 33
Parts that are Required to Install the 240-2784 Air Cleaner Gp
1 9Y-8930 Air Cleaner Gp

4 7X-0344 Bolt
4 8T-4139 Bolt

6 8T-4194 Bolt

1 351-9112 Rod As
2 8T-4244 Nut
2 202-6473 Bolt
3 2S-5658 Hard Washer

1 8T-4132 Nut
1 351-9110 Rod As
1 251-2151 Tube As
2 251-6235 Hose
8 230-2535 Clamp
1 7E-7790 Hose
4 233-8485 Clamp
2 285-6593 U-Bolt
2 285-7524 Strip

4 129-3180 Locknut
1 9X-0262 Adapter
1 161-9926 Pressure Sensor Gp

1 7K-1181 Cable Strap
1 7D-8586 Nonslip Tread
Table 34
Parts that are Required to Install the Precleaner Cups

3 2W-9069 Precleaner Cup Assembly
Table 35
Parts that are Required to Activate the Batteries
2 115-2421 Battery Gp
Table 36
Parts that are Required to Install the 193-6262 Rim Mounting Gp

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

2 8W-0331 Swivel Connector
564 7X-0851 Nut

564 6V-8237 Washer
2 190-6095 Ring
2 251-6360 Extension
2 207-6030 Plate(1)
2 220-8202 Hose As(1)
4 1S-1015 Clip(1)
32 8T-4139 Bolt
8 8T-4244 Nut
4 229-9387 Plate(1)
4 8T-5092 Bolt(1)
2 280-7372 Plate(2)
2 280-9835 Plate(2)
4 6J-0427 Spacer
2 7I-5931 Bracket
4 8T-6868 Bolt

2 5T-9796 Connector
1 281-0569 Hose As(2)
12 137-3615 Bracket(3)
4 3V-8340 Bracket(3)
8 136-9459 Plate As(3)
(1) Use with 793D Extended Life, Wheel, and Brake Group configuration only
(2) Use with 793D Standard Wheel and Brake Group configuration only
(3) Part of 208-8789 Rim Guard Gp
Table 37
Parts that are Required to Install the Odometer
141-1513 (1)
155-6138 (2)
1 Odometer Assembly
5T-8673 (3)
141-1514 (4)
1 122-1478 Plate As
2 5B-5839 Spacer
2 8T-4184 Bolt

(1) The 141-1513 Odometer Assembly is part of 143-2253 Odometer.
(3) The 5T-8673 Odometer Assembly is part of 188-3648 Odometer Gp.
(4) The 141-1514 Odometer Assembly is part of 188-3649 Odometer Gp.
Table 38
Parts that are Required to Install the 126-1358 Hydraulic Tank Guard Gp

1 119-8732 Cover
1 270-8622 Cover
Table 39
Parts that are Required to Install the 284-4927 Truck Body Mounting Gp

2 8X-5063 Deflector
1 105-4727 Mud Flap
1 6G-9703 Cable
1 105-0314 Coupler
2 8T-4649 Bolt
2 6V-7676 Nut
1 8W-0109 Plate
1 2B-0974 Clevis Pin
2 7I-5517 Pin As
1 8W-2896 Washer
2 6G-9697 Washer
2 8W-8677 Plate
4 8T-4184 Bolt
10 219-7595 Pad As
30 8X-3046 Shim
2 8X-3044 Plate (1)
24 8T-4910 Bolt
30 7D-1649 Hard Washer
24 8T-4244 Nut
16 8T-4137 Bolt

16 4K-8864 Clip
2 233-1880 Bracket As(2)
2 227-5875 Ejector
2 6G-7773 Pin
2 3D-0404 Washer
4 205-4178 Pad
4 205-4179 Shackle
2 205-4181 Chain
(1) A 8X-3044 Plate that has a thickness of 8 mm (0.3150 inch) should be used in place of four 8X-3046 Shims that have a thickness of
2 mm (0.0787 inch) each
(2) Part of 260-9120 Body and Canopy As
Table 40
Parts that are Required to Install the 8X-3380 Cylinder Mounting Gp
2 237-0417 Pin As
4 8X-4043 Spacer
2 8X-4044 Plate
10 8T-4183 Bolt
Table 41
Parts that are Required to Install the 251-4831 Film Gp
1 299-7935 Film
1 311-3585 Film
1 311-3586 Film
1 311-3587 Film
1 311-3591 Film
2 311-3595 Film
Approximate Weights
Personal injury or death can result from lifting a heavy assembly.
The heavy assembly can fall if using an incorrect hoist to lift the load.
Be sure the hoist has the correct capacity to lift a heavy assembly.
Approximate weight of the assembly is given below.
Personal injury or death can result from improper lifting or blocking.
When a hoist or jack is used to lift any part or component, stand clear of
the area. Be sure the hoist or jack has the correct capacity to lift a
component. Install blocks or stands before performance of any work
under a heavy component.
Approximate weights of the components are shown. Clean all surfaces

where parts are to be installed.
Table 42
Module Weight
Truck frame module without rear axle housing (1) 43545 kg (96000 lb)
Rear axle housing with final drives 24494 kg (54000 lb)
Truck frame module and rear axle housing with final drives (1) 68038 kg (150000 lb)
Front suspension cylinder, wheel, and brake assembly 6504 kg (14340 lb)
Tire 3500 kg (7800 lb)
Rim 1583 kg (3490 lb)
Body pivot pin 41 kg (90 lb)
Fuel tank (2) 1150 kg (2525 lb)
Fuel tank (3) 1700 kg (3725 lb)
Fuel tank (4) 2020 kg (4455 lb)
Right side platform assembly 1130 kg (2490 lb)

Body (center) 12160 kg (26800 lb)
Body (center) with liners 18430 kg (40620 lb)
Body (two sides) 6530 kg (14400 lb)
Canopy 4170 kg (9200 lb)
Liners(5) 3500 kg (7710 lb)
Tail extension assembly 304 kg (670 lb)

Sideboard assembly 118 kg (260 lb)
Cab with catwalks and handholds 2132 kg (4700 lb)
Completed body without liners(6) 45359 kg (100000 lb)

(1) The weight of the truck frame is distributed equally between the front and back lifting points.
(2) Tank capacity 2839 L (750 US gal)
(5) The total weight of the liners can weigh as much as 18144 kg (40000 lb).
(6) A completed body with liners can weigh as much as 63503 kg (140000 lb). When you lift a completed body, use a suitable lifting device.
Specifications
Table 43
Item Specifications
Wheel base 5900 mm (232 inch)

Length 12866 mm (506.5 inch)
Ground to top of canopy 6604 mm (260 inch)
Ground to upper edge of body 5865 mm (230.9 inch)
Turning radius 32.40 m (106.3 ft)

Width of body assembly 7411 mm (291.8 inch)
Width of truck frame at rear tires 7406 mm (291.5 inch)
Torque Specifications
Tighten the 24 rear axle housing bolts to a torque of 2800 ± 350 N·m (2065 ± 260 lb ft).
Tighten the 72 bolts that mount the rear wheel rim to a torque of 900 ± 100N·m (664 ± 74 lb ft).
Tighten the 70 nuts that mount the front wheel rim to a torque of 1000 ± 125 N·m (738 ± 92 lb ft).
Tighten the lower 12 bolts and nuts that mount the front suspension cylinder to a torque of 1500 ± 150 N·m
(1106 ± 110 lb ft) plus 60 ± 5 degrees.
Tighten the upper 20 bolts that mount the front suspension cylinder to a torque of 1000 ± 100 N·m
(738 ± 74 lb ft) plus 60 ± 5 degrees.
Tighten the eight bolts that mount the cap for the front suspension cylinder to a torque of 800 ± 100 N·m
(590 ± 74 lb ft).
Tighten one nut (or four nuts if equipped) that mounts the ball stud to a torque of 2550 ± 100 N·m
(1881 ± 74 lb ft).
Tighten the 20 cab mounting bolts to a torque of 1904 ± 68 N·m (1405 ± 50 lb ft).
Tighten the 21 cab support mounting bolts to a torque of 1600 ± 200 N·m (1180 ± 148 lb ft).
Tighten the bolts for the fuel tank to a torque of 460 ± 60 N·m (339 ± 44 lb ft).
Tighten the fuel tank caps to a torque of 800 ± 100 N·m (590 ± 74 lb ft).
Tighten the bolts for the platform assembly to a torque of 460 ± 60 N·m (339 ± 44 lb ft).
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.
Illustration 1 g00629745
Lift angles for lifting slings.
(A) The load capacity is 100 percent of the working load limit for the sling.
(B) The load capacity is 86 percent of the working load limit for the sling.
(C) The load capacity is 70 percent of the working load limit for the sling.
(D) The load capacity is 50 percent of the working load limit for the sling.
Necessary Lifting Capacity

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

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

The following supplies and equipment are used for the assembly procedure:
Obtain six 208 L (55 US gal) barrels of hoist, converter, and brake oil (TDTO, TO-4).
Obtain 227 L (60 US gal) of transmission/drive train oil (TDTO). Ambient temperatures that are extreme
may require a different oil viscosity. Refer to Service Manual, SEBU6250, "Caterpillar Machine Lubricant
Recommendations".
Obtain one 133 L (35 US gal) barrel of steering oil. The steering oil should be of one of the following types:
HYDO, TDTO, DEO CF-4, API CF-4 and CE-compliant oils.
Obtain one crane or a suitable lifting device with a 54430 kg (120000 lb) lifting capacity. Obtain one crane
or a suitable lifting device with a 36287 kg (80000 lb) lifting capacity.
Obtain cables, lifting straps, and chains that have adequate lifting capacity.
Obtain several shackles. The shackles should have a working load limit of 27240 kg (60053 lb).
Obtain one portable air compressor. The air compressor should have enough capacity to operate two
25.4 mm (1 inch) impact wrenches. The air compressor should have a minimum capacity of 3 CM
(100 CFM).
Obtain 40 hardwood blocks that are 203 mm (8.0 inch) tall. The blocks should be 203 mm (8.0 inch) wide.
The blocks should be 914 mm (36.0 inch) long.
Obtain one stepladder that is 1.8 m (6 ft) tall. Have two stepladders that are 3.6 m (12 ft) tall.
Obtain at least 94 m (308 ft) of rope that is 19 mm (0.75 inch) in diameter. When you install the body on the
chassis, use the rope to guide the body into position.
Obtain 20 nitrogen bottles that are T-size to inflate the tires and charge the suspension cylinders.
Obtain one lift truck that can lift 6810 kg (15000 lb).
Obtain two 7X-1062 Ether Cylinders.
Obtain a paint spray gun.
Obtain three 138-7573 Link Brackets and three 138-7574 Link Brackets.
Four metal stands. The metal stands support the truck body before the truck body is installed to the truck
frame.
Obtain 4C-4188 Paint Remover. The solvent cleans the parts on the truck.
Obtain Loctite 242 Blue Threadlocker for the cab mounting bolts.
Obtain 4C-5593 Thread Lubricant for the front suspension cylinders
Required Tools
Use a 5P-3520 Spanner Wrench to torque the ball studs for the steering system.
Use a 5S-6084 Socket to tighten the ball studs for the steering system.
Use a 6V-6080 Torque Multiplier to tighten the components that follow: the bolts for the front suspension
cylinder, steering arm mounting nuts, ball stud nuts, and wheel rim mounting nuts.
Use a 2P-2336 Socket to tighten the ROPS cab mount bolts.
Use a 9U-5089 Socket to tighten the wheel rim mounting nuts.
Use a 8T-9293 Torque Wrench to torque the ROPS cab mounting bolts.
Use a 6V-4170 Adapter for the mounting group for the front suspension.
Use a 6V-4154 Box Wrench for the mounting group for the front suspension.
Use a 6V-3146 Extension for the mounting group for the front suspension.
Use a 2P-8261 Adapter (3/4 inch to 1.0 inch) for the mounting group for the front suspension.
Use a 9U-5089 Socket for the rear axle housing, the mount for the front cylinder, and the cab support.
Use a 5S-6076 Extension with the 2P-2336 Socket and with the 2P-2338 Socket.
Use a 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 Gp ( 300 N·m (221 lb ft)).
Use a 8T-5183 Extension for the torque wrench.
Use a 8T-3196 Wrench for the mounting nuts on the front suspension cylinder.
Use a pair of 6V-0006 Pliers to install the connector for the AETA.
When you are instructed, apply 4C-5593 Anti-Seize Thread Lubricant to threads.
When you are instructed, apply 4C-5599 High Temperature Anti-Seize Compound to threads.
Site for the Assembly of the Truck
Typical view of the layout for the 793D Off-Highway Truck.
Typical view of the 793D chassis
Typical view of the 793D components
Typical view of the 793D skid with the cab, rims, fuel tank, and handrail
Typical view of the 793D Extended Life, Wheel, and Brake Group rear axle assembly
Typical view of the standard rear axle assembly for the 793D
Typical view of the 793D lifting points
1. The work area for the truck chassis and the components should be flat, smooth, and well draining. An area
30.5 m (100 ft) by 24.5 m (80 ft) is needed for the assembly of the truck.
2. The truck chassis should be located in the center of the assembly area. Keep the assembly area around the
truck chassis clear. Also, the assembly area must be left unobstructed in order for the crane to lift the
components properly.
3. Attach a suitable cable or a strap at four places on the chassis.
Note: Straps and clevises are used to lift the front and the rear of the chassis.
Typical view of the alternate lifting devices on a similar chassis
Note: A spreader bar and cables can be used to lift the rear of the chassis. The spreader bar is a steel rod that
is 89 mm (3.5 inch) in diameter and 4191 mm (165 inch) in length. Cables and clevises are used to lift the
front of the chassis.
Typical view
4. Use two cranes to lift the 793D chassis from the trailer. The chassis weighs approximately 43545 kg
(96000 lb).
Typical front view of a similar chassis that is blocked
Typical view
5. Carefully lower the chassis onto support blocks.
Note: The wood blocks are 203 mm (8.0 inch) by 203 mm (8 inch). The wood blocks are stacked alternately.
A suitable metal stand can be used under the rear of the frame.
Note: 1320 mm (52 inch) is the height that is required to install the rear tires.
Note: 1600 mm (63 inch) is the height that is required to install the front tires.
Typical view of a similar chassis on metal stands
Typical view of a similar chassis that is blocked
6. Illustration 14 shows an alternate blocking method using steel plates and steel stands.
View of rear axle assembly from the 793D Extended Life, Wheel, and Brake Group configuration
7. Attach a clevis to each existing lifting bracket. Attach suitable lifting devices to lift the rear axle assembly
and final drives from the trailer. The weight of the rear axle assembly and final drives is approximately
24494 kg (54000 lb).
View of rear axle assembly from the 793D Extended Life, Wheel, and Brake Group configuration
8. Place the rear axle assembly behind the frame .
Note: Refer to Illustration 2 for placement of the components.
Typical view
View of the skid with the components for the right platform
Typical view
View of the LH front strut assembly, outrigger, and hardware for a standard truck
Typical view
View of the RH front strut assembly
The rear outrigger is shown with the optional rear access for a standard truck.
View of the front strut assembly for the left side from the 793D Extended Life, Wheel, and Brake Group configuration
View of the cab
View of the fuel tank
9. Use a suitable lifting device to unload the remaining components. Place the components away from the
crane. Refer to Illustration 2 for placement of the components.
10. Set the wooden boxes of smaller components out of the way. Open the boxes and check the components that
are in each box.
Note: Do not open the bags of hardware. The bags are marked for easy identification. Place the hardware
with the correct components. Refer to the photos in this special instruction. The photos will help to position
the components.
Remove the Eyes from the Frame
Typical view
(A) 15 ± 2 mm (0.59 ± 0.0787 inch)
NOTICE
Do not grind through the weld or the parent material of the frame.
1. Use a torch to remove the tie down eyes from the frame. Leave the weld and the parent material to
dimension (A).
2. Clean all the areas that were affected in Step 1. Paint the areas to inhibit rust.
Install the Rear Axle

The installation of the rear axle requires parts from the following groups:
384-0740 Axle Housing Support Gp
246-6747 Rear Suspension Gp
8X-0249 Final Drive Gp
393-7414 Drive Shaft Guard Gp
Table 44
Parts that are Required to Install the Rear Axle
Item Qty Part Number Description
C 24 9X-6152 Bolt(1)
D 24 3S-6162 Hard Washer(1)
E 1 8X-0433 Slip Joint(2)
F 8 2N-2486 Bolt(2)
R 2 150-3981 Plate(3)
S 12 7Y-5217 Bolt(3)
T 18 8T-3282 Hard Washer(3)
U 2 150-3772 Pin(3)
Y 2 150-3982 Plate(3)
Z 6 6V-3532 Bolt(3)
1 1 398-7352 Guard As
2 18 8T-4136 Bolt
3 30 8T-4222 Plated Washer
4 1 431-6277 Plate As
5 1 431-6300 Guard
6 8 8T-4137 Bolt
7 1 456-0303 Guard
8 2 368-6204 Plate
9 4 8T-4195 Bolt
(1) Part of 384-0740 Axle Housing Support Gp
(2) 8X-0433 Slip Joint and 2N-2486 Bolt are part of 8X-0249 Drive Shaft.
(3) Part of 246-6747 Rear Suspension Gp
1. Use 4C-4204 Paint Remover to prepare the frame mounting surface.
View of rear frame
2. Remove three bolts (A) to remove the wood block. Discard the hardware.
3. Repeat step 2 for the left side of the frame.
View of rear frame rail
4. Remove bar (B).
View of left side of the rear axle housing
5. Use 4C-4204 Paint Remover to remove paint from the left side of the rear axle housing.
6. Repeat step 5 for the right side of the rear axle housing assembly.
7. Remove two bolts and the cover from the front of the transmission on the rear axle housing assembly.
Discard the bolts.
8. Prepare the transmission yoke to install the drive shaft slip joint.
Inspect the universal joints and mating yokes for damage to the key, keyway, threaded holes, and pilot
diameters.
Note: If damage is present in any of the areas, replace the universal joint or yoke accordingly.
Clean the mating surface of the yoke assembly, including the threaded holes and universal joint assembly.
Ensure that the yoke assembly is free of wax, dirt, debris, paint, and grease.
9. Remove the cable straps and bolts (F) from drive shaft slip joint (E).
10. Inspect the universal joints and mating yokes for damage to the key, keyway, threaded holes, and pilot
diameters.
Note: If damage is present in any of the areas, replace the universal joint or yoke accordingly.
Clean the mating surface of the slip joint. Ensure that the slip joint is free of wax, dirt, debris, paint, and
grease. Repeat for opposite side.
View of the sensor at the LH strut
NOTICE
Before raising the rear struts, disconnect both of the rear strut sensors.
Failure to disconnect the sensors may result in damage to the electrical
connection of the sensor.
11. Use a suitable lifting device to raise rear struts (G). The weight of each rear strut is approximately 601 kg
(1325 lb).
12. Use a suitable lifting device to position the rear axle housing and the final drives to the frame.
Note: The weight of the rear axle assembly and final drives is approximately 24494 kg (54000 lb).
View of the right side of rear axle housing and final drive
13. Install 12 bolts (C) and 12 washers (D) to secure the rear axle housing.
Note: Use an impact wrench to tighten bolts (C). Do not torque bolts (C) yet.
Repeat for the other side of the machine.
14. Remove two bolts (H) and two washers (J) to remove retainer (K) and pin (L).
Note: The weight of the pin is 16.7 kg (37 lb).
15. Prepare pin (L) by removing paint and dirt.
16. Use 4C-4204 Paint Remover to remove paint from pin bores. Apply 4C-5593 Anti-Seize Thread Lubricant
to pin (L) and the bores.
17. Use a suitable lifting device to lift lateral control rod (M) into position. The weight of the lateral control rod
is 146 kg (322 lb).
18. Install pin (L). Install retainer (K), two bolts (H), and two washers (J) that were removed in Step 14. Tighten
bolts (H) to a torque value of 475 N·m (350 lb ft).
View of lower strut mount
19. Remove top bolt (N) and washer (P). Retain the hardware. Loosen bottom bolt (N) to position the guard for
the pin removal. Keep top bolt (J) and washer (K).
View of the lower right strut
20. Remove the cap from the elbow.
View of lower strut
21. Attach lubrication line (V) to the elbow.
22. Repeat Step 20 and Step 21 for the other side of the machine.
23. Apply 4C-5593 Anti-Seize Thread Lubricant to pin (U), the frame bore, and the bore in strut (G). Grease
line (V) that is attached to the elbow faces the front of the machine.
View of right rear mount
24. Position rear strut (G) to install pin (U).
Note: The location of the grease port on pin (U) is indicated by an arrow.
25. Install washer (R), six bolts (S), and six washers (T) that were removed in Step 22 to secure pin (U). Tighten
bolts (S) to a torque value of 475 N·m (350 lb ft).
View of grease port for the left strut
26. Repeat Step 19 through Step 25 for the other side.
View of the LH strut and sensor
27. Reconnect both of the sensors for the rear struts.
View of the rear axle assembly from the 793D Extended Life, Wheel, and Brake Group configuration
28. Place wood blocks under the rear axle housing and the final drives to support the assembly.
29. Remove drive shaft guard (W). Retain guard (W) and all mounting hardware.
30. Make sure that torque converter and transmission yokes are aligned and in phase.
Use a suitable lifting device to position drive shaft slip joint (E) to the transmission.
Note: The weight of the slip joint is 127.1 kg (280 lb).
31. Ensure that the universal joints are fully seated prior to tightening the bolts. There are two methods:
A - Use a suitable rubber or wood hammer to seat the universal joints in the yoke.
B - Use designated run-down bolts to completely seat the universal joints in the yoke. Refer to Step
31.a and Step 31.b.
a. Torque the designated "run-down" bolts in a sequential alternating "X" pattern.
b. Remove the designated "run-down" bolts and replace with new 2N-2486 Bolts
Note: Ensure that the universal joints are fully seated prior to tightening the bolts.
32. Insert new 2N-2486 Bolts (F) and torque to 550 ± 20 N·m (406 ± 15 lb ft) in a sequential alternating "X"
pattern.
Static check 2N-2486 Bolts (F) and ensure that the bolts are tightened to a minimum of 530 N·m (391 lb ft)
to maximum of 570 N·m (420 lb ft).
33. Perform a static check on the 2N-2486 Bolts (F) 250 hours after the driveshaft has been installed.
NOTICE
Do not separate the drive shaft. Drive shafts are assembled with the
universal joints in phase for balancing purposes. If the drive shaft must
be separated, use a paint pen to make aligning marks on both sides of
the slip joint. When assembling the drive shaft, make sure the aligning
marks match to ensure proper universal joint phasing and balance
performance.
34. Resecure shaft guard (W) that was previously removed.
Refer to the steps below for instructions to install guard (W).
View of the drive shaft after the center tube
(1) 398-7352 Guard As
(2) 8T-4136 Bolt
(3) 8T-4222 Plated Washer
a. Position guard assembly (1) to the center tube. Secure the top of the guard assembly with three bolts
(2) and three plated washers (3). Secure each side of the guard assembly with three bolts (2) and three
plated washers (3).
(1) 398-7352 Guard As
(2) 8T-4136 Bolt
(4) 431-6277 Plate As
b. Install plate assembly (4) to guard assembly (1) with nine bolts (2) and nine plated washers (3).
(4) 431-6277 Plate As
(5) 431-6300 Guard
(6) 8T-4137 Bolt
c. Install guard (5) to plate assembly (4) with eight bolts (6) and eight plated washers (3).
View of the drive shaft after the center tube, from below
(1) 398-7352 Guard As
(7) 456-0303 Guard
(8) 368-6204 Plate
(9) 8T-4195 Bolt
d. Install guard (7) to guard assembly (1) with two plates (8), using four bolts (9), and four plated
washers (3).
35. Tighten 12 bolts (C) to a torque value of 2800 ± 350 N·m (2065 ± 260 lb ft).
36. Repeat step 35 for the other side.
Connect the Rear Supply Oil Cooler Lines Group

Connecting the rear supply oil cooler lines groups requires parts from one of the following groups:
245-0898 Hydraulic Oil Cooler Lines Gp (Standard Retarding)
193-6294 Hydraulic Oil Cooler Lines Gp (Additional Retarding)
The
Table 45
Parts that are Required to Connect the Rear Supply Oil Cooler Lines Group
1 1 241-5837 Hose As
2 4 8T-4193 Bolt
3 4 9X-8257 Washer
4 2 1P-7016 Half Flange

5 1 3E-6773 O-Ring Seal
View of hose (1) and shipping strap
1. Remove four bolts (2) and four washers (3). Remove two flange halves (4). Discard cover (A).
Note: Make sure that seal (5) is in the housing.
2. Discard four bolts (B), four washers (C), and four nuts (D) from hose assembly (1). Discard two flange
halves (E) and cover (F).
3. Position flange halves (4) on each side of hose (1). Install four bolts (2) and four washers (3) to secure hose
assembly (1) and O-Ring Seal (5).
Connect the Automatic Lubrication Group

Connecting the automatic lubrication group requires parts from the following groups:
193-6213 Automatic Lubrication Gp or 193-6233 Lubrication Lines Gp
193-6257 Automatic Lubrication Gp
Table 46
Parts that are Required to Connect the Automatic Lubrication Group

1 6 8T-6466 Bolt
2 12 8T-4121 Hard Washer

3 6 8T-4133 Nut
4 1 6V-9169 Bulkhead Nut
5 2 4H-6147 Connector
6 1 9M-8662 Coupling
7 1 148-8457 Union Gp
1. Use six bolts (1), 12 hard washers (2), and six nuts (3) to secure lubrication injector bank (A) to the rear axle
housing.
2. Remove cap (B) from hose assembly (C) . Remove cap (D) from lubrication injector bank (A). Attach hose
(C) to lubrication injector bank (A).
3. Secure hose (C) with existing clips and hardware that is provided. The clips and hardware are located on the
top, and left-hand side of the rear axle housing.
View of the left lower pin and strut
4. Remove cap (G) from elbow (H).
5. Attach lubrication line (J) to elbow (H).
6. Position guard (K). Install two bolts and two washers that are provided to secure the guard.
View of the right side lower rear strut and lubrication line that is installed
7. Repeat Step 4 through Step 6 for the other side.
Note: The orientation of the lubrication line is important. Refer to Illustration 72 for both sides of the truck.
View of the left rear upper chassis
8. Attach lubrication line (L) to the body pin bore.
View of the right rear upper chassis
9. Repeat step 8 for the other side.
View of the lateral control rod at the rear axle housing
10. Remove cap (M) from elbow (N) on the rod.
11. Attach lubrication hose (P) to elbow (N).
12. Locate the opposite end of the lateral control rod and remove cap (R) from elbow (S).
13. Attach lubrication hose (T) to elbow (S).
Note: The following step is to be completed after the right-hand platform is installed.
View of the lubrication hoses on the right platform
14. Use the following items to connect the hoses from the Lubrication Pump to the Hood Mount: 6V-9169
Bulkhead Nut (4), two 4H-6147 Connectors (5), 9M-8662 Coupling (6) and 148-8457 Union Gp (7).
15. Attach the lubrication hoses.
16. Use the clips and the fasteners that are provided to secure the lubrication lines.
Install the Right-Hand Platform

The required parts to install the right-hand platform are part of the 193-6252 Platform Mounting Gp.
Note: The right side air cleaner is factory installed to the right side platform.
Table 47
Parts that are Required to Install the Right-Hand Platform

1 2 8X-1991 Plate
2 1 352-0455 Plate
3 2 352-0456 Plate
4 1 350-6681 Plate
5 1 350-6680 Plate As
6 2 350-6683 Plate
7 1 241-4197 Bracket As
8 1 350-6682 Plate
9 1 242-7006 Plate
10 1 8X-1990 Strip
11 3 8T-6430 Bolt
12 3 8T-4123 Washer
13 4 8T-4139 Bolt
14 4 5P-1076 Hard Washer
Typical view of the right-hand platform mounting plates
1. Prepare the right-hand platform mounting plates for welding by removing the paint from the edges.
2. Remove the paint from the area on the edge of the platform assembly and from the bottom of the platform
assembly. The approximate weight of the right side platform assembly is 1130 kg (2491 lb).
View of the rear of the right-hand platform as shipped
(9) 242-7006 Plate
(9) 242-7006 Plate
3. Remove the four bolts and four washers that secure plate (9) from the platform. Retain the bolts, the
washers, and plate (9) for future use.
Prepare plate (9) for welding by removing the paint from the edges.
4. Prepare the area on the platform for welding by removing paint.
Typical RH view of the truck
5. Remove paint from the area on the right side of the frame.
6. Remove paint from top of frame for welding. Remove the paint from the mounting area of the platform.
View of the two existing lifting points
View of existing rear lifting point
7. Use the lifting points that are provided for the positioning of the platform.
View of the platform assembly that is being positioned to the frame
8. Use a suitable lifting device to position the platform to the chassis.
View from the top of the left-hand side of the right-hand platform
(11) 8T-6430 Bolt
(12) 8T-4123 Washer
View from the bottom front of the right-hand platform
(11) 8T-6430 Bolt
(12) 8T-4123 Washer
9. Position the platform assembly. Secure the platform in three locations by using three bolts (11) and three
washers (12).
Note: Tighten the bolts to a torque of 460 ± 60 N·m (339 ± 44 lb ft).
View of the rear of the right-hand fender and air cleaner
(7) 241-4197 Bracket As
(13) 8T-4139 Bolt
(14) 5P-1076 Hard Washer
10. Install four bolts (13) and four hard washers (14) to hold bracket assembly (7) to the frame assembly. Do not
tighten four bolts (13) at this time.
View of the gap between the RH platform and the radiator support
11. The platform must be level before finish welding can begin. If necessary, use a suitable lifting device to
adjustment the platform.
Note: The lifting device for the RH platform must remain in place until the platform is welded completely.
View of the accumulators that are covered
12. Cover the accumulators to protect the accumulator against the weld splatter.
View from under the rear of the right-hand platform
(1) 8X-1991 Plate
(2) 352-0455 Plate
(3) 352-0456 Plate
(4) 350-6681 Plate
(5) 350-6680 Plate As
(6) 350-6683 Plate
(7) 241-4197 Bracket As
View from under the front of the right-hand platform
(1) 8X-1991 Plate
(2) 352-0455 Plate
(3) 352-0456 Plate
(5) 350-6680 Plate As
(6) 350-6683 Plate
(7) 241-4197 Bracket As
(8) 350-6682 Plate

View from the top of the left-hand side of the right-hand platform
(1) 8X-1991 Plate
(9) 242-7006 Plate
(10) 8X-1990 Strip
(11) 8T-6430 Bolt
(12) 8T-4123 Washer

Right-hand view
(1) 8X-1991 Plate
(2) 352-0455 Plate
(3) 352-0456 Plate
(4) 350-6681 Plate
(5) 350-6680 Plate As
(6) 350-6683 Plate
(7) 241-4197 Bracket As
(8) 350-6682 Plate
(AB) 170 ± 5 mm (6.693 ± 0.197 inch)
(AC) 8 ± 1.5 mm (0.315 ± 0.059 inch) Two places
(AD) 16.1 ± 1.5 mm (0.634 ± 0.059 inch)
(AE) 8 ± 1.5 mm (0.315 ± 0.059 inch) Two places
(W1) 6 mm (0.236 inch) fillet weld with 1.5 mm (0.059 inch) penetration

View of Section A-A
(1) 8X-1991 Plate
(2) 352-0455 Plate
(3) 352-0456 Plate
(9) 242-7006 Plate
(11) 8T-6430 Bolt
(12) 8T-4123 Washer
(W3) 6 mm (0.236 inch) fillet weld with 1.5 mm (0.059 inch) penetration (two plates (1))
(W4) 6 mm (0.236 inch) fillet weld with 1.5 mm (0.059 inch) penetration (two places)
(W6) 6 mm (0.236 inch) fillet weld with 1.5 mm (0.059 inch) penetration (two places)

View of Section B-B
(4) 350-6681 Plate
(5) 350-6680 Plate As
(6) 350-6683 Plate
(W7) Four 6 mm (0.236 inch) fillet welds around plate (4). No weld 25 mm (0.984 inch) from the corners and on the curve.
(W8) 3 mm (0.118 inch) Flare bevel weld the entire length of plate assembly (5)

View of Section C-C
(4) 350-6681 Plate
(5) 350-6680 Plate As
(6) 350-6683 Plate
(8) 350-6682 Plate
(W9) 3 mm (0.118 inch) Fillet weld the entire length of plate assembly (5)
( W10) Four 6 mm (0.236 inch) fillet welds around plate (8). No weld 25 mm (0.984 inch) from the corners and on the curve.
(W11) 3 mm (0.118 inch) Beveld weld at the base of plate assembly (5)
( W12) Two 6 mm (0.236 inch) fillet welds on both sides of the two plates (6). No weld 25 mm (0.984 inch) from the corners and on
the curve.

View of Section D-D
(1) 8X-1991 Plate
(2) 352-0455 Plate
(3) 352-0456 Plate
(W13) 3 mm (0.118 inch) fillet weld
(W14) 6 mm (0.236 inch) fillet weld on both sides (two places)
(W15) 3 mm (0.118 inch) flare bevel weld
Note: Do not weld area (AA).
13. Weld the platform in place. Refer to Illustration 98, Illustration 99, and Illustration 100for the locations of
the components. Refer to Illustration 101, Illustration 102, Illustration 103, Illustration 104, and Illustration
105 for the welding and dimension information.

(9) 242-7006 Plate
14. Position plate (9). Install the bolts and washers from Step 3. Weld plate (9) to the frame assembly and the
platform assembly.
15. Paint the welded areas.
16. Final tighten bolts (13) that secure bracket assembly (7).

View of the electrical connections under the right side of the platform assembly
17. Connect the electrical lines for the oil cooler to the platform with clips, bolts, and washers.
18. Connect the load indicator wiring to the platform. Use clips, bolts, and washers that are provided to secure
the wiring.
Connect the Hydraulic Lines to the Tank on the Right-Hand Platform

Connecting the hydraulic lines to the tank on the right-hand platform requires parts from the following groups:
193-6276 Hydraulic Fan Lines Gp
193-6296 Hydraulic Oil Lines Gp
Table 48
Parts that are Required to Hydraulic Lines to the Tank on the Right-Hand Platform
1 1 250-0555 Hose As(1)

3 4 8T-4956 Bolt
5 1 258-8126 Tube As(2)

6 4 8T-4193 Bolt
7 4 9X-8257 Washer
8 1 242-3230 Hose As(2)
9 1 273-1169 Hose As(1)
10 1 252-7156 Hose As(1)
(1) Part of 193-6296 Hydraulic Oil Lines Gp
(2) Part of 193-6276 Hydraulic Fan Lines Gp
1. Remove shipping covers (A) and (B). Discard the covers and the hardware.
2. Position hose assembly (1) to the tank.
3. Position two flange halves (2) around hose assembly (1). Install four bolts (3) and four washers (4) to secure
the hose to the tank.
4. Position hose assembly (5) to the tank.
5. Install four bolts (6) and four washers (7) to secure the hose to the tank.
6. Attach hose assembly (8) to existing fitting (C).
7. Attach hose assembly (9) to existing fitting (D).
8. Attach hose assembly (10) to existing fitting (E).
Connect the Brake Lines Groups to the Rear Axle Housing

Connecting the brake lines groups to the rear axle housing requires parts from the following groups:
193-6244 Service Brake Lines Gp (Rear)
379-4927 Service Brake Control Gp
Table 49
Parts that are Required to Connect the Brake Lines Groups to the Rear Axle Housing
1 1 213-9807 Hose As
2 1 8X-6161 Hose As
3 2 8T-4956 Bolt
5 1 7G-3833 Clip
6 1 7G-3834 Clip
7 1 7G-3832 Grommet
8 1 8X-6169 Hose As
1. Remove caps (A) from hose (1) and hose (2).

View of the traction control valve that is located on the right inside frame rail
2. Attach hose (1) and hose (2) to traction control valve (B).
3. Remove the following hardware and retain the following hardware. Two bolts (3), two washers (4), one top
clip (5), one bottom clip (6) and one grommet (7).
4. Install two bolts (3), two washers (4), one clip (5), one clip (6), and one grommet (7) to secure hose (1) and
hose (2).
5. Remove cap (C) from slack adjuster (D).
6. Attach hose (8) to slack adjuster (D).

View of hose (8) that is installed
7. Use existing hardware to secure hose (8).
Connect the Power Train Oil Lines Group

Connecting the power train oil lines group requires parts from the 240-4803 Power Train Oil Lines Gp
Table 50
Parts that are Required to Connect the Power Train Oil Lines Group

1 1 8X-4094 Block
2 4 6M-9149 Bolt
3 4 7X-0591 Hard Washer

4 1 124-1859 O-Ring Seal

7 4 8T-4184 Bolt
8 1 8T-0568 O-Ring Seal
9 1 128-0931 Adapter
10 1 6V-4590 O-Ring Seal

11 4 6J-2515 Bolt
12 2 197-3295 Half Flange

13 4 8T-4183 Bolt
14 1 191-2962 O-Ring Seal
Note: Remove the caps from the hoses for installation.

View of the bottom of the transmission
(A) 138-0580 Hose As
(B) 131-5525 Hose As
(1) 8X-4094 Block
(2) 6M-9149 Bolt
(3) 7X-0591 Hard Washer
(4) 124-1859 O-Ring Seal
(5) 1P-4584 Half Flange
(6) 8T-4223 Hard Washer
(7) 8T-4184 Bolt
(8) 8T-0568 O-Ring Seal
(9) 128-0931 Adapter
(10) 6V-4590 O-Ring Seal
(11) 6J-2515 Bolt
(12) 197-3295 Half Flange
(13) 8T-4183 Bolt
(14) 191-2962 O-Ring Seal
1. Secure hose assembly (A) and hose assembly (B) to the transmission.
Hose assembly (A) requires the following hardware:
One block (1)
Four bolts (2)
Four hard washers (3)
One O-ring seal (4)
Two half flanges (5)
Four bolts (7)
One O-ring seal (8)
Hose assembly (B) requires the following hardware:
One adapter (9)
One O-ring seal (10)
Four bolts (11)
Two half flanges (12)
Four bolts (13)
One O-ring seal (14)

View of the top of the transmission
(C) 455-6780 Hose As
(D) 128-0928 Hose As
(E) 125-9460 Hose As
(F) 258-6652 Hose As
2. Secure hose assembly (C), hose assembly (D), hose assembly (E), and hose assembly (F) to the side of the
transmission.
3. Use existing clamps and hardware to secure hoses.
Install the Rear Axle Oil Cooler Group (If Equipped)

If equipped, the installation of the rear axle oil cooler group requires parts from the following groups:
320-8197 Rear Axle Oil Cooler Gp
240-2792 Power Train Cooler Lines Gp
Install the 320-8197 Rear Axle Oil Cooler Gp
Table 51
Parts that are Required to Install the Rear Axle Oil Cooler Group
1 1 320-1516 Hose As
2 1 320-1541 Hose As

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

The parts required to install the power train cooler lines group are from the 240-2792 Power Train Cooler Lines
Gp.
Table 52
Parts that are Required to Install the Power Train Cooler Lines Group

1 1 113-6365 Hose As
2 1 8X-8886(1) Hose As
3 1 243-1293 Hose As
4 1 371-0572 Hose As
5 1 271-4905 Hose As
6 1 284-7705 Hose As
7 2 319-6226 Elbow As
8 1 319-6242 Elbow As
9 1 332-8558 Tee As
10 1 153-6270 Tee
11 2 228-7090 O-Ring Seal
12 1 214-7568 O-Ring Seal

(1) Part of the 379-4937 Fan Drive Lines Gp

Location of the rear axle oil pump
(1) 113-6365 Hose As
(2) 8X-8886 Hose As
(3) 243-1293 Hose As
(4) 371-0572 Hose As
(5) 271-4905 Hose As
(6) 284-7705 Hose As
(7) 319-6226 Elbow As
(8) 319-6242 Elbow As
(9) 332-8558 Tee As
(10) 153-6270 Tee
(11) 228-7090 O-Ring Seal
(12) 214-7568 O-Ring Seal
NOTICE
Some hydraulic hose connections require the removal of the protective
shipping plug assembly from the hose and/or the fitting. Some
protective shipping plug assemblies contain an O-ring. Keep all
hydraulic connections clean and dry during the assembly procedure.
1. If not already installed, install elbow assembly (7), elbow assembly (8), tee assembly (9), and tee (10).
Connect hose assembly (1), hose assembly (2), hose assembly (3), hose assembly (4), hose assembly (5),
and hose assembly (6) to the appropriate connectors.
Install the Electrical Connectors

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

View of the rear frame and the rear axle assembly
2. Connect chassis harness (B) to rear chassis harness (C) in two places.
3. Connect the electrical connectors that are on the right side of the frame assembly.
4. Secure the rear electrical harness with the bolts, washers, and clamps that are provided.
Install the Ground Access Arrangement

There are two options for ground access:
364-8158 Stairway Ar (Standard)
354-0520 Stairway Ar (Powered Access)
Install the 364-8158 Stairway Ar (Standard)
Table 53
Parts that are Required to Install the 364-8158 Stairway Ar (Standard)
1 2 344-2424 Stairway Gp
A 12 8T-4184 Bolt(1)
B 12 198-4778 Hard Washer(1)

(1) Part of the 344-2424 Stairway Gp

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

Typical view of right side platform assembly
2. Use a suitable lifting device (C) to position the platform assembly. The approximate weight of the platform
assembly is 63 kg (139 lb).

View of left side of platform
3. Install three bolts (A) and three washers (B) that were removed in Step 1. Install bolts (A). Torque the bolts
to a value of 100 ± 20 N·m (74 ± 15 lb ft).
4. Repeat Step 3 for the right side of the platform assembly.
5. Repeat Step 1 through Step 4 for the left side.
Install the 354-0520 Stairway Ar (Powered Access)

Table 54
Parts that are Required to Install the 354-0520 Stairway Ar (Powered Access)
1 1 354-0522 Plate As
2 16 8T-7338 Bolt
3 16 198-4780 Hard Washer
4 1 328-1150 Platform Gp
5 1 480-1147 Pipe As
6 1 481-2825 Pipe As
7 24 8T-4195 Bolt

9 1 328-1141 Stairway As
10 2 328-1178 Hub
11 16 8T-4182 Bolt
12 16 198-4777 Hard Washer
13 2 5A-4885 Plug Button

14 1 480-1153 Handrail Gp
15 1 480-1162 Handrail Gp
16 2 480-1157 Pipe As
17 2 480-1165 Pipe As
18 8 9X-2041 Screw
19 8 8T-4222 Plated Washer

20 16 457-0270 Bushing
21 16 4W-0435 Quad Ring Seal
22 1 309-1905 Taperlock Stud
23 1 9C-5344 Spacer

25 1 344-5675 Nut
26 2 177-4562 Grommet
27 2 8T-1889 Clip
28 2 8T-1890 Clip
29 1 2V-1771 Grommet
30 1 6D-4246 Clip
31 1 8T-6466 Bolt
32 2 8T-4179 Bolt
34 1 204-8000 Cable Tie Mounting

35 1 204-2281 Cable Strap
36 1 8T-4137 Bolt
37 1 8M-2770 Clip
38 1 9M-8406 Clip

(1) 354-0522 Plate As
(2) 8T-7338 Bolt
(3) 198-4780 Hard Washer
1. Secure plate assembly (1) to the right-hand side of the bumper assembly by using eight bolts (2) and eight
hard washers (3).

Typical view of the top of platform group (4)
( A) Tread plate
(B) Bolt
(C) Washer
(4) 328-1150 Platform Gp
2. Remove tread plate (A) from the top of platform group (1) by removing bolts (B) and washers (C).

(1) 354-0522 Plate As
(2) 8T-7338 Bolt
3. Attach a suitable lifting device to platform group (4).
Note: The approximate weight of platform group (4) is 235 kg (518 lb).
Secure platform group (4) to plate assembly (1) by using eight bolts (2) and eight hard washers (3).
After platform group (4) has been secured, resecure tread plate (A) that was removed in Step 2.

(5) 480-1147 Pipe As
(6) 481-2825 Pipe As
(7) 8T-4195 Bolt
4. Secure pipe assembly (5) to platform group (4) by using eight bolts (7) and eight hard washers (8).
Secure pipe assembly (6) to platform group (4) by using eight bolts (7) and eight hard washers (8).

(9) 328-1141 Stairway As
(10) 328-1178 Hub
(11) 8T-4182 Bolt
(13) 5A-4885 Plug Button
5. Attach a suitable lifting device to stairway assembly (9).
Note: The approximate weight of stairway assembly (9) is 115 kg (250 lb).
Secure stairway assembly (9) to platform group (4) by using two hubs (10), 16 bolts (11), 16 hard washers
(12), and two plug buttons (13).
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(5) 480-1147 Pipe As
(6) 481-2825 Pipe As
(7) 8T-4195 Bolt
(9) 328-1141 Stairway As
(14) 480-1153 Handrail Gp
(15) 480-1162 Handrail Gp
(16) 480-1157 Pipe As
(17) 480-1165 Pipe As
(18) 9X-2041 Screw
(20) 457-0270 Bushing
(21) 4W-0435 Quad Ring Seal
6. Secure handrail group (14) to stairway assembly (9) by using four bolts (7) and four hard washers (8).
Secure handrail group (15) to stairway assembly (9) by using four bolts (7) and four hard washers (8).
7. Secure two pipe assemblies (16) between handrail group (14) and pipe assembly (5) by using four screws
(18), four plated washers (19), eight bushings (20), and eight quad ring seals (21).
Secure two pipe assemblies (17) between handrail group (15) and pipe assembly (6) by using four screws
(18), four plated washers (19), eight bushings (20), and eight quad ring seals (21).

(D) Cover
8. Remove cover (D) from the rear of the platform group. Retain cover (D) and all mounting hardware.

(E) Cable assembly
(F) Cable assembly
(G) Harness assembly
(22) 309-1905 Taperlock Stud
(23) 9C-5344 Spacer
(25) 344-5675 Nut
(26) 177-4562 Grommet
(27) 8T-1889 Clip
(28) 8T-1890 Clip
(29) 2V-1771 Grommet
(30) 6D-4246 Clip
(31) 8T-6466 Bolt
(32) 8T-4179 Bolt
(34) 204-8000 Cable Tie Mounting
(35) 204-2281 Cable Strap
(36) 8T-4137 Bolt
(37) 8M-2770 Clip
(38) 9M-8406 Clip
9. Secure cable assembly (E), cable assembly (F), and harness assembly (G) to platform group (4) by using
taperlock stud (22), spacer (23), hard washer (24), nut (25), and the following clipping:
Clip (28), clip (27), and grommet (26) for cable assembly (F)
Clip (30) and grommet (29) for cable assembly (E)
Clip (38) for harness assembly (G)
10. Secure cable assembly (E) to platform group (4) by using bolt (32) and hard washer (33).
11. Secure cable assembly (F) and harness assembly (G) to platform group (4) by using bolt (31) and hard
washer (24) and the following clipping:
Clip (28), clip (27), and grommet (26) for cable assembly (F)
Cable tie mounting (34) and cable strap (35) for harness assembly (G)
12. Secure cable assembly (F) to platform group (4) by using bolt (32) and hard washer (33).
13. Secure connect harness assembly (G) to platform group (4).
Secure harness assembly (G) to platform group (4) by using bolt (36), hard washer (24), and clip (37).
14. Secure cover (D) that was previously removed by using the retained hardware.
Install the Handrail Group

There are two handrail group options:
193-6282 Handhold Gp (Wide body)
193-6278 Handhold Gp (Standard body)
Note: Parts of the handhold group can be installed at ground level.
Table 55
Parts that are Required to Install the 193-6282 Handhold Gp or the 193-6278 Handhold Gp(1)
1 1 241-6990 Handhold As
2 133 8T-4136 Bolt(2)
3 133 8T-4121 Hard Washer (2)
5 2 8T-7087 Grommet
6 2 5P-7468 Clip
7 2 5P-7469 Clip
8 1 8T-4194 Bolt
9 1 8T-4244 Nut
11 1 242-9547 Handhold As (3)
12 1 242-9538 Handhold As(4)
13 1 242-9815 Handhold As(5)
14 4 8T-4956 Bolt

16 1 290-6591 Brace
17 4 4L-6459 Bolt
18 4 346-3713 Spacer
20 1 8X-9874 Chain
21 1 5P-0765 Hose
22 1 8C-8451 Bolt
24 1 5C-2890 Nut
25 1 6B-8085 Chain Snap

(1) Some required parts may be part of the 193-6251 Handrail Fastener Gp
(2) Part of 193-6251 Handhold Fastener Gp
(3) Wide body only
(5) Optional rear access only
1. Use a suitable lifting device to position handhold (1). The weight of handhold (1) is approximately 48 kg
(106 lb).
2. Install 16 bolts (2) and 16 washers (3) to secure handhold (1).
(62 lb).
5. Position two grommets (5), two clips (6) and two clips (7) around handhold (4) and handhold (A).
Note: Handhold (A) is part of the right platform arrangement.
6. Use bolt (8) and nut (9) to secure two grommets (5), two clips (6) and two clips (7).
(40 lb).

View of the LH side of the machine

View of the cab with wide mount handhold (11) and optional rear access handhold (13)
9. Step 10 through Step 15 can be completed before the cab is installed to the truck frame.
Note: For the trucks that are not equipped with the optional rear access handhold, use the 240-4794
Handhold Gp.
NOTICE
The 793D (S/N: FDB1-UP) Off-Highway Trucks with the wide body use
the 242-9547 Rail (11). The 793D (S/N: FDB1-UP) Off-Highway Trucks
with bodies of standard width use the 242-9538 Handhold As (12)
10. Position the appropriate rail assembly to the catwalk. Install 16 bolts (2) and 16 washers (3) to secure
handhold (11). Install four bolts (14) and four washers (15) to secure handhold (11).
11. Remove six bolts (A) and six washers (B) in preparation for installation of brace (16).
Bottom view of LH catwalk
12. Position brace (16) to the mounting location that is located next to the front outrigger.

Bottom view of LH catwalk
(16) 290-6591 Brace
(17) 4L-6459 Bolt
(18) 346-3713 Spacer
13. Secure brace (16) to the bottom of the left-hand catwalk by using four bolts (17) and four spacers (18).
14. Position handhold (13) to the mounting location. The weight of the handhold is approximately 28.5 kg
(63 lb).
Note: Refer to Illustration 152.
16. Install four bolts (2) and four washers (3) to connect handhold (11) and handhold (13).
17. Position handhold (19) to chassis. Install six bolts (2) and six washers (3) to secure handhold (19).
Note: Handhold (19) weighs approximately 7 kg (15 lb).
18. Install bolt (22), washer (23), and nut (24) to secure chain (20) and hose (21) to handhold (11). Secure chain
snap (25) to chain (20).
Install the 193-6310 Fender Gp and the Mud Guards

Table 56
Parts that are Required to Install the 193-6310 Fender Gp
1 1 290-9011 Fender As
2 10 8T-4195 Bolt
4 1 290-6591 Brace(1)
5 4 8T-4194 Bolt
7 2 8T-4139 Bolt

9 2 8T-4244 Nut
10 1 8X-4295 Guard
11 3 8X-4294 Strip
12 37 8T-0722 Bolt
13 38 8T-4133 Nut
14 1 8W-7899 Guard
15 1 8X-4296 Strip
16 2 251-7661 Deflector
17 1 8X-4285 Plate As(2)

18 1 275-5111 Guard
19 1 8X-4293 Strip
20 1 8X-4289 Plate
21 1 275-5110 Guard
22 1 275-8089 Strip
(1) Part of 240-4784 Rear View Mirror Gp
(2) Part of 240-4794 Handhold Gp

View of LH side of cab
1. Position fender (1) to the mounting location on catwalk (A). Use nine bolts (2) and nine washers (3) to
secure fender (1).
Note: The weight of fender (1) is approximately 51 kg (113 lb).

View of LH left-hand fender (1)

Bottom view of catwalk
2. Install four bolts (5) and four washers (6) to secure brace (4) to the handhold assembly.

Bottom view of the catwalk
3. Position guard (10) and three strips (11) to the catwalk. Install 12 bolts (12), 24 washers (3), and 12 nuts (13)
to secure the guard.

View of RH platform and guard that is installed
4. Position guard (14) and strip (15) to the right platform. Install nine bolts (12), 18 washers (3), and nine nuts
(13) to secure the guard.

View of LH deflector that is installed
5. Remove 13 bolts (D) and 13 washers (E) to remove two strips (C). Retain the hardware.
6. Position deflector (16) and two strips (C). Install 13 bolts (D) and 13 washers (E) to secure the deflector.
7. Repeat Step 5 and Step 6 for the right-hand side.

Rear view of the catwalk

View of tab (F) that is already attached to plate (17)
8. Position plate assembly (17) to the rear outrigger. Install four bolts (12), eight washers (3), and four nuts
(13) to secure the plate assembly.
Note: Position tab (F) of plate assembly (17) to the outside of the catwalk. Refer to Illustration 167.
9. Position guard (18) and strip (19) to plate (17). Install seven bolts (12), 14 washers (3), and seven nuts (13)
to secure the guard.

View under the rear catwalk
10. Position plate (20) to plate (17) and the rear catwalk. Install two bolts (7), four washers (8) and two nuts (9)
to secure the plate.
11. Install one bolt (2), two washers (3) and one nut (13) to secure tab (F) of plate assembly (17) to the left-hand
side of the rear catwalk.

Rear view of the guard that is installed on the left-hand side of the rear catwalk
12. Position guard (21) and strip (22) to plate (17). Install five bolts (12), ten washers (3), and five nuts (13) to
secure the guard.
Install the Mirror Group

There are two mirror group options:
240-4774 Rear View Mirror Gp (EXTERIOR, HEATED)
193-6277 Rear View Mirror Gp
Each mirror group can use the following mirror mounting groups:
240-4784 Rear View Mirror Gp (WIDE TRUCK BODY)
240-4785 Mirror Bracket Gp
Note: This procedure contains information to install a 290-0057 Mirror As on a machine that is equipped with a
standard body or a wide body. If your machine is equipped with a standard body, then refer to Step 4.
Table 57
Parts that are Required to Install the Mirror Group
1 1 250-7605 Bracket As(1)
2 8 8T-4185 Bolt(1)
3 15 8T-4121 Hard Washer(2)
4 1 134-0987 Bracket As(1)
5 1 303-8298 Bracket As(3)
6 2 134-0989 Block(1)
7 2 303-8300 Block(3)
8 4 8T-4186 Bolt(1)
9 4 8T-4910 Bolt(3)
10 4 198-4778 Hard Washer(3)
11 1 290-0057 Mirror As(4)
12 3 8T-4136 Bolt
(1) Wide body only
(2) Additional hard washers (3) can be used if there is a gap between mirror (11) and bracket assembly (4).
(4) 193-6277 Rear View Mirror Gp

Left side view of bracket (1) for wide body
1. Use eight bolts (2) and eight washers (3) to secure bracket (1) to handhold (A).
2. Install four washers (3) and four bolts (8) to secure bracket (4) and blocks (6) to bracket (1).
3. Install three washers (3) and three bolts (12) to secure mirror assembly (11) to the bracket.

View of mirror that is installed on a standard body
4. Install four washers (10) and four bolts (9) to secure bracket (5) and blocks (7) to handhold (B).
5. Repeat Step 3.
Install the Front Suspension

Installation of the front suspension requires the 8X-2808 Suspension Mounting Gp
Table 58
Parts that are Required to Install the Front Suspension

1 2 5T-5202 Bearing Cap(1)
2 2 5T-6255 Key
3 20 8T-6624 Bolt
4 20 5T-1352 Spacer
5 20 9X-8399 Washer
6 20 8T-1583 Nut
7 12 9X-6626 Bolt
8 12 5T-4896 Spacer
10 12 8C-4032 Nut
11 16 117-4935 Plate
12 8 8T-0669 Bolt
(1) One 6V-3249 Bearing and one 6V-0836 Retaining Ring for each cap
Table 59
Tools that are Required to Install the 8X-2808 Suspension Mounting Gp (Front)
A 1 6V-6080 Torque Multiplier Gp
B 1 6V-4170 Adapter
C 1 4C-6724 Socket
D 1 5S-6076 Extension
E 1 8T-3196 Wrench
Note: The weight of the suspension cylinder group is 6504 kg (14340 lb).

View of mounting area for the bearing cap
1. Remove all dirt and shipping grease from the top of the suspension cylinder group.
NOTICE
To install the bearing cap correctly, the retaining ring must face
towards the strut when installed. An incorrectly installed bearing cap
may result in cap bearing failure and/or front strut failure.
2. Clean all mating surfaces of the bearing cap. Position the bearing cap onto the top of the suspension cylinder
group.
3. Remove the paint from the suspension cylinder group.

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

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

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

View of plates that can be used behind cap (1)
14. Install four bolts (12) and four washers (13) to secure cap (1). Plates (11) can be used to fill the gap between
the chassis and cap (1). Tighten bolts (12) to a torque value of 800 ± 100 N·m (590 ± 74 lb ft).
Note: Plates (11) should be installed to fill the gap.
15. Repeat Step 1 through Step 14 for the other side of the machine.
Connect the Brake Cooling Lines Group

There are two brake cooling options:
462-7787 Brake Cooling Lines Gp (Standard)
462-7788 Brake Cooling Lines Gp (Extended Life Powertrain)
Table 60
Parts that are Required to Install the Brake Cooling Lines Group
1 8 8T-4944 Bolt
2 2 265-0975 Tube As
3 2 241-5766 Hose
4 8 209-4589 Clamp
5 4 156-5744 Half Clamp
6 18 8T-4183 Bolt
8 2 8T-4244 Nut
9 16 9X-8257 Washer
10 8 7X-2556 Bolt
11 8 8T-4175 Bolt

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

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

View of LH front wheel
7. Remove the covers from the cooling hose assemblies. Discard the cover.
Secure the hose assemblies by using bolts (9), bolts (10), and washers (11).

View of front RH cooler lines that are installed
8. Repeat for the other side of the machine.
Connect the Steering Links and Steering Cylinders to the Wheel

Groups
Required parts to connect the steering links and steering cylinders to the wheel groups are from the following
groups:
245-0921 Steering Arm Gp
245-0905 Steering Link Gp
8X-0259 Steering Cylinder and Mounting Gp
Extended Life, Wheel, and Brake Group Configuration Equipped Truck.

Table 61
Parts that are Required to Connect the Steering Links and Steering Cylinders to the Wheel Groups
1 4 3J-6899 Locknut
Table 62
Tools that are Required to Connect the Steering Links and Steering Cylinders to the Wheel Groups
AA 1 5P-3520 Spanner Wrench
BB 2 5S-6084 Socket
1. Remove two nuts (1) and two protective sleeves (C) from ball studs on steering link (B) and steering
cylinder (A).

View of LH steering arm and steering link

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

View of LH steering link (B) that is installed
5. Use spanner wrench (AA) to hold ball stud (D) for tightening. Use socket (BB) to tighten nut (1) to a torque
of 2550 ± 100 N·m (1881 ± 74 lb ft).
6. Reinstall retaining ring (G) and cover (H) that was removed in Step 4.
7. Repeat Step 2 through Step 5 for steering cylinder end (A).
8. Repeat Step 2 through Step 7 for the right side.
Standard Equipped Truck
Table 63
Parts that are Required to Install the 8X-2829 Steering Arm Fastener Group

1 20 8T-0283 Bolt
2 20 9X-8399 Washer
3 1 3J-6899 Locknut
1. Check the surfaces for cleanliness and metal burrs.
2. Use a chain and a lever puller to support steering arm (A). Position the steering arm to the left side of the
front suspension cylinder.
3. Install ten bolts (1) and ten washers (2) to secure left steering arm (A) to the left front suspension cylinder.
Note: Tighten the bolts to a torque value of 1600 ± 200 N·m (1180 ± 148 lb ft).
4. Use a chain and a lever puller to support right steering arm (B). Align right steering arm (B) to center
steering arm (C).
5. Remove dirt and grease from the tapered bore of center steering arm (C).
6. Install right steering arm (B) to center steering arm (C).

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

Depending on the wheel arrangement, the following service brake lines groups could be used:
The 245-0896 Service Brake Lines Gp is part of the standard 245-0906 Final Drive and Brake Wheel Ar or
the standard 454-9776 Final Drive and Brake Wheel Ar
The 193-6243 Service Brake Lines Gp is part of the extended life 240-4767 Final Drive and Brake Wheel Ar
or the extended life 454-9778 Final Drive and Brake Wheel Ar
Table 64
Parts that are Required to Install the Service Brake Lines Group to the Front Wheels
1 4 8X-6137 Block
2 4 5T-0968 Block
3 8 8T-4185 Bolt
5 2 148-8358 Elbow
6 1 185-1449 Bracket (LH)
7 1 185-1450 Bracket (RH)

8 2 7X-0871 Tee
9 2 6V-0852 Dust Cap
10 2 164-5567 Fitting Gp
11 2 148-8345 Connector Gp
12 4 0S-1627 Bolt
14 6 7K-1181 Cable Strap
15 2 5J-0451 Hose As
16 2 6D-6489 Pipe Connector
17 2 9C-4937 Breather As
18 2 1S-0996 Clip
1. Install one elbow (5) to the front brake. Attach the existing hose to elbow (5). Use the following items to
secure the hose to the bracket: one block (1), one block (2), two bolts (3) and two washers (4).
2. Install bracket (6) to the front brake. Use two bolts (12) and two washers (13).
Note: Bracket (6) is for the left-hand side of the machine. Bracket (7) is for the right-hand side of the
machine.
3. Install one connector (11) to the front brake. Install tee (8) to connector (11). Install dust cap (9) and fitting
(10) to tee (8).
4. Attach existing hose to tee (8). Secure hose with the following items: one block (1), one block (2), two bolts
(3) and two washers (4).
5. Install one connector (16) to the front brake. Attach one end of hose assembly (15) to connector (16).
6. Use cable straps (14) to secure hose assembly (15) to the existing hose.
7. Attach one breather (17) to the other end of hose assembly (15). Use one clip (18) and the existing hardware
to secure hose assembly (15) to the mount for the front strut.

Right side view
8. Repeat Step 1 through Step 7 for the right-hand side of the machine.
Install the Fuel Tank

Installation of the fuel tank requires parts from the 216-1735 Fuel Tank Fastener Gp
There are two fuel tank sizes available:
The 240-4806 Fuel Tank and Filter Ar and the 359-7705 Fuel Tank and Filter Ar have a capacity of 4353 L
(1150 US gal)
The 240-4799 Fuel Tank and Filter Ar and the 359-7710 Fuel Tank and Filter Ar have a capacity of 4921 L
(1300 US gal)
Note: The 216-1735 Fuel Tank Fastener Gp is for use with all fuel tank sizes.
Reference: Refer to "Install the 8X-0193 Fuel Heater Group (If Equipped)" if the machine is equipped with a
heater for the fuel tank.
Table 65
Parts that are Required to Install the Fuel Tank

1 4 7X-2489 Bolt
2 4 8T-4167 Washer
3 2 8X-2575 Cap
4 1 216-2976 Plate Assembly
5 2 7X-2564 Bolt
6 8 8T-5439 Washer
7 2 8T-4131 Nut
8 4 8N-1214 Mount Assembly

9 2 7N-5656 Sleeve
10 2 7X-2488 Bolt
11 2 6V-7688 Locknut
12 4 8X-2576 Shim Pack
13 2 8T-5005 Bolt

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

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

View of fuel tank support (B) and cap (3).
6. Measure and record inside diameter (AA).
7. Repeat Step 5 and Step 6 for the other side.
8. Remove paint and dirt from mounting pin (C) on the fuel tank.

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

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

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

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

Top view of the fuel tank
21. Use clamps (E) that are provided to secure the hose in two places to the fuel tank.
22. Install two bolts (13) and two washers (14) to secure vent assembly (D) to the truck frame.
Note: Vent assembly (D) is already provided.

View of bottom of the fuel tank
23. Remove six bolts (F) and six washers (G) to remove cover (H). Retain hardware.
24. Connect harness (A) to the electrical connections for the fuel tank sensor.
25. Install the hardware that was removed in Step 23 to secure cover (H).
Install the 238-2848 Water Separator and Fuel Filter Gp (If Equipped)
Table 66

1 1 159-4724 Ball Valve
2 2 7M-8485 O-Ring Seal
3 1 6V-9182 Elbow
4 1 8X-5311 Check Valve As

6 1 6V-9852 Elbow
7 2 7J-9108 O-Ring Seal
9 1 5P-6994 Clip
10 1 8T-4192 Bolt

Side view of the fuel tank
1. Remove cap assembly (A) and O-ring (B) from the fuel tank. Discard the hardware.
Remove cap assembly (C) and O-ring (D) from the fuel tank. Discard the hardware.

View of the side of the fuel tank
(1) 159-4724 Ball Valve
(2) 7M-8485 O-Ring Seal
(3) 6V-9182 Elbow
(4) 8X-5311 Check Valve As
(6) 6V-9852 Elbow
(7) 7J-9108 O-Ring Seal
2. Secure ball valve (1) to the fuel tank with O-ring seal (2). Secure elbow (3) to ball valve (1) with O-ring seal
(2).
Secure check valve assembly (4) to the fuel tank with O-ring seal (5). Secure elbow (6) to check valve
assembly (4) with O-ring seal (7).

(E) 251-3247 Hose As
(F) 478-9475 Hose As
(3) 6V-9182 Elbow
(6) 6V-9852 Elbow
(9) 5P-6994 Clip
(10) 8T-4192 Bolt
3. Remove the caps for shipping from hose assembly (E) and hose assembly (F).
Connect hose assembly (E) with O-ring seal (8) to elbow (3).
Connect hose assembly (F) with O-ring seal (7) to elbow (6).
4. Secure hose assembly (E) and hose assembly (F) to the frame by using clip (9), bolt (10), and hard washer
(11).
Install the 230-1086 Fuel Filter Lines Gp (If Equipped)

Table 67
1 1 159-4724 Ball Valve

3 1 6V-9182 Elbow
4 1 8X-5311 Check Valve As
6 1 6V-9852 Elbow
8 1 7E-6719 Primary Fuel Filter Gp
9 2 8T-4195 Bolt
11 2 6V-9007 Elbow
12 2 3D-2824 O-Ring Seal
13 1 113-9339 Hose As
15 1 5P-6994 Clip
16 1 8T-4192 Bolt

Side view of the fuel tank
1. Remove cap assembly (A) and O-ring (B) from the fuel tank. Discard the hardware.
Remove cap assembly (C) and O-ring (D) from the fuel tank. Discard the hardware.

(1) 159-4724 Ball Valve
(3) 6V-9182 Elbow
(6) 6V-9852 Elbow
(8) 7E-6719 Primary Fuel Filter Gp
(9) 8T-4195 Bolt
(11) 6V-9007 Elbow
(12) 3D-2824 O-Ring Seal
2. Secure ball valve (1) to the fuel tank with O-ring seal (2). Secure elbow (3) to ball valve (1) with O-ring seal
(2).
Secure check valve assembly (4) to the fuel tank with O-ring seal (5). Secure elbow (6) to check valve
assembly (4) with O-ring seal (7).
Secure primary fuel filter group (8) to the fuel tank by using two bolts (9) and two hard washers (10).
Secure two elbows (11) with two O-ring seals (12) to primary fuel filter group (8).

(E) 478-9475 Hose As
(F) 251-3247 Hose As
(1) 159-4724 Ball Valve
(3) 6V-9182 Elbow
(6) 6V-9852 Elbow
(8) 7E-6719 Primary Fuel Filter Gp
(9) 8T-4195 Bolt
(11) 6V-9007 Elbow
(12) 3D-2824 O-Ring Seal
(13) 113-9339 Hose As
(15) 5P-6994 Clip
(16) 8T-4192 Bolt
3. Remove the caps for shipping from hose assembly (E) and hose assembly (F).
Connect hose assembly (E) with O-ring seal (7) to elbow (3).
Connect hose assembly (F) with O-ring seal (14) to elbow (11).
4. Secure one end of hose assembly (13) with O-ring seal (14) to elbow (3). Secure the other end of hose
assembly (13) with O-ring seal (14) to elbow (11).
5. Secure hose assembly (E) and hose assembly (F) to the frame by using clip (15), bolt (16), and hard washer
(17).
Install the 8X-0193 Fuel Heater Group (If Equipped)

Reference: Refer to "Install the Fuel Tank".
Table 68
Parts that are Required to Install the 8X-0193 Fuel Heater Group
1 1 114-8701 Plate
2 2 7X-2568 Bolt (1)
3 1 7W-5300 Fuel Heater
4 4 8T-4194 Bolt

6 2 6B-9081 Reducing Bushing
7 2 8C-6874 Connector
9 1 6V-9852 Swivel Elbow

11 2 8C-6873 Connector
12 2 061-9593 Reducer Bushing
13 1 8T-8899 Elbow
14 1 107-8163 Hose As
15 1 8W-5428 Hose As
(1) These bolts replace the bolts that are included in the Fuel Tank Fastener Gp.

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

Typical view of installed components
8. Connect the other end of hose (14). Connect the other end of hose (15).
9. Connect existing hoses.
Install the 264-7554 Service Center Gp (If Equipped)

Table 69
Parts that are Required to Install the 264-7554 Service Center Gp
1 1 231-7582 Adapter
2 1 5H-6734 O-Ring Seal

3 6 8T-2501 Bolt
7 5 8T-4183 Bolt
9 1 285-5336 Plate
10 2 8T-4137 Bolt
12 1 6V-1867 Clip
13 1 6V-1868 Clip
15 1 8T-4244 Nut

View of back of the fuel tank that faces the frame
1. Remove six bolts (A) to remove cover (B). Discard the hardware.

(1) 231-7582 Adapter
(2) 5H-6734 O-Ring Seal
(3) 8T-2501 Bolt
2. Secure adapter (1) with O-ring seal (2) to the fuel tank by using six bolts (3) and six hard washers (4).

(A) 285-5634 Hose As
(1) 231-7582 Adapter
(5) 1P-4582 Half Flange
(7) 8T-4183 Bolt
(9) 285-5336 Plate
(10) 8T-4137 Bolt
(12) 6V-1867 Clip
(13) 6V-1868 Clip
(15) 8T-4244 Nut
3. Remove the shipping cover from hose assembly (A). Discard the shipping cover and the associated
mounting hardware.
Secure hose assembly (A) with O-ring seal (6) to adapter (1) by using two half flanges (5), four bolts (7),
and four hard washers (8).
Secure plate (9) to the fuel tank by using two bolts (10) and two hard washers (11).
Secure hose assembly (A) to plate (9) by using clip (12), clip (13), grommet (14), bolt (7), two hard washers
(8), and nut (15).
Install the Cab Steering Lines Group

The installation of the cab steering lines group requires parts from the 151-8730 Steering Lines Gp.
Table 70
Parts that are Required to Install the Cab Steering Lines Group
1 2 6V-8639 Connector
2 2 6V-8625 Elbow
3 4 3K-0360 O-Ring Seal
4 1 6V-9200 Elbow

6 1 150-8708 Tube As
7 1 150-8713 Tube As
8 1 150-8709 Tube As
9 1 150-8723 Tube As
10 1 150-8710 Tube As
13 2 5T-6867 Clamp
14 3 5M-3062 Bolt

16 1 9S-1350 Clip
17 1 8X-5968 Bracket As
18 3 8T-4136 Bolt
19 1 6G-8532 Guard As
Note: Steps 1 through3should be completed while the cab is located at ground level.

View of the cab

Parts are located under the hood.
1. Remove the shipping caps.

(1) 6V-8639 Connector
(2) 6V-8625 Elbow
(3) 3K-0360 O-Ring Seal
(4) 6V-9200 Elbow
2. Secure two connectors (1) with two O-ring seals (3) to the steering valve group.
Secure two elbows (2) with two O-ring seals (3) to the steering valve group.
Secure elbow (4) with O-ring seal (5) to the steering valve group.

View of the front of the cab
(1) 6V-8639 Connector
(2) 6V-8625 Elbow
(4) 6V-9200 Elbow
(6) 150-8708 Tube As
(7) 150-8713 Tube As
(8) 150-8709 Tube As
(9) 150-8723 Tube As
(10) 150-8710 Tube As
3. Secure tube assembly (6) with O-ring seal (11) to the upper left connector (1).
Secure tube assembly (7) with O-ring seal (11) to the upper right connector (1).
Secure tube assembly (8) with O-ring seal (11) to the lower left elbow (2).
Secure tube assembly (9) with O-ring seal (11) to the lower right elbow (2).
Secure tube assembly (10) with O-ring seal (12) to the elbow (4).
Note: The following step may need to be completed after the cab is installed on the machine.

View of the bottom of the cab
(6) 150-8708 Tube As
(7) 150-8713 Tube As
(8) 150-8709 Tube As
(9) 150-8723 Tube As
(10) 150-8710 Tube As
(13) 5T-6867 Clamp
(14) 5M-3062 Bolt
(16) 9S-1350 Clip
(17) 8X-5968 Bracket As
(18) 8T-4136 Bolt
4. Secure tube assembly (7) and tube assembly (9) to the machine by using clamp (13), bolt (14), and hard
washer (15).
Secure tube assembly (6) and tube assembly (8) to the machine by using clamp (13), bolt (14), and hard
washer (15).
Secure tube assembly (10) to the machine by using clip (16), bolt (14), and hard washer (15).
Secure bracket assembly (17) to the machine by using bolt (18) and hard washer (15).
The following list matches the identification tags to the tube assemblies:
(T) 1V-6277 Identification Tag to the 150-8708 Tube As
(P) 8R-4853 Identification Tag to the 150-8709 Tube As
(R) 1V-6274 Identification Tag to the 150-8723 Tube As
(LS) 4J-6311 Identification Tag to the 150-8710 Tube As
(L) 1V-6276 Identification Tag to the 150-8713 Tube As
Note: The following step must be completed after the cab is installed on the machine.

View of the bottom of the cab
(18) 8T-4136 Bolt
(19) 6G-8532 Guard As
5. Secure guard assembly (19) to the bottom of the cab by using three bolts (18) and three hard washers (15).
Install the 247-5876 Cab Mounting Gp

Table 71
Parts that are Required to Install the 247-5876 Cab Mounting Gp
1 1 304-2711 Support As
2 9 7X-2582 Bolt
3 23 5T-1352 Spacer
4 1 296-7866 Support As
5 1 298-3859 Walkway As(1)
6 6 130-0099 Bolt
7 8 107-3953 Bolt
(1) Part of 240-4787 Walkway Gp
Note: When you install the support assemblies, ensure that all mating surfaces are free of paint and grease. 4C-
4204 Paint and Decal Remover can be used to remove paint during this procedure.
Note: Before the support assemblies are attached to the truck, the cab mounting surfaces for the cab can be
prepared. Also, the cab mounts can be installed.

Side view of front mounting location for the cab support
1. Remove four bolts and four washers to remove lifting eye (A). Discard the hardware. Prepare the mounting
surface (B) of the frame by removing all paint and grease.
2. Remove all paint and grease from the mating surface of front support assembly (1).

Side view of the front support assembly
3. Use a suitable lifting device to position support assembly (1) to mounting surface (B).
Note: The approximate weight of the support assembly is 173.5 kg (383 lb).

Front view of the front support assembly
4. Install nine bolts (2) and nine spacers (3) to secure support assembly (1). Tighten bolts (2) to a torque value
of 1600 ± 200 N·m (1180 ± 148 lb ft).

Side view of the rear mounting location for the rear support assembly
5. Prepare the mounting surface for rear support assembly (C) by removing all paint and grease.

View of the rear cab support and the optional rear catwalk that is installed
6. Prepare the mounting surface for rear support assembly (4) by removing all paint and grease.
Note: Optional walkway assembly (5) may already be attached to rear support assembly (4).

Front view of the rear support and the walkway assembly that is installed
7. Use a suitable lifting device to position rear support (4) and walkway assembly (5) to mounting surface (C).
The approximate weight of rear support (4) is 300 kg (661 lb). The approximate weight of optional walkway
(5) is 42 kg (93 lb).
8. Install six bolts (6) and six spacers (3) into the top holes of support assembly (4). Install eight bolts (7) and
eight spacers (3) into the bottom holes of support assembly (4). Tighten the bolts to a torque value of
1600 ± 200 N·m (1180 ± 148 lb ft) to secure rear support assembly (4).
Install the Cab Group

The installation of the cab group requires parts from the 163-7226 Cab Mounting Gp.
Table 72
Parts that are Required to Install the Cab Group

1 40 163-0042 Mount
2 8 163-3127 Sleeve
3 6 164-4411 Sleeve
4 6 163-0364 Sleeve
5 20 5T-5807 Retainer
6 8 6V-2624 Bolt
7 6 6B-0388 Bolt
8 6 1K-9420 Bolt
9 4 5T-9893 Shim (1)
10 4 5T-9894 Shim(1)
11 1 9M-8406 Clip(2)
12 1 8T-4137 Bolt(2)
13 1 8T-4121 Hard Washer(2)

(1) Use the shims to obtain a flatness within 0.75 mm (0.03 inch).
(2) Part of the 144-4181 Air Horn Gp

View of the installed front support assembly for the cab
1. Use 4C-4204 Paint Remover or a suitable device to clean the paint from four seats (A) and the cab mounting
area of front support (B).
2. Install four mounts (1) into the top of the bores of support assembly (B). Install four mounts (1) and four
sleeves (2) into the bottom bores of support assembly (B).

Top view of the front cab mounts and sleeves that are installed in the frame
3. Use 4C-4204 Paint Remover or a suitable device to clean the paint from the four seats and cab mounting
area (C) of the frame.
4. Install four mounts (1) into the top bores of the frame. Install four mounts (1) and four sleeves (2) into the
bottom bores of the frame.

View of the installed rear support assembly for the cab
5. Use 4C-4204 Paint Remover or a suitable device to clean the paint from six seats (D) and the cab mounting
area of rear support (E).

Top view of the rear cab mounts and sleeves that are installed in the support assembly
6. Install six mounts (1) into the top bores of support assembly (E). Install six mounts (1) and six sleeves (3)
into the bottom bores of support assembly (E).
Top view of the rear cab mounts and sleeves that are installed in the frame
7. Use 4C-4204 Paint Remover or a suitable device to clean paint from the six seats and cab mounting area (F)
of the frame.
8. Install six mounts (1) into the top bores of the frame. Install six mounts (1) and six sleeves (4) into the
bottom bores of the frame.
9. Use a suitable lifting device to position the cab assembly to support assembly (B) and support assembly (E).
The weight of the cab assembly, catwalks, and the handrail is approximately 2300 kg (5071 lb).
Note: The mating surfaces of the cab assembly must be clean. Also, the mating surfaces must be smooth.

Bottom view of the front support assembly for the cab
10. Apply 9S-3263 Thread Lock Compound to the threads of eight bolts (6). Install four retainers (5) and four
bolts (6) in two places into the cab assembly.
Note: Partially install bolts (6) to allow movement of the cab assembly for the installation of the rear bolts.

Bottom view of rear support assembly (E) for the cab
11. Apply 9S-32639S-3263 Thread Lock Compound to the threads of six bolts (7) and six bolts (8). Install six
retainers (5) and six bolts (7). Install six retainers (5) and six bolts (8).

View of shims
12. If necessary, install shims (9) and (10) to achieve a flatness within 0.75 mm (0.03 inch) with the cab.
13. Tighten all the cab mounting bolts to a torque value of 1904 ± 68 N·m (1405 ± 50 lb ft).

Bottom view of the steering lines and the cab harness
14. Connect cab harness (F) to chassis harness (G). Install clip (11), bolt (12), and washer (13) to secure the
harness.
Install the Handrail Assembly for the Rear Access Arrangement (If
Equipped)
The 456-0270 Handrail As and the required installation parts are part of the 240-4797 Handrail Fastener Gp.
Table 73
Parts that are Required to Install the Handrail Assembly for the Rear Access Arrangement
1 1 456-0270 Handrail As
2 2 8T-5005 Bolt
3 2 1F-7854 Spacer
5 2 8T-0389 Locknut
6 1 296-5446 Spring
7 1 5L-3946 Rod End
9 1 9S-8752 Full Nut
10 1 431-6297 Bracket As
11 2 8T-4195 Bolt
12 1 5G-0817 Conical Bumper
13 1 6V-8186 Full Nut
16 4 5P-7468 Clip
17 4 5P-7469 Clip
18 4 8T-4956 Bolt
20 4 329-3356 Nut
21 1 438-9871 Plate
22 1 456-0271 Plate
23 1 172-8125 Pin
24 1 160-9925 Lanyard
25 1 5C-9553 Bolt
26 1 9X-8256 Washer
27 1 344-5673 Nut
1. Position handhold (1) to walkway (A).
Note: The weight of the handhold is approximately 14.5 kg (32 lb).

View of the rear walkway assembly
(1) 456-0270 Handrail As
(2) 8T-5005 Bolt
(3) 1F-7854 Spacer
(5) 8T-0389 Locknut
2. Secure handrail assembly (1) to the walkway assembly by using bolt (2), spacer (3), two hard washers (4),
and nut (5).

View of the bottom of the walkway assembly
(6) 296-5446 Spring
(7) 5L-3946 Rod End
(9) 9S-8752 Full Nut
3. Secure rod end (7) to the bottom of the walkway assembly by using two hard washers (8) and two nuts (9).
Note: Do not tighten the nuts.
Secure rod end (7) to handrail assembly (1) by using spring (6).
Note: Adjust rod end (7) as needed to adjust the spring tension. Handrail assembly (1) should move freely.

View of the left-hand side of the walkway assembly
(10) 431-6297 Bracket As
(11) 8T-4195 Bolt
(12) 5G-0817 Conical Bumper
(13) 6V-8186 Full Nut
4. Secure bracket assembly (10) to the side of the walkway assembly by using two bolts (11) and two hard
washers (4).
Secure conical bumper (12) to bracket assembly (10) by using full nut (13) and hard washer (14).

(16) 5P-7468 Clip
(17) 5P-7469 Clip
(18) 8T-4956 Bolt
(20) 329-3356 Nut
(21) 438-9871 Plate
(22) 456-0271 Plate
(23) 172-8125 Pin
(24) 160-9925 Lanyard
(25) 5C-9553 Bolt
(26) 9X-8256 Washer
(27) 344-5673 Nut
5. Secure plate (21) to the back of the existing handrail assembly by using two grommets (15), two clips (16),
two clips (17), two bolts (18), four hard washers (19), and two nuts (20).
Secure plate (22) to the existing handrail assembly by using two grommets (15), two clips (16), two clips
(17), two bolts (18), four hard washers (19), and two nuts (20).
Secure pin (23) and lanyard (24) to the handrail assembly by using bolt (25), washer (26), and nut (27).
Install the Air Hoses and Install the Electrical Connection for the Cab
The following groups connect to the side of the cab:
201-7824 Air Starting Control Gp
193-6229 Service Brake Control Gp
193-6213 Automatic Lubrication Gp
193-6233 Lubrication Lines Gp
193-6246 Chassis Wiring Gp
193-6247 Chassis Wiring Gp

View of the hose and electrical connections at right rear of cab
1. Remove the tape and the plugs from the cab assembly.

View of the hose and electrical connections for the cab assembly
(1) Main air supply and the line for the air compressor governor
(2) Air supply to air start control valve
(3) Air line for the parking brake control valve
(4) Air line for the service brake control valve
(5) Air line for the brake diverter valve
(6) Unconnected
(7) Air line for the automatic lubrication system
(A) Transmission
(B) Battery
(C) Chassis 1
(D) Chassis 2
(E) Engine
2. Remove cover (F) to plug in the video cables.
3. Insert the four video cables into the 348-9226 Grommet Assembly (1) and secure the grommet into the
second hole drilled in the plate that is located at the right rear corner of the cab. Torque the nut of the 348-
9226 Grommet Assembly to 20 ± 2 N·m (15 lb ft ± 1 lb ft). Pass the excess video cable into the electronics
bay.
4. Connect the four video cables from the cameras to the four video cables from the display.
Table 74
Video Cables to Display Video Cables to Camera Cable Color
1 Front Red
2 Right Blue
3 Rear Green
4 Left Yellow
5. Secure the harnesses in the electronics bay with the 3S-2093 Cable Strap.
6. Match each hose to the fitting with the same number that is indicated on the side of the cab.
Note: Each air hose has an identification tag with a number.
Note: The 3D-7587 Elbow, that is to be installed for the cabs main air supply, can be found in a shipping bag
behind the cab seat.
7. Match and install the electrical connectors to the side of the cab.
8. Use tie straps to secure the hoses and cab wiring.

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

Typical view of the connection for the horn
10. Connect the air horn hose assembly to the connection in the cab. Secure the hose with a clip on the frame.

View of the air conditioner lines that are installed
11. Connect air conditioner hose assembly (C) and air conditioner hose assembly (D).
Install the Exhaust Pipe Group

The required parts to install the exhaust group are part of the 310-6261 Exhaust Pipe Gp.
Note: The right-hand platform must be installed prior to installing the exhaust pipe group.
Table 75
Parts that are Required to Install the Exhaust Pipe Group
1 1 272-5460 Tube As(1)
4 302-8136 Band Clamp(2)
2 251-6357 Heat Shield(2)
2 242-0799 Bellows As(2)
1 272-5463 Tube As(1)
2 242-0811 Clamp(2)
2 1 272-5466 Tube As(3)
1 269-3301 Bracket As(3)

4 8T-4183 Bolt(3)
4 5P-1076 Hard Washer(3)
4 8T-4244 Nut(3)
(2) Part of tube assembly 1 and tube assembly 2

View of tube assembly (1)
( A) 302-8136 Band Clamp
(B) 251-6357 Heat Shield
(C) 242-0811 Clamp
(D) 242-0801 Bracket As
(E) 302-8136 Band Clamp
1. Remove the shipping strap to lift tube assembly (1) from the pallet.
Note: The weight of tube assembly (1) and bracket assemblies (C) and (D) is approximately 44.5 kg (98 lb).
2. Use a suitable lifting device to position tube assembly (1) to the rear of the RH platform. Remove bracket
assemblies (C) and (D) from tube assembly (1). Retain the hardware.
Note: Remove the shipping covers from the ends of tube assembly (1). Also, remove the shipping covers
from mufflers (F) and (G). Discard the covers.
3. Remove the shipping covers from manifold assembly (K) and manifold assembly (L). Discard the covers.

(H) 8T-4183 Bolt
(J) 8T-4223 Hard Washer
4. Install four bolts (H) and four washers (J) that are provided to secure bracket assembly (D) to the rear of the
RH platform.
5. Use a suitable lifting device to position tube assembly (1) to bracket assembly (D).
6. Position bracket assembly (C) over tube assembly (1). Use the hardware that was retained in Step 2 to secure
tube assembly (1).
Note: Do not tighten the bolt that secures bracket (C). Alignment of the tube assembly may be required
before the final tightening of the clamps.
7. Install band clamp (A) that is provided to secure tube assembly (1) to manifold assembly (L).
Note: Do not finish tightening clamp (A). Alignment of the tube assembly may be required before the final
tightening of the clamps.

Top view of the muffler and tube assembly (1)
8. Position band clamp (E) that is provided to secure tube assembly (1) to muffler (G). Position the top of the
band clamp at the top of the captured slot. Finish tightening band clamp (E) to a torque value of
68 ± 12 N·m (50 ± 9 lb ft).
9. Finish tightening band clamp (A) to a torque value of 12.5 ± 1 N·m (9 ± 1 lb ft).
10. Finish tightening clamp (C).

View of tube assembly (2)
( M) 302-8136 Band Clamp
(N) 242-0811 Clamp
(P) 269-3301 Bracket As
(R) 8T-4183 Bolt
(S) 5P-1076 Hard Washer
(T) 8T-4244 Nut
(U) 251-6357 Heat Shield
(V) 302-8136 Band Clamp
11. Use a suitable lifting device to position tube assembly (2) to the rear of the RH platform. Loosen clamp
assembly (N).
Note: The weight of tube assembly (2) and bracket assemblies (N) and (P) is approximately 26.5 kg (59 lb).

View of tube assembly (2) without the heat shield
12. Position tube assembly (2) next to tube assembly (1). Remove the shipping covers from the ends of tube
assembly (2). Discard the shipping covers.
13. Remove four bolts (R), four washers (S), and four nuts (T) from bracket assembly (P). Retain the hardware.
14. Position bracket assembly (P) to the mounting location. Install four bolts (R), four washers (S), and four nuts
(T) to secure the bracket.
15. Position band clamp (M) that is provided to secure tube assembly (2) to muffler (F). Position the top of band
clamp (M) at the top of the captured slot.
Note: Do not finish tightening band clamp (M) or clamp (N). Alignment of the tube assembly may be
required before the final tightening of the clamps.

View of right side manifold
16. Remove heat shield (U) from tube assembly (2). Position tube assembly (2) to manifold (K). Install clamp
(V) that is provided to secure tube assembly (2) to manifold assembly (K).
17. Finish tightening band clamp (V) to a torque value of 12.5 ± 1 N·m (9 ± 1 lb ft). Finish tightening clamp
(N).
18. Finish tightening band clamp (M) to a torque value of 68 ± 12 N·m (50 ± 9 lb ft). (2) can now be tightened.
Finish tightening clamp (N).
19. Install heat shield (U) over the bellows for tube assembly (2).
Install the 293-5905 Exhaust Pipe Gp (If Equipped)

Note: The right-hand platform must be installed prior to installing the 293-5905 Exhaust Pipe Gp.
Table 76
Parts that are Required to Install the 293-5905 Exhaust Pipe Gp (If Equipped)
1 1 272-5460 Tube As
2 7 7E-8452 Clamp
3 2 242-0799 Bellows As
4 1 292-1009 Bracket As
5 8 8T-4183 Bolt
7 4 8T-4244 Nut
8 1 290-8577 Tube As
9 2 242-0811 Clamp
10 2 5G-3845 Boss
11 2 7X-7729 Washer
12 2 8T-4172 Bolt
13 2 251-6357 Heat Shield
14 1 292-1008 Bracket As
16 1 290-8578 Tube As
1. Position tube assembly (1) onto the left side manifold (A). Install clamp (2) to hold the tube to the manifold.
Note: Do not tighten clamp (2). Alignment of the tube assembly may be required before the final tightening
of the clamp.

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

View of right side manifold
4. Position tube assembly (8) into bellows (3). Install clamp (2) to hold the assemblies together.
Note: Do not tighten clamp (2). Alignment of the tube assembly may be required before the final tightening
of the clamps.
5. Position tube assembly (8) into bracket assembly (4).
6. Clamps (2) can now be tightened.

Side view for reference only
7. Position clamp (9) to bracket assembly (4). See illustration 306. Install boss (10), washer (11), and bolt (12)
to secure the clamp to tube assembly (8).
8. Install heat shield (13) over bellows (3).

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

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

Side view of the two clamps around the tube assembly
13. Position clamp (9) to bracket assembly (14). See illustration 313. Install boss (10), washer (11), and bolt (12)
to secure the clamp to tube assembly (16).
14. Install heat shield (13) over bellows (3).
Install the 240-2780 Muffler Gp

Note: Some hardware is installed onto the platform before the platform is installed on the chassis.
Table 77
Parts that are Required to Install the 240-2780 Muffler Gp

1 1 8X-3142 Extension Pipe
2 1 242-8869 Extension Pipe
3 3 6V-6317 Bolt
4 3 2Y-5829 Nut
5 6 6V-5839 Washer

Rear view of the mufflers on the RH platform

Top view of mufflers
1. Remove clamp (G) from muffler (A). Retain the clamp. Remove the protective cover from muffler (A).
Note: Mufflers (A) and (B) are factory installed on the right side platform.

View of the extension pipe that is installed
2. Loosen bolt (D), washers (E), and nut (F). Slide extension pipe (1) through clamp assembly (C). Slide clamp
(G) onto extension pipe (1).
3. Slide extension pipe (1) onto muffler (A). Use the hardware that is provided on clamp (G) to secure
extension pipe (1) to the muffler. Tighten bolt (D) to secure extension pipe (1) to the platform.
Note: Apply 4C-5598 High Temperature Anti-Seize to the exhaust pipe joint.
Note: Lubricate the clamp bolt threads. Lubricate the clamp surface before installation.
4. Remove the protective cover from muffler (B).

Bottom view of the muffler and the extension pipe
5. Position extension pipe (2) onto muffler (B). Install bolt (3), nut (3), and two washers (5) in three places to
secure extension pipe (2) to the muffler. Tighten bolts (3) to a torque value of 30 ± 7 N·m (22 ± 5 lb ft).
Note: Apply 4C-5598 High Temperature Anti-Seize to the male end of the muffler before installation.
Note: Lubricate the bolt threads before installation.
Install the 294-0849 Muffler Gp (If Equipped)

Note: Some hardware is installed onto the platform before the platform is installed on the chassis.
Table 78
Parts that are Required to Install the 294-0849 Muffler Gp (If Equipped)
1 2 6V-3823 Bolt
2 2 6V-7687 Locknut
3 2 6N-9298 Clamp
4 2 290-8576 Extension Pipe

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

View of mufflers (A) and (B)
2. Slide one pipe extension (4) through one clamp assembly (3). Slide pipe extension (4) onto muffler (A).
Install one bolt (1) and one locknut (2) into clamp assembly (3) to secure pipe extension (4) onto muffler
(A).
Note: Apply 4C-5598 High Temperature Anti-Seize to the male end of the mufflers before installation of the
pipe extensions.
Note: Lubricate the bolt threads and the clamp surfaces before installation of the clamp assemblies.
3. Slide the other pipe extension (4) through the other clamp assembly (3). Slide pipe extension (4) onto
muffler (B). Install the other bolt (1) and the other locknut (2) into clamp assembly (3) to secure pipe
extension (4) onto muffler (B).
Install the 8X-4180 Hood Latch Gp

Table 79
Parts that are Required to Install the 8X-4180 Hood Latch Gp
1 2 5S-7379 Bolt

3 1 2G-9399 Rod
4 1 6F-8499 Spring
5 1 8X-4425 Bracket Assembly
6 1 3B-4615 Cotter Pin
7 1 0T-0883 Washer
8 1 276-7617 Plate As
9 8 8T-4136 Bolt

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

Table 80
Parts that are Required to Install the 240-2784 Air Cleaner Gp

1 1 9Y-8930 Air Cleaner Gp
2 1 241-4197 Bracket As
3 4 7X-0344 Bolt
5 4 8T-4139 Bolt
7 6 8T-4194 Bolt
9 1 351-9112 Rod As
10 2 8T-4244 Nut
11 2 202-6473 Bolt
12 3 2S-5658 Hard Washer
13 1 8T-4132 Nut
14 1 351-9110 Rod As
15 1 251-2151 Tube As
16 2 251-6235 Hose
17 8 230-2535 Clamp
18 1 7E-7790 Hose
19 4 233-8485 Clamp
20 2 285-6593 U-Bolt
21 2 285-7524 Strip
23 4 129-3180 Locknut
24 1 9X-0262 Adapter
26 1 161-9926 Pressure Sensor Gp
27 1 7K-1181 Cable Strap
28 1 7D-8586 Nonslip Tread
1. Use a suitable lifting device to remove the air cleaner group from the shipping pallet. The approximate
weight of the air cleaner group is 191 kg (421 lb).
NOTICE
When positioning the air cleaner group for installation, removing
precleaner cup assemblies may be required to avoid any damage.

LH front view of the truck and the air cleaner group without the precleaner cup assemblies
(1) 9Y-8930 Air Cleaner Gp
2. Position air cleaner group (1) to the mounting location.

(1) 9Y-8930 Air Cleaner Gp
(2) 241-4197 Bracket As
(3) 7X-0344 Bolt
(5) 8T-4139 Bolt
3. Secure air cleaner group (1) to the machine by using bracket assembly (2), four bolts (3), four hard washers
(4), four bolts (5), and four hard washers (6).
Note: Do not remove the lifting device from the air cleaner assembly.

(7) 8T-4194 Bolt
4. Secure the plate assembly attached to the rear of the air cleaner group to the front of the front cab outrigger
by using four bolts (7) and four washers (8). Do not finish tightening bolts (7).
Note: Do not remove the lifting device from the air cleaner assembly.

(7) 8T-4194 Bolt
(9) 351-9112 Rod As
(10) 8T-4244 Nut
(11) 202-6473 Bolt
(12) 2S-5658 Hard Washer
(13) 8T-4132 Nut
5. Secure rod assembly (9) to the bottom of the front cab outrigger by using bolt (7), two hard washers (6), and
nut (10). Secure the other end of rod assembly (9) to the plate assembly on the rear of the air cleaner group
by using bolt (11), two hard washers (12), and nut (13).

(7) 8T-4194 Bolt
(10) 8T-4244 Nut
(11) 202-6473 Bolt
(12) 2S-5658 Hard Washer
(14) 351-9110 Rod As
6. Secure rod assembly (14) to the front of the front cab outrigger by using bolt (11) and hard washer (12).
Secure the other end of rod assembly (14) to the top of the plate assembly on the rear of the air cleaner group
by using bolt (6), two hard washers (7), and nut (10).

Typical view of the air intake tube assembly, as shipped
(15) 251-2151 Tube As
7. Remove the clamps and the shipping covers in three places from tube assembly (15). Discard the covers,
retain the clamps and the other hardware.

Rear view of the LH air cleaner group
8. Remove the two shipping covers from the rear of the air cleaner group. Discard the covers.

Front LH view of intake shipping cover
9. Remove the shipping cover from the tube at the front of the engine. Discard the cover.

(15) 251-2151 Tube As
(16) 251-6235 Hose
(17) 230-2535 Clamp
(18) 7E-7790 Hose
(19) 233-8485 Clamp
Note: Apply 207-1601 Rubber Lubricant immediately before the assembly of hose to the mating part.
Position the parts quickly and complete the assembly as the lubricant will evaporate quickly. If needed,
reapply the lubricant.
10. Secure tube assembly (15) tube on the front of the engine by using hose (18) and four clamps (19). Secure
tube assembly (15) to the rear of the air cleaner group by using two hoses (16) and eight clamps (17).
Rotate each pair of clamps until the t-bolts are located 180 degrees from each other. Tighten the clamps to a
torque value of 7.5 ± 1 N·m (66 ± 9 lb in).

(A) Bracket assembly
(B) Plate
(15) 251-2151 Tube As
(20) 285-6593 U-Bolt
(21) 285-7524 Strip
(23) 129-3180 Locknut
11. Secure tube assembly (15) to bracket assembly (A) and to plate (B) by using two U-bolts (20), two strips
(21), four hard washers (22), and four locknuts (23).
Note: Tighten the locknuts to a torque of 30 ± 7 N·m (22 ± 5 lb ft).

(C) Harness assembly
(15) 251-2151 Tube As
(24) 9X-0262 Adapter
(26) 161-9926 Pressure Sensor Gp
(27) 7K-1181 Cable Strap
12. Secure adapter (24) with O-ring seal (25) to the top of tube assembly (15). Secure pressure sensor group (26)
to adapter (24) with O-ring seal (25).
Connect pressure sensor group (26) to the existing harness assembly (C).
Note: Tighten sensor (26) to a torque value of 10 ± 2 N·m (7.3 ± 1.5 lb ft)
Secure the loose slack of pressure sensor group (26) with cable strap (27).
Note: The adapter and pressure sensor can be installed onto the tube assembly prior to the installation of the
tube assembly.

View of the left side and wiring that is installed
13. Install the wiring group. Use existing clips, bolts, and washers.
14. Reinstall the three precleaner cup assemblies. Each precleaner cup assembly consists of one 2W-9069
Precleaner Cup Assembly and one 2M-0879 O-Ring Seal.

View of battery cables on the RH side
15. Prior to positioning the RH tube assembly, locate battery cables (R) under the RH platform.

View of battery cables on the RH side
16. Secure battery cables (R) with the clips and bolts that are provided.
Bottom view of the RH tube assembly that is installed
17. Repeat Step 7 through Step 16 for the right side.

View of the top of the left-hand air cleaner group
(28) 7D-8586 Nonslip Tread
18. Install nonslip tread (28) to the top of the air cleaner on the left-hand side.
Install the Precleaner Cups

Table 81
Parts that are Required to Install the Precleaner Cups
16 3 2W-9069 Precleaner Cup Assembly

Front view of the RH air cleaner group
1. Install one precleaner cup assembly (16) and one O-ring seal (17) in three places to the bottom of the RH air
cleaner assembly.
Activate the Batteries

Table 82
Parts that are Required to Activate the Batteries
A 2 115-2421 Battery Gp

View of batteries that are installed
1. Locate two batteries (A) that are installed into the top of the RH platform.

View of activation of battery (A)
2. To charge the batteries or fill the batteries, refer to Special Instruction, REHS0458, "Activation of 101-4000
Batteries, 115-2421 Batteries, and 9X-9730 Batteries That Are Shipped Without Electrolyte".
Install the Tires with the Rim Mounting Group 193-6262 Rim Mounting
Gp
There are four rim mounting group options:
455-0037 Rim Mounting Gp

The following instructions are specific for the 193-6262 Rim Mounting Gp.
Instructions to install the 208-8789 Rim Guard Gp are also included in the following sections.
Table 83
Parts that are Required to Install the 193-6262 Rim Mounting Gp

1 6 8W-0338 O-Ring Seal
2 6 5T-9790 Tire Valve
3 2 8W-0331 Swivel Connector
4 564 7X-0851 Nut
5 564 6V-8237 Washer
6 2 190-6095 Ring
7 2 251-6360 Extension
8 2 207-6030 Plate(1)
9 2 220-8202 Hose As (1)
10 4 1S-1015 Clip(1)
11 32 8T-4139 Bolt
13 8 8T-4244 Nut
14 4 229-9387 Plate(1)
15 4 8T-5092 Bolt(1)
16 2 280-7372 Plate(2)
17 2 280-9835 Plate(2)
18 4 6J-0427 Spacer
19 2 7I-5931 Bracket
20 4 8T-6868 Bolt
22 2 5T-9796 Connector
23 1 281-0569 Hose As(2)

24 12 137-3615 Bracket(3)
25 4 3V-8340 Bracket(3)
26 8 136-9459 Plate As(3)
(1) Use with 793D Extended Life, Wheel, and Brake Group configuration only
(2) Use with 793D Standard Wheel and Brake Group configuration only
(3) Part of 208-8789 Rim Guard Gp
Servicing and changing tires and rims can be dangerous and should be
done only by trained personnel using proper tools and procedures.
Do not attempt to assemble this machine until you read and you
understand the assembly instructions.
Improper assembly procedures could result in injury or death.
Note: Ensure that the pattern of the tread is oriented to the desired position. Inflate the tire with dry nitrogen to
operating pressure. Refer to Operation and Maintenance Manual, SEBU7174, "Tire Inflation Information".
Note: When the tire is inflated in an area that is 20 °C (68 °F) and the tire operates in freezing temperatures, the
tire is underinflated. Low tire pressure shortens tire life. Refer to Operation and Maintenance Manual, SEBU5898,
"Cold Weather Recommendations for Caterpillar machines" for cold-weather conditions.
Note: Use a 6V-4040 Inflation Group to inflate the tire from a nitrogen cylinder. Refer to Special Instruction,
SMHS7867 for the tire inflation instructions.
Install the Front Tires
1. Remove the grease and the metal burrs from the wheel and the mounting area. Use cleaning solvent and 4C-
4188 Paint Remover to clean the parts. Failure to clean the parts will result in a poor joint.

View of the front lifting points and lifting straps
2. Install clevis assemblies and lifting straps to the frame assembly.
Note: Inspect the locations of the straps. Metal will tear the straps.
3. Use a suitable lifting device to raise the front of the truck.
Note: Keep the hoist attached to the truck, until the front tires and rims are installed.
4. Use a tire handler to position the left tire and rim to the hub.
Note: The valve stem must face the outside.
Note: The weight of the rim is 1583 kg (3490 lb). The weight of the typical tire is 3500 kg (7800 lb).
5. Install 70 nuts (4) and 70 washers (5) to secure the rim and tire assembly. Secure the nuts with an impact
wrench. Do not final torque the nuts.
Note: Position the washer so the part number is visible during installation.
6. Repeat Step 1 through Step 5 for the right tire.
Install the Rear Tires

Use with 793D Extended Life, Wheel, and Brake Group configuration only

Use with 793D Standard Wheel and Brake Group configuration only
Note: The shop or a tire servicing person installs the rim assembly.
1. Use the following parts to assemble the rims to the rear tires: four O-Ring seals (1) , four tire valves (2) , two
connectors (22) for the inside tires and two extensions (7) for the outside tires. Before continuing, ensure
that the thread pattern is oriented to the desired position. Inflate the tire with dry nitrogen to operating
pressure. Refer to Operation and Maintenance Manual, SEBU7174, "Tire Inflation Information".
2. Attach a suitable lifting device to lift ring (6).
Note: The weight of ring (6) is approximately 175 kg (386 lb).
3. Remove nuts (E) and washers (F) from the rear wheel assembly.
4. Remove ring (6) from the final drive.
Note: Ring (6) will be used later to install the outside rim and tire assembly.

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

View of front wheel that is blocked

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

View of the nuts that are tightened with an impact wrench
10. Tighten the nuts with an impact wrench.
11. Repeat Step 1 through Step 10 on the other rim and the other tire.
NOTICE
If the truck is to be moved with only the inner rear wheel and tire
installed, then nuts (G) must be installed to secure the final drive
assembly to the rear axle assembly.
12. Tighten the nuts on the two front tires and the two inside rear tires to a torque of 1000 ± 125 N·m
(738 ± 92 lb ft).
13. Attach one end of hose assembly (9) or (23) to connector (22).
Note: Hose (9) is for the 793D Extended Life, Wheel, and Brake Group configuration.
Note: Hose (23) is for the 793D Standard Wheel and Brake Group configuration.
Note: Refer to illustration 349 and 350.
14. Position six brackets (24) and two brackets (25) to the wheel assembly. Position four plate assemblies (26) to
the brackets. Install 14 bolts (11) and 14 washers (21) to secure plates (26). Tighten bolts (11) to a torque
value of 55 ± 10 N·m (41 ± 7 lb ft).
Note: Position the valve stem in the correct position before the installation of the plates.
Note: Step 14 only applies to machines with mud guards for the rim on standard wheel assemblies.
15. Repeat Step 14 for the other side.
16. Position two clips (10) around hose assembly (9). Install two bolts (11), two washers (12) and two nuts (13)
to secure hose assembly (9) to plate (8). See illustration 349.

View of the 793D Extended Life, Wheel, and Brake Group configuration
17. Position plate (8) to the final drive assembly. Position two plates (14). Install two bolts (15), four washers
(12) and two nuts (13) to secure plate (8) and plates (14) to the final drive assembly.
Note: Step 16 and Step 17 are for the 793D Extended Life, Wheel, and Brake Group configuration.
19. Position plate (16) and plate (17) around hose assembly (23). Install two bolts (11) and two washers (12) to
secure the plates.
Note: Reference illustration 350.
Note: Step 19 is for the 793D Standard Wheel and Brake Group configuration.

View of the rings for assembly to the rear wheels

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

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

Table 84
Parts that are Required to Install the Odometer
141-1513 (1)
155-6138 (2)
1 1 Odometer Assembly
5T-8673 (3)
141-1514 (4)
2 1 122-1478 Plate As
3 2 5B-5839 Spacer
4 2 8T-4184 Bolt

(3) The 5T-8673 Odometer Assembly is part of 188-3648 Odometer Gp.
(4) The 141-1514 Odometer Assembly is part of 188-3649 Odometer Gp.
1. Use the existing fastener to attach the appropriate odometer assembly (1) to plate assembly (2).
2. Position two spacers (3) between plate assembly (2) and the rear wheel assembly.
3. Install two bolts (4) and two hard washers (5) to secure plate assembly (2) to the rear wheel assembly.
Install the 126-1358 Hydraulic Tank Guard Gp

Table 85
Parts that are Required to Install the 126-1358 Hydraulic Tank Guard Gp
1 1 119-8732 Cover
2 1 270-8622 Cover

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

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

View of the ether cylinder
1. Install two 7X-1062 Ether Cylinders.
Install the Truck Body

There are two options for mounting the truck body:
261-8621 Truck Body Mounting Gp
284-4927 Truck Body Mounting Gp
Note: Be sure to remove all lifting eyes prior to the installation of the body and canopy to the chassis.
NOTICE
Failure to use a 8X-3044 Plate that has a thickness of 8 mm
(0.3150 inch) in place of four 8X-3046 Shims that have a thickness of
2 mm (0.0787 inch) each can result in failure of the body pad retention
bolts.
Table 86
Parts that are Required to Install the 284-4927 Truck Body Mounting Gp
1 2 8X-5063 Deflector
2 1 105-4727 Mud Flap
3 1 6G-9703 Cable
4 1 105-0314 Coupler
5 2 8T-4649 Bolt
7 2 6V-7676 Nut
8 1 8W-0109 Plate
9 1 2B-0974 Clevis Pin
12 2 7I-5517 Pin As
13 1 8W-2896 Washer
14 2 6G-9697 Washer
15 2 8W-8677 Plate
17 4 8T-4184 Bolt
18 10 219-7595 Pad As
19 30 8X-3046 Shim
20 2 8X-3044 Plate (1)
21 24 8T-4910 Bolt
22 30 7D-1649 Hard Washer

23 24 8T-4244 Nut
24 16 8T-4137 Bolt
26 16 4K-8864 Clip
27 2 233-1880 Bracket As(2)
28 2 227-5875 Ejector
29 2 6G-7773 Pin
30 2 3D-0404 Washer
32 4 205-4178 Pad
33 4 205-4179 Shackle
34 2 205-4181 Chain
(1) A 8X-3044 Plate that has a thickness of 8 mm (0.3150 inch) should be used in place of four 8X-3046 Shims that have a thickness of
2 mm (0.0787 inch) each
(2) Part of 260-9120 Body and Canopy As
1. Use a suitable lifting device to position the truck body onto suitable supports.
Note: The weight of the completed truck body with the liners is approximately 63503 kg (140000 lb).

View of the right side front deflector that is installed
2. Position deflector assembly (1) to the body. Install five bolts (A), five washers (B), and five nuts (C) that are
provided to secure the deflector assembly to the body.
3. Repeat Step 2 for the other side of the machine.

View of mud flap that is installed
4. Position mud flap assembly (2) to the body. Install five bolts (D), five washers (E), and five nuts (F) to
secure the mud flap assembly.

Bottom view of the body
5. Position cable (3) to existing bracket (G) on the body. Position coupler (4) through the end of cable (3).
Install two bolts (5), two washers (6) and two locknuts (7) to secure the coupler to the bracket.
6. Position cable (3) over existing bracket (H). Position plate (8) to bracket (H). Install pin (9), washer (10),
and cotter (11) to secure plate (8) and cable (3) to the body.
7. Remove paint and dirt from four bores in the body and two bores in the chassis.
8. Remove dirt and grease from two pin assemblies (12).
Note: The weight of one pin assembly is 42 kg (93 lb).
9. Use a suitable lifting device to position the body to the chassis.
Note: The weight of the completed truck body with the liners is approximately 63503 kg (140000 lb).
Note: The 376-4554 Pin As should be used to assist in lifting the truck body.

View of right side pin assembly that is being installed
10. Install pin assembly (12).


View of left side pin assembly and washers that are installed
11. Install washer (13) and washer (14) as required.
Note: Washer (13) is 6 mm (0.24 inch) thick.
Note: Washer (14) is 10 mm (0.40 inch)thick.
12. Position plate (15) to the body. Install two hard washers (16) and two bolts (17) to secure the plate.

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

View of the LH hoist cylinder that is secured

View of the LH shipping bracket that is being removed
15. Use a torch to remove the shipping bracket and the retaining bolt.
16. Repeat Step 14 and Step 15 for the other side of the machine.

Rear view of the truck body that is lowered onto two wood blocks
Note: Refer to "Install the 8X-3380 Cylinder Mounting Gp" for the installation of the hoist cylinders to the
body assembly.
17. If necessary, position the truck on a level surface. The body and cylinder installation must be completed to
proceed to the following steps.
18. Raise the dump body.

RH view
(J) Rockers
(K) Body rail
(L) Frame rail
(18) Rocker pads

View of shims (19)
19. Lower the body slowly. If the body contacts both of the factory installed rocker pads on rockers (J) at the
same time, then go to Step 24. If the body does not contact both rocker pads (18) at the same time, shims
(19) are required under the rocker pad that must be raised. Refer to Step 20 to install the shims.
Note: If the rocker pad needs to be raised more than 8 mm (0.315 inch), then plate (20) should be used.
Refer to Service Magazine, SEPD0861-00, "A New Plate for the Assembly of the Truck Body Is Available".
20. Raise the dump body and install the proper safety device to secure the dump body in the RAISE position.

Top view of RH rocker pad
21. Remove bolt (21) and washer (22) in three places. Retain the hardware. Add required shims (19) and/or plate
(20) between the top of rocker (J) and rocker pad (18).
22. Install hardware that was retained from Step 21 to secure rocker pad (18), shim (19) and/or plate (20).
23. Remove the safety device. Repeat Step 18 through Step 22 until both of the rocker pads come into contact
with the body at the same time.
24. Raise or lower the body to bring the body and frame rails parallel to each other.
25. Measure the distance between body rail (K) and frame rail (L) at the front of the body and at the rear of the
body. Ensure that the distance is the same at the front of the body and at the rear of the body.

View of pad, plate, and shims

View of four pad assemblies that are installed
26. Install one pad (18) and the required shims (19) and/or plates (20) in four places. Install three bolts (21),
three washers (22) and three nuts (23) in four places to secure the pads and shims. Evenly tighten bolts (21)
to a torque of 105 ± 20 N·m (80 ± 15 lb ft).
Note: Block the body in position when you install the shims and pads.
28. Remove the block and lower the body to the DOWN position.
29. Measure the gap between the rocker pads (18) and the body. Add equal amounts of shim (19) and/or plates
(20) to each side to take up the gap. Refer to Step 19 for the proper procedure to add shims (19) or plates
(20).
30. Raise and lower the body to make sure that all mounted pads have even contact with the frame.

Bottom LH view of the body pivot area
31. Attach arm (M) of the body position sensor to the truck body. Secure arm (M) with existing bolt (N).
Note: The body position sensor will be calibrated later in the assembly procedure.
32. Position the grease line for the hoist cylinder to the bottom of the body assembly. Install 16 bolts (24), 16
washers (25), and 16 clips (26) to secure the grease lines.

View of the lubrication line for the cylinder
33. Install the grease line to the hoist cylinders.
NOTICE
The rock ejector brackets should be installed after the body has been
installed.

Rear view of rock ejector bracket that is centered between rear tires
34. Attach a string and a plumb bob to the center of bracket (27). Position bracket (27) to the body. Check the
distance that separates the string and the wheel group assembly. The string must be centered in the middle of
the two tires. Bracket (27) that is installed should be centered in the forward position, in the rear position,
and in the side position. Refer to Illustration 402.
35. After the position of bracket (27) has been determined, prepare the surface for welding by removing paint
and dirt from the body.
Note: Reference this table for weld specifications.

Side view of rock ejector bracket that is tack welded
36. Position rock ejector bracket (27) to the bottom of the body. The approximate weight of the bracket is 64 kg
(141 lb).
Table 87
Weld Tolerances
Weld Description
W5 10 mm (0.40 inch) with a 1.50 mm (0.06 inch) penetration (two Places)
W6 8 mm (0.31 inch) with a 1.50 mm (0.06 inch) penetration (two Places)
W7 6 mm (0.23 inch)with a 2.5 mm (0.098 inch) penetration (two Places)

Bottom view of the body

Bottom view of the bracket for the ejector
37. Weld bracket (27) to the body.
Note: Refer to Table 87 for welding requirements.
38. Use a suitable lifting device to position ejector (28) to bracket (27).
Note: The ejector weighs approximately 115 kg (254 lb).
39. Install pin (29) and slowly lower the rock ejector between the rear tires.
40. Check the clearance on both sides of the rock ejector to the rear tires.
41. Install washer (30) and two cotter pins (31) to secure ejector (28) to the bracket.

Side view of rock ejector assembly
(P) 1075 ± 10 mm (42.3 ± 0.4 inch)
(R) 1618.6 ± 10 mm (63.7 ± 0.4 inch)
42. Remove paint and dirt from the body and ejector (28) to prepare the surfaces to weld two pads (32).
43. Weld one pad (32) to the body and weld one pad (32) to ejector (28).
Note: Refer to table 87 for weld specifications.

LH rear view
44. Install two shackles (33) and chain (34).
Install the 8X-3380 Cylinder Mounting Gp

Table 88
Parts that are Required to Install the 8X-3380 Cylinder Mounting Gp
1 2 237-0417 Pin As
2 4 8X-4043 Spacer
3 2 8X-4044 Plate
4 10 8T-4183 Bolt
1. Clean the paint from the mounting surfaces of the hoist cylinder.
2. Position the lift cylinder to the body pin bore.
3. Install one pin (1) and two spacers (2).
4. Position plate (3) to the body.
5. Install bolt (4) and washer (5) to secure plate (3).
6. Repeat Step 1 through 5 for the other side of the machine.
7. Remove the bracket that holds the cylinder .
Install the 251-4831 Film Gp

Table 89
Parts that are Required to Install the 251-4831 Film Gp
1 1 299-7935 Film
2 1 311-3585 Film
3 1 311-3586 Film
4 1 311-3587 Film
5 1 311-3591 Film
6 2 311-3595 Film
Note: The film on the right side platform is installed at the factory.

Front view
(1) 299-7935 Film
(AA) 1650 ± 5 mm (64.960 ± 0.197 inch)
(AB) 30 ± 3 mm (1.181 ± 0.118 inch)

Left-hand front corner
(2) 311-3585 Film (left-hand side)
(3) 311-3586 Film (right-hand side)
(AC) 480 ± 5 mm (18.897 ± 0.197 inch)

Left-hand body
(4) 311-3587 Film (left-hand side)
(5) 311-3591 Film (right-hand side)

Right-hand front
(6) 311-3595 Film
(AD) 73 ± 3 mm (2.874 ± 0.118 inch)
(AE) 37 ± 3 mm (1.457 ± 0.118 inch)

Left-hand front
(6) 311-3595 Film
(AF) 10 ± 2 mm (0.394 ± 0.079 inch)
(AG) 20 ± 3 mm (0.787 ± 0.118 inch)
1. Clean the area.

Typical view
2. Position the film to the fender. Apply tape only at the top to hold film in place.
Note: Do not remove the backing from the film.

Typical view
3. Raise the film to spray a solution on the fender.
Note: Do not lower the film.

Typical view
4. Remove the backing from the film.

Typical view
5. Position the film to the fender.

Typical view
6. Use a heat gun and a plastic straight edge to dry and smooth the film.
Note: The straight edge is used to remove any air bubbles.

Typical view
7. Remove the protective paper from the face of the film.

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

certain latches are fully engaged on both sides before transporting or
pulling the attachment.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting, and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "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.
Reference: Testing and Adjusting, RENR8330, "Brake System Air - Purge"
Align the Front Wheels

Reference: Testing and Adjusting, RENR8330, "Front Wheel - Align"
Installation of the Cat® Detect Object Detection

The information that is contained in this Special Instruction guides the user in the installation of the Caterpillar
Integrated Object Detection System for Off-Highway Trucks.
Do not perform any of the procedures until you have read the information in this publication.
Reference: Special Instruction, REHS1841, "General Welding Procedures" for additional welding instructions.

View of the object detection locations
Reference: Refer to Operation and Maintenance Manual, SEBU8454, "Cat® Integrated Object Detection System
for Off-Highway Trucks" for the orientation of the radar. The radar orientation is critical for the operation of the
object detection system.
Important Safety Information

Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you
understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools.
Failure to follow these procedures can result in personal injury. The following procedures should also be observed.
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs.
A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to
perform these functions properly.
Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are
not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every
possible circumstance that might involve a potential hazard.
Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure
that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is
safe.
Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication,
maintenance, or repair procedures used.
Prepare the Machine

Typical view
(1) Pin
(2) Cable
1. Raise the truck body and install retaining cable (2) for the truck body.
2. Set the parking brake.
3. Turn the key start switch and the disconnect switch to the OFF position.
Required Parts for Installation of the Cat® Detect Object Detection

Table 90
Required Parts for Assembling the 336-6684 Camera Gp to the Brackets
8 n/a(1) Cover
8 n/a(1) Bolt
4 n/a(1) Camera
8 n/a(1) Bolt
8 n/a(1) Nut
8 n/a(1) Nut
3 305-3748 Plate As
4 n/a(1) Camera Harness
1 348-9537 Plate As
9 8T-6466 Bolt
14 8T-4133 Nut
1 312-4475 Bracket
1 348-8145 Bracket
4 8T-4136 Bolt
8 7X-7729 Washer
1 8M-2773 Clip
2 305-3747 Plate As
(1) Part of the 336-6684 Camera Gp
Table 91
Required Parts for Assembling the Radar Boxes to the Brackets

8 347-7917 Object Detection Box Gp(1)
4 379-8133 Plate As
16 8T-4137 Bolt
8 380-4489 Plate
16 7X-7729 Washer
16 8T-4195 Bolt
(1) Each object detection box group includes a 365-1271 Object Detection Sensor Gp
Table 92
Required Parts for Installing the Front Hardware
2 - Radar Box Groups(1)(2)
1 - Camera Assembly(3)
2 371-7772 Plate As
1 379-8129 Plate As
8 8T-4195 Bolt
24 7X-7729 Washer
8 8T-4186 Bolt
8 6V-7744 Locknut
3 8T-4136 Bolt
2 147-0385 Clip
1 033-8248 Clip
1 380-8404 Sensor Harness As
4 8T-4183 Bolt
1 130-5300 Clip
1 5M-3062 Bolt
2 380-6932 Bracket
4 5C-9553 Bolt
4 9X-8256 Washer
(1) With 379-8133 Plate As
(2) Assembled in "Assemble the Radar Boxes to the Brackets"
(3) Assembled in "Assemble the Front Camera to the Brackets"
Table 93
Required Parts for Installation of the Left Side Hardware
1 363-7065 Plate As
6 8T-4195 Bolt
4 7W-9094 Spacer
1 378-7007 Plate As
4 8T-4183 Bolt
2 7X-7729 Washer
1 372-9143 Plate
4 8T-4189 Bolt
6 8T-4137 Bolt
1 219-6485 Flood Lamp Gp

2 147-0385 Clip
2 4D-7794 Clip
1 8M-2773 Clip
1 8T-4136 Bolt
1 8T-4133 Nut
(1) With 378-6997 Bracket As
(3) Assembled in "Assembly the Side Cameras to the Brackets"
Table 94
Required Parts for the Installation of the Right Side Hardware
1 363-7065 Plate As
6 8T-4195 Bolt
4 7W-9094 Spacer
1 378-7007 Plate As
4 8T-4183 Bolt

2 7X-7729 Washer
1 372-9143 Plate
4 8T-4189 Bolt
6 8T-4137 Bolt
1 219-6485 Flood Lamp Gp
4 7N-3718 Clip
2 4D-7794 Clip
1 6D-4246 Clip
(3) Assembled in "Assembly the Side Cameras to the Brackets"
Table 95
Required Parts for the Installation of the Rear Hardware

2 360-3866 Plate As
10 8T-4195 Bolt
50 7X-7729 Washer
4 349-4915 Bracket
4 8T-4196 Bolt
20 8T-4186 Bolt
16 6V-7744 Locknut
4 380-6932 Bracket
8 5C-9553 Bolt
8 9X-8256 Washer
1 383-6217 Sensor Harness As

2 4D-7794 Clip
4 147-0385 Clip
4 124-0174 Clip
1 8M-2773 Clip
1 4D-9517 Clip
1 8T-4137 Bolt
1 033-8248 Clip
1 130-5300 Clip
(5) Assembled in "Assemble the Camera Components"
Install the Components for the Cat® Detect Object Detection

Assemble the Camera Components
Table 96
Required Parts for Assembling the 336-6684 Camera Gp to the Brackets

1 8 n/a(1) Cover
2 8 n/a(1) Bolt
3 4 n/a(1) Camera
4 8 n/a(1) Bolt
5 8 n/a(1) Nut
6 8 n/a(1) Nut
7 3 305-3748 Plate As
8 4 n/a(1) Camera Harness
9 1 348-9537 Plate As
10 9 8T-6466 Bolt
12 14 8T-4133 Nut
13 1 312-4475 Bracket
14 1 348-8145 Bracket
15 4 8T-4136 Bolt
16 8 7X-7729 Washer
17 1 8M-2773 Clip
18 2 305-3747 Plate As
(1) Part of the 336-6684 Camera Gp
Note: An arrow is at the top of the camera lens which indicates the up direction of the camera. The camera that is
going to be installed on the rear of the truck needs to have this arrow installed facing up.

(1) Cover
(2) Bolt
(3) Camera
(4) Bolt
(5) Nut
(6) Nut
1. Assemble the four cameras with the parts that are supplied with the cameras.
Refer to Illustration 427.
Note: Do not tighten the nuts (6). The nuts will be used in the following procedure to attach the camera to
the brackets for the camera.

View of the front and side cameras
(7) 305-3748 Plate As
(8) Camera harness

View of the rear camera
(8) Camera harness
(9) 348-9537 Plate As
2. Route the camera harness and the connector through the hole that is provided in plate assembly (7) and plate
assembly (9). Place the grommet that is provided on the harness for the camera through the hole. Repeat this
procedure for all the cameras.

View of the front and side cameras
(4) Bolt
(6) Nut
(7) 305-3748 Plate As

View of the rear camera
(4) Bolt
(6) Nut
(9) 348-9537 Plate As
3. Use bolts (4) and nuts (6) to secure the 336-6684 Camera Groups to the plate assemblies.
Assemble the Front Camera to the Brackets

Camera assembled to the front bracket
(7) 305-3748 Plate As
(10) 8T-6466 Bolt
(12) 8T-4133 Nut
(13) 312-4475 Bracket
1. Secure plate assembly (7) to bracket (13) by using three bolts (10), six hard washers (11), and three nuts
(12).

Camera assembled to the front bracket
(A) Camera harness
(12) 8T-4133 Nut
(13) 312-4475 Bracket
(14) 348-8145 Bracket
(15) 8T-4136 Bolt
(16) 7X-7729 Washer
(17) 8M-2773 Clip
2. Secure bracket (13) to bracket (14) by using four bolts (15), eight washers (16), and four nuts (12).
3. Secure camera harness (A) to bracket (13) by using one clip (17), one bolt (15), two hard washers (11), and
one nut (12).
Assembly the Side Cameras to the Brackets

Side camera and plate assembly
(7) 305-3748 Plate As
(10) 8T-6466 Bolt
(12) 8T-4133 Nut
(18) 305-3747 Plate As
1. For the two side cameras, mount the camera groups and plate assemblies (7) to plate assembly (18) by using
six bolts (10), 12 hard washers (11), and six nuts (12).
Assemble the Radar Boxes to the Brackets
NOTICE
The 365-1271 Object Detection Sensor Groups must be handled gently.
Table 97
Required Parts for Assembling the Radar Boxes to the Brackets
1 8 347-7917 Object Detection Box Gp(1)
2 4 379-8133 Plate As
3 16 8T-4137 Bolt
4 8 380-4489 Plate
5 16 7X-7729 Washer
6 16 8T-4195 Bolt
7 2 372-9144 Bracket As
9 2 378-6997 Bracket As
(1) Each object detection box group includes a 365-1271 Object Detection Sensor Gp
Note: Mounting location is important. Each radar box must be mounted in the designated location that is labeled
on the harness connector for each box.
The boxes for the Object Detection System are assembled before shipping. Use the following procedure to
assemble the mounting brackets to the radar boxes.
Note: Inspect the grommet on the bottom of the radar box to ensure that the sealant has not been disturbed during
shipment. If the seal is not intact, use silicone sealant to seal the grommet.

Front and lower rear radar boxes
(1) 347-7917 Object Detection Box Gp
(2) 379-8133 Plate As
(3) 8T-4137 Bolts
(4) 380-4489 Plate
(5) 7X-7729 Washer
1. Locate four object detection box groups (1) and four plate assemblies (2).
2. Secure four box groups (1) to four plate assemblies (2) by using 16 bolts (3), four plates (4), and eight hard
washers (5).
Note: The four box groups assembled in Step 2 are for the front two locations and the two lower rear
locations.
Note: Ensure that each box group is assembled with two hard washers (5) and one plate (4). Plates (4)
should be on the outside facing section of each box group.

Upper rear radar boxes
(4) 380-4489 Plate
(5) 7X-7729 Washer
(6) 8T-4195 Bolt
(7) 372-9144 Bracket As
3. Locate two object detection box groups (1) and two bracket assemblies (7).
4. Secure two box groups (1) to two bracket assemblies (7) by using eight bolts (6), two plates (4), eight hard
washers (8), and four hard washers (5).
Note: The two box groups assembled in Step 4 are for the upper two rear locations.
Note: Hard washers (8) are located between box group (1) and bracket assembly (7).
Note: Ensure that each box group is assembled with two hard washers (5) and one plate (4). Plates (4)
should be on the side of the box group that faces the right side of the machine.

Side radar box
(4) 380-4489 Plate
(5) 7X-7729 Washer
(6) 8T-4195 Bolt
(9) 378-6997 Bracket As
5. Locate two object detection box groups (1) and two brackets (9).
6. Secure two box groups (1) to two brackets (9) by using eight bolts (6), two plates (4), eight hard washers (8),
and four washers (5).
Note: The two box groups assembled in Step 6 are for the two side locations.
Note: Hard washers (8) are located between box group (1) and bracket (9).
Installation of the Front Hardware
Table 98
Required Parts for Installing the Front Hardware
- 2 - Radar Box Groups(1)(2)
- 1 - Camera Assembly(3)
1 2 371-7772 Plate As
2 1 379-8129 Plate As
3 8 8T-4195 Bolt
4 24 7X-7729 Washer
5 8 8T-4186 Bolt
6 8 6V-7744 Locknut
7 3 8T-4136 Bolt

9 2 147-0385 Clip
10 1 033-8248 Clip
11 1 380-8404 Sensor Harness As
12 4 8T-4183 Bolt
14 1 130-5300 Clip
15 1 5M-3062 Bolt
17 2 380-6932 Bracket
18 4 5C-9553 Bolt
19 4 9X-8256 Washer
(2) Previously assembled in "Assemble the Radar Boxes to the Brackets"
(3) Previously assembled in "Assemble the Front Camera to the Brackets"
Each radar box has a specific mounting location. The radar sensors have individual part numbers on the harnesses
at the bottom of the box.
Installation of the Box Group for the Object Detection (Front)

(1) 371-7772 Plate As
(2) 379-8129 Plate As
(3) 8T-4195 Bolt
(4) 7X-7729 Washer
(5) 8T-4186 Bolt
(6) 6V-7744 Locknut
1. Secure two plate assemblies (1) to plate assembly (2) by using four bolts (3) and four washers (4).
2. Secure the two assembled radar box groups to plate assembly (2) by using eight bolts (5), 16 washers (4),
and eight locknuts (6).

(1) 371-7772 Plate As
(2) 379-8129 Plate As
(7) 8T-4136 Bolt
(9) 147-0385 Clip
(10) 033-8248 Clip
(11) 380-8404 Sensor Harness As
3. Connect sensor harness assembly (11) to the radar box groups.
4. Secure sensor harness assembly (11) to plate assembly (2) and one plate assembly (1) by using three bolts
(7), three hard washers (8), two clips (9), and one clip (10).

View of the front of the bumper assembly
(A) Wiring harness assembly
(1) 371-7772 Plate As
(12) 8T-4183 Bolt
(14) 130-5300 Clip
(15) 5M-3062 Bolt
5. Secure the two plate assemblies (1) to the front of the bumper by using four bolts (12) and four hard washers
(13).
6. Connect sensor harness assembly (11) to existing wiring harness assembly (A).
7. Secure sensor harness assembly (11) to the top of the front bumper by using one clip (14), one bolt (15), and
one hard washer (16).

View of the front of the bumper assembly
(17) 380-6932 Bracket
(18) 5C-9553 Bolt
(19) 9X-8256 Washer
8. Secure two brackets (17) onto the bracket assemblies for the radar boxes by using four bolts (18) and four
washers (19).
Note: Brackets (17) must be installed to help ensure that the radars are oriented in the proper location.
Installation of the Camera Group (Front)

(B) Harness assembly
(3) 8T-4195 Bolt
(4) 7X-7729 Washer
1. Secure the front camera that was previously assembled to the front of the platform assembly at the top of the
stairway by using four bolts (3) and four washers (4).
2. Connect existing harness assembly (B) to the harness assembly for the camera assembly.
Installation fo the Left Side Hardware

Table 99
Required Parts for Installation of the Left Side Hardware
1 1 363-7065 Plate As
2 6 8T-4195 Bolt
3 4 7W-9094 Spacer
4 1 378-7007 Plate As
5 4 8T-4183 Bolt
7 2 7X-7729 Washer
8 1 372-9143 Plate
9 4 8T-4189 Bolt
11 6 8T-4137 Bolt
13 1 219-6485 Flood Lamp Gp
14 2 147-0385 Clip
15 2 4D-7794 Clip
16 1 124-3019 Bracket As
17 1 8M-2773 Clip
18 1 8T-4136 Bolt
19 1 8T-4133 Nut
(3) Previously assembled in "Assembly the Side Cameras to the Brackets"
Installation of the Radar Box Group for the Object Detection (Left-Hand Side)

View of the left side of the left-hand walkway
(1) 363-7065 Plate As
(2) 8T-4195 Bolt
(3) 7W-9094 Spacer
1. Secure plate assembly (1) to the side of the left-hand walkway by using four bolts (2) and four spacers (3).

(1) 363-7065 Plate As
(4) 378-7007 Plate As
(5) 8T-4183 Bolt
2. Secure one plate assembly (4) to plate assembly (1) by using four bolts (5) and four hard washers (6).

(2) 8T-4195 Bolt
(4) 378-7007 Plate As
(7) 7X-7729 Washer
3. Secure one side radar group that was previously assembled to plate assembly (4) by using two bolts (2) and
two washers (7).

(8) 372-9143 Plate
(9) 8T-4189 Bolt
4. Secure one plate (8) to the top of the radar group by using four bolts (9) and four hard washers (10).
Installation of the Camera Group (Left-Hand Side)

(11) 8T-4137 Bolt
1. Secure one camera assembly that was previously assembled to the left-hand walkway by using four bolts
(11) and four hard washers (12).
Installation of the Lamp Group (Left-Hand Side)

(13) 219-6485 Flood Lamp Gp
1. Secure one flood lamp group (13) to the side of the camera assembly bracket. Use the hardware provided
with flood lamp group (13) to secure lamp group (13).
Note: Tighten nut (A) to a maximum torque of 20 N·m (177 lb in).
Connect the Harness Assemblies (Left-Hand Side)

(11) 8T-4137 Bolt
(14) 147-0385 Clip
(15) 4D-7794 Clip
(16) 124-3019 Bracket As
(17) 8M-2773 Clip
(18) 8T-4136 Bolt
(19) 8T-4133 Nut
1. Connect the existing harness assembly to the flood lamp group, the camera assembly, and the radar
assembly.
2. Secure the harness assembly by using two bolts (11), four hard washers (12), two clips (14), two clips (15),
one bracket assembly (16), one clip (17), one bolt (18), and one nut (19).
One clip (14) must be secured between the bracket for the camera assembly and the flood lamp group.
Secure both clips (15) with the existing hardware that secures the bracket for the camera assembly to the
side of the walkway assembly.
Installation of the Right Side Hardware
Table 100
Required Parts for the Installation of the Right Side Hardware
1 1 363-7065 Plate As
2 6 8T-4195 Bolt
3 4 7W-9094 Spacer
4 1 378-7007 Plate As
5 4 8T-4183 Bolt
7 2 7X-7729 Washer
8 1 372-9143 Plate
9 4 8T-4189 Bolt
11 6 8T-4137 Bolt
13 1 219-6485 Flood Lamp Gp
14 4 7N-3718 Clip
15 2 4D-7794 Clip
16 1 6D-4246 Clip
17 1 124-3019 Bracket As
18 1 217-4590 Bracket As
(3) Previously assembled in "Assembly the Side Cameras to the Brackets"
Installation of the Radar Box Group for the Object Detection (Right-Hand Side)

View of the right side of the right-hand platform
(1) 363-7065 Plate As
(2) 8T-4195 Bolt
(3) 7W-9094 Spacer
1. Secure plate assembly (1) to the right side of the right-hand platform by using four bolts (2) and four spacers
(3).

(1) 363-7065 Plate As
(4) 378-7007 Plate As
(5) 8T-4183 Bolt
2. Secure plate assembly (4) to plate assembly (1) by using four bolts (5) and four hard washers (6).

(2) 8T-4195 Bolt
(4) 378-7007 Plate As
(7) 7X-7729 Washer
3. Secure one side radar group that was previously assembled to plate assembly (4) by using two bolts (2) and
two washers (7).

(8) 372-9143 Plate
(9) 8T-4189 Bolt
4. Secure one plate (8) to the top of the radar group by using four bolts (9) and four hard washers (10).
Installation of the Camera Group (Right-Hand Side)

(11) 8T-4137 Bolt
1. Secure one camera assembly that was previously assembled to the right-hand platform by using four bolts
(11) and four hard washers (12).
Installation of the Lamp Group (Right-Hand Side)

(13) 219-6485 Flood Lamp Gp
1. Secure one flood lamp group (13) to the side of the camera assembly bracket. Use the hardware provided
with flood lamp group (13) to secure lamp group (13).
Note: Tighten nut (A) to a maximum torque of 20 N·m (177 lb in).
Connect the Harness Assemblies (Right-Hand Side)

(11) 8T-4137 Bolt
(14) 7N-3718 Clip
(15) 4D-7794 Clip
(16) 6D-4246 Clip
(17) 124-3019 Bracket As
(18) 217-4590 Bracket As
1. Connect the existing harness assembly to the flood lamp group, the camera assembly, and the radar
assembly.
2. Secure the harness assembly by using two bolts (11), two hard washers (12), four clips (14), two clips (15),
one clip (16), one bracket assembly (17) and one bracket assembly (18).
Clips (14) and bracket assembly (17) must be secured using the existing hardware for mounting the radar
box assembly.
Bracket assembly (18) must be secured between the bracket for the camera assembly and the flood lamp
group.
Installation of the Rear Hardware
Table 101
Required Parts for the Installation of the Rear Hardware
A 2 - Radar Box Groups(1)(2)
B 2 - Radar Box Groups(3)(4)

1 2 360-3866 Plate As
2 10 8T-4195 Bolt
3 50 7X-7729 Washer
4 4 349-4915 Bracket
5 4 8T-4196 Bolt
6 20 8T-4186 Bolt
7 16 6V-7744 Locknut
8 4 380-6932 Bracket
9 8 5C-9553 Bolt
10 8 9X-8256 Washer
11 1 383-6217 Sensor Harness As
12 2 4D-7794 Clip
13 4 147-0385 Clip
14 4 124-0174 Clip
15 1 8M-2773 Clip
16 1 4D-9517 Clip
17 1 8T-4137 Bolt
19 1 033-8248 Clip
20 1 130-5300 Clip
(5) Previously assembled in "Assemble the Camera Components"
Installation of the Radar Box Groups for the Object Detection (Rear)

View of the rear of the machine
(1) 360-3866 Plate As
(2) 8T-4195 Bolt
(3) 7X-7729 Washer
(4) 349-4915 Bracket
(5) 8T-4196 Bolt
(6) 8T-4186 Bolt
1. Secure two plate assemblies (1) to the frame at the rear of the machine by using eight bolts (2) and eight
washers (3).
2. Secure two brackets (4) to plate assemblies (1) by using four bolts (5) and four washers (3).
3. Secure two brackets (4) to the frame at the rear of the machine by using four bolts (6) and four washers (3).

(A) Upper radar box assembled with 372-9144 Bracket As
(B) Lower radar box assembled with 379-8133 Plate As
(3) 7X-7729 Washer
(4) 349-4915 Bracket
(6) 8T-4186 Bolt
(7) 6V-7744 Locknut
4. Secure two radar boxes (A) to two upper brackets (4) and two radar boxes (B) to two lower brackets (4) by
using 16 bolts (6), 32 washers (3), and 16 locknuts (7).

(A) Upper radar box assembled with 372-9144 Bracket As
(8) 380-6932 Bracket
(9) 5C-9553 Bolt
(10) 9X-8256 Washer
5. Secure four brackets (8) onto the bracket assemblies for the radar boxes by using eight bolts (9) and eight
washers (10).
Note: Brackets (8) must be installed to help ensure that the radars are oriented in the proper location.
Installation of the Camera Group (Rear)

(C) Harness assembly
(2) 8T-4195 Bolt
(3) 7X-7729 Washer
1. Secure the rear camera group to the rear of the frame by using two bolts (2) and two washers (3).
2. Connect the harness for the camera assembly to existing harness assembly (C).
Connect the Harness Assemblies (Rear)

(D) Harness assembly
(12) 4D-7794 Clip
(13) 147-0385 Clip
1. Connect sensor harness assembly (11) to existing harness assembly (D).
2. Secure harness assembly (11) to the frame by using two clips (12) and three clips (13).
Note: Two clips (12) and three clips (13) shown in Illustration 461 must be secured by using existing bolts
and studs.

(13) 147-0385 Clip
(14) 124-0174 Clip
(15) 8M-2773 Clip
(14) 124-0174 Clip
(16) 4D-9517 Clip
(17) 8T-4137 Bolt
(19) 033-8248 Clip
(20) 130-5300 Clip
3. Connect sensor harness assembly (11) to the four radar box assemblies.
4. Secure sensor harness assembly (11) by using one clip (13), four clips (14), one clip (15), one clip (16), one
bolt (17), one hard washer (18), one clip (19), and one clip (20). Refer to Illustration 462 and Illustration 463
for the location of the hardware.
Note: Except for clip (19) and clips (20), all clips use existing hardware to secure harness assembly (11).
Installation of the Hardware in the Cab
Install the components for the display. Refer to the Illustrations below.

(1) 355-9048 Monitor Display Gp

(1) 355-9048 Monitor Display Gp
(2) 352-5603 Bracket As
(3) 6V-4248 Bolt
(5) 9X-2045 Screw
1. Install monitor display group (1) to bracket assembly (2) with two bolts (3) and two washers (4).
2. Install bracket assembly (2) to the cab with two screws (5).
3. Connect the three 319-6830 Sensor Harness As 12-pin connectors to the corresponding connectors on the
back of the display. The video cable connects to the green connector. The 12-pin connector with two wires
connects to the black connector and the 12-pin connector with five wires connects to the gray connector.

(6) 213-0143 Connector
4. Connect the 19-pin bulkhead connector (6) of the 359-7645 Cab Harness As.
Flash the Software onto the Display

The display is shipped with the application software installed. Use the following procedure to flash the application
software into the display.
Note: Flashing the software may be required.
Required Material
Caterpillar Electronic Technician CAT (ET)
Communication Adapter
345-7489 Monitor Harness As
Software
Table 102
Part
System Description Notes
Number
8 Radar 387-3090 Caterpillar Integrated Object Detection System Radar and

System Camera
393-0420 Caterpillar Integrated Object Detection System Cameras only
Radar and
393-0419 Caterpillar Integrated Object Detection System
12 Radar Camera
System Caterpillar Integrated Object Detection System (Vision
393-0420 Cameras only
Only)
Perform the following procedure to flash program the ECM. The ECM is flashed to upgrade the software. Flash
programming of the ECM must be done if the ECM has been replaced. Caterpillar Electronic Technician (Cat ET)
contains the program WinFlash. WinFlash is used to load the software into the ECM. The following procedure is
used to flash the software into the display.
Procedure
1. Ensure that the key start switch and the disconnect switch are in the OFF position.
2. Disconnect the center 12-pin connector from the display.
3. Connect the 345-7489 Monitor Harness As between the system harness for the display and the center
connector on the display.
4. Connect the 7X-1425 Data Link Cable As between the 7X-1700 Communication Adapter Gp and Cat ET.
5. Connect the 139-4166 Data Link Cable As between the 7X-1700 Communication Adapter Gp and the
diagnostic connector of the 345-7489 Monitor Harness As.
6. Turn power back on to the display.
7. Use WinFlash to load the software.
8. Disconnect the 345-7489 Monitor Harness As from the system harness for the display and the center
connector on the display.
9. Connect the 12-pin connector of the system harness to the center connector of the display.
10. Turn the disconnect switch and the key start switch to the ON position.
11. Verify that the display turns on and the Caterpillar Integrated Object Detection system starts.
Note: Refer to Special Instruction, REHS5191 regarding information for the CIODS.
Object Detection Sensor - Adjustment for Eight Sensor System

There are two angle adjustments for the object detection sensors. The adjustments are the Azimuth or horizontal
adjustment and the Elevation or the vertical adjust. The angles that are provided in the tables below are the angles
that were found to work best. These angles are a guideline and are adjusted a few degrees to bring the detection
area of the system into an acceptable limit. This adjustment is necessary because of differences in machines that
are not controlled by Caterpillar. The type of tires that are used on a machine may affect the height of the machine.
This procedure must be used with the Operation and Maintenance Manual, SEBU8454, "Cat® Integrated Object
Detection System for Off-Highway Trucks".
Table 103
793D Front and Rear Radar Angles (As Measured with Angle Finder)
Front Radar Rear Radar

Radar
Azimuth (deg) Elevation (deg) Azimuth (deg) Elevation (deg)
Left Upper N/A N/A 15 right of center 8 down
Right Upper N/A N/A 15 left of center 8 down
Left Lower 25 left of center 1 Down 20 right of center 9 down
Right Lower 25 right of center 1 Down 20 left of center 9 down
Table 104
793D Side Radar Angles
Radar Elevation (deg)
Left Top 55
Right Top 55
Table 105
793D Front and Rear Radar Angles (As Measured with Degree Marks on Bracket)
Front Radar Rear Radar

Radar
Left Upper N/A N/A 15 right of center -2 down
Right Upper N/A N/A 15 left of center -2 down
Left Lower 0 left of center 1 down 20 right of center -1 down
Right Lower 0 right of center 1 down 20 left of center -1 down
Table 106
Left Top 55
Right Top 55
Object Detection Sensor - Adjustment for 12 Sensor System

Refer to Operation and Maintenance Manual, KENR8668, "Cat® Integrated Object Detection System for Off-
Highway Trucks" for assistance in adjusting the sensors for the 12 sensor system.
Table 107
793D Front and Rear Radar Angles
Radar Front Radar Rear Radar
Left Upper 20 left of center 20 down 15 right of center 20 down
Right Upper 20 right of center 20 down 20 left of center 20 down
Left Lower 25 left of center 2 down 25 right of center 7 down
Right Lower 25 left of center 2 down 25 left of center 7 down
Table 108
Left Top 45
Left Bottom 65
Right Top 45
Right Bottom 65
Azimuth Adjustment Procedure

Azimuth adjustment for Short Range Radar and Medium Range Radar Brackets
Table 109
Required Tools
13mm Wrench 1
Protractor 1
1. Loosen the four azimuth adjustment bolts on the brackets for the radars.
2. Use a protractor to set the proper azimuth angle that is listed in Table 107 or adjust the angle to fine-tune the
system.
3. Carefully tighten the four azimuth adjustment bolts on the brackets for the radars.
4. Check the angle again to verify that the bracket is set to the proper angle.
5. Tighten the bolts.
7. Proceed to the"Elevation Adjustment Procedure".
Elevation Adjustment Procedure

Elevation adjustment bolts for Long Range Radar
Table 110
Required Tools
10 mm Wrench 1
Inclinometer or Digital Level 1
1. Loosen the four adjustment bolts on the bracket for the radar.
2. Use an inclinometer or a digital level to set the proper elevation angle that is listed in Table 107 or adjust the
angle to fine-tune the system.
3. Carefully tighten the four azimuth adjustment bolts on the brackets for the radars.
5. Tighten the bolts.
7. Perform the Operation and Maintenance Manual, SEBU8454, "Cat® Integrated Object Detection System for
Off-Highway Trucks".
Perform the Commissioning Procedure for the Machine

Note: Refer to the Operations & Maintenance Manual for the oil level and viscosity recommendations.
Table 111
Commissioning Unit / Dealer Information
Date: Dealer:
Serial Number: Dealer Code:
SMU: Customer:
Completed By: Job Site:
Unit Number: Transmission Serial #:
Engine Serial #: TC Serial #:
Fluid Level Checks

Note: Refer to Operation and Maintenance Manual, SEBU7792, "793D Off-Highway Truck"
Table 112
Check the Fluid Level of the following Systems Check if OK
Engine Coolant System(1)
Transmission and Torque Converter
Steering Hydraulic Tank
Hoist and Brake Hydraulic Tank
Engine Crankcase
Left Rear Final Drive
Right Rear Final Drive

Rear Axle
Autolube Grease
Left Front Wheel Station
Right Front Wheel Station
Window Washer Reservoir
Fuel
(1) Check the After Cooler level and the Jacket Water level.
VIMS Self-Test
Turn the ignition switch key from the OFF position to the ON position to activate the VIMS self-test. Do not start
the truck.
Table 113
Check for the Illumination of the Lights in the instrument panel(1) Check if OK
Body indicator position

Action Indicator
Retarder Indicator
TCS Indicator
Alert Indicator
(1) All the indicator lights will illuminate at the same time for several seconds and then turn off.
Check the Configuration of the Electronic Control Modules (ECM)

Reference: Service Manual, RENR2630, "784C, 785B, 785C, 789B, 789C, 793B, 793C, 793D, 797, 797B Off-
Highway Truck/Tractors Vital Information Management System (VIMS)"
Reference: Testing and Adjusting, Troubleshooting, RENR2631, "784C, 785B, 785C, 789B, 789C, 793B, 793C,
793D, 797, 797BOff-Highway Truck/Tractors Vital Information Management System (VIMS)"

View of the 171-4400 Communication Adapter Gp
1. Connect a laptop computer to the Caterpillar Diagnostic Connector on the fuse panel behind the operator
seat.
2. to power the electrical system of the truck, perform the steps that follow:
a. Connect the batteries.

View of the ground level switches
b. Turn battery disconnect switch (14) to the ON position.
c. Switch manual engine shutdown switch (13) to the OFF position.
d. In the cab, turn the key to the ON position.
e. DO NOT START THE TRUCK.
Note: When the key is in the "ON" position, the VIMS will perform a 4 to 6 second self test. Disregard the
VIMS self test at this time.
3. Use your laptop computer to open VIMS.

Typical view of the electronic control modules for the 793 machine
4. Select 3516B 793 . Click OK.
5. The Electronic Technician (ET) Selector screen should display the truck model for each control. Make sure
that the model is correct for each of the controls.
6. Select "Service". Select "Configuration".
7. Select "Configuration Group 1".

Typical view
8. Select Equipment ID.
9. Click Equipment ID to change the Equipment ID value. Select change.
Note: The equipment ID should match the machine serial number.
10. Enter the desired new value and click OK.
11. Check the "Engine Serial Number". The "Engine Serial Number" must match the engine serial number on
the engine.
12. Adjust the "Fuel Ratio Control Offset", if necessary. The "Fuel Ratio Control Offset" has an adjustable range
of -25 to 25. The normal setting for the "Fuel Ratio Control Offset" is 0.
Note: Refer to Testing and Adjusting, SENR1123, "Fuel Ratio Control"
13. Verify the "Ether Control" setting. Set the "Ether Control" setting as desired to the "Enabled" or the
"Disabled" position.
14. If equipped, verify that the "Oil Renewal Rate" control is set as desired. The "Oil Renewal Rate" has an
adjustable range from -50 to 50.
Note: Refer to Systems Operation, RENR2223, "Oil Renewal System".
15. If equipped, verify the "Engine Pre-Lube" setting. A truck that is equipped with the engine prelube
attachment can be "Enabled".
16. Verify the "Cold Clylinder Cut-Out" setting. "Enable" or "Disable" the "Cold Clylinder Cut-Out" as desired.
Check for Active Diagnostic Codes and Logged Diagnostic Codes
1. Click the engine "ECM".
2. Click "Diagnostic". Click "Active Diag. Codes".
3. Resolve any of the active diagnostic codes.
4. Select the "INCLUDE ALL ECMs" at the bottom right of the screen.
5. At the bottom left of the screen, click the clear button to clear the codes.
6. Click "Diagnostics". Select "Logged Diag. Codes".

Typical view
7. Clear any logged diagnostic codes by highlighting an event. Next, click the "Clear" button that is located in
the lower left corner of the screen.

Typical view
8. Click "Diagnostics". Select "Events" and click "Logged Events".
9. If necessary, resolve and clear any logged events.
10. Clear the logged event by selecting an event and clicking the "Clear" button that is located in the lower left
corner of the screen.
Note: Depending on the event, a factory assigned password is required to clear some of the events that are
logged on the engine "ECM".
Injector Code Setting and Calibration
1. Click "Service". Select "Calibrations". Select and click "Injector Codes Calibration".

Typical view for reference only
2. Illustration 489 is a typical view of the injector trim codes and is for reference only.
3. Record all the injector trim codes for your machine in the table that is provided below.
Table 114
Engine Injector Trim Code(1)
Injector Trim Code Injector Trim Code
1 9
2 10
3 11
4 12
5 13
6 14
7 15
8 16
(1) Default is 1100
Note: An Injector trim code is stamped on each injector. If an injector is changed, the new injector trim code
must be updated in the engine "ECM".
Ether Control Test (If Equipped)

Note: The ether control must be enabled to perform the ether control test.

Values for the injectors are typical
1. Click "Diagnostics". Select "Diagnostic Tests". Select and click "Override Parameters".
2. To test the ether control operation, select "Ether Injection". Click the "Change" button that is located in the
lower left corner of the screen.
3. Click the drop-down for the "New Value:" and toggle the value from "Off" to "On". Click "OK".
4. Click "OK" in the verification box.
Note: An audible click should be heard after clicking "Yes" on the verification box.

Typical view
5. If the ether control test is acceptable, select "Ether Injection Override" to return the mode to normal.
Engine Pre-Lube Control Setting (If Equipped)
1. If equipped, select "Engine Pre-Lube". Click the "Change" button that is located in the lower left corner of
the screen.
Note: You should hear the engine pre-lube system energize
4. When the engine pre-lube test is completed, select "Disable Override" to return the mode to normal.
Oil Renewal Control Setting (If Equipped)
1. Click the engine "ECM".
2. To test the oil renewal setting, select "Oil Renewal". Click the "Change" button that is located in the lower
left corner of the screen.
Note: An audible sound from the "Oil Renwal" system should be heard after clicking "OK" on the
verification box.
5. When the oil renewal test is completed, click "Disable Override" to return the mode to normal.
6. Click "Service". Select and click "Configuration" to go back to the main configuration screen.
7. Typical view of the "Main Configuration Screen"
Transmission Control and Brake Control Settings
1. Select and click "Configuration Group 1" under the heading "Transmission 793".
Note: Do not adjust the "Hoist System Enable Status" or the "Hoist Lower Valve Adjustment Status" at this
time.
2. If the truck is equipped with the oil renewal attachment, verify that the control is set as desired.
3. Adjust all the values as required by the machine configuration. Also, adjust the values required by the mine.
4. Select and click "Configuration Group 1" under "Brake 793".
5. Verify the "Equipment ID" matches the machine serial number.
6. Select "Brake System" under "Brake 793".
7. Set the "Desired Engine Retard Speed" between 1850 RPM and 1950 RPM.
8. Select "Differential System" under "Brake 793" "ECM".
9. If a differential cooler is installed on the machine, change the value to "Installed". If a differential cooler is
not installed on the machine, change the value to "Not Installed".
10. Select "Cooling System" under "Brake 793" "ECM".
11. The "Engine Cooling Fan Configuration" value should be set to "Additional Cooling"
Note: For all merchandising arrangements, the "Engine Cooling Fan Configuration" should be set to
"Additional Cooling".
12. The "Brake Cooling Pump Configuration" value should be set to "Standard Cooling" for all machines except
the "Extra Retarding Truck" and the "High Altitude Arrangement Truck".

Typical view
13. Under "VIMS Main 793", select "Configuration Group 1".
14. Verify the product "I.D." matches the machine serial number.
15. Verify the parameters that are in the value column.
16. Disconnect (ET) from the laptop.
17. The Electronic Technician (ET) portion of the commissioning procedure is complete.
VIMS

View of the upper VIMS cable that is installed and the ET cable below that is to be removed
1. Connect a 127-9797 Cable As to the "RS-232" port on the laptop computer. Connect the other end of the
127-9797 Cable As to the diagnostic port in the panel behind the operators seat. Observe the gauges,
warning lights, and service lights when using the laptop computer during the operation of the truck.
Note: The key is in the ON position.
2. Start the "VIMS" PC software.
Note: The low brake/air pressure indicator causes the alert indicator to flash. The "VIMS" Message Center
should provide the following instruction: Do Not Move The Machine. This message is on display until the
starting reservoir and the service reservoir are charged to one half of the maximum operating pressure. Do
not turn off the parking brake switch before the pressure is obtained. The horn will sound a warning.
3. Refer to Service Manual, RENR2630, "Vital Information Management System (VIMS)" for additional
information. There are three levels of warnings. Level 1 is one red light. Level 2 is two red lights ON. Level
3 is two red lights ON and the alarm sounds.
4. Click "File". Select and click "Connect Machine".
5. After the connection is completed, click "Data". Select and click "Download".
6. In the "Download Data" box, select all the boxes under "Download".
7. In the "Download Data" box, select everything under "Reset After Download".
8. Click "Download" after the download selections are completed.
9. Click "Configure". Select and click "Assign Serial/Equipment Number".
10. In the "Assign Serial/Equipment Number" box, change the serial number to match the new truck serial
number.
11. In the "Assign Serial/Equipment Number" box, change the "Equipment" number to correspond to the new
customer machine number. Click OK.
12. Click "Configure". Select and click "Reset Date/Time/SMH".

Typical view
13. Select "Reset Date/Time" and change as necessary.
14. Select "Reset SMH" and set to Zero.
15. Click OK.
Prepare to Start the Engine
1. Verify all the fluids are at an acceptable level.
Front view of the truck
2. Disable the engine at ground level.
Note: The engine should be disabled so the engine will not start.
3. Chock the wheels.
4. Enable the parking brake.
5. Prime the pump drive housing and the hoist pump with the recommended oil or crank the engine. Crank the
engine over two times for 15 seconds to fill the compartments with oil.
Engine Start Up
NOTICE
A low brake pressure condition will cause the alert indicator to flash.
The "VIMS" message center should provide the following
instruction:"DO NOT MOVE THE MACHINE." This message is on
display until the starting reservoir and the service reservoir are
charged to one half of the maximum operating pressure. "DO NOT"
turn off the parking brake switch before the pressure is obtained. The
horn will sound a warning.
1. Verify that the fluids are at an acceptable level.
Note: See the checklist below.

Front view of the truck
2. Enable the engine at ground level to start the engine.
3. Start the engine.
Note: VIMS may instruct you to shut down the engine to resolve any issues. All issues must be resolved
before restarting the engine.
4. Verify that the pressures are acceptable for operation.
5. Run the engine for 10 seconds.
6. Disable the engine at ground level.
7. Check for leaks.
8. Check and fill the following systems as needed:
Transmission and Torque Converter
Common Rail Tank
Engine
Separate Circuit After Cooler (SCAC) and Water Jacket
Brake/Hoist
9. Restart the engine and operate the engine for 30 seconds.
10. With the engine operating, turn the steering wheel from the center position three rotations to the left. Next,
turn the steering wheel back to the center position.
11. With the engine operating, turn the steering wheel from the center position three rotations to the right. Next,
turn the steering wheel back to the center position.
12. Turn off the engine. Disable the engine at ground level and check all fluid levels. Check for leaks.
13. Restart the engine and operate the engine for 60 seconds.
14. Turn off the engine. Disable the engine at ground level and check for leaks.
15. Restart the engine. Operate the engine until normal operation temperatures are reached. Check for leaks.
16. Adjust all the fluid levels as required.
Automatic Retarder Control (ARC) Purge Procedure

Refer to Testing and Adjusting, RENR8330, "793D Off-Highway Truck Air System and Brakes"
NOTICE
A procedure is required to purge any air that may be in the (ARC)
system. Purge air from the (ARC) system if the following events have
occurred:
Initial assembly of the machine
The automatic retarder control valve has been replaced
Any hoses that supply oil to the automatic retarder control valve have been disconnected
Any hoses that supply the oil from the automatic retarder control valve to the brakes have been disconnected
Autolube
NOTICE
Before sending the machine to work, set the "Lube Cycle Time" to an
interval of 60 minutes. Set the "Lube Cycle Time" to a duration of 75
seconds. Be satisfied that all the automated grease injectors are
receiving a sufficient supply of grease.

View of the left side grease injectors

View of the right side grease injectors

View of the rear grease injectors
1. If necessary, adjust the grease injectors as required.
2. Turn the key to the ON position.
Note: Do not start the truck.
3. Using the "VIMS" key pad, enter the code 582738 to verify the lubrication settings.
4. Press OK.
5. Verify the autolube interval.

Typical view of the "VIMS" screen
6. If necessary, use the left arrow or the right arrow to set the correct interval.
7. Press OK.

Typical view of the "VIMS" screen
8. Verify the autolube duration.
9. If necessary, repeat Step 6 and Step 7 for the autolube duration.
Prepare the Truck for Pressure Checks
1. The engine should be at normal operating temperature and the transmission should be in neutral.
2. Engage the parking brake.
3. Chock the wheels
4. After the engine has started, the automatic elevated low idle will activate in 10 minutes. When activated, the
automatic elevated low idle increases the idle RPM gradually at a rate of 33 RPM per second.
5. After the activation of the elevated idle speed, or if the coolant temperature rises above 70 °C (158 °F), the
operator may reset the 10 minute delay. Tapping the accelerator pedal to more than 25 percent of the pedals
total travel will reset the 10 minute delay and return the engine to low idle.
Air Pressure Check
1. Prepare to start the truck.
Note: The parking brake should be applied.
2. Chock the wheels.
4. At the VIMS screen, enter the code 452.
5. Accelerate the engine to 1920 RPM.
6. The air dryer should expel air at 827 ± 34 kPa (120 ± 5 psi).
7. The air pressure at the VIMS screen should read 827 kPa (120 psi). For adjustment of the air pressure Refer
to Testing and Adjusting, "793D Off-Highway Truck Air System and Brakes"
8. Stop the engine.
Air Leakage Check
1. Turn the key to the ON position.
Note: Do not start the engine.
2. At the VIMS screen, enter the code 452.

Typical view of the parking brake that is engaged
3. Release the parking brake for approximately 2 minutes.
4. The air pressure should not drop more than 1 PSI in 2 minutes
5. Apply the parking brake.
6. Apply the service brake.
7. Repeat Steps 3 and 4.
8. Apply the secondary brake.
9. Repeat Steps 3 and 4.
10. Start the engine
Note: Wheels are chocked
11. Raise the air pressure governor to the maximum pressure of 827 ± 34 kPa (120 ± 5 psi)

Right side view of the cab
12. Open the valve to purge the air and reduce the air pressure to 455 kPa (66 psi)
13. A pressure of 455 kPa (66 psi) should produce a level "I" warning on the VIMS screen.
Note: If the truck is in gear, then a level "III" warning would be produced.
14. Perform an air system integrity test. The air system integrity test will check the entire air system of the truck.
The air tank should contain 827 kPa (120 psi).
Truck should remain shutdown and undisturbed for 5-6 hours (recommended).
Air system pressure drop should not exceed 138 kPa (20 psi).
If the air system pressure drop exceeds 138 kPa (20 psi), refer to Troubleshooting Compressed Air
System Components and Performance, REHS1428 for troubleshooting instructions.
Note: The truck requires 518 kPa (75 psi) to start the engine, if equipped with air start.
Heater Voltage Check
1. Locate the air dryer near the left front wheel of the machine.
2. Check the amount of heater voltage at the electrical connection of the dryer.
3. Use the table below to record your results.
Table 115
Air Dryer Check Actual Reading
24 V or more at the air dryer
Hoist Enable System
Note: The hoist enable system must be enabled after the truck is assembled.
1. Start Electronic Technician "ET" and select "Transmission 793".
2. Click "Service". Select and click "Configuration".
3. Under the heading "Transmission 793" select "Configuration Group 1". Select and click "Hoist System
Enable Status".
4. Click the"Change" button at the bottom of the screen.
5. Use the drop-down to change the "Hoist System Enable Status" to "Enabled". Click "OK". Select "OK" in
the verification box.
Steering System Test

Reference: Testing and Adjusting, "793D Off-Highway Truck Steering System"
1. With the engine running, record the pressures in the table provided.
Table 116
Steering Pressure Test(1)
Test Actual
Test the pressure setting for the (Priority Valve) Solenoid Valve and Manifold
(Rear Axle Fan, Brake Cooling, Drive Motor, Lubrication, and Steering)
Test the pump high-pressure cutoff at low idle

1.________________
Test the steering cycle time at high idle. With all the brakes released, turn the 2.________________
steering wheel from left to right and right to left. 3.________________
Avg.______________
Test the steering wheel turns from stop to stop at high idle. With all the brakes Left to Right
released, turn the steering wheel at 1 revolution per second 1.________________
2.________________
3.________________
Avg.______________
Right to Left
1.________________
Test the steering wheel turns from stop to stop at high idle. With all the brakes
2.________________
released, turn the steering wheel at 1 revolution per second
3.________________
Avg.______________
Test the accumulator nitrogen charge pressure(2)
Test the accumulator nitrogen charge pressure(3)

(1) Steering oil temperature during tests 90.5° ± 30.5°C (195° ± 55°F)
(2) The first of two accumulators
(3) The second of two accumulators
Torque Converter Test
Reference: Testing and Adjusting, "793D Off-Highway Truck Power Train"
1. Use the table below to record the performance of the torque converter.
Note: Engine speed is reduced to 1600 rpm when the transmission is in reverse and the body is in the raised
position. The torque converter stall test must be performed when the transmission is in the first forward gear
and the body is in the lowered position.
Table 117
Test Actual
Torque Converter Oil Temperature (during tests) > 80 °C (176 °F) < 121 °C (250 °F)
Low Idle
Torque Converter Inlet Pressure(1) High Idle
Stall
Torque Converter Stall RPM

Low Idle
Torque Converter Outlet Pressure at Stall RPM
High Idle
Low Idle
Transmission Charge Pressure (Converter Drive)
High Idle
Transmission Charge Pressure (Direct Drive)

Lockup Clutch Maximum Pressure
NEUTRAL/DIRECT DRIVE(2)
(1) Maximum pressure at high idle with cold oil.
(2) At 1300 RPM
Transmission Test
Reference: Testing and Adjusting, "793D Off-Highway Truck Power Train"
1. Use the table below to record the transmission and torque converter pressures.
Table 118
Converter Drive Pressures
Actual
Low Idle High Idle
Pump Pressure(1)
Lube Pressure
Pilot Pressure(2) XXX
> 82 °C (180 °F)

Transmission Oil Temperature (during tests)
< 121 °C (250 °F)
(1) Adjust with the Transmission Relief Valve
(2) Result of setting Direct Drive Pump Pressure
Traction Control System (TCS) Test

Reference: TestingandAdjusting, "69D, 769D, 773D, 773E, 775E, 776D, 777D, 784C, 785C, 789C, 793C, 793C
XQ, and 793D Off-highway Truck/Tractors and 771D and 775D Quarry Trucks Braking System"
1. Operate the engine at low idle and record the pressure in the table provided.
2. Operate the engine at high idle and record the pressure in the table provided.
3. Use the table below to record the TCS pressures.
Table 119
TCS Control Pressures
Low Idle High Idle

Left Side Left Side
Right Side Right Side
Towing Motor Test
If needed, refer to Testing and Adjusting, RENR8330, "793D Off-Highway Truck Air System and Brakes"

(1) Location of the pressure taps for the parking brake release pressure
1. Install a 8T-0857 Pressure Gauge ( 0 to 10000 kPa (0 to 1450 psi)) to the pressure taps for the parking brake
release pressure.
2. Turn the engine start switch to the ON position.
3. Apply the manual retarder.
4. Release the parking brake.

Switch for the electric powered parking and secondary brake release pump
5. Activate the towing motor switch.
Note: Hold the switch until the pressure that is shown on the pressure gauge stops rising.
6. Record the pressure for the left side and right side in the table provided.
Table 120
Towing Motor Pressure
Side Actual
Left
Right
Parking Brake Retract Pressure Test

Reference: Testing and Adjusting, "793D Off-Highway Truck Air System and Brakes"
This test will show if the parking brake release pump section is working properly. This test will also show if the
relief valve for the parking brake release system is set correctly.
1. Record the results of the pressure test in the table that is provided.
Table 121
Parking Brake Pressure
Setting Actual
Relief Valve
Measure and Record Front and Rear Brake Baseline Measurements

Reference: Testing and Adjusting, RENR8330, "793D Off-Highway Truck Air System and Brakes", "Service
Brake Discs - Check"
Table 122
Brake Wear
Piston Front Front Brake Percent of Rear Rear Brake Percent of

Travel Brake wear Brake wear
Baseline
Rebuild
1
Rebuild
2
Rebuild
3
Rebuild
4
Rebuild
5
Rebuild
6
Rebuild
7
Transmission Field Test
1. Stop the engine.

Front view of truck
2. If equipped, activate transmission neutralizer switch (1).
Note: Go to step 7 if the machine is not equipped with a transmission neutralizer switch.
3. When the transmission neutralizer switch activated, indicator light (2) should be on.
4. With the truck in first gear, try to start the engine.
5. With the truck in reverse, try to start the engine.
6. Use the table below to record the results of Step 4 and Step 5.
Table 123
Transmission Neutralizer Switch
Gear Switch Activated Engine does not start. Check if OK
First
Reverse
7. Complete the operations below and record the results in the table provided.
Table 124
Transmission Field Test
Operation Check
if OK
Gear indicator on the dash corresponds with the gear the machine is operating in.
Parking brake indicator flashes when the parking brake is engaged.(1)

With the hoist lever in the raised position, the machine should not shift into reverse gear.
With the gear selector in REVERSE, put the hoist lever in the raised position. The transmission should
shift into NEUTRAL.
With the gear selector in REVERSE, put the hoist lever in the lower position. The transmission should
shift into NEUTRAL.
While traveling in sixth gear at full throttle, shift the transmission from SIXTH gear down to FIRST
gear. The transmission should not downshift. When safe, the transmission will downshift. (2)
While traveling at a speed of 7 mph in FIRST gear, shift the transmission to REVERSE. The
transmission should shift into NEUTRAL then shift into reverse at 3.2 km/h (2 mph)(3)
(1) Produces a level 1 VIMS warning
(2) Checks the downshift inhibitor
(3) Checks the reverse shift inhibitor.
Transmission and Torque Converter Filters

The transmission system uses 343-4465 Oil Filter Elements, which have to be replaced by a service filter
element after 8 hours of machine operation. Failure to change to a service element may result in clogging of
the filter.
Replace the 343-4465 Oil Filter Element with a 343-4465 Oil Filter Element or a 1R-0741 Oil Filter Element
Assembly.
Note: The 343-4465 Oil Filter Element is recommended for replacement, however the 1R-0741 Oil Filter Element
Assembly is also an acceptable replacement.
Note: The 343-4465 Oil Filter Element is for power train use only and not approved for hydraulic
applications.
Contamination is one of the major causes of transmission control system failure. Some power train oil systems
were cleaned with fine cleanout filters, which frequently caused oil to bypass the filter. The use of cleanout filters
in power train oil systems is no longer recommended. A new line of advanced efficiencyCaterpillartransmission
filters have been introduced for use in power train application.
Note: Replace all clean-out filters as specified by assembly procedure.
Traction Control System Field Test
Note: The steering system should be checked and adjusted as required before proceeding with the test.
Note: Sound the horn for the all clear before starting the engine.
2. Activate the TCS switch.
3. With the TCS switch activated and the engine at low idle, drive the machine to the right in a tight circle.
Note: The rear wheels should lock and unlock.
4. With the TCS switch activated and the engine at low idle, drive the machine to the left in a tight circle.
Note: The rear wheels should lock and unlock.
5. Compare the turning radius of Step 3 to the turning radius of Step 4.
Note: The size of the turning radius for both of the circles that were driven should be similar.
Service Brake Field Test
1. Park the truck on a level surface.
2. Start the engine and allow the air pressure to reach the cutout pressure.
3. Depress the service brake control fully.
4. Move the parking brake control to the OFF position. Do not depress the secondary brake control.
5. Move the transmission control to into gear.
6. With the brake pedal depressed, increase the engine speed to 1300 rpm. The machine should not move.
7. If the machine moves, inspect the brake system for wear or for damage. Correct the air pressure. See the
Systems Operation/Testing And Adjusting, "Braking System Troubleshooting".
8. Move the transmission control to the NEUTRAL position.
Retarder Brake Field Test

Note: The retarder air control valve activates the front brakes and the rear brakes.
1. Park the machine on a level surface.
2. Start the engine and allow the air pressure to reach the cutout pressure.

View of the retarder lever in the up position
3. Pull the retarder control completely to the down position.
4. Move the parking brake control to the OFF position. If the machine moves, see Systems Operation/Testing
And Adjusting, "Braking System Troubleshooting".
5. Move the transmission control into gear.
6. Increase engine speed to 1300 rpm. The machine should not move.
7. If the machine moves, inspect the brake system for wear or for damage. Correct the air pressure. See
Secondary Brake Field Test

If needed, refer to Testing and Adjusting, RENR8330, "793D Off-Highway Truck Air System and Brakes" or
Troubleshooting, SENR1503, "69D, 769D, 773D, 773E, 775E, 776D, 777D, 784C, 785C, 789C, 793C, 793C XQ,
and 793D Off-Highway Truck/Tractors and 771D and 775D Quarry Trucks Braking System".
Note: The secondary brake air control valve activates all the wheel brakes. The wheel brakes are applied by spring
pressure and the wheel brakes are released by oil pressure.
1. Start the engine. Allow the pressure to reach the cutout pressure.
2. Do not depress the secondary brake control.
4. Depress the secondary brake control fully.
5. Release the parking brake.
Note: The parking brake warning light flashes when the secondary brake is engaged. A Level iii warning
will activate when the following conditions are true:
The engine is running.
The transmission is in forward or reverse.
The parking brake is ON.
6. Move the transmission control into gear.
7. Increase engine speed to 1300 rpm. The machine should not move.
8. If the machine moves, inspect the brake system for wear or for damage. Correct the air pressure. See the
Truck Payload - Calibrate
The payload system must be calibrated if the "VIMSpc" software is used to assign a new serial number to the
VIMS electronic control module. If, the strut pressures are adjusted the payload system must be recalibrated. The
payload system must also be calibrated after the replacement of:
VIMS electronic control module
Suspension Cylinders
Suspension Cylinder Pressure Sensors
The VIMS Truck Payload System will not operate until a successful payload calibration has been completed.
Security
Note: This service program code only functions while the service tool "VIMSpc" is connected.
The following information describes the service program code 729225 (PAYCAL). The PAYCAL service program
code uses the following procedure to calibrate the VIMS Truck Payload System:
1. Ensure that the truck body is empty. Carryback weight will affect the payload measurement.
2. Start the VIMS software.
3. Click "Configure". Select and click "Calibrate Truck Payload".
4. Operate the truck to a minimum ground speed of 6.4 km/h (4 mph) on hard level ground.
5. Move the transmission gear selector to the neutral position and allow the truck to coast. DO NOT use the
service brakes or the retarder.
6. Before the trucks stops, type PAYCAL. Click OK.

Typical view of the message center
7. After the "PAYLOAD CALIBRATED" is shown on the message screen, go to the VIMS screen.
8. In the VIMS screen, click OK.

Typical view of the message center
If the above message is shown on the message screen, repeat the procedure again. Make sure that the ground speed
is at a minimum of 6.4 km/h (4 mph). DO NOT use the service brakes and/or the retarder.
Cab Instrumentation and Functional Checks
Operators Seat
Table 125
Check for Seat Adjustability Check if OK
Check the range of the light to heavy dampening for the seat
Full range of the back reclining positions

Full range of the seat suspension travel
Operators Seat Belt
Table 126
Check Seat Belt Latch and Seat Belt Adjustability Check if OK
Adjust the length of the safety belt
Fasten the seat belt catch into the buckle

The seat belt must not be able to slip after adjusting
The seat belt catch should unlatch from the buckle when required
Engine Start
Table 127
Check the Ignition Switch, Horn, and Engine Start Check if OK
Turn the ignition key to the ON position(1)

Sound the horn for all clear
Turn the key to the START position to activate the starting motor.
After the diesel engine starts, release the key. The key should return to the ON position
Turn the ignition key to the OFF position. The engine should stop
(1) The key in the ON position enables the electrical circuits in the cab and activates the VIMS self-test
Pressurize the Cab
Table 128
Check the Operation of the Blower Motor to Pressurize the Cab(1) Check if OK
Turn the ignition key to the ON position
Check the four settings for the blower speed(2)

Turn the ignition key to the OFF position
(1) Pressurizing the Cab helps to eliminate dust in the operators compartment
(2) There should be an audible sound between the different settings
Climate Control

Right front view of the engine
(1) Outlet heater valve
(2) Inlet heater valve
Table 129
Check the operation of the Heater and the Air Conditioner Check if OK
Sound the horn for all clear
Start the engine

Turn the climate control to cool
Push the top of the A/C switch to activate
Air from the dash vents should be cold(1)

Push the top of the A/C switch to deactivate
Turn the climate control to warm
The lines for the heater valves should be open(2)
Air from the dash vents should be warm(1)

(1) When the engine is at operating temperature
(2) Refer to illustration 550
Window Wipers
Table 130
Check the Operation of the window Wiper and Washer Check if OK
From the OFF position, turn the window wipers to the LOW setting
Turn the window wiper to the HIGH setting
Press the button to activate the window washer fluid

Turn the window wiper to the first INTERMITTENT setting
Turn the window wiper to the second INTERMITTENT setting
Turn the window wiper to the third INTERMITTENT setting

Turn the window wipers to the OFF position
Panel and Running Lights
View of overhead panel

(3) Low Beam
(4) High Beam
(5) Driving Light
(6) Fog Light
Table 131
Check if
Check the operation of the Panel Lights and the Headlights(1)
OK
Push the top half of switch (1) to the first detent to activate the instrument panel lights, marker
lights, and the tail lights
Push the top half of switch (1) to the second detent to activate low beam headlights (3) and driving
lights (5)
Use multifunction switch (2)(2) to toggle between lights (3), (5) and high beam lights (4)(3)
Push the bottom half of switch (1) to the OFF position to deactivate the headlights
(1) The tail lights should be on any time a light switch is activated
Hazard Lights

View of overhead panel
Table 132
Check the operation of the hazard Lights Check if OK
Push the top half of switch (7) to activate the hazard lights
Push the bottom half of switch (7) to deactivate the hazard lights
Fog Lights
Table 133
Check the operation of the Fog Lights Check if OK
Push the top half of switch (8) to activate fog lights (6)(1)
Push the bottom half of switch (8) to deactivate fog lights (6)(1)
(1) Refer to Illustration 554 for the location of the switch
Reverse Lights
Table 134
Check the operation of the Reverse Lights Check if OK
Push the top half of switch (9) to activate the reverse lights(1)
Push the bottom half of switch (9) to deactivate the reverse lights(1)
Auxiliary Lights

View of the ground level switches

Front view of auxiliary light (1)
Table 135
Check the operation of the Auxiliary Lights(1) Check if OK
Push the top half of switch (10) to activate the auxiliary lights (2)
If necessary, adjust auxiliary light (1) to provide light for the steps
Push the bottom half of switch (10) to deactivate the auxiliary lights(2)
Activate auxiliary lights using toggle switch (11)(3)
Deactivate auxiliary lights using toggle switch (11)(3)

(1) The auxiliary lights can be activated from two places on the machine. The position of one switch will determine whether the other switch
is in the ON position or in the OFF position.
Engine Shutdown Switch
Table 136
Check the operation of the Engine Shutdown Switch Check if OK
Start the engine
Activate engine shutdown switch (12)(1)

Engine shuts down
Deactivate engine shutdown switch (12)

Cab Dome Light
Table 137
Check the operation of the Cab Dome Light Switch(1) Check if OK

Push dome light switch to the ON position to turn ON the light
Push dome light switch to the OFF position to turn the light OFF
(1) The dome light and switch are located above the operator in the cab
Cigar Lighter
Table 138
Check the operation of the Cigar Lighter(1) Check if OK

Push the lighter inward and release the lighter
When the lighter is ready to use, the lighter will move outward.
(1) The lighter can also be used as a 12 V power receptacle
Backup Alarm
Table 139
Check the operation of the backup alarm(1) Check if OK
Move the transmission direction and the speed control lever to the REVERSE position
The back-up alarm should sound immediately(2)

(1) Make sure that the area behind the machine is clear of personnel and clear of obstacles
(2) The backup alarm should sound until the transmission direction and speed control lever are moved to the NEUTRAL position or the
FORWARD
Calibrate the Body Position Sensor
Refer to Testing and Adjusting, SENR1502, "784C, 785C, 785D, 789C, 793C, and 793D Off-Highway
Truck/Tractors Power Train Electronic Control System" for instructions on calibrating the body position sensor.
Hoist Lower Valve Adjustment Status (Snub)
Lowering the hoist is adjustable. Adjusting the hoist compensates for the differences in valves. The adjustment
range is -5 to +5 with zero as the default. A positive adjustment factor will increase the lower valve command.
Increasing the lower valve command causes the body to come down harder. A negative adjustment factor will
decrease the lower valve command. Decreasing the lower valve command causes the body to come down softer.
Note: When the Hoist Lower Valve is adjusted too high, too much oil can be diverted to the hoist system. If the
hoist system is in the float mode, the brake oil heats up faster. Retarding capability is also decreased. To set the
Hoist Lower Valve, follow the procedure below.
1. Raise the truck body.
2. Connect the safety retaining cable to the body.

View of the 6V-7830 Tetragauge
3. Connect a 6V-7830 Tetragauge to one of the outlet ports on the hoist pump.
4. Remove the safety retaining cable from the body.
5. With the engine that is running, place the hoist lever in the body float position.
6. With the engine operating at high idle and the body in the snub position, record the pressure.
Note: If the pressure at the hoist outlet port is more than 1723 kPa (250 psi), then proceed to Step 7 and Step
8.
7. Enter Configuration Group One in the transmission ECM.
8. Adjust the Hoist Lower Valve to a desired setting. The procedure begins at 0. Adjust the settings in
increments of 1 in the positive position or in the negative position.
9. Select "Hoist Lower Valve Adjustment Status".
10. Select "Change".
11. Insert the new value in the "Hoist Lower Valve Adjustment Status" box. Click "OK". Select "Yes" in the
verification box.
12. Repeat Step 5 through Step 11 until the pressure is below 1724 kPa (250 psi).
Note: When the pressure is greater than 1724 kPa (250 psi), the adjustment is set too high. Pressure too high
causes too much oil to be diverted to the hoist valve. Too much oil diverted to the hoist valve causes the brake oil
to overheat when the body is in the body float position. Reduce the Hoist Lower Valve Adjustment in ET. Repeat
Step 1 through Step 6 to lower the pressure below 1724 kPa (250 psi).
Note: The body down snub function cushions the shock when the body hits the bed of the truck. When the body is
lowered, the body position sensor detects the position of the body. When the body is close to the rail of the truck,
the ECM will go into snub mode. When the operators request is less than the snub mode, the ECM will use the
operators request. When the ECM uses the operators request, the ECM ensures that the snub function will never
cause the body to go down faster than the hoist lever modulation. The body snub function will be Canceled as the
operator moves the hoist lever out of the body float position or the body lower position. The body snub function
will not start until the body is raised above the body position sensor activation point.
Suspension Charge
If needed, refer to Special Instruction, SEHS9411, "Servicing the Suspension Cylinders for Off-Highway Trucks".

Left front view of the strut
1. Measure the visible chrome on the four struts to verify the charge.
2. Record the strut measurements in the table provided.
Table 140
Exposed Chrome on the Struts
Left front strut

Right front strut
Left rear strut

Right rear strut
Body Installation
Table 141
Record Body information
Body Manufacturer/Part Number
Serial Number
Condition
Body to Chassis Interference
1. After the body is installed and properly shimmed, check the interference between the body and the chassis.
2. If the truck is equipped with body heat, verify the proper adjustment of the body heat connection.
3. Check the hoses on top of the hydraulic tank, fuel tank, and the hoses between the frame rails. If necessary,
adjust the grease line at the top of the hoist cylinder to prevent any damage.
Tire Specifications
1. Record the tire specifications in the table provided.
Table 142
Tire Size Manufacturer
Left Front
Right Front
Left Rear Outside

Left Rear Inside
Right Rear Inside

Right Rear Outside
Miscellaneous Checks
If needed, refer to Operation and Maintenance Manual, SEBU7792, "793D Off-Highway Truck"
1. Perform the following checks and record your results in the table provided.
Table 143
Miscellaneous Checks
Take Digital Photos of Completed Truck
Missing Parts(1)
Assembly Issues
Performance Issues
Dealer Installed Attachments(2)
Dealer Comments(3)
Verify the function of all Cab Controls
Payload Target
(1) Develop a list of all the part numbers and the next highest part number level.
(2) Take digital photos of all dealer installed attachments.
(3) Record positive and negative comments.
Copyright 1993 - 2020 Caterpillar Inc. Thu Jan 16 2020 23:09:46 GMT-0500 (hora estándar de Perú)
All Rights Reserved.
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16/1/2020 Media Search - REHS2210 - Assembly Procedure For the 793D Off-Highway Truck {7000, 7006, 7960}

Assembly Procedure For the 793D Off-Highway Truck {7000, 7006,

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

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

Reference: Special Instruction, SMHS7867, "Use of 6V-4040 Inflation Group"

Improper assembly procedures could result in injury or death.

24 3S-6162 Hard Washer(1)

30 8T-4222 Plated Washer

Qty Part Number Description

2 1P-7016 Half Flange

Qty Part Number Description

12 8T-4121 Hard Washer

1 6V-9169 Bulkhead Nut

Qty Part Number Description

1 250-0555 Hose As(1)

2 1P-4582 Half Flange

4 8T-4223 Hard Washer

1 258-8126 Tube As(2)

1 273-1169 Hose As(2)

Qty Part Number Description

2 8T-4223 Hard Washer

4 7X-0591 Hard Washer

2 1P-4584 Half Flange

8 8T-4223 Hard Washer

1 6V-4590 O-Ring Seal

2 197-3295 Half Flange

Qty Part Number Description

2 228-7090 O-Ring Seal

1 214-7568 O-Ring Seal

Qty Part Number Description

Qty Part Number Description

24 8T-7934 Hard Washer

2 5A-4885 Plug Button

8 8T-4222 Plated Washer

16 4W-0435 Quad Ring Seal

1 309-1905 Taperlock Stud

3 8T-4121 Hard Washer

2 8T-4223 Hard Washer

1 204-8000 Cable Tie Mounting

1 204-2281 Cable Strap

Qty Part Number Description

133 8T-4136 Bolt(2)

133 8T-4121 Hard Washer (2)

1 242-9547 Handhold As (3)

1 242-9815 Handhold As(5)

4 8T-4223 Hard Washer

1 8T-4205 Hard Washer

1 6B-8085 Chain Snap

Qty Part Number Description

85 8T-4121 Hard Washer

4 198-4778 Hard Washer

4 8T-4223 Hard Washer

1 8X-4285 Plate As(2)

Qty Part Number Description

1 250-7605 Bracket As(1)

15 8T-4121 Hard Washer(2)

1 134-0987 Bracket As(1)

1 303-8298 Bracket As(3)

4 198-4778 Hard Washer(3)

1 290-0057 Mirror As(4)

Qty Part Number Description

2 5T-5202 Bearing Cap(1)

12 146-1799 Hard Washer