Commissioning Procedure for the 793F, 793F Tier 4, and the 793F CMD Off-Highway Truck {1000, 7000, 7961} Caterpillar

Commissioning Procedure for the 793F, 793F Tier 4, and the 793F CMD Off-Highway Truck {1000, 7000, 7961}

Usage:

793F D3T

Off-Highway Truck/Tractor: 793F (S/N: SND1-UP; SSP1-UP; D3T1-UP; RBT1-UP)

Introduction

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Personal injury or death can result from air in the oil for the brake hydraulic system.
Air in the system can prevent complete brake application and it is possible that the wheels on the machine can not be stopped.

Air must not be in the oil for the brake hydraulic system to function properly.

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Personal injury or death can result from machine movement.

Place blocks in front of and behind the wheels to make sure the machine does not move while the parking brakes are disengaged.

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Do not check for leaks with your hands. Pin hole (very small) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use cardboard or paper to locate pin hole leaks.

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Illustration 1	g01962775

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When it is necessary to work under the machine with the body (bed) raised, attach the body (bed) retaining cables to the body retaining pins. Install the body retaining pins through the ends of the retaining cables. Always use both retaining cables.

Failure to properly secure the body (bed) may result in personal injury or death.

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, PERJ1017, "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.

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NOTICE

This machine is equipped with a Tier 4 Certified Engine system that is configured to meet the emissions requirements mandated by the United States Environmental Protection Agency (EPA). Care must be taken to comply with all instructions within this document to ensure that the engine, as assembled (including the exhaust piping, DEF Fluid lines, and controls), performs as designed to meet and maintain Tier 4 emissions requirements. Also, to meet the EPA regulatory requirements related to recording the combination of engine and emissions components that will be placed into service with the machine. Return the required information to the address listed in the "Mandatory Reporting for T4 Machines" Section.

Reference: Operations and Maintenance Manual, SEBU8406, "793F and 793F XQ Off-Highway Trucks"

Reference: Special Instruction, REHS5464, "Accumulator Discharging and Charging Procedures"

Reference: Systems Operation and Testing and Adjusting, KENR5397, "C175-16 and C175-20 Engines for 793F and 797F Off-Highway Trucks"

Reference: Service Manual, KENR9023, "793F and 797F Off-Highway Truck/Tractors VIMS, Monitoring, and Payload"

Reference: Testing and Adjusting, KENR8738, "793F and 793F XQ Off-Highway Truck Braking System"

Reference: Service Manual, KENR9949, "Off-Highway Truck Automatic Lubrication System for Electric Start Equipped Trucks"

Reference: Service Manual, SENR4724, "Off-Highway Trucks Automatic Lubrication System for Air Start Equipped Trucks"

Reference: Testing and Adjusting, KENR8572, "793F Off-Highway Truck Air System"

Reference: Testing and Adjusting, KENR8393, "793F and 797F Off-Highway Trucks Power Train Electronic Control System"

Reference: Testing and Adjusting, KENR8570, "793F and 793F XQ Off-Highway Truck Hydraulic System"

Reference: Service Magazine, SEPD1178, "Switch Settings for the Payload Monitors"

This Special Instruction contains the following necessary procedures for the 793F and the 793F XQ Off-Highway Truck commissioning procedure.

Note: The photographs in this publication are for illustrative purposes. Do not perform any procedures in this publication or order any parts until you understand the information that is contained in this publication.

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Table 1
Dealer Information for Commissioning Procedure
Date
Serial Number
Service Meter Units
Name of the Technician
Unit Number
Engine Serial Number
Pump Electronic Tank Unit (PETU) Serial Number⁽¹⁾
Clean Emissions Module (CFM) Serial Number⁽¹⁾
Dealer
Dealer Code
Customer
Job Site
Transmission Serial Number
Torque Converter Serial Number
Right-Hand Wheel Station Serial Number
Left-Hand Wheel Station Serial Number
Rear Axle Serial Number
Body Manufacturer/Part Number
Body Serial Number
General Body Condition

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⁽¹⁾	If Tier 4 equipped

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Table 2
Tire Information
	Tire Size	Manufacturer
Left Front
Right Front
Left Rear Outside
Left Rear Inside
Right Rear Inside
Right Rear Outside

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Table 3
Miscellaneous Checks
Take Digital Photos of Completed Truck
Missing Parts⁽¹⁾
Performance Issues
Dealer Installed Attachments⁽²⁾
Dealer Comments⁽³⁾
Verify the function of all Cab Controls
Verify the function of the Engine Aftertreatment⁽⁴⁾
Payload Target

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⁽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.
⁽⁴⁾	If Tier 4 equipped

Required Tooling

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Illustration 2	g02571852
Tooling (A) 198-4240 Digital Pressure Indicator Gp

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Table 4
Required Tools
Tool	Item	Qty	Part No	Description
A			198-4240	Digital Pressure Indicator Gp
	A1	1	198-4234	Digital Indicator
	A2	1	198-4237	Pressure Sensor Gp (0 kPa to 3,445 kPa (0 psi to 500 psi))
	A2	1	198-4238⁽¹⁾	Pressure Sensor Gp (0 kPa to 34,450 kPa (0 psi to 5,000 psi))
	A2	1	198-4239	Pressure Sensor Gp (0 kPa to 41,368 kPa (0 psi to 6,000 psi))
	A2	1	251-9600⁽²⁾	Pressure Sensor Gp (0 kPa to 68,900 kPa (0 psi to 10,000 psi))
	A3	1	198-4236	Adapter Cable As

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⁽¹⁾	This sensor must be purchased separately, the sensor is not included in the 198-4240 Digital Pressure Indicator Gp
⁽²⁾	This sensor can only be used on large diameter pressure taps like 6V-3965 Fitting.

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Illustration 3	g02726620

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Table 5
Required Tools
Tool	Item	Qty	Part No	Description
B	B1	1	8T-0862	Pressure Gauge (-100 TO 500 kPa (-15 TO 72 psi))
	B1	1	8T-0863	Pressure Gauge (0 TO 250 kPa (0 TO 36 psi))
	B1	1	8T-0853	Pressure Gauge (0 TO 400 kPa (0 TO 58 psi))
	B1	1	8T-0854	Pressure Gauge (0 TO 1,000 kPa (0 TO 144 psi))
	B1	1	8T-0855	Pressure Gauge (0 TO 4,000 kPa (0 TO 580 psi))
	B1	1	8T-0856	Pressure Gauge (0 TO 6,000 kPa (0 TO 860 psi))
	B1	1	8T-0857	Pressure Gauge (0 TO 10,000 kPa (0 TO 1,450 psi))
	B1	1	8T-0858	Pressure Gauge (0 TO 16,000 kPa (0 TO 2,300 psi))
	B1	1	8T-0859	Pressure Gauge (0 TO 25,000 kPa (0 TO 3,600 psi))
	B1	1	8T-0860	Pressure Gauge (0 TO 40,000 kPa (0 TO 5,800 psi))
	B1	1	8T-0861	Pressure Gauge (0 TO 60,000 kPa (0 TO 8,600 psi))
	B2	1	6V-3989	Fitting
	B3	2	6V-4143	Quick Connect Coupler
	B4	1	177-7860	Hose As 3.0 m (10 ft)
	B4	1	177-7861	Hose As 4.3 m (14 ft)
	B4	1	177-7862	Hose As 5.5 m (18 ft)

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Illustration 4	g03334430
Tooling (C) 317-7484 Communication Adapter III

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Table 6
Required Tools
Tool	Item	Qty	Part Number	Description
C		1	317-7484⁽¹⁾	Communication Adapter Gp
	C1	1	370-4617	Cable As (USB PC Communication)
	C2	1	317-7485	Communication Adapter III
	C3	1	327-8981	Cable As (Data Link)

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⁽¹⁾	Caterpillar Electronic Technician (Cat^®ET) and Software CD, NETG5057 are required when using the communication adapter.

Note: With the release of Tier 4 Final engines, additional emissions control system components have been added to the engine to reduce the NOx output. The most recent version of Cat® Electronic Technician (ET) must be used when connecting to the Electronics Control Modules. Refer to Special Instruction, REHS8170 for instructions on properly setting up the computer and Comm3 adapter for use on Tier 4 applications.

Power the Electrical System

To power the electrical system of the truck, perform the steps that follow:
1. Connect the batteries.
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  Illustration 6 g03447501
  
  Typical view of the ground level switches (SSP, SND, RBT machines)
  
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  Illustration 7 g06183129
  
  Typical view of the ground level switches (D3T machines)
2. Rotate battery disconnect switch (1) clockwise to the Energize the 24 V system.
3. Switch manual engine shutdown switch (2) to the OFF position.
4. In the cab, turn the key to the ON position.
  DO NOT START THE TRUCK.
  Note: When the key is in the "ON" position, VIMS will perform a self-test. Each self-test takes approximately 4 to 6 seconds to complete. Disregard the VIMS self-test at this time.

Fluid Level Checks

Note: Refer to Operation and Maintenance Manual, SEBU8406, "Capacities (Refill)" for information on checking the fluid levels.

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Table 7
Checking the Fluid Levels	Check if OK
Engine Coolant System⁽¹⁾
Hoist and Brake Cooling⁽²⁾
Brake⁽²⁾
Steering and Hydraulic Fan⁽²⁾
Transmission and Torque Converter
Engine Crankcase
Left Rear Final Drive
Right Rear Final Drive
Rear Axle
Grease for the Autolube
Left Front Wheel Station
Right Front Wheel Station
Window Washer Reservoir
Fuel
Fuel
Diesel Exhaust Fluid (DEF)⁽³⁾
Oil Reservoir for the Powered Access Stairway⁽⁴⁾

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⁽¹⁾	Check the Jacket Water level.
⁽²⁾	Part of the hydraulic tank
⁽³⁾	If Tier 4 equipped
⁽⁴⁾	If equipped

Cab Instrumentation and Functional Checks

Operators Seat

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Table 8
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

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Table 9
Check Seat Belt Latch and Seat Belt Adjustability	Check if OK
Adjust the length of the seat 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
Ensure that the seat belt alarm works properly

Pressurize the Cab

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Table 10
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

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⁽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

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Illustration 8	g02079413
Right left view of the engine (1) Supply heater valve (2) Return heater valve

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Table 11
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⁾
Turn the ignition key to the OFF position

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⁽¹⁾	When the engine is at operating temperature
⁽²⁾	Refer to illustration 8

Air Conditioner Condenser Drain Line

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Illustration 9	g06200475
View of the window washer bottle inside the rear of the cab (1) Air conditioner condenser drain line (2) Drain line valve

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Table 12
Check the Connection for the Air Conditioner Condenser Drain Line	Check if OK
The air conditioner condenser drain line (1) is attached to the drain line valve.
Turn drain line valve (2) to the OPEN position.

Window Wipers

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Table 13
Check the Operation of the Window Wiper and Washer	Check if OK
Turn the ignition key to the ON position
From the OFF position, turn the window wipers to the LOW setting by using multifunction switch (3) from Illustration 11
Turn the window wiper to the HIGH setting
Press the button to activate the window washer fluid
Turn the window wiper to the first INTERMITTENT setting
Turn the window wiper to the second INTERMITTENT setting
Turn the window wiper to the third INTERMITTENT setting
Turn the window wipers to the OFF position
Turn the ignition key to the OFF position

Panel and Running Lights

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Illustration 10	g02074793
(1) Switch for headlights, parking lights, and taillights (2) Panel light switch

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Illustration 11	g03319224
(3) Multifunction switch (4) Horn

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Illustration 12	g03319235
(5) Low Beam (6) High Beam (7) Fog Light

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Table 14
Check the Operation of the Panel Lights and the Headlights⁽¹⁾	Check if OK
Turn the ignition key to the OFF position
Push switch (1) to activate low beam headlights (5)
Push the top half of switch (2) to the first detent to activate the instrument panel lights, marker lights, and the tail lights
Use multifunction switch (3) to toggle between low beam lights (5) and high beam lights (6)
Push the bottom half of switch (1) to the OFF position to deactivate the headlights
Ensure that all headlights are in the correct position, not to blind on coming traffic
Sound horn (4)

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⁽¹⁾	The tail lights should be on any time a light switch is activated

Hazard Lights

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Illustration 13	g06183131
(8) Hazard flasher switch

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Table 15
Check the Operation of the Hazard Lights	Check if OK
Turn the ignition key to the OFF position
Push the top half of switch (8) to activate the hazard lights
Push the bottom half of switch (8) to deactivate the hazard lights

Fog Lights

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Illustration 14	g06183132
(9) Switch for the front fog lights

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Table 16
Check the Operation of the Fog Lights	Check if OK
Turn the ignition key to the OFF position
Push the top half of switch (9) to activate fog lights (7)
Push the bottom half of switch (9) to deactivate fog lights (7)

Access Lights

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Illustration 15	g06183133
(10) Switch for the access lights in the cab

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Illustration 16	g06183138
(11) Switch for the access lights at ground level (SSP, SND, and RBT machines)

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Illustration 17	g06183135
(11) Switch for the access lights at ground level (D3T machines)

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Illustration 18	g02075295
Typical view of the access light

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Table 17
Check the Operation of the Access Lights⁽¹⁾	Check if OK
Turn the ignition key to the OFF position
Push the top half of switch (10) or switch (11) to activate the access lights
If necessary, adjust the access light to provide light for the steps
Push the bottom half of switch (10) or switch (11) to deactivate the access lights

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⁽¹⁾	The access 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.

Cab Dome Light

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Table 18
Check the Operation of the Cab Dome Light Switch⁽¹⁾	Check if OK
Turn the ignition key to the OFF position
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

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⁽¹⁾	The dome light and switch are located above the operator in the cab

Cigar Lighter

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Table 19
Check the Operation of the Cigar Lighter⁽¹⁾	Check if OK
Turn the ignition key to the ON position
Push the lighter inward and release the lighter
When the lighter is ready to use, the lighter will move outward.

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⁽¹⁾	The lighter can also be used as a 12 V power receptacle

Backup Alarm

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Table 20
Check the Operation of the backup alarm⁽¹⁾	Check if OK
Turn the ignition key to the ON position
Move the transmission direction and the speed control lever to the REVERSE position
The backup alarm should sound immediately⁽²⁾

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⁽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

Workshop Horn (If Equipped)

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Illustration 19	g06201358
(1) Workshop horn switch

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Illustration 20	g06201372
(2) Location of the workshop horn

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Table 21
Check the Operation of the Workshop Horn	Check if OK
Turn the ignition key to the ON position
Press the top of switch (1)
The workshop horn (2) should sound immediately

Rear View Mirrors (If Equipped)

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Illustration 21	g06200986
Extra rear view mirrors (1) Left side rear view mirror (2) Right side rear view mirror

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Table 22
Check the Extra Rear View Mirrors	Check if OK
Left rear view mirror (1) is mounted and adjusted
Right rear view mirror (2) is mounted and adjusted

Extra Lights (If Equipped)

____________________

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Illustration 22	g06203983
Front, left corner of a 793F Off-Highway Truck (1) 426-5380 Flood Lamp Gp also known as the berm light (2) Left work lamp (3) Left 334-5409 Signal Lamp Gps

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Illustration 23	g06204007
Front, right corner of a 793F Off-Highway Truck (2) Right work lamp (3) Right 334-5409 Signal Lamp Gps

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Illustration 24	g06204037
Looking forward at the transmission service lights on the back of the main beam (4) Transmission service lights

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Illustration 25	g06204054
The engine service lights on the front of the main beam pointing forward (5) Engine service lights

The following lights make up the extra lights.

Berm light (1)
Work lamps (2)
Side signal lamp groups (3)
Transmission service lights (4)
Engine service lights (5)

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Illustration 26	g06203742
Top view of the operator compartment (6) Multifunction switch (7) Switch for the side signal lamp groups (8) Berm light switch (9) Work lamp switch

Berm Light

The berm light (if equipped) (1) in Illustration 22 is mounted on top of the running light at the front left corner of the machine. The berm light points away from the machine. Illuminate the berm light by pressing the top of switch (8) in Illustration 26. Press the bottom of switch (8) to turn off the berm light.

Work Lamps

Two work lamps are mounted on the machine. One work lamp (2) is mounted on the left side of machine between side marker and turn lights (3). Refer to Illustration 22. One work lamp (2) is mounted on the right side of the machine on top of the handrail. Refer to Illustration 23. Both work lamps are pointed back at a 45 degree angle. Both work lamps illuminate the area outside the back tires to help the operator position the machine. Press the top of switch (9) in Illustration 26 to illuminate the work lamps. Press the bottom of switch (9) in Illustration 26 to turn off the work lamps.

Side Signal Lamp Groups

The side signal lamps (3) contain the side marker lights and the turn lights. Two side signal lamp groups are mounted on both the left side and the right side of the machine. Refer to Illustration 22 and Illustration 23. The side marker lights and the turn lights are wired into the standard marker lights and turn signals. The side marker lights illuminate when you press the top half of switch (7) in Illustration 26 to the first detent. For a left turn, you move multifunction switch (6) in Illustration 26 down. Move the multifunction switch up to turn off the left turn signal. For a right turn, move multifunction switch (6) in Illustration 26 up. To turn off the right turn signal, move the multifunction switch down. For additional information on the operation of multifunction switch (6), refer to Operation and Maintenance Manual, SEBU8406, "793F and 793F XQ Off-Highway Trucks", Directional Turn Signals.

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Illustration 27	g06204058
Electronic control group (11) on the front, right corner of the machine (10) Engine service lighting switch (11) Electronic control group

Transmission Service Lights and Engine Service Lights

Two transmission service lights (4) in Illustration 24 illuminate the transmission. Two engine service lights (5) in Illustration 25 illuminate the back of the engine. Two standard service lights illuminate the front of the engine. All the service lights are controlled by engine service lighting switch (10) in Illustration 27. Engine service light switch (10) is located in electronic control group (11) on the front, right corner of the machine. Refer to Illustration 27. Move the light switch to the ON position to illuminate all the service lights. Move the light switch to the OFF position to turn off the service lights.

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Table 23
Check the Operation of all Extra Lights	Check if OK
Turn the ignition key to the OFF position
Push the top of switch (8) to turn on the berm light
Push the bottom of switch (8) to turn off the berm light
Push the top of switch (9) to turn on both work lights
Push the bottom of switch (9) to turn off both work lights
Push the top of switch (7) to the first detent to turn on all marker lights
Push the bottom of switch (7) to turn off all marker lights
Push down on multifunction switch (6) to actuate all left turn signals
Push up on multifunction switch (6) to turn off all left turn signals
Push up on multifunction switch (6) to actuate the right turn signals
Push down on multifunction switch (6) to turn off the right turn signals
Move engine service light (10) to the ON position to illuminate all service lights.
Move engine service light (10) to the OFF position to turn off all service lights.

Emergency Stop Switch (If Equipped)

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Illustration 28	g06208106
Cab location of the emergency stop switch (1)

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Illustration 29	g06208113
Ground level location of emergency stop switch (1)

There are two emergency stop switches (1) on the machine. The emergency stop switches are in the cab and at ground level at the front, right corner of the machine.

Cycle the emergency stop switches before starting the engine at the beginning of every shift to verify operation.

The emergency stop switches disconnect the valves and the power output of the electronic control units for the engine. Disconnecting this power causes the engine to shutdown. No working movements can be performed after the engine is shutdown.

To use the emergency stop switch, the operator must bring the machine to a complete stop. Press the emergency stop switch in to the OFF position. Pressing the emergency stop switch will enable an emergency shutdown sequence . The shutdown sequence will perform the following actions:

Stop the engine
Stop the engine cooling fan
Engage the parking brake
Hoist will stay in hold
Horn will sound
Cab HVAC blower will stop
Hazard lights will flash
The Cat MineStar system will be notified

The power supply to the machine is not interrupted when the emergency stop switch is pressed. The following items will continue to function:

Cab
Lighting
Fire Suppression System (If Equipped)

The emergency stop switch has a detent in the OFF position. The operator must pull out the emergency stop switch to reset the switch to the ON position. The operator must cycle the engine start switch from the OFF position to the ON position, and back to the OFF position to reset the computers.

Note: The length of time the horn will sound is configured through the Cat Electronic Technician (Cat ET) Service Tool. The maximum length of time the horn will sound is 60 seconds. The accumulators can also be configured through Cat ET. The standard setting is OFF.

When you press the emergency stop switch, fire suppression (if equipped) is not activated. When fire suppression (if equipped) is initiated, the emergency stop shut down sequence is activated.

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Illustration 30	g06208217

When you press the emergency stop switch, the emergency stop shutdown sequence will also override the idle shutdown timer (if equipped) (2).

To test the emergency stop switch, do the following:

Bring the machine to a complete stop
Run the machine at LOW idle
Place the hoist control in the HOLD position
Run the HVAC blower on HIGH fan speed
Turn off all the parking and hazard lights
Press one of the emergency stop switches

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Table 24
Check the Emergency Stop Switch	Check if OK
Did the engine stop?
Turn the engine start switch to the START position. The engine should not start.
Did the engine cooling fan stop?
Did the parking brake engage? Check in Cat ET
Did the horn sound?
Did the cab HVAC blower stop?
Did the hazard lights flash?
Did the Cat MineStar system get notified?

Check the Operation of the Fast Fill Service Center (If Equipped)

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Illustration 31	g06201955
Fast fill service center (A)

The control box for the Fast Fill Service Center (A) is mounted on the front, left corner of the bumper. The full fluid level is monitored by a fluid level sensor that is at each of the fluid reservoirs.

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Illustration 32	g06201880
Fast fill service center (1) Fill and evacuation port for steering oil (2) Sample port for hoist/brake oil (3) Fill and evacuation port for torque converter oil (4) Fill and evacuation port for engine oil (5) Sample port for engine coolant (6) Keypad to check the level of each fluid section, and to check the system indicators (7) Evacuation port for hoist/brake oil (8) Sample port for steering oil (9) Fill and evacuation port for brake oil coolant (10) Sample port for transmission/torque converter oil (11) Evacuation port for transmission oil (12) Sample port for engine oil (13) Fill and evacuation port for engine coolant (14) Power switch (15) SOS port

Illustration 32 identifies the ports on the fast fill service center.

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Illustration 33	g06201921
Detail of the keypad (16) Full (17) Normal (18) Add (19) Test button (20) Hoist and brake system oil level (21) Engine coolant level (22) Engine oil level (23) Steering system oil level (24) Transmission oil level (25) Automatic lubrication reservoir level

Each of the six fluid sections contains a fluid indicator, and test button (19). The fluid indicator has three levels.

(16) Full
(17) Normal
(18) Add

When a fluid system is full, the indicator (16), indicator (17), and indicator (18) will illuminate continuously. Stop the flow of fluid to the corresponding fast fill port when the three indicators are illuminated.

When a fluid system is at or above normal operating level, indicator (17) and indicator (18) will illuminate continuously.

When a fluid system is below normal operating level, indicator (18) will flash.

To test a fluid section, move power switch (14) to the DOWN position. Press and hold test button (19) for that fluid section. The fluid indicator for the corresponding system will flash once and then illuminate continuously if the indicators are working properly. Test the indicators before filling any system with the corresponding fast fill port.

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Table 25
Check the Operation of the Fast Fill Service Center	Check if OK
Turn power switch (14) to the DOWN position
Press and hold test button (19). The indicator will flash once and illuminate continuously.
Press and hold test button (20). The indicator will flash once and illuminate continuously.
Press and hold test button (21). The indicator will flash once and illuminate continuously.
Press and hold test button (22). The indicator will flash once and illuminate continuously.
Press and hold test button (23). The indicator will flash once and illuminate continuously.
Press and hold test button (24). The indicator will flash once and illuminate continuously.

Automatic Lubrication Reservoir (If Equipped)

The automatic lubrication group is installed on the front, left corner of the machine behind the ladder platform assembly. The reservoir assembly for the automatic lubrication group holds the grease. Both the electric drive lubrication group, and the air drive lubrication group use the same reservoir assembly.

The capacity of the reservoir assembly was increased from 27.2 kg (60.00 lb) to 40.8 kg (90.00 lb). The level switch has been updated to a level sensor, and a fill screen has been added to improve system reliability.

Review the information in Autolube in this document.

Fill the automatic lubrication group reservoir. For the proper procedure, refer to Operation and Maintenance Manual, SEBU8406, Automatic Lubrication Reservoir - Fill.

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Illustration 34	g06209697
Front, left corner of the machine (A) Fast fill service center

To check the level of the grease reservoir, perform the following steps.

Locate fast fill service center (A) that is on the front, left corner of the machine.
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Illustration 35 g06209702

Close-up view of the fast fill service center
(1) Reservoir keypad
(2) Power switch
Locate keypad (1) that is on right side of the service center.
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Illustration 36 g06209703

Keypad
(3) Full indicator
(4) Normal indicator
(5) Add indicator
(7) Grease reservoir test button
Test button (7) is for the automatic lubrication reservoir. To check the level of the grease in the reservoir, move power switch (2) to the DOWN position.
Press and hold test button (7). The fluid indicator will flash once and then illuminate continuously if the indicators are working properly.

The fluid indicator has three levels.

(3) Full
(4) Normal
(5) Add

When a fluid system is full, the indicator (3), indicator (4), and indicator (5) will illuminate continuously. Stop the flow of fluid to the corresponding fast fill port when the three indicators are illuminated.

When a fluid system is at or above normal operating level, indicator (4) and indicator (5) will illuminate continuously.

When a fluid system is below normal operating level, indicator (5) will flash.

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Table 26
Check the Level of the Automatic Lubrication Reservoir	Check if OK
Turn power switch (2) to the DOWN position
Press and hold test button (6). The indicator will flash once and illuminate continuously.

VIMS Self-Test

Turn the ignition key from the OFF position to the ON position to activate the VIMS self-test. Monitor the instrument cluster for the different lighted icons. Do not start the truck.
The gauges should sweep from zero to half scale, then back to zero, and then all the way to the right or full scale. After the sweep test, the gauges should show the current values. Complete Table 27.
Next, the fault levels will activate. The source of the configuration codes will display on the message center.

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Illustration 37	g03319264
(1) Action light (2) Body up (3) Retarder (4) Traction Control System (TCS)

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Table 27
Check for the Illumination of the Lights in the instrument panel⁽¹⁾	Check if OK
Action Indicator (1)
Body Up indicator (2)
Retarder Indicator (3)
TCS Indicator (4)

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⁽¹⁾	All the indicator lights will illuminate at the same time for several seconds. After, the lights illuminate the indicator lights will turn off.

Select the Display Preferences in Advisor

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Illustration 38	g03228258

From the home screen in Advisor, select "Settings".
Select "Display settings" and choose the desired value for the following options:
- "Language" Adjust the display language
- "Units" Set the display units
- "Contrast" Adjust the display contrast
- "Lights "ON"" Adjust backlight with lights "ON"
- "Lights "OFF"" Adjust backlight with lights "OFF"
- "Date Format" Select the desired format
- "Time Format" Select desired format

Input the Machine Information in Advisor

Note: Inputting the machine information in advisor will automatically populate the information in each ECM.

From the home screen in Advisor, select "Settings".
Select "Machine" and enter the correct "Product ID" and "Equipment ID".

Check the Configuration of the Electronic Control Modules (ECM)

Reference: Service Manual, KENR9023, "793F and 797F Off-Highway Truck/Tractors VIMS, Monitoring, and Payload"

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Illustration 39	g02134783
(1) Cat ^® ET connector (2) 12 V connector (3) VIMS connector

Connect a laptop computer to the Caterpillar Diagnostic Connector behind the seats of the cab.
Use your laptop computer to open Cat ET.
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Illustration 40 g02138800
Select C175 793. Click "OK".
The Cat ET Selector screen should display the truck model for each control. Make sure that the model is correct for each of the controls.
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Illustration 41 g02138804
From the toolbar, select "Service", and select "Configuration".
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Illustration 42 g02138110

Typical view
In the "ECM Identification Parameters" field, Select "Equipment ID".
Double-click "Equipment ID" to change the value for the equipment ID, or select "change".
Verify that the equipment ID matches the machine serial number. If the Equipment ID does not match, change the Equipment ID and click "OK".
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Illustration 43 g02138155

Typical view (SSP, SND, RBT machines)
For SSP, SND, and RBT machines, check the "Engine Serial Number". The "Engine Serial Number" must match the engine serial number that is on the engine. If the Engine Serial Number is not correct, update the Engine Serial Number.
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Illustration 44 g06190239

Typical view (D3T machines)

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Illustration 45 g06190238

Typical view (D3T machines)
For D3T machines, check the "Engine Serial Number". The "Engine Serial Number" must match the engine serial number that is on the engine. If the Engine Serial Number is not correct, update the Engine Serial Number.
Also check the serial number of the Pump Electronic Tank Unit (PETU) and the Clean Emissions Module (CEM). Update the serial numbers, as needed.
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Illustration 46 g02138815
Verify the "Ether Control" setting. Set the "Ether Control" setting to the "Enabled" or the "Disabled" position.
Note: Refer to Systems Operation and Testing and Adjusting, KENR5397, "C175-16 and C175-20 Engines for 793F and 797F Off-Highway Trucks" for information on the engine.
Verify that the "Engine Coolant Temperature Control Module Installation Status" is set to "Installed".
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Illustration 47 g02138816
If equipped, verify that the "Oil Renewal Rate" control is correctly set to "0". The "Oil Renewal Rate" has an adjustable range from -50 to 50.
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Illustration 48 g02138819
If equipped, verify that the "Engine Pre-Lube" is enabled.
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Illustration 49 g06076999
If equipped, verify that the "Electronic Fuel Transfer Pump Installation Status" is set to the desired value.
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Illustration 50 g06077004
If equipped, verify that the "Ether Solenoid Configuration" is set to the desired value.
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Illustration 51 g06076986
If equipped, verify that the "Operator Final Inducement Action" is set to the desired value.
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Illustration 52 g06076994
If equipped, verify that the "Operator Inducement Regulation Configuration" is set to the desired value.
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Illustration 53 g06076990
If equipped, verify that the "Operator Inducement Progress Configuration" is set to the desired value.
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Illustration 54 g02138897
From the toolbar, select "Service". Then select "ECM Date/Time".
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Illustration 55 g02138900
Input the correct time zone, the date, and the time.

Check for Active Diagnostic Codes and Logged Diagnostic Codes

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Illustration 56	g03231919

From the toolbar, click "Diagnostic". Click "Active Diag. Codes".
Resolve any of the active diagnostic codes.
For additional information on diagnostic codes, refer to Troubleshooting, KENR8396, "793F and 797F Off-Highway Trucks Chassis Electronic Control System".
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Illustration 57 g02138822
From the toolbar, click "Diagnostics". Click "Logged Diag. Codes".
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Illustration 58 g02138826

Typical view
Clear any logged diagnostic codes by highlighting an event. Next, click the "Clear" button that is located in the lower left corner of the screen.
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Illustration 59 g02138827
From the toolbar, click "Diagnostics". Select "Events" and click "Logged Events".
If necessary, resolve any logged events and clear any logged events.
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: A factory assigned password may be required to clear some events that are logged on the engine "ECM".
Note: Clearing emissions diagnostic codes will require a factory password.

Create a Product Status Report

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Illustration 60	g03228437

From the toolbar, click "Information" and "Product Status Report".
Run the product status report.
Note: The Product Status Report will show the injector codes for Table 28.

Injector Code Setting and Calibration

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Illustration 61	g02138256

From the toolbar, click "Service". Select "Calibrations". Click "Injector Trim Calibration".

Confirm that all the injectors have trim files. Record all the injector trim calibration values in Table 28.

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Table 28
Injector 1
Injector 2
Injector 3
Injector 4
Injector 5
Injector 6
Injector 7
Injector 8
Injector 9
Injector 10
Injector 11
Injector 12
Injector 13
Injector 14
Injector 15
Injector 16

Ether Control Test (If Equipped)

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

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Illustration 62	g02138268
Values for the injectors are typical.

Click "Diagnostics". Select "Diagnostic Tests". click "Override Parameters".
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Illustration 63 g02138832
To test the ether control operation, select "Ether Injection". Click the "Change" button that is located in the lower left corner of the screen.
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Illustration 64 g02138866
Click the drop-down menu for the "New Value:" and change the selection from "Off" to "On". Click "OK".
Click "OK" in the verification box.
Note: An audible click should be heard after clicking "OK" on the verification box.
If the ether control test is acceptable, select "Ether Injection Override" to return the mode to normal.

Settings for the Engine Prelube

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Illustration 65	g02138870

Select "Engine Pre-Lube". Click the "Change" button that is located in the lower left corner of the screen.
Click the drop-down menu for the "New Value:" and change the selection from "Off" to "On". Click "OK".
Click "OK" in the verification box.
Note: The operator should hear the engine prelube system energize.
When the test for the engine prelube is completed, select "Disable Override" to return the mode to normal.

Settings for the Oil Renewal System (If Equipped)

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Illustration 66	g02138874

To test the oil renewal system, select "Oil Renewal". Click the "Change" button that is located in the lower left corner of the screen.
Click the drop-down menu for the "New Value:" and change the selection "Off" to "On". Click "OK".
Click "OK" in the verification box.
Note: An audible sound from the "Oil Renwal" system should be heard after clicking "OK" on the verification box.
When the test for the oil renewal system is completed, click "Disable Override" to return the mode to normal.
From the toolbar, click "Service". Click "Configuration" to go back to the main configuration screen.

Settings for the Chassis Control

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Illustration 67	g02138274

Click "Machine Configuration" under the heading "Chassis 793".
Click "Starting System Configuration". Select the type of Starting System Configuration that is on the machine. Click "OK".
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Illustration 68 g06076926
Expand the "Information Systems" section and click the "VIMS Analysis Control Module Installation Status".
Verify that the "VIMS Analysis Control Module Installation Status" is set to the desired value.
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Illustration 69 g06076958
Expand the "Machine Configuration" section and click the "Operator Seat Belt Monitor Installation Status".
Verify that the "Operator Seat Belt Monitor Installation Status" is set to the desired value.
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Illustration 70 g06076933
Expand the "Machine Configuration" section and click the "Crank Cycle Rest Interval".
Verify that the "Crank Cycle Rest Interval" is set to the desired value.
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Illustration 71 g06076865
Verify that the "Auto Lube Interval" is set to the desired value.
Note: 60 minutes is the default value.
If the interval is not correct, change the "Auto Lube Interval" to the desired value.

Settings for the Transmission Control

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Illustration 72	g02138885

Click "Configuration Group 1" under "Transmission 793".
The correct proper torque shift installation status must be entered in order to enter the differential serial numbers.
Check the "Transmission Serial Number". The serial number should match the serial number that is on the transmission. If the serial number is incorrect, input the correct Transmission Serial Number. ET and the software is only looking at the serial number prefix. So the accepted prefixes are PJT, LHT, JA5, AS6, or just leave it blank. Leaving blank will result in the transmission being configured as a PJT transmission. It is important that the proper hardware configuration, serial number configuration, and torque shift mode selection all coincide properly with each other, otherwise transmission damage may occur.
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Illustration 73 g02138887
Check the "Machine Speed Limit". If there is a requirement for a speed limit, input the correct speed limit.

Settings for the Brake Control

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Illustration 74	g02138283

Click "Configuration Group 1" under "Brake 793".
Verify that the "Equipment ID" matches the machine serial number.
Set the "Maximum Desired Engine Retard Speed" between 1850 RPM and 1950 RPM.
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Illustration 75 g02138891
Verify that the correct "Engine Cooling Fan Configuration" is selected.
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Illustration 76 g02138893
If equipped, verify that the correct "Differential High Speed Fan Install Status" is selected.
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Illustration 77 g03739001
For "RBT" machines only, select the wheel station type.
Note: "Extended Life Wheel" or "Standard Wheel" are choices.

Settings for the VIMS Main Module

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Illustration 78	g02138894

Under "VIMS Main Module", select "General Information".
Verify that the "Product ID" matches the machine serial number. If the "Product ID" does not match, enter the correct "Product ID" through Advisor. Use the following steps:
1. In Advisor, select "Settings", "Machine", and "Product ID". Enter the correct "Product ID".

Settings for the Monitor Module

Set the "Service Mode" password for Advisor.

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Illustration 79	g03321031

In "Monitoring System Parameters" select "Service Mode Enable Code".
Note: The default number is "0".
To set the password, input any five or less digit number. and click "OK".
Note: The password can only be changed through Cat ET.
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Illustration 80 g03321113
Click "Yes" on the next window.
Verify that the value has changed.

VIMS

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Illustration 81	g03076359
View of the back of the cab (1) Cat ^® ET connector (2) 12 V Connector (3) "VIMS" Connector

Connect a laptop computer to the "VIMS" connector.
Note: Ensure that the key is in the ON position.
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Illustration 82 g02134815

Instrument cluster for the 793F
(1) Action Indicator

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Illustration 83 g02138901
Start the "VIMS" PC software.
Note: Some alert messages should appear.
Note: Refer to Service Manual, KENR9023, "793F and 797F Off-Highway Truck/Tractors VIMS, Monitoring, and Payload" for additional information on warnings.
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Illustration 84 g02138903
Click "File". Click "Connect Machine".
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Illustration 85 g02138904
Select the "Cab" and click "OK".
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Illustration 86 g02139075
After the connection is completed click "Data" from the toolbar. Click "Download".
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Illustration 87 g02139077
In the "Download Data" box, select all the boxes under "Download".
In the "Download Data" box, select everything under "Reset After Download".
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Illustration 88 g02139079
Click "Download" after the download selections has completed.
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Illustration 89 g02139080
From the toolbar, click "Configure". Click "Assign Serial/Equipment Number".
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Illustration 90 g02139082
In the "Assign Serial/Equipment Number" box, verify that the serial number matches the new serial number.
In the "Assign Serial/Equipment Number" box, change the "Equipment" number to correspond to the new customer machine number. Click "OK".
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Illustration 91 g02139099
From the toolbar, click "Configure". Click "Reset Date/Time/SMH".
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Illustration 92 g02139107
Select "Reset Date/Time" and change, as necessary.
Select "Reset SMH" and set to Zero.
Click OK.

Advisor Panel Setup

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Illustration 93	g03077840
Typical view of the "Home" menu from the Advisor panel

The profile of the operator is accessed from the "Home" menu.

Refer to Operation and Maintenance Manual, SEBU8406, "Monitoring System" for instructions on setting up the operator profiles.

Prepare to Start the Engine

Verify that all the fluids are at an acceptable level.
Note: Refer to the Operation and Maintenance Manual, SEBU8406, "Capacities (Refill)" for the fluid capacities.
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Illustration 94 g03447516

Typical view of the ground level switches (SSP, SND, RBT machines)

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Illustration 95 g06183141

Typical view of the ground level switches (D3T machines)
Move manual engine shutdown switch (2) to the OFF position.
Note: The engine should be disabled so the engine will not start.
Rotate battery disconnect switch (1) clockwise to Energize the 24 V system.
Chock the wheels.
Ensure that the transmission control is in the "P" position.

Purge the Air from the Fuel System (SSP, SND, and RBT Machines)

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, PERJ1017, "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.

Note: Due to the time required to charge the fuel system, there is an update to the low-pressure fuel system purging.

Prerequisite is a minimum of 40% fuel level in the fuel tank.
A hose with a shut off valve at one end and a hydraulic socket, which fits on a hydraulic quick disconnect, on the other end is required.
A suitable container for fuel is needed

Assemble a hose to purge the air from the fuel system. A hose with a shut off valve at one end and a hydraulic socket, which fits on a hydraulic quick disconnect, on the other end is required.
Chock the wheels.
Note: Ensure that the machine is not locked out.
Note: During the following steps, verify that there are no leaks in the fuel system.
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Illustration 96 g03447518

Typical view of the ground level controls (SSP, SND, RBT machines)
(1) Engine lockout control
Move engine lockout control (1) clockwise to the engaged position.
Note: You should have 24 V DC to the truck.
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Illustration 97 g06190269

(7) Pressure tap
(8) Pressure tap
(9) Pressure tap
(10) Fuel priming pump switch
Install the previously assembled hose and hydraulic socket to pressure tap (7) at the fuel priming pump outlet.
Note: Ensure that the hose drains the fuel into a suitable container.
Open the shutoff valve on the end of the assembled hose, then activate fuel priming pump switch (10).
When fuel begins to flow and run clear of bubbles, close the valve and release fuel priming switch (10).
Move the hose and hydraulic socket to pressure tap (8).
Open the shutoff valve on the end on the assembled hose, and activate fuel priming switch (10).
When fuel begins to flow and run clear of bubbles, close the valve and release fuel priming switch (10).
Move the hose and hydraulic socket to pressure tap (9).
Open the shutoff valve on the end on the assembled hose, and activate fuel priming switch (10).
When fuel begins to flow and run clear of bubbles, close the valve and release fuel priming switch (10).
Remove the hose and hydraulic socket from the quick disconnect.
The fuel system should be purged of air.
Rotate engine lockout control (1) to the clockwise most position.
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.

Purge the Air from the Fuel System (D3T Machines)

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, PERJ1017, "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.

Note: Due to the time required to charge the fuel system, there is an update to the low-pressure fuel system purging.

Prerequisite is a minimum of 40% fuel level in the fuel tank.

Assemble a hose to purge the air from the fuel system. A hose with a shut off valve at one end and a hydraulic socket, which fits on a hydraulic quick disconnect, on the other end is required.
Chock the wheels.
Note: Ensure that the machine is not locked out.
Note: During the following steps, verify that there are no leaks in the fuel system.
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Illustration 98 g06183145

Typical view of the ground level controls (D3T machines)
(1) Engine lockout control
Move engine lockout control (1) clockwise to the engaged position.
Note: You should have 24 V DC to the truck.
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Illustration 99 g06190477

Typical view of the right-hand side of the engine (D3T machines)
(2) Fuel priming pump switch
Activate fuel priming pump switch (2).
Rotate engine lockout control (1) to the clockwise most position.
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.

Hydraulic System Prime

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Air must not be in the oil for the brake hydraulic system to function properly.

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Personal injury or death can result from machine movement.

Place blocks in front of and behind the wheels to make sure the machine does not move while the parking brakes are disengaged.

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Failure to properly secure the body (bed) may result in personal injury or death.

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, PERJ1017, "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.

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Table 29
Tools Needed
Qty	Part Number	Description
4	177-7862	Hose As
4	6V-4143	Quick Connect Coupler
4	-	Shut Off Valve⁽¹⁾

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⁽¹⁾	Use shut off valve with 1/8-27 NPTF THD

Assemble four drain hoses by connecting a suitable shut off valve at one end of each hose assembly. Connect a quick connect coupler on the other end of each hose assembly. Refer to parts listed in table 29.
Note: Suitable containers for hydraulic oil are required.
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Illustration 100 g03709600

Typical view of the RH side
(A) Steering case drain filter

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Illustration 101 g03709617

Close-up view of the steering case drain filter
(A) Steering case drain filter
(B) Pressure tap
Install one of the previously assembled drain hoses and quick connect coupler to pressure tap (B) at the bottom of steering case drain filter (A).
Note: Ensure that the hose drains the oil into a suitable container.
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Illustration 102 g03709780

View of the LH side
(D) Brake filter
(E) Pressure tap

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Illustration 103 g03709849

View of the inside RH side of the frame
(F) Brake-Hoist pump
(G) Pressure tap
Install one of the previously assembled drain hoses and quick connect coupler to pressure tap (E) at the side of brake filter (D).
Note: Ensure that the hose drains the oil into a suitable container.
Install two of the previously assembled drain hoses and quick connect coupler to pressure taps (G) on brake-hoist pump (F).
Note: Ensure that the hoses drain the oil into a suitable container.
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Illustration 104 g06183384

Typical view of the ground level controls (SSP, SND, and RBT machines)
(C) Engine lockout control

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Illustration 105 g06183389

Typical view of the ground level controls (D3T machines)
(C) Engine lockout control
Ensure engine lockout control (C) is in the clockwise most position to the engaged position.
Note: You should have 24 V DC to the truck.
Open the shutoff valve on the end of the drain hoses. Crank the engine over in 15 second increments until the oil begins to flow and run clear of bubbles.
Close the valves and turn the key in the cab to the off position.
Remove the drain hoses and quick connect coupler from the quick disconnect couplers on the steering case drain filter, brake filter, and brake-hoist pump.
Ensure engine lockout control (C) is in the clockwise most position to the engaged position.

Engine Start-Up

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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.

Chock the wheels.
Connect a laptop computer with Cat ET to the machine.
In Cat ET , verify that the Engine Pre-Lube is "Enabled".
In Cat ET , clear any Active, logged Diagnostic Codes and Events.
Verify that the fluids are at an acceptable level.
Note: See the checklist below.
Note: Refer to Operations and Maintenance Manual, SEBU8406, "Capacities (Refill)" for the capacities for the 793F.

Prime the pump drive and the hoist pump with the recommended oils.

Note: Refer to Operations and Maintenance Manual, SEBU8406, "Capacities (Refill)" for the correct oils.

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NOTICE

Do not stop the prelube. If the prelube is stopped and restarted, the engine will bypass the prelube and start without having the appropriate oil to the engine. Early bearing failure can result from improper prelube.

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Illustration 106	g06183415
Typical view of the ground level controls (SSP, SND, and RBT machines) (4) Engine lockout control (5) Engine shutdown switch

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Illustration 107	g06183419
Typical view of the ground level controls (D3T machines) (4) Engine lockout control (5) Engine shutdown switch

Turn engine lockout control (4) clockwise to turn the lockout OFF. The engine is now able to start.
Note: The prelube pump should run until approximately 55 kPa (8 psi) is seen by the engine ECM.
Crank over the engine for 5 seconds to fill the pumps with oil. Turn off the engine and verify that the fluids are still at an acceptable level. Fill, as needed.
Repeat Step 8.
Crank over the engine for 10 seconds to fill the pumps with oil. Turn off the engine and verify that the fluids are still at an acceptable level. Fill, as needed.
Turn the key to the ON position. Turn the key to the START position and start the engine.
Note: If any issues occur, resolve the issues before proceeding.
Run the engine for 10 seconds and turn the key to the OFF position.
Enable engine shutdown switch (5) at ground level to stop the engine. Verify that the fluids are still at an acceptable level. Fill, as needed.
Disable engine shutdown switch (5) to allow the engine to be started.
Start the engine and run the engine for 60 seconds and turn the key to the OFF position.
Repeat Step 13
Repeat Step 14 and Step 15.
Turn the key to the ON position and run the engine until normal operating temperatures are reached.

Engine Start Checklist

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Table 30
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

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⁽¹⁾	The key in the ON position will enable the electrical circuits in the cab and activate the VIMS self test

Engine Shutdown Switch Checklist

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Illustration 108	g03447639
Typical view of the ground level controls (SSP, SND, and RBT machines) (11) Engine shutdown switch

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Illustration 109	g06183421
Typical view of the ground level controls (D3T machines) (11) Engine shutdown switch

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Table 31
Check the Operation of the Engine Shutdown Switch	Check if OK
Start the engine
Activate engine shutdown switch (11)
Engine shuts down
Deactivate engine shutdown switch (11)

Perform the Aftertreatment System Functional Test

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NOTICE

Confirm that the latest software vintage is flashed to the engine and aftertreatment prior to performing functional testing.

Use a laptop computer to open Cat Electronic Technician (ET).
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Illustration 110 g06076684

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Illustration 111 g06078034

View of the serial number plate on the Clean Emissions Module (CEM)

Note: The serial number plate for the Clean Emissions Module (CEM) is on the mounting structure (cradle) of the CEM.
Confirm correct serial numbers for the Clean Emissions Module (CEM) and Pump Electronic Tank Unit (PETU).
1. Check the value of the "Factory Installed Aftertreatment #1 Identification Number" and ensure that the serial number is correct. If incorrect, enter the correct number.
2. Check the value of the "Aftertreatment DEF Pump Electronics Tank Unit Identification Number" and ensure that the serial number is correct. If incorrect, enter the correct number.
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Illustration 112 g03825970
From the toolbar, select "Diagnostics" then "Diagnostic Tests".
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Illustration 113 g06076761
Select "Aftertreatment System Functional Test" and click "Start".
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Illustration 114 g03825152
Read and understand the warning. Click "OK" to proceed to the test.
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Illustration 115 g03825157
Click "Next" to proceed to the test.

Autolube

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NOTICE

Be satisfied that all of the automated grease injectors are receiving a sufficient supply of grease.

Note: The autolube system only pumps when the machine is moving. The timer does not activate unless ground speed is detected.

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Illustration 116	g02074533
View of the left side grease injectors

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Illustration 117	g02074535
View of the right side grease injectors

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Illustration 118	g02074534
View of the rear grease injectors

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Illustration 119	g02074536
View of the left inside grease injectors

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NOTICE

Purging the air from the link lines is crucial. Failure to purge the air can result in pin and machine damage.

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Illustration 120	g02074538
View of the right inside grease injectors

Purge the air from each individual grease line.
Note: Purging the grease lines may require a hand pump.
Adjust the grease injectors, as required. Refer to Service Manual, KENR9949, "Off-Highway Truck Automatic Lubrication System for Electric Start Equipped Trucks" or Service Manual, SENR4724, "Off-Highway Trucks Automatic Lubrication System for Air Start Equipped Trucks" for information on adjusting the grease injectors.
Turn the key to the ON position.
Note: Do not start the truck.
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Illustration 121 g02138313
Through the Advisor, select "Service".
Select "All Parameters", then "System Tests", and then "Manual Lube Mode".
If necessary, use the left arrow or the right arrow to set the correct interval.
Press OK.
If necessary, repeat Step 6 and Step 7 for the autolube interval.

Miscellaneous Checks

Prepare the Truck for Pressure Checks

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Illustration 122	g01340699

Chock the wheels.
The engine should be at normal operating temperature and the transmission should be in the PARK position.
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.
After the activation of the elevated idle speed, or if the coolant temperature rises above 77° C (170° 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 (If Equipped)

Note: Trucks that start electrically are not equipped with an air system.

Prepare to start the truck.
Note: The transmission control should be in the PARK position.
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Illustration 123 g01340699
Chock the wheels.
Start the engine.
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Illustration 124 g02138319
In the Advisor, select "Monitor".
Note: The "Monitor" menu is accessed from the "Home" menu. The "Monitor" menu allows the user to view the machine parameters that are being monitored. Four parameters are displayed on the Advisor screen at one time. To change a parameter, highlight the parameter and click "OK". Use the arrows buttons to scroll through the list of parameters. Select the desired parameter and click "OK".
View the pressure of the "System Air Pressure".
Accelerate the engine to high idle.
Note: The air dryer should expel air at 827 ± 34 kPa (120 ± 5 psi).
Note: The air pressure that is shown on the Advisor should read 827 kPa (120 psi).
For adjustment of the air pressure, refer to Testing and Adjusting, KENR8572, "793F Off-Highway Truck Air System".

Air System Leak Test

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 and Air Dryer Voltage Check

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Illustration 125	g02074639
View of the right side of the machine

Locate the air dryer near the right front wheel of the machine.
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Illustration 126 g01341861

Typical view
Check the amount of voltage that is for the heater at the electrical connection of the dryer.
Use the table below to record your results.
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Table 32
Air Dryer Check Actual Reading

24 V or more at the air dryer

Check the Braking and Steering Accumulator Precharge Pressures

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Illustration 127	g01962775

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Failure to properly secure the body (bed) may result in personal injury or death.

Check the precharge pressures of the braking and the steering accumulators.

Note: Refer to Special Instruction, REHS5464, "Accumulator Discharging and Charging Procedures" for instruction and tooling for checking the accumulator pressures.

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Table 33
Braking Accumulator Precharge Pressure/Temperature Relationship

Ambient Temperature	Pressure⁽¹⁾
−7 °C (20 °F)	6201 kPa (900 psi)
−1 °C (30 °F)	6339 kPa (920 psi)
4 °C (40 °F)	6477 kPa (940 psi)
10 °C (50 °F)	6580 kPa (955 psi)
16 °C (61 °F)	6718 kPa (975 psi)
21 °C (70 °F)	6895 kPa (1000 psi)
27 °C (81 °F)	7028 kPa (1020 psi)
32 °C (90 °F)	7166 kPa (1040 psi)
38 °C (100 °F)	7308 kPa (1060 psi)
43 °C (110 °F)	7411 kPa (1075 psi)
49 °C (120 °F)	7584 kPa (1100 psi)

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⁽¹⁾	The allowable tolerance on nominal pressure is 345 kPa (50 psi).

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Table 34
Steering Accumulator Precharge Pressure/Temperature Relationship
Ambient Temperature	Pressure⁽¹⁾
−7 °C (20 °F)	6005 kPa (871 psi)
−1 °C (30 °F)	6060 kPa (879 psi)
4 °C (40 °F)	6170 kPa (895 psi)
10 °C (50 °F)	6280 kPa (911 psi)
16 °C (60 °F)	6390 kPa (927 psi)
21 °C (70 °F)	6500 kPa (943 psi)
27 °C (80 °F)	6610 kPa (959 psi)
32 °C (90 °F)	6720 kPa (975 psi)
38 °C (100 °F)	6830 kPa (991 psi)
43 °C (110 °F)	6940 kPa (1007 psi)
49 °C (120 °F)	6995 kPa (1015 psi)

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⁽¹⁾	Nominal allowable tolerance equals ± 70 kPa (± 10 psi).

Transmission - Test

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Illustration 128	g01962775

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Failure to properly secure the body (bed) may result in personal injury or death.

For instructions on calibrating the engagement pressure for the transmission clutches and the fill time for the transmission clutches, refer to Testing and Adjusting, KENR8394, "Engagement Pressure for the Transmission Clutch - Calibrate" and Testing and Adjusting, KENR8394, "Fill Time for the Transmission Clutch - Calibrate"

Use the tables below to record the transmission and torque converter pressures.

Note: The main relief pressure should be checked prior to performing the calibration. If main relief pressure is too low, the calibrations would have to be rerun.

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Table 35
Transmission Specifications
	Specification	Actual
Transmission Oil Temperature (During Tests)	80° to 121°C (176° to 250°F)
Main Relief Pressure⁽¹⁾	Low idle: 2655 to 2930 kPa (385 to 425 psi)
Main Relief Pressure⁽¹⁾	High idle: 2895 to 3170 kPa (420 to 460 psi)
Transmission Lubrication Oil Pressure⁽¹⁾	Low idle: 20 to 48 kPa (3 to 7 psi)
Transmission Lubrication Oil Pressure⁽¹⁾	High idle: 117 to 180 kPa (17 to 26 psi)

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⁽¹⁾	Refer to Illustration 130

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Table 36
Clutch Pressures
Clutch Pressures
Transmission Speed	CLUTCHES ENGAGED	Clutch Pressure⁽¹⁾		Actual
Transmission Speed	CLUTCHES ENGAGED	Prefix "PJT" and "JA5" Transmission	Prefix "AS6" Transmission	Actual
NEUTRAL	3	1725 ± 138 kPa (250 ± 20 psi)	1480 ± 138 kPa (215 ± 20 psi)
REVERSE	Clutch 1	2425 ± 138 kPa (352 ± 20 psi)	1895 ± 138 kPa (275 ± 20 psi)
REVERSE	Clutch 6	2805 ± 138 kPa (407 ± 20 psi)	2895 ± 138 kPa (420 ± 20 psi)
FIRST	Clutch 1	2425 ± 138 kPa (352 ± 20 psi)	1895 ± 138 kPa (275 ± 20 psi)
FIRST	Clutch 5	2725 ± 138 kPa (395 ± 20 psi)	2480 ± 138 kPa (360 ± 20 psi)
SECOND	Clutch 2	1725 ± 138 kPa (250 ± 20 psi)	1480 ± 138 kPa (215 ± 20 psi)
SECOND	Clutch 5	1725 ± 138 kPa (250 ± 20 psi)	2480 ± 138 kPa (360 ± 20 psi)
THIRD	Clutch 1	1725 ± 138 kPa (250 ± 20 psi)	1655 ± 138 kPa (240 ± 20 psi)
THIRD	Clutch 4	1725 ± 138 kPa (250 ± 20 psi)	2240 ± 138 kPa (325 ± 20 psi)
FOURTH	Clutch 2	1725 ± 138 kPa (250 ± 20 psi)	1480 ± 138 kPa (215 ± 20 psi)
FOURTH	Clutch 4	2150 ± 138 kPa (312 ± 20 psi)	2240 ± 138 kPa (325 ± 20 psi)
FIFTH	Clutch 1	1725 ± 138 kPa (250 ± 20 psi)	1655 ± 138 kPa (240 ± 20 psi)
FIFTH	Clutch 3	1725 ± 138 kPa (250 ± 20 psi)	1480 ± 138 kPa (215 ± 20 psi)
SIXTH	Clutch 2	1725 ± 138 kPa (250 ± 20 psi)	1480 ± 138 kPa (215 ± 20 psi)
SIXTH	Clutch 3	1725 ± 138 kPa (250 ± 20 psi)	1480 ± 138 kPa (215 ± 20 psi)

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⁽¹⁾	Depending on main relief pressure, the clutch pressure may be lower than listed in the following table. Clutch pressure cannot be higher than the main relief pressure.

Chock the wheels.

On the Cat ET screen choose Transmission ECM.

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Illustration 129	g03182457

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Illustration 130	g03229739
View of the right side of the transmission (1) Pressure tap for the clutch No. 1 modulating valve (2) Pressure tap for the clutch No. 2 modulating valve (3) Pressure tap for the clutch No. 3 modulating valve (4) Pressure tap for the clutch No. 4 modulating valve (5) Pressure tap for the clutch No. 5 modulating valve (6) Pressure tap for the clutch No. 6 modulating valve (7) Pressure tap for the transmission main relief pressure (8) Pressure tap for the torque converter inlet pressure (9) Pressure tap for the transmission lubrication pressure

Select Transmission Monitoring.
Perform the transmission tests that are listed in Table 35. Run the engine at LOW IDLE and record the data into the chart. Run the engine at HIGH IDLE and record the data into the chart.
Note: Refer to Table 4 for tooling (A) or Table 5 for tooling (B).

Transmission Clutch Engagement Pressure Calibration

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NOTICE

Before starting the transmission calibration test, oil temperature must be 70° to 85°C (158° to 185°F). After the test begins, temperature must stay at 65° to 105°C (149° to 221°F).

Note: The calibration of the lockup clutch is also completed during the transmission clutch engagement pressure calibration.

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Illustration 131	g01962775

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Failure to properly secure the body (bed) may result in personal injury or death.

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Personal injury or death can result from sudden machine movement.
Sudden movement of the machine can cause injury to persons on or near the machine.

Prevent possible injury by performing the procedure that follows before working on the machine.

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Personal injury can result from hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.

Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

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NOTICE

Do not connect or disconnect hose fittings to or from the quick disconnect nipples when there is pressure in the system. This will prevent damage to the seals that are in the fitting.

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, PERJ1017, "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.

Note: If you install a new transmission solenoid valve, shift the transmission into a gear that uses the solenoid valve. Shift the transmission at least 12 times. Allow sufficient time for the corresponding clutch to become fully pressurized. Refer to table 37 for information on the solenoids.

Park the machine on a smooth, level surface.
Chock the wheels.
Operate the machine to warm the transmission oil to at least 50 °C (122 °F).Caterpillar Electronic Technician (Cat ET) can be used to monitor the temperature of the oil. The transmission pump main relief valve (MRV) pressures need to be correct before proceeding to step 4.
Refer to Testing and Adjusting, KENR8371, "Transmission - Test" for the correct main relief valve pump pressure specifications.

Install the tooling (A) or tooling (B) on the pressure tap of the modulating valve for the transmission clutch. Installation is on the clutch that is being calibrated. Refer to Illustration 130 and Illustration 146 for the locations.

Note: Multiple sensors and gauges from tooling (A) or tooling (B) will be required.

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Table 37
Gears That Are Associated With The Transmission Solenoids
Gear	Enabled Solenoids
Neutral	1 or 3
1F	1 and 5
2F	2 and 5
3F	1 and 4
4F	2 and 4
5F	1 and 3
6F	2 and 3
Reverse	1 and 6

Place the transmission gear lever in the PARK position.
Fully release the service brake pedal.
Set the engine speed to low idle.
Note: During the calibration, Cat ET will alter the engine speed.
Connect Cat ET to the service connector.
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Illustration 132 g03259876
Choose "Transmission 793" from the list to select the calibration.
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Illustration 133 g03259917
From the toolbar, select "Service" then "Calibrations".
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Illustration 134 g03259936
Select the "Transmission Clutch Engagement Pressure Calibration" and click "Start".
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Illustration 135 g03259976
Select all the clutches and click "Begin".
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Illustration 136 g03260056

Typical view
(A) Location of the target pressure

Note: Location (A) on the ET screen will show the pressure that must be reached during the calibration. This pressure may change between clutches. The pressure that is shown in ET is the most accurate pressure and should be used.
Note: During the "Engagement Calibration", a number that corresponds to the electrical current of the particular transmission solenoid valve is displayed. The electrical current of the transmission solenoid valve controls the transmission clutch pressure.
View tooling (A) or tooling (B) to view the clutch pressure. The target pressure for each clutch is controlled through the Cat ET screen. Adjust the current by use of the increment and/or decrement buttons to select the target value. Observe the change in the value that is displayed on tooling (A) or tooling (B) until the target value is achieved.
After the correct pressure is reached, click "Next".
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Illustration 137 g03260396
The window that pops up should show a "CALIBRATION SUCCESSFUL" message. Click "Continue" to calibrate the next clutch pressure.
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Illustration 138 g03260516
Continue to calibrate all the clutch pressures until the last clutch has been calibrated. Click "Finish" to complete the calibration.

Reference: For more information, refer to Testing and Adjusting, "Fill Time for the Transmission Clutch - Calibrate" for the machine that is being tested.

If the clutch pressure is out of specification, refer to Testing and Adjusting, KENR8394, "Engagement Pressure for the Transmission Clutch - Calibrate" and Testing and Adjusting, KENR8394, "Fill Time for the Transmission Clutch - Calibrate".

Transmission Fill Calibration

Improper calibration of the transmission clutch fill will cause transmission shifting problems. The automatic calibration procedure for setting the transmission clutch fill will achieve greater consistency when the transmission is shifted. The main relief valve must be calibrated.

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Personal injury or death can result from sudden machine movement.
Sudden movement of the machine can cause injury to persons on or near the machine.

Prevent possible injury by performing the procedure that follows before working on the machine.

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, PERJ1017, "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.

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NOTICE

Before starting the transmission calibration test, oil temperature must be 70° to 85°C (158° to 185°F). After the test begins, temperature must stay at 65° to 105°C (149° to 221°F).

The CaterpillarElectronic Technician (Cat ET) is used to access the calibration procedures. A message on the Cat ET screen will give instructions that guide the user through the calibration procedure. Refer to the manual that is provided with the Cat ET for more information about Cat ET.

Chock the wheels.
Connect the communication cable between a laptop computer, equipped with a current version of Cat ET software, and the service connector of the truck.
Open the Cat ET. Select the transmission Electronic Control Module (ECM) for the machine that is being calibrated.
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Illustration 139 g03260638
From the toolbar, select "Service" then "Calibrations".
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Illustration 140 g03260637
Select "Transmission Fill Calibration" and click "Start".
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Illustration 141 g03260678
If the conditions listed above in Preparation for Calibration Procedure are met, the display will inform the technician to press NEXT to advance to the next step.
Note: During the calibration of the transmission clutch fill, many transmission clutch fills are occurring. Remain seated. There will be some vibration and noise as the clutches are being calibrated. If any of the conditions for calibration are violated during the calibration, the calibration will be stopped. Do not operate the air conditioning or hydraulics during the calibration of the solenoids. During the automatic calibration function, avoid performing steering movements.
Note: At any time during the calibration, the user can abort the calibration by pressing the CANCEL button. Depressing the service brake pedal will also abort the calibration.
Note: The engine must achieve the requested speed in a maximum of 5 seconds. If the engine does not reach the requested rpm in the given amount of time, the ECM will abort calibration due to an incorrect engine speed.
The display will continuously display "Calibrating Clutch #1". The ECM will fill clutch 1 and the ECM will drain clutch #1 several times. The ECM will formulate the optimal hold current and the optimal ramp levels for the solenoid that operates the modulating valve for clutch #1. When the ECM has completed calibrating this clutch, Cat ET automatically moves to the next step.
The procedure will continue for all clutches during the calibration process.
Once the calibration has been completed successfully, the ECM will write the calibration data to memory.
Operate the machinery to check the quality of transmission shift.
Resume normal operation of the machine.

Transmission and Machine Field Test

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Table 38
Transmission and Machine Field Test
Machine Lockout Control (Engaged/Disengaged)	Engine Lockout Control (Engaged/Disengaged)	Transmission Control Position	Engine Running (Yes/No)	Result	Check if OK
Engaged	Disengaged	D	Y	Machine should not move
Engaged	Disengaged	R	Y	Machine should not move
Disengaged	Engaged	P	N	Machine should not start
Disengaged	Disengaged	D	N	Machine should not start
Disengaged	Disengaged	R	N	Machine should not start

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Illustration 142	g03447680
Typical view of the ground level controls (SSP, SND, and RBT machines) (1) Machine lockout control (2) Indicator light (3) Engine lockout control (4) Indicator light

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Illustration 143	g06183441
Typical view of the ground level controls (D3T machines) (1) Machine lockout control (2) Indicator light (3) Engine lockout control (4) Indicator light

With the machine off, rotate machine lockout control (1) counterclockwise to activate (engage) the lockout. Lockout indicator light (2) should illuminate.
Start the engine and move the transmission control to the D position.
Note: The machine should not move.
Move the transmission control to the R position.
Note: The machine should not move.
Move the transmission control to the P position.
Turn off the machine.
Rotate machine lockout control (1) clockwise to deactivate the lockout. Lockout indicator light (2) should turn off.
Rotate engine lockout control (3) counterclockwise to activate (engage) the lockout. Lockout indicator light (4) should illuminate.
With the transmission control in the P position, try to start the machine.
Note: Engine should not start.
Rotate engine lockout control (3) clockwise to deactivate the lockout. Lockout indicator light (4) should turn off.
Move the transmission control to the D position. Try to start the engine.
Note: Engine should not start.
Move the transmission control to the R position. Try to start the engine.
Note: Engine should not start.
Return the transmission control to the P position.
Use the Table 38 to record the results of Step 7 and Step 11.

Torque Converter - Test

Reference: Testing and Adjusting, KENR8393, "793F Off-Highway Truck Power Train"

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 gear and the body is in the lowered position.

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Table 39
Torque Converter Specifications
	Specification	Actual
Torque Converter Oil Temperature (during tests)	> 80 °C (176 °F) < 121 °C (250 °F)
Torque Converter Inlet Relief Pressure⁽¹⁾	High Idle 700 ± 100 kPa (100 ± 15 psi)
Torque Converter Outlet Relief Pressure⁽²⁾	Low idle 140 ± 70 kPa (20 ± 10 psi)	Low idle:
Torque Converter Outlet Relief Pressure⁽²⁾	High idle 517 ± 100 kPa (75 ± 15 psi)	High idle:
Maximum Torque Converter Stall RPM ⁽³⁾	Standard Ar. 1508 RPM
Maximum Torque Converter Stall RPM ⁽³⁾	High Altitude Ar. 1692 RPM
Lockup Clutch Maximum Pressure NEUTRAL/CONVERTER DRIVE/HIGH IDLE⁽⁴⁾	0 to 35 kPa (0 to 5 psi)

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⁽¹⁾	Refer to Illustration 130
⁽²⁾	Refer to Illustration 146
⁽³⁾	Torque Limiting strategy reduces engine RPM.
⁽⁴⁾	Lockup Clutch maximum pressure in DIRECT DRIVE is set during the transmission calibration procedure.

Chock the wheels.
On the Cat ET screen toolbar, click File - Select ECM, and choose "Transmission ECM".
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Illustration 144 g01950000

Select “Torque Converter Monitoring”.

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Illustration 145	g01962775

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Failure to properly secure the body (bed) may result in personal injury or death.

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Illustration 146	g03176284
Rear view of the torque converter (1) Pressure tap for the outlet relief valve (2) Pressure tap for the Inlet relief valve (3) Pressure tap for the lockup clutch solenoid

Note: The lockup clutch solenoid pressure is adjusted during the transmission clutch engagement pressure calibration.

Note: Torque converter inlet relief pressure can be tested on the transmission pressure taps. Refer to Illustration 130.

Connect tooling (A) or tooling (B) to the appropriate test port.
Note: Refer to Table 4 for tooling (A) or Table 5 for tooling (B).
Perform the torque converter tests and record the results in Table 39.

Torque Converter Stall - Test

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Personal injury can result if the machine moves during testing. If the machine begins to move during testing, reduce the engine speed immediately and place the transmission control in the P position in order to engage the parking brake.

The torque converter stall test must be performed when the transmission is in the first gear and the body is in the lowered position.

Chock the wheels.
Fasten the seat belt before you test the brakes.
Check the area around the machine. Make sure that the machine is clear of personnel and clear of obstacles.
Test the brakes on a dry, level surface.
Start the engine.
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Illustration 147 g01923774
From the home screen in Advisor, select "Monitor". Select "Parameters" and choose the "Actual Engine RPM".
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Illustration 148 g01519336
When the transmission control is in the P position, fully depress the service brake pedal. Then, depress button (3) for the high gear limit RAISE and depress button (4) for the high gear limit LOWER at the same time.
While both buttons are depressed, Move the transmission control to the D position.
Note: The buttons can now be released and the parking brake will remain on.
With the service brake pedal still fully depressed, and fully depress the accelerator pedal. The machine should not move.
Check the engine rpm on Advisor. The torque converter should stall at 1508 RPM for standard arrangements, 1692 RPM for high altitude arrangements.
Record the results in Table 39.
Reduce the engine speed to an idle. Move the transmission control to the P position. Stop the engine.

Brake System - Test

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Illustration 149	g01962775

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Failure to properly secure the body (bed) may result in personal injury or death.

Perform the braking system tests. Refer to the Operation and Maintenance Manual, SEBU8406, "Braking System - Test" for instructions on testing the service, secondary, and parking brakes.

Brake oil testing temperature should be between 60° to 121°C (140° to 250°F).

Note: The service brake accumulators must be precharged to 6895 kPa (1000 psi), and the air must be purged from the brake system.

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Table 40
Brake System Specifications
		Specification	Actual
Main Relief Pressure⁽¹⁾		23100 ± 345 kPa (3350 ± 50 psi)
Service Brake Cut-In at Accumulator⁽²⁾		14480 ± 483 kPa (2100 ± 70 psi)
Service Brake Cut-Out at Accumulator⁽²⁾		20685 ± 483 kPa (3000 ± 70 psi)
Pump Stand-By Pressure⁽¹⁾		1034 ± 1034 kPa (150 ± 150 psi)
Brake Pilot Pressure (Foot Pedal)⁽³⁾		4950 ± 400 kPa (720 ± 58 psi)
Service and Secondary Brake Accumulator Pressure after Ground Level Shutdown⁽²⁾		No loss in pressure for extended period
Service and Secondary Brake Accumulator Pressure after Key Off⁽²⁾		0 kPa (0 psi) in less than 120 seconds
Parking Brake Release Pressure (Retarder Lever Applied)⁽⁴⁾		4600 ± 800 kPa (665 ± 116 psi)
Parking Brake Pressure (Secondary Brake Pedal Applied)⁽⁵⁾		0 kPa (0 psi)
Parking Brake Pressure (Transmission Control in the P Position)⁽⁶⁾		0 kPa (0 psi)
Towing Motor⁽⁷⁾		3790 kPa to 4480 kPa (550 psi to 650 psi) within 120 seconds
Brake Application Pressure at Slack Adjusters⁽⁸⁾	Service Brake Applied Standard Retarding Front and Rear Slack Adjuster	4200 kPa to 5000 kPa (609 psi to 725 psi)
	Service Brake Applied Extended Life Retarding Front Slack Adjuster	3025 kPa to 4225 kPa (438 psi to 612 psi)
	Service Brake Applied Extended Life Retarding Rear Slack Adjuster	4200 kPa to 5000 kPa (609 psi to 725 psi)
	Manual Retarder Lever Applied Standard Retarding Front and Rear Slack Adjuster	3800 kPa to 5400 kPa (551 psi to 783 psi)
	Manual Retarder Lever Applied Extended Life Retarding Front Slack Adjuster	2825 kPa to 4425 kPa (409 psi to 641 psi)
	Manual Retarder Lever Applied Extended Life Retarding Rear Slack Adjuster	3800 kPa to 5400 kPa (551 psi to 783 psi)

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⁽¹⁾	Refer to Illustration 154
⁽²⁾	Refer to Illustration 158
⁽³⁾	Refer to Illustration 160
⁽⁴⁾	Refer to Illustration 163
⁽⁵⁾	Refer to Illustration 163
⁽⁶⁾	Refer to Illustration 163
⁽⁷⁾	Refer to Illustration 168
⁽⁸⁾	Refer to Illustration 171 and Illustration 172

Brake System Purge Procedure

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NOTICE

Purge any air that may be in the service brake system. Purge air from the service brake system if the following events have occurred:

Initial assembly of the machine
The brake manifold has been replaced
Any hose that supplies oil to the brake manifold have been disconnected.
Any hose that supplies oil to the brakes from the brake manifold have been disconnected.

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Table 41
Tools Needed
Item	Part Number	Description	Qty
1	6V-3965	Fitting (TEST)	1
2	177-7862	Hose As	1
3	6V-4143	Coupler	2

There are purge valves for the hydraulic brakes on each wheel. Before you use the purge valves to remove air from the oil in the system, the tank for the hydraulic brakes must be full.

Note: Purge only one wheel at a time.

Brake Unloader Valve

Chock the wheels.
Apply the parking brake. Applying the parking brake will release the pressure in the lines.
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Illustration 150 g03486038

(1) Brake unloader valve
Connect a suitable drain hose assembly to the bleeder valve on brake unloader valve (1).
Connect a drain hose from the unloader valve to the hydraulic tank or to a suitable container.
Run the engine at low idle. Move the transmission lever to the NEUTRAL position.
Pull down the retarder control or pump the service brake pedal.
Repeat this step until there is a continuous flow of oil.
Close the purge valve. Move the retarder control to the OFF position. Activate the parking brake to release the pressure. Remove the jumper hose from the bleeder valve.

Service Brakes and Retarder System

Chock the wheels.
Apply the parking brake. Applying the parking brake will release the pressure in the lines.
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Illustration 151 g03229196

Typical view of a front wheel
(A) Bleeder port (front wheel)

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Illustration 152 g03229197

Typical view of the back of the rear axle
(A) Bleeder port (rear wheel)
Connect a suitable drain hose to bleeder port (A) on one wheel.
Connect the drain hose from the port "A" to the hydraulic tank or to a suitable container.
Run the engine at low idle. Move the transmission control lever to the NEUTRAL position.
Use a wrench to open the bleeder screw.
Pull down the retarder control or depress the service brake pedal until there is a continuous flow of oil.
Close the bleeder screw. Move the retarder control to the OFF position or release the service brake pedal.
Move the transmission control to the P position.
Remove the drain hose from bleeder port (A).
Repeat these steps for the other three wheels.
After completing the purge, turn off the machine and remove all equipment.

Brake Pilot (Foot Pedal)

Assemble a hose to purge the air from the brake system. A hose with a shut off valve at one end and a hydraulic socket, which fits on a hydraulic quick disconnect, on the other end is required.
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Illustration 153 g03321181
Connect the hose that was assembled in Step 1 to tap (B).
Connect the drain hose from the port "B" to the hydraulic tank or to a suitable container.
Open the shutoff valve on the end of the hose.
Start the engine and run the engine at low idle.
Depress the service brake pedal until there is a continuous flow of oil.
When oil begins to flow and run clear of bubbles, close the valve and release service brake pedal.
After completing the purge, turn off the machine and remove all equipment.
Repeat Step 2 through Step 7 for port (C).
Note: The service brake pedal, or the manual retarder lever may be used.

Parking Brake

Though the parking brake application is mechanical, removing the air from the parking brake release system is important. Start the machine. Depress the service brake pedal and move the transmission lever from the P position, to the N position, and back to the P position five times. The air will be purged from the lines. Actuate the brake in intervals of approximately 1 minute.

Brake Valve Main Relief - Test

Testing the brake main relief valve can be completed by using overrides in Cat ET, or by unplugging a solenoid valve on the back of the brake control valve. Complete one of the following two tests:

"Brake Valve Main Relief - Test With Cat ET"
"Brake Valve Main Relief - Test Without Cat ET"

Brake Valve Main Relief - Test With Cat ET

Chock the wheels.
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Illustration 154 g03487156

(1) Pressure tap at the brake oil filter
Install tooling (A) or tooling (B) onto pressure tap (1).
Note: Refer to Table 4 for tooling (A) or Table 5 for tooling (B).
Start the engine.
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Illustration 155 g03183176

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NOTICE

Do not run the brake unloader override for more than 60 seconds. Unnecessary high brake oil temperature may result and system damage can occur.
From the toolbar in Cat ET, click "Diagnostics" and click "Diagnostic Tests". Click the "Override Parameters" for the "Brake 793". Set the override for the brake unloader valve to ON.
Click the override for the brake unloader valve and change the override to OFF.
Click the override for the brake unloader valve again, and change the override back to ON. Check the pressure from pressure tap (1). Record the pressure in Table 40.
Note: Pressure should be 23100 ± 345 kPa (3350 ± 50 psi).
Turn off the machine and remove all test equipment.
Adjust the pressure and repeat the test, if required.

Brake Valve Main Relief - Test Without Cat ET

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Illustration 156	g01962775

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Failure to properly secure the body (bed) may result in personal injury or death.

Chock the wheels.
Install tooling (A) or tooling (B) onto pressure tap (1) from Illustration 154.
Note: Refer to Table 4 for tooling (A) or Table 5 for tooling (B).
Start the engine.
Raise the body, and secure the body with retaining cables.
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Illustration 157 g03333630

View of the rear of the brake control valve
(2) Solenoid valve

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NOTICE

Do not leave solenoid valve (2) unplugged for more than 15 seconds. Unnecessary high brake oil temperature may result and system damage can occur.
Unplug the harness assembly from solenoid valve (2). Record the pressure on tooling (A) or tooling (B) in Table 40.
Note: Pressure should be 23100 ± 345 kPa (3350 ± 50 psi).
Reconnect the harness assembly to solenoid valve (2).
Turn off the machine and remove all test equipment.
Adjust the pressure and repeat the test, if required.

Service Brake Cut-In and Cut-Out at the Accumulators

Chock the wheels.
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Illustration 158 g03487325

(1) Parking and secondary brake accumulator pressure tap
(2) Service brake accumulator pressure tap
Connect tooling (A) or tooling (B) to pressure tap (2) for the service brake accumulators.
Note: Refer to Table 4 for tooling (A) or Table 5 for tooling (B).
Start the engine. Check the pressure on tooling (A) or tooling (B).
Cut-in ... Start of charge
Cut-out ... End of charge
Brake Cut-in Cut-out Pressure

Cut-In ... 14480 ± 483 kPa (2100 ± 70 psi)
Cut-Out ... 20685 ± 483 kPa (3000 ± 70 psi)

Record the pressures in Table 40.
Turn off the machine and remove all test equipment.

Brake Pump Stand-by Pressure - Test

Chock the wheels.
Install tooling (A) or tooling (B) onto pressure tap (1) from Illustration 154.
Note: Refer to Table 4 for tooling (A) or Table 5 for tooling (B).
Start the engine. When the pump is not charging, check the pressure on tooling (A) or tooling (B).
The pressure should be 1034 ± 1034 kPa (150 ± 150 psi). Record the pressure in Table 40.
Turn off the machine and remove all test equipment.

Brake Pilot Pressure (Foot Pedal) - Test

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Illustration 159	g01962775

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Failure to properly secure the body (bed) may result in personal injury or death.

Chock the wheels.
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Illustration 160 g03185120

(1) Pressure tap near the brake control valve
Install tooling (A) or tooling (B) onto pressure tap (1) from Illustration 160.
Note: Refer to Table 4 for tooling (A) or Table 5 for tooling (B).
Start the engine. Apply the service brake pedal several times. Then, apply the service brake pedal and hold. Check the pressure on tooling (A) or tooling (B).
Note: The pressure should be 4950 ± 400 kPa (720 ± 58 psi).
Record the pressure in Table 40.
Turn off the machine and remove all test equipment.

Service and Secondary Brake Accumulator Pressure - Test

Chock the wheels.
Install tooling (A) or tooling (B) onto pressure tap (1) and pressure tap (2) from Illustration 158.
Note: Refer to Table 4 for tooling (A) or Table 5 for tooling (B).
Start the engine and let the accumulators charge completely.
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Illustration 161 g03447699

Typical view of the ground level switches (SSP, SND, RBT machines)
(1) Engine lockout control

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Illustration 162 g06183454

Typical view of the ground level switches (SSP, SND, RBT machines)
(1) Engine lockout control
From the bumper, move engine shutdown switch (1) up to stop the engine.
With engine shutdown switch (1) up and the engine off, the accumulator pressure should not drain for an extended period.
Record the results in Table 40.
Start the engine and let the accumulators charge completely.
From the cab, turn the key to the OFF position.
With the key in the OFF position, the accumulator pressure should drop to approximately 0 kPa (0 psi) in less than 120 seconds.
Record the results in Table 40.
Remove all test equipment.

Parking Brake Release Pressure - Test

Chock the wheels.
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Illustration 163 g03185716

(1) Pressure taps for the rear parking brake release pressure
Install tooling (A) or tooling (B) onto pressure taps (1) from Illustration 163.
Note: Refer to Table 4 for tooling (A) or Table 5 for tooling (B).
Start the engine. Apply the retarder lever. Shift the transmission lever into the N position.
Check the pressure on tooling (A) or tooling (B).
Note: The pressure should be 4600 ± 800 kPa (665 ± 116 psi).
Record the results in Table 40.
Apply the secondary brake pedal.
Check the pressure on tooling (A) or tooling (B).
Note: The pressure should be 0 kPa (0 psi).
Record the results in Table 40.
Release the secondary brake pedal. Move the transmission lever into the P Position.
Check the pressure on tooling (A) or tooling (B).
Note: The pressure should be 0 kPa (0 psi).
Record the results in Table 40.
Turn off the machine and remove all test equipment.

Traction Control Valve - Test

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Illustration 164	g01962775

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Failure to properly secure the body (bed) may result in personal injury or death.

Chock the wheels.
Connect a laptop computer and open Cat ET. Navigate to the Brake ECM AETA valve solenoids.
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Illustration 165 g03487336

(1) Pressure tap for the right wheel
(2) Pressure tap for the left wheel
Install tooling (A) or tooling (B) onto pressure tap (1) and pressure tap (2) from Illustration 165.
Note: Refer to Table 4 for tooling (A) or Table 5 for tooling (B).
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Illustration 166 g03185964

The TCS test switch is located in the overhead controls in the operator station
(3) TCS switch
Start the engine and run the engine at low idle. Apply the retarder lever, move the transmission lever to the N position, and ensure that the parking brake is off. Activate traction control switch (3).
Check the pressure on tooling (A) or tooling (B). Record the results in Table 40.
The hydraulic pressure at the left traction control valve will show a fall and rise in 30 seconds. Then, the right traction control valve will show a fall and rise over 30 seconds. The cycle will repeat.
Note: The left side (lower pressure tap) must fall first if the hydraulic lines are connected correctly.
Turn off the machine and remove all test equipment.

Parking Brake Holding Ability Test

Reference: Operation and Maintenance Manual, SEBU8406, "Braking System - Test"

Chock the wheels.
Fasten the seat belt before you test the brakes.
Check the area around the machine. Make sure that the machine is clear of personnel and clear of obstacles.
Test the brakes on a dry, level surface.
Start the engine.
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Illustration 167 g01519336
When the transmission control is in the P position, depress button (3) for the high gear limit RAISE and depress button (4) for the high gear limit LOWER at the same time.
While both buttons are depressed, Move the transmission control to the D position.
Note: The buttons can now be released and the parking brake will remain on.
Gradually increase the engine speed to 1300 rpm. The machine should not move.
Reduce the engine speed to an idle. Move the transmission control to the P position. Stop the engine.

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NOTICE

If the machine moved while testing the brakes, contact your Cat dealer. Have the Cat dealer inspect and, if necessary, repair the parking/secondary brakes before returning the machine to operation.

Towing Motor Test

Chock the wheels.
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Illustration 168 g03182603

(1) Location of the pressure tap for the parking brake release pressure
Connect tooling (A) or tooling (B) to pressure tap (1).
Note: Refer to Table 4 for tooling (A) or Table 5 for tooling (B).
Turn the engine start switch to the ON position. Place the transmission control into the NEUTRAL position.
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Illustration 169 g02074719

Switch for the electric powered parking and secondary brake release pump
Activate the switch for the towing motor. Hold the switch until the pressure that is shown on the pressure gauge stops rising.
The pressure on tooling (A) or tooling (B) should rise to 3790 kPa to 4480 kPa (550 psi to 650 psi) within 120 seconds.
Record the results in Table 40.
Turn off the machine and remove all test equipment.

Brake Application Pressure at the Front Slack Adjuster - Test

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Illustration 170	g01962775

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Failure to properly secure the body (bed) may result in personal injury or death.

Chock the wheels.
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Illustration 171 g03186356

(1) Pressure tap at the front slack adjuster

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Illustration 172 g03229498

(2) Pressure tap at the rear slack adjuster
Connect tooling (A) or tooling (B) to pressure tap (1) and pressure tap (2) from Illustration 171 and Illustration 172.
Note: Refer to Table 4 for tooling (A) or Table 5 for tooling (B).
Start the engine and run the engine at low idle. Apply the service brake pedal.
Check the pressure on tooling (A) or tooling (B).
Brake pressure with the service brake pedal applied

Standard Retarding (Front and Rear Slack Adjuster) ... 4200 kPa to 5000 kPa (609 psi to 725 psi)
Extended Life Retarding (Front Slack Adjuster) ... 3025 kPa to 4225 kPa (438 psi to 612 psi)
Extended Life Retarding (Front Slack Adjuster) ... 4200 kPa to 5000 kPa (609 psi to 725 psi)
Release the service brake pedal.
Apply the manual retarder.
Check the pressure on tooling (A) or tooling (B).
Brake pressure with retarder lever applied

Standard Retarding (Front and Rear Slack Adjuster) ... 3800 kPa to 5400 kPa (551 psi to 783 psi)
Extended Life Retarding (Front Slack Adjuster) ... 2825 kPa to 4425 kPa (409 psi to 641 psi)
Extended Life Retarding (Rear Slack Adjuster) ... 3800 kPa to 5400 kPa (551 psi to 783 psi)
Turn off the machine and remove all test equipment.

Automatic Retarder Control (ARC) - Test

Chock the wheels.
Ensure that Cat ET is connected.
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Illustration 173 g03187256

(1) Switch for the automatic retarder control (ARC)
Start the engine and run the engine at low idle. Depress switch (1) for the ARC. Verify the ARC status in Cat ET at the Brake ECM "Status" screen.
Turn off the machine.

Set the Front and Rear Brake Wear Indicators (If Equipped)

Location of the Brake Wear Indicators

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Illustration 174	g03243396
Front wheel (standard)

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Illustration 175	g03243438
Rear wheel (standard)

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Illustration 176	g03243443
Front wheel (extended life)

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Illustration 177	g03243446
Rear wheel (extended life)

Instructions to Set the Brake Wear Indicators

Chock the wheels.
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Illustration 178 g01974859

Typical view of an installed brake wear indicator
Remove cap (A) from the brake wear indicator.
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Illustration 179 g01975013

Typical view of newly installed brake discs
Apply forward pressure to indicator rod (B) so that the indicator rod contacts brake piston (C).
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Illustration 180 g01975034
Push dowel bushing (D) into the body until the end of dowel bushing (D) is flush with the notched shoulder that is on indicator rod (B).
Reinstall cap (A) that was removed in Step 2. Tighten cap (A) to a torque of 34 ± 4 N·m (300 ± 35 lb in).
Refer to Testing and Adjusting, KENR8738, "Service Brake Discs - Check - Standard" for instructions on checking the brake wear.

Measure and Record Front and Rear Brake Baseline Measurements

Reference: Testing and Adjusting, KENR8738, "793F and 793F CMD Off-Highway Truck Braking System", "Service Brake Discs - Check"

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Table 42
Brake Wear
		Front Brake		Rear Brake
		Piston Travel	Percent of Wear	Rear Brake	Percent of Wear
Baseline	Left
Baseline	Right
Rebuild 1	Left
Rebuild 1	Right
Rebuild 2	Left
Rebuild 2	Right
Rebuild 3	Left
Rebuild 3	Right
Rebuild 4	Left
Rebuild 4	Right
Rebuild 5	Left
Rebuild 5	Right
Rebuild 6	Left
Rebuild 6	Right
Rebuild 7	Left
Rebuild 7	Right

Brake Cooling System - Test

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Table 43
Brake Cooling System Specifications
	Specification	Actual
Brake Cooling Pressure	450 ± 138 kPa (65 ± 20 psi)

Chock the wheels.
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Illustration 181 g03187458

Standard brake cooling screen
(1) Pressure tap on brake cooling screen

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Illustration 182 g03187459

Extended life brake cooling screens
(1) Pressure tap on brake cooling screen
Connect tooling (A) or tooling (B) to pressure tap (1).
Note: Refer to Table 4 for tooling (A) or Table 5 for tooling (B).
Note: There aretwopressuretaps (1) on the extended life retarding arrangement.
Start the machine.
From the toolbar in Cat ET, click "Diagnostics" then click "Diagnostic Tests". Select the "Override Parameters" in "Brake 793".
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Illustration 183 g03187616
Select the "Brake Cooling Pump Speed" and click "Change". Set the brake cooling pump speed to 1200 rpm for standard retarding machines and 1750 rpm for extended life retarding machines.
Select the "Engine Speed" and click "Change". Set the engine speed to 1960 rpm (high idle).
Check the pressure at tooling (A) or tooling (B).
The pressure should be 450 ± 138 kPa (65 ± 20 psi). Record the results in Table 43.
Turn off the machine and remove all test equipment.

Steering System and Hydraulic Fan System - Test

Ensure that the steering accumulators are at the correct precharge before performing any tests.

Reference: Testing and Adjusting, KENR8574, "793F Off-Highway Truck Hydraulic Fan and Steering System"

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Table 44
Steering System and Hydraulic System Specifications⁽¹⁾
	Target	Actual
Accumulator pressure⁽²⁾	22750 ± 345 kPa (3300 ± 50 psi)


Cycle time for the steering system at high idle. With all the brakes released, turn the steering wheel from left to right. Then from right to left.	3 to 5 seconds	1.________________ 2.________________ 3.________________ Avg.______________
Steering wheel turns from stop to stop at high idle. With all the brakes released, turn the steering wheel at 1 revolution per second	3 to 5 seconds	Left to Right 1.________________ 2.________________ 3.________________ Avg.______________
Steering wheel turns from stop to stop at high idle. With all the brakes released, turn the steering wheel at 1 revolution per second	3 to 5 seconds	Right to Left 1.________________ 2.________________ 3.________________ Avg.______________
Pressure setting for the (Priority Valve) Solenoid Valve and Manifold (Rear Axle Fan, Brake Cooling, Drive Motor, Lubrication, and Steering)⁽³⁾	18271 ± 690 kPa (2650 ± 100 psi)

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⁽¹⁾	Steering oil temperature during tests 90.5° ± 30.5°C (195° ± 55°F)
⁽²⁾	Refer to Illustration 184
⁽³⁾	Refer to Illustration 186

Steering Accumulator Pressure - Test

Chock the wheels.
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Illustration 184 g03178001

(1) Pressure tap for the steering accumulator pressure
Connect tooling (A) or tooling (B) to pressure tap (1).
Note: Refer to Table 4 for tooling (A) or Table 5 for tooling (B).
Start the engine. Turn the wheels all the way to the left. Check for leaks.
Note: Accumulator pressure should be 22750 ± 345 kPa (3300 ± 50 psi).
Turn the wheels all the way to the right. Check for leaks.
Note: Accumulator pressure should be 22750 ± 345 kPa (3300 ± 50 psi).
With the accumulators fully charged, shut off the engine with the ground level shutdown switch. Monitor the pressure at pressure tap (1).
Note: The pressure should not drop below 17927 kPa (2600 psi) in 10 seconds.
Return the ground level shutdown switch to the ON position, and turn the key switch to the OFF position. Monitor the pressure at pressure tap (1).
Note: The pressure should drop to below 345 kPa (50 psi) in 120 seconds.
Verify that there are no leaks.
Turn off the machine and remove all test equipment.
Record the results in Table 44.

Steering System Internal Leakage Test

Chock the wheels.
Start the engine and run the engine at high idle.
Turn the steering wheel from stop to stop at approximately one rotation per second. Record the results in Table 44.
Note: Time should be approximately 3 to 5 seconds. If more time is required to complete the turn, there may be internal leakage in the steering system.
Turn off the machine.

Priority Valve Relief Pressure Test

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Illustration 185	g01962775

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Failure to properly secure the body (bed) may result in personal injury or death.

Chock the wheels.
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Illustration 186 g03178024

(1) Priority valve
(2) Relief valve on priority valve (1)
( 3) Pressure tap
Connect tooling (A) or tooling (B) to pressure tap (3).
Note: Refer to Table 4 for tooling (A) or Table 5 for tooling (B).
Start the engine.
Open Cat ET and go to the overrides. Adjust the speed of the motor that drives the brake oil cooling pumps to 1945 rpm with the engine speed at 700 rpm (low idle).
Note: The steering pressure at pressure tap (3) should drop to approximately 18271 ± 690 kPa (2650 ± 100 psi).
Note: Adjustment to the steering pressure can be made at relief valve (2).
Record the results in Table 44.
Turn off the machine and remove all test equipment.

Hydraulic Fan - Test

Chock the wheels.
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Illustration 187 g03180797

Typical view of the override screen in Cat ^® ET
Open Cat ET and go to the "Overrides" screen to view the "Engine Speed" and the "Engine Fan Speed". Also, be prepared to adjust the "Desired Engine Cooling Fan Speed Override".
Ensure that the correct cooling arrangement is configured in Cat ET.
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Illustration 188 g03179298

View of the front right side of the inner frame
(1) Pressure tap for the hydraulic fan pressure
Connect tooling (A) or tooling (B) to pressure tap (1).
Note: Refer to Table 4 for tooling (A) or Table 5 for tooling (B).
Start the engine and run the engine at high idle. Check the hydraulic fan system pressure at pressure tap (1).
Note: The pressure can be between 0 to 35000 kPa (0 psi to 5000 psi).

Reduce the engine speed to 700 rpm (low idle). Turn on the A/C. Check the engine fan speed in Cat ET.

Note: The fan speed should be approximately 335 rpm.

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Table 45
Incremental Fan Speed Overrides with the A/C Off.
Engine Speed (High Idle/Low Idle)	Target Fan Speed (rpm)	Actual Fan Speed	Actual Pressure From Illustration 188
HI and LI	200 rpm
HI and LI	400 rpm
HI	500 rpm
HI	650 rpm Standard Retarding
HI	817 rpm Additional Retarding
NA	Unplugged Solenoid 670 rpm to 750 rpm Standard Retarding
NA	Unplugged Solenoid 850 rpm Additional Retarding

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Illustration 189	g03178082
(2) High-pressure cutoff adjustment screw

If the truck is equipped with standard retarding, adjust the pump high-pressure cutoff on the hydraulic fan pump to a maximum of 750 rpm.
If the truck is equipped with extended life retarding, adjust the pump high-pressure cutoff on the hydraulic fan pump to a maximum of 850 rpm.
Note: If the environmental conditions (sea level) limit the fan speed below 850 rpm, do not adjust the high-pressure cutoff to above 35000 kPa (5000 psi).
Verify that there are no leaks.
Turn off the machine and remove all test equipment.

Hoist System - Test

The hoist oil temperature should be 60° to 82°C (140° to 180°F).

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Table 46
Hoist System Specifications
	Specifications	Actual
Hoist Raise Pump Pressure⁽¹⁾	20370 + 700/ - 0 kPa (2950 + 100/ - 0 psi)
Hoist Lower Pump Pressure	3450 + 350/ - 0 kPa (500 + 50/ - 0 psi)
Cycle Time for Raise (Full Lower to Full Raise)	19 - 22 seconds
Cycle Time for Raise (Full Raise to Full Lower)	17 - 19 seconds
Hoist Pilot Pressure⁽²⁾	3800 ± 345 kPa (550 ± 50 psi)

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⁽¹⁾	Refer to Illustration 200
⁽²⁾	Refer to Illustration 202

Hoist Enable System

Note: The hoist enable system must be enabled after the truck is assembled.

Chock the wheels.
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Illustration 190 g02139117
Start Cat ET and select "Chassis 793".
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Illustration 191 g02138804
From the toolbar, click "Service". Click "Configuration".
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Illustration 192 g06076881
Under the heading "Hoist System", click "Hoist System Enable Status".
Click the"Change" button that is at the bottom of the screen.
Use the drop-down menu to change the status of the hoist system to "Enabled". Click "OK". Select "OK" in the verification box.

Calibrate the Body Position Sensor

Refer to Testing and Adjusting, KENR8396, "Position Sensor (Body) - Calibrate" for additional instructions.

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Illustration 193	g02451337
Typical rod linkage (1) Rod end (2) Nut (3) Rod (4) Body position sensor (5) Centers of the rod ends

Recommended starting distance of centers of the rod ends (5) is 360 mm (14.20 inch).

Body position sensor (4) is located near the pivot pin for the body. A lever is attached between the sensor and the body. When the body is raised or lowered, the lever rotates the sensor. This action changes the Pulse Width Modulation (PWM) signal that is sent to the Chassis ECM.

If the expected PWM signal does not occur, then the Chassis ECM generates an event code. The code is logged to VIMS^TM.

Full Lower Calibration

Required Conditions

The following conditions must be met for 23 seconds:

The engine is running with no ground speed.
The payload is zero.
The hoist control lever must be in FLOAT mode.
The duty cycle output is within the range of 3 percent to 30 percent.

Note: The recommended duty cycle output is within the range of 14 percent to 19 percent.

The following occurs when all the conditions are met for 23 seconds:

The calibration value will be the average of the values that were recorded during that 23 seconds.

Expected Values

When the bed is fully lowered, the Chassis ECM expects a value that is greater than 1 percent PWM.

If the expected PWM value is not obtained, then an FMI-04 will be logged. If this event occurs, then perform the Rod Adjustment in the "Body Position Sensor - Adjust" section.

Tolerance Range

The standard range for the calibration limits is plus or minus 2 percent of the last calibration point. If the tolerance range is not exceeded, then the lower calibration point will not change.

If the tolerance range is exceeded, then the upper calibration point will default to a 50 percent duty cycle until the upper calibration is performed. The lower calibration point will change to the average value over the last 23 seconds.

This change occurs because there has been a mechanical change in the system that measures the output of the sensor. For example, a change could occur under any of the following conditions:

The nuts that secure the adjustment rod are loose.
There is excessive wear on the body pins.
The adjustment rod is bent or damaged.
The sensor is damaged.

Any of these conditions could affect the duty cycle of the full lower calibration.

Full Raise Calibration

Required Conditions

The following conditions must be met for 500 milliseconds:

The engine is running with no ground speed.
The duty cycle output is in a range of 50 percent to 95 percent.
The current full up duty cycle must be greater than the previous full up duty cycle.
The hoist control lever must be in RAISE mode or in HOLD mode.

Note: When the bed has reached the maximum height, the operator should move the hoist lever from the RAISE position to the HOLD position. Five seconds after the hoist lever is in position the calibration will begin.

The following occurs when all the conditions are met for 500 milliseconds:

The calibration value will be the average of the values that were recorded during the 500 milliseconds.
If the current upper calibration value is less than the previous upper calibration value, then the value will not change.

Expected Values

When the bed is fully raised, the Chassis ECM expects a value of less than 96 percent PWM.

If the expected PWM value is not obtained, then an FMI-03 will be logged. If this event occurs, then perform the Rod Adjustment in the "Body Position Sensor - Adjust" section.

Body Position Sensor - Adjust

Rod Adjustment

The following adjustment may be required for the Chassis ECM to calibrate the position sensor:

Disconnect rod (3) from the body.
Loosen nut (2) on rod (3).
Twist the rod (3) to obtain the correct distance between the centers of the rod ends (5).
Tighten nut (2).
Reattach rod (3) to the body.

Angle Verification

Verify that the angle of the body is within tolerance when any of the following components are replaced:

A sensor
A body
An ECM

Note: If the angle is not within tolerance, then the Chassis ECM cannot correctly calibrate the position sensor.

Lower the body to the frame rails. If the value is less than 7 degrees, the software in the Chassis ECM calibrates the sensor. The calibration is performed automatically by the Chassis ECM when the body is raised and lowered. If the value is not less than 7 degrees, then perform the Rod Adjustment in the "Body Position Sensor - Adjust" section.

Body Up Gear Limit

Chock the wheels.
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Illustration 194 g02138804
From the toolbar, click "Service". Click "Configuration".
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Illustration 195 g06076908
Under the heading "Hoist System", click "Body Up Gear Limit".
Click the"Change" button that is at the bottom of the screen.
To change the status of the Body Up Gear Limit, choose a gear. Click "OK". Select "OK" in the verification box.
Note: Caterpillar recommends configuring the body up gear limit to first gear.

Hoist Lower Valve Adjustment Status (Snub)

Lowering the hoist is adjustable. Adjusting the hoist lower valve 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. A positive adjustment factor causes the body to come down harder. A negative adjustment factor will decrease the lower valve command. A negative adjustment factor 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.

Chock the wheels.
Raise the truck body.
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Illustration 196 g02075237

Typical view
Connect the safety retaining cables to the body.
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Illustration 197 g03319386
Connect tooling (A) or tooling (B) to one of the outlet ports on the hoist pump.
Note: Refer to Table 4 for tooling (A) or Table 5 for tooling (B).
Remove the safety retaining cables from the body.
With the engine that is running, place the hoist lever in the body float position.
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 8.
Start Cat ET.
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Illustration 198 g06076876
In the "Chassis 793" tab click "Hoist System".
Select "Hoist Lower Valve Adjustment Status".
Select "Change".
Insert the new value in the "Hoist Lower Valve Adjustment Status" box. Click "OK". Select "OK" in the verification box.
Repeat Step 6 through Step 12 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 that is too high causes too much oil to be diverted to the hoist valve. Excess oil causes the brake oil to overheat when the body is in the body float position. Reduce the Hoist Lower Valve Adjustment in Cat ET. Repeat Step 2 through Step 7 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 follows the operators request, the ECM ensures that the snub function will not 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.

Hoist Pump Pressure - Test

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Illustration 199	g01962775

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Failure to properly secure the body (bed) may result in personal injury or death.

Chock the wheels.
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Illustration 200 g03190896
Connect tooling (A) or tooling (B) to pressure tap (1) and pressure tap (2).
Note: Refer to Table 4 for tooling (A) or Table 5 for tooling (B).
With the transmission in the P position, start the machine and run the machine at high idle.
Shift the hoist lever to the RAISE position. Check the pressures.
Hoist raise pressure should be 20370 + 700/ - 0 kPa (2950 + 100/ - 0 psi).
Record the results in Table 46.
Sift the hoist lever to the LOWER position. Check the pressures.
Hoist lower pressure should be 3450 + 350/ - 0 kPa (500 + 50/ - 0 psi).
Record the results in Table 46.
Check for leaks. Turn off the machine and remove all test equipment.
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Illustration 201 g03191661

(2) Relief valve
(3) High pressure raise relief valve
(4) Lower pressure lower relief valve
If required, adjust the pressure at the relief valve (2) on top of the hoist control valve.
High pressure raise relief valve (3) shim specifications

Pressure change per 5J-2722 Shim 1.22 mm (0.0480 inch) Thickness ... 2417 kPa (350 psi)
Pressure change per 5J-2721 Shim 0.13 mm (0.0051 inch) Thickness ... 2417 kPa (350 psi)

Low-pressure lower relief valve (4) shim specifications

Pressure change per 5J-2722 Shim 1.22 mm (0.0480 inch) Thickness ... 477 kPa (69 psi)
Pressure change per 5J-2721 Shim 0.13 mm (0.0051 inch) Thickness ... 51 kPa (7 psi)

Hoist Cycle Time - Test

Chock the wheels.
Start the machine and run the machine at high idle.
Shift the hoist lever to the RAISE position. Time the results from full down to full up. Record the results in Table 46.
Verify that the snub feature is working correctly.
Move the hoist lever to the LOWER position. Time the results from full up to full down. Record the results in Table 46.
Verify that the snub feature is working correctly.
Check for leaks. Turn off the machine.

Hoist Pilot Pressure - Test

Chock the wheels.
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Illustration 202 g03191376

(1) Pressure tap for the hoist pilot pressure
Connect tooling (A) or tooling (B) to pressure tap (1).
Note: Refer to Table 4 for tooling (A) or Table 5 for tooling (B).
Start the machine. Shift the hoist lever to the HOLD position. Check the pressure.
The pressure should be approximately 3800 ± 345 kPa (550 ± 50 psi).
Record the results in Table 46.
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Illustration 203 g03191661

(2) Relief valve
(3) High pressure raise relief valve
(4) Lower pressure lower relief valve
If required, adjust the pressure at the relief valve (2) on top of the hoist control valve.
High pressure raise relief valve (3) shim specifications

Pressure change per 5J-2722 Shim 1.22 mm (0.0480 inch) Thickness ... 2417 kPa (350 psi)
Pressure change per 5J-2721 Shim 0.13 mm (0.0051 inch) Thickness ... 2417 kPa (350 psi)

Low-pressure lower relief valve (4) shim specifications

Pressure change per 5J-2722 Shim 1.22 mm (0.0480 inch) Thickness ... 477 kPa (69 psi)
Pressure change per 5J-2721 Shim 0.13 mm (0.0051 inch) Thickness ... 51 kPa (7 psi)

Lowering the Body with Engine Stopped

When the engine is stopped, the hoist must be supplied with pilot oil pressure to lower the body. The parking brake release pump can be used to provide pilot oil to the hoist.

Turn the engine start switch to the ON position.
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Illustration 204 g01778554
Move hoist control (1) to the LOWER position.
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Illustration 205 g01778573
Press and hold brake release switch (2) for 20 seconds.
If the body does not lower, or if the body does not lower completely, move the hoist control to the RAISE position for 15 seconds and repeat Step 2 and Step 3.

Lowering without Electrical Power

If the engine is inoperable and the machine is without electrical power, use an auxiliary power unit (APU) as a separate hydraulic source. An APU that is designed to use with this machine is available through your Caterpillar dealer. Consult your Caterpillar dealer for further information on the selection and the proper operation of an APU.

Rear Axle Lubrication System - Test

The rear axle oil temperature must be at least 18°C (64°F) prior to testing. Do not complete the following test if oil temperature is not at least 18°C (64°F).

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NOTICE

Damage to the machine may occur if the rear axle oil temperature is not above 18°C (64°F).

Chock the wheels prior to performing any tests.

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Table 47
Rear Axle Lubrication System Specifications⁽¹⁾
Engine Speed (RPM)	Diff. Lube Temp.	Rear Axle Lube System Status	Final Drive Lube System Status	Rear Axle Drive Motor Inlet Pressure		Rear Axle Filter Inlet Pressure		Final Drive Lube Pressure
Engine Speed (RPM)	Diff. Lube Temp.	Rear Axle Lube System Status	Final Drive Lube System Status	Spec.	Actual	Spec.	Actual	Spec.	Actual
700-1960	18° to 35°C (64° ± 95°F)	ON	OFF	16500 kPa to 23500 kPa (2390 psi to 3410 psi)		950 kPa to 1650 kPa (137 psi to 239 psi)		120 kPa to 200 kPa (17 psi to 29 psi)
700-1960	50° to 59°C (122° to 138°F)	ON	OFF	13500 kPa to 16500 kPa (1960 psi to 2390 psi)		800 kPa to 1250 kPa (116 psi to 181 psi)		120 kPa to 180 kPa (17 psi to 26 psi)
700-1960	60° to 75°C (140° to 167°F)	ON	ON	12500 kPa to 15500 kPa (1810 psi to 2250 psi)		750 kPa to 1200 kPa (108 psi to 174 psi)		180 kPa to 350 kPa (26 psi to 50 psi)
700-1960	ALL	OFF	OFF	0 kPa to 500 kPa (0 psi to 70 psi)		0 kPa to 50 kPa (0 psi to 7 psi)		0 kPa to 50 kPa (0 psi to 7 psi)

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⁽¹⁾	The rear axle oil temperature must be at least 18°C (64°F) prior to testing. Do not complete the following test if oil temperature is not at least 18°C (64°F).

Chock the wheels.
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Illustration 206 g03188838

View of the front of the rear axle
(1) Pressure tap for the rear axle filter inlet
(2) Pressure tap for the final drive lubrication
Connect tooling (A) or tooling (B) to pressure tap (1) and pressure tap (2).
Note: Refer to Table 4 for tooling (A) or Table 5 for tooling (B).
Start the engine.

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NOTICE

The rear axle oil temperature must be above 18°C (64°F). Damage to the machine may occur if the rear axle oil temperature is not above 18°C (64°F).
Run the engine at high idle.
Check the pressures. Refer to Table 47.
Pressure at pressure tap (1) should be 0 kPa to 50 kPa (0 psi to 7 psi).
Pressure at pressure tap (2) should be 0 kPa to 50 kPa (0 psi to 7 psi).
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Illustration 207 g03266796

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NOTICE

The rear axle oil temperature must be above 18°C (64°F). Damage to the machine may occur if the rear axle oil temperature is not above 18°C (64°F).
In Cat ET, go to the brake overrides.
Enable the "Rear Axle Pump Drive Oil Divert Solenoid Override".
Check the pressures. Refer to Table 47.
Pressure at pressure tap (1) should be 950 kPa to 1650 kPa (137 psi to 239 psi).
Pressure at pressure tap (2) should be 120 kPa to 200 kPa (17 psi to 29 psi).
Enable the "Final Drive Oil Bypass Solenoid Override". Refer to Illustration 207.
Check the pressures. Refer to Table 47.
Pressure at pressure tap (1) should be 750 kPa to 1200 kPa (108 psi to 174 psi).
Pressure at pressure tap (2) should be 180 kPa to 350 kPa (26 psi to 50 psi).
If the truck is equipped with the Rear Axle Cooling Fan, complete Step 10a through Step 10c. If the truck is not equipped with the Rear Axle Cooling Fan, refer to Step 11.
1. Disable the "Final Drive Oil Bypass Solenoid Override". Refer to Illustration 207.
2. Enable the "Differential High Speed Fan Solenoid Override".
3. Visually check the operation of the Rear Axle Cooling Fan. Looking at the truck from the rear, the fan should be rotating in the counterclockwise direction.
Disable all overrides in Cat ET and turn off the machine. Remove all test equipment.

Charge the Suspension Cylinders

Refer to Special Instruction, SEHS9411, "Servicing the Suspension Cylinders for Off-Highway Trucks" for the correct instructions.

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NOTICE

Care must be taken to maintain corner weights.

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Illustration 208	g02079473
Typical view of the left front suspension cylinder

Measure the visible chrome on the four suspension cylinders to verify the charge.

Record the suspension cylinder measurements in the table provided.

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Table 48
	Exposed Chrome on the Collapsed Suspension Cylinders		Ride Height		Extended Charge Pressure
	Target (for reference only)	Actual	Target	Actual	Target (for reference only)	Actual
Left front suspension cylinder	20 mm (0.79 inch)		254 ± 13 mm (10 ± 0.5 inch)		1800 kPa (260 psi)
Right front suspension cylinder
Left rear suspension cylinder	78.5 mm (3.0 inch)		203 ± 13 mm (8.0 ± 0.5 inch)		1250 kPa (181 psi)
Right rear suspension cylinder

Note: Oil height should be 25.4 mm (1.0 inch).

Truck Payload - Calibrate

Refer to Testing and Adjusting, KENR9023, "Payload System - Calibrate" for instructions on calibrating the payload.

Refer to Service Magazine, SEPD1178, "Switch Settings for the Payload Monitors" for additional information on the switch settings for the payload monitors.

The following information describes the calibration for the truck payload.

Note: The TPMS will not operate until a successful payload calibration has been completed.

Note: For security, this service program code will only function while Cat ET is connected or the service mode in the Advisor is enabled.

The following conditions must be met to calibrate the payload system:
1. Ensure that the truck body is empty. Carryback weight of the material that is stuck in the truck body can affect the payload measurements.
2. Operate the empty truck to a minimum ground speed of 4 MPH on hard level ground.
3. Move the shift control lever to the neutral position and allow the truck to coast to a stop. Do NOT use the service brakes or the retarder.
4. After the truck stops moving, calibrate the payload system.
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Illustration 209 g03231436
From the Home Screen in Advisor, select "Service", then "Calibrations", then "Truck Payload" and hit "OK".
The payload calibration will begin.
Follow the instructions on Advisor.
The Advisor display will show a "Calibration Complete" message if the calibration was successful.

Traction Control System (TCS) - Test

Reference: Operation and Maintenance Manual, SEBU8406, "Traction Control System (TCS) - 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.

Note: This procedure determines if the Traction Control System (TCS) is functioning. This procedure also determines if the left rear brake and the right rear brake activate at the correct time.

Find a clear area and a level area that is large enough to turn the machine in a complete circle. Start the machine and move the transmission control to the 1 position.
Turn the steering wheel all the way to the left. With the engine at an idle, slowly drive forward in a complete circle.
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Illustration 210 g02004873

The TCS test switch is located in the overhead controls in the operator station.
Continue to turn the machine and push the top half of TCS test switch (1). Hold the test switch down. The test will begin.
The machine will gradually slow down.
Release the test switch. The test will end and the machine will increase speed.
Turn the steering wheel all the way to the right. With the engine at an idle, slowly drive forward in a complete circle.
Continue to turn the machine and push the top half of the TCS test switch. Hold the test switch down. The test will begin.
The machine will gradually slow down.
Release the test switch. The test will end and the machine will increase speed.
If the TCS did not function properly, consult your Caterpillar dealer for information and service.

Transmission and Torque Converter Filters

The transmission system uses 340-0403 Oil Filter Element As, which have to be replaced by a service filter element after 50 hours of machine operation. Failure to change to a service element may result in clogging of the filter.

Replace the element assemblies with a new 340-0403 Oil Filter Element As.

Note: The 340-0403 Oil Filter Element As is for power train use only and not approved for hydraulic applications.

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Illustration 211	g03245998

Obtain an S·O·S sample from sampling valve (1) prior to changing the oil filter element assemblies. Refer to Operation and Maintenance Manual, SEBU8406, "Torque Converter and Transmission Oil Sample - Obtain" for additional information about oil samples.

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.

Engine Performance Footprint

Perform the following steps to create a baseline/footprint of the engine performance. This information will help to establish a baseline of information to help troubleshoot any future problems that might occur.

Create Performance Groups

Connect a laptop computer with Cat ET to the machine.
Open Cat ET.
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Illustration 212 g03256756
From the toolbar, select "Information" and "Status".
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Illustration 213 g03258496
Scroll to the bottom of screen and double-click "TEMPORARY GROUP".
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Illustration 214 g03258536
Create Performance Group 1. One at a time, select each of the following parameters from the column on the left. Click the right pointing arrow to add each parameter to the column on the right.
Performance Group 1
- Percent Fuel Command/Position
- Fuel Actuator Position Command
- Desired Fuel Rail Pressure
- Fuel Rail Pressure
- Engine Speed
- Desired Engine Speed
- Engine Load Factor
- Throttle Position
- Delivered Fuel Volume
- Intake Manifold Pressure
- Intake Manifold Pressure #2
Note: The following two performance groups should also get created:
Performance Group 2
- Unfiltered Oil Pressure (Absolute)
- Engine Oil Pressure (Absolute)
- Right Exhaust Temperature
- Left Exhaust Temperature
- Unfiltered Fuel Pressure (absolute)
- Fuel Pressure (Absolute)
- Atmospheric Pressure
- Engine Coolant Pump Outlet Temperature
- Engine Coolant Temperature
- Intake Manifold Air Temperature
- Intake Manifold Air Temperature #2
Performance Group 3
- Air Filter #1 Restriction
- Air Filter #2 Restriction
- Air Filter #3 Restriction
- Air Filter #4 Restriction
- Fuel Rail Temperature
- Fuel Temperature
- Engine Oil Temperature
- Fuel Transfer Pump Intake Pressure
- Torque Limit Fuel Volume
- Smoke Limit Fuel Volume
- Crankcase Pressure
Click "OK".
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Illustration 215 g03258618
Click "Change"
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Illustration 216 g03258620
Click "Save As".
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Illustration 217 g03258656
Type the new name for the group in the "Save As" window.
The following three groups should be created:
- Performance Group 1
- Performance Group 2
- Performance Group 3
Click "OK" to close the "Save As" window. Click "OK" to close the "Maintain Groups" window.
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Illustration 218 g03259499
Repeat the above steps until the following three performance groups are created:
- Performance Group 1
- Performance Group 2
- Performance Group 3
Refer to Step 5 for a list of the parameters in each performance group.

Save the Performance Group Screen

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Illustration 219	g03259616

After the correct conditions are met, click "Hold" on the bottom of the screen.
Note: Clicking "Hold" will stop the values from changing.
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Illustration 220 g03259617
From the toolbar, click "File" and "Print To File".
Note: A wait of approximately 15 seconds may be required to process information.
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Illustration 221 g03259661
In the "Save As" window, select the location and file name and click "Save".
Repeat Step 1 through Step 3 for each performance group under low idle, high idle, and load stall test conditions.
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Illustration 222 g03259698
To view a saved file, from the toolbar, select "File", "Open", and "Report File".
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Illustration 223 g03259756
Select the file to open, and click "Open".

Checks Before the Delivery of the 793F Off-Highway Truck

The page that is following is a list of assembly checks and systems checks that are recommended. Do this checklist before the truck is delivered to the customer. Do all the checks and verify that the systems function properly.

Refer to the Air System and Brakes Testing and Adjusting, "Service Brake Discs – Check". Also, refer to Guideline for Reusable Parts and Salvage, SEBF8095, "Service Brakes for Off-Highway Trucks and Tractors" to determine the service intervals. Record all data in the Air System and Brakes Testing and Adjusting, "Worksheets".

Use the Service Manual and use the Operation and Maintenance Manual to correct any system problems before you deliver the truck.

Create a Product Status Report

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Illustration 224	g03228437

From the toolbar, click "Information" and "Product Status Report".
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Illustration 225 g03394193
Run the Product Status Report.
Note: The Product Status Report will show the injector codes for Table 28.

After you complete the final check, sign your name and the name of the dealer. Make copies of the check procedure, and the Product Status Report as an ".xml" file. Mail (or e-mail) the copies to the following address:

Note: If needing to view the ".xml" file, word-processing software can be used.

Caterpillar Inc.
Attention: MCE Product Support
793F Off-Highway Trucks
N. 27th and Pershing Road
Decatur, IL 62525

Pre-delivery Worksheet

Note: All product improvement programs (PIP) for safety must be completed.

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Table 49
	Visual Inspection	Service Points and Fluid Levels	Operation	After Operation
Engine ⁽¹⁾ ⁽²⁾	_ Paint _ Outside Damage _ Leaks _ Torque marking of all aftertreatment joints _ Flexpipe Ball and Slip joints torqued to the specified value in Special Instruction, UENR6766, "Assembly Procedure for the 793F Off-Highway Truck"	_ Oil _ Coolant _ Fuel _ Batteries OVC > (12.45) _ VDC1 _ VDC2 _ Air Filters _ Drain Water from Fuel Tank _ Drain Water Separator _ Open Coolant conditioner Valves _ Grease Fittings _ Diesel Exhaust Fluid	_ Priming Pump _ Governor Control _ Air Compressor _ Smoke Color _ Unusual Noise	_ Air Cleaner Indicator _ V-Belt Tension _ Leaks - Oil, Air, Fuel, Coolant, Diesel Exhaust Fluid (DEF) _ Friction on Hoses _ Friction on Wires _ Loose Wire Connections _ Loose Fasteners or Lost Fasteners
Power Train	_ Paint _ Outside Damage _ Tires - Cuts, gouges	_ Transmission _ Differential _ Final Drives _ Tire Pressure _ Grease Fittings _ Front and Rear Axle Bolt Torques _ Front and Rear Universal Torques _ Wheel to Rim Torques	_ Transmission - Each Gear _ Neutral Start _ Transmission Lever Lock _ Back - Up Alarm _ Neutralizer Valve _ Unusual Noise	_ Leaks - Oil _ Loose Fasteners or lost Fasteners _ Tires - Cuts, Gouges
Steering and Brakes	_ Paint _ Outside Damage	_ Brake Fluid _ Drain Water from Air Tank _ Grease Fittings	_ Steering _ Retarder _ Service Brakes _ Parking Brakes _ Air Dryer _ Unusual Noise	_ Leaks - Oil, Air _ Loose Fasteners or Lost Fasteners
Chassis	_ Sheet Metal _ Paint _ Damage	_ Grease Fittings	_ Enclosure Doors - Locks and Latches	_ Loose Fasteners or Lost Fasteners _ Welds
Hydraulic	_ Cylinder Rods	_ Hydraulic Tank _ Grease Fittings	_ Controls _ Too much Drift _ Unusual Noise	_ Leaks - Oil _ Friction or Lost Fasteners
Truck Body	_ Paint _ Damage _ Liners	_ Grease Fittings _ Body Pads _ Retention Cable	_ Body Positions	_ Welds _ Loose Fasteners or Lost Fasteners _ Damage
Cab	_ Sheet Metal _ Paint _ Glass	_ Front Window Washer _ Air Filters _ Grease Fittings _ Torque on ROPS Support	_ Disconnect Switch _ VIMS _ Hoist Control _ Horn _Seat Belts _ Seat Adjustments _ All Switches and Controls _ Doors and Windows _ Locks and Latches _ Mirrors Adjustment _ Front Window Wipers _ Front Window Washers _ Heater _ Air Conditioner/Pressurizer Lights - Outside and Cab _ Gauges _ Unusual Noise _ Steering Column Adjustment	_ Operation Guide _ Maintenance Guide _ Parts Book _ Seat Cover _ Steps and Grab Irons _ Loose Fasteners or Lost Fasteners _ Loose Wire Connections _ Leaks - Water
Misc. and Attachments	_ Special Assembly Parts _ S/N Plates _ Correct Attachments _ Hand Tools _ Paint	_ Attachment Fluid Levels _ Charge on Fire Suppression System _ Grease Fittings _ Automatic Lubrication System	_ Attachments _ Engine Shutdown Switch _ Fire Suppression Test Switch	_ Warning Plates _ Decals _ Leaks _ Loose Fasteners or Lost Fasteners

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⁽¹⁾	If the machine was in storage, the engine needs pressure lubrication. Pressure lubrication must occur before the engine is started.
⁽²⁾	For cold-weather operation, refer to Special Publication, SEBU5898.

Mandatory Reporting for T4 Machines

In the cases where the aftertreatment (CEM and PETU) are not applied to the engine in the engine manufacturing assembly facility, the dealer/distributor who completes the assembly must meet the respective regulatory requirements (EPA- 40 C.F.R. Â§ 1068.260) which are also included in the AFTERTREATMENT ASSEMBLY AGREEMENT established between the dealer/distributor and Caterpillar. The dealer/distributor obligations include adherence to the provided assembly and testing instructions, and the return (to Caterpillar) of the part and serial number relationship of the engine and applied aftertreatment (both CEM and PETU and SOFTWARE).

Completion of the activities outlined below, satisfies compliance with the required dealer/distributor obligations

Ensure adherence to the provided assembly and testing instructions for the engine and aftertreatment system.
Verify the aftertreatment system is functioning properly by completing the aftertreatment system functional test.
Confirm the system has no active faults.
Generate a product status report. Ensure all available ECMs are included.
Send a copy of the product status report to the following email address:
Emissions_Compliance@cat.com

Object Detection Sensor - Adjust for Eight Sensors

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 Testing and Adjusting, KENR8668, "Object Detection Sensor - Calibration".

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Table 50
793F Radar Angles (As Measured)
Radar	Azimuth (deg)	Elevation (deg)
Left Front	25 Out	1 Down
Right Front	25 Out	1 Down
Left Rear Upper	20 In	20 Down
Right Rear Upper	20 In	20 Down
Left Rear Lower	20 In	9 Down
Right Rear Lower	20 In	9 Down
Left Side	0	55 Down
Right Side	0	55 Down

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Table 51
793F Radar Angles (Using Angles on Brackets))
Radar	Azimuth (deg)	Elevation (deg)
Left Front	25 Out	1 Down
Right Front	25 Out	1 Down
Left Rear Upper	20 In	10 Down
Right Rear Upper	20 In	10 Down
Left Rear Lower	0 In	-1 Down
Right Rear Lower	0 In	-1 Down
Left Side	0	55 Down
Right Side	0	55 Down

Object Detection Sensor - Adjust for 12 Sensors

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Table 52
793F Front and Rear Radar Angles
Radar	Front Radar		Rear Radar
Radar	Azimuth (deg)	Elevation (deg)	Azimuth (deg)	Elevation (deg)
Left Upper	20 left of center	20 down	20 right of center	30 down
Right Upper	20 right of center	20 down	20 left of center	30 down
Left Lower	25 left of center	2 down	20 right of center	9 down
Right Lower	25 left of center	2 down	20 left of center	9 down

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Table 53
793F Side Radar Angles
Radar	Elevation (deg)
Left Top	45
Left Bottom	65
Right Top	45
Right Bottom	65

Azimuth Adjustment Procedure

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Illustration 226	g02798504

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Illustration 227	g02798505
Azimuth adjustment for Short Range Radar and Medium Range Radar Brackets

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Table 54
Required Tools
13mm Wrench	1
Protractor	1

Loosen the four azimuth adjustment bolts on the brackets for the radars.
Use a protractor to set the proper azimuth angle that is listed in Table 52 or adjust the angle to fine-tune the system.
Carefully tighten the four azimuth adjustment bolts on the brackets for the radars.
Check the angle again to verify that the bracket is set to the proper angle.
Tighten the bolts.
Check the angle again to verify that the bracket is set to the proper angle.
Proceed to the"Elevation Adjustment Procedure".

Elevation Adjustment Procedure

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Illustration 228	g02798504

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Illustration 229	g02798505
Elevation adjustment bolts for Long Range Radar

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Table 55
Required Tools
10 mm Wrench	1
Inclinometer or Digital Level	1

Loosen the four adjustment bolts on the bracket for the radar.
Use an inclinometer or a digital level to set the proper elevation angle that is listed in Table 52 or adjust the angle to fine-tune the system.
Carefully tighten the four azimuth adjustment bolts on the brackets for the radars.
Check the angle again to verify that the bracket is set to the proper angle.
Tighten the bolts.
Check the angle again to verify that the bracket is set to the proper angle.
Perform the Testing and Adjusting, KENR8668, "Object Detection Sensor - Calibration".

Caterpillar Information System:

PL83 and PL87 Pipelayer Systems Speed Sensor (Transmission Output)

990K Wheel Loader Systems Speed Sensor (Transmission Input)

824K Wheel Dozer, 825K Soil Compactor and 826K Landfill Compactor Machine Systems Pressure Sensor (Steering Pilot Oil)

988K Wheel Loader Systems Pressure Sensor (Torque Converter Impeller Clutch Oil)

CP56B, CP68B, CS56B and CS68B Vibratory Soil Compactors Propel System Propel Lines

834K Wheel Dozer Systems and 836K Landfill Compactor Systems Modulating Valve (Torque Converter Impeller Clutch)

R3000H Load Haul Dump Power Train MID 081 - CID 0627 - FMI 04

R3000H Load Haul Dump Power Train MID 081 - CID 0627 - FMI 03

2012/08/27 A New Pump Coupling is Now Available for the Steering, Pilot, and Braking Pump for R2900G Load Haul Dump Machines {4268, 4306, 5085}

559C and 579C Knuckleboom Loaders Hydraulic System Pressure - Release

793F CMD Off-Highway Trucks Electrical Enclosure (Command) - Check/Clean

CW14 Pneumatic CompactorEngine Supplement Engine Enclosure (Hood) - Remove and Install

Commissioning Procedure For the 797F and the 797F XQ Off-Highway Truck {0374, 1000, 7000, 7961} Commissioning Procedure For the 797F and the 797F XQ Off-Highway Truck {0374, 1000, 7000, 7961}

CW14 Pneumatic CompactorEngine Supplement Battery - Remove and Install

2012/08/28 An Improved Filter Group is Now Available For Certain D5N Track-Type Tractors and 561N Pipelayers {3004, 3016, 3067}

789D and 789D XQ Off-Highway Trucks Machine Systems Seat - Remove and Install

CB34B, CB34B XW, CB36B and CC34B Utility Compactors Operator Controls

CW14 Pneumatic CompactorEngine Supplement Fuel Priming Pump and Fuel Filter Base - Remove and Install

2012/09/06 New Onboard Software Version 6.8 Is Now Available for Cat® Terrain for Draglines on Certain Machine Control and Guidance Products {7490, 7605}

789D and 789D XQ Off-Highway Trucks Machine Systems Tire and Rim (Front) - Remove and Install

2012/09/06 A New Flywheel Speed Sensor Is Used on Certain 3500 Off-Highway Truck Engines {1907}

CW14 Pneumatic CompactorEngine Supplement Clean Emissions Module - Remove and Install

Incorrectly Machined Bearing Cage May Cause Bearing to Lose Oil Film{3075, 3159, 7551} Incorrectly Machined Bearing Cage May Cause Bearing to Lose Oil Film{3075, 3159, 7551}

CB44B and CB54B Vibratory Asphalt Compactors Engine Supplement Engine - Remove and Install




Illustration 6	g03447501
Typical view of the ground level switches (SSP, SND, RBT machines)




Illustration 7	g06183129
Typical view of the ground level switches (D3T machines)




Illustration 35	g06209702
Close-up view of the fast fill service center (1) Reservoir keypad (2) Power switch




Illustration 36	g06209703
Keypad (3) Full indicator (4) Normal indicator (5) Add indicator (7) Grease reservoir test button




Illustration 43	g02138155
Typical view (SSP, SND, RBT machines)




Illustration 82	g02134815
Instrument cluster for the 793F (1) Action Indicator




Illustration 94	g03447516
Typical view of the ground level switches (SSP, SND, RBT machines)




Illustration 95	g06183141
Typical view of the ground level switches (D3T machines)




Illustration 96	g03447518
Typical view of the ground level controls (SSP, SND, RBT machines) (1) Engine lockout control




Illustration 97	g06190269
(7) Pressure tap (8) Pressure tap (9) Pressure tap (10) Fuel priming pump switch




Illustration 5	g02073718




Illustration 98	g06183145
Typical view of the ground level controls (D3T machines) (1) Engine lockout control




Illustration 99	g06190477
Typical view of the right-hand side of the engine (D3T machines) (2) Fuel priming pump switch




Illustration 100	g03709600
Typical view of the RH side (A) Steering case drain filter




Illustration 101	g03709617
Close-up view of the steering case drain filter (A) Steering case drain filter (B) Pressure tap




Illustration 102	g03709780
View of the LH side (D) Brake filter (E) Pressure tap




Illustration 103	g03709849
View of the inside RH side of the frame (F) Brake-Hoist pump (G) Pressure tap




Illustration 104	g06183384
Typical view of the ground level controls (SSP, SND, and RBT machines) (C) Engine lockout control




Illustration 105	g06183389
Typical view of the ground level controls (D3T machines) (C) Engine lockout control




Illustration 111	g06078034
View of the serial number plate on the Clean Emissions Module (CEM)

Air Dryer Check	Actual Reading
24 V or more at the air dryer




Illustration 136	g03260056
Typical view (A) Location of the target pressure




Illustration 151	g03229196
Typical view of a front wheel (A) Bleeder port (front wheel)




Illustration 152	g03229197
Typical view of the back of the rear axle (A) Bleeder port (rear wheel)




Illustration 154	g03487156
(1) Pressure tap at the brake oil filter




Illustration 157	g03333630
View of the rear of the brake control valve (2) Solenoid valve




Illustration 158	g03487325
(1) Parking and secondary brake accumulator pressure tap (2) Service brake accumulator pressure tap




Illustration 160	g03185120
(1) Pressure tap near the brake control valve




Illustration 161	g03447699
Typical view of the ground level switches (SSP, SND, RBT machines) (1) Engine lockout control




Illustration 162	g06183454
Typical view of the ground level switches (SSP, SND, RBT machines) (1) Engine lockout control




Illustration 163	g03185716
(1) Pressure taps for the rear parking brake release pressure