793C Off-Highway Truck Machine Systems Caterpillar

Installation Procedure

Show/hide table

Illustration 1	g00482030

Show/hide table

Illustration 2	g00481687

1. Position the truck body on the four floor supports. The truck body weighs approximately 44,230 kg (97,510.3 lb).

2. Use six bolts (25), six washers, and six nuts (26) in order to assemble plate (27) to the truck body. Use strip (30), twelve bolts (28), and twelve nuts (29) in order to assemble mud flap (33) to plate (27).

3. Repeat Step 2 for remaining mud flaps (31), (32), and (34).
   Show/hide table

   Illustration 3	g00481528
   The clevis and the strap attached to the rear of the truck body.

   Show/hide table

   Illustration 4	g00481583
   The clevis and the strap attached to the front of truck body.

   Show/hide table

   Illustration 5	g00481658

   Show/hide table

   Illustration 6	g00482561

4. Install two pin assemblies (18) through the first lifting eyes on the body. Later, the pin assemblies will be inserted through the lifting eyes on the frame to the second lifting eyes on the body. Pin assembly (18) weighs approximately 22.7 kg (50.05 lb).
   Show/hide table

   Illustration 7	g00481653

   Show/hide table

   Illustration 8	g00482161

5. Install two pin assemblies (24) into the truck body. Pin assembly (24) weighs approximately 41 kg (90.4 lb).
   Show/hide table

   Illustration 9	g00482165

   Show/hide table

   Illustration 10	g00482167

6. Install one washer (22) on each hinge pin (24).

   Note: If washers (22) will be replaced, two different sized washers are available. The thickness of the two different washers is 10.0 mm (0.39 inch) or 6.0 mm (0.24 inch). Use two washers that are 6.0 mm (0.24 inch) thick if the two washers that are 10.0 mm (0.39 inch) thick will not assemble.

7. Repeat Step 5 and Step 6 for the remaining hinge pin.
   Show/hide table

   Illustration 11	g00481638

8. One mechanic should check the alignment. A second mechanic should use a hammer to pound in the pin assembly. The pin assembly should have the proper attitude for the installation of the mounting block and the bolts.

9. Use two bolts (21) and two hard washers in order to install one plate (23).

   Note: Bolts (21) should be tightened to a torque of 100 ± 20 N·m (73.8 ± 14.8 lb ft).

   Show/hide table

   Illustration 12	g00481632

10. Use a lift truck or another suitable method in order to support hoist cylinder (20). Remove the chain. Position the head end of the hoist cylinder in the bracket on the truck body. The hoist cylinder weighs approximately 1150 kg (2535.3 lb).
    Show/hide table

    Illustration 13	g00481628

11. Assemble two spacers (16) on pin assembly (18).

12. Insert pin assembly (18) until the pin is seated. Install plate (19), the two washers, and two bolts (17).

13. Repeat Step 10 through Step 12 on the remaining hoist cylinder.

    Note: Tighten bolts (17) to a torque of 100 ± 20 N·m (73.8 ± 14.8 lb ft).

14. If pad assemblies (9) and (12) are being replaced, use the following procedure in order to determine the requirement for shims (8) and (13).

    1. Align the truck body and the frame rails parallel. The nominal distance between the rails is 42.0 mm (1.65 inch).

    2. Measure the actual distance between the rails. Place pad assemblies (9) on the top of the main frame. As required, use shims (8) in order to produce zero clearance between the rails. Install three bolts (10), three washers, and three nuts (11). Repeat this process for the seven remaining pad assemblies.

       Note: Tighten bolts (10) to a torque of 100 ± 20 N·m (73.8 ± 14.8 lb ft).

    3. In order to install two pad assemblies (12) on top of the main crossbeam, align the pad assemblies parallel with the front body supports. Measure the distance between the pad assemblies. As required, use shims (13) in order to produce a compression of 1.5 mm (0.06 inch) at each of the two locations. The nominal distance between the pad assemblies and the front body support is 44.0 mm (1.73 inch). Install three bolts (14), the three washers, and three nuts (15).

       Note: Tighten bolts (14) to a torque of 100 ± 20 N·m (73.8 ± 14.8 lb ft).

15. Use sixteen bolts (5), sixteen washers, and sixteen clips (6) in order to install grease lines (7) of the hoist cylinder to the bottom of the truck body.

    Note: Tighten bolts (5) to a torque of 100 ± 20 N·m (73.8 ± 14.8 lb ft).

    Show/hide table

    Illustration 14	g00481591

16. Use a lift truck to position ejector (4) on the truck body.
    Show/hide table

    Illustration 15	g00482037

17. Install one washer (3), pin (1), and cotter (2). Bend the cotters with pliers in order to retain the pin.

18. Lower the rock ejector between the tires. Check for adequate clearance on both sides of the rock ejector.

19. Repeat Step 16 through Step 18 on the remaining rock ejector.