793C Off-Highway Truck/Tractor Power Train Caterpillar

Installation Procedure

Note: During the installation procedure, inspect the O-ring seals. If necessary, replace the O-ring seals.

Note: Before the installation of the seals, use 1U-6396 O-Ring Assembly Compound to lubricate the seals.

Show/hide table

Illustration 1	g00517056

1. Install the hoist to support the transmission, the rear axle housing, and the wheel group assembly. Remove the chocks at the tires.

2. Use the jack under the rear frame bearing and chains at the rear frame bearing to move the rear frame bearing toward the crossmember.

3. Use the lift truck to move the group. Move the transmission, the rear axle housing, and the wheel group assembly toward the front of the truck. Reposition the hoist to support the rear frame bearing. The transmission, the rear axle housing, and the wheel group assembly weigh approximately 42000 kg (92594.04 lb).

4. Connect the rear frame bearing to the frame. Raise the front end of rear frame support (122) by approximately 75 mm (2.9 inch).

5. Install 12 washers and 12 bolts (121).

   Note: During the installation of bolts (121), do not reuse the bolts. Use new bolts. Before installation, apply 2P-2506 Thread Compound to the threads and the washers. Tighten the bolts to a torque of 545 ± 50 N·m (402 ± 37 lb ft). Then, turn the bolts by an extra 60° ± 5°.

   Show/hide table

   Illustration 2	g00517055

6. Use Tool (A) or (A1) to lower the rear end of the truck frame.

7. Raise the upper end of lateral control rod (120). Install pin (119)(not shown). Install retainer (118)(not shown), the washer, and bolt (117) (not shown). Support the weight of the lateral control rod. The lateral control rod weighs approximately 150 kg (330.7 lb).

8. Connect hose (116).

9. Position a suitable lift truck behind the differential housing. Use chains to secure the differential housing to the lift truck.

10. Install rear suspension cylinder (115). Use Tool (B) to replace the nitrogen charge in the rear suspension cylinders.
    Show/hide table

    Illustration 3	g00517051
    For Tooling (A)

11. Position Tool (A) under the hoist cylinder brackets. Support the rear of the truck. Use Tool (A) to lower the frame. The weight on Tool (A) is approximately 47000 kg (103617.1 lb).
    Show/hide table

    Illustration 4	g06406464
    For Tooling (A1)

12. Position Tool (A1) under the hoist cylinder brackets. Support the rear of the truck. Use Tool (A1) to lower the frame. The weight on Tool (A1) is approximately 47000 kg (103617.1 lb). Refer to Tool Operating Manual, NEHS1328, "Lift Group (Stand - 60 Ton)" for more information on Tooling (A1).
    Show/hide table

    Illustration 5	g00517050

13. Position the hose. Connect hose (112). Install split flange (111), four washers, and four bolts (110).

14. Repeat Step 13 for hoses (113) and (114).

15. Connect hose (107).

16. Install the two hoses and the bracket as an assembly. Install bracket (109), the washer, and bolt (108).
    Show/hide table

    Illustration 6	g00517049

17. Connect hose (104). Install split flange (103), four washers, and four bolts (102).

18. Connect hose (101). Install split flange (106), four washers, and four bolts (105).
    Show/hide table

    Illustration 7	g00517048

19. Position the hose. Connect the hose. Install split flange (100), four washers, and four bolts (99).
    Show/hide table

    Illustration 8	g00517047

20. Connect drive shaft (98). Install four bolts (97).
    Show/hide table

    Illustration 9	g00517045

21. Position the hoses. Install two spacers (93), plate (92), two bolts (90), clip (91), and two washers.

22. Install two clips (96), the washer, and bolt (95).

23. Install split flange (88), four washers, and four bolts (87).

24. Connect transmission output speed sensor (86) of the EPTC II.

25. Connect right rear brake oil temperature sensor (94).

26. Install rear drive shaft guard (89), nine washers, and nine bolts (85).
    Show/hide table

    Illustration 10	g00517040

    Show/hide table

    Illustration 11	g00517042

    Show/hide table

    Illustration 12	g00517044

27. Install six clips (70), six washers, and six bolts (69).

28. Connect electrical harness connection (84).

29. Connect clip (83), the washer, and bolt (82).

30. Connect hoses (78), (79), (80), and (81).

31. Connect the electrical harness connection to solenoid valve (75). Repeat this procedure for two remaining solenoid valves (76) and (77).

32. Install guard (74), two clips (73), four washers, and four bolts (72).

33. Connect transmission oil temperature sensor (71).

34. Connect hoses (67) and (68).
    Show/hide table

    Illustration 13	g00517038

35. Install four clips (63), four washers, and four bolts (62).

36. Position the hose. Connect hose (66). Install split flange (65), four washers, and four bolts (64).
    Show/hide table

    Illustration 14	g00517016

37. Install split flange (57), four washers, and four bolts (56).

38. Connect left rear brake oil temperature sensor (54) of VIMS.

39. Install clip (61), the washer, and bolt (60).

40. Connect hose (55). Install bolt (58), the washer, and split clamp (59).
    Show/hide table

    Illustration 15	g00517015

41. Install clip (53), the washer, and bolt (52).

42. Connect hose (50).

43. Install split clamp (49), the washer, and bolt (48).

44. Install clip (47), the washer, and bolt (46).

45. Install two split clamps (45), two washers, and two bolts (44).

46. Connect differential oil pressure sensor (43) of VIMS.

47. Connect differential oil temperature sensor (51) of VIMS.

48. Install four clips (42), four washers, and four bolts (41).
    Show/hide table

    Illustration 16	g00517014

49. Connect left wheel speed sensor (40) of the TCS.

50. Install two clips (39), two washers, and two bolts (38).
    Show/hide table

    Illustration 17	g00517013

51. Connect right wheel speed sensor (37) of the TCS.

52. Install two clips (36), two washers, and two bolts (35).
    Show/hide table

    Illustration 18	g00517009

    Show/hide table

    Illustration 19	g00529796

53. Install two clips (22), two washers, and two bolts (21).

54. Install clip (28), the washer, and bolt (27).

55. Connect oil level switch (30) of VIMS for the left differential.

56. Connect oil level switch (33) of VIMS for the right differential.

57. Connect the harness from bypass switch (32) of VIMS for the differential oil filter. Install two nuts (31).

58. Position lubrication injector banks (25) between the rear lamps. Install two clips (26), eight washers, and four bolts (24).

59. Install bolt (9), the washer, clip (10), and clip (11).

60. Install clip (8), the washer, and bolt (7).

61. Install clip (6), clip (5), the washer, and bolt (4).

62. Install clip (3), clip (2), the washer, and bolt (1).

63. Connect hose (23).

64. Install clip (15), clip (14), nut (13), the two washers, and bolt (12).

65. Install clamp (18), split clamp (17), the washer, and bolt (16).

66. Connect hoses (19) and (20).

67. Install hoses (29) and (34).

68. Refill the oil in the differential housing. The capacity of the differential housing is approximately 663 L (174.9 US gal).

69. Refill the oil in the transmission and torque converter system. The capacity of the transmission and torque converter system is approximately 227 L (59.9 US gal).

70. Refill the oil in the hoist and the brake tank. The capacity of the hoist and brake tank is approximately 1137 L (300.4 US gal).

End By:

1. Install the truck body.