Frame Replacement for the 793B and 793C Off-Highway Trucks{1353, 7000, 7000, 7051} Caterpillar

Frame Replacement for the 793B and 793C Off-Highway Trucks{1353, 7000, 7000, 7051}

Usage:

793B 1HL

Off-Highway Truck:: 793B (S/N: 1HL1-UP); 793C (S/N: 4AR1-217); 793C (S/N: 4AR218-UP; ATY1-UP; 4GZ1-UP)

Introduction

Refer to the beginning of the manual for 793B (S/N: 1HL1-UP) and early 793C S/N:4AR1-217. Refer to the ""Off-Highway Truck 793C (S/N: 4AR418-UP; 4GZ1-UP; ATY1-UP)" " title for the correct rework procedure for the other models listed.

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NOTICE

Refer to the safety portion of this manual regardless of the model being reworked.

This Special Instruction is intended for fabrication of the frame and replacement of the previous 793B and 793C models utilizing either 290-9814 Frame Gp or 290-9817 Frame Gp .

Do not perform any procedure in this publication until you understand all of the information. Do not order any parts until you understand all of the information in this publication. This Special Instruction is not all inclusive. Bosses are excluded. Optional attachments may change rework procedures. After reviewing this document, reference the frame that is being replaced in order to ensure that all of the necessary changes are completed. Also, verify dimensions prior to welding. 290-9814 Frame Gp and 290-9817 Frame Gp are fabricated with the 793D hardware, so existing parts may need to be relocated or removed in order to complete the special instruction.

Safety

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Do not attempt to assemble this machine until you read and you understand the assembly instructions.

Improper assembly procedures could result in injury or death.

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Accidental engine starting can cause injury or death to personnel working on the equipment.
To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system.

Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

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Personal injury or death can result from improper lifting or blocking.
When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component.

Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

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Sudden movement or accidental starting of the machine can cause personal injury or death to persons on or near the machine.
To prevent personal injury or death, perform the following:
Park the machine on a smooth level surface.
Lower the bucket and or attachments to the ground.
Stop the engine and engage the parking brake.
Block the wheels and install the steering frame lock.
Turn the battery disconnect switch to the OFF position and remove the key.

Place a Special Instruction, SEHS7332, "Do Not Operate" tag at the battery disconnect switch location to inform personnel that the machine is being worked on.

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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 work tools have been lowered to the ground, and the 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 allow any dirt or foreign material to get into the hydraulic system during assembly, connection of lines, when components are filled with fluid, or during any maintenance operation.

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Note: Refer to Special Instruction, REHS1841-02, "General Welding Procedures" for proper welding procedures.

Note: Cleanliness is an important factor. Before the removal procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.

Note: Put identification marks on all hose assemblies and on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies. This will help to prevent fluid loss and this helps to prevent contaminants from entering the system.

Note: Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Required Parts

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Table 1
Qty	Part Number	Part Description
1	290-9814	Frame Gp
1	101-8962 ⁽¹⁾	Bracket As
1	106-7395 ⁽¹⁾	Plate As
2	107-1851	Blocks
2	107-2572	Plates
1	107-2679	Pedestal Assembly
1	107-2680	Pedestal Assembly
1	107-2680	Pedestal Assembly
1	107-4886	Plate
1	107-4887	Plate
4	116-7144 ⁽¹⁾	Plates
2	116-7145 ⁽¹⁾	Blocks
1	130-6397	Block
2	8X-0388	Plates
2	8X-0389	Plates
2	8X-0390	Plates
1	8X-2772	Plate As
2	8X-2773	Plates
1	8X-3800	Plate
4	8X-5933 ⁽¹⁾	Bracket As
1	8X-5934 ⁽¹⁾ ⁽²⁾	Bracket As
1	8X-5935	Bracket As
1	8X-5937 ⁽¹⁾	Plate As
1	8X-5938 ⁽¹⁾ ⁽²⁾	Plate As
2	8X-5941 ⁽¹⁾	Blocks
1	8X-5943 ⁽²⁾	Plate
1	8X-5947 ⁽¹⁾ ⁽²⁾	Plate
2	8X-5948 ⁽¹⁾ ⁽²⁾	Blocks
1	8X-5950 ⁽¹⁾	Bracket
1	8X-5954 ⁽¹⁾	Plate
1	8X-5955 ⁽¹⁾	Gusset
1	8X-5956 ⁽¹⁾ ⁽²⁾	Block
1	8X-5957 ⁽¹⁾	Block
4	8X-5958 ⁽¹⁾	Plates
2	8X-5959 ⁽¹⁾	Plates
2	8X-5960 ⁽¹⁾	Plates
3	8X-5966 ⁽¹⁾	Blocks
1	8X-5975 ⁽¹⁾	Block
1	8X-5980 ⁽¹⁾	Plate As
1	8X-6100 ⁽¹⁾	Bracket As
1	8X-6101 ⁽¹⁾	Bracket As
1	8X-6103 ⁽¹⁾	Block
2	8X-6196	Blocks
2	8X-6327 ⁽¹⁾	Lugs
2	8X-6757	Plates
4	8X-6758	Gussets
1	8X-7195	Plate
2	8X-7238	Blocks
1	8X-7853	Block
1	8X-8442	Plate As
1	8X-9614 ⁽¹⁾ ⁽²⁾	Block
2	6S-8014	Rings
2	8X-0396	Pipe Assembly
3	8X-5940	Blocks
2	8X-8324	Angles
1	101-6996	Plate
1	102-9162	Plate
4	118-0652	Plates
1	124-4378	Plate
1	130-5686	Plate
1	6N-5451	Gusset
1	7D-5254 ⁽¹⁾	Angle
1	8X-1985	Plate
1	8X-4421	Bars
1	8X-4576	Plate
1	8X-5932 ⁽¹⁾	Bracket As
2	8X-5946 ⁽¹⁾	Plates
1	8X-5953 ⁽¹⁾	Plate
1	8X-6106 ⁽¹⁾	Plate
1	8X-6107 ⁽¹⁾	Plate
1	8X-6110	Block

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^( 1 )	793B S/N:1HL only
^( 2 )	Located on the torque tube

Removal Procedure

Refer to the Disassemble and Assemble manual and the Field Installation Special Instruction for information regarding the disassembly process of the truck.

Installation of the Radiator Mounting Bracket

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Table 2
Parts Needed
Item	Qty	Part Number	Description
1	1	290-9814	Frame Gp
2	2	107-2572	Plates
3	2	8X-0388	Plate
4	2	8X-0389	Plates
5	2	8X-0390	Plates
6	2	8X-8324	Angles
7	2	8X-0396	Pipe Assembly
8	2	6S-8014	Rings
9	1	8X-7195	Plates
10	2	8X-6757	Plates
11	4	8X-6758	Gussets

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Table 3
Welding Specifications
Item	Description
W1	3 mm (0.1 inch) square groove weld
W2	6 mm (0.2 inch) bevel groove weld
W3	10 mm (0.4 inch) fillet weld with a required penetration of 1.5 mm (0.06 inch)
W4	6 mm (0.2362 inch) fillet weld with a required penetration of 1.5 mm (0.06 inch)
W5	8 mm (0.3 inch) fillet weld with a required penetration of 1.5 mm (0.06 inch)
W6	8 mm (0.3 inch) bevel groove weld
W7	8 mm (0.3 inch) fillet weld with a required penetration of 1.5 mm (0.06 inch)
W8	8 mm (0.3 inch) bevel groove weld in two places
W9	6 mm (0.2 inch) fillet weld with a required penetration of 1.5 mm (0.06 inch)
W10	6 mm (0.2 inch) fillet weld on both sides with a required penetration of 1.5 mm (0.06 inch)
W11	6 mm (0.2 inch) fillet weld all around with a penetration of 1.5 mm (0.06 inch)
W12	6 mm (0.2 inch) fillet weld with a required penetration of 1.5 mm (0.06 inch)
W13	6 mm (0.2 inch) fillet weld with a required penetration of 1.5 mm (0.06 inch)
W14	6 mm (0.2 inch) with a required penetration of 1.5 mm (0.06 inch)
W15	6 mm (0.2 inch) with a required penetration of 1.5 mm (0.06 inch)
W16	5 mm (0.2 inch)
W17	10 mm (0.4 inch) fillet weld with a required penetration of 1.5 mm (0.06 inch)
W18	10 mm (0.4 inch) fillet weld on both sides with a required penetration of 1.5 mm (0.06 inch)

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Illustration 1	g01351275

Frame (1) is fabricated in order to replace the worn 793B frame.

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Illustration 2	g01342933

Weld two plates (2) to the radiator support group.
(A) ... 10 ± 3 mm (0.4 ± 0.1 inch)

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Illustration 3	g01379944
Outside LH view (B) 12 ± 5 mm (0.5 ± 0.2 inch)

Locate and weld plate (3) .

Locate and weld two plates (4) .

Locate and weld one plate (5) .
Note: Repeat Steps 4, 5 and 6 in order to install plates (3), (4) and (5) on the other side of the truck.

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Illustration 4	g01351325
Front view

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Illustration 5	g01343145
LH side view

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Illustration 6	g01390709
Top view

Use a suitable lifting device in order to position the radiator supports to the frame assembly.
Note: Each radiator support weighs approximately 171 kg (377 lb).
(C) ... 2532 ± 3 mm (99.7 ± 0.1 inch)
(D) ... 2815 ± 3 mm (110.8 ± 0.1 inch)
(E) ... 758.6 ± 3 mm (29.87 ± 0.12 inch)
(F) ... 101 ± 3 mm (4 ± 0.1 inch)
(G) ... 630.2 ± 5 mm (24.81 ± 0.20 inch)
(H) ... 2300 ± 5 mm (90.6 ± 0.2 inch)

Weld the radiator supports to the frame assembly.

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Illustration 7	g01351530
LH front view

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Illustration 8	g01351805
Outside LH view

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Illustration 9	g01390567
View A-A

Locate and weld two angles (6), two pipe assemblies (7) and two rings (8) .

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Illustration 10	g01367202

Locate and weld plate (9) .
(J) ... 15 ± 5 mm (0.6 ± 0.2 inch)
(K) ... 60 ± 5 mm (2.4 ± 0.2 inch)

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Illustration 11	g01351593
Top view of the frame

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Illustration 12	g01353680
Front view

Locate and weld the supports to the frame assembly. The supports are made up of two plates (10) and four gussets (11) .
(C) ... 2532 ± 3 mm (99.7 ± 0.1 inch)
(D) ... 2815 ± 3 mm (110.8 ± 0.1 inch)
(E) ... 758.6 ± 3 mm (29.87 ± 0.12 inch)
(F) ... 101 ± 3 mm (4 ± 0.1 inch)
(G) ... 630.2 ± 5 mm (24.81 ± 0.20 inch)
(L) ... 2815 ± 4 mm (110.8 ± 0.2 inch)
(M) ... 2300 ± 5 mm (90.6 ± 0.5 inch)
(N) ... 1486.5 ± 3 mm (58.52 ± 0.12 inch)

Installation of Light Structures

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Table 4
Parts Needed
Item	Qty	Part Number	Description
1	1	8X-5935	Bracket As ⁽¹⁾ only
2	1	8X-5937	Plate As ⁽²⁾
3	2	8X-5959	Plates ⁽²⁾
4	4	8X-5958	Plates ⁽²⁾
5	1	8X-6101	Bracket As ⁽²⁾
6	1	8X-6100	Bracket As ⁽²⁾
7	1	106-7395	Plate As ⁽²⁾
8	1	8X-2772	Plate As ⁽²⁾

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^( 1 )	793B S/N:1HL 793C S/N:4AR1-217
^( 2 )	793B S/N:1HLonly

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Table 5
Welding Specifications
Item	Description
W1	6 mm (0.24 inch) fillet weld with a required penetration of 1.5 mm (0.06 inch)
W2	6 mm (0.24 inch) fillet weld with a required penetration of 1.5 mm (0.06 inch)
W3	6 mm (0.24 inch) fillet weld with a required penetration of 1.5 mm (0.06 inch)
W4	6 mm (0.24inch) fillet weld with a required penetration of 1.5 mm (0.06 inch)
W5	6 mm (0.24inch) fillet weld with a required penetration of 1.5 mm (0.06 inch)
W6	8 mm (0.32 inch) fillet weld with a required penetration of 1.5 mm (0.06 inch)
W7	14 mm (0.6 inch) fillet weld with a required penetration of 1.5 mm (0.06 inch)
W8	5 mm (0.2 inch) bevel groove weld on both sides with a required length of 25 mm (1 inch) to 100 mm (3.9 inch)

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Illustration 13	g01341784

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Illustration 14	g01401276
Inside RH frame view

Note: Remember to prepare the material properly before installing any items. The preparation includes the removal of dirt, paint, oil or any other substance that will cause problems with the installation process. To properly prepare material refer to Special Instruction, REHS1841-02, "General Welding Procedures".

Locate and weld bracket assembly (1) .
(A) ... 802 ± 5 mm (31.6 ± 0.2 inch)
(B) ... 303 ± 3 mm (11.91 ± 0.1 inch)

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Illustration 15	g01401338
(2) Plate As (C) 1017 ± 2 mm (40.04 ± 0.08 inch)

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Illustration 16	g01342110

Locate and weld plate assembly (2) to the hoist tube.
Note: Step 2 refers to 793B S/N:1HL. Later models have a 793D hoist valve mount that is previously installed.

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Illustration 17	g01342323
Front view (D) 1915 ± 3 mm (75.39 ± 0.12 inch) (E) 1162.4 ± 3 mm (45.76 ± 0.12 inch) (F) 581.2 ± 5 mm (22.88 ± 0.20 inch) (G) 1274.3 ± 3 mm (50.17 ± 0.12 inch)

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Illustration 18	g01342626
LH view (H) 128 ± 3 mm (5.04 ± 0.12 inch) (J) 19 ± 3 mm (0.75 ± 0.12 inch) (K) 27 ± 5 mm (1.06 ± 0.20 inch)

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Illustration 19	g01397191
RH view (L) 128 ± 3 mm (5.04 ± 0.12 inch) (M) 19 ± 3 mm (0.75 ± 0.12 inch) (N) 27 ± 5 mm (1.06 ± 0.20 inch)

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Illustration 20	g01342854
View of the plates that are installed

Locate and weld one plate (3) to two plates (4) .
Refer to Illustrations 18, 19 and 20 in order to position plates (3) and plates (4) .

Locate and weld plate assembly (3) and (4) to the frame assembly.
Note: Repeat Steps 3 and 4 for the other side of the truck.

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Illustration 21	g01373249
Top LH view of rear corner (P) 393.8 ± 3 mm (15.50 ± 0.12 inch) (R) 81.5 ± 3 mm (3.21 ± 0.12 inch) (S) 111.9 ± 3 mm (4.41 ± 0.12 inch) (T) 46 ± 3 mm (1.8 ± 0.1 inch)

Locate and weld bracket assembly (5).

Locate and weld bracket assembly (6) .

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Illustration 22	g01367554
Inside LH frame view (U) 463 ± 5 mm (18.23 ± 0.20 inch) (V) 72 ± 5 mm (2.83 ± 0.20 inch)

Locate and weld plate assembly (7) .
.
Note: Step 7 refers only to 793B S/N:1HL.

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Illustration 23	g01401361
Top view

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Illustration 24	g01355420
Side view

Locate and weld plate assembly (8) .

Torque Tube Fabrication

Note: The Torque Tube Fabrication applies only to 793B S/N:1HL trucks.

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Table 6
Parts Needed
Item	Qty	Part Number	Description
1	1	8X-5934	Bracket As
2	1	8X-5956	Block
3	1	8X-5938	Plate As
4	1	8X-5947	Plate
5	1	8X-5943	Plate
6	1	8X-9614	Block

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Table 7
Welding Specifications
Item	Description
W1	6 mm (0.2362 inch) bevel weld
W2	6 mm (0.2362 inch) with a fillet weld with a required penetration of 1.5 mm (0.06 inch)
W3	6 mm (0.2362 inch) with a fillet weld on both sides with a required penetration of 1.5 mm (0.06 inch)
W4	6 mm (0.2362 inch) with a fillet weld all around with a required penetration of 1.5 mm (0.06 inch)
W5	6 mm (0.2362 inch) with a fillet weld all around with a required penetration of 1.5 mm (0.06 inch)
W6	5 mm (0.20 inch) fillet weld on both sides

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Illustration 25	g01367975

Locate and weld bracket assembly (1) .
(A) ... 563.4 ± 3 mm (22.18 ± 0.12 inch)
Note: Dimension (A) is measured from the centerline of the frame. Refer to Illustration 23.

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Illustration 26	g01368091
View A-A

Locate and weld block (2) .
(B) ... 35.5 degrees ± 1 degree

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Illustration 27	g01368833
View A-A

Locate and weld plate assembly (3) .
(C) ... 199.7 ± 3 mm (7.86 ± 0.12 inch)
(D) ... 255.2 ± 3 mm (10.05 ± 0.12 inch)

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Illustration 28	g01368339
View B-B

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Illustration 29	g01368515
Front view

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Illustration 30	g01390776
View C-C

Locate and weld plate (4). Locate and weld plate (5) .
(E) ... 50 degrees ± 1
Note: The angle is measured from the Datum 02.
(F) ... 12 mm (0.5 inch)
(G) ... 19.9 ± 3 mm (0.78 ± 0.12 inch)
Note: The measurement is taken from Datum 02.
(H) ... 139.7 ± 3 mm (5.50 ± 0.12 inch)
(J) ... 603.3 ± 3 mm (23.75 ± 0.12 inch)
Note: Datum 01 is the center of the torque tube assembly. The measured distance is from the center of the torque tube assembly. Refer to Illustration 29.

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Illustration 31	g01368579
Front view (K) 35.5 ± 3 mm (1.40 ± 0.12 inch)

Locate and weld block (6) .
Note: Datum 01 is the centerline of the torque tube. The centerline of block (6) is also on the centerline of the torque tube.

Miscellaneous Installations

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Table 8
Parts Needed
Item	Qty	Part Number	Description
1	1	8X-5980 ⁽¹⁾	Plate As
2	1	8X-5975 ⁽¹⁾	Block
3	2	8X-7238	Blocks
4	4	116-7144 ⁽¹⁾	Plates
5	2	116-7145 ⁽¹⁾	Blocks
6	4	8X-5933 ⁽¹⁾	Bracket As
7	2	8X-2773	Plates
8	1	8X-8442	Plate As
9	2	8X-5941 ⁽¹⁾	Blocks
10	1	130-6397	Block
11	1	8X-5957 ⁽¹⁾	Block
12	1	8X-6103 ⁽¹⁾	Block
13	1	107-4886	Plate
14	2	8X-5960 ⁽¹⁾	Plates
15	3	8X-5966 ⁽¹⁾	Blocks
16	1	7D-5254 ⁽¹⁾	Angle
17	1	102-9162	Plate
18	4	118-0652	Plates
19	1	124-4378	Plate
20	2	8X-4421	Bars
21	1	101-6996	Plate
22	1	8X-4576	Plate
23	1	8X-1985	Plate
24	1	8X-5953 ⁽¹⁾	Plate
25	2	8X-5946 ⁽¹⁾	Plates
26	1	8X-5932 ⁽¹⁾	Bracket As
27	1	8X-6107 ⁽¹⁾	Plate
28	1	8X-6110	Block
29	1	8X-6106 ⁽¹⁾	Plate
30	1	6N-5451	Gusset
31	1	130-5686	Plate

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^( 1 )

Applies only to 793B S/N:1HL

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Table 9
Welding Specifications
Item	Description
W1	5 mm (0.20 inch) fillet weld
W2	6 mm (0.24inch) fillet weld on both sides with a required penetration of 1.5 mm (0.06 inch)
W3	8 mm (0.32 inch) fillet weld on both sides with a required penetration of 1.5 mm (0.06 inch)
W4	6 mm (0.24inch) fillet weld with a required penetration of 1.5 mm (0.06 inch)
W5	6 mm (0.24inch) fillet weld with a required penetration of 1.5 mm (0.06 inch)
W6	5 mm (0.20 inch) fillet weld on both sides
W7	5 mm (0.20 inch) fillet weld on both sides
W8	6 mm (0.24inch) fillet weld with a required penetration of 1.5 mm (0.06 inch)
W9	6 mm (0.24inch) fillet weld with a required penetration of 1.5 mm (0.06 inch)
W10	6 mm (0.24inch) fillet weld on both sides with a required penetration of 1.5 mm (0.06 inch)
W11	6 mm (0.24inch) fillet weld all around with a required penetration of 1.5 mm (0.06 inch)
W12	5 mm (0.20 inch) with a required weld length of 25 mm (0.98 inch) to 100 mm (3.94 inch)
W13	6 mm (0.24inch) fillet weld all around with a required penetration of 1.5 mm (0.06 inch)
W14	6 mm (0.24inch) fillet weld with a required penetration of 1.5 mm (0.06 inch)
W15	5 mm (0.20 inch) fillet weld on both sides
W16	5 mm (0.2 inch) fillet weld on both sides
W17	6 mm (0.24inch) with a required weld length of 25 mm (1 inch) to 75 mm (3 inch)
W18	6 mm (0.24 inch) fillet weld on both sides with a required penetration of 1.5 mm (0.06 inch)
W19	6 mm (0.24 inch) fillet weld on both sides with a required penetration of 1.5 mm (0.06 inch)
W20	8 mm (0.32 inch) fillet weld with a required penetration of 1.5 mm (0.06 inch) in four places
W21	6 mm (0.24inch) fillet weld all around with a required penetration of 1.5 mm (0.06 inch)
W22	6 mm (0.24inch) fillet weld all around with a required penetration of 1.5 mm (0.06 inch)
W23	6 mm (0.24inch) fillet weld with a required penetration of 1.5 mm (0.06 inch)
W24	6 mm (0.24inch) fillet weld all around with a required penetration of 1.5 mm (0.06 inch)
W25	6 mm (0.24 inch) fillet weld on both sides with a required penetration of 1.5 mm (0.06 inch)
W26	6 mm (0.24inch) fillet weld all around with a required penetration of 1.5 mm (0.06 inch)
W27	6 mm (0.24 inch) fillet weld on both sides with a required penetration of 1.5 mm (0.06 inch)
W28	8 mm (0.32 inch) fillet weld on both sides with a required penetration of 1.5 mm (0.06 inch)

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Illustration 32	g01401364
Front view of strut area

Use the table below in order to correctly position plate assembly (1) to the frame for your particular truck.

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Table 10
793B S/N:1HL		793C S/N:4AR1-217
Detail	Measured Distance	Detail	Measured Distance
A	164 ± 5 mm (6.46 ± 0.2 inch)	A	275 ± 5 mm (10.8 ± 0.2 inch)
B	610 ± 5 mm (24.0 ± 0.2 inch)	B	725 ± 5 mm (28.5 ± 0.2 inch)

Note: Refer to Illustration 32.

Weld plate assembly (1) to the frame.

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Illustration 33	g01368889
Inside LH frame view (C) 619 ± 3 mm (24.40 ± 0.12 inch) (D) 92 ± 3 mm (3.60 ± 0.12 inch)

Locate and weld block (2) .

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NOTICE

Before proceding to Step 4 refer to Illustration 34 or Illustration 35 for your particular truck.

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Illustration 34	g01368905
Outside LH frame view of 793B S/N:1HL trucks (E) 200 ± 3 mm (7.90 ± 0.12 inch) (F) 170 ± 5 mm (6.70 ± 0.20 inch) (G) 33 ± 5 mm (1.30 ± 0.20 inch)

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Illustration 35	g01386266
Outside LH frame view of 793C S/N:4AR1-217 trucks (H) 43 ± 5 mm (1.7 ± 0.2 inch) (J) 200 ± 3 mm (7.9 ± 0.1 inch) (K) 201 ± 5 mm (7.9 ± 0.2 inch)

Locate and weld two blocks (3) .
Note: Use Illustration 34 or Illustration 35 for your particular truck.

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Illustration 36	g01381707
View of outside LH frame view (L) 342 ± 3 mm (13.5 ± 0.1 inch) (M) 817 ± 3 mm (32.2 ± 0.1 inch)

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Illustration 37	g01369169
Frame view of outside LH and outside RH (N) 356 ± 3 mm (14.0 ± 0.1 inch) (P) 563 ± 5 mm (22.2 ± 0.2 inch)

Locate and weld four plates (4). Locate and weld two blocks (5) .
Note: Measurement (L) in Illustration 36 is needed for both sides.

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Illustration 38	g01370275
Outside LH frame view

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Illustration 39	g01390277

Locate and weld four bracket assemblies (6) .
(R) ... 81 ± 3 mm (3.2 ± 0.1 inch)
(S) ... 278 ± 5 mm (10.9 ± 0.2 inch)
(T) ... 689 ± 5 mm (27.1 ± 0.2 inch)
(U) ... 689 ± 5 mm (27.1 ± 0.2 inch)
(V) ... 82 ± 3 mm (3.2 ± 0.1 inch)
(W) ... 50 mm (2.0 inch)
Note: Do not weld four brackets (6) in area (W). Refer to Illustration 39 to view area (W) .
(X) ... 457 ± 5 mm (18.0 ± 0.2 inch)

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Illustration 40	g01370370
The left illustration is the RH front view The right illustration is the outside LH frame view (Y) 102 ± 3 mm (4.02 ± 0.12 inch) (Z) 3 ± 1 mm (0.12 ± 0.04 inch)

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Illustration 41	g01393425
Front view

Locate and weld two plates (7) .
Note: Install each plate (7) at the front locations of the frame.

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Illustration 42	g01370652
LH front view (AA) 40 ± 1 mm (1.60 ± 0.04 inch)

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Illustration 43	g01397426
Outside LH view (AB) 345 ± 1.5 mm (13.60 ± 0.06 inch)

Locate and weld plate assembly (8) .

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Illustration 44	g01370796
Inside LH frame view (AC) 619 ± 3 mm (24.40 ± 0.12 inch) (AD) 460 ± 3 mm (18.11 ± 0.12 inch) (AE) 92 ± 3 mm (3.60 ± 0.12 inch)

Locate and weld two blocks (9) .

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Illustration 45	g01386279
Inside RH frame view (AF) 108 ± 2 mm (4.25 ± 0.08 inch) (AG) 20 ± 2 mm (0.79 ± 0.08 inch) (AH) 65 ± 5 mm (2.56 ± 0.20 inch)

Locate and weld block (10) .

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Illustration 46	g01371057
Inside LH frame view (AJ) 180 ± 5 mm (7.09 ± 0.20 inch) (AK) 308 ± 5 mm (12.13 ± 0.20 inch)

Locate and weld block (11) .

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Illustration 47	g01373980
Inside LH frame view (AL) 425 ± 5 mm (16.7 ± 0.2 inch) (AM) 230 ± 5 mm (9.1 ± 0.2 inch) (AN) 157 ± 5 mm (6.2 ± 0.2 inch)

Locate and weld block (12) .

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Illustration 48	g01382718
Illustration 48 applies to 793B S/N:1HL trucks only Outside LH frame view (AP) 209 ± 3 mm (8.2 ± 0.1 inch)

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Illustration 49	g01386286
Illustration 49 applies to 793C S/N:4AR1-217 trucks only Outside LH frame view (AR) 40 ± 5 mm (1.6 ± 0.2 inch)

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Illustration 50	g01386296
Illustration 50 applies to 793B S/N:1HL and 793 C S/N:4AR1-217 trucks Outside LH frame view (AS) 617.5 ± 5 mm (24.31 ± 0.20 inch)

Locate and weld plate (13) .

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Illustration 51	g01371207
Inside LH frame view (AT) 316 ± 5 mm (12.44 ± 0.20 inch) (AU) 126 ± 3 mm (5 ± 0.12 inch) (AV) 58 ± 5 mm (2.3 ± 0.2 inch)

Locate and weld two plates (14) .

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Illustration 52	g01401375
Inside LH frame view (AW) 330 ± 3 mm (13.0 ± 0.1 inch) (AX) 750 ± 3 mm (29.5 ± 0.12 inch) (AY) 430 ± 3 mm (17.0 ± 0.1 inch) (AZ) 166 ± 5 mm (6.5 ± 0.2 inch) (BA) 414 ± 5 mm (16.3 ± 0.2 inch) (BB) 305 ± 5 mm (12.0 ± 0.2 inch)

Locate and weld three blocks (15) .
Note: Only weld the end of block (15) as shown in Illustration 52. There are three blocks to weld onto the frame.
Note: On the new frame there will be blocks in the locations where block (15) needs to be installed. Replace the current block with block (15) .

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Illustration 53	g01401425
Inside LH frame view (BC) 229 ± 5 mm (9.0 ± 0.2 inch) (BD) 92 ± 5 mm (3.6 ± 0.2 inch)

Locate and weld angle (16) .

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Illustration 54	g01386349
Inside LH frame view (BE) 410 ± 3 mm (16.1 ± 0.1 inch) (BF) 84 ± 3 mm (3.3 ± 0.1 inch)

Locate and weld plate (17) .

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Illustration 55	g01401434
Inside LH frame view (BG) 24 ± 3 mm (0.9 ± 0.1 inch)

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Illustration 56	g01376089
View B-B (BH) 256 ± 2 mm (10.1± 0.1 inch) (BJ) 104 ± 5 mm (4.1± 0.2 inch)

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Illustration 57	g01386373
Inside RH frame view Illustration 57 applies to 793B S/N:1HL trucks (BK) 200 ± 5 mm (7.9 ± 0.2 inch) (BL) 256 ± 2 mm (10.1 ± 0.1 inch)

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Illustration 58	g01386375
Inside RH frame view Illustration 58 applies to 793C S/N:4AR1-217 trucks (BM) 100 ± 5 mm (3.9 ± 0.2 inch) (BN) 256 ± 1.5 mm (10.08 ± 0.06 inch) (BP) 750 ± 5 mm (29.5 ± 0.2 inch)

Locate and weld two plates (18) .
Note: Ilustrations 57 and 58 apply to Step 18. Select the appropriate Illustration for your particular truck.

Repeat Step 18 for the other side of the frame.

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Illustration 59	g01382585
Front view of strut area (BR) 541 ± 5 mm (21.3 ± 0.2 inch). This measurement applies to 793 B S/N:1HL. (BS) 294 ± 5 mm (11.6 ± 0.2 inch). This measurement applies to 793 BS/N:1HL. (BR ) 472 ± 5 mm (18.6 ± 0.2 inch).This measurement applies to 793 CS/N:4AR1-217. (BS) 100 ± 5 mm (3.9 ± 0.2 inch). This measurement applies to 793 C S/N:4AR1-217.

Locate and weld plate (19) .

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Illustration 60	g01386433
Top view of frame (BT) 894 ± 5 mm (35.2 ± 0.2 inch) (BU) 547 ± 3 mm (21.5 ± 0.1 inch)

Locate and weld two bars (20) .

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Illustration 61	g01401491
Outside RH frame view (BV) 1729 ± 3 mm (68.1 ± 0.1 inch)

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Illustration 62	g01401502
Top view of frame (BW) 194 ± 1mm (7.60 ± 0.04 inch)

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Illustration 63	g01386631
View of Plate (21), Plate (22), and Plate (23) assembled (BX) 8 ± 2 mm (0.32 ± 0.08 inch)

Locate and weld plate (21) .

Locate and weld plate (22) .

Locate and weld plate (23) .

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Illustration 64	g01375230
Outside LH frame view (BY) 358 ± 3 mm (14.1 ± 0.1 inch) (BZ) 86 ± 3 mm (3.3858 ± 0.1181 inch)

Locate and weld plate (24) .

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Illustration 65	g01375248
Outside RH frame view (CA) 225 ± 3 mm (8.9 ± 0.1 inch) (CB) 935 ± 5 mm (36.8 ± 0.2 inch) (CC) 1262 ± 5 mm (49.7 ± 0.2 inch)

Locate and weld two plates (25) .

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Illustration 66	g01375267
Outside RH frame view (CD) 98 ± 3 mm (3.9 ± 0.1 inch) (CE) 60 mm (2.4 inch) (CF) 689 ± 5 mm (27.1 ± 0.2 inch)

Locate and weld bracket assembly (26) .

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Illustration 67	g01391784
Inside LH frame view

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Illustration 68	g01375269
Inside LH frame view (CG) 4454 ± 5 mm (175.4 ± 0.2 inch) from Datum 01 (CH) 308 ± 5 mm (12.1 ± 0.2 inch) (CJ) 180 ± 5 mm (7.1 ± 0.2 inch)

Note: Refer to Illustration 67.

Locate and weld plate (27) .

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Illustration 69	g01377751
Illustration 69 applies to 793BS/N:1HL trucks only Inside LH frame view (CK) 229 ± 5 mm (9.02 ± 0.20 inch) (CL) 274 ± 5 mm (10.8 ± 0.2 inch)

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Illustration 70	g01386761
Inside view of the RH frame Illustration 70 applies to 793C S/N:4AR1-217 trucks only. (CK) 436 ± 5 mm (17.2 ± 0.2 inch) (CL) 86 ± 5 mm (3.4 ± 0.2 inch)

Locate and weld block (28) .
Note: Illustrations 69 and 70 apply to Step 29. Select the appropriate illustration for your particular truck.

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Illustration 71	g01375274
Inside LH frame view (CM) 1180 ± 5 mm (46.5± 0.2 inch) (CN) 386 ± 5 mm (15.2 ± 0.2 inch)

Locate and weld plate (29) .

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Illustration 72	g01386771
Inside RH frame view (CP) 101 ± 5 mm (4.0 ± 0.2 inch)

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Illustration 73	g01391814
View C-C (CR) 35 ± 2 mm (1.4 ± 0.1 inch)

Locate and weld gusset (30 ). Locate and weld plate (31) .

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Illustration 74	g01386798
Inside RH frame view (CS) 302.2 ± 5 mm (11.90 ± 0.20 inch) (CT) 335 ± 2 mm (13.2 ± 0.1 inch) (CU) 372 ± 5 mm (14.6 ± 0.2 inch)

Locate and weld two lugs (32) .

793 Off-Highway Truck Frame Replacement 793C (S/N: 4AR218-UP; 4GZ; ATY)

Note: This instruction applies only to the off-highway trucks listed above.

Removal Procedure

Refer to the Disassemble and Assemble manual and the Field Installation Special Instruction for information regarding the disassembley process of the truck.

Required Parts

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Table 11
Qty	Part Number	Part Description
1	290-9817 ⁽¹⁾ ⁽²⁾	Frame Gp
2	107-1851 ⁽¹⁾ ⁽²⁾	Blocks
1	107-4886 ⁽¹⁾ ⁽²⁾	Plate
1	107-4887 ⁽¹⁾ ⁽²⁾	Plate
1	130-6397 ⁽¹⁾ ⁽²⁾	Block
1	8X-2772 ⁽¹⁾ ⁽²⁾ ⁽³⁾	Plate As
1	8X-5935 ⁽¹⁾ ⁽²⁾ ⁽³⁾	Bracket As
1	8X-5980 ⁽¹⁾	Plate As
2	8X-6327 ⁽¹⁾ ⁽²⁾	Lugs
2	8X-7238 ⁽³⁾	Blocks
1	8X-7853 ⁽¹⁾ ⁽²⁾ ⁽³⁾	Block
1	101-6996 ⁽²⁾ ⁽³⁾	Plate
1	102-9162 ⁽³⁾	Plate
4	118-0652 ⁽³⁾	Plates
1	130-5686 ⁽¹⁾ ⁽²⁾ ⁽³⁾	Plate
1	6N-5451 ⁽¹⁾ ⁽²⁾ ⁽³⁾	Gusset
1	8X-1985 ⁽¹⁾ ⁽²⁾ ⁽³⁾	Plate
2	8X-4421 ⁽¹⁾ ⁽²⁾ ⁽³⁾	Bars
1	8X-6110 ⁽¹⁾ ⁽²⁾ ⁽³⁾	Block

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^( 1 )	Applies to 793C S/N:ATY1-UP
^( 2 )	Applies to 793C S/N:4GZ1-UP
^( 3 )	Applies to 793C S/N:4AR218-UP

Light Structure Installation

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Table 12
Parts Needed
Item	Qty	Part Number	Description
1	1	8X-5935 ⁽¹⁾ ⁽²⁾ ⁽³⁾	Bracket As
2	1	8X-2772 ⁽¹⁾ ⁽²⁾ ⁽³⁾	Plate As

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Table 13
Welding Specifications
Item	Description
W1	6 mm (0.2362 inch) fillet weld with a required penetration of 1.5 mm (0.06 inch)
W2	5 mm (0.2 inch) fillet weld with a required length of 25 mm (1.0 inch) to 100 mm (3.9 inch)
W3	14 mm (0.6 inch) fillet weld with a required penetration of 1.5 mm (0.06 inch)

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Illustration 75	g01341784

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Illustration 76	g01401523
Inside RH frame view

Note: Remember to prepare the material properly before installing any items. the preparation includes the removal of dirt, paint, oil or any other substance that will cause problems with the installation process. To properly prepare material refer to Special Instruction, REHS1841-02, "General Welding Procedures".

Install bracket assembly (1) .
(A) ... 802 ± 5 mm (31.6 ± 0.2 inch)
(B) ... 303 ± 3 mm (11.9 ± 0.1 inch)

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Illustration 77	g01401527
Top frame view

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Illustration 78	g01385120
Side view of Plate As (2) (C) 2 ± 3 mm (0.1 ± 0.1 inch)

Locate and weld plate assembly (2) .
Note: Position the centerline of plate assembly (2) to the centerline of the bumper.

Miscellaneous Installations

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Table 14
Parts Needed
Item	Qty	Part Number	Description
1	1	8X-5980 ⁽¹⁾	Plate As
2	2	8X-7238 ⁽²⁾	Blocks
3	1	130-6397 ⁽¹⁾ ⁽²⁾ ⁽³⁾	Block
4	1	107-4886 ⁽¹⁾ ⁽²⁾ ⁽³⁾	Plate
5	1	102-9162 ⁽²⁾	Plate
6	4	118-0652 ⁽²⁾	Plates
7	2	8X-4421 ⁽¹⁾ ⁽²⁾ ⁽³⁾	Bars
8	1	101-6996 ⁽²⁾ ⁽³⁾	Plate
9	1	8X-4576 ⁽¹⁾ ⁽²⁾ ⁽³⁾	Plate
10	1	8X-1985 ⁽¹⁾ ⁽²⁾ ⁽³⁾	Plate
11	1	8X-6110 ⁽¹⁾ ⁽²⁾ ⁽³⁾	Block
12	2	6N-5451 ⁽¹⁾ ⁽²⁾ ⁽³⁾	Gussets
13	1	130-5686 ⁽¹⁾ ⁽²⁾ ⁽³⁾	Plate
14	2	8X-6327 ⁽¹⁾ ⁽³⁾	Lugs

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^( 1 )	Applies to 793C S/N:ATY1-UP
^( 2 )	Applies to 793C (S/N: 4AR218-UP)
^( 3 )	Applis to 793C S/N:4GZ1-UP

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Table 15
Welding Specifications
Item	Description
W1	5 mm (0.20 inch) fillet weld
W2	8 mm (0.32 inch) fillet weld on both sides with a required penetration of 1.5 mm (0.06 inch)
W3	6 mm (0.24inch) fillet weld with a required penetration of 1.5 mm (0.06 inch)
W4	5 mm (0.2 inch) fillet weld on both sides
W5	6 mm (0.24 inch) fillet weld on both sides with a required penetration of 1.5 mm (0.06 inch)
W6	8 mm (0.32 inch) fillet weld with a required penetration of 1.5 mm (0.06 inch) in four places
W7	6 mm (0.24 inch) fillet weld on both sides with a required penetration of 1.5 mm (0.06 inch)
W8	6 mm (0.24 inch) fillet weld on both sides with a required penetration of 1.5 mm (0.06 inch)
W9	8 mm (0.32 inch) fillet weld on both sides with a required penetration of 1.5 mm (0.06 inch)

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Illustration 79	g01401535
Front view of strut area (A) 725 ± 5 mm (28.5 ± 0.2 inch) this measurement applies to the 793C S/N:4AR218-UP ; S/N:4GZ1-UP (A) 750 ± 5 mm (29.5 ± 0.2 inch) this measurement applies to the 793C S/N:ATY1-UP (B) 275 ± 5 mm (10.8 ± 0.2 inch) this measurement applies to the 793C S/N:4AR218-UP ; S/N:4GZ1-UP ; S/N:ATY1-UP

Locate and weld plate assembly (1) .

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Illustration 80	g01386268
Outside LH frame view Illustration 80 applies to 793C S/N:4AR218-UP only (C) 43 ± 5 mm (1.7 ± 0.2 inch) (D) 200 ± 3 mm (7.9 ± 0.1 inch) (E) 201 ± 5 mm (7.9 ± 0.2 inch)

Locate and weld two blocks (2) .

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Illustration 81	g01386276
Inside RH frame view (F) 108 ± 2 mm (4.25 ± 0.08 inch) (G) 20 ± 2 mm (0.79 ± 0.08 inch) (H) 65 ± 5 mm (2.56 ± 0.20 inch)

Locate and weld block (3) .

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Illustration 82	g01385562
Illustration 82 applies to 793C S/N:4AR218-UP, ; S/N:4GZ and ; S/N:ATY models Outside LH frame view (J) 40 ± 5 mm (1.6 ± 0.2 inch)

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Illustration 83	g01386283
Illustration 83 applies to models 793C S/N:4AR218-UP, ; S/N:4GZ and ; S/N:ATY Outside LH frame view (K) 617.5 ± 5 mm (24.31 ± 0.20 inch)

Locate and weld plate (4) .
Note: Illustrations 82 and 83 both apply to Step 4.

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Illustration 84	g01386346
Inside LH frame view (L) 410 ± 3 mm (16.1 ± 0.1 inch) (M) 84 ± 3 mm (3.3 ± 0.1 inch)

Locate and weld plate (5) .

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Illustration 85	g01386367
Inside RH frame view Illustration 85 applies to 793C S/N:4AR218-UP trucks (N) 100 ± 5 mm (3.9 ± 0.2 inch) (P) 256 ± 1.5 mm (10.08 ± 0.06 inch) (Q) 800 ± 5 mm (31.5 ± 0.2 inch)

Locate and weld two plates (6) .

Repeat Step 6 for the other side of the frame.

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Illustration 86	g01386434
Top view of frame (R) 894 ± 5 mm (35.2 ± 0.2 inch) (S) 547 ± 3 mm (21.5 ± 0.1 inch)

Locate and weld one bar (7) .

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Illustration 87	g01401536
Outside RH frame view (T) 1729 ± 3 mm (68.1 ± 0.1 inch)

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Illustration 88	g01401539
Top view of frame (U) 194 ± 1mm (7.60 ± 0.04 inch)

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Illustration 89	g01386633
View of Plate (8), Plate (9), and Plate (10) assembled (V) 8 ± 2 mm (0.32 ± 0.08 inch)

Locate and weld plate (8) .

Locate and weld plate (9) .

Locate and weld plate (10) .

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Illustration 90	g01386750
Inside view of the RH frame (W) 436 ± 5 mm (17.2 ± 0.2 inch) (X) 86 ± 5 mm (3.4 ± 0.2 inch)

Locate and weld block (11) .

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Illustration 91	g01386770
Inside RH frame view (Y) 101 ± 5 mm (4.0 ± 0.2 inch)

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Illustration 92	g01392477
View A-A (Z) 35 ± 2 mm (1.4 ± 0.1 inch)

Locate and weld two gussets (12). Locate and weld one plate (13) .

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Illustration 93	g01386803
Inside RH frame view Illustration 93 applies to 793C S/N:4GZ and ; S/N:ATY only

Use the table below in order to locate and weld two lugs (14).

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Table 16
793C S/N:4GZ		793C S/N:ATY
Detail	Measured Distance	Detail	Measured Distance
AA	193.5 ± 1.5 mm (7.61 ± 0.06 inch)	AA	193.5 ± 1.5 mm (7.61 ± 0.06 inch)
BB	164.5 ± 1.5 mm (6.48 ± 0.06 inch)	BB	164.5 ± 3 mm (6.48 ± 0.12 inch)
Z	529 ± 3 mm (20.8 ± 0.1 inch)	Z	529 ± 5 mm (20.8 ± 0.2 inch)