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Comisionado - 793f

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0% found this document useful (0 votes)

209 views157 pages

Comisionado - 793f

Uploaded by

Percy Herrera Zeballos

We take content rights seriously. If you suspect this is your content, claim it here.

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Download as PDF, TXT or read online on Scribd

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Special Instruction
Commissioning Procedure for the 793F, 793F Tier 4, and the 793F CMD Off-Highway Truck {1000, 7000, 7961}
Media Number -REHS6121-10 Publication Date -14/08/2015 Date Updated -04/10/2017

i06688996

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

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

Introduction

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.

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.

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

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.

NOTICE

Care must be taken to ensure that fluids are contained during

performance of inspection, maintenance, testing, adjusting, and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain fluids on
Cat® products.

Dispose of all fluids according to local regulations and mandates.

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, perform the checks, and record the
results as instructed in the "Checks Before the Delivery of the 793F Off
-Highway Truck" Section at the end of the following procedure.
Complete and return the required information to the following address
listed in "Checks Before the Delivery of the 793F Off-Highway Truck".

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.

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
(1)
If Tier 4 equipped

Table 2
Tire Information
Tire Size Manufacturer
Left Front
Right Front

Left Rear Outside

Left Rear Inside
Right Rear Inside
Right Rear Outside

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
(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

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

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

(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.

Illustration 3 g02726620

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

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

Table 6
Required Tools
Part
Tool Item Qty Description
Number
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)
(1) ®
Caterpillar Electronic Technician (Cat ET) and Software CD, NETG5057 are required when using the communication adapter.

Power the Electrical System

1. To power the electrical system of the truck, perform the steps that follow:

Illustration 5 g02073718

a. Connect the batteries.

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)

b. Rotate battery disconnect switch (1) clockwise to the Energize the 24 V system.

c. Switch manual engine shutdown switch (2) to the OFF position.

d. 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.

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)
(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

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

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

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
(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

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

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
(1)
When the engine is at operating temperature

(2)
Refer to illustration 8

Air Conditioner Condenser Drain Line

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

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

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

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

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

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

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

Hazard Lights

Illustration 13 g06183131
(8) Hazard flasher switch

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

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

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

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

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

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

Illustration 18 g02075295
Typical view of the access light

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
(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

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

Cigar Lighter

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

Backup Alarm

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)
(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)

Illustration 19 g06201358
(1) Workshop horn switch

Illustration 20 g06201372
(2) Location of the workshop horn

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)

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

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)

____________________

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

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

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

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)

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.

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.

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)

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

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.

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

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)

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.

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.

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.

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.

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.

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

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

2. Locate keypad (1) that is on right side of the service center.

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

3. 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.

4. 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.

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

1. 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.

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

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)
(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

Illustration 38 g03228258

1. From the home screen in Advisor, select "Settings".

2. 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.

1. From the home screen in Advisor, select "Settings".

2. 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"

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

1. Connect a laptop computer to the Caterpillar Diagnostic Connector behind the seats of the cab.

2. Use your laptop computer to open Cat ET.

Illustration 40 g02138800

3. 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.

Illustration 41 g02138804

4. From the toolbar, select "Service", and select "Configuration".

Illustration 42 g02138110
Typical view

5. In the "ECM Identification Parameters" field, Select "Equipment ID".

6. Double-click "Equipment ID" to change the value for the equipment ID, or select "change".

7. Verify that the equipment ID matches the machine serial number. If the Equipment ID does not match, change the Equipment ID and click
"OK".

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

8. 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.

Illustration 44 g06190239
Typical view (D3T machines)

Illustration 45 g06190238
Typical view (D3T machines)

9. 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.

Illustration 46 g02138815

10. 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.

11. Verify that the "Engine Coolant Temperature Control Module Installation Status" is set to "Installed".

Illustration 47 g02138816

12. 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.

Illustration 48 g02138819

13. If equipped, verify that the "Engine Pre-Lube" is enabled.

Illustration 49 g06076999

14. If equipped, verify that the "Electronic Fuel Transfer Pump Installation Status" is set to the desired value.

Illustration 50 g06077004

15. If equipped, verify that the "Ether Solenoid Configuration" is set to the desired value.

Illustration 51 g06076986

16. If equipped, verify that the "Operator Final Inducement Action" is set to the desired value.

Illustration 52 g06076994

17. If equipped, verify that the "Operator Inducement Regulation Configuration" is set to the desired value.

Illustration 53 g06076990

18. If equipped, verify that the "Operator Inducement Progress Configuration" is set to the desired value.

Illustration 54 g02138897

19. From the toolbar, select "Service". Then select "ECM Date/Time".

Illustration 55 g02138900

20. Input the correct time zone, the date, and the time.

Check for Active Diagnostic Codes and Logged Diagnostic Codes

Illustration 56 g03231919

1. From the toolbar, click "Diagnostic". Click "Active Diag. Codes".

2. 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".

Illustration 57 g02138822

3. From the toolbar, click "Diagnostics". Click "Logged Diag. Codes".

Illustration 58 g02138826
Typical view

4. 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.

Illustration 59 g02138827

5. From the toolbar, click "Diagnostics". Select "Events" and click "Logged Events".

6. If necessary, resolve any logged events and clear any logged events.

7. 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

Illustration 60 g03228437

1. 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

Illustration 61 g02138256

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

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

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.

Illustration 62 g02138268
Values for the injectors are typical.

1. Click "Diagnostics". Select "Diagnostic Tests". click "Override Parameters".

Illustration 63 g02138832

2. To test the ether control operation, select "Ether Injection". Click the "Change" button that is located in the lower left corner of the screen.

Illustration 64 g02138866

3. Click the drop-down menu for the "New Value:" and change the selection from "Off" to "On". Click "OK".

4. Click "OK" in the verification box.

Note: An audible click should be heard after clicking "OK" on the verification box.

5. If the ether control test is acceptable, select "Ether Injection Override" to return the mode to normal.

Settings for the Engine Prelube

Illustration 65 g02138870

1. Select "Engine Pre-Lube". Click the "Change" button that is located in the lower left corner of the screen.

2. Click the drop-down menu for the "New Value:" and change the selection from "Off" to "On". Click "OK".

3. Click "OK" in the verification box.

Note: The operator should hear the engine prelube system energize.

4. 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)

Illustration 66 g02138874

1. To test the oil renewal system, select "Oil Renewal". Click the "Change" button that is located in the lower left corner of the screen.

2. Click the drop-down menu for the "New Value:" and change the selection "Off" to "On". Click "OK".

3. 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.

4. When the test for the oil renewal system is completed, click "Disable Override" to return the mode to normal.

5. From the toolbar, click "Service". Click "Configuration" to go back to the main configuration screen.

Settings for the Chassis Control

Illustration 67 g02138274

1. Click "Machine Configuration" under the heading "Chassis 793".

2. Click "Starting System Configuration". Select the type of Starting System Configuration that is on the machine. Click "OK".

Illustration 68 g06076926

3. 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.

Illustration 69 g06076958

4. 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.

Illustration 70 g06076933

5. 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.

Illustration 71 g06076865

6. 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

Illustration 72 g02138885

1. Click "Configuration Group 1" under "Transmission 793".

2. 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.

3. Check the "Torque Converter Serial Number". The serial number should match the serial number that is on the torque converter. If the serial
number is incorrect, input the correct Torque Converter Serial Number.

Illustration 73 g02138887

4. Check the "Machine Speed Limit". If there is a requirement for a speed limit, input the correct speed limit.

Settings for the Brake Control

Illustration 74 g02138283

1. Click "Configuration Group 1" under "Brake 793".

2. Verify that the "Equipment ID" matches the machine serial number.

3. Set the "Maximum Desired Engine Retard Speed" between 1850 RPM and 1950 RPM.

Illustration 75 g02138891

4. Verify that the correct "Engine Cooling Fan Configuration" is selected.

Illustration 76 g02138893

5. If equipped, verify that the correct "Differential High Speed Fan Install Status" is selected.

Illustration 77 g03739001

6. For "RBT" machines only, select the wheel station type.

Note: "Extended Life Wheel" or "Standard Wheel" are choices.

Settings for the VIMS Main Module

Illustration 78 g02138894

1. Under "VIMS Main Module", select "General Information".

2. 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:

a. 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.

Illustration 79 g03321031

1. In "Monitoring System Parameters" select "Service Mode Enable Code".

Note: The default number is "0".

2. To set the password, input any five or less digit number. and click "OK".

Note: The password can only be changed through Cat ET.

Illustration 80 g03321113

3. Click "Yes" on the next window.

Verify that the value has changed.

VIMS

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

1. Connect a laptop computer to the "VIMS" connector.

Note: Ensure that the key is in the ON position.

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

Illustration 83 g02138901

2. 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.

Illustration 84 g02138903

3. Click "File". Click "Connect Machine".

Illustration 85 g02138904

4. Select the "Cab" and click "OK".

Illustration 86 g02139075

5. After the connection is completed click "Data" from the toolbar. Click "Download".

Illustration 87 g02139077

6. In the "Download Data" box, select all the boxes under "Download".

7. In the "Download Data" box, select everything under "Reset After Download".

Illustration 88 g02139079

8. Click "Download" after the download selections has completed.

Illustration 89 g02139080

9. From the toolbar, click "Configure". Click "Assign Serial/Equipment Number".

Illustration 90 g02139082

10. In the "Assign Serial/Equipment Number" box, verify that the serial number matches the new serial number.

11. In the "Assign Serial/Equipment Number" box, change the "Equipment" number to correspond to the new customer machine number. Click
"OK".

Illustration 91 g02139099

12. From the toolbar, click "Configure". Click "Reset Date/Time/SMH".

Illustration 92 g02139107

13. Select "Reset Date/Time" and change, as necessary.

14. Select "Reset SMH" and set to Zero.

15. Click OK.

Advisor Panel Setup

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

1. 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.

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)

2. Move manual engine shutdown switch (2) to the OFF position.

Note: The engine should be disabled so the engine will not start.

3. Rotate battery disconnect switch (1) clockwise to Energize the 24 V system.

4. Chock the wheels.

5. Ensure that the transmission control is in the "P" position.

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

NOTICE

Care must be taken to ensure that fluids are contained during

Refer to Special Publication, NENG2500, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain fluids on
Cat® products.

Dispose of all fluids according to local regulations and mandates.

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

1. 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.

2. 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.

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

3. Move engine lockout control (1) clockwise to the engaged position.

Note: You should have 24 V DC to the truck.

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

4. 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.

5. 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).

6. Move the hose and hydraulic socket to pressure tap (8).

7. 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).

8. Move the hose and hydraulic socket to pressure tap (9).

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).

10. Remove the hose and hydraulic socket from the quick disconnect.

The fuel system should be purged of air.

11. Rotate engine lockout control (1) to the clockwise most position.

12. 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)

NOTICE

Care must be taken to ensure that fluids are contained during

Refer to Special Publication, NENG2500, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain fluids on
Cat® products.

Dispose of all fluids according to local regulations and mandates.

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.

1. 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.

2. 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.

Illustration 98 g06183145

Typical view of the ground level controls (D3T machines)

(1) Engine lockout control

3. Move engine lockout control (1) clockwise to the engaged position.

Note: You should have 24 V DC to the truck.

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

4. Activate fuel priming pump switch (2).

5. Rotate engine lockout control (1) to the clockwise most position.

6. 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

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.

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.

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

NOTICE

Care must be taken to ensure that fluids are contained during

Refer to Special Publication, NENG2500, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain fluids on
Cat® products.

Dispose of all fluids according to local regulations and mandates.

Table 29
Tools Needed
Qty Part Number Description
4 177-7862 Hose As
4 6V-4143 Quick Connect Coupler
4 - Shut Off Valve(1)
(1)
Use shut off valve with 1/8-27 NPTF THD

1. 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.

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

2. 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.

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

3. 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.

4. 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.

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

5. 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.

6. 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.

7. Close the valves and turn the key in the cab to the off position.

8. 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.

9. Ensure engine lockout control (C) is in the clockwise most position to the engaged position.

Engine Start-Up

NOTICE

A low brake pressure condition will cause the alert indicator to flash.
The "VIMS" message center should provide the following
instruction:"DO NOT MOVE THE MACHINE." This message is on
display until the starting reservoir and the service reservoir are
charged to one half of the maximum operating pressure. "DO NOT"
turn off the parking brake switch before the pressure is obtained. The
horn will sound a warning.

1. Chock the wheels.

2. Connect a laptop computer with Cat ET to the machine.

3. In Cat ET , verify that the Engine Pre-Lube is "Enabled".

4. In Cat ET , clear any Active, logged Diagnostic Codes and Events.

5. 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.

6. 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.

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.

Illustration 106 g06183415

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

Illustration 107 g06183419

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

7. 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.

8. 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.

9. Repeat Step 8.

10. 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.

11. 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.

12. Run the engine for 10 seconds and turn the key to the OFF position.

13. 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.

14. Start the engine and run the engine for 60 seconds and turn the key to the OFF position.

15. Repeat Step 13

16. Repeat Step 14 and Step 15.

17. Turn the key to the ON position and run the engine until normal operating temperatures are reached.

Engine Start Checklist

Table 30
Check the Ignition Switch, Horn, and Engine Start Check if OK
(1)
Turn the ignition key to the ON position
Sound the horn for all clear
Turn the key to the START position to activate the starting motor.

After the diesel engine starts, release the key. The key should return to the ON position
Turn the ignition key to the OFF position. The engine should stop
(1)
The key in the ON position will enable the electrical circuits in the cab and activate the VIMS self test

Engine Shutdown Switch Checklist

Illustration 108 g03447639

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

Illustration 109 g06183421

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

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

NOTICE

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

1. Use a laptop computer to open Cat Electronic Technician (ET).

Illustration 110 g06076684

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.

2. Confirm correct serial numbers for the Clean Emissions Module (CEM) and Pump Electronic Tank Unit (PETU).

a. 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.

b. 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.

Illustration 112 g03825970

3. From the toolbar, select "Diagnostics" then "Diagnostic Tests".

Illustration 113 g06076761

4. Select "Aftertreatment System Functional Test" and click "Start".

Illustration 114 g03825152

5. Read and understand the warning. Click "OK" to proceed to the test.

Illustration 115 g03825157

6. Click "Next" to proceed to the test.

Autolube

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.

Illustration 116 g02074533

View of the left side grease injectors

Illustration 117 g02074535

View of the right side grease injectors

Illustration 118 g02074534

View of the rear grease injectors

Illustration 119 g02074536

View of the left inside grease injectors

NOTICE

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

Illustration 120 g02074538

View of the right inside grease injectors

1. Purge the air from each individual grease line.

Note: Purging the grease lines may require a hand pump.

2. 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.

3. Turn the key to the ON position.

Note: Do not start the truck.

Illustration 121 g02138313

4. Through the Advisor, select "Service".

5. Select "All Parameters", then "System Tests", and then "Manual Lube Mode".

6. If necessary, use the left arrow or the right arrow to set the correct interval.

7. Press OK.

8. If necessary, repeat Step 6 and Step 7 for the autolube interval.

Miscellaneous Checks
Prepare the Truck for Pressure Checks

Illustration 122 g01340699

1. Chock the wheels.

2. The engine should be at normal operating temperature and the transmission should be in the PARK position.

3. 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.

4. 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.

1. Prepare to start the truck.

Note: The transmission control should be in the PARK position.

Illustration 123 g01340699

2. Chock the wheels.

3. Start the engine.

Illustration 124 g02138319

4. 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".

5. View the pressure of the "System Air Pressure".

6. 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).

7. 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

Illustration 125 g02074639

View of the right side of the machine

1. Locate the air dryer near the right front wheel of the machine.

Illustration 126 g01341861

Typical view

2. Check the amount of voltage that is for the heater at the electrical connection of the dryer.

3. Use the table below to record your results.

Table 32
Air Dryer Check Actual Reading
24 V or more at the air dryer

Check the Braking and Steering Accumulator Precharge Pressures

Illustration 127 g01962775

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

1. 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.

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

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

Transmission - Test

Illustration 128 g01962775

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"

1. 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.

Table 35
Transmission Specifications
Specification Actual
Transmission Oil Temperature (During Tests) 80° to 121°C (176° to 250°F)
Low idle: 2655 to 2930 kPa (385 to 425 psi)
Main Relief Pressure(1)
High idle: 2895 to 3170 kPa (420 to 460 psi)
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)
(1)
Refer to Illustration 130

Table 36
Clutch Pressures
Clutch Pressure(1)
Transmission Speed CLUTCHES ENGAGED Actual
Prefix "PJT" and "JA5" Transmission Prefix "AS6" Transmission
NEUTRAL 3 1725 ± 138 kPa (250 ± 20 psi) 1480 ± 138 kPa (215 ± 20 psi)
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)
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)
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)
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)
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)
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)
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)
(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.

2. Chock the wheels.

3. On the Cat ET screen choose Transmission ECM.

Illustration 129 g03182457

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

4. Select Transmission Monitoring.

5. 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

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.

Illustration 131 g01962775

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

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.

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.

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.

NOTICE

Care must be taken to ensure that fluids are contained during

Refer to Special Publication, NENG2500, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain fluids on
Cat® products.

Dispose of all fluids according to local regulations and mandates.

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.

1. Park the machine on a smooth, level surface.

2. Chock the wheels.

3. 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.

4. 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.

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

5. Place the transmission gear lever in the PARK position.

6. Fully release the service brake pedal.

7. Set the engine speed to low idle.

Note: During the calibration, Cat ET will alter the engine speed.

8. Connect Cat ET to the service connector.

Illustration 132 g03259876

9. Choose "Transmission 793" from the list to select the calibration.

Illustration 133 g03259917

10. From the toolbar, select "Service" then "Calibrations".

Illustration 134 g03259936

11. Select the "Transmission Clutch Engagement Pressure Calibration" and click "Start".

Illustration 135 g03259976

12. Select all the clutches and click "Begin".

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.

13. 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.

14. After the correct pressure is reached, click "Next".

Illustration 137 g03260396

15. The window that pops up should show a "CALIBRATION SUCCESSFUL" message. Click "Continue" to calibrate the next clutch pressure.

Illustration 138 g03260516

16. 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.

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.

Personal injury can result from hydraulic oil pressure and hot oil.

NOTICE

Care must be taken to ensure that fluids are contained during

Refer to Special Publication, NENG2500, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain fluids on
Cat® products.

Dispose of all fluids according to local regulations and mandates.

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.

1. Chock the wheels.

2. Connect the communication cable between a laptop computer, equipped with a current version of Cat ET software, and the service connector
of the truck.

3. Open the Cat ET. Select the transmission Electronic Control Module (ECM) for the machine that is being calibrated.

Illustration 139 g03260638

4. From the toolbar, select "Service" then "Calibrations".

Illustration 140 g03260637

5. Select "Transmission Fill Calibration" and click "Start".

Illustration 141 g03260678

6. 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.

7. 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.

8. Once the calibration has been completed successfully, the ECM will write the calibration data to memory.

9. Operate the machinery to check the quality of transmission shift.

10. Resume normal operation of the machine.

Transmission and Machine Field Test

Table 38
Transmission and Machine Field Test
Engine
Machine Lockout Control Engine Lockout Control Transmission Check if
Running Result
(Engaged/Disengaged) (Engaged/Disengaged) Control Position OK
(Yes/No)

Engaged Disengaged D Y Machine

should not
move
Machine
Engaged Disengaged R Y should not
move
Machine
Disengaged Engaged P N should not
start
Machine
Disengaged Disengaged D N should not
start
Machine
Disengaged Disengaged R N should not
start

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

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

1. With the machine off, rotate machine lockout control (1) counterclockwise to activate (engage) the lockout. Lockout indicator light (2)
should illuminate.

2. Start the engine and move the transmission control to the D position.

Note: The machine should not move.

3. Move the transmission control to the R position.

Note: The machine should not move.

4. Move the transmission control to the P position.

5. Turn off the machine.

6. Rotate machine lockout control (1) clockwise to deactivate the lockout. Lockout indicator light (2) should turn off.

7. Rotate engine lockout control (3) counterclockwise to activate (engage) the lockout. Lockout indicator light (4) should illuminate.

8. With the transmission control in the P position, try to start the machine.

Note: Engine should not start.

9. Rotate engine lockout control (3) clockwise to deactivate the lockout. Lockout indicator light (4) should turn off.

10. Move the transmission control to the D position. Try to start the engine.

Note: Engine should not start.

11. Move the transmission control to the R position. Try to start the engine.

Note: Engine should not start.

12. Return the transmission control to the P position.

13. 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"

1. Use the table below to record the performance of the torque converter.

Note: Engine speed is reduced to 1600 rpm when the transmission is in reverse and the body is in the raised position. The torque converter
stall test must be performed when the transmission is in the first gear and the body is in the lowered position.

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

1. Chock the wheels.

2. On the Cat ET screen toolbar, click File - Select ECM, and choose "Transmission ECM".

Illustration 144 g01950000

3. Select “Torque Converter Monitoring”.

Illustration 145 g01962775

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

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.

4. 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).

5. Perform the torque converter tests and record the results in Table 39.

Torque Converter Stall - Test

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.

1. Chock the wheels.

2. Fasten the seat belt before you test the brakes.

3. Check the area around the machine. Make sure that the machine is clear of personnel and clear of obstacles.

4. Test the brakes on a dry, level surface.

5. Start the engine.

Illustration 147 g01923774

6. From the home screen in Advisor, select "Monitor". Select "Parameters" and choose the "Actual Engine RPM".

Illustration 148 g01519336

7. 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.

8. 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.

9. With the service brake pedal still fully depressed, and fully depress the accelerator pedal. The machine should not move.

10. 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.

11. Reduce the engine speed to an idle. Move the transmission control to the P position. Stop the engine.

Brake System - Test

Illustration 149 g01962775

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.

Table 40
Brake System Specifications
Specification Actual
(1)
Main Relief Pressure 23100 ± 345 kPa (3350 ± 50 psi)
(2)
Service Brake Cut-In at Accumulator 14480 ± 483 kPa (2100 ± 70 psi)
(2)
Service Brake Cut-Out at Accumulator 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
No loss in pressure for extended period
Shutdown(2)

Service and Secondary Brake Accumulator Pressure after Key Off(2) 0 kPa (0 psi) in less than 120 seconds
(4)
Parking Brake Release Pressure (Retarder Lever Applied) 4600 ± 800 kPa (665 ± 116 psi)
(5)
Parking Brake Pressure (Secondary Brake Pedal Applied) 0 kPa (0 psi)
Parking Brake Pressure (Transmission Control in the P Position)(6) 0 kPa (0 psi)
3790 kPa to 4480 kPa (550 psi to 650 psi) within 120
Towing Motor(7)
seconds
Service Brake Applied
Standard Retarding
4200 kPa to 5000 kPa (609 psi to 725 psi)
Front and Rear Slack
Adjuster
Service Brake Applied
Extended Life Retarding 3025 kPa to 4225 kPa (438 psi to 612 psi)
Front Slack Adjuster
Service Brake Applied
Extended Life Retarding 4200 kPa to 5000 kPa (609 psi to 725 psi)
Rear Slack Adjuster

Brake Application Pressure at Slack Manual Retarder Lever

Adjusters(8) Applied
Standard Retarding 3800 kPa to 5400 kPa (551 psi to 783 psi)
Front and Rear Slack
Adjuster
Manual Retarder Lever
Applied
2825 kPa to 4425 kPa (409 psi to 641 psi)
Extended Life Retarding
Front Slack Adjuster
Manual Retarder Lever
Applied
3800 kPa to 5400 kPa (551 psi to 783 psi)
Extended Life Retarding
Rear Slack Adjuster
(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

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.

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

1. Chock the wheels.

2. Apply the parking brake. Applying the parking brake will release the pressure in the lines.

Illustration 150 g03486038

(1) Brake unloader valve

3. Connect a suitable drain hose assembly to the bleeder valve on brake unloader valve (1).

4. Connect a drain hose from the unloader valve to the hydraulic tank or to a suitable container.

5. Run the engine at low idle. Move the transmission lever to the NEUTRAL position.

6. Pull down the retarder control or pump the service brake pedal.

Repeat this step until there is a continuous flow of oil.

7. 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

1. Chock the wheels.

2. Apply the parking brake. Applying the parking brake will release the pressure in the lines.

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)

3. Connect a suitable drain hose to bleeder port (A) on one wheel.

4. Connect the drain hose from the port "A" to the hydraulic tank or to a suitable container.

5. Run the engine at low idle. Move the transmission control lever to the NEUTRAL position.

6. Use a wrench to open the bleeder screw.

7. Pull down the retarder control or depress the service brake pedal until there is a continuous flow of oil.

8. Close the bleeder screw. Move the retarder control to the OFF position or release the service brake pedal.

9. Move the transmission control to the P position.

10. Remove the drain hose from bleeder port (A).

11. Repeat these steps for the other three wheels.

12. After completing the purge, turn off the machine and remove all equipment.

Brake Pilot (Foot Pedal)

1. 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.

Illustration 153 g03321181

2. Connect the hose that was assembled in Step 1 to tap (B).

3. Connect the drain hose from the port "B" to the hydraulic tank or to a suitable container.

4. Open the shutoff valve on the end of the hose.

5. Start the engine and run the engine at low idle.

6. 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.

7. After completing the purge, turn off the machine and remove all equipment.

8. 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

1. Chock the wheels.

Illustration 154 g03487156

(1) Pressure tap at the brake oil filter

2. Install tooling (A) or tooling (B) onto pressure tap (1).

Note: Refer to Table 4 for tooling (A) or Table 5 for tooling (B).

3. Start the engine.

Illustration 155 g03183176

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.

4. 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.

5. Click the override for the brake unloader valve and change the override to OFF.

6. 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).

7. 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

Illustration 156 g01962775

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

1. Chock the wheels.

2. 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).

3. Start the engine.

4. Raise the body, and secure the body with retaining cables.

Illustration 157 g03333630

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

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.

5. 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).

6. Reconnect the harness assembly to solenoid valve (2).

7. 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

1. Chock the wheels.

Illustration 158 g03487325

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

2. 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).

3. 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.

4. Turn off the machine and remove all test equipment.

Brake Pump Stand-by Pressure - Test

1. Chock the wheels.

2. 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).

3. 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.

4. Turn off the machine and remove all test equipment.

Brake Pilot Pressure (Foot Pedal) - Test

Illustration 159 g01962775

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

1. Chock the wheels.

Illustration 160 g03185120

(1) Pressure tap near the brake control valve

2. 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).

3. 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.

4. Turn off the machine and remove all test equipment.

Service and Secondary Brake Accumulator Pressure - Test

1. Chock the wheels.

2. 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).

3. Start the engine and let the accumulators charge completely.

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

4. 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.

5. Start the engine and let the accumulators charge completely.

6. 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.

7. Remove all test equipment.

Parking Brake Release Pressure - Test

1. Chock the wheels.

Illustration 163 g03185716

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

2. 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).

3. 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.

4. 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.

5. 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.

6. Turn off the machine and remove all test equipment.

Traction Control Valve - Test

Illustration 164 g01962775

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

1. Chock the wheels.

2. Connect a laptop computer and open Cat ET. Navigate to the Brake ECM AETA valve solenoids.

Illustration 165 g03487336

(1) Pressure tap for the right wheel
(2) Pressure tap for the left wheel

3. 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).

Illustration 166 g03185964

The TCS test switch is located in the overhead controls in the operator station
(3) TCS switch

4. 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.

5. Turn off the machine and remove all test equipment.

Parking Brake Holding Ability Test

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

1. Chock the wheels.

2. Fasten the seat belt before you test the brakes.

3. Check the area around the machine. Make sure that the machine is clear of personnel and clear of obstacles.

4. Test the brakes on a dry, level surface.

5. Start the engine.

Illustration 167 g01519336

6. 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.

7. 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.

8. Gradually increase the engine speed to 1300 rpm. The machine should not move.

9. Reduce the engine speed to an idle. Move the transmission control to the P position. Stop the engine.

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

1. Chock the wheels.

Illustration 168 g03182603

(1) Location of the pressure tap for the parking brake release pressure

2. Connect tooling (A) or tooling (B) to pressure tap (1).

Note: Refer to Table 4 for tooling (A) or Table 5 for tooling (B).

3. Turn the engine start switch to the ON position. Place the transmission control into the NEUTRAL position.

Illustration 169 g02074719

Switch for the electric powered parking and secondary brake release pump

4. 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.

5. Turn off the machine and remove all test equipment.

Brake Application Pressure at the Front Slack Adjuster - Test

Illustration 170 g01962775

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

1. Chock the wheels.

Illustration 171 g03186356

(1) Pressure tap at the front slack adjuster

Illustration 172 g03229498

(2) Pressure tap at the rear slack adjuster

2. 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).

3. 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)

4. Release the service brake pedal.

5. 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)

6. Turn off the machine and remove all test equipment.

Automatic Retarder Control (ARC) - Test

1. Chock the wheels.

2. Ensure that Cat ET is connected.

Illustration 173 g03187256

(1) Switch for the automatic retarder control (ARC)

3. 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.

4. Turn off the machine.

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

Location of the Brake Wear Indicators

Illustration 174 g03243396

Front wheel (standard)

Illustration 175 g03243438

Rear wheel (standard)

Illustration 176 g03243443

Front wheel (extended life)

Illustration 177 g03243446

Rear wheel (extended life)

Instructions to Set the Brake Wear Indicators

1. Chock the wheels.

Illustration 178 g01974859

Typical view of an installed brake wear indicator

2. Remove cap (A) from the brake wear indicator.

Illustration 179 g01975013

Typical view of newly installed brake discs

3. Apply forward pressure to indicator rod (B) so that the indicator rod contacts brake piston (C).

Illustration 180 g01975034

4. 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).

5. Reinstall cap (A) that was removed in Step 2. Tighten cap (A) to a torque of 34 ± 4 N·m (300 ± 35 lb in).

6. 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"

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

Brake Cooling System - Test

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

1. Chock the wheels.

Illustration 181 g03187458

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

Illustration 182 g03187459

Extended life brake cooling screens
(1) Pressure tap on brake cooling screen

2. 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 are two pressure taps (1) on the extended life retarding arrangement.

3. Start the machine.

4. From the toolbar in Cat ET, click "Diagnostics" then click "Diagnostic Tests". Select the "Override Parameters" in "Brake 793".

Illustration 183 g03187616

5. 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.

6. Select the "Engine Speed" and click "Change". Set the engine speed to 1960 rpm (high idle).

7. 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.

8. 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"

Table 44
Steering System and Hydraulic System Specifications(1)
Target Actual
22750 ± 345 kPa
Accumulator pressure(2)
(3300 ± 50 psi)
1.________________
Cycle time for the steering system at high idle.
2.________________
With all the brakes released, turn the steering wheel from left to right. Then from 3 to 5 seconds
3.________________
right to left.
Avg.______________
Left to Right
1.________________
Steering wheel turns from stop to stop at high idle.
3 to 5 seconds 2.________________
With all the brakes released, turn the steering wheel at 1 revolution per second
3.________________
Avg.______________
Right to Left
1.________________
Steering wheel turns from stop to stop at high idle.
3 to 5 seconds 2.________________
With all the brakes released, turn the steering wheel at 1 revolution per second
3.________________
Avg.______________
Pressure setting for the (Priority Valve) Solenoid Valve and Manifold (Rear Axle 18271 ± 690 kPa
Fan, Brake Cooling, Drive Motor, Lubrication, and Steering)(3) (2650 ± 100 psi)
(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

1. Chock the wheels.

Illustration 184 g03178001

(1) Pressure tap for the steering accumulator pressure

2. Connect tooling (A) or tooling (B) to pressure tap (1).

Note: Refer to Table 4 for tooling (A) or Table 5 for tooling (B).

3. 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).

4. Turn the wheels all the way to the right. Check for leaks.

Note: Accumulator pressure should be 22750 ± 345 kPa (3300 ± 50 psi).

5. 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.

6. 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.

7. Verify that there are no leaks.

8. Turn off the machine and remove all test equipment.

9. Record the results in Table 44.

Steering System Internal Leakage Test

1. Chock the wheels.

2. Start the engine and run the engine at high idle.

3. 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.

4. Turn off the machine.

Priority Valve Relief Pressure Test

Illustration 185 g01962775

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

1. Chock the wheels.

Illustration 186 g03178024

(1) Priority valve
(2) Relief valve on priority valve (1)
( 3) Pressure tap

2. Connect tooling (A) or tooling (B) to pressure tap (3).

Note: Refer to Table 4 for tooling (A) or Table 5 for tooling (B).

3. Start the engine.

4. 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.

5. Turn off the machine and remove all test equipment.

Hydraulic Fan - Test

1. Chock the wheels.

Illustration 187 g03180797

Typical view of the override screen in Cat ® ET

2. 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.

Illustration 188 g03179298

View of the front right side of the inner frame
(1) Pressure tap for the hydraulic fan pressure

3. Connect tooling (A) or tooling (B) to pressure tap (1).

Note: Refer to Table 4 for tooling (A) or Table 5 for tooling (B).

4. 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).

5. 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.

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

Illustration 189 g03178082

(2) High-pressure cutoff adjustment screw

6. 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).

7. Verify that there are no leaks.

8. 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).

Table 46
Hoist System Specifications
Specifications Actual
(1)
Hoist Raise Pump Pressure 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)
(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.

1. Chock the wheels.

Illustration 190 g02139117

2. Start Cat ET and select "Chassis 793".

Illustration 191 g02138804

3. From the toolbar, click "Service". Click "Configuration".

Illustration 192 g06076881

4. Under the heading "Hoist System", click "Hoist System Enable Status".

5. Click the"Change" button that is at the bottom of the screen.

6. 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.

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 VIMSTM.

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:

1. Disconnect rod (3) from the body.

2. Loosen nut (2) on rod (3).

3. Twist the rod (3) to obtain the correct distance between the centers of the rod ends (5).

4. Tighten nut (2).

5. 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

1. Chock the wheels.

Illustration 194 g02138804

2. From the toolbar, click "Service". Click "Configuration".

Illustration 195 g06076908

3. Under the heading "Hoist System", click "Body Up Gear Limit".

4. Click the"Change" button that is at the bottom of the screen.

5. 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.

1. Chock the wheels.

2. Raise the truck body.

Illustration 196 g02075237

Typical view

3. Connect the safety retaining cables to the body.

Illustration 197 g03319386

4. 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).

5. Remove the safety retaining cables from the body.

6. With the engine that is running, place the hoist lever in the body float position.

7. 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.

8. Start Cat ET.

Illustration 198 g06076876

9. In the "Chassis 793" tab click "Hoist System".

10. Select "Hoist Lower Valve Adjustment Status".

11. Select "Change".

12. Insert the new value in the "Hoist Lower Valve Adjustment Status" box. Click "OK". Select "OK" in the verification box.

13. 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

Illustration 199 g01962775

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.

1. Chock the wheels.

Illustration 200 g03190896

2. 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).

3. With the transmission in the P position, start the machine and run the machine at high idle.

4. 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.

5. 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.

6. Check for leaks. Turn off the machine and remove all test equipment.

Illustration 201 g03191661

(2) Relief valve
(3) High pressure raise relief valve
(4) Lower pressure lower relief valve

7. 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

1. Chock the wheels.

2. Start the machine and run the machine at high idle.

3. 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.

4. 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.

5. Check for leaks. Turn off the machine.

Hoist Pilot Pressure - Test

1. Chock the wheels.

Illustration 202 g03191376

(1) Pressure tap for the hoist pilot pressure

2. Connect tooling (A) or tooling (B) to pressure tap (1).

Note: Refer to Table 4 for tooling (A) or Table 5 for tooling (B).

3. 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.

Illustration 203 g03191661

(2) Relief valve
(3) High pressure raise relief valve
(4) Lower pressure lower relief valve

4. 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.

1. Turn the engine start switch to the ON position.

Illustration 204 g01778554

2. Move hoist control (1) to the LOWER position.

Illustration 205 g01778573

3. Press and hold brake release switch (2) for 20 seconds.

4. 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).

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.

Table 47
Rear Axle Lubrication System Specifications(1)
Rear Final Rear Axle Drive Motor Inlet Rear Axle Filter Inlet
Engine Axle Drive Final Drive Lube Pressure
Diff. Lube Pressure Pressure
Speed Lube Lube
Temp.
(RPM) System System Spec. Actual Spec. Actual Spec. Actual
Status Status
ON OFF

700- 18° to 35°C 16500 kPa to 23500 kPa 950 kPa to 1650 kPa 120 kPa to 200 kPa
1960 (64° ± 95°F) (2390 psi to 3410 psi) (137 psi to 239 psi) (17 psi to 29 psi)
700- 50° to 59°C 13500 kPa to 16500 kPa 800 kPa to 1250 kPa 120 kPa to 180 kPa
ON OFF
1960 (122° to 138°F) (1960 psi to 2390 psi) (116 psi to 181 psi) (17 psi to 26 psi)
700- 60° to 75°C 12500 kPa to 15500 kPa 750 kPa to 1200 kPa 180 kPa to 350 kPa
ON ON
1960 (140° to 167°F) (1810 psi to 2250 psi) (108 psi to 174 psi) (26 psi to 50 psi)
700- 0 kPa to 500 kPa 0 kPa to 50 kPa 0 kPa to 50 kPa
ALL OFF OFF
1960 (0 psi to 70 psi) (0 psi to 7 psi) (0 psi to 7 psi)
(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).

1. Chock the wheels.

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

2. 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).

3. Start the engine.

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).

4. Run the engine at high idle.

5. 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).

Illustration 207 g03266796

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).

6. In Cat ET, go to the brake overrides.

Enable the "Rear Axle Pump Drive Oil Divert Solenoid Override".

7. 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).

8. Enable the "Final Drive Oil Bypass Solenoid Override". Refer to Illustration 207.

9. 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).

10. If the truck is equipped with the Rear Axle Cooling Fan, complete Step 10.a through Step 10.c. If the truck is not equipped with the Rear
Axle Cooling Fan, refer to Step 11.

a. Disable the "Final Drive Oil Bypass Solenoid Override". Refer to Illustration 207.

b. Enable the "Differential High Speed Fan Solenoid Override".

c. 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.

11. 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.

NOTICE

Care must be taken to maintain corner weights.

Illustration 208 g02079473

Typical view of the left front suspension cylinder

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

2. Record the suspension cylinder measurements in the table provided.

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

1. The following conditions must be met to calibrate the payload system:

a. Ensure that the truck body is empty. Carryback weight of the material that is stuck in the truck body can affect the payload
measurements.

b. Operate the empty truck to a minimum ground speed of 4 MPH on hard level ground.

c. 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.

d. After the truck stops moving, calibrate the payload system.

Illustration 209 g03231436

2. From the Home Screen in Advisor, select "Service", then "Calibrations", then "Truck Payload" and hit "OK".

The payload calibration will begin.

3. 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.

1. 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.

2. Turn the steering wheel all the way to the left. With the engine at an idle, slowly drive forward in a complete circle.

Illustration 210 g02004873

The TCS test switch is located in the overhead controls in the operator station.

3. Continue to turn the machine and push the top half of TCS test switch (1). Hold the test switch down. The test will begin.

4. The machine will gradually slow down.

5. Release the test switch. The test will end and the machine will increase speed.

6. Turn the steering wheel all the way to the right. With the engine at an idle, slowly drive forward in a complete circle.

7. Continue to turn the machine and push the top half of the TCS test switch. Hold the test switch down. The test will begin.

8. The machine will gradually slow down.

9. Release the test switch. The test will end and the machine will increase speed.

10. 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.

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

1. Connect a laptop computer with Cat ET to the machine.

2. Open Cat ET.

Illustration 212 g03256756

3. From the toolbar, select "Information" and "Status".

Illustration 213 g03258496

4. Scroll to the bottom of screen and double-click "TEMPORARY GROUP".

Illustration 214 g03258536

5. 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

6. Click "OK".

Illustration 215 g03258618

7. Click "Change"

Illustration 216 g03258620

8. Click "Save As".

Illustration 217 g03258656

9. 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

10. Click "OK" to close the "Save As" window. Click "OK" to close the "Maintain Groups" window.

Illustration 218 g03259499

11. 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

Illustration 219 g03259616

1. After the correct conditions are met, click "Hold" on the bottom of the screen.

Note: Clicking "Hold" will stop the values from changing.

Illustration 220 g03259617

2. From the toolbar, click "File" and "Print To File".

Note: A wait of approximately 15 seconds may be required to process information.

Illustration 221 g03259661

3. In the "Save As" window, select the location and file name and click "Save".

4. Repeat Step 1 through Step 3 for each performance group under low idle, high idle, and load stall test conditions.

Illustration 222 g03259698

5. To view a saved file, from the toolbar, select "File", "Open", and "Report File".

Illustration 223 g03259756

6. 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

Illustration 224 g03228437

1. From the toolbar, click "Information" and "Product Status Report".

Illustration 225 g03394193

2. 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 addresses:

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

Caterpillar Inc.
Attn: Emissions Compliance
12009 State Rte 29
Bldg VV, Dock 55
Mossville, IL 61552

Also, email a copy of the check procedure to:

Emissions_Compliance@cat.com

Dealer:____________________

Inspector Signature:____________________

Customer:____________________

Product Identification Number:____________________

Predelivery Worksheet
Table 49
Machine Pump Electronic Tank Clean Emissions
Personnel Engine Serial Inspector
Date Model Serial Unit (PETU) Serial Module (CEM) Serial Hours
ID Number Name
Number Number Number(1)

(1)
CEM Serial Number Plate is on the mounting structure (cradle) of the CEM

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

Table 50
Service Points and
Visual Inspection Operation After Operation
Fluid Levels
_ Oil
_ Coolant
_ Fuel
_ Air Cleaner Indicator
_ Batteries OVC >
_ V-Belt Tension
_ Paint (12.45) _ VDC1 _
_ Leaks - Oil, Air, Fuel,
_ Outside Damage VDC2
_ Priming Pump Coolant, Diesel Exhaust
_ Leaks _ Air Filters
_ Governor Control Fluid (DEF)
_ Torque marking of all aftertreatment joints _ Drain Water from
Engine (1) (2) _ Air Compressor _ Friction on Hoses
_ Flexpipe Ball and Slip joints torqued to the Fuel Tank
_ Smoke Color _ Friction on Wires
specified value in Special Instruction, _ Drain Water
_ Unusual Noise _ Loose Wire
UENR6766, "Assembly Procedure for the Separator
Connections
793F Off-Highway Truck" _ Open Coolant
_ Loose Fasteners or
conditioner Valves
Lost Fasteners
_ Grease Fittings
_ Diesel Exhaust
Fluid
_ Transmission
_ Differential
_ Final Drives _ Transmission - Each
_ Tire Pressure Gear
_ Leaks - Oil
_ Paint _ Grease Fittings _ Neutral Start
_ Loose Fasteners or
Power Train _ Outside Damage _ Front and Rear _ Transmission Lever Lock
lost Fasteners
_ Tires - Cuts, gouges Axle Bolt Torques _ Back - Up Alarm
_ Tires - Cuts, Gouges
_ Front and Rear _ Neutralizer Valve
Universal Torques _ Unusual Noise
_ Wheel to Rim
Torques
_ Steering
_ Brake Fluid _ Retarder
_ Leaks - Oil, Air
Steering and _ Paint _ Drain Water from _ Service Brakes
_ Loose Fasteners or
Brakes _ Outside Damage Air Tank _ Parking Brakes
Lost Fasteners
_ Grease Fittings _ Air Dryer
_ Unusual Noise
_ Sheet Metal _ Loose Fasteners or
_ Enclosure Doors - Locks
Chassis _ Paint _ Grease Fittings Lost Fasteners
and Latches
_ Damage _ Welds
_ Controls _ Leaks - Oil
_ Hydraulic Tank
Hydraulic _ Cylinder Rods _ Too much Drift _ Friction or Lost
_ Grease Fittings
_ Unusual Noise Fasteners
_ Welds
_ Paint _ Grease Fittings
_ Loose Fasteners or
Truck Body _ Damage _ Body Pads _ Body Positions
Lost Fasteners
_ Liners _ Retention Cable
_ Damage
Cab _ Sheet Metal _ Front Window _ Disconnect Switch _ Operation Guide
_ Paint Washer _ VIMS _ Maintenance Guide
_ Glass _ Air Filters _ Hoist Control _ Parts Book
_ Grease Fittings _ Horn _ Seat Cover
_ Torque on ROPS _Seat Belts _ Steps and Grab Irons
Support _ Seat Adjustments _ Loose Fasteners or
_ All Switches and Lost Fasteners
Controls _ Loose Wire
_ Doors and Windows Connections
_ Locks and Latches _ Leaks - Water
_ Mirrors Adjustment
_ Front Window Wipers
_ Front Window Washers

_ Heater
_ Air
Conditioner/Pressurizer
Lights - Outside and Cab
_ Gauges
_ Unusual Noise
_ Steering Column
Adjustment
_ Attachment Fluid
_ Special Assembly Parts Levels _ Warning Plates
_ Attachments
_ S/N Plates _ Charge on Fire _ Decals
Misc. and _ Engine Shutdown Switch
_ Correct Attachments Suppression System _ Leaks
Attachments _ Fire Suppression Test
_ Hand Tools _ Grease Fittings _ Loose Fasteners or
Switch
_ Paint _ Automatic Lost Fasteners
Lubrication System
(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.

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".

Table 51
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

Table 52
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

Table 53

793F Front and Rear Radar Angles

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

Table 54
793F Side Radar Angles
Radar Elevation (deg)
Left Top 45
Left Bottom 65
Right Top 45
Right Bottom 65

Azimuth Adjustment Procedure

Illustration 226 g02798504

Illustration 227 g02798505

Azimuth adjustment for Short Range Radar and Medium Range Radar Brackets

Table 55
Required Tools
13mm Wrench 1
Protractor 1

1. Loosen the four azimuth adjustment bolts on the brackets for the radars.

2. Use a protractor to set the proper azimuth angle that is listed in Table 53 or adjust the angle to fine-tune the system.

3. Carefully tighten the four azimuth adjustment bolts on the brackets for the radars.

4. Check the angle again to verify that the bracket is set to the proper angle.

5. Tighten the bolts.

6. Check the angle again to verify that the bracket is set to the proper angle.

7. Proceed to the"Elevation Adjustment Procedure".

Elevation Adjustment Procedure

Illustration 228 g02798504

Illustration 229 g02798505

Elevation adjustment bolts for Long Range Radar

Table 56
Required Tools
10 mm Wrench 1

Inclinometer or Digital Level 1

1. Loosen the four adjustment bolts on the bracket for the radar.

2. Use an inclinometer or a digital level to set the proper elevation angle that is listed in Table 53 or adjust the angle to fine-tune the system.

3. Carefully tighten the four azimuth adjustment bolts on the brackets for the radars.

4. Check the angle again to verify that the bracket is set to the proper angle.

5. Tighten the bolts.

6. Check the angle again to verify that the bracket is set to the proper angle.

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

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 08/12/2017

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