Global Service Learning: 793D (FDB) Off-Highway Truck

SERV1817
April 2006
GLOBAL SERVICE LEARNING
TECHNICAL PRESENTATION
793D (FDB)
OFF-HIGHWAY TRUCK
Service Training Meeting Guide

(STMG)
793D (FDB) OFF-HIGHWAY TRUCK
MEETING GUIDE VISUALS AND SCRIPT
AUDIENCE
Level II - Service personnel who understand the principles of machine systems operation,
diagnostic equipment, and procedures for testing and adjusting.
CONTENT
This presentation provides basic maintenance information and describes the systems operation
of the engine, power train, steering, hoist, and the air system and brakes for the 793D
Off-highway Truck.
OBJECTIVES
After learning the information in this meeting guide, the serviceman will be able to:
1. locate and identify the major components in the engine, power train, steering, hoist, and
the air system and brakes;
2. explain the operation of the major components in the systems; and
3. trace the flow of oil or air through the systems.
REFERENCES
793D (FDB) Off-Highway Truck Service Manual RENR8320
793D (FDB) Operation and Maintenance Manual SEBU7792
793D (FDB) Parts Manual SEBP3976
Cold Weather Recommendations for Caterpillar Machines SEBU5898
Caterpillar Machine Fluids Recommendations SEBU6250
793D (FDB) Off-Highway Trucks - (New Product Introduction V8N1) SERV7105
PREREQUISITES
Interactive Video Course "Fundamentals of Mobile Hydraulics" TEMV9001
Interactive Video Course "Fundamentals of Electrical Systems" TEMV9002
STMG 546 "Graphic Fluid Power Symbols" SERV1546
Estimated Time: 40 Hours

Visuals: 227
Handouts: 5
Form: SERV1817
Date: 04/06
© 2006 Caterpillar Inc.

SERV1817 -3- Text Reference
04/06
SUPPLEMENTAL MATERIAL
Specification Sheets
7793C Off-Highway Truck AEHQ5186
793D Off-Highway Truck AEHQ5600
Video Tapes
3500 EUI Service Introduction SEVN2241
Suspension Cylinder Charging TEVN2155
Mining Trucks--Cleanliness
and Component Life SEVN4142
Oil Sampling--The Right Way PEVN4638
Service Training Meeting Guides

STMG 682 "793C Off-Highway Truck (4AR)" (available on SERV1000 Legacy) SESV1682
STMG 706 "785C/789C Off-Highway Trucks" SERV1706
STMG 660 "785B/789B/793B Off-Highway Trucks--Maintenance"
(available on SERV1000 Legacy) SERV1660
STMG 681 "3500B Engine Controls--Electronic Unit Injection (EUI)" SERV1681
Technical Instruction Modules

Vital Information Management System--Introduction (available on SERV1000) SEGV2597
Automatic Electronic Traction Aid (available on SERV1000) SEGV2585
Booklets
C-Series Mining Trucks--3500B Diesel Engines LEDH8400
Know Your Cooling System SEBD0518
Diesel Fuels and Your Engine SEBD0717
Oil and Your Engine SEBD0640
04/06
SUPPLEMENTAL MATERIAL (CONTINUED)

Special Instructions
Accessing Flash Software for Machines REHS0494

Caterpillar Electronic Controls Service Code Information Description List REHS0126
Use of CE Connector Tools SEHS9065
Servicing DT Connectors SEHS9615
Use of 6V3000 Sure-Seal Repair Kit SMHS7531
Use of 8T5200 Signal Generator/Counter Group SEHS8579
Suspension Cylinder Servicing SEHS9411
Repair of Steering Accumulators SEHS8757
Adjustment Of The Valve Lash And The Valve Bridge With
The 147-5482 Valve Lash Gauge Group REHS0128
Using 1U5000 Auxiliary Power Unit SEHS8715
Using 1U5525 Auxiliary Power Unit Attachments SEHS8880
Brochures
How to Take a Good Oil Sample PEHP6001

Air Filter Service Indicator PEHP9013
Caterpillar Automatic Retarder Control AEDK0075
Caterpillar Truck Frames AEDK0707
Mining Truck Bodies: Selecting the Right Body System for Your Job AEDK0083
Miscellaneous
Window Decal "VIMS Keypad Parameters" SEEU6995

Pocket Card "Electronic Diagnostic Codes" NEEG2500
Chart "Practical Pressure Conversions" SEES5677
Guideline for Reusable Parts "Cleaning Rear Axle
Housing Assemblies (785/789)" SEBF8366
04/06
TABLE OF CONTENTS
INTRODUCTION ........................................................................................................................7
WALK AROUND INSPECTION...............................................................................................12
OPERATOR'S STATION............................................................................................................43
Vital Information Management System (VIMS) ..................................................................57
ENGINE......................................................................................................................................70
Engine Control System .........................................................................................................72
Cooling Systems ...................................................................................................................87
Jacket Water Cooling System ...............................................................................................89
Aftercooler Cooling System .................................................................................................94
Lubrication System ...............................................................................................................99
Engine Oil Renewal System (attachment) ..........................................................................102
Fuel System.........................................................................................................................105
Air Induction and Exhaust System......................................................................................110
Hydraulic Fan......................................................................................................................121
POWER TRAIN .......................................................................................................................131

Power Train Hydraulic System ...........................................................................................136
Transmission/Chassis Electronic Control System ..............................................................166
Rear Axle Oil Lubrication ..................................................................................................182
STEERING SYSTEM ..............................................................................................................195
HOIST SYSTEM ......................................................................................................................213
AIR SYSTEM AND BRAKES ................................................................................................236

Air Charging System...........................................................................................................238
Brake Systems.....................................................................................................................244
BRAKE ELECTRONIC CONTROL SYSTEM .....................................................................275

Manual Retarder Control ....................................................................................................278
Automatic Retarder Control (ARC)....................................................................................279
Traction Control System (TCS) ..........................................................................................289
CONCLUSION.........................................................................................................................297
VISUAL LIST ..........................................................................................................................298
SERVICEMAN'S HANDOUTS...............................................................................................301
HYDRAULIC SCHEMATIC COLOR CODE.........................................................................301

04/06
NOTES
04/06
793D
OFF-HIGHWAY TRUCK
© 2006 Caterpillar Inc.
INTRODUCTION
Shown is the left side of a 793D truck. The 793D is available in four different normal altitude
configurations, and a high altitude arrangement. All configurations deliver increased speed on
grade and include key components that are performance matched to the hauling application and
site conditions. The following list explains the five arrangements:
Standard - The standard arrangement is designed for exceptional, all-around performance.

Three factors combine to produce up to 9% more power at the wheels than the 793C, including;
5% more engine horsepower; a common rail hydraulic system for greater power train efficiency;
and a hydraulically driven demand fan that reduces parasitic load by operating only when
needed. More power at the wheels reduces cycle times and lowers cost-per-ton.
Extended Life Wheel Groups - Developed for uphill hauling applications. This arrangement is
designed to extend wheel life and hauling performance on long uphill hauls. Extended life
wheel groups are built with larger, more durable components, including larger spindles, wider
wheel bearing spacing, a larger braking surface, and extended life friction disc material for
longer brake life and more time between overhauls.
Extra Top Speed - Developed for long, flat haul applications. The extra top speed
configuration delivers a 10% increase in maximum speed to 60 km/h (37 mph) via a new input
transfer gear group. This arrangement also includes Extended Life Wheel Groups.
04/06
Extra Retarding - Developed for downhill loaded applications. This configuration typically
delivers an extra gear of retarding capability of 35% more speed on downhill grades. Extra
retarding is achieved by adding more robust wheel groups, larger brakes, extended life friction
material, and additional cooling capacity.
High Altitude - Developed for high altitude applications. The 3516B short stroke engine
delivers enhanced power management at higher altitudes from 2750 to 1600 m (9,000 to 12,000
ft). This arrangement also includes Extra Retarding.
- Serial No. Prefix: FDB

- Load carrying capacity: 218 metric tons (240 tons)
- Gross Machine Weight (GMW): 383739 kg (846000 lbs.)
- Length: 12.9 m (42.2 ft.)
- Width: 7.4 m (24.3 ft.)
- Height: 6.4 m (21 ft.)
- Body Up Height: 13.2 m (43.3 ft.)
- Maximum ground speed at 2000 engine rpm: 54.3 km/h (33.7 mph) (60 km/h (37 mph) for
the Extra Top Speed Arrangement)
04/06
Shown is the right side of the 793D truck. The large air tank on the right platform supplies air
for starting the truck and for the service brake and retarder system.
The main hydraulic tank is also visible. The hydraulic tank supplies oil for the hoist system and
the brake system.
The 793D uses the torque converter case as the supply tank for the torque converter and the
transmission.
The Brake System ECM controls both the ARC and the TCS functions. The TCS is connected
to the CAT Data Link. The Electronic Technician (ET) service tool can be used to diagnose the
TCS.
SERV1817 - 10 - Text Reference
04/06
The 793D is similar in appearance to the 793C and may be difficult to recognize from a distance.
The 793D can be recognized by the four air filters and the diagonal access ladder. The 789C has
only two air filters mounted in the same locations and is equipped with two vertical ladders.
The 793D uses a Next Generation Modular Radiator (NGMR). The NGMR has improved heat
rejection compared to the previous radiator. Changes to the cooling module has resulted in the
following improvements:
- Reduced weight due to elimination of redundant structures

- Changes to module mounting for easier removal
- Built-in surge tank
- Hydraulic fan drive versus belt drive
- Wider ladder attached directly to cooling module
04/06
The truck bodies on 793D trucks are mandatory options. The following hree body styles are
available for the 793D trucks:
- A 12 degree flat floor design that provides uniform load dumping, excellent load retention,
and a low center of gravity.
- A dual-slope design with a "V" bottom main floor to reduce shock loading, center the load,
and reduce spills.
- A Mine Specific Design (MSD II) Body. The lightweight MSD II body is based on the flat
floor design and is customized to maximize payload potential and minimize cost-per-ton.
All internal wear surfaces of the truck bodies are made with 400 Brinell hardness steel. All
attachment body liners are also made with 400 Brinell hardness steel. The external components
of the bodies are made of steel with a yield strength of 6205 bar (90000 psi).
The forward two thirds of the body floor is made with 20 mm (.79 in.) thick 400 Brinell steel
plate. The rear one third of the body floor is made with a 10 mm (.39 in.) thick 400 Brinell sub
plate and a 20 mm (.79 in.) thick 400 Brinell body grid liner plate. As an option, the grid liner
plate can be made with 500 Brinell steel.
The rear suspension cylinders absorb bending and twisting stresses rather than transmitting them
to the main frame.
04/06
793D MAINTENANCE
ice
793D Serv
Procedure
WALK AROUND INSPECTION

5
WALK AROUND INSPECTION
Before working on or operating the truck, read the Operation and Maintenance Manual
thoroughly for information on safety, maintenance, and operating techniques.
Safety Precautions and Warnings are provided in the manual and on the truck. Be sure to
identify and understand all symbols before starting the truck.
The first step to perform when approaching the truck is to make a thorough walk around
inspection. Look around and under the truck for loose or missing bolts, for trash to build-up,
and for coolant, fuel, or oil leaks. Look for indications of cracks. Pay close attention to high
stress areas as shown in the Operation and Maintenance Manual.
04/06
Grease Drain Hoist and
MAINTENANCE Reservoir Air Reservoir Brake Oil Level
10 HOURS/DAILY Level Moisture
Batteries
Air Filters
Suspension
Steering Oil Level
Cylinder Height
Coolant Level
Ether Cylinders Rear Axle
Oil Level
Belts and Breather
Engine Oil Level
Inspect Frame
Windshield for Cracks and
Washer Level Body Support Pads
And A/C Filters
Check for Leaks
Drain Air Reservoir Moisture
and Trash Build-up
Wash Windows, Transmission and Brake Cylinder

Cab Fresh Air Filters, Torque Converter Breathers
Seat Belt, Oil Level
Indicators and Gauges,
Brake Tests,
793D
Secondary Steering
Backup Alarm, and
Traction Control System
Suspension Cylinder Height

and Grease Breathers
Front Wheel Breathers Tire Inflation

Pressure
Wheel Nuts
Final Drive
Check Fuel Level Primary Magnetic Plug
and Drain Moisture Fuel Filter
The following list identifies the items that must be serviced every 10 Hours or Daily.
Walk-Around Inspection:
- Check for loose or missing bolts, for leaks, for trash build-up, and for cracks in frame
structures and body support pads
- Tire condition and inflation pressure - Seat belts
- Front and rear wheel magnetic plugs - Suspension cylinders
- Wheel nuts - Fuel level and moisture
- Primary fuel filter - Hoist and brake oil
- Front and rear axle breathers - Air tank moisture
- Transmission/Converter oil - Radiator and coolant
- Brake cylinders and breathers - Ether cylinders
- Fan belts - Engine crankcase oil
- Steering system oil - Air filters and precleaners
- Batteries - Cab fresh air filters
- Windshield washer fluid level - Secondary steering
- Back-up alarm - Brakes
04/06
The front wheel bearing oil level is checked and filled by removing the plug (1) in the center of
the wheel bearing cover. The oil should be level with the bottom of the plug hole. The fill plug
is a magnetic plug. Inspect the fill plug weekly for metal particles. If any metal particles are
found, remove the wheel cover and inspect the bearings for wear. The oil is drained by
removing the drain plug (2).
The service interval for changing the front wheel bearing oil is 500 hours.
Check the tire inflation pressure. Operating the truck with the wrong tire inflation pressure can
cause heat build-up in the tire and accelerate tire wear.
NOTE: Care must be taken to ensure that fluids are contained while performing any
inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to
collect the fluid in suitable containers before opening any compartment or disassembling
any component containing fluids. Refer to the "Tools and Shop Products Guide" (Form
NENG2500) for tools and supplies suitable to collect and contain fluids in Caterpillar
machines. Dispose of fluids according to local regulations and mandates.
04/06
Check the front suspension cylinders for leaks or structural damage. Check the charge condition
of the front suspension cylinders when the truck is empty and on level ground. Measure the
charge height of the suspension cylinders and compare the dimension with the dimension that
was recorded the last time the cylinders were charged. Recharge the cylinders with oil and
nitrogen if necessary.
Inspect the condition of the front wheel bearing axle housing breather (1). The breather prevents
pressure from building up in the axle housing. Pressure in the axle housing may cause brake
cooling oil to leak through the Duo-Cone seals in the wheel brake assemblies.
Two grease outlet fittings (2) are located on the front of each suspension cylinder. The grease
supply line for the Auto Lubrication System is located at the rear of the suspension cylinder. No
grease outlet fittings should be located on the same side of the suspension cylinder as the grease
fill location. An outlet fitting positioned on the same side of the suspension cylinder as the
grease fill location will prevent proper lubrication of the cylinder.
Make sure that grease is flowing from the outlet fittings to verify that the suspension cylinders
are being lubricated and that the pressure in the cylinders is not excessive.
INSTRUCTOR NOTE: For more detailed information on servicing the suspension system,
refer to the Special Instruction "Suspension Cylinder Servicing" (Form SEHS9411).
04/06
The steering solenoid and relief valve manifold is located on the frame near the right side of the
engine. Steering system oil samples can be taken at the Scheduled Oil Sampling (S•O•S) tap
(arrow) located on the steering solenoid and relief valve manifold.
04/06
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11
Shown in the top visual is the primary fuel filter (1) that is used on the truck. The filter is
mounted on the back side of the fuel tank. Fuel is pulled through the filter by the fuel transfer
pump which is mounted on the right side of the engine.
Shown in the bottom visual are the optional primary fuel filters and fuel water separators (2)
that can be used in place of the single primary filter. These filters are located on the inside of
the right front frame rail near the engine. A valve located on the bottom of the filter provides a
means to drain the water that has separated from the fuel.
A drain valve (not shown) located on the bottom of the fuel tank allows condensation to be
removed from the fuel tank before flowing to the fuel/water separators.
04/06
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Located behind the right front tire are the rear brake oil coolers (1), the steering oil cooler (5),
the parking brake release filter (2), and the torque converter charging filter (3). There are two
rear brake oil cooler screens located behind the oil coolers. The screens should be inspected and
cleaned whenever there is an indication of a brake problem.
One of the three injector banks (4) for the automatic lubrication system is also in this location.
These injectors are adjustable and regulate the quantity of grease that is injected during each
cycle (approximately once per hour).
A solenoid air valve provides a controlled air supply for the automatic lubrication system. The
solenoid air valve is energized by the Transmission/Chassis ECM. The Vital Information
Management System (VIMS) provides the Transmission/Chassis ECM with the instructions for
when and for how long to energize the solenoid. The solenoid is energized for 75 seconds ten
minutes after the machine is started. Every 60 minutes thereafter, the solenoid is energized for
75 seconds until the machine is stopped (shut down). These settings are adjustable through the
VIMS keypad in the cab.
Transmission and torque converter oil samples can be taken at the Scheduled Oil Sampling
(S•O•S) oil analysis tap (6).
INSTRUCTOR NOTE: For more detailed information on servicing the automatic

lubrication system, refer to the Service Manual Module "Automatic Lubrication System"
(Form SENR4724).
04/06
13
Shown is the hoist and brake hydraulic tank and the oil level sight gauges. The oil level is
normally checked with the upper sight gauge (1). The oil level should first be checked with cold
oil and the engine stopped. The level should again be checked with warm oil and the engine
running.
The lower sight gauge (2) can be used to fill the hydraulic tank when the hoist cylinders are in
the RAISED position. When the hoist cylinders are lowered, the hydraulic oil level will
increase. After the hoist cylinders are lowered, check the hydraulic tank oil level with the upper
sight gauge.
Inspect the hydraulic tank breather (3) for plugging.
When filling the hydraulic tank after an oil change, fill the tank with oil to the FULL COLD
mark on the sight gauge. Turn on the engine manual shutdown switch so the engine will not
start. Crank the engine for approximately 15 seconds. The oil level will decrease as oil fills the
hydraulic system. Add more oil to the tank to raise the oil level to the FULL COLD mark.
Crank the engine for an additional 15 seconds. Repeat this step as required until the oil level
stabilizes at the FULL COLD mark.
Turn off the engine manual shutdown switch and start the engine. Warm the hydraulic oil. Add
more oil to the tank as required to raise the oil level to the FULL WARM mark.
04/06
14
The rear axles are equipped with double reduction planetary-type final drives. Rotate the final
drive until the cover and plug are positioned as shown. The final drive oil level is checked and
filled by removing the magnetic plug (arrow). The oil should be level with the bottom of the
plug hole. Fill the rear axle housing with oil before filling the final drives with oil. Allow
enough time for the oil to settle in all of the compartments. This can be as much as 20 minutes
during cold temperatures.
The magnetic inspection plugs should be removed weekly from the final drives and checked for
metal particles. For some conditions, checking the magnetic plugs is the only way to identify a
problem which may exist.
NOTICE
The rear axle is a common sump for the differential and both final drives. If a final drive
or the differential fails, the other final drive components must also be checked for
contamination and then flushed. Failure to completely flush the rear axle after a failure
can cause a repeat failure within a short time.
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3
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The differential oil level is checked by viewing the oil level through sight glass (1). The oil
should be level with the bottom of the inspection hole.
The oil level switch (2) provides input signals to the VIMS which informs the operator of the
rear axle oil level.
A rear axle oil filter (3) is used to remove contaminants from the rear axle housing.
Check the charge condition of the rear suspension cylinders when the truck is empty and on
level ground.
The second of three injector banks (4) for the automatic lubrication system is mounted on the top
rear of the differential housing.
Above the lubrication injectors is a breather (5) for the rear axle. Inspect the condition of the
breather at regular intervals. The breather prevents pressure from building up in the axle
housing. Excessive pressure in the axle housing can cause brake cooling oil to leak through the
Duo-Cone seals in the wheel brake assemblies.
Differential and final drive oil samples can be taken at the Scheduled Oil Sampling (S•O•S) oil
analysis tap (6).
INSTRUCTOR NOTE: For more detailed information on servicing the suspension system,
refer to the Special Instruction "Suspension Cylinder Servicing" (Form SEHS9411).
04/06
16
The cable that holds the body up is stored below the rear of the body. Whenever work is to be
performed while the body is raised, the truck body retaining cable must be connected between
the body and the rear hitch to hold the body in the raised position.
WARNING
The space between the body and the frame becomes a zero clearance area when the body is
lowered. Failure to install the cable can result in injury or death to personnel working in
this area.
04/06
17
The fuel tank is located on the left side of the truck. The fuel level sight gauges (arrow) are used
to check the fuel level during the walk around inspection.
04/06
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Located behind the fuel tank are the front brake oil cooling filter and the rear brake oil cooling
filter (1). Oil not used to raise or lower the hoist cylinders flows from the hoist valve through
the brake oil filters and the brake oil coolers to the brakes.
An oil filter bypass switch (3) is located on the filter housing. The oil filter bypass switch
provides an input signal to the Brake ECM. The Brake ECM sends the signal to the VIMS,
which informs the operator if the filters are restricted.
Hoist and brake oil samples can be taken at the Scheduled Oil Sampling (S•O•S) oil analysis
tap (2).
04/06
19
Supply oil for the torque converter and the transmission is contained in the torque converter
case. Sight gauges (1) are used to check the oil level for the torque converter and the
transmission.
NOTE: The FULL COLD oil level mark should only be used with the engine OFF. The
FULL WARM oil level mark should only be used with the engine RUNNING.
Torque converter and transmission oil is added at the fill tube (2).
When filling the torque converter and transmission oil sump after an oil change, fill the sump
with oil to the top of the upper sight gauge. Turn off the engine manual shutdown switch so the
engine will not start. Crank the engine for approximately 15 seconds. The oil level will
decrease as oil fills the torque converter and transmission system. Add more oil to the sump to
raise the oil level to the FULL COLD mark. Crank the engine for an additional 15 seconds.
Repeat this step as required until the oil level stabilizes. Do not shift out of NEUTRAL until
after the oil level is correct.
Turn off the engine manual shutdown switch and start the engine. Warm the torque converter
and transmission oil. Add more oil to the sump as required to raise the torque converter and
transmission oil level to the FULL WARM mark.
04/06
20
The scavenge screen for the torque converter and transmission oil is located behind the
cover (1).
Shown is the location of the torque converter outlet screen (2). Oil flows from the torque
converter outlet relief valve through the torque converter outlet screen to the torque converter
and transmission oil cooler located on the right side of the engine.
04/06
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Inspect the condition of the two breathers (1) (one visible) for the brake cylinders. The second
breather is located behind the cross tube. Oil should not leak from the breathers. Oil leaking
from the breathers is an indication that the oil piston seals in the brake cylinder need
replacement. Air flow from the breathers during a brake application is an indication that the
brake cylinder air piston seals need replacement.
If air is in the system or a loss of oil downstream from the cylinders occurs, the piston in the
cylinder will overstroke and cause an indicator rod to extend and open the brake overstroke
switch (2). The switch provides an input signal to the VIMS, which informs the operator of the
condition of the service brake oil circuit. If an overstroke condition occurs, the problem must be
repaired and the indicator rod pushed in to end the warning.
04/06
22
Shown is the location of the transmission charging filter (1) outside the left frame rail.
Transmission charging oil flows through the transmission charging filter to the transmission
control valves on top of the transmission and to the torque converter lockup clutch valve located
on top of the torque converter.
An oil filter bypass switch (2) is located on top of the filter housing. The oil filter bypass switch
provides an input signal to the Brake ECM. The Brake ECM sends the signal to the VIMS
which informs the operator if the filter is restricted.
The third injector bank (3) for the automatic lubrication system is also located in this area.
04/06
23
The air dryer (arrow) is located in front of the left front suspension cylinder. The 793D trucks
use only one air dryer to accommodate the air compressor.
The air system can be charged from a remote air supply through a ground level connector
located inside the left frame.
04/06
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The engine oil filters (1) are located on the left side of the engine. Engine oil should be added at
the fill tube (2) and checked with the dipstick (3).
The engine lubrication system is equipped with two oil pressure sensors (4). A sensor is located
on each end of the oil filter base. One sensor measures engine oil pressure before the filters.
The other sensor measures oil pressure after the filters. The sensors provide input signals to the
Engine Electronic Control Module (ECM). The Engine ECM provides input signals to the
VIMS, which informs the operator of the engine oil pressure. Together, these sensors inform the
operator if the engine oil filters are restricted.
04/06
25
If equipped, the engine oil can be added through the fast fill service center that is located on the
front bumper of the machine. Oil may also be added through the oil change connector (1)
located in the left front corner of the oil pan, if equipped.
An engine oil level switch (2) provides an input signal to the Engine ECM. The Engine ECM
sends the input signal to the VIMS, which informs the operator of the engine oil level. The oil
level switch tells the operator when the engine oil level is low and it is unsafe to operate the
truck without causing damage to the engine. The ENG OIL LEVEL LOW message is a
Category 2 or 3 Warning.
04/06
26
The secondary fuel filters are located above the engine oil filters on the left side of the engine.
The secondary fuel filters are 4 micron filters. The clearances in the fuel injectors are 5 micron.
Failure to use 4 micron secondary fuel filters may cause early injector failures.
The fuel priming pump switch (1) is located above the fuel filters. The fuel priming pump is
located on the opposite side of the engine. The fuel priming pump is used to fill the filters after
they are changed.
A fuel filter bypass switch (2) is located on the filter base. The bypass switch provides an input
signal to the Engine ECM. The Engine ECM sends the signal to the VIMS, which informs the
operator if the filters are restricted.
If fuel filter restriction exceeds 138 kPa (20 psi), a fuel filter restriction event is logged. No
factory password is required to clear this event.
NOTE: If the fuel system requires priming, it may be necessary to block the fuel return
line during priming to force the fuel into the injectors.
NOTICE
Failure to use 4 micron secondary fuel filters may cause early injector failures.
04/06
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Before climbing the truck ladder, make sure that the manual engine shutdown switch (1) is OFF.
The engine will not start if the manual shutdown switch is ON. If necessary, the switch can be
used to stop the engine from the ground level. Do this periodically to check the secondary
steering system (refer to Visual 161).
The toggle switches (2) control the lights in the engine compartment and above the access
ladder.
The RS-232 service connector (3) is used to connect a laptop computer with VIMS-PC software
to upload new source and configuration files, view real time data, or download logged
information from the VIMS.
The battery disconnect switch (4) and VIMS service connector key switch (5) must be in the ON
position before the laptop computer with VIMS software will communicate with the VIMS.
The blue service lamp (6) is part of the VIMS. When the key start switch is turned to the ON
position, the VIMS runs through a self-test. During the self-test the service lamp will flash three
times if there are logged events stored in the VIMS Main Module and once if there are no logged
events.
During normal operation, the service lamp will turn ON to notify service personnel that the
VIMS has an active data (machine) or maintenance (system) event. The service lamp flashes to
indicate when an event is considered abusive to the machine.
04/06
28
While climbing the ladder, make a thorough inspection of the radiator. Be sure that no debris or
dirt is trapped in the cores.
The VIMS will also provide the operator with an air filter restriction warning when the filter
restriction is approximately 6.2 kPa (25 in. of water). Black exhaust smoke is also an indication
of air filter restriction.
Check the dust valves (1) for plugging. If necessary, disconnect the clamp and open the cover
for additional cleaning. The dust valve is OPEN when the engine is OFF and closes when the
engine is running. The dust valve must be flexible and closed when the engine is running or the
precleaner will not function properly and the air filters will have a shortened life. Replace the
dust valve if the rubber is not flexible.
Two filter elements are installed in the filter housings. The large element is the primary element
and the small element is the secondary element.
Air intake system tips:

- The primary element can be cleaned a maximum of six times.
- Never clean the secondary element for reuse. Always replace the secondary element.
- Air filter restriction causes black exhaust smoke, high exhaust temperatures, and low
power.
04/06
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2
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The cooling system on the 793D is divided into two systems. The two systems are the jacket
water cooling system and the aftercooler cooling system. These two systems are not connected.
When servicing the cooling systems, be sure to drain and fill both systems separately.
The engine cooling system shunt tank (1) is located on the top tank above the radiator. The
coolant levels are checked at the shunt tank. Use the gauges (2) on top of the shunt tank to
check the two coolant levels.
Two coolant level switches (not shown) are located on the rear of the top tank below the
platform to monitor the coolant level of both cooling systems. The coolant level switches
provide input signals to the VIMS which informs the operator of the engine coolant levels.
The jacket water and the aftercooler cooling systems each have their own relief valve (3). If a
cooling system overheats or if coolant is leaking from a relief valve, clean or replace the relief
valve.
The water used in the cooling system is critical for good cooling system performance. Use
distilled or deionized water whenever possible to prevent acids or scale deposits in the cooling
system. Acids and scale deposits result from contaminants that are found in most common water
sources.
Never use water alone. All water is corrosive at engine operating temperatures without coolant
additives. Also, water alone has none of the lubrication properties which are required for water
pump seals.
04/06
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30
Located on the right platform are the automatic lubrication system grease tank (1), the main air
system tank (2), and the steering system tank (3).
Check the level of the grease in the automatic lubrication system tank with the grease level
indicator located on top of the tank.
A drain valve is located at the bottom right of the main air system tank. Drain the condensation
from the air tank each morning.
04/06
3
4
5
6
31
The oil level for the steering system tank is checked at the upper sight gauge (1) when the oil is
cold and the engine is stopped. After the engine is started, the oil level will decrease as the oil
fills the steering accumulators.
After the accumulators are filled, the oil level should be checked again at the lower sight gauge
(2). When the engine is running and the accumulators are fully charged, the oil level should not
be below the ENGINE RUNNING marking of the lower gauge. If the ENGINE RUNNING
level is not correct, check the nitrogen charge in each accumulator. A low nitrogen charge will
allow excess oil to be stored in the accumulators and will reduce the secondary steering capacity.
Before removing the cap to add oil to the steering system, be sure that the engine was shut off
with the key start switch, and the steering oil has returned to the tank from the accumulators.
Then, depress the pressure release button (3) on the breather to release any remaining pressure
from the tank.
Also located on the tank are the main steering oil filter (4) and the case drain filters (5) and (6).
Oil returning from the steering pump, the priority valve, the rear axle motor, and the brake
cooling motor returns to the tank through filter (5). Oil returning from the fan pump and the fan
motor returns to the the tank through filter (6).
04/06
If the steering pump fails or if the engine cannot be started, the connector (8) is used to attach an
Auxiliary Power Unit (APU). The APU will provide supply oil from the steering tank at the
connector to charge the steering accumulators.
The steering oil temperature sensor (7) provides an input signal to the VIMS, which informs the
operator of the steering system oil temperature.
INSTRUCTOR NOTE: For more detailed information on servicing the steering

accumulators, refer to the Service Manual Module "793D Off-highway Truck Steering
System" (Form RENR8336) and the Special Instruction "Repair of 4T8719 Bladder
Accumulator Group" (Form SEHS8757). For more information on using the APU, refer
to the Special Instructions "Using 1U5000 Auxiliary Power Unit (APU)" (Form
SEHS8715) and "Using the 1U5525 Attachment Group" (Form SEHS8880).
04/06
32
Another small air tank (not visible) is located behind the cab. The air tank behind the cab
supplies air to the parking and secondary brakes and provides air to the front brake diverter
valve. Drain the moisture from the tank daily with the drain valve (arrow).
04/06
1 2
33
A turbocharger inlet pressure sensor (1) is located in both intake tubes from the air cleaners to
the turbochargers. The Engine ECM uses the turbocharger inlet pressure sensors in combination
with the atmospheric pressure sensor to determine air filter restriction. The ECM provides the
input signal to the VIMS which informs the operator of the air filter restriction.
If air filter restriction exceeds 6.25 kPa (25 in. of water), an air filter restriction event will be
logged, and the ECM will derate the fuel delivery (maximum derating of 20%) to prevent
excessive exhaust temperatures. A factory password is required to clear this event.
The Engine ECM will automatically inject ether from the ether cylinders (2) during cranking.
The duration of automatic ether injection depends on the jacket water coolant temperature. The
duration will vary from 10 to 130 seconds.
The operator can also inject ether manually with the ether switch in the cab. The manual ether
injection duration is 5 seconds.
Ether will be injected only if the engine coolant temperature is below 10° C (50° F) and engine
speed is below 1900 rpm.
Ether starting tip:
- Cold weather causes rough combustion and white exhaust smoke from unburned fuel.
Ether injection will reduce the duration and severity of unburned fuel symptoms.
04/06
34
The windshield washer reservoir (1) is located in the compartment in front of the cab. Keep the
reservoir full of windshield washer fluid.
The air conditioner filter (2) is also located in the compartment in front of the cab. Clean or
replace the filter element when a reduction of circulation in the cab is noticed.
04/06
35
Some of the 10 Hours or Daily checks performed in the operator's compartment are:
- Brakes: Check operation

- Indicators and gauges: Test operation
- Seat belt: Inspect
- Back-up alarm: Test operation
- Secondary steering: Test operation
The brakes are checked by engaging one of the brake systems and placing the shift lever in
FIRST FORWARD. Accelerate the engine until the truck moves. The truck must not move
below 1300 rpm. This procedure should be repeated for the parking, secondary, and service
brake systems.
The cab fresh air filter is located behind the cover (arrow). Clean or replace the cab fresh air
filter when necessary.
INSTRUCTOR NOTE: Refer to the Operation and Maintenance Manual for more
information on the remaining tests performed in the cab.
04/06
36
OPERATOR'S STATION
The VIMS controls the Truck Payload Measurement System (TPMS) on the 793D trucks. There
are two sets of TPMS external loading lamps on the truck. One set of lamps is on the left side of
the cab (arrow) and the other set is on the right platform. The lamps are green and red. The
lamps inform the loader operator of the loading progress toward a target payload weight (set
through the VIMS Keypad). The lamps are active only during the loading cycle and are off at all
other times.
During loading, the green (continue loading) lamps will be ON until the payload is 95% of the
target weight setting. Then, the red (stop loading) lamp will light. A "last pass" indication can
be programmed into the system using the VIMS Keypad. With last pass indication, the VIMS
calculates an average loader pass size and predicts payload weight. If the predicted weight after
the NEXT loader pass will be above 95% of the target weight setting, the red lamps FLASH.
The red lamps will be ON continuously after the last pass (when fully loaded).
A minimum of three loader passes are required for the "last pass" indication option to function
correctly.
INSTRUCTOR NOTE: The attachment TPMS 10 inch LED display scoreboard is shown.
04/06
37
Shown is a view of the operator's seat and the trainer's seat..

04/06
38
The 793D truck hoist system is electronically controlled. The hoist control lever (arrow)
activates the four positions of the hoist control valve. The four positions are: RAISE, HOLD,
FLOAT, and LOWER.
A fifth position of the hoist valve is called the SNUB position. The operator does not have
control over the SNUB position. The body position sensor controls the SNUB position of the
hoist valve. When the body is lowered, just before the body contacts the frame, the
Transmission/Chassis ECM signals the hoist solenoids to move the hoist valve spool to the
SNUB position. In the SNUB position, the body float speed is reduced to prevent hard contact
of the body with the frame.
The truck should normally be operated with the hoist lever in the FLOAT position. Traveling
with the hoist in the FLOAT position will make sure the weight of the body is on the frame and
body pads and not on the hoist cylinders. The hoist valve will actually be in the SNUB position.
If the transmission is in REVERSE when the body is being raised, the hoist lever sensor is used
to shift the transmission to NEUTRAL. The transmission will remain in NEUTRAL until:
1. The hoist lever is moved into the HOLD or FLOAT position; and
2. the shift lever has been cycled into and out of NEUTRAL.
NOTE: If the truck is started with the body raised and the hoist lever in FLOAT, the
lever must be moved into HOLD and then FLOAT before the body will lower.
04/06
39
Shown is an overall view of the dash from the left side of the cab. Some of the features are:
- Telescopic/tilt steering column for individual adjustment
- Intermittent wiper/washer, turn signal control, and dimmer switch
- Enhanced instrument layout

- Backlit rocker switches
- Steering wheel mounted electric horn control
04/06
40
The operator controls to the left of the steering column are:
- Telescopic/tilt steering column adjustment lever (1): Push for telescoping and pull for tilt.
- Intermittent wiper/washer, turn signal control, and dimmer switch (2).
- Steering wheel mounted electric horn control (3).
- Cigarette lighter (4): The cigarette lighter socket receives a 12-Volt power supply. This
socket can be used as a power supply for 12 volt appliances. Another 12-Volt power port is
provided behind the operator's seat.
04/06
41
Shown is a closer view of the intermittent wiper/washer, turn signal control, and dimmer switch.
Windshield washer: Push the button at the end of the lever to activate the electrically powered
windshield washer.
The intermittent wiper switch has the following six positions:

- OFF (0)
- Intermittent position 1 (one bar)
- Intermittent position 2 (two bars)
- Intermittent position 3 (three bars)
- Low speed continuous wiper (I)
- High speed continuous wiper (II)
Dimmer switch: Pull the lever toward the operator for BRIGHT lights, and push the lever away
from the operator for DIM lights.
Turn signals: To activate the turn signals, lift the lever for a RIGHT turn, and lower the lever for
a LEFT turn.
04/06
42
Located on the right side of the steering column is the manual retarder lever. The manual
retarder lever is used to modulate engagement of the service brakes on all four wheels. The
retarder system allows the machine to maintain a constant speed on long downgrades. The
retarder will not apply all of the normal braking capacity.
Located on the dash to the right of the retarder lever are (from left to right):
- the key start switch

- the temperature variable knob
- the fan speed switch
NOTICE
Do not use the retarder control as a parking brake or to stop the machine.
04/06
1 2 3
43
Located on the floor of the cab are:

- Secondary brake pedal (1): Used to modulate application of the parking brakes on all four
wheels.
- Service brake pedal (2): Used to modulate engagement of the service brakes on all four
wheels. For more precise modulation of the service brakes, use the manual retarder lever
on the right side of the steering column.
- Throttle pedal (3): A throttle position sensor is attached to the throttle pedal. The throttle
position sensor provides the throttle position input signals to the Engine ECM.
NOTE: The 793D truck throttle position must be programmed to the 10 to 90% setting.
The setting is changed in the Engine ECM configuration screen with ET.
The Engine ECM provides an elevated engine idle speed of 1600 rpm when the engine oil
temperature is below 60° C (140° F). The rpm is gradually reduced to 1000 rpm between 60° C
(140° F) and 71° C (160° F). When the temperature is above 71° C (160° F), the engine will idle
at LOW IDLE (700 rpm).
Increasing the low idle speed helps prevent incomplete combustion and overcooling. To
temporarily reduce the elevated idle speed, the operator can release the parking brake or depress
the throttle momentarily, and the idle speed will decrease to LOW IDLE for 10 minutes.
04/06
1
3
44
To the right of the operator's seat is the shift console. Located on the shift console are the
transmission shift lever (1), the parking brake air valve (2), and parking brake reset valve (3).
The "D" Series truck transmissions have SIX speeds FORWARD and ONE speed REVERSE.
The top gear limit and body up gear limit are programmable through the Transmission/Chassis
ECM. The top gear limit can be changed from THIRD to SIXTH. The body up gear limit can
be changed from FIRST to THIRD.
The parking brake reset valve (3) prevents the machine from moving if the operator leaves the
truck with the parking brake lever in the released position and system air pressure decays to less
than 413 kPa (60 psi). If the system air pressure has drained to less than 413 kPa (60 psi), the
parking brake reset valve will pop up and must be RESET before the truck can be moved.
To reset the valve, put the parking brake lever in the ON position and allow the air pressure to
build to the maximum pressure. Then, push the amber knob of the parking brake reset valve IN
until it is below the surface of the shift console. The amber knob of the parking brake reset
valve must be pushed IN before the parking brakes will release, regardless of the position of the
parking brake lever.
04/06
1 2 3 4 5
45
Located in the overhead panel are the following switches:
- Hazard lights (1)
- Headlights and parking/tail lights (2)
- Fog lights (3)
- Back-up lights (4)
- Front flood/ladder lights (5)

04/06
46
Shown is the circuit breaker panel located behind the operator's seat. The 793D trucks use only
circuit breakers to protect the electrical circuits.
A 12-Volt/5 amp power port (1) provides a power supply for 12-Volt appliances, such as a laptop
computer.
A laptop computer with the VIMS software installed can be connected to the diagnostic
connector (2) to obtain diagnostic and production information from the VIMS Electronic
Control.
A laptop computer with the Electronic Technician (ET) software installed can be connected to
the CAT Data Link connector (3) to obtain diagnostic information and perform programming
functions on all the electronic controls.
04/06
47
Shown is the center of the front dash panel. Eight dash indicators, the four-gauge cluster
module, and the speedometer/tachometer module are visible.
The four dash indicators to the left of the four-gauge cluster module are (from top to bottom):
- Left turn
- Body up: Lights when the body is up. Input is from the body position sensor.
- Reverse: Lights when the shift lever switch is in REVERSE.
- High beam
The four dash indicators to the right of the speedometer/tachometer module are (from top to
bottom):
- Right turn
- Action lamp: Lights when a Category 2, 2-S or Category 3 Warning is active.
- Retarder: Lights when the retarder is ENGAGED (Auto or Manual). Flashes rapidly when
a fault in the ARC system is detected.
- TCS: Lights when the Traction Control System (TCS) is ENGAGED. Flashes rapidly
when a fault in the TCS system is detected.
04/06
The four systems monitored by the four-gauge cluster module are (top and bottom, left to right):
- Engine coolant temperature: Maximum operating temperature is 107° C (225° F).
- Brake oil temperature: Maximum operating temperature is 121° C (250° F).
- System air pressure: Minimum operating pressure is 450 kPa (65 psi).
- Fuel level: Minimum operating levels are 15% (Category 1) and 10% (Category 2).
The three systems monitored by the speedometer/tachometer module are:
- Tachometer: Displays the engine speed in rpm.
- Ground speed: Displayed in the left side of the three-digit display area and can be
displayed in miles per hour (mph) or kilometers per hour (km/h).
- Actual gear: Displayed in the right side of the three-digit display area and consists of two
digits that show the actual transmission gear that is engaged. The left digit shows the
actual gear (such as "1," "2," etc.). The right digit shows the direction selected
("F"-Forward, "N"-Neutral or "R"-Reverse).
04/06
48
To the right of the Speedometer/Tachometer Module are several rocker switches. The rocker
switches control the following systems:
Top row (from left to right)

- Throttle back-up: Raises the engine speed to 1300 rpm if the throttle sensor signal is
invalid.
- Ether starting aid: Allows the operator to manually inject ether if the engine oil
temperature is below 10° C (50° F) and engine speed is below 1900 rpm. The manual
ether injection duration is five seconds.
- ARC: Activates the Automatic Retarder Control (ARC) system.
- Brake release/hoist pilot: Used to release the parking brakes for towing and to provide
hoist pilot oil to lower the body with a dead engine. The small latch must be pushed UP
before the switch can be pushed DOWN.
- TCS test: Tests the Traction Control System (TCS). Use this switch when turning in a
tight circle with the engine at LOW IDLE and the transmission in FIRST GEAR. The
brakes should ENGAGE and RELEASE repeatedly. The test must be performed while
turning in both directions to complete the test.
Bottom row (from left to right)

- Panel Lights: Use this switch to DIM the panel lights.
- Air Conditioning: Use this switch to turn ON the air conditioner.
04/06
49
Vital Information Management System (VIMS)
Shown is the Vital Information Management System (VIMS) message center module (1) and the
keypad module (2).
The message center module consists of an alert indicator, a universal gauge, and a message
display window. The alert indicator flashes when a Category 1, 2, 2-S, or 3 Warning is present.
The universal gauge displays active or logged data (machine) and maintenance (system)
events. The universal gauge will also display the status of a sensor parameter selected for
viewing by depressing the GAUGE key on the keypad.
The message display window shows various types of text information to the operator, depending
on the menu selected with the keypad. An active event will override most displays until
acknowledged by depressing the OK Key.
04/06
VITAL INFORMATION
MANAGEMENT SYSTEM (VIMS)
MESSAGE CENTER AND OPERATOR KEYPAD
Data Logger
Indicator Dots
Alert
Indicator Universal
ENG COOL TEMP [135]
Gauge
60 Deg F
Red
Indicator Display
Gauge OK
F1 ABC DEF
Key
F2 F3 GH1 JKL MNO
PRS TUV WXY

ID
50
Shown are the message center and keypad modules used on 793D Trucks. The keypad module
allows the operator or a service technician to interact with the VIMS. Some of the functions that
can be performed using the keypad are:
OK Key: Used to complete keypad entries and to acknowledge events. Acknowledging an

event will remove the event from the display temporarily. Severe events cannot be
acknowledged.
F1 Key: Provides additional information on the current event being displayed. For
maintenance (system) events, the MID, CID, and FMI are displayed. For data (machine), the
current parameter value is displayed (temperature, pressure, rpm).
F2 and F3 Keys: Not used on Off-highway Trucks.
Gauge key: Used to request the universal gauge and the message display window to show the
value of any sensor parameter. Depressing the arrow keys will scroll through the parameters.
Entering the parameter number and then the GAUGE key selects that parameter.
04/06
Numeric Keys: Used to enter numeric information such as the individual gauge parameter
number, service program codes and responses to VIMS requests.
NOTE: Service program codes can be found in the Serviceman's Handouts.
Left Arrow Key: Used to scroll backwards through the current display selection.
Right Arrow Key: Used to scroll forward through the current display selection.
ID Key: Used by the operator to enter his or her identification number. This number is stored
with all event information that may follow, until a new identification number is entered. Printed
reports show this number with each event.
Red indicator: Located above the OK Key, a red indicator is flashed each time a key is
pressed. This tells the operator or service technician that the keystroke was accepted.
Data Logger Indicator Dots: Located in the upper right corner of the message center module
are four indicator dots. The VIMS can store up to 30 minutes of information from all of the
sensors installed on the truck. This information can be stored by turning on the data logger with
the keypad (DLOG). When the data logger is turned on with the keypad, the data logger
indicator dots will scroll until the data logger is turned off.
NOTE: The data logger indicator dots will not scroll if the data logger is turned on with
the VIMS PC.
The VIMS provides three Warning Categories. The first category requires only operator
awareness. The second category states that the operation of the machine and the maintenance
procedure of the machine must be changed. The third Warning Category states that the machine
must be safely shut down immediately.
Warning Category 1
For a Category 1 Warning, the alert indicator will flash. The universal gauge may display the
parameter and a message will appear in the message display window. A Category 1 Warning
alerts the operator that a machine system requires attention. The "OK" key on the keypad can
be used to acknowledge the warning. Some warnings will be silenced for a predetermined
period. After this time period, if the abnormal condition is still present, the warning will
reappear.
04/06
Warning Category 2
For a Category 2 Warning, the alert indicator and the action lamp will flash. The universal
gauge may display the parameter and a message will appear in the message display window. A
Category 2 warning alerts the operator that a change in machine operation is required to avoid
possible damage to the indicated system. The "OK" key on the keypad can be used to
acknowledge the warning. Some warnings will be silenced for a predetermined period. After
this time period, if the abnormal condition is still present, the warning will reappear.
Warning Category 2-S

For a Category 2-S Warning, the alert indicator and the action lamp will flash and a continuous
action alarm will sound, which indicates a SEVERE Category 2 Warning. The universal gauge
may display the parameter and a message will appear in the message display window. A
Category 2-S Warning alerts the operator to immediately change the operation of the machine
to avoid possible damage to the indicated system. When the change in operation is made to an
acceptable condition, the action alarm will turn off.
Warning Category 3
For a Category 3 Warning, the alert indicator and the action lamp will flash and the action alarm
will sound intermittently. The universal gauge may display the parameter and a message will
appear in the message display window. A Category 3 Warning alerts the operator that the
machine must be safely shut down immediately to avoid damage to the machine or prevent
personal injury. Some Category 3 Warnings cannot be stopped by pressing the "OK" key.
04/06
793D ELECTRONIC SYSTEMS

VIMS-PC VIMS
- Gauges
- Monitoring
- Prognostics
Mph
12 Km/h 3F - Warnings
- Telemetry
VIMS Main Module - Payload Measurement
ET Service Tool ABL2M - Clock Synchronization
RS232 Link - Machine Id
- Auto-lube
Engine ECM
- Emission Control - Fuel Injection
- Engine Shutdowns - Ether Injection
- Throttle Position - Wastegate Control
- Throttle Bypass - Engine Speed
- Engine Speed - Diagnostics
- Manual Start Aid - Fan Control
CAT Data Link
- Engine Pre-lube
Brake ECM Transmission /

(ARC) (TCS) Chassis ECM
- Top Gear Limit - Shift Control
- Reverse Neutralize - Neutral-start
- Load Counter - Back-up Alarm
- Neutral Coast Inhibit - Overspeed Protection
- Body Up Gear Limit - CTS
- Starter Protection - Engine Pre-lube
- Body Hoist Control - Directional Shift Management
- Traction Control System (TCS) - Speed Limiter - Autolube
- Auto Retarder Control (ARC)
- Rear Axle Cooling
- Brake Cooling Control
51
VIMS uses one ABL2M ECM to receive the input signals from switches and sensors and also
functions as the Main Module. The VIMS also communicates with other electronic controls on
the machine. The VIMS provides the operator and the service technician with a complete look
at the current and past conditions of all the systems on the truck.
The VIMS Main Module hardware is ABL2M version 4.0. The main module must be
programmed with Flash File software using ET before the VIMS will function.
04/06
52
Shown are the Electronic Control Modules (ECM's). Located in the compartment at the rear of
the cab are the VIMS Main Module (1), the Brake ECM (2), and the Transmission/Chassis
ECM (3).
The Brake ECM controls the Automatic Retarder Control (ARC) system, the Traction Control
System (TCS), and rear axle cooling.
The Transmission/Chassis ECM controls the shifting of the transmission, torque converter
lockup, the hoist system, the neutral-start feature, power train filter, temperature monitoring, and
the automatic lubrication feature.
All these electronic controls, along with the Engine ECM, communicate with each other on the
CAT Data Link. All the information from these controls can be accessed through the VIMS
message center or a laptop computer with Electronic Technician (ET) or VIMS PC software.
04/06
VIMS Main Module

ABL2M
INPUT COMPONENTS OUTPUT COMPONENTS
Torque Converter TPMS

Front Aftercooler
Outlet Screen Switch Lamp (Green)
Temperature Sensor
LF Brake Oil
Torque Converter TPMS
Temperature Sensor
Inlet Filter Switch Lamp (Red)
RF Brake Oil
Key Start Switch VIMS Service
Temperature Sensor
Lamp (Blue)
LR Brake Oil VIMS
Aftercooler
Temperature Sensor Action Lamp
Coolant Level Switch
RR Brake Oil VIMS
Temperature Sensor Jacket Water Action Alarm
Coolant Level Switch
Fuel Level Sensor
Alternator Four Gauge
R-terminal Cluster
Ambient Air
Temperature Sensor With 2 Lights
Steering Oil
Dash Temperature Sensor
Speed / Tach
Dimmer Switch St eering Oil Filt er Cluster
Bypass Swit ch With 2 Lights
12 MPH
km/h 3F
Steering Pressure
(High) Switch VIMS Keypad VIMS Message
Center
Left Front Strut with 2 Lights
Pressure Sensor Diagnostic Connector
Right Front Strut (ECAP, ET, Flash)
Pressure Sensor
Telemetry
Left Rear Strut Download Port
Pressure Sensor
Cab Serial
Right Rear Strut
Download Port
Pressure Sensor
53
Shown is a diagram of the VIMS electronic system. Shown on the left are the components on
the machine that provide inputs directly to the VIMS. The VIMS Main Module analyzes these
inputs along with the inputs from the other ECM’s and sends output signals to the components
shown on the right side of the diagram.
04/06
INSTRUCTOR NOTE: Some of the VIMS input and output components are shown
during the discussion of other systems. See the following visual numbers:
161. Steering pressure (HIGH) switch

56. Ambient air temperature sensor
12. Torque converter inlet (charging) filter switch
117. Torque converter outlet screen switch
71. Aftercooler coolant level switch
71. Jacket water coolant level switch
79. Rear aftercooler temperature sensor
151 Steering oil temperature sensor
57. Strut pressure sensors
87. Fuel level sensor
52. ECM location code
58. Alternator R-terminal
48. Dash dimmer switch
213. Brake temperature sensors
49. VIMS keypad
46. Diagnostic connectors
36. TPMS lamps
27. VIMS service lamp
47. VIMS action lamp and alarm
47. VIMS Four gauge cluster module
47. VIMS Speed/Tach module
49. VIMS message center module
04/06
54
Shown is a laptop computer with the VIMS PC diagnostic software installed. The laptop
computer is connected to the VIMS diagnostic connector (RS-232).
Some of the operations that can be performed with a laptop computer with VIMS PC installed
are:
- View real time data (similar to the status menu of ET)
- View payload data
- Start and stop a data logger
- Calibrate the payload system
- Upload source and configuration files (version 3.0 hardware only) (similar to flash
programming other ECM’s with ET)
- Assign serial and equipment numbers
- Reset onboard date, time and hourmeter
- Download event list, data logger, event recorder, payload data, trend data, cumulative data
and histogram data
INSTRUCTOR NOTE: For more detailed information on the VIMS, refer to the Service
Manual Modules "Off-Highway Truck/Tractors Vital Information Management System
(VIMS)--System Operation" (Form RENR2630) and "Off-Highway Truck/Tractors Vital
Information Management System (VIMS)--Testing and Adjusting Troubleshooting" (Form
RENR2631).
04/06
55
The CAT Data Link consists of a pair of twisted wires that connect to all of the Electronic
Control Modules (ECM's) on a machine. The wires are twisted to reduce electrical interference
from unwanted sources such as radio transmissions. All sensors and switches that provide an
input to an ECM can be shared with other ECM's on the CAT Data Link. The ability to share the
inputs eliminates the need for more than one sensor in the same system. A laptop computer with
the Electronic Technician (ET) diagnostic software installed can also be connected to the CAT
Data Link and see the information that is being transmitted between the ECM's.
Shown is the 7X1700 Communication Adapter and a laptop computer with the Electronic
Technician (ET) diagnostic software installed. The communication adapter is connected to the
CAT Data Link diagnostic connector located on the circuit breaker panel.
To perform diagnostic and programming functions with these electronic controls, the service
technician must use a laptop computer with ET.
NOTE: The 7X1700 Communication Adapter has been replaced by the 171-4400
Communication Adapter II. Both Communication adapters will work on the 793D.
04/06
56
Located in the upper left corner of the front radiator grill is the ambient temperature sensor
(arrow). The ambient temperature sensor provides input signals to the VIMS.
The service technician can use the ambient temperature sensor input as an indication of the
ambient temperature when investigating temperature related problems on the machine.
The ambient temperature sensor receives a regulated 8.0 ± 0.5 Volts from the VIMS. To check
the supply voltage of the sensor, connect a multimeter between Pins A and B of the sensor
connector. Set the meter to read "DC Volts."
The ambient temperature sensor output signal is a Pulse Width Modulated (PWM) signal that
varies with temperature. To check the output signal of the ambient temperature sensor, connect
a multimeter between Pins B and C of the ambient temperature sensor connector. Set the meter
to read "Duty Cycle." The duty cycle output of the ambient temperature sensor should be
between 10 and 93% with an operating temperature range between -40° C (-40° F) and 135° C
(275° F).
04/06
57
Located on all four suspension cylinders is a Truck Production Management System (TPMS)
pressure sensor (arrow). The suspension cylinder pressure sensor is commonly referred to as a
"strut sensor." When the truck is being loaded, the strut sensors convert the change in pressure
to a change in frequency signal. The frequency signals are then sent to the VIMS. The VIMS
converts the frequency signals to tons. During LOADING, the payload weight is shown on the
VIMS message center display in metric or U.S. tons.
The strut sensors receive +Battery Volts from the VIMS circuit breaker. To check the supply
voltage to the sensors, connect a multimeter between Pins A and B of the sensor connector. Set
the meter to read "DC Volts."
The strut sensors send frequency output signals to the VIMS. To check the output signal of the
strut sensors, connect a multimeter between Pins B and C of the strut sensor connector. Set the
meter to read "Frequency."
04/06
58
The "R" terminal (arrow) on the alternator provides a voltage and a frequency input to the
VIMS. Normal voltage from the alternator "R" terminal should be between 12.4 and 14.75 DC
Volts. The corresponding output from the alternator +battery terminal should be approximately
2X the "R" terminal value (24.8 to 29.5 DC Volts).
The frequency from the alternator "R" terminal should be greater than 94 Hz ± 10%. A
frequency less than 94 Hz is an indication that the speed of the alternator is low. The probable
cause is a slipping belt, a loose pulley, or an internal alternator problem.
Approximately 10 different system voltage events can be shown on the VIMS message center
display. The events can be a category level 1 or 3 depending on the severity of the problem.

Global Service Learning: 793D (FDB) Off-Highway Truck

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SERV1817

GLOBAL SERVICE LEARNING

Service Training Meeting Guide

Estimated Time: 40 Hours

© 2006 Caterpillar Inc.

Service Training Meeting Guides

Technical Instruction Modules

SUPPLEMENTAL MATERIAL (CONTINUED)

Accessing Flash Software for Machines REHS0494

How to Take a Good Oil Sample PEHP6001

Window Decal "VIMS Keypad Parameters" SEEU6995

WALK AROUND INSPECTION...............................................................................................12

POWER TRAIN .......................................................................................................................131

STEERING SYSTEM ..............................................................................................................195

HOIST SYSTEM ......................................................................................................................213

AIR SYSTEM AND BRAKES ................................................................................................236

BRAKE ELECTRONIC CONTROL SYSTEM .....................................................................275

VISUAL LIST ..........................................................................................................................298

HYDRAULIC SCHEMATIC COLOR CODE.........................................................................301

© 2006 Caterpillar Inc.

Standard - The standard arrangement is designed for exceptional, all-around performance.

- Serial No. Prefix: FDB

- Reduced weight due to elimination of redundant structures

WALK AROUND INSPECTION

WALK AROUND INSPECTION

Wash Windows, Transmission and Brake Cylinder

Suspension Cylinder Height

Front Wheel Breathers Tire Inflation

INSTRUCTOR NOTE: For more detailed information on servicing the automatic

Inspect the hydraulic tank breather (3) for plugging.

Air intake system tips:

INSTRUCTOR NOTE: For more detailed information on servicing the steering

Ether starting tip:

- Brakes: Check operation

Shown is a view of the operator's seat and the trainer's seat..

- Telescopic/tilt steering column for individual adjustment

- Intermittent wiper/washer, turn signal control, and dimmer switch

- Enhanced instrument layout

The operator controls to the left of the steering column are:

- Intermittent wiper/washer, turn signal control, and dimmer switch (2).

- Steering wheel mounted electric horn control (3).

The intermittent wiper switch has the following six positions:

- Intermittent position 1 (one bar)

- Intermittent position 2 (two bars)

- Intermittent position 3 (three bars)

- Low speed continuous wiper (I)

- High speed continuous wiper (II)

- the key start switch

Located on the floor of the cab are:

Located in the overhead panel are the following switches:

- Hazard lights (1)

- Headlights and parking/tail lights (2)

- Fog lights (3)

- Back-up lights (4)

- Front flood/ladder lights (5)

- Reverse: Lights when the shift lever switch is in REVERSE.

- Action lamp: Lights when a Category 2, 2-S or Category 3 Warning is active.

- Engine coolant temperature: Maximum operating temperature is 107° C (225° F).

- Brake oil temperature: Maximum operating temperature is 121° C (250° F).

The three systems monitored by the speedometer/tachometer module are:

- Tachometer: Displays the engine speed in rpm.

Top row (from left to right)

Bottom row (from left to right)