Service Magazine

REYD5630

Table of Contents: Improved Rear Suspension Link Mounts are Now Used on
Certain 793F Off-Highway Trucks ................................. 14
SMCS Code: 0679; 3260; Publish Date: 19-Dec-
An Improved Injector Sleeve Installation Procedure Is 2016 ............................................................. 14
Now Published for Certain C175 Off-Highway Truck A New Clean Fuel Module Pump is Available for Certain
Engines .................................................................. 4 Large Off-Highway Trucks .......................................... 14
SMCS Code: 1125; 1713; Publish Date: 27-Jan- SMCS Code: 1255; 1256; Publish Date: 18-Oct-
2017 ............................................................... 4 2016 ............................................................. 14
A New Lip Seal, Yoke, and Distributor in the Torque A Cylinder Head Bolt Alignment Sleeve is Available for
Converter Group is Now Used on Certain 789 and 793 C175 Machine Engines.............................................. 15
Off-Highway Trucks .................................................... 4 SMCS Code: 1100; Publish Date: 25-Oct-
SMCS Code: 0719; 3101; Publish Date: 23-Feb- 2016 ............................................................. 15
2017 ............................................................... 4 New Intake Manifold Is Now Used for C175-16
Consolidation of C175 Machine Engine Engines ................................................................ 16
Arrangements ........................................................... 6 SMCS Code: 1058; Publish Date: 24-Aug-
SMCS Code: 1000; Publish Date: 12-Dec-2016 ............ 6 2016 ............................................................. 16
Improved Torque Converter Housing and Flywheel A New Fuel Transfer Pump Support Bracket Assembly Is
Assembly are Now Used on Certain 793F Off-Highway Now Used on Certain C175-20 Off-Highway Truck
Trucks. ................................................................... 9 Engines ................................................................ 17
SMCS Code: 1156; 1158; Publish Date: 22-Nov- SMCS Code: 1000; 1251; Publish Date: 10-Apr-
2016 ............................................................... 9 2017 ............................................................. 17
Adjust Compensator Valve for Fan and Steering Pump A New Button Plug Is Used on Certain C175-16 Off-
Prior to Installation on Certain Off-Highway Trucks ............... 9 Highway Truck Engines ............................................. 18
SMCS Code: 5070; 5455; Publish Date: 24-Oct- SMCS Code: 0663; 1157; Publish Date: 17-Aug-
2016 ............................................................... 9 2016 ............................................................. 18
The Procedure to Upgrade the Bracket Assemblies in the A New Alternator Pulley Is Used on Certain C175 Off-
Air Lines Group on Certain 793F Off-Highway Trucks is Highway Truck Engines ............................................. 18
Updated.................................................................11 SMCS Code: 1425; Publish Date: 27-Sep-
SMCS Code: 1063; 1071; Publish Date: 22-Nov- 2016 ............................................................. 18
2016 ..............................................................11 A New Transmission Lip Seal is Now Used on Certain
New Aluminum Air to Air After Cooler Cores are Now 785, 789, and 793 Off-Highway Trucks. .......................... 19
Available for Certain 793F Off-Highway Trucks ................. 12 SMCS Code: 3030; 3159; Publish Date: 18-Oct-
SMCS Code: 1063; Publish Date: 24-Oct- 2016 ............................................................. 19
2016 ............................................................. 12 Use of the Integral Seal on Certain C175 Machine
New High-Pressure Fuel Pumps Are Now Used on Engines ................................................................ 20
Certain C175 Off-Highway Truck Engines........................ 13 SMCS Code: 1100; Publish Date: 30-Nov-
SMCS Code: 1255; 1256; Publish Date: 16-Nov- 2016 ............................................................. 20
2016 ............................................................. 13 A New Electronic Thermostat Motor Mount Assembly is
A Oil Filter Bracket Assembly Is Now Used on Certain Now Used on Certain Large Off-Highway Trucks ............... 23
C175-16 Off-Highway Truck Engines ............................. 13 SMCS Code: 135V; Publish Date: 20-Jul-2016 ........... 23
SMCS Code: 1306; Publish Date: 12-May-
2017 ............................................................. 13

1
A New Engine Oil Pump Is Now Used For Certain Off- A New High Pressure Fuel Pump Adapter Is Now Used On
Highway Truck Engines ............................................. 24 Certain Off-Highway Trucks......................................... 43
SMCS Code: 1304; Publish Date: 22-Dec- SMCS Code: 1162; 1206; Publish Date: 14-Sep-
2016 ............................................................. 24 2015 ............................................................. 43
A New Special Instruction has been Published, Best An Improved Radiator Top Tank Hose Routing Is Now
Practices for Ensuring the C175 Oil System is Full and Used on Certain 793F Off-Highway Trucks....................... 43
Free of Contamination ............................................... 25 SMCS Code: 1353; Publish Date: 03-Aug-
SMCS Code: 1318; 1348; Publish Date: 25-Apr- 2015 ............................................................. 43
2016 ............................................................. 25 A New Thermostat Control Module Shield Is Used On
A New Spacer is Now Used in the Rear Axle Housing Certain 793F, 795F, And 797F Off-Highway Trucks............. 46
Group on Certain 793F and 793D Off-Highway SMCS Code: 135V; Publish Date: 05-Aug-
Trucks .................................................................. 25 2015 ............................................................. 47
SMCS Code: 3260; Publish Date: 11-May- Rear Axle Oil Cooler Lines Routing can be Modified on
2016 ............................................................. 25 Certain 793F Off-Highway Trucks.................................. 47
Incorrect Torque Callout for Turbine Outlet V-Band Clamp SMCS Code: 1365; Publish Date: 03-Feb-
on C175 Off-Highway Truck Engines ............................. 28 2016 ............................................................. 47
SMCS Code: 1061; Publish Date: 31-Mar- A New Fuel Injector Is Now Available for Certain 793F,
2016 ............................................................. 28 795F, 797F, 797 Retrofit, and 794 AC Off-Highway Truck
A New Head to Block Oil Feed Dowel Is Now Available Engines. ............................................................... 50
for C175 Off Highway Truck Engines ............................. 28 SMCS Code: 1254; 1290; Publish Date: 14-Nov-
SMCS Code: 1100; 1201; Publish Date: 21-Apr- 2016 ............................................................. 50
2016 ............................................................. 28 An Improved Breather Lines Routing for Rear Axle
Procedures to Improve the Cooling Systems on 793F and Housing Group Is Now Used on Certain 793F Off-
793F AC Off-Highway Trucks. Equipped with Standard Highway Trucks. ...................................................... 51
Cooling or Extra Cooling are Available............................ 32 SMCS Code: 3260; Publish Date: 02-Jul-2015 ........... 51
SMCS Code: 1380; 7960; Publish Date: 18-Feb- The Front Pedestal Frame Support Has Been Improved
2016 ............................................................. 32 on Certain 793F Off-Highway Trucks.............................. 52
Improved Harness Routing for Transmission Hydraulic SMCS Code: 0679; 7051; Publish Date: 29-May-
Temperature Sensor is Now Used on Certain 793F Off- 2015 ............................................................. 52
Highway Trucks....................................................... 34 The Orientation of the Low Pressure Fuel System Check
SMCS Code: 1408; 3030; Publish Date: 18-Feb- Valve has been Improved on Certain 793F Off-Highway
2016 ............................................................. 34 Trucks. ................................................................. 53
New Camshafts and Lifter Levers are Available for SMCS Code: 1274; Publish Date: 05-Aug-
Certain C175 Powered Off-Highway Trucks ..................... 34 2015 ............................................................. 53
SMCS Code: 1209; 1210; Publish Date: 04-Jan- A New Turbine Inlet Manifold Support Bracket Is Used on
2017 ............................................................. 34 C175 Off-Highway Truck Engines.................................. 58
New Wiring Harness Assembly for the Rear Power Train SMCS Code: 1059; Publish Date: 16-Jul-2015 ........... 58
Is Now Available for Certain 793F Off-Highway Improved Oil Lines Groups Are Used for Certain C175
Trucks. ................................................................. 35 Off-Highway Truck Engines. ........................................ 59
SMCS Code: 1408; 1634; Publish Date: 22-Feb- SMCS Code: 1378; Publish Date: 19-Mar-
2016 ............................................................. 35 2015 ............................................................. 59
New Plates and Retainers for the Brake and Wheel The Power Train Has Been Updated on the 793F Off-
Groups are Now Used on Certain 793D and 793F Off- Highway Truck. ....................................................... 67
Highway Trucks with Standard Wheel Configuration ........... 36 SMCS Code: 0679; 3030; Publish Date: 12-Mar-
SMCS Code: 4008; 4201; Publish Date: 14-Dec- 2015 ............................................................. 67
2015 ............................................................. 36 Rework Procedure for Mounting the Improved Fuel
Cat ® Reman Announces the Availability of Priming Switch Bracket on Certain 793F, 795F, and 797F
Remanufactured Short Blocks for 793F, 795F, and 797F Off- Large Off-Highway Trucks .......................................... 68
Highway Truck Engines. ............................................ 37 SMCS Code: 1258; 1408; Publish Date: 05-Nov-
SMCS Code: 1201; 1307; Publish Date: 06-Jan- 2015 ............................................................. 68
2016 ............................................................. 37 Cat Reman Announces the Addition of Drivetrain
A New Fuel Transfer Pump and Improved Fuel Lines Components for Large Mining Trucks ............................. 71
Routings are Available for Certain Off-Highway Truck SMCS Code: 3030; 3101; Publish Date: 21-Oct-
Engines ................................................................ 41 2014 ............................................................. 71
SMCS Code: 1256; 1274; Publish Date: 06-Jul- A New Differential and Bevel Gear Group is Used on the
2016 ............................................................. 41 793D and 793F Off-Highway Trucks. ............................. 73
An Improved Engine Prelube Pump Is Now Available for SMCS Code: 3256; 3258; Publish Date: 04-May-
Certain Off-Highway Trucks......................................... 42 2017 ............................................................. 73
SMCS Code: 1307; 1319; Publish Date: 10-Sep-
2015 ............................................................. 42

2
Cat ® Reman Announces the Availability of Type 2 SMCS Code: 1386; 1387; Publish Date: 03-Jan-
Cylinder Packs and Connecting Rods for Certain C175 Machine 2014 ............................................................. 88
Engines. ............................................................... 75 Loctite 609 or Loctite 648 Are Now Used to Retain the
SMCS Code: 1218; 1239; Publish Date: 13-Aug- Carrier Bearing on Certain OEM. and Off-Highway
2015 ............................................................. 75 Trucks. ................................................................. 89
A New Oil Filler Elbow Is Now Used on C175 Off- SMCS Code: 0649; 3159; Publish Date: 05-Nov-
Highway Truck Engines. ............................................ 76 2015 ............................................................. 89
SMCS Code: 1316; 7513; Publish Date: 12-Dec- A New Oil Filter Group Is Now Used On Certain C175
2014 ............................................................. 76 Off-Highway Truck. Engines ........................................ 90
A New Engine Oil Level Sensor Guard Is Used for SMCS Code: 1308; Publish Date: 06-Feb-
Certain C175 Off-Highway Truck Engines. ....................... 76 2014 ............................................................. 91
SMCS Code: 1439; 7422; Publish Date: 05-Dec- A New Oil Pressure Control Valve Group Is Used on
2014 ............................................................. 76 Certain C175 Off-Highway Trucks ................................. 93
A Procedure to Convert to a Bottom Fill Radiator on SMCS Code: 1304; 5117; Publish Date: 03-Oct-
Certain Large Off-Highway Trucks. is Available ................. 77 2013 ............................................................. 93
SMCS Code: 1350; 1353; Publish Date: 01-Sep- A New Engine Oil Prelubrication Pump Mounting Group
2014 ............................................................. 77 Is Now Available for Certain Large Off-Highway
An Improved Power Train Oil Lines Group Is Now Used Trucks. ................................................................. 95
on Certain 793F Off-Highway Trucks.............................. 79 SMCS Code: 1304; 1307; Publish Date: 09-Jun-
SMCS Code: 3016; 3154; Publish Date: 19-Sep- 2017 ............................................................. 95
2014 ............................................................. 80 A New Special Instruction is Available to Update the Air
A Procedure to Upgrade the Transmission Wiring Group Lines Group on Certain 793F Off-Highway Trucks. ............ 103
on Certain 793F Off-Highway Trucks. is Available .............. 81 SMCS Code: 1071; Publish Date: 01-Aug-
SMCS Code: 1408; 3030; Publish Date: 30-Sep- 2013 ............................................................ 103
2014 ............................................................. 81 New Connecting Rod Bolts Are Available for Certain
New Oil Tubes Are Used on 793F and 795F Off-Highway C175 Engines. ....................................................... 103
Truck Engines......................................................... 82 SMCS Code: 1218; Publish Date: 15-Jul-
SMCS Code: 1307; Publish Date: 17-Jul-2014 ........... 82 2013 ............................................................ 103
New Coolant Tubes Are Now Used for Certain 793F and A New Special Instruction, Procedure to Install a Fuel
795F Off-Highway Trucks. .......................................... 82 Line Heater on the 793F Off-Highway Trucks is
SMCS Code: 1380; Publish Date: 17-Jul-2014 ........... 82 Available .............................................................. 104
A Procedure to Update the Brake Cooling Tube on 793F SMCS Code: 1273; 1296; Publish Date: 11-Jun-
Off-Highway Trucks. is Now Available ............................ 83 2013 ............................................................ 104
SMCS Code: 1380; Publish Date: 19-May- New Bolts and New Idler Shafts Are Used for the
2014 ............................................................. 83 Accessory Drive On C175 Off-Highway Truck
The Rear Axle Oil Cooler Arrangement has been Engines. .............................................................. 104
Improved for Certain 793D and 793F Off-Highway SMCS Code: 1207; 7553; Publish Date: 18-Mar-
Trucks. ................................................................. 84 2013 ............................................................ 104
SMCS Code: 1359; 1365; Publish Date: 23-Apr- A New Oil Cross Under Tube Is Available for C175-16
2014 ............................................................. 84 Off-Highway Truck Engines. ....................................... 106
A Procedure to Improve the Air to Air After Cooler Lines SMCS Code: 1307; Publish Date: 31-Jan-
Group on the 793F Off-Highway. Truck is Available ............ 84 2013 ............................................................ 106
SMCS Code: 1063; 1071; Publish Date: 31-Jul- A New Fuel Filter Base Assembly Is Used on C175 Off-
2014 ............................................................. 85 Highway Truck Engines ............................................ 106
New Fan Shroud Assembly for the Rear Axle Oil Cooler SMCS Code: 1261; Publish Date: 18-Dec-
Is Now Available on Certain 793F and 793D Off-Highway 2012 ............................................................ 106
Trucks .................................................................. 85 A New Special instruction, Procedure to Improve the
SMCS Code: 1365; Publish Date: 27-Feb- Draining of Torque Converter Oil from the Flywheel
2014 ............................................................. 85 Housing on Certain 793F Off-Highway Trucks.................. 107
A Procedure to Install a Bracket Assembly Over the SMCS Code: 1157; 3103; Publish Date: 30-Oct-
Lower Torque Converter Oil Level Sensor on the 793F 2012 ............................................................ 107
Off-Highway. Truck is Available. ................................... 86 New Design for Securing the Lanyard and Hasp for the
SMCS Code: 1408; 1439; Publish Date: 02-Apr- Cap on the Oil Filler Tube of C175 Off-Highway Truck
2014 ............................................................. 86 Engines. .............................................................. 107
A New Cylinder Head Group Is Used on C175 Off- SMCS Code: 1316; 7513; Publish Date: 15-Nov-
Highway Truck Engines. ............................................ 87 2012 ............................................................ 107
SMCS Code: 1100; Publish Date: 09-Jan- New Oil Renewal System (ORS) Lines are Available for
2014 ............................................................. 87 Certain Off-Highway Truck Engines .............................. 108
The Hydraulic Fan Lines Group Has Been Updated on SMCS Code: 1307; Publish Date: 12-Nov-
Certain 793F Off-Highway Trucks.................................. 88 2012 ............................................................ 108

3
A New Pump Drive Group is Now Used on Certain 793F Proper Installation Practices for C175 Exhaust
Off-Highway Trucks. ................................................ 110 Bellows................................................................ 138
SMCS Code: 3108; 5070; Publish Date: 07-Nov- SMCS Code: 1061; Publish Date: 30-Aug-
2012 ............................................................ 110 2012 ............................................................ 138
A New Retainer Is Now Used in the Differential Group on New Optional Service Replacement Wheel Studs are
793D and 793F Off-Highway Trucks. ............................ 114 Now Available........................................................ 139
SMCS Code: 3256; 3258; Publish Date: 27-Sep- SMCS Code: 4201; Publish Date: 20-Aug-
2013 ............................................................ 114 2013 ............................................................ 139
A New Seal Assembly for the Differential and Bevel Gear
Group Is Now Used on Certain 793 Off-Highway
Trucks. ................................................................ 114 i06925026
SMCS Code: 3256; 3258; Publish Date: 03-Apr-
2013 ............................................................ 114 An Improved Injector Sleeve
The Exhaust Tubes are Updated on the 793F, 795F AC,
and 797F Off-Highway Trucks. .................................... 116
Installation Procedure Is Now
SMCS Code: 1061; 1062; Publish Date: 19-Sep- Published for Certain C175
2012 ............................................................ 116 Off-Highway Truck Engines
A New Alternator Belt Guard And New Alternator
Supports Are Used on C175 Off-Highway Truck SMCS Code: 1125; 1713; Publish Date: 27-Jan-2017
Engines. .............................................................. 119
SMCS Code: 1405; 7150; Publish Date: 19-Dec- Off-Highway Truck/Tractor.
2012 ............................................................ 119 793F (S/N: RBT1-Up) (S/N: SND) (S/N:
A New Engine Oil Pump Inlet Adapter Is Used on C175 SSP) (S/N: SXP)
Off-Highway Truck Engines. ....................................... 120 794 (S/N: MN5) (S/N: MT5)
SMCS Code: 1302; 1304; Publish Date: 29-Aug- 795FAC (S/N: ERM)
2012 ............................................................ 120 795FACXQ (S/N: SNT)
A Summary of Updates for Type 2 C175 Off-Highway 797F (S/N: LAJ) (S/N: WSP)
Truck Engines........................................................ 121
SMCS Code: 1000; Publish Date: 31-Oct- Disassembly and Assembly, KENR6052 has been
2012 ............................................................ 121 updated with a new installation procedure for the cyl-
New Core Engine Components Are Used in C175 Off- inder head injector sleeve on C175 off-highway truck
Highway Truck Engines. ........................................... 122 engines.
SMCS Code: 1202; 1205; Publish Date: 20-Jul- Antiseize is applied to the threads of the injector
2016 ............................................................ 122 sleeve and the injector sleeve is torqued to 200 N·m
A New Outer Support Is Used in the Trunnion Group for (147.5 lb ft), loosened one rotation, then torqued
C175-16 Off-Highway Truck Engines............................. 126 again to 200 N·m (147.5 lb ft)
SMCS Code: 1153; 1154; Publish Date: 11-Apr-
2012 ............................................................ 126 This improved process should be applied to heads
A New Cylinder Block and Flywheel Housing Are Used rebuilt in dealer Component Repair Centers (CRCs).
for C175 Off-Highway Truck Engines............................. 128 ■
SMCS Code: 1157; 1201; Publish Date: 10-May-
2012 ............................................................ 128
i06921751
A New Valve Lifter Group and Dowel Are Used in C175
Off-Highway Truck Engines. ....................................... 129
SMCS Code: 1209; Publish Date: 15-May-
A New Lip Seal, Yoke, and Dis-
2012 ............................................................ 129 tributor in the Torque Convert-
New Oil Pans and Oil Lines Are Used on C175 Off- er Group is Now Used on
Highway Truck Engines. ........................................... 131
SMCS Code: 1302; 1307; Publish Date: 02-Oct- Certain 789 and 793 Off-High-
2012 ............................................................ 131 way Trucks
A New Front Housing Is Used on C175 Off-Highway
SMCS Code: 0719; 3101; Publish Date: 23-Feb-
Truck Engines........................................................ 135
2017
SMCS Code: 1151; 1162; Publish Date: 11-Apr-
2012 ............................................................ 136
A New Torque Specification Is Used for the V-Band
Off-Highway Truck/Tractor.
Clamp of the Turbocharger on C175 Off-Highway Truck 789C (S/N: 2BW1375-2128)
Engines. .............................................................. 137 789D (S/N: SHH1-319) (S/N: SPD)
SMCS Code: 1052; 7553; Publish Date: 22-Apr- 793B (S/N: 1HL)
2014 ............................................................ 137 793C (S/N: 4GZ)
793D (S/N: FDB788-1881)

4
 793F (S/N: RBT1-186) (S/N: SND) (S/N: (Table 2, contd)
SSP114-1169) (S/N: SXP1-103) 9S-
Plug
1 -
4185
Description Of Change: A new lip seal, yoke, and
distributor in the torque convertor group is now used 459- Lip Type 133-
1
0683 Seal 4296
on certain 789C, D, and 793B, C, D, F machines. The
new lip seal, yoke, and distributor have tighter toler- 459-
Wear
ances that seal the convertor input shaft extending 1
0686
Sleeve -
the service life of the torque convertor group. Seal
194- 194-
Adaptable To: The table below outlines the new and 1
2220
Yoke
2221
former part numbers for the various machines. This
change is adaptable to the products within the listed 4L- O-Ring
1 -
serial numbers, and are effective with all products 9564 Seal
after the listed serial numbers. 9P- Seal
2 -
Table 1 7118 Ring
Required Tools 6I-
1 Gasket -
8427
Qty Part Number Description
8L- O-Ring
1 509-3263 Installer Tool(Lip Seal) 1 -
2786 Seal
1 509-3264 Installer Tool(Wear Rings) 486- Oil Dis- 6I-
1
6991 tributor 8426
Table 2 9S-
299- 1 Plug
Part Information 789D 4185
0725
Torque New Former 459- Lip Type 296-
Sales Descrip- 1
Convert- Qty Part Part 0683 Seal 3460
Model tion
er Gp Number Number Wear
459-
Seal 1 Sleeve
9P- 0686
2 - Seal
7118 Ring
476- 225-
6I- 1 Yoke
1 Gasket - 8753 0086
8427
4L- O-Ring
8L- O-Ring 1 -
1 - 9564 Seal
2786 Seal
9P- Seal
486- Distribu- 6I- 2 -
1 7118 Ring
6991 tor 8426
789C 9S- 6I-
116- 1 Plug - 1 Gasket -
793C 4185 8427
5810
459- Lip Type 133- 8L- O-Ring
1 1 -
0683 Seal 4296 2786 Seal

Wear 486- Oil Dis- 6I-

459- 1
1 Sleeve - 6991 tributor 8426
0686
Seal 9S-
245- 1 Plug -
793D 4185
194- 194- 2715
1 Yoke
2220 2221 459- Lip Type 296-
1
4L- O-Ring 0683 Seal 3460
1 -
9564 Seal Wear
459-
Seal 1 Sleeve -
9P- 0686
2 - Seal
7118 Ring
476- 225-
6I- 1 Yoke
793B 1 Gasket 8753 0086
116- 8427
793C 4L- O-Ring
5808 486- Oil Dis- 1 -
1 9564 Seal
6991 tributor
253- 9P- Seal
8L- O-Ring 6I- 793D 2
1 2532 7118 Ring
2786 Seal 8426

(continued) (continued)

5
(Table 2, contd)
6I- (Table 2, contd)
1 Gasket
8427
481- 279-
8L- O-Ring 1 Yoke
1 7680 2540
2786 Seal
4L- O-Ring
486- Oil Dis- 6I- 1
1 9564 Seal
6991 tributor 8426
9S- ■
1 Plug
4185
459- Lip Type 296- i06889782
1
0683 Seal 3460

459-
Wear Consolidation of C175 Ma-
1 Sleeve
0686
Seal chine Engine Arrangements
476- 225- SMCS Code: 1000; Publish Date: 12-Dec-2016
1 Yoke
8753 0086
4L- O-Ring Off-Highway Truck/Tractor.
1
9564 Seal 793F (S/N: RBT1-Up) (S/N: SND) (S/N:
9P- Seal SSP) (S/N: SXP)
2
7118 Ring 795FAC (S/N: ERM)
6I- 795FACXQ (S/N: SNT)
1 Gasket
8427 797F (S/N: LAJ) (S/N: WSP)
8L- O-Ring Certain C175 machine engine arrangements have
1
2786 Seal
been canceled and removed from the serviceable
486- Oil Dis- 6I- parts list to consolidate engine arrangements. The
1
6991 tributor 8426 extra quiet arrangements have been removed and
9S- can be serviced by the standard engine arrangement
279- 1 Plug plus a conversion kit. The command for hauling spe-
793F 4185
2519
cific arrangements have also been removed and can
459- Lip Type 296- be serviced by the standard engine arrangement plus
1
0683 Seal 3460
a conversion kit. Also, 2 of the Reman engine ar-
Wear rangements used for Type 1 replacements have also
459-
1
0686
Sleeve been removed and can be service by the true Reman
Seal equivalent arrangement.
481- 279-
1
7680
Yoke
2540
Refer to Tables 1 and 2 for the new and canceled en-
gine arrangement part numbers and the new conver-
4L- O-Ring sion kit part numbers.
1
9564 Seal

9P- Seal
Refer to Table 3 for the new and canceled Reman en-
2
7118 Ring gine arrangement part numbers.

6I- Refer to Tables 4 and 5 for the conversion kit bill of

1 Gasket
8427 material. The 378-5492 Engine Conversion Ar and
8L- O-Ring
492-8151 Engine Conversion Ar Kits are not
1 serviced.
2786 Seal
486- Oil Dis- 6I-
306- 1
793F 6991 tributor 8426
7231
9S-
1 Plug
4185
459- Lip Type 296-
1
0683 Seal 3460
Wear
459-
1 Sleeve
0686
Seal

(continued)

6
Table 1
LRC Service Replacement Engines

Sales Model Serial Prefix Canceled Part New Part Number Conversion Kit Part
Number Number
793F Low Altitude XQ SND 421-3010 421-3009 493-7656

793F Low Altitude Com- RBT 415-1197 421-3009 378-5492

mand For Hauling

793F High Altitude Com- RBT 438-8666 398-1018 378-5492

mand For Hauling

795F Low Altitude XQ SNT 423-7578 447-0897 493-7656

797F Low Altitude XQ WSP 421-3014 421-3013 493-7657

797F Low Altitude Com- AT7 418-8764 421-3013 492-8151

mand For Hauling(1)
(1) The 420-1861 Alternator Wiring Gp is required to convert a standard engine to a Commnand For Hauling engine. The required parts are
listed in Table 6 .

Table 2
Regulated Service Replacement Engines

Sales Model Serial Prefix Canceled Part New Part Number Conversion Kit Part
Number Number
793F Low Altitude XQ SND 365-9321 365-9319 493-7656

793F Low Altitude Com- RBT 423-3500 365-9319 378-5492

mand For Hauling

793F High Altitude Com- RBT N/A N/A 378-5492

mand For Hauling

795F Low Altitude XQ SNT N/A N/A 493-7656

797F Low Altitude XQ WSP 365-9329 365-9327 493-7657

797F Low Altitude Com- AT7 423-3502 365-9327 492-8151

mand For Hauling(1)

Reference: Special Instruction, M0077562 for the in-

stallation of the 493-7656 Engine Conversion Kit on
793F and 795F XQ engines.
Reference: Special Instruction, M0072296 for the in-
stallation of the 493-7657 Engine Conversion Kit on
797F XQ engines.
Table 3
Reman Service Replacement Engines

Sales Model Serial Prefix Canceled Part Number New Part Number
795F Low Altitude Reman ERM 20R-1492 20R-4667
797F Low Altitude Reman LAJ 20R-1363 20R-4668

Table 4 (Table 4, contd)

378-5492 Engine Conversion Ar 378-5492 Engine Conversion Ar

Qty Part Number Part Description Qty Part Number Part Description

2 1V-6645 Spacer 2 5A-3604 Bolt

1 2Y-5829 Nut 7 5G-3676 Grommet

3 5P-8245 Hard Washer

(continued)
(continued)

7
(Table 4, contd) Table 5
378-5492 Engine Conversion Ar 492-8151 Engine Conversion Ar

Qty Part Number Part Description Qty Part Number Part Description
7 6V-1820 Bolt 2 5A-3604 Bolt
6 6V-2317 Bolt 2 5P-8245 Hard Washer
1 6V-3531 Bolt 5 6V-1820 Bolt
2 6V-4249 Bolt 6 6V-2317 Bolt
2 6V-5815 Bolt 1 6V-3531 Bolt
10 6V-5839 Washer 2 6V-5815 Bolt
1 6V-7673 Bolt 5 6V-5839 Washer
2 6V-8336 Bolt 2 6V-8336 Bolt
7 7S-3916 Clip 2 8C-2926 Bolt

7 7S-3919 Clip 2 8T-0355 Bolt

2 8C-2926 Bolt 2 9M-1974 Hard Washer

2 8T-0355 Bolt 1 131-3718 O-Ring Seal

1 8Y-1816 Spacer 1 154-1580 Hard Washer

2 9M-1974 Hard Washer 1 160-8492 Bolt

1 9X-6772 Cable Strap 7 198-4766 Hard Washer

1 235-2484 Lip Type Seal
1 131-3718 O-Ring Seal
1 273-1104 Cover
1 132-5789 Clip
1 322-9743 Charging Alternator Gp
1 154-1580 Hard Washer
1 325-4723 Pulley
1 160-8492 Bolt
7 198-4766 Hard Washer 1 329-8797 Belt Tensioner

1 235-2484 Lip Type Seal 1 346-9011 Plate

1 350-2565 Pulley As
1 273-1104 Cover
1 322-9743 Charging Alternator Gp 1 350-7106 Serpentine Belt

1 325-4723 Pulley 1 364-4337 Support

1 329-8797 Belt Tensioner 1 364-4357 Plate

1 346-9011 Plate 1 420-7738 Support

1 350-2565 Pulley As 1 434-1013 Alternator Guard As

1 350-7106 Serpentine Belt

Table 6
1 356-7361 Cable As 420-1861 Alternator Wiring Gp
1 364-4337 Support
Qty Part Number Part Description
1 364-4357 Plate
1 4P-7428 Clip
1 382-4651 Alternator Wiring Gp
6 5G-3676 Grommet
1 382-4652 Cable As
1 6V-1820 Bolt
1 420-7738 Support
1 6V-4249 Bolt
1 434-1013 Alternator Guard As
3 6V-5839 Washer
5 7S-3916 Clip

5 7S-3919 Clip

4 9X-6772 Cable Strap

(continued)

8
(Table 6, contd)
420-1861 Alternator Wiring Gp

Qty Part Number Part Description

1 132-5789 Clip

1 193-3973 Cable Strap

1 204-8000 Cable Tie Mounting

1 420-1863 Cable As
1 521-2843 Cable As

i06854274

Improved Torque Converter

Housing and Flywheel Assem-
bly are Now Used on Certain Illustration 2 g06144525
793F Off-Highway Trucks 370-6647 Flywheel Gp
SMCS Code: 1156; 1158; Publish Date: 22-Nov- (2) 494-0343 Flywheel As
2016
Table 1

Off-Highway Truck/Tractor. New Parts List

793F (S/N: RBT1-186) (S/N: SND) (S/N: Former
Item Qty New Part Description
SSP) (S/N: SXP) part
Clutch Housing
Description Of Change: Improved torque converter 1 1 440-3135 320-1235
As
housing and flywheel assembly are now used on the
machines listed above. The improved torque convert- 2 1 494-0343 Flywheel As 370-6548
er housing and flywheel assembly has new fillet
spline tooth root with induction heat treatment.
New clutch housing assembly (1) replaces the former
Adaptable To: 320-1235 Clutch Housing As in 306-7231 Torque
Converter Gp.

New flywheel assembly (2) replaces the former

370-6548 Flywheel As in 370-6647 Flywheel Gp.
Improved torque converter housing (1) and flywheel
assembly (2) are adaptable to the machines within
the listed serial numbers, and is effective with all ma-
chines after the listed serial numbers.

i06837064

Adjust Compensator Valve for

Fan and Steering Pump Prior
to Installation on Certain Off-
Highway Trucks
SMCS Code: 5070; 5455; Publish Date: 24-Oct-2016
Illustration 1 g06144451
306-7231 Torque Converter Gp
Off-Highway Truck/Tractor.
(1) 440-3135 Clutch Housing As
789D (S/N: TWP1-Up)
793D (S/N: FDB)

9
 793F (S/N: RBT) (S/N: SND) (S/N: SSP)
(S/N: SXP)
797 (S/N: 5YW)
797B (S/N: JSM)
797F (S/N: LAJ) (S/N: WSP)
Reference: Testing and Adjusting, KENR8746,
"797F and 797F XQ Off-Highway Truck Hydraulic
Fan System"
Reference: Testing and Adjusting, KENR8574,
"793F and 793F XQ Off-Highway Truck Hydraulic
Fan and Steering System"
Reference: Bench Test Procedures, REHS1479,
"Bench Test Procedure for Hydraulic Piston Pumps"

Pre-adjustment is required when installing a new

215-6758 Pump Control Valve Gp. Measurements
from the old compensator are needed for the pre-
adjustment.

Illustration 1 g06130517

(1) 215-6758 Pump Control Valve Gp (C) High-pressure cut off adjustment (D) Flow control adjustment length
length

During installation of the new 215-6758 Pump Con- 1. Before removing the failed compensator, measure
trol Valve Gp (1), ensure that the below adjustments the adjustment screw lengths (C) and (D) of the
are made. failed compensator.

10
2. Adjust the new 215-6758 compensator adjust-
ment screws to the same lengths as the failed
compensator.
Note: Make adjustments before operating the
machine
3. Proceed to bench testing or Testing and Adjusting
procedures for the normal final compensator
adjustments.

i06836515

The Procedure to Upgrade the

Bracket Assemblies in the Air
Lines Group on Certain 793F
Off-Highway Trucks is
Updated
SMCS Code: 1063; 1071; Publish Date: 22-Nov-
2016

Off-Highway Truck/Tractor.
793F (S/N: RBT1-171) (S/N: SND) (S/N:
SSP) (S/N: SXP)
793FAC (S/N: EMD)
Description Of Change: New mounting blocks and
shims are now used on certain 793F Off-Highway
Trucks. The new mounting has increased durability
and promotes proper ATAAC tube alignment. Special
Instruction, REHS8000 has been updated to reflect
these changes.
Adaptable To:

Illustration 1 g06139627
New mounting and shims

11
The new pill style 480-9578 Block (1) replaces the
424-6577 Block in the 296-7535 Air Lines Gp.
The 481-0469 Shim (2) and 481-0472 Shim (3)
are used as needed for proper tube alignment.
Table 1
Parts List
Item Qty New Part Number Description Former Part Number
1 2 480-9578 Block 424-6577

2 2 481-0469 Shim -

3 4 481-0472 Shim -

4 8 198-4777 Hard Washer 6V-5839

5 8 231-0336 Taperlock Stud 8T-4195

6 8 344-5675 Nut -

The new mounting is adaptable to machines listed

above and effective in production with all machines
after.
For a complete procedure and parts required to up-
date the lines group refer to the latest version ofSpe-
cial Instruction, REHS8000, "Procedure to Upgrade
the Bracket Assemblies in the Air Lines Group on
Certain 793F Off-Highway Trucks".

The Special Instruction can be found on the Caterpil-

lar Service Information System (SIS) and through the
normal literature distribution system at your local Cat
dealer.

i06836469

New Aluminum Air to Air After

Cooler Cores are Now Avail-
able for Certain 793F Off-High-
way Trucks
SMCS Code: 1063; Publish Date: 24-Oct-2016

Off-Highway Truck/Tractor.
Illustration 1 g06137279
793F (S/N: RBT1-186) (S/N: SND) (S/N:
Aftercooler Core Assembly
SSP) (S/N: SXP)
Reference: Special Instruction, SEHS0303, “Proce- The new after cooler assembly (1) is adaptable to the
dure to Replace the Air to Air After Cooler on 793F machines within the listed serial numbers, and effec-
Off-Highway Trucks” tive with all machines after the listed serial numbers.

Reference: Service Magazine, SEPD2013, "New Note: The new aluminum core is applicable only to
Aluminum Air to Air After Cooler Cores are Now the low altitude machines.
Available for Certain 793F Off-Highway Trucks" For a complete list of parts and the procedure for re-
New aluminum air to air after cooler (ATAAC) cores placing the copper ATAAC cores with new aluminum
are now available on the machines listed above. The ATAAC cores in the field machines, refer to most re-
new aluminum ATAAC is lesser in weight and have a cent version of Special Instruction, SEHS0303, “Pro-
lower operating cost. cedure to Replace the Air to Air After Cooler on 793F
Off-Highway Trucks”.

12
The special instruction can be found on the Caterpil- Future dated orders and committed planned repair
lar service information system (SIS) and through the orders (CPROs) should be placed against the new
normal literature distribution system at your local Cat part numbers starting on October 01, 2016, and all
dealer. other types of orders should be placed against the
current pumps. Once the current pumps are de-
■ pleted, the orders will be filled with the new part
numbers.
i06869093
The new and current high-pressure fuel pumps are
listed in Table 2 .
New High-Pressure Fuel Table 2
Pumps Are Now Used on Cer- New Part Part Name Current Part
tain C175 Off-Highway Truck Number Number

Engines 20R-6600 Fuel Pump Gp 20R-2423

SMCS Code: 1255; 1256; Publish Date: 16-Nov- 20R-6601 Fuel Pump Gp 20R-2424
2016 20R-6602 Fuel Pump Gp 20R-5141

505-1183 Fuel Pump Gp 383-2034

Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N: 505-1184 Fuel Pump Gp 383-2035
SSP) (S/N: SXP) 505-1185 Fuel Pump Gp 387-3284
793FAC (S/N: EMD)
794 (S/N: MN5) (S/N: MT5)
This change is effective for the engine serial numbers
795FAC (S/N: ERM) listed in Table 3 .
795FACXQ (S/N: SNT) Table 3
797F (S/N: LAJ) (S/N: WSP) Effective Serial Numbers
Description Of Change: New high-pressure fuel B7B02076-Up
pumps are in the process of being released. All the
high-pressure fuel pumps have been built with ro- B7C01004-Up
bustness and quality improvements, including an im- JTL01157-Up
proved inlet check valve (ICV), since July 2015.
THR00125-Up
Adaptable To: The new high-pressure fuel pumps
replace the current high-pressure fuel pumps. A4K01027-Up

LLM01500-Up
The current high-pressure fuel pumps starting with
the serial numbers in Table 1 have the
improvements. ■
Table 1
Current Part Number Serial Number i07043994

20R-2423 3RP0887
A Oil Filter Bracket Assembly
20R-2424 4RP0361
Is Now Used on Certain C175-
20R-5141 3RD0001
16 Off-Highway Truck Engines
383-2034 3PP4963
SMCS Code: 1306; Publish Date: 12-May-2017
383-2035 4PP2198
387-3284 3DP0936 Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
The new high-pressure fuel pumps are adaptable to SSP)
the above machine engines back to first production. 793FAC (S/N: EMD)
The new part number high-pressure fuel pumps listed
794 (S/N: MN5) (S/N: MT5)
in Table 2 are equivalent to the current part number 795FAC (S/N: ERM)
pumps, but are being released to make identifying 795FACXQ (S/N: SNT)
pumps built with the improvements easier. Each new
part number will become available at different times, Description Of Change: The new oil filter bracket
as the stock of the current pumps are depleted, and assembly does not attach directly to the oil pan, and
stock of the new pumps is received. is more robust than the previous oil filter bracket. Al-
so, new fuel transfer pump brackets are used with the
oil filter bracket assembly.

13
Adaptable To: The new 504-3813 Oil Filter Bracket
Assembly replaces the existing 425-7266 Oil Filter
Bracket.

The new and former transfer pump brackets are listed

in Table 1 .
Table 1
Transfer Pump New Bracket Former Bracket
Part Number Part Number Part Number
313-6693 511-9781
460-2162
447-7162 522-6027

Reference: Reference Special Instruction,

M0074988 for all required parts and assembly
instructions.

This change is effective with the engine serial num-

bers listed in Table 2 .
Table 2
Effective Serial Numbers
Illustration 1 g06132911
B7B02089-UP
B7C01004-UP For complete procedure, parts and the tools required
to improve the rear suspension link mounts, refer to
JTL01157-UP
the most recent version of Special Instruction,
THR00125-UP M0075788, "The Rear Suspension Link Mounts are
Improved on Certain 793F Off-Highway trucks".
HN200156-UP
ZK202086-UP The special instruction can be found on Caterpillar
Service Information System (SIS) and through the
normal literature system at your local Cat dealer.
■
Improved rear suspension link mounts are adaptable
i06822280 to the machines within the listed serial numbers, and
effective in production with all machines after the
Improved Rear Suspension listed serial numbers.
Link Mounts are Now Used on ■
Certain 793F Off-Highway
Trucks i06814794

SMCS Code: 0679; 3260; Publish Date: 19-Dec- A New Clean Fuel Module
2016
Pump is Available for Certain
Off-Highway Truck/Tractor. Large Off-Highway Trucks
793F (S/N: RBT1-186) (S/N: SND) (S/N: SMCS Code: 1255; 1256; Publish Date: 18-Oct-2016
SSP) (S/N: SXP)
793FAC (S/N: EMD) Off-Highway Truck/Tractor.
793F (S/N: RBT169-186) (S/N: SND127-
Reference: Special Instruction, M0075788, "The
Rear Suspension Link Mounts are Improved on Cer- 133) (S/N: SSP113-1165) (S/N: SXP1-
tain 793F Off-Highway trucks " 103)
794 (S/N: MN5) (S/N: MT5)
Description Of Change: Improved rear suspension 795FAC (S/N: ERM153-293)
link mounts are now used in the machines listed
above. Brackets (1) with non-metallic pads are in-
797F (S/N: LAJ143-618) (S/N: WSP1-
stalled onto the rear axle housing to limit the move- 129)
ment allowed of the link and thereby improving the
Description Of Change: New clean fuel module
lubrication to the joint.
pump is available for the machines listed above. The
Adaptable To: new fuel pump group aligns more easily for servicing
and this new alignment of fuel pump group and O-
ring seal provides improved service life.

14
Adaptable To: 795FAC (S/N: ERM)
795FACXQ (S/N: SNT)
797F (S/N: LAJ) (S/N: WSP)
Description Of Change: A cylinder head bolt align-
ment sleeve 498-3113 Insert is available for C175
engines.
Adaptable To: The new alignment sleeve is adapt-
able back to first production of the serial numbers
listed above.

Illustration 1 g06128685
(1) 511-5018 Fuel Pump Gp
(2) 225-6948 O-Ring Seal

Table 1
Part List
New Part Former Part
Item Qty Part Name
Number Number
Fuel Pump
1 1 511-5018 457-5703
Gp Illustration 1 g06122261

2 2 225-6948 O-Ring Seal —

Two sleeves are required per cylinder head. Refer to
3 2 238-5084 O-Ring Seal — Illustration 1 for the location of these 2 sleeves. The
sleeve prevents contact between the shank of the
bolt and the inner diameter of the head bolt hole.
New fuel pump group (1) replaces the 457-5703
Fuel Pump Gp.

The fuel pump group (1) and O-ring seal (2) are part
of Fuel Filter Lines Gp. The example shown in Illus-
tration 1 is the 797F configuration.

New fuel pump group (1), O-ring seal (2), and O-ring
seal (3) are adaptable to the machines within the
listed serial numbers, and effective with all machines
after the listed serial numbers.

i06804654

A Cylinder Head Bolt Align-

ment Sleeve is Available for
C175 Machine Engines
SMCS Code: 1100; Publish Date: 25-Oct-2016

Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP) (S/N: SXP)
794 (S/N: MN5) (S/N: MT5)

15
Illustration 2 g06132368
Before and after Illustration.

The chamfer on the sleeve should be placed down- 793FAC (S/N: EMD)
ward to aid installation into cylinder head bolt hole. 794 (S/N: MN5) (S/N: MT5)
The sleeves should be installed flush with the top of 795FAC (S/N: ERM)
the cylinder head. A plastic hammer can be used to
lightly tap the sleeve into place.
795FACXQ (S/N: SNT)

Serviceable cylinder head assemblies will begin Description Of Change: The new intake manifold
has a different intake temperature and pressure sen-
being assembled with the sleeves installed.
sor mounting surface.
Table 1
Effective Serial Numbers Adaptable To: The following changes are adaptable
to the products within the listed serial numbers, and
THR00125-UP are effective with all products after the listed serial
B7B02075-UP numbers.
JTL01157-UP The new 503-5084 Intake Manifold replaces the for-
LLM01500-UP mer 341-4032 Intake Manifold.
A4K01027-UP The new intake manifold allows the temperature sen-
HN200141-UP sor to be installed in a better position, and simplifies
the assembly by removing the 8T-7861 O-Ring
HN300105-UP Connector, 6V-8077 Elbow, and 331-1137 Adapt-
HN400127-UP er for the sensor. The new intake manifold can also
accept the previous sensor configuration with the
ZK202077-UP
adapters.
ZK302100-UP
This change is effective for the engine serial numbers
ZK404020-UP listed in Table 1 .
Table 1
■ Effective Serial Number
B7B02072-Up
i06757987
B7C01004-Up
New Intake Manifold Is Now JTL01157-Up
Used for C175-16 Engines THR00125-Up
SMCS Code: 1058; Publish Date: 24-Aug-2016

Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP)

16
Illustration 1 g06115579 Illustration 2 g06115586
Former Design New Design
(1) Temperature sensor (1) Temperature sensor
(2) Pressure sensor (2) Pressure sensor
(3) Remove these three adapters (3) 503-5084 Manifold
(4) 341-4032 Inlet Manifold
■

i07006139

A New Fuel Transfer Pump

Support Bracket Assembly Is
Now Used on Certain C175-20
Off-Highway Truck Engines
SMCS Code: 1000; 1251; Publish Date: 10-Apr-2017

Off-Highway Truck/Tractor.
797F (S/N: LAJ1-Up) (S/N: WSP)
Description Of Change: The new bracket assembly
utilizes a two piece assembly that provides better
strength than the one piece bracket.

Adaptable To: The new 503-0033 Block and

526-4590 Plate replace the former 460-2163
Bracket As.

The new bracket assembly is adaptable to the above

engines back to first production.

For the complete procedure, parts, and tools required

to improve the bracket assembly, refer to Special In-
struction, M0074984, "Assembly Instructions for the
New C175-20 Two Piece Fuel Transfer Pump
Bracket".

17
This change is effective for engine serial numbers
LLM01511-UP.

i06792193

A New Button Plug Is Used on

Certain C175-16 Off-Highway
Truck Engines
SMCS Code: 0663; 1157; Publish Date: 17-Aug-
2016

Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP) (S/N: SXP)
793FAC (S/N: EMD)
794 (S/N: MN5) (S/N: MT5)
795FAC (S/N: ERM)
795FACXQ (S/N: SNT)
Description Of Change: The new button plug keeps
contamination from building up in the rear housing.

Adaptable To: The new 9X-2223 Button Plug repla-

ces the former 130-9210 Bolt. Illustration 1 g06098699
Bolt location
Analysis has shown that the 130-9210 Bolt on the
right-hand side of the rear housing, near the PTO ■
drive, is not required to create a leak free, secure joint
for the rear housing to the engine block.
i06827034
The new button plug is adaptable to the above en-
gines back to first production. A New Alternator Pulley Is
This change is effective for the engine serial numbers Used on Certain C175 Off-
listed in Table 1 . Highway Truck Engines
Table 1
SMCS Code: 1425; Publish Date: 27-Sep-2016
Effective Serial Numbers
B7B02073-Up Off-Highway Truck/Tractor.
B7C01004-Up 793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP) (S/N: SXP)
JTL01157-Up
793FAC (S/N: EMD)
THR00125-Up 794 (S/N: MN5) (S/N: MT5)
795FAC (S/N: ERM)
795FACXQ (S/N: SNT)
797F (S/N: LAJ) (S/N: WSP)
Description Of Change: The new pulley has an in-
creased inner diameter to improve the fit over the al-
ternator shaft.
Adaptable To: The new 510-6090 Pulley replaces
the former 448-7924 Pulley.

The new pulley is adaptable to the above engines

back to first production.

This change is effective for the engine serial numbers

listed in Table 1 .

18
Table 1
Effective Serial Numbers
B7B02072-Up

B7C01004-Up

JTL01157-Up

THR00125-Up

LLM01497-Up

A4K01027-Up

Illustration 1 g06096392
244-0454 Transfer Gear Gp
(1) 459-0683 Lip Type Seal

Table 1
New Parts List
Former
Sales New Part Description
Item part
Model Number
number
223-
361-7171 Lip Type Seal
9743
Illustration 1 g06104576
Wear Sleeve
1 785 C 361-7172 -
■ Seal
Universal Joint
481-8208 312-6539
i06837621 Yoke
223-
A New Transmission Lip Seal 361-7171 Lip Type Seal
9743
is Now Used on Certain 785, 2 785 D 361-7172
Wear Sleeve
-
Seal
789, and 793 Off-Highway
Universal Joint
Trucks 481-8208
Yoke
-

SMCS Code: 3030; 3159; Publish Date: 18-Oct-2016 133-

459-0683 Lip Type Seal
4296
Off-Highway Truck/Tractor. 3 789 D Wear Sleeve
459-0686 -
785C (S/N: APX1-Up) Seal
785D (S/N: DMC) (S/N: MSY) 476-8753 Yoke -
789D (S/N: SHH) (S/N: SPD) 133-
459-0683 Lip Type Seal
793D (S/N: FDB) 4296
793F (S/N: RBT) (S/N: SND) (S/N: SSP) 4
793 D
Wear Sleeve
(1) 459-0686 -
(S/N: SXP) Seal

Description Of Change: A new transmission lip seal 476-8753 Yoke -

is now used on machines listed above. The new lip 133-
5 793 F 459-0683 Lip Type Seal
seal is more durable and provides better sealing be- 4296
tween the yoke and bearing cage in input transfer
gear group.
(continued)
Adaptable To:

19
(Table 1, contd) i06874239

New Parts List

Use of the Integral Seal on Cer-
Former
Item
Sales
Model
New Part
Number
Description part tain C175 Machine Engines
number
SMCS Code: 1100; Publish Date: 30-Nov-2016
Wear Sleeve
459-0686 -
Seal
Off-Highway Truck/Tractor.
481-7680 Yoke - 793F (S/N: RBT1-Up) (S/N: SND) (S/N:
(1) New 310-0853 Bearing Cage As replaces the former SSP) (S/N: SXP)
244-0468 Cover As.
793FAC (S/N: EMD)
New 459-0683 Lip Type Seal (1) replaces the for- 794 (S/N: MN5) (S/N: MT5)
mer 133-4296 Lip Type Seal in 244-0454 Trans- 795FAC (S/N: ERM)
fer Gear Gp. 795FACXQ (S/N: SNT)
797F (S/N: LAJ) (S/N: WSP)
New 481-7680 Yoke replaces the former
279-2540 Yoke As in 359-6202 Transfer Gear Gp The 370-8028 Integral Seal (Standard Integral
and 279-2530 Transfer Gear Gp. Seal) is for use on a cylinder block that has not had
the top deck milled or on a cylinder block that has
New 476-8753 Yoke replaces the former been milled. The cylinder block has a top deck height
225-0086 Yoke As in 244-0454 Transfer Gear between 112.325 mm (4.4222 inch) and 112.675 mm
Gp. (4.4360 inch).
New lip type seal (1) is adaptable to the machines The 394-0295 Integral Seal (Thicker Integral Seal)
and effective in production with the machines that are is for use on a cylinder block that has had the top
listed in Table 3 . deck milled. The cylinder block has a top deck height
between 112.000 mm (4.4094 inch) and 112.325 mm
The following table outlines the required tools to in-
(4.4222 inch).
stall the seals and wear sleeves.
Table 2 Refer to Table 1 and Illustration 1 for additional
Required Tools for Installation information.
Part Number Description Installation Tool

361-7171 Lip Type Seal 509-3262

459-0683 Lip Type Seal 509-3263

361-7172 Wear Sleeve Seal 509-3265

459-0686 Wear Sleeve Seal 509-3264

Table 3
Sales Adaptable to Effective in Produc-
Model Machines tion with Machines
785 C APX1-2391 APX2392-Up

DMC1-182 DMC183-Up
785 D
MSY1-679 MSY680-Up

SPD1-705 SPD706-Up
789 D
SHH1-319 SHH320-Up

793 D FDB1-1859 FDB1860-Up

SND1-133 SND134-Up

SSP1-1171 SSP1172-Up
793 F
SXP1-103 SXP104-Up

RBT1-183 RBT184-Up

20
Table 1
Top Deck Height Requirements and Integral Seal Part Numbers

Part Number Top Deck Height Minimum Valve Maximum Value

370-8028 Dimension (G)(1) 112.325 mm (4.4222 inch) 112.675 mm (4.4360 inch)

394-0295 Dimension (G)(1) 112.000 mm (4.4094 inch) 112.325 mm (4.4222 inch)

(1) Refer to dimension (G) in Illustration 1.

21
Illustration 1 g06071400

22
Illustration 2 g06149080
Location of the block tag indicating top deck height

794 (S/N: MN5) (S/N: MT5)

795FAC (S/N: ERM)
795FACXQ (S/N: SNT)
797F (S/N: LAJ) (S/N: WSP)
Description Of Change: An improved electronic
thermostat is now used on certain large off-highway
trucks. The new assembly has increased service life
and durability.

Adaptable To:
Table 1
Required Parts
Part Former Part
Illustration 3 g06149083 Item Qty Part Name
Number Number
Typical example of a tag indicating top deck height
1 2 118-8706 O-Ring Seal ————
■ Housing
2 2 399-8110 ————
Gasket
i06744549 Motor Mount
3 1 494-0384 470-6789
As
A New Electronic Thermostat Motor Mount
4 1 494-0386 466-7407
Motor Mount Assembly is Now As

Used on Certain Large Off- 5 1 494-0387

Motor Mount
As
466-7408
Highway Trucks
SMCS Code: 135V; Publish Date: 20-Jul-2016

Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP) (S/N: SXP)

23
Illustration 1 g06088468
View of electronic thermostat motor mount
(3) 494-0384 Motor Mount As (4) 494-0386 Motor Mount As (5) 494-0387 Motor Mount As

The new electronic thermostat motor mounts are (Table 3, contd)

adaptable to machines and effective in production Sales Model Reference
machines that are listed in table 2 .
Disassembly and Assembly,
794 AC
• 494-0384 Motor Mount As (3) - All S/N Prefix UENR2272
795F AC Disassembly and Assembly,
• 494-0386 Motor Mount As (4) - All S/N Prefix
795F AC XQ KENR8726
• 494-0387 Mount As (5) - S/N Prefix - SSP, RBT, 797F Disassembly and Assembly,
SXP and SND 797F XQ KENR8384

Table 2
Effective in Pro- ■
Adaptable to
Sales Model duction with
Machines
Machines i06714843

(S/N: SSP1166-
793F (S/N: SSP1-1165)
Up) A New Engine Oil Pump Is Now
793F CMD (S/N: RBT1-179) (S/N: RBT180-Up) Used For Certain Off-Highway
793F OEM (S/N: SXP1-103) (S/N: SXP104-Up) Truck Engines
793F XQ (S/N: SND1-133) (S/N: SND134-Up) SMCS Code: 1304; Publish Date: 22-Dec-2016

(S/N: MT51-111) (S/N: MT5112-Up)

794 AC
(S/N: MN51-55) (S/N: MN556-Up)
Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
795F AC (S/N: ERM1-296) (S/N: ERM297-Up) SSP) (S/N: SXP)
795F XQ (S/N: SNT1-101) (S/N: SNT102-Up) 794 (S/N: MN5) (S/N: MT5)
(S/N: LAJ1-614) (S/N: LAJ615-Up)
795FAC (S/N: ERM)
797F
795FACXQ (S/N: SNT)
797F XQ (S/N: WSP1-129) (S/N: WSP130-Up)
Description Of Change: The new engine oil pump
has helical cut gear teeth and an improved material
For each product's corresponding service informa- for the bearings.
tion, refer to table 3 .
Table 3 Adaptable To:
Sales Model Reference
793F
Disassembly and Assembly,
793F OEM
KENR8578
793F XQ

Disassembly and Assembly,

793F CMD
UENR1144

(continued)

24
Illustration 1 g06133710

The new 416-9858 Engine Oil Pump Gp replaces 793F (S/N: RBT1-Up) (S/N: SND) (S/N:
the previous 341-2503 Engine Oil Pump Gp. The SSP) (S/N: SXP)
20R-0403 Engine Oil Pump Gp is replaced by the 793FAC (S/N: EMD)
20R-6900 Engine Oil Pump Gp. Table 1 contains
the effective serial numbers for this change.
794 (S/N: MN5) (S/N: MT5)
Table 1
795FAC (S/N: ERM)
795FACXQ (S/N: SNT)
Effective Serial Numbers
797F (S/N: LAJ) (S/N: WSP)
B7B02076-Up
A new Special Instruction has been published. The
JTL01157-Up Special Instruction outlines best practices for ensur-
THR00125-Up ing the C175 oil system is full and free of
contamination.
HN200137-Up
Refer to Special Instruction, M0070538, "Best Prac-
HN300105-Up tice for Ensuring the Oil System is Full and Free of
ZK202077-Up Contamination", for further information.

■
■
i06658017
i06678342
A New Spacer is Now Used in
A New Special Instruction has the Rear Axle Housing Group
been Published, Best Practi- on Certain 793F and 793D Off-
ces for Ensuring the C175 Oil Highway Trucks
System is Full and Free of SMCS Code: 3260; Publish Date: 11-May-2016
Contamination
SMCS Code: 1318; 1348; Publish Date: 25-Apr-2016 Off-Highway Truck/Tractor.
793D (S/N: FDB1-Up)
Off-Highway Truck/Tractor. 793F (S/N: RBT) (S/N: SND) (S/N: SSP)

25
Description Of Change: An improved spacer is now
available for the machines that are listed above. The
improved spacer is made from oil resistant material
which increases the service life.
Adaptable To: New 431-0060 Spacer replaces the
former part number 125-5894 Spacer in the
280-1622 Rear Axle Housing Gp on certain 793F
Off-Highway Trucks and in 384-1033 Rear Axle
Housing Gp on certain 793D Off-Highway Trucks.

Illustration 1 g06064156
280-1622 Rear Axle Housing Gp
(1) 431-0060 Spacer

26
Illustration 2 g06065814
384-1033 Rear Axle Housing Gp
(1) 431-0060 Spacer

27
The new part number is listed in Table 1 .
Table 1
Former
New Part Part
Item Qty Part
Number Name
Number
431-
1 1 Spacer 125-5894
0060

Table 2
Effective in Pro-
Adaptable to
Sales Model duction with
machines
Machines

793F SSP1-1160 SSP1161-Up

793F CMD RBT1-179 RBT180-Up

793F XQ SND1-133 SND134-Up

793D FDB1-1855 FDB1856-Up

■
Illustration 1 g06061327

i06645199 No action is required on already installed clamps or

engines running in the field. On future installations of
Incorrect Torque Callout for the clamp, reduce the installation torque to 8.5 N·m ,
Turbine Outlet V-Band Clamp following the same torque, tap, and retorque se-
quence as previously instructed.
on C175 Off-Highway Truck
■
Engines
SMCS Code: 1061; Publish Date: 31-Mar-2016 i06612412

Off-Highway Truck/Tractor. A New Head to Block Oil Feed

793F (S/N: RBT1-Up) (S/N: SND) (S/N: Dowel Is Now Available for
SSP) (S/N: SXP)
793FAC (S/N: EMD) C175 Off Highway Truck
794 (S/N: MN5) (S/N: MT5) Engines
795FACXQ (S/N: SNT) SMCS Code: 1100; 1201; Publish Date: 21-Apr-2016
797F (S/N: LAJ) (S/N: WSP)
The 247-3393 Clamp As used on the turbine outlet Off-Highway Truck/Tractor.
bellows for 793F, 794, 795F, and 797F Low altitude 793F (S/N: RBT1-Up) (S/N: SND) (S/N:
arrangement engines was specified at the wrong in- SSP) (S/N: SXP)
stallation torque in the service publications. The pub- 793FAC (S/N: EMD)
lications called for 12 N·m. The clamp torque should 794 (S/N: MN5) (S/N: MT5)
only be 8.5 N·m.
795FAC (S/N: ERM)
795FACXQ (S/N: SNT)
797F (S/N: LAJ) (S/N: WSP)
Description Of Change: The new dowel provides
more protection against the risk of debris entering the
oil system when a cylinder head is removed.

Adaptable To: A new 493-5366 Dowel As replaces

the old 371-6455 Dowel is now used on the C175
cylinder block to cylinder head joint. The new dowel
is adaptable back to first production on the serial
numbers listed above.
This change is effective for the serial numbers listed
in Table 1

28
Table 1
Effective Serial Numbers
B7B02062-Up

B7C01004-Up

THR00125-Up

LLM01491-Up

JTL01157-Up

A4K01027-Up

Note: Only recommended to change or remove oil

dowels at engine PCR or anytime where the block will
be thoroughly cleaned.

Note: Field installation is not recommended.

Installation Procedure

Illustration 1 g06051808
Use caps or plugs to prevent dirt or containments to get into oil system before installing new oil feed dowels.

29
Illustration 2 g06051829

1. Insert to the top of alignment shoulder.

2. Use plastic dead blow hammer to tap in.

3. Tap in until the bottom of the cap is flush with the

block. Do not over drive and damage dowel or
block.
4. If the dowel cap is removed for any reason, torque
the cap to 2 ± 1 N·m (17 ± 9 lb in).

Removal Procedure
Note: Cleanliness is an important factor. Before the
removal procedure, clean the exterior of the compo-
nent thoroughly. Cleaning the exterior will help to pre- Illustration 3 g06051749
vent dirt from entering the internal mechanism.
2. Use proper screw driver and technique to avoid
1. Clean and vacuum thoroughly around the dowel. damage.

30
Illustration 4 g06051756

3. Parts with burrs or damage must be replaced.

31
Illustration 5 g06051763

4. Use a slide hammer or bolt/nut M10 X 1.5 and 793F (S/N: RBT1-Up) (S/N: SND) (S/N:
spacer as shown in Illustration 5. SSP)
■ 793FAC (S/N: EMD)
Description Of Change:
i06608764
Reference: Special Instruction, M0068338, "Field
Procedures to Improve the Procedure to Update the Cooling System on 793F
Off-Highway Trucks with Extra Cooling"
Cooling Systems on 793F and
793F AC Off-Highway Trucks Reference: Special Instruction, M0068340, "Field
Procedure to Update the Cooling System on 793F
Equipped with Standard Cool- Off-Highway Trucks with Standard Cooling"
The new Special Instruction provides the required
ing or Extra Cooling are parts, and the proper procedures to update the water
Available line groups in the cooling arrangements. The updates
allow the machines to operate within the proper heat
SMCS Code: 1380; 7960; Publish Date: 18-Feb- range in the field.
2016
Adaptable To:
Off-Highway Truck/Tractor.

32
Illustration 1 g06044564 Illustration 3 g06044576
Configuration of the new water lines group in the standard cooling Configuration of the improved water lines group in the extra cooling
arrangement arrangement

Illustration 2 g06044568 Illustration 4 g06044583

Configuration of the former water lines group in the standard cool- Configuration of the former water lines group in the extra cooling
ing arrangement arrangement

The improved 290-0571 Water Lines Gp is now The improved 290-0570 Water Lines Gp is now
used on machines equipped with standard cooling. used on machines equipped with extra cooling.

Use the Special Instruction that matches the configu-

ration of your machine. The improved water lines
groups are adaptable to machines SSP1-1019,
EMD1-77, RBT1-171, and SND1-131.
The improved water lines groups became effective in
production with machines SSP1020-Up, EMD78-Up,
RBT172-Up, and SND132-Up.

33
The complete list of material, and the correct proce- i06904379
dures needed to update the cooling arrangements to
the current configurations are available. The needed New Camshafts and Lifter Lev-
parts are listed in the two above listed Special In-
structions. The update procedures are explained in ers are Available for Certain
the two above listed Special Instructions. The Special C175 Powered Off-Highway
Instructions can be found on the Caterpillar Service
Information System (SIS). The Special Instructions Trucks
are also available through the normal literature distri- SMCS Code: 1209; 1210; Publish Date: 04-Jan-
bution system at your local Cat © dealer. 2017
■
Off-Highway Truck/Tractor.
i06601227
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP) (S/N: SXP)
Improved Harness Routing for 793FAC (S/N: EMD)
794 (S/N: MN5) (S/N: MT5)
Transmission Hydraulic Tem- 795FAC (S/N: ERM)
perature Sensor is Now Used 795FACXQ (S/N: SNT)
on Certain 793F Off-Highway 797F (S/N: LAJ) (S/N: WSP)
Trucks Description Of Change: A new camshaft and lifter
lever has been implemented on C175 machine en-
SMCS Code: 1408; 3030; Publish Date: 18-Feb-
gines. A polish improvement has been made to the
2016
lobes of the camshaft and the surface finish on the in-
ner diameter of the lifter lever roller has been
Off-Highway Truck/Tractor. improved.
793F (S/N: D3T1-Up) (S/N: RBT) (S/N:
SND) (S/N: SSP) (S/N: SXP) Adaptable To: The changes are adaptable back to
first production on the serial numbers listed above.
Description Of Change: An improved harness rout- The new and former part numbers are listed below.
ing is now used on the transmission hydraulic tem-
perature sensor on certain 793F Off-Highway Trucks. Note: Do not use the former lifter levers with the
The improved harness routing will reduce pin fretting new camshafts. The new lifter levers need to be
and intermittent diagnostic of the transmission tem- used with the new camshafts.
perature sensor.
Adaptable To: Refer to Special instruction,
M0068230, "Procedure to relocate the harness
mounting location for the transmission temperature
sensor on certain 793F Off-Highway Trucks" to relo-
cate the Transmission Hydraulic Temperature Sensor
connector from the transmission housing to a shock-
mounted harness location.

The improved harness routing for transmission hy-

draulic temperature sensor is adaptable and effective
in production for the following machines given in Ta-
ble 1 .
Table 1
Effective in pro-
Adaptable to
Sales Model duction with
Machines
Machines
D3T1-143 D3T144-UP
SSP1-1158 SSP1159-UP
793F RBT1-175 RBT176-UP
SXP1-103 SXP104-UP
SND1-133 SND134-UP

34
Table 1
Description New Part Number Former Part Number
C175–16 Front Camshaft 488-3487 274-7726

C175–16 Rear Camshaft 488-3489 274-7728

C175–20 Front Camshaft 488-3491 388-8844

C175–20 Rear Camshaft 488-3493 388-8842

Lifter Lever 486-3590 281-9370

Table 2
Reman Part Number
Description New Reman Part Number Former Reman Part Number
C175–16 Front Camshaft 20R-6740 10R-9050

C175–16 Rear Camshaft 20R-6742 10R-9052

C175–20 Front Camshaft 20R-6741 20R-1760

C175–20 Rear Camshaft 20R-6743 20R-1759
Lifter Lever 20R-6744 20R-0456

Table 3 (Table 4, contd)

Effective Serial Numbers for Camshaft Change HN300105-UP

B7B02051-UP HN400122-UP

LLM01473-UP
■
THR00120-UP
B7C01004-UP i06557235
A4K01027-UP
JTL01157-UP
New Wiring Harness Assembly
ZK202071-UP
for the Rear Power Train Is
ZK302094-UP Now Available for Certain 793F
ZK404015-UP Off-Highway Trucks
HN200120-UP SMCS Code: 1408; 1634; Publish Date: 22-Feb-
2016
HN300105-UP
HN400122-UP Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
Table 4
SSP) (S/N: SXP)
Effective Serial Numbers for Lifter Lever Change
Description Of Change: A new wiring harness as-
B7B02058-UP
sembly for the rear power train is now available for
LLM01477-UP the machines listed above. The new wiring harness
THR00120-UP
routing location and installation procedure will extend
the service life of the harness assembly.
B7C01004-UP
For a complete list of material and the correct proce-
A4K01027-UP
dure that is needed in order to install the new wiring
JTL01157-UP harness assembly, refer to Special Instruction,
ZK202071-UP
M0067082, "Procedure to Install Wiring Harness As-
semblies for the Power Train on 793F Off-Highway
ZK302094-UP Truck" and Special Instruction, M0067084, "Proce-
ZK404015-UP dure to Install Wiring Harness Assemblies for the
Power Train on Certain 793F Off-Highway Trucks".
HN200120-UP These special instructions can be found on the Cater-
pillar Service Information System (SIS) and through
the normal literature distribution system at your local
(continued) Cat dealer.

35
Adaptable To: The procedure to install new wiring
harness is adaptable to machines and effective in
production with machines that are listed in Table 1 .
Table 1
Effective in Pro-
Adaptable to
Sales Model duction with
Machines
Machines
SSP1-1150 SSP1151-Up

RBT1-173 RBT174-Up
793F
SXP1-103 SXP104-Up

SND1-133 SND134-Up

i06552499

New Plates and Retainers for

the Brake and Wheel Groups
are Now Used on Certain 793D
and 793F Off-Highway Trucks
with Standard Wheel
Configuration Illustration 1 g06023796
SMCS Code: 4008; 4201; Publish Date: 14-Dec- Service and Parking Brake Gp
2015

Off-Highway Truck/Tractor.
793D (S/N: FDB1-Up)
793F (S/N: RBT) (S/N: SND) (S/N: SSP)
(S/N: SXP)
Description Of Change: New plates and retainers
for the brake and wheel group are now used on the
machines listed above. New end plates and retainers
have a new design that has optimized thickness and
tolerances.
Adaptable To:
Table 1
Required Parts List

Quan- Part Former Part

Item Description
tity Number Number
1 1 375-4396 Plate 198-1450
2 1 375-5961 Retainer 278-7099
3 1 375-5962 Retainer 137-1077

Illustration 2 g06023800
Wheel and Brake Gp

36
 i06574936

Cat ® Reman Announces the

Availability of Remanufactured
Short Blocks for 793F, 795F,
and 797F Off-Highway Truck
Engines
SMCS Code: 1201; 1307; Publish Date: 06-Jan-
2016

Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP)
793FAC (S/N: EMD)
795FAC (S/N: ERM)
797F (S/N: LAJ) (S/N: WSP)
Reman has introduced two different types of blocks:
Type 1 and Type II. All Type 1 blocks provided are
converted to Type II except for the oil gallery inlet
port, which has a different bolt pattern than Type II,
requiring a different oil tube and adapter. These parts
are not included with the short block. Therefore these
parts will need replaced if a different block type is re-
Illustration 3 g06023804 ceived than the one being replaced.
Final Drive, Brake and Wheel Gp
Inspect the adapter bolt pattern on block received to
determine type of block and to order parts. Type 1
New 375-4396 Plate (1) is a part of 334-5020 has an asymmetrical bolt pattern and Type II has a
Service and Parking Brake Gp, 334-5019 Service square bolt pattern.
and Parking Brake Gp, and 470-8607 Service and
Parking Brake Gp in the wheel arrangements. The Reman short block part numbers are listed in Ta-
ble 1 .
New 375-5961 Retainer (2) is a part of 280-2056
Table 1
Wheel and Brake Gp, 252-7174 Wheel and Brake
Gp, and 337-7940 Wheel and Brake Gp in the Sales Model Part Number
wheel arrangements. 793F (C175–16) 20R-6235

New 375-5962 Retainer (3) is a part of 280-2051 795F (C175–16) 20R-6236

Final Drive, Brake and Wheel Gp, 334-5492 Final
Drive, Brake and Wheel Gp, 246-5264 Final Drive, 797F (C175–20) 20R-6237
Brake and Wheel Gp, and 302-8162 Final Drive,
Brake and Wheel Gp in the wheel arrangements.
C175–16 Type 1 Block
The new parts are adaptable to machines and effec-
tive in production with machines that are listed in Ta- Table 2
ble2 . 490-7779 Engine Oil Lines Gp
Table 2
Adaptable to Effective in Produc-
Item Qty Part Number Description
Sales Model
Machines tion with Machines 1 1 9Y-2099 Flange
793D FDB1-614 FDB615-Up
2 1 290-8724 Adapter
SSP1-568 SSP569-Up
3 1 344-9285 Ring
RBT1-118 RBT119-Up
4 1 371-6762 Flange
793F
SXP1-100 SXP101-Up
5 1 454-9113 Tube
SND1-115 SND116-Up 6 1 6V-1196 O-Ring Seal

7 4 6V-4248 Bolt
■

(continued)

37
(Table 2, contd)
490-7779 Engine Oil Lines Gp

Item Qty Part Number Description

8 6 6V-5839 Washer
9 2 8T-0643 Bolt
10 2 269-7885 O-Ring Seal

Illustration 1 g06019006
Asymmetrical bolt pattern

C175–16 Type II Block

Table 3
490-7780 Engine Oil Connection Gp

Item Qty Part Number Description

1 1 481-5898 Flange

2 1 486-6909 Adapter

3 1 487-6604 Tube
4 4 6V-1820 Bolt
5 8 6V-5839 Washer
6 4 6V-5843 Bolt
7 2 269-7885 O-Ring Seal

38
Illustration 2 g06019062
Square bolt pattern

C175–20 Type 1 Block

Table 4
490-7781 Engine Oil Lines Gp

Item Qty Part Number Description

1 1 9Y-2099 Flange

2 1 290-8724 Adapter

3 1 344-9285 Ring

4 1 371-6762 Flange

5 1 432-2372 Tube
6 1 6V-1196 O-Ring Seal

7 4 6V-4248 Bolt
8 6 6V-5839 Washer
9 2 8T-0643 Bolt
10 2 269-7885 O-Ring Seal

39
Illustration 3 g06019114
Asymmetrical bolt pattern

C175–20 Type II Block

Table 5
490-7782 Engine Oil Connection Gp

Item Qty Part Number Description

1 1 481-5898 Flange

2 1 486-6909 Adapter

3 1 488-1757 Tube
4 4 6V-1820 Bolt
5 8 6V-5839 Washer
6 4 6V-5843 Bolt
7 2 269-7885 O-Ring Seal

40
Illustration 4 g06019131
Square bolt pattern

Reference Description Of Change: A new fuel transfer pump

has been implemented on C175 machine engines.
Reference: Service Magazine, SEPD1437, A New Several fuel lines were also rerouted to improve fuel
Cylinder Block and Flywheel Housing Are Used for system performance. The injector bypass line was
C175 Off-Highway Truck Engines changed to send the fuel to the inlet of the secondary
fuel filter instead of returning back to the fuel tank.
Reference: Special Instruction, REHS8661, Proce- The fuel exiting the pressure regulator, mounted to
dure to Retrofit the Oil Filter Housing Group on Cer- the outlet of the secondary filters, is now routing fuel
tain C175 Off Highway Truck Engines to the inlet of the transfer pump. The fuel was previ-
ously returned to the fuel tank.
■
Adaptable To: The changes are adaptable back to
i06709535 first production on the serial numbers listed above.
Before updating to the new transfer pump and fuel
A New Fuel Transfer Pump and line routings, ensure the priming pump and mono-
block changes announced in SEPD 1930, have al-
Improved Fuel Lines Routings ready been performed. REHS 9674 was created to
document a procedure to perform the priming pump
are Available for Certain Off- and mono block update.
Highway Truck Engines
Reference: Refer to Special Instruction M0064898
SMCS Code: 1256; 1274; Publish Date: 06-Jul-2016 for installation instructions and a list of parts required
for the fuel transfer pump and fuel line routing
Off-Highway Truck/Tractor. changes. A list of the previous and new groups are
793F (S/N: RBT1-Up) (S/N: SND) (S/N: provided below for 16 and 20 cylinder engine.
SSP) (S/N: SXP)
793FAC (S/N: EMD)
794 (S/N: MN5) (S/N: MT5)
795FAC (S/N: ERM)
795FACXQ (S/N: SNT)
797F (S/N: LAJ) (S/N: WSP)

41
Table 1
Application Former Part Number Description New Part Number Description
16 Cylinder Truck 377-9341 Fuel Transfer Pump As 453-1566 Fuel Transfer Pump As

16 Cylinder Truck 365-5949 FCV Harness 500-0614 FCV Harness

16 Cylinder Truck 463-5276 Harness As. 500-0615 Harness As.

16 Cylinder Truck 316-1741 Filter GP-Fuel 440-9741 Filter GP-Fuel

16 Cylinder Truck 441-0741 Fuel Manifold Gp 475-1623 Fuel Manifold Gp

16 Cylinder Truck 313-6693 Pump GP-F XFR 447-7162 Pump GP-F XFR

16 Cylinder Truck 328-7085 MTG GP-Pump 457-6771 MTG GP-Pump

16 Cylinder Truck 462-3344 Lines GP-F-INJ-A 475-1622 Lines GP-F INJ-B

16 Cylinder Truck 462-3334 Lines GP Fuel 478-0100 Lines GP-F INJ-A

16 Cylinder Truck 327-6375 Fuel Drain Lines Gp 486-4600 Adapter GP

Table 2
Application Former Part Number Description New Part Number Description
20 Cylinder Truck 377-9342 Fuel Transfer Pump As 453-1566 Fuel Transfer Pump As

20 Cylinder Truck 365-5949 FCV Harness 500-0614 FCV Harness

20 Cylinder Truck 463-5285 Harness As. 500-0616 Harness As.

20 Cylinder Truck 317-1613 Filter GP-Fuel 449-7474 Filter GP-Fuel

20 Cylinder Truck 441-0741 Fuel Manifold Gp 475-1623 Fuel Manifold Gp

20 Cylinder Truck 313-9062 Pump GP-F XFR 447-7162 Pump GP-F XFR

20 Cylinder Truck 328-7085 MTG GP-Pump 421-8119 MTG GP-Pump

20 Cylinder Truck 462-3350 Lines GP-F INJ-A 475-1917 Lines GP-F INJ-B

20 Cylinder Truck 462-3337 Lines GP-Fuel 478-0099 Lines GP-F INJ-A

20 Cylinder Truck 327-4622 Lines GP-Fuel 486-4600 Adapter GP

This change is effective for the serial numbers listed SMCS Code: 1307; 1319; Publish Date: 10-Sep-
in Table 3 . 2015
Table 3
Effective Serial Numbers OEM.
B7B02058-UP
CATWDS (S/N: M3J1-Up)
Off-Highway Truck/Tractor.
LLM01478-UP
785B (S/N: 6HK)
THR00122-UP 785C (S/N: 1HW) (S/N: 5AZ) (S/N: APX)
B7C01004-UP 785D (S/N: DMC) (S/N: MSY)
A4K01027-UP 789B (S/N: 7EK)
JTL01157-UP
789C (S/N: 2BW)
789D (S/N: SHH) (S/N: SPD)
793B (S/N: 1HL)
■
793C (S/N: CBR)
793D (S/N: FDB)
i06268877
793F (S/N: RBT) (S/N: SND) (S/N: SSP)
An Improved Engine Prelube 793FAC (S/N: EMD)
795FAC (S/N: ERM)
Pump Is Now Available for Cer- 797F (S/N: LAJ) (S/N: WSP)
tain Off-Highway Trucks

42
An improved 116-7153 Prelubrication Pump and
Motor Gp, 190-6126 Electric Motor Gp, and
228-5112 Prelubrication Oil Pump Gp is now avail-
able for the machines listed above.
The motor in the prelubrication oil pump are updated
with new internal bushings.

The new improvement will provide better component

reliability and improved service life.

Illustration 1 g03878115
485-0316 Pump Adapter

The new 485-0316 Pump Adapter replaces the pre-

vious 354-1562 Pump Adapter.
Note: Replace the 459-6534 Filter Screen As dur-
ing any high-pressure fuel pump or adapter removal.
Table 1 contains the effective engine serial numbers.
Illustration 1 g03882452
Table 1
(A) Motor Serial Number for the Prelube Pump
Effective Serial Numbers
(B) Serial number is engraved on the Pump housing
LLM01467-Up
The improved motor is effective with serial number
B7B02039-Up
51071 and above. Refer to Illustration 1.
JTL01157-Up
■
A4K01027-Up

i06268354 B7C01004-Up

A New High Pressure Fuel ■

Pump Adapter Is Now Used On
Certain Off-Highway Trucks i06241799

SMCS Code: 1162; 1206; Publish Date: 14-Sep- An Improved Radiator Top
2015
Tank Hose Routing Is Now
Off-Highway Truck/Tractor. Used on Certain 793F Off-
793F (S/N: RBT1-Up) (S/N: SND) (S/N: Highway Trucks
SSP)
793FAC (S/N: EMD) SMCS Code: 1353; Publish Date: 03-Aug-2015
795FAC (S/N: ERM)
795FACXQ (S/N: SNT) Off-Highway Truck/Tractor.
797F (S/N: LAJ) (S/N: WSP) 793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP)
Description Of Change: A new machining process 793FAC (S/N: EMD)
for the high-pressure fuel pump adapter drain hole
helps prevent contamination of the engine front gear Description Of Change: An improved coolant over-
train from debris. flow hose routing for the radiator top tank is now used
on the machines listed above. The new routing with
Adaptable To:

43
additional hose length is routed to the right-hand side
of radiator top tank to improve draining of coolant.
Adaptable To: The improved 335-8380 Radiator
Gp is adaptable to machines and effective in produc-
tion with machines that are listed in Table 1 .
Table 1
Effective in Pro-
Adaptable to
Sales Model duction with
Machines
Machines

793F AC EMD1-77 EMD78-Up

SND1-131p SND132-Up

793F SSP1-1039 SSP1040-Up

RBT1-171 RBT172-Up Illustration 1 g03871013

Use the following rework procedure in order to up-

date the 335-8380 Radiator Gp on the above listed
adaptable machines.

Rework Procedure
Table 2
Required Parts List

Item Quantity Part Number Description

1 4 8X-5496 Boss

2 1170(1) 6V-8523 Hose

3 1 5D-1026 Band Clamp

Illustration 2 g03871014
4 4 095-0912 Clip
View of area A
5 4 5C-9553 Bolt
1. Remove old 6V-8523 Hose (B) and hose mount-
6 4 9X-8256 Washer ing hardware from the radiator top tank. Discard all
(1) Numbers in mm parts.

44
Illustration 3 g03871017
(C) 525.0 mm (20.67 inch)
(D) 200.0 mm (7.87 inch)
(E) 110.0 mm (4.33 inch)
(F) 90.0 mm (3.54 inch)
(G) 50.0 mm (1.97 inch)
(H) 130.0 mm (5.12 inch)
(W1) All around fillet weld

2. Weld four bosses (1) to 380-5101 Coolant Tank

As as per dimensions shown in Illustration 3. Refer
to Special Instruction, REHS1841, "General Weld-
ing Procedures".

Note: Do not change the orientation of coolant drain

port.

45
Illustration 4 g03871019

Illustration 5 g03871044
View of area J

3. Install new hose (2) to coolant drain port with band i06256091
clamp (3).

4. Secure hose (2) to the welded bosses using four

A New Thermostat Control
clips (4), four bolts (5), and four washers (6). Refer Module Shield Is Used On Cer-
to Illustration 4 and Illustration 5.
tain 793F, 795F, And 797F Off-
■ Highway Trucks

46
SMCS Code: 135V; Publish Date: 05-Aug-2015 Table 2
Serial Number Effectivity
Off-Highway Truck/Tractor.
SSP01126-Up
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP) (S/N: SXP) EMD00078-Up
793FAC (S/N: EMD) RBT00172-Up
795FAC (S/N: ERM)
SXP00103-Up
795FACXQ (S/N: SNT)
797F (S/N: LAJ) (S/N: WSP) SND00134-Up
Service Magazine, SEPD2026, 30 July 2015, “A New
ERM00297-Up
Thermostat Control Module Shield Is Used On Cer-
tain 793F And 797F Off-Highway Trucks ”. Disregard SNT00101-Up
this previous article. See the article that follows. Seri-
al number effectivity has been updated. LAJ00593-Up

WSP00130-Up
Description Of Change: A new shield is used on the
thermostat control module to prevent moisture entry
into the electrical connectors on certain 793F, 795F ■
and 797F Off-Highway Trucks.
i06559862
Adaptable To: Table 1 contains the parts needed for
this change. Table 2 contains the serial number
effectivity. Rear Axle Oil Cooler Lines
Reference: Refer to Special Instruction, REHS9683,
Routing can be Modified on
“Installation of the New Shield For the Temperature Certain 793F Off-Highway
Control Module On Certain 793F, 795F, And 797F
Off-Highway Trucks” for installation instructions.
Trucks
Table 1 SMCS Code: 1365; Publish Date: 03-Feb-2016
Item Qty Part Number Part Description
Off-Highway Truck/Tractor.
1 1 125-8534 Plate As 793F (S/N: RBT1-Up) (S/N: SND) (S/N:
2 2 204-2281 Cable Straps SSP) (S/N: SXP)
Service Magazine, SEPD2063, 28 September 2015,
3 2 204-8000 Mounts
“Rear Axle Oil Cooler Lines Routing can be Modified
4 1 243-5821 Bracket As on Certain 793F Off-Highway Trucks ”. Disregard the
Connecting Plug Kit
previous article. Refer to the article that follows.
5 1 282-9886

6 1 311-4859 Heat Shrink Tube Description Of Change: The rear axle oil cooler
lines routing can be modified to accommodate a by-
7 1 350-1571 Bracket As
pass valve in the rear axle cooler circuit. The new
8 1 351-9309 Heat Shrink Tube routing will allow cold oil to bypass the cooler core
and recirculate to the rear axle. This change will allow
9 1 440-3480 Bracket
oil to reach an operating temperature and aids ac-
10 1 440-3481 Bracket As cessing the higher gears during cold weather.
11 1 463-3805 Grommet Assembly
Adaptable To: The modification to 280-1610 Rear
12 1 463-3807 Nut Axle Oil Cooler Gp is adaptable to machines and ef-
fective in production with machines that are listed in
Thermostat Harness
13 1 466-8481 Table 1 .
As
Table 1
14 1 4D-7794 Clip
Effective in Pro-
Adaptable to
15 5 8T-4121 Hard Washers Sales Model duction with
Machines
Machines
16 4 8T-4136 Bolts
SSP1-1146 SSP1147-Up
17 1 8T-4137 Bolt
RBT1-171 RBT172-Up
18 1 8T-4195 Bolt 793F
SXP1-103 SXP104-Up
19 2 9X-6165 Washers
20 1 9X-8243 Heat Shrink Tube SND1-133 SND134-Up

47
Rework Procedure
Use the following rework procedure to update the
280-1610 Rear Axle Oil Cooler Gp on the above
listed adaptable machines:
Table 2
New Parts List

Item Qty Part Number Description

1 1 473-3057 Hose As(1)

2 1 473-3058 Hose As(1)

3 1 473-3055 Hose As(1)

4 1 473-3056 Hose As(1)

5 2 7X-2429 Swivel Tee

6 2 6V-8400 O-Ring Seal

7 2 8C-3364 Elbow

8 4 228-7094 O-Ring Seal

9 2 238-5084 O-Ring Seal

10 3 8T-4196 Bolt
11 3 8T-7934 Hard Washer
12 7 8T-4121 Hard Washer
13 1 453-4765 Bracket
Illustration 1 g03878011
14 1 471-1141 Manifold
15 2 8T-4198 Bolt
16 2 8T-4133 Nut

17 2 9S-6130 Plug

18 4 228-7096 O-Ring Seal

19 1 329-1730 Valve As
20 2 6V-9009 Elbow

21 1 155-2860 Collet Stem

22 1 3P-0774 Gasket
(1) Non-serviceable part, refer to Hydraulic Information System
(HIS), for more hose information

Illustration 2 g03877227
View of area A

1. Remove 359-5555 Hose As (B) and 453-4764

Hose As (C). Discard all parts.

48
2. Remove two 8T-7927 Connectors (D). Discard
the part.

Illustration 5 g06037255

6. Install bracket (13) along with three bolts (10),

Illustration 3 g06014107 three hard washers (11), and three hard washers
(12) as shown in Illustration 5.
3. Install hose assembly (1) and hose assembly (2) to
the rear support assembly as shown in Illustration 7. Secure and install manifold (14) along with two
3. bolts (15) , four hard washers (12), and two nuts
(16) as shown in Illustration 5. Tighten bolts (15) to
55 ± 10 N·m (41 ± 7 lb ft).

8. Install two plugs (17) with two O-Ring Seals (18) to

manifold (14) as shown in Illustration 5. Tighten
two plugs (17) to 150 ± 20 N·m (111 ± 15 lb ft).

9. Install gasket (22) onto valve assembly (19). Install

valve assembly (19) to manifold (14). Tighten valve
assembly (19) to 190 ± 30 N·m (140 ± 22 lb ft).

Illustration 4 g03877256
Detailed view of area E

4. Install two swivel tees (5) and two O-Ring Seals (6)
as shown in Illustration 4.
5. Install two elbows (7), two O-Ring seals (8), and
two O-Ring seals (9). Tighten elbows (7) to
200 ± 25 N·m (148 ± 18 lb ft) as shown in Illustra-
tion 4.
Illustration 6 g03878435
(G) Angle is 45 degrees.
(H) Angle is 70 degrees.

49
10. Install two elbows (20) to manifold (14) with two O- increases the robustness of the fuel injector for in-
Ring seals (8) and two O-Ring seals (18). Orient creased life.
two elbows (20) as per dimension shown in Illustra-
tion 5. Tighten two elbows (20) to 200 ± 30 N·m Adaptable To: The new 443-9454 Fuel Injector re-
(148 ± 22 lb ft). places the existing 331-5895 Fuel Injector for 793F
and 797F. The new 443-9454 Fuel Injector also re-
places the 331-5894 Fuel Injector for the 795F. The
Reman 20R-5566 Fuel Injector replaces the exist-
ing 10R-8998 Fuel Injector and 10R-9004 Fuel In-
jector Gp. The new fuel injector is adaptable back to
first production on the serial numbers listed above.
New engine software is required to support the new
fuel injector. Engines must be equipped with the fol-
lowing engine software or newer software as shown
in Table 1 . An interlock code mismatch will be dis-
played in Cat ET if a new injector and trim file are in-
stalled with a previous version of engine software.
Note: The new fuel injectors are interchangeable with
the previous fuel injectors. It is NOT required to
change an entire set on a given engine. An engine
can run with a mixed set of new and old injector part
numbers as long as the engine software has been
updated.
Table 1
Sales Model Engine Software
Illustration 7 g06014137
793F Low Altitude 485-8816 Engine Software
11. Install hose assembly (3) and hose assembly (4)
793F High Altitude 485-8817 Engine Software
as shown in Illustration 7.
793F Lesser Regulated Coun-
■ 485-8821 Engine Software
tries (LRC)

795F Low Altitude 485-8814 Engine Software

i06867812
795F (LRC) 485-8820 Engine Software
A New Fuel Injector Is Now 797F Low Altitude 485-8815 Engine Software
Available for Certain 793F, 797F High Altitude 485-8818 Engine Software
795F, 797F, 797 Retrofit, and 797F (LRC) 485-8819 Engine Software
794 AC Off-Highway Truck 794 AC 485-8822 Engine Software
Engines 485-8823 Engine Software
797 North American Retrofit
SMCS Code: 1254; 1290; Publish Date: 14-Nov-
2016 797 Export Retrofit 485-8824 Engine Software

793F AC 485-8825 Engine Software

Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N: This change is effective for the engine serial numbers
SSP) listed in Table 2 .
794 (S/N: MN5) (S/N: MT5) Table 2
795FAC (S/N: ERM) Effective Serial Numbers
795FACXQ (S/N: SNT)
B7B02039-UP
797F (S/N: LAJ) (S/N: WSP)
Service Magazine, SEPD2052, 11 September 2015, JTL01157-UP
“A New Fuel Injector Is Now Available for Certain THR00115-UP
793F, 795F, and 797F Off-Highway Truck Engines”.
Disregard this article, the machine effectivity and soft- LLM01467-UP
ware part numbers have been updated. Refer to the A4K01027-UP
article that follows.
Description Of Change: The new fuel injector has ■
an improved valve and armature design that

50
 i06207512 (Table 2, contd)
13 1 353-7954 Grommet
An Improved Breather Lines Clip
14 1 8T-1889
Routing for Rear Axle Housing Clip
15 1 8T-1890
Group Is Now Used on Certain
16 1 370-1480 Grommet
793F Off-Highway Trucks 17 1 375-3192 Clip
SMCS Code: 3260; Publish Date: 02-Jul-2015
18 1 375-3193 Clip

Off-Highway Truck/Tractor. 19 1 125-0810 Hose As

793F (S/N: RBT1-Up) (S/N: SND) (S/N: 20 1 3J-5390 Plug
SSP)
21 1 2T-1925 Elbow
Description Of Change: The breather assembly is 22 1 6V-8397 O-Ring Seal
now updated to the new location on the frame assem-
bly on the machines listed below. The new location
provides better clipping of breather assembly and im-
proves service life.
Adaptable To: The improved breather lines routing
for 280-1622 Rear Axle Housing Gp is adaptable to
machines and effective in production with machines
that are listed in Table 1 .
Table 1
Effective in Pro-
Adaptable to
Sales Model duction with
Machines
Machines

SSP1-1127 SSP1128-Up

793F RBT1-171 RBT172-Up

SND1-133 SND134-Up Illustration 1 g03856339

Rework Procedure
Use the following rework procedure in order to up-
date the 280-1622 Rear Axle Housing Gp on the
above listed adaptable machines:
Table 2
New Parts List

Item Quantity Part Number Description

1 1 9C-6809 Block
2 1 235-3350 Bracket
3 2 8T-4136 Bolt
4 4 8T-4121 Hard Washer
5 1 9C-4937 Breather As

6 1 345-3921 Adapter

7 1 3K-0360 O-Ring Seal

8 1 8C-8835 Bulkhead Adapter

Illustration 2 g03859666
9 1 228-7089 O-Ring Seal
View A
10 1 6V-9168 Nut (A) 55.0 mm (2.17 inch)
11 1 8T-4195 Bolt (W1) 6 mm (0.2 inch) fillet weld on both sides of the block

12 1 8T-4133 Nut

(continued)

51
Illustration 3 g03859670
(B) 120.0 mm (4.72 inch)

1. Position block (1) on the frame assembly as per

the dimensions shown in Illustration 2 and 3.
2. Weld block (1) on the frame assembly as shown in
Illustration 2. Refer Special Instruction, Illustration 5 g03859797
REHS1841, "General Welding Procedures"
5. Install hose assembly (19) using clip (11), clip (12),
grommet (13), nut (14), hard washer (4), and bolt
(15).

6. Install clip (16), clip (17), and grommet (18) to

tube.
7. Install plug (20), elbow (21), and O-Ring seal (22)
to hose assembly.
Use parts that are listed in Table 2 to update new
breather assembly (5) for the 280-1622 Rear Axle
Housing Gp. Refer to Illustration 4 and 5 for proper
routing and location of parts.

i06181401

The Front Pedestal Frame Sup-

port Has Been Improved on
Certain 793F Off-Highway
Illustration 4 g03859671
Trucks
3. Install new bracket (2) to block (1) with bolts (3), SMCS Code: 0679; 7051; Publish Date: 29-May-
and hard washers (4). 2015
4. Secure breather (5) with adapter (6), O-Ring seal
(7), bulk head adapter (8), O-Ring seal (9), and nut Off-Highway Truck/Tractor.
(10). 793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP)
793FAC (S/N: EMD)
Description Of Change:

52
 2. If there are no cracks in the welds, then add weld
material to the top of the plate increasing the weld
size to 10 mm (0.40 inch) and add weld material to
the bottom of the plate increasing the weld size to
14 mm (0.55 inch).

3. If cracks are present gouge/grind the existing weld

and sand smooth. Weld the top of the plate to us-
ing a 10 mm (0.40 inch) fillet weld and weld the
bottom of the plate using a 14 mm (0.55 inch) fillet
weld.

i06177917

Illustration 1 g03840078
The Orientation of the Low
Pressure Fuel System Check
Valve has been Improved on
Certain 793F Off-Highway
Trucks
SMCS Code: 1274; Publish Date: 05-Aug-2015

Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP) (S/N: SXP)
793FAC (S/N: EMD)
Description Of Change: The orientation of the low-
Illustration 2 g03840204 pressure fuel system check valve and manifold orien-
tation has been improved on certain 793F Off-High-
The front pedestal frame support has been improved way Trucks. The new low-pressure fuel system check
on certain 793F Off-Highway Trucks. The weld sizes valve orientation will help prevent sediment from col-
for plates (A) have been increased in size. lecting in the fuel system.
Adaptable To: Changes are adaptable to machines: Adaptable To: The new low-pressure fuel system
check valve orientation is adaptable to the following
• SSP1-1019 machines:
• EMD1-77 • EMD1-77
• RBT1-171 • SND1-133
• SND1-131 • SSP1-1121
Effective in production with machines: • SXP1-102
• SSP1020-UP • RBT1-171
• EMD78-UP The new low-pressure fuel system check valve orien-
• RBT172-UP tation is effective with the following machines:

• SND132-UP • EMD78-Up

Use the following steps in order to update the front • SND134-Up

pedestal frame support. • SSP1122-Up
1. Inspect the welds at the top and bottom of plate • SXP103-Up
(A).
• RBT172-Up

Refer to the procedure below for required parts and

instructions to update the fuel system.

53
Safety
Before you attempt the procedures documented in
this Special Instruction, make sure that you have
read and understand the information in this
document.
Before starting any work on the machine, ensure that
the machine has properly been locked out and
tagged out.

NOTICE

NOTICE

Machine Preparation
Refer to Operation and Maintenance Manual, “Pre-
pare the Machine for Maintenance”.

Required Parts
Table 1
Required Parts

Item Qty Part Number Description

1 1 468-7528 Plate
2 1 468-7507 Hose As
3 1 163-2426 Check Valve

4 2 8L-2779 O-Ring Seal

5 1 214-7568 O-Ring Seal

6 2 238-5082 O-Ring Seal

7 2 228-7092 O-Ring Seal

8 1(1) 8W-5161 Manifold

(1) If needed

54
Procedure

Illustration 1 g03839411

(A) Hose assembly (D) 8W-5161 Manifold (G) Hose assembly

(B) Plate (E) Adapter (H) Hose assembly
(C) Check valve group (F) Adapter

1. Remove and discard hose assembly (A), check

valve group (C), and plate (B).

55
 Disconnect hose assembly (G) and hose assem-
bly (H) from manifold (D). Remove and retain
adapter (E), adapter (F), manifold (D), and all
bolts, washers, nuts, and any affected clipping.
Discard all O-Ring seals.
Inspect manifold (D) and replace, if needed.

Illustration 2 g03839413
(1) 468-7528 Plate
(8) 8W-5161 Manifold

2. Secure manifold (8) to plate (1) by using the re-

tained bolts, washers, and nuts.

56
Illustration 3 g03839526

(E) Adapter (1) 468-7528 Plate (5) 214-7568 O-Ring Seal

(F) Adapter (2) 468-7507 Hose As (6) 238-5082 O-Ring Seal
(G) Hose assembly (3) 163-2426 Check Valve (7) 228-7092 O-Ring Seal
(H) Hose assembly (4) 8L-2779 O-Ring Seal (8) 8W-5161 Manifold

3. Secure adapter (E), adapter (F), hose assembly 4. Secure check valve (3) with O-Ring seal (5) to
(G), and hose assembly (H) to manifold (8) with manifold (8).
two O-Ring seals (6) and two O-Ring seals (7).
Secure hose assembly (2) with O-Ring seal (4) to
check valve (3).

57
5. Secure the lower fuel hose assembly to the bottom
of plate (1) by using the retained clipping, bolt, and
washers.
6. Secure plate (1) to the frame by using the retained
bolts and washers.

Illustration 4 g03839603

(2) 468-7507 Hose As (4) 8L-2779 O-Ring Seal

7. Secure the other end of hose assembly (2) with O- SMCS Code: 1059; Publish Date: 16-Jul-2015
Ring seal (4) to the previous connection on the left-
hand side of the engine. Off-Highway Truck/Tractor.
Secure hose assembly (2) in the same locations 793F (S/N: RBT1-Up) (S/N: SND) (S/N:
as the previous hose assembly by using the re- SSP)
tained clipping and hardware. 793FAC (S/N: EMD)
■ 795FAC (S/N: ERM)
795FACXQ (S/N: SNT)
i06158956
797F (S/N: LAJ) (S/N: WSP)
Description Of Change: The new bracket utilizes
A New Turbine Inlet Manifold new mounting hardware, including two support plates
Support Bracket Is Used on for an improved connection and increased durability.
C175 Off-Highway Truck Adaptable To: The new 461-6026 Bracket repla-
ces the existing 378-8940 Bracket. The new brack-
Engines et is adaptable back to first production on the serial
numbers listed above.

58
Refer to Table 1 for a list of part numbers needed to
install the new bracket.

Illustration 1 g03833359

(1) 322-5830 Bolt (3) 461-6026 Bracket (5) 099-0169 Bolt

(2) 373-9176 Spacer (4) 461-6027 Plate (6) 198-4768 Hard Washer

Table 1 (Table 2, contd)

New Part Number Description Quantity LLM01462-Up

099-0169 Bolt 2 A4K01027-Up

198-4768 Hard Washer 2

461-6026 Bracket 1 ■
461-6027 Plate 2
i06069161

This change is effective for the serial numbers listed Improved Oil Lines Groups Are
in Table 2 .
Table 2 Used for Certain C175 Off-
Effective Engine Serial Numbers Highway Truck Engines
B7B02029-Up SMCS Code: 1378; Publish Date: 19-Mar-2015
B7C01004-Up
Off-Highway Truck/Tractor.
JTL01156-Up 793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP)
793FAC (S/N: EMD)
(continued)
795FAC (S/N: ERM)
795FACXQ (S/N: SNT)

59
 797F (S/N: LAJ) (S/N: WSP)
Description Of Change: The improved engine oil
lines groups offer improved clamp joints for their re-
spective oil cooler bypass tube.
Adaptable To: The improved engine oil lines groups
are adaptable back to first production on the serial
numbers listed above.
Refer to Table 1 for the affected engine oil lines group
numbers.
Table 1
Improved Group Numbers
394-3930 Engine Oil Lines Gp

394-3933 Engine Oil Lines Gp

394-3936 Engine Oil Lines Gp

394-3939 Engine Oil Lines Gp

Refer to Table 2 for the list of parts needed to update

the existing oil lines.
Table 2
New Part Number Description Quantity

344-9285 Ring 1

371-6762 Flange 2

269-7885 O-Ring Seal 2

8T-0643 Bolt 4
6V-5839 Washer 4
6V-1196 O-Ring Seal 2

This change is effective for the serial numbers listed

in Table 3 .
Table 3
Effective Serial Numbers
B7B01981-Up

B7C01004 -Up

JTL01151 -Up

LLM01431-Up

A4K01026-Up

Installation Instructions
Refer to Illustration 1 for the location of the oil cooler
bypass tube that will be reworked.

60
Illustration 1 g03803150

(1) Oil cooler bypass tube

61
Illustration 2 g03803416

(2) 260-9153 Plug (3) 241-6157 Plugs

1. Remove plugs (2) and (3) in order to drain the oil

into a suitable container.

62
Illustration 3 g03804122

(4) 6V-5230 Bolts

63
Illustration 4 g03804137
Detail view of the tube end.
(4) 6V-5230 Bolts (6) 1W-4072 Retainers (8) 9Y-2099 Flange
(5) 6V-5839 Washers (7) 1W-4099 Retaining Ring

2. Remove bolts (4), washers (5) and retainers (6).

Slide the oil cooler bypass tube out.

Note: The washers are the only reusable parts.

3. Remove the flange (8). Discard the retaining ring

(7) and all of the O-ring seals.

64
Illustration 5 g03804139

(9) 371-6762 Flange (10) 344-9285 Ring

4. Install the flange (9) and the ring (10) as shown in

Illustration 5.
Note: The inside diameter of the flange (9 ) is ta-
pered. The flange must be positioned on the tube
with the large end of the taper toward the end.

65
Illustration 6 g03804140

(11) 269-7885 O-Ring Seal (8) 9Y-2099 Flange

5. Install the O-ring (11) onto the tube end. Lubricate

the O-ring with clean engine oil. Press the tube
end into the flange (8) that was removed. Do not
force the tube to the bottom of the flange. Leave
some space (A). Do not pinch or roll the O-ring.

Note: Ensure the O-ring (11) and mating surface are

lubricated.

66
Illustration 7 g03804143

(12) 6V-1196 O-Ring Seal (5) 6V-5839 Washers (13) 8T-0643 Bolts

6. Install the oil bypass tube SMCS Code: 0679; 3030; Publish Date: 12-Mar-
2015
Note: Use retention compound on the O-ring (12).
Off-Highway Truck/Tractor.
a. Using retention compound, install the O-ring 793F (S/N: RBT1-Up) (S/N: SND) (S/N:
(12) to the face of the flange (8). SSP)
b. Slide the tube into position and start the bolts Reference: Special Instruction, SEHS0006, "Proce-
(13). dure to Install A Rear Axle Tie Rod Stiffener to the
793F Off-Highway Truck"
Note: Ensure that the O-rings do not fall out or be-
come pinched. Reference: Disassembly and Assembly, KENR8397,
"793F Off-Highway Truck Power Train"

c. Torque the bolts (13) to 55 ± 10 N·m

(41 ± 7 lb ft).

i06093149

The Power Train Has Been Up-

dated on the 793F Off-Highway
Truck

67
 793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP)
793FAC (S/N: EMD)
795FAC (S/N: ERM)
795FACXQ (S/N: SNT)
797F (S/N: LAJ) (S/N: WSP)
Description Of Change: A rework procedure is now
used for mounting the improved Fuel Priming Switch
Bracket on certain Large Off-Highway Trucks that are
listed above.

Adaptable To: Perform the below rework procedure

to update the fuel priming switch and the mounting
bracket.

Rework Procedure

Illustration 1 g03749093

The 278-8433 Power Train Ar has been updated on

the 793F Off-Highway Truck. A rear axle tie rod stiff-
ener has been added to stiffen the drivetrain system
by stiffening the axle housing.

The change is adaptable to machines SSP1-1094,

RBT1-171, SND1-116 and SND118-131.

The change is effective in production with machines

(S/N: SSP1095-Up), RBT172-Up and SND132-Up.
For a complete list of material and the correct proce-
dure that is needed in order to install the tie rod stiff-
ener, refer to Special Instruction, SEHS0006,
"Procedure to Install A Rear Axle Tie Rod Stiffener to
the 793F Off-Highway Truck".
For universal joint disassembly and assembly, refer
Illustration 1 g03748097
to Disassembly and Assembly, KENR8397, "793F
Off-Highway Truck Power Train". 1. Unplug the existing Fuel Priming Switch from the
The Special Instruction and Disassembly and Assem- Engine Harness. Remove and discard the existing
Fuel Priming and mounting bracket.
bly can be found on the Caterpillar service informa-
tion system (SIS) and through the normal literature
distribution system at your local Cat dealer.

i06532548

Rework Procedure for Mount-

ing the Improved Fuel Priming
Switch Bracket on Certain
793F, 795F, and 797F Large
Off-Highway Trucks
SMCS Code: 1258; 1408; Publish Date: 05-Nov-
2015

Off-Highway Truck/Tractor.

68
Illustration 2 g03748099

2. Reinstall two Hex nuts, onto one of the existing

bracket studs. Use the 2 hex nuts as a single jam
nut and remove the stud from the oil pan. Repeat
this procedure to remove the other stud.

Illustration 4 g03748103

4. Install the 198-4766 Hard Washer (3) onto each

stud and secure to the oil pan with the 2Y-5928
Flange (4). Torque to 74 ± 3 N·m (55 ± 2 lb ft).

Illustration 3 g03748147

3. Install two of the new 5P-7970 Nut (1) onto one

of the new 467-8237 Taperlock Stud (2). Use
these two nuts as a single jam nut to install the
studs into the oil pan. Torque the stud to
35 ± 5 N·m (26 ± 4 lb ft). Remove both hex nuts
and repeat this process for the other stud.

Illustration 5 g03748104
(5) 301-2980 Toggle Switch

5. Install the replacement switch into the new bracket

as shown in the Illustration.

69
Illustration 6 g03748105
(4) 2Y-5829 Nut
(6) 115-3069 Connector Clip Assembly
(7) 4P-7581 Clip
(8) 6V-4248 Bolt
(9) 9X-6772 Cable Strap
(10) 6V-5839 Washer

6. Install the mounting hardware to the new Mounting

Bracket and install on the oil pan as shown in the Il-
lustration. Torque the 5P-7970 Nut to 28 ± 7 N·m
(248 ± 62 lb in)

Illustration 7 g03748106

(1) 5P-7970 Nut (4) 2Y-5829 Nut (13) 156-0283 Hard Washer
(2) 467-8237 Taperlock Stud (11) 454-8554 Bracket As (14) 4S-5719 Spacer
(3) 198-4766 Hard Washer (12) 8T-9658 Spacer (15) 155-0576 Isolation Mount

7. Reinstall the Engine Harness into the Fuel Priming

Switch.
Refer to the below Table 1 for the required parts:

70
Table 1
Parts Required 785 (S/N: 8GB)
Qty Part Number Description 785B (S/N: 6HK)
785C (S/N: 1HW) (S/N: 5AZ) (S/N: APX)
3 2Y-5829 Nut
785D (S/N: DMC) (S/N: MSY)
1 4P-7581 Clip 785G (S/N: RTL)
2 4S-5719 Spacer 789 (S/N: 9ZC)
789B (S/N: 7EK)
2 5P-7970 Nut
789C (S/N: 2BW)
1 6V-4248 Bolt
789D (S/N: SHH) (S/N: SPD)
2 6V-5839 Washers 793 (S/N: 3SJ)
2 8T-9658 Spacer 793B (S/N: 1HL)
793C (S/N: 4AR) (S/N: 4GZ) (S/N: ATY)
1 9X-6772 Cable Strap
(S/N: CBR)
1 115-3069 Connector Clip Assembly 793D (S/N: FDB)
4 155-0576 Isolation Mount 793F (S/N: RBT) (S/N: SND) (S/N: SSP)
4 156-0283 Hard Washer
(S/N: SXP)
793FAC (S/N: EMD)
2 198-4766 Hard Washer
795FAC (S/N: ERM)
1 301-2980 Toggle Switch 795FACXQ (S/N: SNT)
1 454-8554 Bracket As 797B (S/N: JSM)
2 467-8237 Taperlock Stud
797F (S/N: LAJ) (S/N: WSP)
Transmission.
TH55-KRESS (S/N: KCH)
The mounting procedure is adaptable to and effective
in production for the machines that are listed in the
Unit Rig Mining Truck.
Table 2 given below: MT4400AC (S/N: SE4)
Service Magazine, SEPD1869, 14 October 2014,
Table 2
“Cat Reman Announces the Addition of Drivetrain
Sales Model Adaptable Serial Effective Serial Components for Large Mining Trucks”. Disregard this
Number Prefix Number Prefix article. See the information in this publication.
793F SSP1-1071 SSP1072-Up

793F AC EMD1-77 EMD78-Up

Announcement and Recommended
Action
793F CMD RBT1-171 RBT172-Up

793F XQ SND1-131 SND132-Up To help dealers better manage and control rebuild
costs, Cat Reman announces the addition of multiple
795F AC ERM1-296 ERM297-Up parts for Large Mining Truck applications. With a Cat
Reman option, dealers can now take advantage of an
795F XQ SNT1-101 SNT102-Up
off-the-shelf solution backed by standard Caterpillar
797F LAJ1-558 LAJ559-Up warranty that will be salvaged by and to the latest
Caterpillar specifications and processes. Cat® Re-
797F XQ WSP1-129 WSP130-Up man products assist dealers with cost-effective repair
options and meets customer's demand for quick re-
■ pair turnaround. Consult the Caterpillar NPR in SIS-
WEB (https://sis.cat.com) or the Cross Reference link
on the Reman Dealer Extranet1 for product coverage
i05957564
and cross-reference. 1 (http://catreman.cat.com/cda/
layout?m=302096&x=7). Part numbers being made
Cat Reman Announces the Ad- available and the type of product the part number
dition of Drivetrain Compo- supports is listed below.
nents for Large Mining Trucks
SMCS Code: 3030; 3101; Publish Date: 21-Oct-2014

Off-Highway Truck/Tractor.
777B (S/N: 4YC1-Up)
784B (S/N: 5RK)
784C (S/N: 2PZ)

71
Illustration 1 g03738370

Features and Benefits

The benefits Reman offers are the quality control
processes that can be in place in a production type
environment. Reman offers potential advantages to
dealers in that a Reman solution available immedi-
ately can eliminate costly downtime and lack of con-
trol where those parts had been outsourced to job
shops outside the dealer's control. This new service
option can help reduce turnaround time and decrease
downtime. Customers who want fast repair turn-
around, superior quality and reliability, and lower re-
pair costs will benefit from the use of these remanu-
factured components. Caterpillar remanufactured
components provide immediate, off-the-shelf avail-
ability at a fraction of the new price.

Illustration 2 g03736408

72
 i07030627 Table 1
Effectivity of the New Differential and Bevel Gear Groups
A New Differential and Bevel
Adaptable to Effective in Production
Gear Group is Used on the Sales Model
Machines with Machines
793D and 793F Off-Highway 793D FDB1-1833 FDB1834-Up
Trucks 793F SSP1-1081 SSP1082-Up
SMCS Code: 3256; 3258; Publish Date: 04-May- 793F CMD RBT1-171 RBT172-Up
2017
793F XQ SND1-131 SND132-Up
Off-Highway Truck/Tractor.
793D (S/N: FDB1-Up) The new differential and bevel gear groups are adapt-
793F (S/N: RBT) (S/N: SND) (S/N: SSP) able to the machines and effective in production with
Service Magazine, SEPD1937, 23 December 2014, the machines listed in Table 1 .
“A New Differential and Bevel Gear Group is Used on
the 793D and 793F Off-Highway Trucks”. Part num-
bers 453-2978 Thrust Bearing Race and
453-2979 Thrust Bearing in tables 2,3, and 4 have
been updated. Disregard this article. See the article
that follows:
Description Of Change: The new differential and
bevel gear group contains a new differential group, a
new differential housing assembly, new thrust bear-
ings, and new thrust bearing races.
The new differential group contains new bevel gears.
The new bevel gears are manufactured with an im-
proved surface finish to help reduce wear on thrust
washers. The improved finish of the bevel gears re-
sults in a more flat surface for the thrust bearings.
The new differential housing assembly is designed to
use new, needle thrust bearings, and new, flat thrust
bearing races. The new thrust bearings and the new
thrust bearing races will better handle the forces in
the differential. Illustration 1 g03737744
Back of the differential and bevel gear group
All the changes will improve the service life of the dif-
ferential and bevel gear group in the field.

Adaptable To: For the FDB machines, the new

466-7421 Differential and Bevel Gear Gp replaces
the former 193-6222 Differential and Bevel Gear
Gp. The new differential and bevel gear group con-
tains the new 466-3322 Differential Gp.
For the SSP and SND machines, the new 466-3323
Differential and Bevel Gear Gp replaces the former
280-1609 Differential and Bevel Gear Gp. The new
differential and bevel gear group contains the new
466-3322 Differential Gp.

For the RBT machines, the new 466-7422 Differen-

tial and Bevel Gear Gp replaces the former
379-8891 Differential and Bevel Gear Gp . The new
differential and bevel gear group contains the new
466-3322 Differential Gp.

Illustration 2 g03737751
Front of the differential and bevel gear group

73
Illustration 3 g03737755
Exploded view of the new 466-3322 Differential Gp

(Table 2, contd)
282-1775 Differential Gp

Differential Housing
5 1 466-3321
As

6 2 453-2978(1) Thrust Washer

7 2 453-2979(1) Thrust Bearing

8 2 448-0727 Bevel Gear

Bevel Gear and
8X-0466 Transmission Mount-
ing Gp

9 1 7X-4778 O-Ring Seal

10 1 5D-6428 O-Ring Seal

(1) Use both the 453-2979 Thrust Bearing Race and the
453-2978 Thrust Bearing to replace one former 309-7671
Thrust Washer

Table 3
Parts to Update SSP and SND Machines
Illustration 4 g03737757
Front of the differential and bevel gear group Group Item Qty New Part Description

Table 2 Differential and Bev-

280-1609
el Gear Gp
Parts to Update FDB Machines
1 1 1P-3708 Rectangular Seal
Group Item Qty New Part Description
2 1 6M-5218 O-Ring Seal
Differential and Bev-
193-6222 3 1 387-1379 O-Ring Seal
el Gear Gp

1 1 1P-3708 Rectangular Seal 4 17 6V-5684 Bolts

2 1 6M-5218 O-Ring Seal 282-1775 Differential Gp

3 1 387-1379 O-Ring Seal Differential Housing

5 1 466-3321
As
4 17 6V-5684 Bolts
6 2 453-2978(1) Thrust Washer

(continued)
(continued)

74
(Table 3, contd) SMCS Code: 1218; 1239; Publish Date: 13-Aug-
7 2 453-2979(1) Thrust Bearing 2015

8 2 448-0727 Bevel Gear

Off-Highway Truck/Tractor.
Bevel Gear and 793F (S/N: D3T1-Up) (S/N: RBT) (S/N:
280-1602 Transmission Mount-
ing Gp
SND) (S/N: SSP) (S/N: SXP)
793FAC (S/N: EMD)
9 1 7X-4778 O-Ring Seal 794 (S/N: MN5) (S/N: MT5)
10 1 5D-6428 O-Ring Seal 795FAC (S/N: ERM)
(1) Use both the 453-2979 Thrust Bearing Race and the
795FACXQ (S/N: SNT)
453-2978 Thrust Bearing to replace one former 309-7671 797 (S/N: 5YW)
Thrust Washer 797B (S/N: JSM)
Table 4 797F (S/N: LAJ) (S/N: WSP)
Service Magazine, SEPD1876, 27 October 2014,
Parts to Update RBT Machines
“Cat ® Reman Announces the Availability of Type 2
Group Item Qty New Part Description Cylinder Packs and Connecting Rods for Certain
C175 Machine Engines”. Disregard the previous ar-
Differential and Bev- ticle. The following article table has been updated.
379-8891
el Gear Gp

1 1 1P-3708 Rectangular Seal

Cat © Reman offers products at an excellent value to
the customers.
2 1 6M-5218 O-Ring Seal
Customers who want fast repair turn-around superior
3 1 387-1379 O-Ring Seal quality and reliability and lower repair costs will bene-
4 17 6V-5684 Bolts fit from the use of these Remanufactured
components.
282-1775 Differential Gp
Cat Reman components provide immediate off the
Differential Housing
5 1 466-3321
As
shelf availability at a fraction of the new price.

6 2 453-2978(1) Thrust Washer The features and benefits are listed in Table 1 .
7 2 453-2979(1) Thrust Bearing The new and Reman cylinder pack and connecting
8 2 448-0727 Bevel Gear rod part numbers are listed in Table 2 .
Bevel Gear and Note: Type 1 cores are acceptable against Type 2
280-1602 Transmission Mount- cylinder packs and connecting rods.
ing Gp
Table 1
9 1 7X-4778 O-Ring Seal
Features Benefits
10 1 5D-6428 O-Ring Seal
All engineering changes and Improved reliability and
(1) Use both the 453-2979 Thrust Bearing Race and the updates included performance
453-2978 Thrust Bearing to replace one former 309-7671
Thrust Washer Worldwide availability through Customer access regardless of
Cat parts distribution system location
Earlier machines that are currently in production can
Off -the shelf availability Downtime reduced through ex-
be updated to the current configuration. Use the parts change product
listed in the above table for your machine to update
the earlier machines to the current configuration. To Same as new Caterpillar Customer support
update the earlier machines, all the listed parts must warranty
be installed on a machine at the same time.

i06264863

Cat ® Reman Announces the

Availability of Type 2 Cylinder
Packs and Connecting Rods
for Certain C175 Machine
Engines

75
Table 2
Reman Prod- Cylinder Reman New Connect- New CR Serial Number Prefix
uct Part ing Rod Piston
Description Number
ODD 20R-2805 434-0487 5YW, JSM, SSP, LAJ, EMD, ERM, RBT, SXP,
Connecting Rod N/A N/A WSP, SND, MN5, SNT, D3T, MT5
EVEN 20R-2806 434-0488
ODD 20R-2807 434-0487 5YW, JSM, SSP, LAJ, ERM, WSP, MN5, SNT,
323-4018 15.3:1 MT5
EVEN 20R-2808 434-0488
Cylinder Pack
ODD 20R-2809 434-0487 5YW, JSM, SSP, LAJ, EMD, ERM, RBT, SXP,
323-4017 16.7:1 SND, MN5, MT5
EVEN 20R-2810 434-0488

i05931785

A New Oil Filler Elbow Is Now

Used on C175 Off-Highway
Truck Engines
SMCS Code: 1316; 7513; Publish Date: 12-Dec-
2014

Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP)
793FAC (S/N: EMD)
795FAC (S/N: ERM)
795FACXQ (S/N: SNT)
797F (S/N: LAJ) (S/N: WSP)
Description Of Change: The new oil fill tube elbow Illustration 1 g03728682
has improved surface finish for an increased sealing 462-6427 Oil Filler Elbow
capability of the oil fill cap.
■
Adaptable To: The new 462-6427 Oil Filler Elbow
replaces the existing 378-6975 Oil Filler Elbow.
The new oil filler elbow is adaptable back to first pro- i05919870
duction on the serial numbers listed above.
A New Engine Oil Level Sensor
This change is effective for the serial numbers listed
in table 1 . Guard Is Used for Certain C175
Table 1 Off-Highway Truck Engines
Effective Engine Serial Numbers
SMCS Code: 1439; 7422; Publish Date: 05-Dec-
LLM01405-Up 2014
B7B01947-Up
Off-Highway Truck/Tractor.
JTL01151-Up 793F (S/N: RBT1-Up) (S/N: SND) (S/N:
A4K01023-Up SSP)
793FAC (S/N: EMD)
B7C01004-Up
795FAC (S/N: ERM)
795FACXQ (S/N: SNT)
797F (S/N: LAJ) (S/N: WSP)
Description Of Change: A new oil level sensor
guard has been developed that avoids potential rub
points.

76
Adaptable To: The new 454-8550 Sensor Guard
As is a direct replacement for the former 377-2354
Sensor Guard As. Use two 032-9828 Grommets to
secure the wiring to the new guard.
The new 454-8550 Sensor Guard As is adaptable
back to the first production of the listed engines.

Illustration 2 g03767756
Slightly different routing for the bottom sensor of C175-20 Engines

The change is effective at the factory with the engine

serial numbers that are listed in the table below.
Table 1

Illustration 1 g03754492 Effective Serial Numbers

Routing for C175-16 Engines LLM01401-Up
(1) 032-9828 Grommets
B7B01941-Up
(2) 454-8550 Sensor Guard As
B7C01004-Up

JTL01145-Up

A4K01023-Up

i05904736

A Procedure to Convert to a
Bottom Fill Radiator on Certain
Large Off-Highway Trucks is
Available
SMCS Code: 1350; 1353; Publish Date: 01-Sep-
2014

Off-Highway Truck/Tractor.
785C (S/N: 5AZ1-Up) (S/N: APX)
785D (S/N: DMC) (S/N: MSY)
789C (S/N: 2BW)
789D (S/N: SHH) (S/N: SPD) (S/N: TWP)

77
 793F (S/N: RBT) (S/N: SND) (S/N: SSP)
(S/N: SXP)
793FAC (S/N: EMD)
795FAC (S/N: ERM)
795FACXQ (S/N: SNT)
797F (S/N: LAJ) (S/N: WSP)
Reference: Operation and Maintenance Manual,
“Cooling System Coolant (ELC) - Change” for infor-
mation regarding the optional bottom fill procedure.

Description Of Change: An optional bottom fill pro-

cedure is now available for the radiator. The bottom
fill procedure reduces pump failures, reduces fill time,
and reduce the cost for the customer.

Adaptable To: Use the following steps and needed

hardware to convert the top fill radiator to an optional
bottom fill radiator.

Illustration 1 g03720872
Typical view of the drain on the radiator on 793 through 797 models.

1. The drain valve on the radiator can have the elbow • 241-6189 Fitting As
and drain hose removed and replaced by quick dis-
connect parts detailed below, or the customer may • 152-5718 Dust Cap
use a different combination of parts based on indi-
vidual needs:

• 148-8357 Elbow As

78
Illustration 2 g03720878
Typical view of the drain on the radiator on 785 through 789 models.

2. The drain valve on the radiator can have the drain (Table 1, contd)
hose removed and replaced by quick disconnect
793F (S/N: SSP1-UP)
detailed below, or the customer may use a different
combination of parts based on individual needs: 793F CMD (S/N: RBT1-UP)

• 268-1582 Coupler 793F AC (S/N: EMD1-UP)

The optional bottom fill procedure is adaptable to the 793F XQ (S/N: SND1-UP)
following machines that are listed in Table 1 . 793F OEM (S/N: SXP1-UP)
Table 1
795F AC (S/N: ERM1-UP)
Sales Model Adaptable to Machines
795F XQ (S/N: SNT1-UP)
785C (S/N: APX1-UP)
797F (S/N: LAJ1-UP)
785C HA (S/N: 5AZ1-UP)
797F XQ (S/N: WSP1-UP)
785D (S/N: MSY1-UP)

785D OEM (S/N: DMC1-UP)

■
789C (S/N: 2BW1-UP)
i05883784
789D (S/N: SPD1-UP)

789D XQ (S/N: SHH1-UP) An Improved Power Train Oil

789D OEM (S/N: TWP1-UP) Lines Group Is Now Used on
Certain 793F Off-Highway
(continued) Trucks

79
SMCS Code: 3016; 3154; Publish Date: 19-Sep-
2014

Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP)
Description Of Change: The Improved power train
oil lines group has a new plate assembly on the ma-
chine listed above. The new plate assembly will pro-
vide better clearance to the transmission hose
assembly and increase the service life.
Adaptable To: New 459-3182 Plate As replaces
the former 341-6261 Plate As in the 421-8573
Power Train Oil Lines Gp. Illustration 1 g03713993

The improved 421-8573 Power Train Oil Lines Gp

is adaptable to machine and effective in production
with machines that are listed in Table 1 .
Table 1
Adaptable to Effective in produc-
Sales Model
Machines tion with Machines

SSP1-1040 SSP1041-Up

793F RBT1-171 RBT172-Up

SND1-131 SND132-Up

Use the following rework procedure in order to up-

date the above listed adaptable machine with the
new 459-3182 Plate As.

Rework Procedure
Table 2
Required Parts List

Item Qty Part Number Description Illustration 2 g03713399

1 1 459-3182 Plate As View of area A

2 2 8T-0568 O-Ring Seal 1. Remove two 8T-4139 Bolts (B), two 8T-4223
Hard Washer (C), 8T-4183 Bolt (E), 8T-4223
Hard Washer (F), 130-8433 Grommet (G),
6V-4357 Clip, (H), and 6V-4356 Clip from the
power train oil lines group. Save all parts.

2. Remove 341-6261 Plate As (D) from the power

train oil lines group. Discard the part.

80
 Illustration 5 g03713584
View of area L

2. Install new O-Ring seals (2) using two 1P-4584

Half Flanges (M), four 8T-4184 Bolts (N), and
four 8T-4223 Hard Washers (P) to avoid more
stress in the hose assembly near coupling. As
Illustration 3 g03713430 shown in Illustration 5.
3. Install new plate assembly (1) in power train oil 3. Install the end of 341-6253 Hose As (K) to the
lines group using two 8T-4139 Bolts (B) and two existing 1P-4584 Half Flanges (M) using new O-
8T-4223 Hard Washers (C). Refer to Illustration Ring seals (2). Secure the half flanges using four
3. 8T-4184 Bolts (N), and four 8T-4223 Hard
Washers (P).
4. Secure 341-6253 Hose As (K) using 8T-4183
Bolt (E), 8T-4223 Hard Washer (F), 130-8433 ■
Grommet (G), 6V-4357 Clip, (H), and 6V-4356
Clip (J) that were saved in step 1. Refer to Illustra-
tion 3 for proper orientation. i05830029

A Procedure to Upgrade the

Optional Parts to be Added (If Hose Transmission Wiring Group on
assembly is disassembled for Certain 793F Off-Highway
routing) Trucks is Available
SMCS Code: 1408; 3030; Publish Date: 30-Sep-
2014

Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP)
Reference: Special Instruction, REHS9534, “Proce-
dure to Upgrade the Transmission Wiring Group on
Certain 793F Off-Highway Trucks”
Description Of Change: A procedure to upgrade the
transmission wiring group is now available. The up-
graded transmission wiring group will help to secure
the harness assembly and improve the service life.
Illustration 4 g03713533
Adaptable To: The new transmission wiring group is
1. Assemble 341-6253 Hose As (K) through the adaptable to the following machines:
new plate assembly (1) to the coupling. Refer to Il-
lustration 4 for proper orientation. • SND1-131
Note: If there is more stress in the 341-6253 Hose • SSP1-1060
As near coupling area, adjust the hose routing to fol-
low a natural path. Refer to Illustration 4. • RBT1-171

81
The new transmission wiring group is effective with
the following machines:
• SND132-Up

• SSP1061-Up
• RBT172-Up

For instructions on upgrading the transmission wiring

group, refer to Special Instruction, REHS9534, “Pro-
cedure to Upgrade the Transmission Wiring Group
on Certain 793F Off-Highway Trucks”.

i05862320

New Oil Tubes Are Used on

793F and 795F Off-Highway
Truck Engines Illustration 1 g03682040
SMCS Code: 1307; Publish Date: 17-Jul-2014 Location of the new oil tubes

Off-Highway Truck/Tractor. Note: The new tubes must be changed together to

793F (S/N: RBT1-Up) (S/N: SND) (S/N: avoid an interference issue. The new tubes are not
SSP) compatible with the former tubes.
793FAC (S/N: EMD) Refer to Table 1 for a list of the new and former part
795FAC (S/N: ERM) numbers.
795FACXQ (S/N: SNT) Table 1
Service Magazine, SEPD1812, 09 July 2014, “New New Part Number Former Part Number
Oil Tubes Are Used on 793F and 795F Off-Highway
Truck Engines”. Disregard the previous article, serial 454-8557 433-6643
numbers have been added. 454-8558 394-3931

Description Of Change: The new oil tubes are de-

signed to allow more space between the tube and the This change is effective for the engine serial numbers
hydraulic hose for the cooling fan. listed in Table 2 .
Table 2
Adaptable To: The new tubes replace the existing
Effective Engine Serial Numbers
tubes. The new tubes are adaptable back to first pro-
duction on the serial numbers listed above. JTL01124-Up

The new tubes are only compatible with the B7B01865-Up

445-4930 Engine Oil Filter Gp. Refer to Special In- ZK201112-Up
struction, “REHS8661” for the procedure to retrofit an
engine with the 445-4930 Engine Oil Filter Gp. B7C01004-Up

i05800911

New Coolant Tubes Are Now

Used for Certain 793F and
795F Off-Highway Trucks
SMCS Code: 1380; Publish Date: 17-Jul-2014

Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP)
793FAC (S/N: EMD)

82
 795FAC (S/N: ERM)
795FACXQ (S/N: SNT)
Description Of Change: The new coolant tube as-
semblies do not have welded bosses for the vent line.
The vent line now attaches to the 260-8447 Elbow
and the 293-5021 Elbow.
Adaptable To: The new coolant tube assemblies re-
place the existing new coolant tube assemblies.

The new coolant tube assemblies are adaptable to

the above engines back to first production.

Note: The 380-1423 Elbow must be installed to be

compatible with this tube update. Illustration 2 g03675939

The new parts and former parts are listed in Table 1 . New design for 793F and 795F
Table 1 (3) 380-1423 Elbow
(4) 458-6019 Hose As
New Part Former Part Qty (5) 452-3043 Tube As
(6) 458-6511 Tube As
452-3043 Tube As 394-1118 Tube As 1
458-6019 Hose As - 1 The effective engine serial numbers are listed in Ta-
ble 2 .
458-6511 Tube As 380-1425 Tube As 1 Table 2
Effective Engine Serial Numbers
JTL01124-Up

B7C01004-Up

B7B01879-Up

ZK201112-Up

i05792460

A Procedure to Update the

Illustration 1 g03676183
Brake Cooling Tube on 793F
Former design Off-Highway Trucks is Now
(1) 394-1118 Tube As Available
(2) 380-1425 Tube As
(3) 380-1423 Elbow SMCS Code: 1380; Publish Date: 19-May-2014

Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP)
Description Of Change: A procedure to update the
brake cooling tube on a 793F is now available. Refer
to Special Instruction, REHS9322, “Procedure to Up-
date the Brake Cooling Tube on 793F Off-Highway
Trucks”. The special instruction covers the needed
parts and the procedure to install a new brake cooling
tube.
Adaptable To:

83
Illustration 1 g03671104
A view of the new 438-5135 Tube As

The new 438-5135 Tube As replaces the old

291-1637 Tube As. The procedure is adaptable to
the following machines:
• SND1-131
• SSP1-1019

• RBT1-171
The procedure is effective with the following
Illustration 1 g03665315
machines:
• SND132-Up Table 1
New Parts List
• SSP1020-Up
Item Qty Part Description
• RBT172-Up 1 1 087-4588 Elbow

■ 2 1 228-7092 O-Ring Seal

3 1 238-5080 O-Ring Seal

i05770755

The Rear Axle Oil Cooler Ar- The improved 250-9238 Rear Axle Oil Cooler Ar
and 278-8440 Rear Axle Oil Cooler Ar are adapt-
rangement has been Improved able to machines and effective in production with ma-
for Certain 793D and 793F Off- chines listed in Table 2 .
Table 2
Highway Trucks Effective in Pro-
Adaptable to
SMCS Code: 1359; 1365; Publish Date: 23-Apr-2014 Sales Model duction with
Machines
Machines

Off-Highway Truck/Tractor. 793D FDB1-1828 FDB1829-Up

793D (S/N: FDB1-Up) SSP1-1019 SSP1020-Up
793F (S/N: RBT) (S/N: SND) (S/N: SSP)
793F RBT1-171 RBT172-Up
Description Of Change: A new elbow and two new SND132-Up
SND1-131
O-Ring seals improves the hydraulic fan drive lines
group in the rear axle oil cooler arrangement.
■
The improved arrangement will provide adequate
clearance between components and eliminate any in-
i05768571
terferences, and improves the service life of the oil
cooler.
A Procedure to Improve the Air
Adaptable To: to Air After Cooler Lines Group

84
on the 793F Off-Highway
Truck is Available
SMCS Code: 1063; 1071; Publish Date: 31-Jul-2014

Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP)
793FAC (S/N: EMD)
Description Of Change: A new procedure will pro-
vide improved mounting of the Air to Air After Cooler
(ATAAC) lines group.
For a complete list of materials and the correct proce-
dure, refer to the following document:
Reference: Special Instruction, REHS9343, “Proce-
dure to Improve the Air to Air After Cooler Lines
Group on the 793F Off-Highway Truck”.
This special instruction can be found on the Caterpil-
lar Service Information System (SIS) and through the
normal literature distribution system at your local Cat
dealer.

Adaptable To:

Illustration 1 g03662342

Table 1 i05694724

Sales Model Adaptable Machines Effective in Production

with Machines New Fan Shroud Assembly for
793F AC EMD1-77 EMD78-Up the Rear Axle Oil Cooler Is
SND1-131 SND132-Up Now Available on Certain 793F
793F SSP1-1018 SSP1019-Up and 793D Off-Highway Trucks
RBT1-171 RBT172-Up SMCS Code: 1365; Publish Date: 27-Feb-2014

■
Off-Highway Truck/Tractor.
793D (S/N: FDB1-Up)
793F (S/N: RBT) (S/N: SND) (S/N: SSP)

85
New 438-2257 Fan Shroud Assembly is now used
on the machines listed above. The new fan shroud
assembly provides better clearance to the fan guard
grill and improves the fit in the field.

Illustration 1 g03638976

New 438-2257 Fan Shroud As (1) replaces the for-

mer 180-2441 Shroud in the 320-8196 Rear Axle
Oil Cooler Gp.
New 438-2257 Fan Shroud As (1) is effective in
production with machines, FDB1-Up, RBT1-Up,
SSP1-Up, and SND1-Up.

i05667923

A Procedure to Install a Brack-

et Assembly Over the Lower
Torque Converter Oil Level
Sensor on the 793F Off-High-
way Truck is Available.
SMCS Code: 1408; 1439; Publish Date: 02-Apr-2014

Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP)

86
 This special instruction can be found on the Caterpil-
lar Service Information System (SIS) and through the
normal literature distribution system at your local Cat
dealer.

i05623811

A New Cylinder Head Group Is

Used on C175 Off-Highway
Truck Engines
SMCS Code: 1100; Publish Date: 09-Jan-2014

Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP) (S/N: SXP)
793FAC (S/N: EMD)
795FAC (S/N: ERM)
797F (S/N: LAJ) (S/N: WSP)
Service Magazine, SEPD1712, 17 December 2013,
“A New Cylinder Head Group Is Used on C175 Off-
Highway Truck Engines”. The original article has
been revised to specify the usage of the new parts.

Illustration 1 g03607799 Description Of Change: The new exhaust valve pro-

vides improved durability and resistance to higher
This special instruction contains the necessary pro- component operating temperatures at altitudes over
cedures in order to install a bracket assembly over 2134 m (7000 ft). The new exhaust valve is part of
the lower torque converter oil level sensor. The new the new cylinder head group.
bracket assembly that is now used will provide added
protection to the low oil level sensor. The new design Adaptable To: The new 433-1104 Exhaust Valve is
has additional clipping and a more robust pigtail rout- part of the new 439-5473 Cylinder Head Gp. The
ing that will provide longer component life. The new 433-1104 Exhaust Valve is a direct replacement for
455-2641 Bracket As is part of the 279-2522 Sen- 254-2073 Exhaust Valve. The 439-5473 Cylinder
sor Wiring Gp. The new 455-2641 Bracket As is Head Gp is a direct replacement for 345-8448 Cyl-
adaptable and effective in production with the ma- inder Head Gp.
chines listed in Table 1 .
Table 1
The new 433-1104 Exhaust Valve cannot be used
on commercial engine applications that utilize the
Sales Model Adaptable to Effective in Pro- 328-7083 Cylinder Head Gp.
Machines duction Machines
793F SSP1-1010 SSP1011-UP The new cylinder head group is adaptable back to
first production of the serial numbers listed above.
793F CMD RBT1-171 RBT172-UP Refer to Table 2 for the effective engine serial
793F XQ SND1-131 SND132-UP numbers.
Table 1

Note: The special instruction contains two proce- New Part Number Former Part Number
dures that are specific to the effectivity that is listed. 433-1104 Exhaust Valve 254-2073 Exhaust Valve
Refer to the instructions that are specific to the ma-
chine that is being worked on. 439-5473 Cylinder Head Gp 345-8448 Cylinder Head Gp

20R-0703 Cylinder Head Gp 10R-9021 Cylinder Head Gp

For a complete list of materials and the correct proce- (Reman) (Reman)
dure that is needed in order to install the bracket as-
sembly, refer to the following document:
Reference: Special Instruction, REHS9319, “A Pro-
cedure to Install a Bracket Assembly Over the Lower
Torque Converter Oil Level Sensor on the 793F Off-
Highway Truck is Available.”.

87
Table 2
Effectivity
A4K01008-Up

B7B01612-Up

B7C01004-Up

JTL01094-Up

LLM01299-Up

ZK201048-Up

ZK301049-Up

i05476610

The Hydraulic Fan Lines

Group Has Been Updated on
Certain 793F Off-Highway
Trucks
SMCS Code: 1386; 1387; Publish Date: 03-Jan-
2014

Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP)
793FAC (S/N: EMD)
Description Of Change: The tube assembly in the
hydraulic fan lines group has been improved with a
saddle style boss. The new saddle style boss pro-
vides a stronger welded joint and better sealing.

Adaptable To:
Table 1
New Part List

Item Qty Part Number Description

1 1 293-0742 Tube As

- 1 235-2479 Rectangular Seal

- 2 238-5084 O-Ring Seal

- 1 6V-4590 O-Ring Seal

88
Illustration 1 g03482617
323-1176 Hydraulic Fan Lines Gp

Follow the below procedure to install the tube assem- Table 2

bly in the hydraulic fan lines group. Adaptable to Effective with
Sales Model
Machines Machines
1. Prepare the machine for maintenance as per your
machine OMM guidelines. 793F SSP1-981 SSP982-Up

2. Drain the fluid from the lines group. 793F AC EMD1-77 EMD78-Up

793F CMD RBT1-171 RBT172-Up

3. Remove the old 293-0742 Tube As. Discard the
part. 793F XQ SND1-131 SND132-Up

i06535064

Loctite 609 or Loctite 648 Are

Now Used to Retain the Carrier
Bearing on Certain OEM and
Off-Highway Trucks
SMCS Code: 0649; 3159; Publish Date: 05-Nov-
2015

Illustration 2 g03482619 OEM.

CATWDS (S/N: M4J1-Up)
4. Install the improved tube assembly (1) with Off-Highway Truck/Tractor.
235-2479 Rectangular Seal at location (A),
238-5084 O-Ring Seals at location (B), and
785C (S/N: 1HW) (S/N: 5AZ) (S/N: APX)
6V-4590 O-Ring Seal at location (C) as shown in 785D (S/N: DMC) (S/N: MSY)
the Illustration 2. 789C (S/N: 2BW)
5. Refill the fluid and ensure that there is no leakage
789D (S/N: SHH) (S/N: SPD)
in the tube assembly. 793C (S/N: ATY) (S/N: CBR)
793D (S/N: FDB)
The new tube assembly is adaptable to machines 793F (S/N: RBT) (S/N: SND) (S/N: SSP)
and effective in production with machines that are Service Magazine, SEPD1685, 24 October 2013,
listed in Table 2 . “Loctite 609 or Loctite 648 Are Now Used to Retain
the Carrier Bearing on Certain OEM and Off-Highway

89
Trucks”. Disregard this article. Refer to the article that
follows.
Description Of Change:

Illustration 1 g03495676

In the input transfer gear group, bearing mount (Loc- (Table 2, contd)
tite 609 or Loctite 648) is now used to improve reten- 785D MSY1-597 MSY598-Up
tion of the 128-3936 Bearing on the 8E-9296
Carrier As. 785D OEM
DMC1-160 DMC161-Up
M4J1-214 M4J215-Up
Adaptable To: The use of Loctite 609 or Loctite 648
789C 2BW1-83001 2BW83002-Up
applies to the transmission arrangements listed in Ta-
ble 1 . The use of Loctite 609 or Loctite 648 is adapt- 789D SPD1-505 SPD506-Up
able to transmission arrangements and effective in
production with the machines that are listed in Table 789D XQ SHH1-319 SHH320-Up
2. ATY1-1124 ATY1125-Up
Table 1 793C
CBR1-108 CBR109-Up
351-0988 Transmission Ar
793D FDB1-1748 FDB1749-Up
240-7184 Transmission Ar
793F SSP1-880 SSP881-Up
3T-0034 Transmission Ar
793F CMD RBT1-164 RBT165-Up
279-2520 Transmission Ar
793F XQ SND1-128 SND129-Up
359-6200 Transmission Ar

Table 2 ■
Sales Model Adaptable To Effective With
i05611150
1HW1-134 1HW135-Up
785C
APX1-2221 APX2222-Up
A New Oil Filter Group Is Now
785C HA 5AZ01-427 5AZ428-Up
Used On Certain C175 Off-
Highway Truck Engines
(continued)

90
SMCS Code: 1308; Publish Date: 06-Feb-2014

Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP)
793FAC (S/N: EMD)
795FAC (S/N: ERM)
797F (S/N: LAJ) (S/N: WSP)
Description Of Change: A new oil filter group, oil
tubes, and wiring harnesses are now used on the en-
gines listed above. The new oil filter group will reduce
the possibility of contaminating the lubrication
system.
Adaptable To: The new 445-4930 Engine Oil Filter
Gp with the new parts is shown below in Illustrations
4 and 5. The former 339-3301 Filter can be conta-
minated with debris at oil filter changes due to the di-
rection of oil flow through the filter. The outside of the
former 340-6283 Filter is the "clean" side. The new
Illustration 2 g03491662
oil filter housing reverses the flow of oil through the
new 394-4550 Engine Oil Filter Element. The out- Keep Area Clean
side of the new filter element is now the "dirty" side.
The new oil tubes and filter element are not compati-
The filter housing cap now has two drain plugs (1) as ble with the former 339-3301 Oil Filter Housing.
shown in Illustration 1. The drain plugs allow oil to The new 394-4550 Engine Oil Filter Element has a
drain more efficiently from the inner diameter (ID) handle attached to one end of the element (see Illus-
and outer diameter (OD) of the filter element during tration 3 ). Ensure that this handle is oriented at the
changes. The ID of the cap (Illustration 2 ) must re- bottom of the oil filter canister to aid in removal during
main clean during filter changes because the cap is filter changes.
exposed to the "clean" side of the oil system.

Illustration 3 g03507113
Illustration 1 g03491596
(1) Drain Plugs The wiring harness was updated to increase the
length of the wiring to the unfiltered oil pressure sen-
sor. The wiring harness also improved the routing
around the air compressor.

Refer to Special Instruction, REHS8661, "Procedure

to Retrofit the Oil Filter Housing Group on Certain C-
175 Off-Highway Truck Engines".

91
Illustration 4 g03453693
C175-20
(1) 432-2373 Tube (3) 424-0195 Flange (5) 445-4930 Engine Oil Filter Gp
(2) 394-3937 Tube (4) 394-4550 Engine Oil Filter Element

Illustration 5 g03453732
C175-16
(3) 424-0195 Flange (5) 445-4930 Engine Oil Filter Gp (7) 394-3931 Tube
(4) 394-4550 Engine Oil Filter Element (6) 433-6643 Tube

92
Table 1
793F / 795F New Parts SMCS Code: 1304; 5117; Publish Date: 03-Oct-2013
445-4930 Oil Filter Group

433-6643 Oil Tube from Oil Filter to the Block

Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
Oil Tube From Cross Under Line to the Oil
394-3931
Filter
SSP)
793FAC (S/N: EMD)
424-0195 Flange
795FAC (S/N: ERM)
394-4550 Filter Element 797F (S/N: LAJ) (S/N: WSP)
447-1587 Harness
Description Of Change: The two new oil pressure
control valve gps eliminate an external hose by incor-
Table 2 porating an internal passage within the body of the
797F New Parts regulator.
445-4930 Oil Filter Group The two new oil pressure control valve gps are
Oil Tube From Cross Under Line to the Oil shimmed differently to regulate the oil pressure to the
394-3937 same value for type 1 and type 2 engines.
Filter
432-2373 Oil Tube from Oil Filter to the Block Adaptable To: The 380-4432 Pressure Control
424-0195 Flange Valve Gp and the 424-9011 Pressure Control Valve
Gp replace the 354-4924 Pressure Control Valve
394-4550 Filter Element Gp.
447-1588 Right Hand Engine Harness
The 380-4432 Pressure Control Valve Gp and the
424-9011 Pressure Control Valve Gp are adaptable
Table 3 to the above engines back to first production.
797 Retrofit Parts
Refer to Table 1 to cross reference the engine type
445-4930 Oil Filter Group with the correct part number.
Oil Tube From Cross Under Line to the Oil Table 1
394-3937
Filter Type 1 424-9011 Pressure Engine serial numbers 1 -
432-2373 Oil Tube from Oil Filter to the Block engine Control Valve Gp 999

424-0195 Flange Type 2 380-4432 Pressure Engine serial numbers

engine Control Valve Gp 1000 - Up
394-4550 Filter Element

447-2429 Right Hand Engine Harness

Additional parts are required when any of the
354-4924 Pressure Control Valve Gp prior to this
This change is effective with the engine serial num- change are replaced with the new the 380-4432
bers listed below. Pressure Control Valve Gp or the 424-9011 Pres-
Table 4 sure Control Valve Gp.
Effective Engine Serial Numbers The additional parts are listed in Table 2 .
793F B7B01612-UP Table 2

793F AC B7C01004-UP Qty Parts

795F AC JTL01094-UP 1 228-7102 O-Ring Seal
797F LLM01299-UP 1 241-6158 Plug
C175-16 Reman ZK201048-UP 1 418-1262 Hose As
C175-20 Retrofit A4K01008-UP
C175-20 Reman ZK301049-UP

i05396495

A New Oil Pressure Control

Valve Group Is Used on Cer-
tain C175 Off-Highway Trucks
93
Illustration 1 g03411119 Illustration 2 g03411120
The old oil 354-4924 Pressure Control Valve Gp design The new oil 380-4432 Pressure Control Valve Gp design
(1) 354-4924 Pressure Control Valve Gp (2) 380-4432 Pressure Control Valve Gp
(3) 418-1262 Hose As
(4) 241-6158 Plug
(5) 228-7102 O-Ring Seal

94
 SMCS Code: 1304; 1307; Publish Date: 09-Jun-
2017

Off-Highway Truck/Tractor.
785C (S/N: APX1-2304)
785D (S/N: DMC) (S/N: MSY)
793D (S/N: FDB)
793F (S/N: RBT) (S/N: SND) (S/N: SSP)
793FAC (S/N: EMD)
795FAC (S/N: ERM)
Description Of Change: A new mounting group for
the prelubrication oil pump group is now available for
the machines listed above. The new mounting group
consist of a single plate assembly to support the oil
pump group.
The new single plate assembly will offer better reli-
ability and extended service life for the prelubrication
oil pump group.
Note: A separate rework procedure to update prelu-
brication pump lines group on 793D machines is
available in this Service Magazine.
Adaptable To:
Table 1
Illustration 3 g03411148 New Parts List
The new oil 424-9011 Pressure Control Valve Gp design
Item Qty Part Description
(3) 418-1262 Hose As
(4) 241-6158 Plug 1 2 169-5033 U-Bolt
(5) 228-7102 O-Ring Seal
(6) 424-9011 Pressure Control Valve Gp 2 1 422-2061 Hose As
3 1 423-6671 Plate As
The effective serial numbers are listed below in Table
3. 4 4 2K-4973 Locknut
Table 3 5 4 5P-1075 Hard Washer
Effective Serial Numbers 6 1 8T-4186 Bolt
A4k01007-Up 7 2 6V-0826 Grommet
B7B01581-Up 8 1 4S-1962 Clip

B7C01004-Up 9 1 125-8534 Plate As

JTL01090-Up 10 1 8T-4137 Bolt

LLM01296-Up 11 1 8T-4121 (1) Hard Washer

ZK201035-Up 12 1 7S-3919 Clip

ZK301038-Up 13 1 7S-3916 Clip

14 1 133-6934 Spacer
■ 15 1 8T-4136 Bolt
16 1 8T-4133 Nut
i07050741
- 2 119-5708 (2) Clip
A New Engine Oil Prelubrica- - 1 1S-0994 (2) Clip
tion Pump Mounting Group Is - 2 4D-9517 (2) Clip
Now Available for Certain (1) Use only for machines 793F
(2)
Large Off-Highway Trucks (3)Use during routing of lines group
(4) Use during routing of lines group

95
Illustration 1 g03410378
Typical example

The new plate assembly (3) is welded to the engine

cross beam. The prelubrication oil pump group (A) is
then mounted on the plate assembly with two U-bolts
(1), four locknuts (4), and four hard washers (5). After
mounting, hose assembly (2) is attached to the oil
pump group (A).

96
Illustration 2 g06212360
Typical example
Prelube wiring group of 793F machines

Use one bolt (7), two grommets (8), one clip (9), one
plate assembly (10), one bolt (11), and one hard
washer (12) to mount the prelube wiring group for
793F machines. For proper mounting location and
orientation, refer to Illustration 2.

97
Illustration 3 g06212361
Typical example
Prelube wiring group of 795F machines

Use one clip (13), two grommets (8), one clip (14),
one spacer (15), one clip (9), one plate assembly
(10), one bolt (16), one hard washer (12), and nut
(17) to mount the prelube wiring group for 795F ma-
chines. For proper mounting location and orientation,
refer to Illustration 3.
New plate assembly (3) for mounting prelubrication
oil pump group is adaptable to the machines within
the listed serial numbers, and is effective with all ma-
chines after the listed serial numbers.

98
Rework Procedure to Install
423-6671 Plate As on 421-9085
Support As for 793F Off-Highway
Trucks

Illustration 4 g06212363
Top view of 421-9085 Support As
(A) 53 mm (2.1 inch) (W1) 8 mm (0.3 inch) fillet weld on all (W3) 3 mm (0.1 inch) fillet weld all
(B) 36 mm (1.4 inch) around the inside oval around boss
(C) 18 mm (0.7 inch) (W2) 3 mm (0.1 inch) fillet weld both (1) 421-9085 Support As
(D) 18 mm (0.7 inch) sides wrap corners (2) 423-6671 Plate As

1. Position two weld bosses (3) and plate assembly

(2) on support assembly (1). Weld as per dimen-
sion shown in Illustration 4 and Illustration 5.

Rework Procedure to Update Prelu-

brication Pump Lines Group on
793D Off-Highway Trucks
Table 2
Required Parts List

Item Qty Part Description

1 2 119-5708 Clip
Illustration 5 g06212365
Side view of 421-9085 Support As 2 2 8T-4137 Bolt

(W2) 3 mm (0.1 inch) fillet weld both sides wrap corners 3 3 8T-4121 Hard Washer
(1) 421-9085 Support As
(2) 423-6671 Plate As 4 1 1S-0994 Clip
(3) 8T-3851 Weld Boss

(continued)

99
(Table 2, contd)
5 1 8Y-4489 Boss
6 1 423-6671 Plate As
7 2 169-5033 U-Bolt
8 4 2K-4973 Locknut
9 4 5P-1075 Hard Washer

10 2 4D-9517 Clip

11 1 8T-4136 Bolt

Illustration 6 g03412535

Illustration 7 g03412536
View of area A

1. Remove and keep aside all the wirings from the

prelubrication oil pump group (B).

2. Remove two U-bolts (C), four button head screws

(D), one 4D-9517 Clip (E), one 314-2531 Plate
(F), and two 8W-6702 Plates (G) from the support
assembly (H). Save 4D-9517 Clip (E) and dis-
card all other parts.

100
Illustration 8 g03412898

Illustration 9 g03412904

3. Relocate prelube wire (J) to the existing boss on

under side of support assembly (H) using two clips
(1), one bolt (2), one washer (3), and a clip (4). Ori-
ent the clips as shown in the Illustration 9.
Note: Weld 9R-2613 Weld Boss on under side of
the support assembly, if the weld boss is not exists.

101
Illustration 10 g03412916
Top view of support assembly
(K) Dimension is 596 ± 3 mm (23.5 ± 0.1 inch)
(L) Dimension is 490.5 mm (19.3 inch)
(K) Dimension is 351 ± 3 mm (13.8 ± 0.1 inch)
(W1) 3 mm (0.1 inch) fillet weld on all around the inside oval
(W2) 8 mm (0.3 inch) fillet weld on all around the inside oval

4. On the support assembly, position the new boss

(5) and a plate assembly (6). Weld as per dimen-
sion shown in Illustration 10.

Illustration 11 g03412926

5. Mount the prelubrication oil pump group (B) on the

plate assembly (6) with two U-bolts (7), four nuts
(8), and four hard washers (9).

102
 SMCS Code: 1071; Publish Date: 01-Aug-2013

Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP)
Reference: Special Instruction, REHS8000, "Proce-
dure to Upgrade the Bracket Assemblies in the Air
Lines Group on Certain 793F Off-Highway Trucks"
The new special instruction provides the correct pro-
cedure and the needed parts in order to upgrade the
bracket assemblies in the air lines group. The air
lines group is part of the air-to-air aftercooler used on
793F Off-Highway Trucks.
For a complete list of material and the correct proce-
dure that is needed in order to update the bracket as-
semblies to the current configuration, refer to Special
Instruction, REHS8000, "Procedure to Upgrade the
Bracket Assemblies in the Air Lines Group on Certain
793F Off-Highway Trucks". The special instruction
Illustration 12 g03412927
can be found on the Caterpillar service information
6. Relocate the prelubrication wiring (P) with one clip system (SIS), and through the normal literature distri-
(10), one bolt (11), and one hard washer (3) to the bution system at your local Cat ® dealer.
welded new boss (4).
■
7. Use one clip (E), one bolt (2), and one hard washer
(3) to secure the prelubrication wiring (P) on the i05380986
existing boss. Use clip (E) that was saved in Step
2
New Connecting Rod Bolts Are
Available for Certain C175
Engines
SMCS Code: 1218; Publish Date: 15-Jul-2013

Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP)
793FAC (S/N: EMD)
795FAC (S/N: ERM)
797F (S/N: LAJ) (S/N: WSP)
Description Of Change: The new connecting rod
bolts have elastomer rings bonded to the shank of
Illustration 13 g03409902 the bolts. The design and function of these bolts is
dependent upon compression of the rings within the
8. Reinstall all the prelubrication pump wires that bolts hole.
were saved in Step 1. Reinstall Oil lines, if the oil
lines were removed. The serviceable connecting rod assembly part num-
bers have been changed to contain the new connect-
■
ing rod bolts. The connecting rods will be shipped
with two shipping bolts that secure the cap to the rod.
i05355529 Four plugs will be installed in the remaining bolt holes
to prevent contamination. The new connecting rod
A New Special Instruction is bolts will be shipped in a separate container within
the connecting rod container. The shipping bolts can
Available to Update the Air be discarded before installation.
Lines Group on Certain 793F
Off-Highway Trucks

103
Note: Do not use solvents such as brake cleaner or i05318449
carburetor cleaner to clean the bolts. The solvents
can damage the elastomer rings on the shank of the A New Special Instruction,
bolts. 4C-6796 Mineral Spirits is approved for use of
cleaning the bolts. “Procedure to Install a Fuel
Adaptable To:
Line Heater on the 793F Off-
Highway Trucks” is Available
SMCS Code: 1273; 1296; Publish Date: 11-Jun-2013

Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP)

Illustration 1 g03361207
(1) 428-7386 Bolt As

The 428-7386 Bolt As replaces the 290-2541 Bolt

for the connecting rod assembly.

Reference: Refer to Specifications, KENR5396,

“Connecting Rod - Type 1” or “Connecting Rod - Type
2” for installation instructions.

Reference: Also refer to https://dealer.cat.com/cda/

alias/Service-Training/Instructional-Videos “Replac-
ing C175 Engine Connecting Rod Bolts Video” for
video installation instructions.
Illustration 1 g03374075
Table 1 contains the part changes for the connecting
rod assemblies. Table 2 contains the effective serial This new special instruction contains information to
numbers. install the 350-5792 Fuel Heater Gp on the 793F
Table 1 Off-Highway Truck for cold climate applications.
Previous Part Number New Part Number For a complete list of material and the procedure for
417-7902 Connecting Rod 434-0488 Connecting Rod Gp installing the fuel heater group to the current configu-
ration, refer to Special Instruction, REHS8605, "Pro-
417-7903 Connecting Rod 434-0489 Connecting Rod Gp
cedure to Install a Fuel Line Heater on the 793F Off-
Highway Truck". The special instruction can be found
Table 2 on the Caterpillar service information system (SIS)
Effective Serial Numbers and through the normal literature distribution system
at your local Cat dealer.
793F B7B01490-Up

B7C01004-Up
■
793F AC

795F AC JTL01066-Up i05235769

797 Retrofit A4K01006-Up

LLM01270-Up
New Bolts and New Idler
797F
Shafts Are Used for the Acces-
C175-16 Reman ZK201002-Up
sory Drive On C175 Off-High-
C175-20 Reman ZK301006-Up
way Truck Engines
■ SMCS Code: 1207; 7553; Publish Date: 18-Mar-
2013

Off-Highway Truck/Tractor.

104
 793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP)
793FAC (S/N: EMD)
795FAC (S/N: ERM)
797B (S/N: JSM)
797F (S/N: LAJ) (S/N: WSP)
Description Of Change: The new idler shaft im-
proves oil flow around the contact surfaces of the id-
ler gear. The clearance holes for the M12 bolts in the
new shaft have been changed. The M12 bolts have
been shortened to improve the natural frequency of
the bolts.
Adaptable To: The new 7X-2436 Bolts and
7X-2549 Bolts are used with new idler shafts. Refer
to Table 1 for the list of parts.
The new parts are adaptable back to first production
of engines used in the machine serial numbers listed
above.
Table 1 Illustration 1 g03341434

Parts List Typical example of 793 and 795 applications.

(1) 430-8140 Idler Shaft
Sales Qty (2) 7X-2436 Bolt
Part Number
Model (3) 255-5469 Bolts
2 255-5469 Bolts
1 430-8140 Idler Shaft

793 and 795 1 7X-2436 Bolt (M12)

2 5P-8245 Hard Washer

1 5D-4311 O-Ring Seal

2 255-5469 Bolts
1 430-8141 Idler Shaft

797 2 7X-2549 Bolt (M12)

2 5P-8245 Hard Washer

1 5D-4311 O-Ring Seal

Illustration 2 g03341436
Typical example of 797 applications.
(3) 255-5469 Bolts
(4) 430-8141 Idler Shaft
(5) 7X-2549 Bolts
(6) 5P-8245 Hard Washer

Table 2
Effectivity
SSP00912
EMD00101
RBT00165

(continued)

105
(Table 2, contd) Table 1
Effectivity Effective Engine Serial Numbers
SND00131 B7B01371-Up
JTL01055-Up
ERM00279
JSM00294
■
LAJ00458
WSP00125 i05164840

■ A New Fuel Filter Base Assem-

bly Is Used on C175 Off-High-
i05226734
way Truck Engines
A New Oil Cross Under Tube Is SMCS Code: 1261; Publish Date: 18-Dec-2012
Available for C175-16 Off-High- Off-Highway Truck/Tractor.
way Truck Engines 793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SMCS Code: 1307; Publish Date: 31-Jan-2013 SSP)
793FAC (S/N: EMD)
Off-Highway Truck/Tractor. 795FAC (S/N: ERM)
793F (S/N: RBT1-Up) (S/N: SND) (S/N: 797F (S/N: LAJ) (S/N: WSP)
SSP)
Description Of Change:
795FAC (S/N: ERM)
Description Of Change: The new tube has an im-
proved fit to account for assembly variation.

Adaptable To: The 416-4848 Tube As replaces the

391-1363 Tube As on the engines that are listed
above.

The 416-4848 Tube As is adaptable to engine serial

numbers B7B01000-Up and JTL01000-Up.

The 416-4848 Tube As is also adaptable back to

first production if the oil pan has been updated to the
378-9955 Oil Pan Gp or the 378-9956 Oil Pan
Gp. Effectivity is listed in Table 1 .
Illustration 1 g03317959
New filter base assembly cross-sectional view
(A) 15.6 ± 0.8 mm (0.6 ± 0.03 inch)

A new fuel filter base assembly is used on C175 off-

highway truck engines. The new design of the fuel fil-
ter base utilizes increased thread engagement of
6 mm (0.24 inch) in order to prevent stripping
threads, and cracking of the boss of the fuel filter
base.
Adaptable To: The 421-3352 replaces the current
236-5484 Fuel Filter Base As. The change is adapt-
able back to first production of the engine.

The change is effective at the factory with the ma-

chine serial number prefixes that are listed in Table 1
.

Illustration 1 g03339125
(1) Tube assembly

106
Table 1
Serial Number Prefixes SMCS Code: 1316; 7513; Publish Date: 15-Nov-
B7B01371-Up 2012
LLM01177-Up
Off-Highway Truck/Tractor.
JTL01055-Up 793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP)
■ 795FAC (S/N: ERM)
797F (S/N: LAJ) (S/N: WSP)
i05141341
Description Of Change: The new design uses fas-
teners that provide a longer service life for the mount-
A New Special instruction, ing tab on the oil filler tube.
“Procedure to Improve the Adaptable To: The new fasteners are identified in
Draining of Torque Converter Table 1 and Illustration 1.
Oil from the Flywheel Housing Table 1

on Certain 793F Off-Highway Item Qty Part

Trucks” (1) 1 423-3063 Oil Filler Hasp

(2) 1 8T-4196 Bolt

SMCS Code: 1157; 3103; Publish Date: 30-Oct-2012
(3) 3 8T-4896 Hard Washer
Off-Highway Truck/Tractor. (4) 1 424-4093 Spacer
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP) (5) 1 189-1943 Locknut

Reference: For a complete list of material and the

correct procedure that is needed in order to add the
external hose to the back of flywheel housing, refer to
Special instruction, REHS7614, “Procedure to Im-
prove the Draining of Torque Converter Oil from the
Flywheel Housing on Certain 793F Off-Highway
Trucks”.

This special instruction contains information that is

needed to improve the draining of oil out of the fly-
wheel housing and back to the torque converter. This
special instruction contains information to install an
external drain hose. The installed external drain hose
will help to avoid aeration of the torque converter oil.

The special instruction can be found on the Caterpil-

lar Service Information System (SIS) and through the
normal literature distribution system at your local Cat
dealer.
The new special instruction is adaptable to the ma-
chines SSP1-534, RBT1-116, and SND1-114.

i05133802

New Design for Securing the

Lanyard and Hasp for the Cap
on the Oil Filler Tube of C175
Off-Highway Truck Engines

107
Illustration 1 g03292456
New fasteners for the lanyard and the hasp
(1) 423-3063 Oil Filler Hasp (3) 8T-4896 Hard Washer (5) 189-1943 Locknut
(2) 8T-4196 Bolt (4) 424-4093 Spacer

There is one washer (3) between the head of bolt (2) Certain Off-Highway Truck
and the lanyard. Another washer (3) is between the
other side of the lanyard and the mounting tab on the Engines
oil filler tube. The third washer (3) is between the oth- SMCS Code: 1307; Publish Date: 12-Nov-2012
er side of the mounting tab and hasp (1) for the pad-
lock. Spacer (4), between the other side of the hasp
and locknut (5), enables rotation of the hasp.
Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
The new design is adaptable to the above machine SSP)
engines back to first production. The new design is 793FAC (S/N: EMD)
effective with the following engine serial numbers: 795FAC (S/N: ERM)
• B7B01368 797F (S/N: LAJ) (S/N: WSP)
• JTL01057 Description Of Change: The oil lines for the ORS
have been rerouted to improve the robustness of the
• LLM01177 line clips.

■ Adaptable To: The new 339-3497 Hose As repla-

ces the former 319-8074 Hose As used on 793 and
795 Off-Highway Truck Engines
i05130613

The new 362-5291 Hose As replaces the former

New Oil Renewal System 271-4235 Hose As used on 797 Off-Highway Truck
(ORS) Lines are Available for Engines

108
The new parts are listed in Table 2 .
The new hoses are adaptable back to first production
of the engine listed above with an ORS, using the
parts listed below.
The new 362-5291 Hose As is effective with the fol-
lowing serial numbers:
• LAJ00420
• WSP00123

Illustration 2 g03296098
Typical example of the new 793 and 795 Off-Highway Truck En-
gines ORS hose routing.
(2) 339-3497 Hose As
(3) 6D-3479 Clip
(4) 419-8224 Bracket
(5) 6V-1820 Bolt
(6) 6V-5839 Washer
(7) 2Y-5829 Nut

Illustration 1 g03296096
Typical example of the former 793 and 795 Off-Highway Truck En-
gines ORS hose routing.
(1) 319-8074 Hose As

Illustration 3 g03296021
Typical example of the former 797 Off-Highway Truck Engines
ORS hose routing.
(8) 271-4235 Hose As

109
 Table 2
Required Parts for 797 Off-Highway Truck Engines

Qty Part Number

1 362-5291 Hose As
1 228-7101 O-Ring Seal

1 228-7088 O-Ring Seal

1 6V-8940 O-Ring Reducer

2 6V-5839 Washer
2 6D-3479 Clip

1 228-7092 O-Ring Seal

1 238-5082 O-Ring Seal

1 6V-9007 Elbow
2 6V-4248 Bolt

Illustration 4 g03296023
■
Typical example of the new 797 Off-Highway Truck Engines ORS
hose routing. i05171130
(3) 6D-3479 Clip
(9) 362-5291 Hose As A New Pump Drive Group is
Table 1 Now Used on Certain 793F Off-
Required Parts for 793 and 795 Off-Highway Trucks Highway Trucks
Qty Part Number SMCS Code: 3108; 5070; Publish Date: 07-Nov-
2012
1 8T-0372 Bolt
5 228-7088 O-Ring Seal Off-Highway Truck/Tractor.
2 228-7101 O-Ring Seal
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP)
1 339-3497 Hose As
1 419-8224 Bracket
Description Of Change: The Hydraulic pump and
mounting group has been improved with new pump
1 6V-1820 Bolt drive group. The new pump drive group relocates the
1 2Y-5829 Nut drain port and internal features to allow for proper oil
evacuation during operation. The drain port actively
3 6V-5839 Washer lubricates the input bearing and improves the service
1 6V-8940 O-Ring Reducer life of the bearing and the gears.
1 228-7092 O-Ring Seal Adaptable To:
1 238-5082 O-Ring Seal

1 6V-9849 Elbow
1 6V-9007 Elbow
1 8T-6725 Connector
1 228-7089 O-Ring Seal

1 228-7102 O-Ring Seal

110
Illustration 1 g03318178

The new 386-4902 Pump Drive Gp (1) is the part

of the 278-8447 Hydraulic Pump and Mounting Gp
in the hydraulic arrangement.
The 386-4902 Pump Drive Gp is the direct replace-
ment for 149-3060 Pump Drive Gp.
The 386-4902 Pump Drive Gp is adaptable to the
machine SSP1-758, RBT1-164 and SND1-121.

The 386-4902 Pump Drive Gp is effective in pro-

duction with the machine SSP759-Up, RBT165-Up
and SND122-Up Illustration 2 g03318179
Unacceptable amount of debris

111
 (Table 1, contd)
8 1 386-4054 Tube As
9 1 6V-8774 Tee

10 1 214-7568 O-Ring Seal

11 1 386-4053 Tube As
12 1 2K-2939 O-Ring Seal

13 1 8T-1682 Elbow
14 1 228-7095 O-Ring Seal

15 1 238-5086 O-Ring Seal

16 1 375-5400 Hose As

Use the following procedure to install the new pump

drive group:

Reference: Disassembly and Assembly, KENR8579,

"Gear Pump (Brake, Hoist) - Remove and Install"

Reference: Disassembly and Assembly, KENR8579,

"Piston Pump (Hydraulic Fan, Steering) - Remove
and Install"

Reference: Disassembly and Assembly, KENR8579,

"Pump Drive - Remove and Install"

Illustration 3 g03318180
Acceptable amount of debris

The 8T-6332 Magnetic Plug (2) for the 386-4902

Pump Drive Gp (1) should be inspected every 500
hours.

• If the magnetic plug has an unacceptable amount

of debris as shown in Illustration 2, remove the
pump drive group and replace.

• If the magnetic plug has an acceptable amount of

debris as shown in Illustration 3, use the same
pump drive group.

Procedure to install the Pump drive Illustration 4 g03318182

group Hydraulic pump and mounting group

Table 1 1. Disconnect and remove the 278-8447 Hydraulic

Pump and Mounting Gp from the truck.
Required Parts List

Item Qty Part Description 2. Remove the 297-8451 Hydraulic Pump and
Mounting Gp (BRAKE, HOIST) (5), 297-8452
1 1 386-4902 Pump Drive Gp Hydraulic Pump and Mounting Gp (HYDRAULIC
FAN, STEERING) (4) from the Hydraulic pump
6 1 6V-9850 Elbow and mounting group. Retain all Hardware.
7 3 228-7089 O-Ring Seal
3. Remove the old 149-3060 Pump Drive Gp (3).

(continued)

112
 Illustration 6 g03318184

7. Install the 297-8451 Hydraulic Pump and Mount-

ing Gp (BRAKE, HOIST) (5), 297-8452 Hydraul-
ic Pump and Mounting Gp (HYDRAULIC FAN,
STEERING) (4) to the new 386-4902 Pump
Drive Gp (1) with new 2K-2939 O-Ring Seal
Illustration 5 g03318183 (12) in the same position as they were removed.
Refer Illustration 6.
4. Connect 6V-9850 Elbow (6) and 228-7089 O-
Ring Seal (7) to one end of the 386-4054 Tube
As (8) and 6V-8774 Tee (9), 214-7568 O-Ring
Seal (10) and two quantities of 228-7089 O-Ring
Seal (7) to other end of the 386-4054 Tube As
(8) as shown in Illustration 5.

5. Connect 386-4053 Tube As (11) as shown in Il-

lustration 5.
6. Assemble all the tube and fittings to the new
386-4902 Pump Drive Gp (1) as shown in Illus-
tration 5.

Illustration 7 g03318185

8. Install the drain port fitting 8T-1682 Elbow (13),

228-7095 O-Ring Seal (14), and 238-5086 O-
Ring Seal (15) which is located on the opposite
side of the Pump drive group as shown in Illustra-
tion 7.
9. Install the 278-8447 Hydraulic Pump and Mount-
ing Gp on to the truck.

113
 Illustration 8 g03318186

10. Discard the existing 366-0350 Hose As and in-

stall the new 375-5400 Hose As (16) as shown
in Illustration 8. All other connections will be the
same.

■ Illustration 1 g03253761
Differential housing assembly (2)
i05458549
The new 374-4846 Retainer (1) replaces the for-
A New Retainer Is Now Used in mer 4D-7541 Retainer in the 282-1775 Differential
Gp.
the Differential Group on 793D
The new 374-4846 Retainer is adaptable to the ma-
and 793F Off-Highway Trucks chines FDB1-1807, SSP1-977, RBT1-171, and
SMCS Code: 3256; 3258; Publish Date: 27-Sep- SND1-131.
2013
The new 374-4846 Retainer is effective in the pro-
duction with the machines FDB1808-Up, SSP978-
Off-Highway Truck/Tractor. Up, RBT172-Up, and SND132-Up.
793D (S/N: FDB1-Up)
793F (S/N: RBT) (S/N: SND) (S/N: SSP) ■
Service Magazine, SEPD1583, 20 March 2013, “A
New Retainer Is Now Used in the Differential Group i05052992
on 793D and 793F Off-Highway Trucks”. The infor-
mation in this article has changed. Disregard this ar- A New Seal Assembly for the
ticle. The correct information follows:
Differential and Bevel Gear
Description Of Change: The retainer for the differ-
ential group has been redesigned to reduce the con- Group Is Now Used on Certain
tact wear with the differential housing assembly. The 793 Off-Highway Trucks
result of the redesigned retainer is improved service
life of the housing assembly. The new retainer has a SMCS Code: 3256; 3258; Publish Date: 03-Apr-2013
larger flange diameter with more surface area and a
smoother surface finish. Off-Highway Truck/Tractor.
793D (S/N: FDB1-Up)
Adaptable To:
793F (S/N: RBT) (S/N: SND) (S/N: SSP)
Reference: Disassembly and Assembly ,
RENR8332, "Drive Shaft Guard - Remove and
Install".
Reference: Disassembly and Assembly ,
RENR8328, "Drive Shaft (Main) - Remove and
Install".
Reference: Disassembly and Assembly ,
KENR8397, "Drive Shaft (Main) - Remove and
Install".

114
Reference: Disassembly and Assembly ,
KENR8397, "Transmission Planetary".
Reference: Disassembly and Assembly ,
KENR8397, "Differential and Bevel Gear ".
Reference: Disassembly and Assembly ,
RENR8328, "Differential and Bevel Gear -
Assemble".
Reference: Disassembly and Assembly ,
KENR8397, "Differential and Bevel Gear -
Assemble".
Description Of Change: The new lip type seal has a
PTFE insert with higher speed capability. The new
seal prevents oil transfer between the differential and
transmission.

Adaptable To: The new 387-1379 Seal As is

adaptable and effective in production with the ma-
chines that are listed in Table 1 .
Table 1 Illustration 2 g03251457
Adaptable to the Effective with the Bearing cage assembly removed
Sales Model
machines machines
Table 2
793D FDB1-1765 FDB1766-Up
Parts List for Differential and Bevel Gear Group
SSP1-902 SSP903-Up
Item Qty Part Number Description
793F SND1-131 SND132-Up
1 1 387-1379 Seal As
RBT1-164 RBT165-Up
2 17 6V-5684 Bolt
3 17 5P-8245 Hard Washer

4 1 6M-5218 O-Ring Seal

The new 387-1379 Seal As (1) replaces the former

9X-7397 Seal As in the 193-6222 Differential and
Bevel Gear Gp, 280-1609 Differential and Bevel
Gear Gp and 379-8891 Differential and Bevel Gear
Gp.

The 6V-5684 Bolt (2), 5P-8245 Hard Washer (3),

and 6M-5218 O-Ring Seal (4) are part of
193-6222 Differential and Bevel Gear Gp,
280-1609 Differential and Bevel Gear Gp and
379-8891 Differential and Bevel Gear Gp.
Refer to Disassembly and Assembly , RENR8332,
"Drive Shaft Guard - Remove and Install" for 793D
Off-Highway Trucks.

Refer to Disassembly and Assembly , RENR8328,

"Drive Shaft (Main) - Remove and Install" for 793D
Illustration 1 g03251456 Off-Highway Trucks.
Typical example
Refer to Disassembly and Assembly , KENR8397,
Differential and bevel gear group "Drive Shaft (Main) - Remove and Install" for 793F
Off-Highway Trucks.

Refer to Disassembly and Assembly , KENR8397,

"Transmission Planetary" for 793F Off-Highway
Trucks.

115
Refer to Disassembly and Assembly , KENR8397, (Table 1, contd)
"Differential and Bevel Gear " for 793F Off-Highway 300-8725 298-3666
Trucks.
298-3667
Refer to Disassembly and Assembly , RENR8328, 357-7201
"Differential and Bevel Gear - Assemble" for 793D
Off-Highway Trucks. 357-7202
308-0285 311-2152
Refer to Disassembly and Assembly , KENR8397,
"Differential and Bevel Gear - Assemble" for 793F 311-2171
Off-Highway Trucks. 797F 272-3392 282-9576

■ 282-9577
282-9578
i05037492 282-9579

The Exhaust Tubes are Up- 290-3507 371-2125

dated on the 793F, 795F AC, 371-2128

351-3811 384-6453
and 797F Off-Highway Trucks
384-8673
SMCS Code: 1061; 1062; Publish Date: 19-Sep-
2012
The tube assemblies in Table 1 have been updated.
The updated tube assemblies are adaptable to the
Off-Highway Truck/Tractor. following machines: SSP1-740, SND1-121, ERM1-
793F (S/N: RBT1-Up) (S/N: SND) (S/N: 269, LAJ1-392 and WSP1-119
SSP)
795FAC (S/N: ERM) The updated tube assemblies became effective in
797F (S/N: LAJ) (S/N: WSP) production with the following machines: SSP741-Up,
SND122-Up, ERM270-Up, LAJ393-Up and WSP120-
Description Of Change: A 3.0 mm (0.12 inch) vent Up
hole has been added in the outer layer of the exhaust
tube assemblies. The hole is located at the lowest Earlier machines can be updated. The hole must be
point on the installed exhaust tube assemblies in or- located at the lowest point on the installed exhaust
der to prevent water from entering the cavity. The tube assemblies in order to prevent water from enter-
new hole allows the cavity between the inner and out- ing the cavity. Do not drill a hole through a weld, near
er walls of the exhaust tube assemblies to be vented a strap assembly, or near a tube assembly elbow.
to the atmosphere. Venting prevents a pressure Use the following information to update earlier ma-
build-up that can cause the inner wall to collapse and chines to the new configuration.
restrict the exhaust flow on the machine.

Adaptable To:
Table 1
Parts Updated

Sales Model Group Tube Assembly

793F 290-8857 311-6207

319-5307
319-6019
326-8935 311-6207
319-5307
319-6019
350-2258 350-2275
350-2282
352-8071
795F AC 284-5880 298-3666
298-3667

(continued)

116
Illustration 1 g03229799

(1) Position of the vent on the lower ex-

haust tube assemblies

117
Illustration 2 g03229816

(2) Position of the vent on the upper ex-

haust tube assemblies

Drill a 3.0 mm (0.12 inch) hole in the outer layer of

the exhaust tube assemblies at point (1) and (2).

118
Illustration 3 g03229878
Position of the vent on the 793F Off-Highway Trucks
(A) 125 mm (4.9 inch) (B) 75 mm (3.0 inch)

For the 793F Off-Highway Trucks, drill the hole on

the bottom of the installed exhaust tube assemblies.
Position the hole between 75 mm (3.0 inch) and
125 mm (4.9 inch) back from the engine connection
flange.

i05198499

A New Alternator Belt Guard

And New Alternator Supports
Are Used on C175 Off-Highway
Truck Engines
SMCS Code: 1405; 7150; Publish Date: 19-Dec-
2012

Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP)
795FAC (S/N: ERM)
797F (S/N: LAJ) (S/N: WSP)
Description Of Change: The new one-piece alterna-
tor belt guard is more rugged than the original two-
piece guard.

Adaptable To:

119
Illustration 1 g03179302

(1) New 430-7671 Alternator Guard As (2) Former 333-0645 Belt Guard Gp
(Table 1, contd)
The new 399-3381 Belt Guard Gp replaces the 1 430-7671 Alternator Guard As
original 333-0645 Belt Guard Gp in the above ma-
chine engines. The original belt guard is not 5 198-4766 Hard Washer
canceled. 5 6V-1820 Bolt

The new 430-7671 Alternator Guard As is part of

Table 2
the new 399-3381 Belt Guard Gp, refer to Table 1
for the parts list. Effective Engine Serial Numbers

The new guard is adaptable to the above machine B7B01365

engines back to first production along with the instal- JTL01055
lation of the new supports listed below.
LLM01175
The new guard requires a new 420-7737 Support
on the following machines: ■
• ERM
i04998749
• LAJ
A New Engine Oil Pump Inlet
• SND
Adapter Is Used on C175 Off-
• SSP
Highway Truck Engines
• WSP SMCS Code: 1302; 1304; Publish Date: 29-Aug-
2012
RBT machines require installing a new 420-7738
Support
Table 1
Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
399-3381 Belt Guard Gp
SSP)
Qty Part Number 795FAC (S/N: ERM)
797F (S/N: LAJ) (S/N: WSP)
(continued)

120
Description Of Change: The new adapter has been
redesigned to allow additional adjustments to aid in
the alignment of the adapter and the oil supply elbow.

Adaptable To: The new 399-3138 Oil Pump Adapt-

er replaces the former 382-4005 Oil Pump Adapter
which is canceled. The former adapter can come in
contact with the interior bore of the oil supply elbow.
The contact is caused by misalignment between the
adapter and the oil supply elbow. The misalignment
can cause the o-ring to become less compressed on
one side causing a small oil leak over time.

Illustration 2 g03176556
(A) Enlarged mounting holes

Table 1
Parts List
Qty Part Number

1 107-6280 O-Ring Seal

1 112-1579 O-Ring Seal

3 198-4766 Hard Washer

3 6V-5842 Bolt
1 399-3138 Oil Pump Adapter

Table 2
Effectivity

ERM00283-UP
LAJ00435-UP
SND00122-UP
SSP00830-UP
RBT00161-UP
WSP00123-UP

i04938389
Illustration 1 g03176017
(1) 301-0613 Elbow
(2) 112-1579 O-Ring Seal
A Summary of Updates for
(3) 382-4005 Oil Pump Adapter Type 2 C175 Off-Highway
Truck Engines
SMCS Code: 1000; Publish Date: 31-Oct-2012

Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP)

121
 793FAC (S/N: EMD) (Table 2, contd)
795FAC (S/N: ERM) 797F 282-2060 LAJ00353
797F (S/N: LAJ) (S/N: WSP) 262-1300 LAJ00367
The following articles describe the updates that im- 365-9326 LAJ00373
prove the durability of the engines: 360-1647
797F XQ WSP00115
• Service Magazine, SEPD1422, “A New Camshaft
and Thrust Washer Are Used in C175-20 Off-High- ■
way Truck Engines”

• Service Magazine, SEPD1423, “A New Front i06753348

Housing Is Used on C175 Off-Highway Truck

Engines” New Core Engine Components
• Service Magazine, SEPD1437, “A New Cylinder
Are Used in C175 Off-Highway
Block and Flywheel Housing Are Used for C175 Truck Engines
Off-Highway Truck Engines”
SMCS Code: 1202; 1205; Publish Date: 20-Jul-2016
• Service Magazine, SEPD1439, “A New Valve
Lifter Group and Dowel Are Used in C175 Off- Off-Highway Truck/Tractor.
Highway Truck Engines” 793F (S/N: RBT1-Up) (S/N: SND) (S/N:
• Service Magazine, SEPD1447, “A New Crankshaft SSP)
Vibration Damper is Used on C175-20 797F Off- 795FAC (S/N: ERM)
Highway Truck Engines” 797F (S/N: LAJ) (S/N: WSP)
Service Magazine, SEPD1517, New Core Engine
• Service Magazine, SEPD1457, “New Oil Pans and Components Are Used in C175 Off-Highway Truck
Oil Lines Are Used on C175 Off-Highway Truck Engines. Disregard the information in the article that
Engines ” is listed above. Refer to the information in the follow-
ing article.
• Service Magazine, SEPD1493, “Serviceability of
Connecting Rod Bearings in Type 2 C175 Off- Description Of Change: The following new compo-
Highway Truck Engines” nents have been changed in order to increase the du-
rability of the engine.
• Service Magazine, SEPD1517, “New Core Engine
Components Are Used in C175 Off-Highway Truck • Crankshaft
Engines”
• Connecting Rod
Table 1
Sales Model Effective Serial Number • Connecting Rod Bearing
C175-16 B7B1000-Up • Crankshaft Vibration Damper
C175-16 JTL1000-Up Adaptable To: The changes are effective with the fol-
C175-20 LLM1000-Up lowing engine serial numbers:

• JTL01000
Table 2
Sales Model Engine Effective Serial • LLM01000
Arrangement Number
• B7B01000
793F 250-7100 SSP00649
The change is effective with the machine serial num-
365-9318 SSP00672
bers listed in Table 1 . Refer to Tables 2 , 3 and 4 for
365-9320 SSP00705 part number changes.
793F XQ 360-1646 SND00116

793F CMD 381-8006 RBT00123

795F AC 288-8962 ERM00240

365-9324 ERM00251

(continued)

122
Crankshaft

Illustration 1 g02942880
Crankshaft

• The diameter of the pin journal was reduced by 8

mm.

• The connecting rod bolt torque-turn procedure has

been updated for the new connecting rod.
• The straight length of the pin journal was in-
creased by 4 mm but the overall length of the
crankshaft was not increased.

• The oil hole pattern was optimized in order to re-

duce cavitation.
• The dowels on the front and rear of the crankshaft
were removed. For better serviceability, the dow-
els are now pressed into the rear crankshaft gear,
the flywheel, the damper for 797F engines., and
the damper adapter for 793F and 795F engines. .

Connecting Rod
Reference: Refer to the Disassembly and Assembly,
KENR6052-02, "Pistons, Liners, and Connecting
Rods - Install" for the updated connecting rod bolt
torque.

123
Illustration 2 g02943082
Section view of the connecting rod

• The connecting rod bore diameter was decreased

by 7 mm (3.5 mm from each side). As a result, the
thickness of the mating section for the connecting
rod and the cap was increased. The thickness in-
creases the rod stiffness and reduces bending
under a load.

• A honed pattern was designed into the bearing

bore instead of the previously shot-peened
surface.

• The angle of the oil passage was changed from

entering the bore at 15 degrees past top center to
40 degrees. The relocation of the oil passage
moves the hole further from the loading zone.
• The oil hole for the rod eye bushing was relocated.

124
Connecting Rod Bearing

Illustration 3 g02943085
Bearing

• The wall thickness was increased by 0.5 mm, Table 1

which allows higher and more consistent contact Engine Effective Serial
pressure between the outer bearing diameter and Sales Model
Arrangement Number
the rod bore.
250-7100 SSP00649
• The oil hole is now slotted and offset 40 degrees
793F 365-9318 SSP00672
past the top center of the rod.
365-9320 SSP00705
• Install the 376-6457 Connecting Rod Bearing in
793F XQ 360-1646 SND00116
any of the new connecting rods for the odd-num-
bered cylinders. 793F CMD 381-8006 RBT00123

• Install the 376-6458 Connecting Rod Bearing in 288-8962 ERM00240

795F AC
any of the new connecting rods for the even-num- 365-9324 ERM00251
bered cylinders.
282-2060 LAJ00353
Note: The connecting rod bearings are no longer du- 797F 262-1300 LAJ00367
al sourced.
365-9326 LAJ00373
Note: Do not mix the bearing halves between the dif- 797F XQ 360-1647 WSP00115
ferent part numbers.
Table 2

Crankshaft Vibration Damper 793F

New Pt. No. Former Pt. No. Description
• The viscosity of the fluid in the 793F and 795F
damper was changed to accommodate the dy- 357-6282 229-9809 Bushing
namic changes of the crankshaft. The design of 366-5649 269-0588 Spacer
the damper was not changed.
417-7903 316-0063 Connecting Rod(1)
• For the changes to the 797F damper, refer to
376-6457 322-3031 Connecting Rod Bearing(1)
Service Magazine, SEPD1447, “A New Crankshaft
Vibration Damper is Used on C175-20 797F Off- 417-7902 316-0062 Connecting Rod(2)
Highway Truck Engines”.
376-6458 322-3030 Connecting Rod Bearing(2)

(continued)

125
(Table 2, contd) (Table 4, contd)
356-7064 317-8521 Crankshaft 378-5615 254-2075 Crankshaft Gear(3)
378-5615 254-2075 Crankshaft Gear(3) 378-5616 273-3814 Crankshaft Gear(4)
378-5615 254-2075 Crankshaft Gear(4) 370-6549 334-8990 Flywheel As
370-6548 334-8991 Flywheel As 391-8715 288-6598 Damper Gp
370-6871 283-1672 Adapter (1) Odd-numbered cylinder
(2) Even-numbered cylinder
362-7672 283-1678 Damper Gp (3) Front
(4) Rear
146-3173 1S-2199 Dowel(5)
(1) Odd-numbered cylinder ■
(2) Even-numbered cylinder
(3) Front
(4) Rear i04836511
(5) Damper
A New Outer Support Is Used
Table 3
795F
in the Trunnion Group for
New Pt. No. Former Pt. No. Description
C175-16 Off-Highway Truck
357-6282 229-9809 Bushing
Engines
SMCS Code: 1153; 1154; Publish Date: 11-Apr-2012
366-5649 269-0588 Spacer

417-7903 316-0063 Connecting Rod(1) Off-Highway Truck/Tractor.

376-6457 322-3031 Connecting Rod Bearing(1) 793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP)
417-7902 316-0062 Connecting Rod(2)
793FAC (S/N: EMD)
376-6458 322-3030 Connecting Rod Bearing(2) 795FAC (S/N: ERM)
356-7064 317-8521 Crankshaft
Description Of Change:
378-5615 254-2075 Crankshaft Gear(3)
With the original outer support, the engine required
378-5615 254-2075 Crankshaft Gear(4) removal from the chassis in order to remove the stub
370-6548 334-8991 Flywheel As shafts for access to the idler gears.

370-6871 283-1672 Adapter The new outer support has a crescent-shaped scal-
lop void on each side. The design enables the stub
362-7672 283-1678 Damper Gp shafts to be removed while the engine is in chassis.
146-3173 1S-2199 Dowel(5) Removal of the stub shafts enable the idler gears to
be serviced.
(1) Odd-numbered cylinder
(2) Even-numbered cylinder
(3)
Adaptable To:
Front
(4) Rear
(5) Damper

Table 4
797F
New Pt. No. Former Pt. No. Description

357-6282 229-9809 Bushing

366-5649 269-0588 Spacer

417-7903 316-0063 Connecting Rod(1)

376-6457 322-3031 Connecting Rod Bearing(1)

417-7902 316-0062 Connecting Rod(2)

376-6458 322-3030 Connecting Rod Bearing(2)

359-0941 289-2487 Crankshaft

(continued)

126
Illustration 1 g02967558

(1) 391-0787 Outer Support (2) 250-7063 Outer Support

The 250-7062 Engine Trunnion Gp now uses the

new 391-0787 Outer Support, replacing the former
250-7063 Outer Support which is canceled.
The part number of the 250-7062 Engine Trunnion
Gp has not changed. Except for the outer support, all
of the other original parts are still used.
The parts in the 250-7062 Engine Trunnion Gp are
identified in Table 1 and Illustration 2.
The modified 250-7062 Engine Trunnion Gp is ef-
fective with the following serial numbers:

• SSP00626
• SND00116

• ERM00231
Table 1
Item Qty Part

1 1 391-0787 Outer Support

3 16 8T-4193 Bolt
4 16 3E-4356 Hard Washer
5 1 259-9073 Mount As
6 20 281-1112 Bolt
7 20 171-3010 Hard Washer

127
 The oil inlet port on the right side of the engine toward
the rear was also relocated to accommodate the new
housing bolts. A new oil tube and adapter from the
engine oil filter is used for the oil supply.
The flywheel housing has a new cover for the acces-
sory drive. The cover improves the serviceability of
the shaft bearing for the power take-off. The location
of the cover created the need for new breather tubes
and mounting locations.

Adaptable To:
The new cylinder block and flywheel housing must be
used as a pair. The four added bolts prevent compati-
bility with the previous cylinder block and flywheel
housing.

Effective engine serial numbers are listed in Table 3 .

Effective machine serial numbers are listed in Table 4
.
Table 1
Parts for the C175-16 Off-Highway Truck Engines Qty

373-7688 Flywheel Housing As 1

372-5045 Cover 1
371-6161 Tube 1
Illustration 2 g02967561
363-7294 Face Seal 1
(1) 391-0787 Outer Support
(3) 8T-4193 Bolt 371-0574 Bracket As 1
(4) 3E-4356 Hard Washer
(5) 259-9073 Mount As 368-3882 Cover 1
(6) 281-1112 Bolt
371-6159 Oil Line Adapter 1
(7) 171-3010 Hard Washer
371-6160 Tube 1
■
370-4041 Cylinder Block 1

i04802795
Table 2

A New Cylinder Block and Fly- Parts for the C175-20 Off-Highway Truck Engines Qty

wheel Housing Are Used for 373-7691 Flywheel Housing As 1

C175 Off-Highway Truck 371-5016 Housing Cover Assembly 1

Engines 371-6156 Tube 1

SMCS Code: 1157; 1201; Publish Date: 10-May- 371-6155 Tube 1

2012 373-2286 Bracket As 1
363-7294 Face Seal 1
Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N: 371-0574 Bracket As 1
SSP) 368-3882 Cover 1
795FAC (S/N: ERM) 371-6159 Oil Line Adapter 1
797F (S/N: LAJ) (S/N: WSP)
371-6154 Tube 1
Description Of Change: The new cylinder block and 370-4044 Cylinder Block 1
flywheel housing have four additional bolt holes. The
four additional bolts provide a more secure joint at
the rear of the engine.

The engine crankshaft position sensor was relocated

in order to accommodate the new bolts. There is a
new bracket for the sensor and a new cover for the
sensor connector.

128
 Illustration 3 g02924017
New oil supply tube and adapter

Table 3
Sales Model Effective Serial Number
C175-16 B7B1000-Up
Illustration 1 g02892857
C175-16 JTL1000-Up
Locations of four additional bolt holes in the cylinder block
C175-20 LLM1000-Up

Table 4
Sales Model Engine Effective Serial
Arrangement Number

793F 250-7100 SSP00649

365-9318 SSP00672
365-9320 SSP00705
793F XQ 360-1646 SND00116

793F CMD 381-8006 RBT00123

795F AC 288-8962 ERM00240
365-9324 ERM00251
797F 282-2060 LAJ00353
262-1300 LAJ00367
365-9326 LAJ00373
797F XQ 360-1647 WSP00115

Illustration 2 g02893596
(1) 371-0574 Bracket As ■
(2) 368-3882 Cover
i04802071

A New Valve Lifter Group and

Dowel Are Used in C175 Off-
Highway Truck Engines
SMCS Code: 1209; Publish Date: 15-May-2012

Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP)
795FAC (S/N: ERM)
797F (S/N: LAJ) (S/N: WSP)

129
Description Of Change: Previously, the hollow dow-
els for the valve lifter housing were pressed into the
housing. When the valve lifter group was removed,
debris could enter the lubrication system through the
holes in the cylinder block.
The hollow dowels for the valve lifter housing are now
pressed into the cylinder block. The dowels stay in
the block when the lifter group is removed in order to
help prevent debris from entering the oil holes.

The holes for the dowels in the new housing assem-

bly are larger than the holes for the original housing
assembly. The dowels stay in the cylinder block when
the new housing assembly is removed.
Adaptable To:

The new 397-4038 Valve Lifter Gp is now used in

place of the previously used 357-4825 Valve Lifter
Gp, which is not canceled.

The only differences between the two lifter groups

are the housings. The part numbers in both lifter
groups are listed in Table 1 .
Table 1
Qty 397-4038 Valve Lifter Gp 357-4825 Valve Lifter Gp

1 384-5330 Housing As 357-4824 Housing As

Illustration 1 g02984137
4 281-9370 Valve Lifter As (1) 384-3712 Hollow Dowel
2 357-9456 Bolt (A) Dimension 12 ± 0.5 mm (0.47 ± 0.02 inch)

1 357-4823 Shaft As If a new lifter housing is needed for an engine built

1 242-1377 Sleeve prior to the change, two new dowels must be pressed
into the block. Obtain two 384-3712 Hollow Dowels
Required Service Parts for Retrofit for use with the new housing.
2 384-3712 Hollow Dowel n/a
(A) Height of the dowel above the block
. . . . . . . . . . . . . . . . . 12 ± 0.5 mm ((0.47 ± 0.02 inch))
Note: The use of a vacuum to catch debris during re-
moval of the lifter housing is recommended.

130
 SMCS Code: 1302; 1307; Publish Date: 02-Oct-2012

Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP)
795FAC (S/N: ERM)
797F (S/N: LAJ) (S/N: WSP)
Service Magazine, SEPD1457, 6 June 2012, “New
Oil Pans and Oil Lines Are Used on C175 Off-High-
way Truck Engines”. The original article has been re-
vised to describe the reuse of certain original parts.

Description Of Change: New oil pans and oil cross

under tubes are used for the above Off-Highway
Truck Engines.

The new oil pans incorporate a press in place seal

between the oil pan segments, and the oil pan to
block joint.

The new oil pans also have mounting holes to secure

Illustration 2 g02929871 the cast cross under oil tube to the bottom of the oil
(2) Holes in the valve lifter housing for the dowels. pans.

Table 2 Adaptable To: The new oil pans and cross under
tubes are adaptable to machines dating back to first
Effective Engine Serial Numbers
production. The new oil pans and cross under tubes
B7B01000 must be updated together.
JTL01000 Note: The oil inlet port on the right side of the engine
LLM01000 was relocated to accommodate the new rear housing
bolts. If updating the oil pan and cross under tube of
Table 3 an engine built prior to the effectivity listed in Table 3 ,
the oil tube and adapter connecting the oil filter to the
Effective Machine Serial Numbers engine block must be reused. Below are the oil
Sales Model Engine Serial Number adapter and oil tube part numbers from the original oil
Arrangement lines group:
793F 250-7100 SSP00649 • For C175-16 reuse the original 290-8724 Adapt-
365-9318 SSP00672 er and the original 288-8955 Tube
365-9320 SSP00705 • For C175-20 reuse the original 290-8724 Adapt-
360-1646 SND00116 er and the original 332-8936 Tube
381-8006 RBT00123 Effective engine serial numbers are listed in Table 3 .
795F 288-8962 ERM00240
Effective machine serial numbers are listed in Table 4
365-9324 ERM00251 .
797F 282-2060 LAJ00353
262-1300 LAJ00367
C175-16
365-9326 LAJ00373 The new groups and the original groups are listed in
table 1 . Parts from the original groups will remain
360-1647 WSP00115
serviceable.
Table 1
■
Sales Model New Group Original Group

i05106412 793F / 795F 378-9955 Oil Pan 300-5521 Oil Pan

Gp Gp
New Oil Pans and Oil Lines Are 793F / 795F 371-6162 Engine 294-5598 Engine
Used on C175 Off-Highway Oil Lines Gp Oil Lines Gp

Truck Engines
(continued)

131
(Table 1, contd)

Sales Model New Group Original Group

793F XQ / 795F XQ 378-9956 Oil Pan 354-5829 Oil Pan
Gp Gp

793F XQ / 795F XQ 371-6162 Engine 294-5598 Engine

Oil Lines Gp Oil Lines Gp

Illustration 1 g02923776

(1) 391-7216 Face Seal (3) 391-4885 Oil Pan (5) 391-4884 Oil Pan
(2) 391-7217 Face Seal (4) 391-7218 Face Seal

132
Illustration 2 g02923777

(6) 371-6762 Flange (12) 6V-5839 Washers (18) 6V-7970 O-Ring Seal
(7) 344-9285 Ring (13) 370-5724 Tube (19) 391-1364 Flange
(8) 269-7885 O-Ring Seal (14) 6V-8004 Bolts (20) 131-3718 O-Ring Seal
(9) 9Y-2099 Flange (15) 5P-8245 Hard Washers (21) 9X-8271 Bolts
(10) 6V-1196 O-Ring Seal (16) 383-1187 Elbow As (22) 391-1363 Tube As
(11) 8T-0643 Bolts (17) 8C-4424 Plug

C175-20
The new groups and the original groups are listed in
table 2 . Parts from the original groups will remain
serviceable.
Table 2

Sales Model New Group Original Group

797F 378-9957 Oil Pan 302-5395 Oil Pan
Gp Gp

797F 371-6163 Engine 308-7225 Engine

Oil Lines Gp Oil Lines Gp

797F XQ 378-9958 Oil Pan 357-6130 Oil Pan

Gp Gp

797F XQ 371-6163 Engine 308-7225 Engine

Oil Lines Gp Oil Lines Gp

133
Illustration 3 g02923218

(1) 391-7219 Face Seal (6) 391-4888 Oil Pan (11) 198-4766 Hard Washers
(2) 391-7221 Face Seal (7) 6V-4249 Bolts (12) 391-4887 Oil Pan
(3) 391-7220 Face Seal (8) 8M-7145 Washers (13) 391-4886 Oil Pan
(4) 391-7222 Face Seal (9) 394-7231 Stiffener Plate
(5) 391-7223 Face Seal (10) 6V-4249 Bolts

134
Illustration 4 g02923596

(10) 210-4460 Bolts (17) 259-4600 O-Ring Seal (24) 5P-8245 Hard Washers
(11) 8T-0356 Bolts (18) 129-9454 Flange (25) 383-1188 Elbow As
(12) 6V-5839 Washers (19) 131-3718 O-Ring Seal (26) 8C-4424 Plug
(13) 348-5663 Elbow (20) 8T-0643 Bolts (27) 6V-7970 O-Ring Seal
(14) 6V-1196 O-Ring Seal (21) 6V-5839 Washers (28) 370-5726 Tube
(15) 371-6761 Flange (22) 370-5728 Tube (29) 370-5727 Elbow
(16) 344-9286 Ring (23) 6V-8004 Bolts

Table 3 (Table 4, contd)

Sales Model Effective Serial Number 795F AC 288-8962 ERM00240

C175-16 B7B1000-Up 365-9324 ERM00251

C175-16 JTL1000-Up 797F 282-2060 LAJ00353

C175-20 LLM1000-Up 262-1300 LAJ00367

365-9326 LAJ00373
Table 4 797F XQ 360-1647 WSP00115
Sales Model Engine Effective Serial
Arrangement Number
■
793F 250-7100 SSP00649
365-9318 SSP00672 i04784129

365-9320 SSP00705
A New Front Housing Is Used
793F XQ 360-1646 SND00116
on C175 Off-Highway Truck
793F CMD 381-8006 RBT00123
Engines
(continued)

135
SMCS Code: 1151; 1162; Publish Date: 11-Apr-2012

Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP)
795FAC (S/N: ERM)
797F (S/N: LAJ) (S/N: WSP)
Description Of Change: The new housing assembly
incorporates a face seal that is pressed in place. The
face seal and the additional O-ring seals help to pro-
vide protection against leaks.

The elbows for the oil supply to the turbocharger

have been enlarged at the ends that thread into the
front housing. The elbows are able to supply more lu-
brication to the turbochargers. The holes in the hous-
ing have been enlarged in order to accommodate the
new elbows.

Adaptable To:
The new parts are identified in Illustration 1 and in Ta-
ble 1 .

Illustration 1 g02894197

(1) 384-0902 Housing As (4) 8T-7524 O-Ring Seal (not shown) (6) Locations of the 5P-5599 O-Ring
(2) 363-7294 Face Seal (5) 310-7258 O-Ring Seal Seal (not shown, the O-ring seals are
(3) 268-1552 Elbow on the opposite side of the housing)

Table 1 (Table 1, contd)

Item Qty Part 2 1 363-7294 Face Seal

1 1 384-0902 Housing As 3 2 268-1552 Elbow

(continued) (continued)

136
(Table 1, contd) Service Magazine, SEPD1766, 08 April 2014, “A
4 2 8T-7524 O-Ring Seal New Torque Specification Is Used for the V-Band
Clamp of the Turbocharger on Certain 3500 and
5 2 310-7258 O-Ring Seal C175 Off-Highway Truck Engines”. The original ar-
ticle has been revised to remove 3500 from title.
6 4 5P-5599 O-Ring Seal

Note: The grooves for the four 5P-5599 O-Ring

Seals are machined into the housing. The four O-
rings are installed between the bolts in the idler gears
and the housing.

The new parts are effective with the serial numbers

that are listed in Tables 2 and 3 .
Table 2
Sales Model Effective Serial Number
C175-16 B7B1000-Up

C175-16 JTL1000-Up

C175-20 LLM1000-Up

Table 3
Sales Model Engine Effective Serial
Arrangement Number

793F 250-7100 SSP00649

365-9318 SSP00672
365-9320 SSP00705
793F XQ 360-1646 SND00116

793F CMD 381-8006 RBT00123

795F AC 288-8962 ERM00240 Illustration 1 g03653737
(A) 20 degrees
365-9324 ERM00251 (1) Turbine housing clamp
797F 282-2060 LAJ00353
The alignment of the v-band clamp cannot exceed 20
262-1300 LAJ00367
degrees from the inlet port of the turbine housing. Po-
365-9326 LAJ00373 sition the clamp in order to ensure no contact be-
tween the housing and t-bolt.
797F XQ 360-1647 WSP00115

i05777518

A New Torque Specification Is

Used for the V-Band Clamp of
the Turbocharger on C175 Off-
Highway Truck Engines
SMCS Code: 1052; 7553; Publish Date: 22-Apr-2014

Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP)
793FAC (S/N: EMD)
795FAC (S/N: ERM)
797B (S/N: JSM)
Illustration 2 g03344275
797F (S/N: LAJ) (S/N: WSP)
(2) Nut

137
Use the following torque procedure in order to secure If the bellows are not installed properly, or if there is
the nut of the clamp on the turbocharger gross misalignment between the mating parts, the
bellows will fail prematurely.
Note: Lubricate threads before assembly with
4C-5599 Anti-Seize Compound or equivalent.

1. Tighten nut (2) to 20 N·m (15 lb ft).

2. Tap lightly around the clamp.

3. Tighten the nut again to 30 ± 2 N·m (22 ± 1.5 lb ft)

4. Tap lightly around the clamp again.

5. Tighten the nut again to 30 ± 2 N·m (22 ± 1.5 lb ft)

Note: Tighten the nut again after running the engine
to operating temperature. Allow the engine to cool
before tightening the nut again. The clamp is a one
time use only part. Do not retighten a loose clamp,
replace.
Table 1
Turbocharger Part Number Serial Number Prefix

327-7738 RBT, SND, SSP

Illustration 1 g02532917
343-5684 SSP
Example of premature failure due to misalignment.
362-1621 ERM, JSM, LAJ, WSP, EMD

362-1622 JSM
Note: These guidelines are recommended any time
that the exhaust system is disturbed for service and/
442-0113 JSM, ERM, LAJ, WSP, EMD or replacement purposes, regardless of machine
age.
■
NOTICE
i05034236
Do not reuse the exhaust bellows or the clamps for
the bellows. The used parts will loosen and the joint
will separate. Always install new bellows and clamps.
Proper Installation Practices
for C175 Exhaust Bellows
SMCS Code: 1061; Publish Date: 30-Aug-2012

Off-Highway Truck/Tractor.
793F (S/N: RBT1-Up) (S/N: SND) (S/N:
SSP)
793FAC (S/N: EMD2-Up)
795FAC (S/N: ERM1-Up)
797F (S/N: LAJ) (S/N: WSP)
Service Magazine, SEPD1273, 29 April 2011, “Prop-
er Installation Practices for C175 Exhaust Bellows”.
The original article was revised to add a notice pro-
hibiting reuse of the bellows and clamps.

Several exhaust bellows assemblies are used on

C175 applications. The bellows have the following
functions:

• Transfer exhaust gases

• Compensate for slight misalignment between mat-
ing parts Illustration 2 g02534196
(1) Center line between the mating surfaces.
• Allow for relative movement between the mating (2) Turbo side of the bellows
parts (3) Bellows
(4) End of the air duct

138
The alignment of the bellows is important. Two seal- 785 (S/N: 8GB408-Up)
ing surfaces that do not align with each other have 785B (S/N: 6HK1-Up)
improper lateral alignment. The proper lateral adjust- 785C (S/N: 1HW) (S/N: 5AZ) (S/N: APX)
ment is shown in illustration 2.
789 (S/N: 9ZC382-Up)
Visually check centerline (1) to determine whether 789B (S/N: 7EK1-Up)
ends (2) and (4) are properly aligned. Do not force 789C (S/N: 2BW)
the bellows into the position. Do not force end (2) or 793 (S/N: 3SJ)
end (4) into bellows (3).
793B (S/N: 1HL)
Be sure that the bellows are assembled in a relaxed 793C (S/N: 4AR) (S/N: 4GZ) (S/N: ATY)
state. 793D (S/N: FDB)
793F (S/N: RBT) (S/N: SND) (S/N: SSP)
• Alignment is key.
(S/N: SXP)
• Assemble the bellows loosely. Service Magazine, SEPD0588, 23 July 2001, “New
Optional Service Replacement Wheel Studs are Now
• Finger tighten fasteners. Available”. Disregard this article. See the article that
follows.
• No observed flexing of the bellows.
Reference: Special Instruction, SEHS9575, "Proce-
• The convolutes are parallel with each other. dure For Salvaging Off-Highway Truck Wheel Bolt/
Stud Holes"
• No dings, dents, or gouges in the bellows.
Optional service replacement studs for the wheels
• Always adjust mating components for best align- are available for the repair of the rear wheels and the
ment before the final torquing is started. front wheels.

The studs have a larger spline area. Drill the original

hole to 28.575 mm (1.125 inch) for the new studs.
The old procedure of welding the original hole, relo-
cating the hole, and redrilling the hole is not required.

Note: Use the reference that is listed above to find

the locations of the hole for each specific truck.

Table 1 shows the original stud, the original hole size,

the optional service replacement stud, and the hole
size that is needed for the replacement stud.

Note: Caterpillar does not recommend operating a

truck with any broken studs, any missing studs, or
any missing nuts.

Illustration 3 g02532841
(5) Example of the correct alignment and center line.

i05420492

New Optional Service Replace-

ment Wheel Studs are Now
Available
SMCS Code: 4201; Publish Date: 20-Aug-2013

Off-Highway Truck/Tractor.
784B (S/N: 5RK1-Up)
784C (S/N: 2PZ)

139
Table 1
Part Number of Option-
Part Number of Current Hole Size for Optional Re-
Model Current Diameter of Hole al Service Replacement
Stud placement Stud
Stud
27.051 ± 0.102 mm 28.575 ± 0.102 mm
784B (S/N: 5RK1-Up) 8X-2560 185-6134
(1.065 ± 0.004 inch) (1.125 ± 0.004 inch)

27.051 ± 0.102 mm 28.575 ± 0.102 mm

784C (S/N: 2PZ1-Up) 8X-2561 185-6135
(1.065 ± 0.004 inch) (1.125 ± 0.004 inch)

27.051 ± 0.102 mm 28.575 ± 0.102 mm

785 (S/N: 8GB408-Up) 8X-2560 185-6134
(1.065 ± 0.004 inch) (1.125 ± 0.004 inch)

785B (S/N: 6HK1-Up)

785C (S/N: 1HW1-Up; APX1- 27.051 ± 0.102 mm 28.575 ± 0.102 mm
8X-2561 185-6135
Up) (1.065 ± 0.004 inch) (1.125 ± 0.004 inch)
785C HAA (S/N: 5AZ1-Up)

789 (S/N: 9ZC382-Up)

27.051 ± 0.102 mm 28.575 ± 0.102 mm
789B (S/N: 7EK1-Up) 8X-2560 185-6134
(1.065 ± 0.004 inch) (1.125 ± 0.004 inch)
789C (S/N: 2BW1-Up)

793 (S/N: 3SJ1-Up)

793B (S/N: 1HL1-Up)
793C (S/N: 4AR1-Up; 4GZ1-Up; 27.051 ± 0.102 mm 28.575 ± 0.102 mm
8X-0274 185-6133
ATY1-Up) 793D (S/N: FDB1- (1.065 ± 0.004 inch) (1.125 ± 0.004 inch)
Up) 793F (S/N: SSP1-Up;
RBT1-Up; SND1-Up; SXP1-Up)

140
141
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©2017 Caterpillar dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may
All Rights Reserved not be used without permission.

142