793B-1HL SERIES TO 793C-4AR CONVERSION

This conversion was put together to allow a 793B O.H.T. that had 45 to
50,000 hours of operation be rebuilt and converted to a 793C OHT of 4AR
serial number vintage. The purpose of this undertaking was to,

1. Improve reliability/Availability
2. Reduce operating cost, and
3. Extend life of basic vehicle to approx. 100,000 hours.

The major obstacle in this project was mainframe fatigue of 50,000 hours on
not so good haul road conditions. It was insisted that the rear half of
mainframe be replaced and the front half be ultrasonic inspected and repaired
where required.
This program consists of a complete new hydraulic system called Simplified
Hydraulics where the old Lines gp. Transmission and Lines Gp. Torque
Converter are combined into one system, Lines Gp Power Train with Sump
located in new Torque Converter housing. The Hoist system improvements
include removing valves from inside of Hydraulic Tank for serviceability and
going from mechanical to electronic actuation.
The Brake Cooling system was improved by using larger coolers and
increasing coolant flow.
The Electronic on the vehicle were updated to be computable with V.I.M.S.
Vital Information Management System version 9.6 and Electronic Hoist
Control.
The changes were so extensive in the Electrical and Hydraulic systems it was
decided to replace all wiring harnesses and cables as well as all hose
assemblies, pump and valves.
All other major components etc. Suspension system, Steering Cylinders, Hoist
Cylinders, Brakes, Drive Shafts and all Power Train components will be
disassembled, inspected and reassembled to meet zero base criteria.
The Engine will be changed from 3516A to 3516B with 2300 gross H.P.

Page 1 of 8
 793B S/N 1HL CONVERSION TO 793C S/N 4AR
THESE GROUPS ARE COMMON B TO C

109-2893 Common Ar Truck

8X-0270 Wheel Gp Suspension & Brake (Front)
Front Suspension will be disassembled, inspected and
reassembled with new Seals and Wear Bands.
Front Brake will be disassembled and inspected,
reassembled with new components etc: Bearings,
Seals and Discs
159-0038 Wheel Gp Final Drive & Brake (Rear)
Final Drive and Brake will be disassembled, inspected
and reassembled with new components etc: Bearings,
Seals, Gears and Discs as required by inspection.
9T-8911 Cyllinder Gp Telescoping (Hoist)
This is the old 793B hoist Cylinder, it will be
disassembled and inspected and reassembled with
new Bearings, Seals and Wear Rings.
8X-0247 Rim Gp-Demount
Tire and Rim configuration are determined by Mine Site
personnel and will be updated and furnished at their
diseration.
(Not part of the update).
124-7683 Installation Ar
8X-0223 Catwalk Gp
This group will be inspected and components will be
repaired or replaced based on condition.
8X-0250 Axle Gp Mounting &1
Parts will be inspected, no replacement expected.
8X-2808 Mounting Gp Suspension
Parts will be inspected, bearing may be replaced.
8X-2809 Fastener Gp Rear Wheel
New Seals required.
8X-2812 Mounting Gp Cab
Replace Isolation Mounts Cab to Main Frame.
8X-2829 Fastener Gp Steering Arm
OK use all old components
(see note A)
8X-2835 Lines Gp Steering (Cab)2
New Seal required.
8X-2837 Walkway Gp
This group will be inspected and components will be
repaired or replaced based on condition probably new
steps.
1
Note A: Bolts in critical areas that have been assembled and disassembled for several times
should be replaced.
2
Note A: Bolts in critical areas that have been assembled and disassembled for several times
should be replaced.

Page 2 of 8
 8X-3380 Mounting Gp Cylinder (Hoist)
Replace spacers at Body Mounting
8X-4180 Latch Gp Hood
No parts required unless damaged.
8X-4453 Fastener Gp Handrail
No parts required unless damaged or missing.
8X-9330 Lighting Group (Ladder)
Replace all parts.
9Y-8888 Piping Gp Exhaust
OK use all old components.
124-8210 Lines Gp Oil Cooler
3 new Tube Assemblies and 1 new Hose As.
126-1358 Guard Gp Hydraulic Tank
No new parts required, move guards from old Tank to
new Tank.
131-3541 Lines Gp Service Brake
Order all new parts.
135-0854 Lighting Gp Signal
New Harness and new Lamp.
137-3614 Mounting Gp Rim
Change from old group 8X-2642 to new group is
removal of parts.
142-4027 Mounting Gp Platform
New Bracket As and reinforcement.
142-4044 Cleaner Gp Air
New Bracket and reinforcement.
143-0343 Fender Gp Truck
New parts required if new Radiator and Mounting is
installed.
124-7684 Cab Arrangement
It was determined that the purchase of a new Cab
Arrangement from Cat Parts Dept. which is completely
assembled and tested is the most economical way to
go based on the disassembly, purchase of all new
components, re-assembly and test on site including
labor costs.
124-7685 Chassis Arrangement
8X-0203 Horn Gp Air
No parts requires unless damaged or missing.
8X-0208 Linkage Gp Steering
Check Ball Studs for wear, replace if needed.
8X-0263 Mounting Gp Hydraulic Tank
New Isolation Mounts
(see note A)3
8X-0268 Lines Gp Heater
Replaced all heater house.
8X-2792 Tank Gp Windshield Washer
3
Note A: Bolts in critical areas that have been assembled and disassembled for several times
should be replaced.

Page 3 of 8
 This group probably requires replacement.
8X-2793 Suspension Gp Rear
Rear Struts will be disassembled, inspected and
reassembled with new Seals and Wear Bands.
124-7690 Control Gp Brake (R)(Chassis)
This group will be replaced completely.
125-1475 Dryer Gp Air
125-4975 Lines Gp Grease (Central)
This group will be replaced completely.
126-3953 Lubrication Gp Auto
This group will be replaced completely.
If CAT system is not used on truck, the initial supply
hoses will be custom made for Tank location.
8X-0202 Hood Gp Truck
Retaining the old 1HL Radiator allows use the old Hood
gp. Inspect and repair as required. If updating to new
Expansion Tank system, front Hood rework.
2A-6541 (w/old Hood) Tread Gp Safety4
127-4908 (w/new Hood)
Replace all (stick-on) anti-skid material after paint.
130-3851 Lines Gp Fuel
Install new Fuel Lines. Lines rerouted to top rear of
Steering Box.
136-1515 Cover Gp Expansion
Not required unless updating to latest cooling system.
2A-6543 Lines Gp Air Conditioner
Order all new parts.
(not applicable to Freeport)
2A-6537 Cowling Gp
No changes when using old 1HL Radiator.
Inspect for damaged and sheet metal repairs. Install
new Baffles.
8X-0204 Ladder Gp
Inspect, straighten and repair as required. No new parts
expected.
2A-6538 Frame Gp Truck
New rear half Frame will be purchased from CAT. This
will consist of everything behind Dead-Chicken Casting
without superstructure. Front half Frame will be
Ultrasonic inspected and repaired as needed.
142-4042 Wiring Gp Lighting &
This group will be replaced completely to be compatible
with updated systems and V.I.M.S. 9.6 and later
versions.
123-6993 Installation Ar Engine

9Y-8887 Piping Gp Exhaust

4
Note A: Bolts in critical areas that have been assembled and disassembled for several times
should be replaced.

Page 4 of 8
 Inspect to determine condition, Springs, Seal-Ring and
Heat Shield probable parts required.
9Y-8891 Condenser Gp Mtg &
Inspect, test and repair if needed no new parts
required.
(not on Freeport machines)
9Y-8925 Support Gp - Engine
Replace Resilient Mounts and Hardware.
123-6971 Extension Gp Drain (Oil)
Need with new B-Series Engine. Orders complete Gp.
123-6972 Sensor Gp Mtg &
New Sensor pressure and Ladder Clips.
124-8216 Lines Gp Water
B-Series Engine and new Cooler location. Order
complete group.
124-8217 Lines Gp Water (Exp. Tank)
Expansion Tank relocated from top of Air Tank on RH
Platform to top of front Hood. Order group complete.
(not used at Freeport)
127-0895 Fan Gp Suction
All components same as 1HL except V-Belt set (3516B
Engine).
133-9256 Aid Gp Ether
New Valves and new Fittings for 3516B Engine.
(not used at Freeport)
142-4046 or 9Y-8885 Radiator Gp
Radiator is same size with same cooling capacity. Minor
changes to top Tank to accommodate new Expansion
Tank. Location lower Mounting changed to facilitate
Engine removal. Inspect Radiator, disassemble, repair
and reseal.
New configuration on aftercooler side and relocation of
Brake Oil Cooler requires Hose As and Tube As
change.
(Freeport using old Radiator and Exp. Tank)
144-4142 Lines Gp Air (Chassis)
Same as old group except one new Hose As from
Compressor to Air Intake Elbow. Install new Flexible
Joints and Clamps.
152-9801 & 188-7224 Core As Brake Cooler
Old trucks had two Brake Coolers, under Main Cross
Beam. New system has one larger Cooler under Main
Cross Beam and two smaller Coolers on outside of RH
Frame Rail.
124-7691 Hydraulic Ar

Page 5 of 8
 Update vehicle reflects the latest configuration of
Hydraulics. It has split systems that has a separate
Brake Cooling system to Eliminate cross contamination.
A new Hoist Control system and modified Torque
Converter system with separate Sump which allows a
smaller main Hydraulic Tank.
5T-6942 Covers Gp Protection
OK use all old components.
6G-8390 Covers Gp Protection
OK use all old components.
7I-5076 Accumulator Gp Mtg. &
Disassemble and inspect, reseal with new Bladders.
8X-0259 Cylinder Gp Mtg. & (Steering)
Cylinder will be disassembled, inspected and
reassembled with new Seals and packing Plug any
parts than need replaced (Ballstuds).
8X-2797 Fastener Gp (Pump Drive)
OK use all old components
122-7997 Tank Gp Hydraulic
Order complete from CAT assembled and tested.
124-7693 Pump Gp Mtg. & (Steering)
Order complete. Steering Pump relocated from Drive
Gp Aux. at Rear of Engine to Pump Drive box on
inside of RH Frame Rail
124-7694 Lines Gp Steering Oil (Chassis)
Order complete to insure integrity of Steering system.
124-7696 Lines Gp Service Brake (Rear)
Order complete to insure integrity of Brake system
124-7698 Lines Gp Hoist Oil
Order complete, Hoist system redesigned with valves
located outside of Tank and system is electronically
controlled.
124-7700 Lines Gp Oil Cooler
Order complete. Coolers were removed from RH side
of Engine and moved to RH outside Frame Rail. One
cooler removed from under main Beam.
124-7704 Lines Gp Power Train
Order complete. The new redesigned simplified
Hydraulic system combined Lines Gp. Torque
Converter and Lines Gp. Transmission into one group,
Lines Gp. Power Train.
124-7720 Pump Gp Gear (Hoist)(2)
Order Complete. Old Hoist system had two pumps with
Control Valve located inside of Hydraulic Tank. New
system has one Pump and new Hydraulic Valve outside
of Tank.
125-0518 Pump Gp Gear (Brake (4)
Order complete. Pump size increased to provide 88%
increase in system flow.
125-0814 Drive Gp Pump

Page 6 of 8
 New Cage As to provide proper orientation of part
outlets. This group will be inspected and components
will be replaced based on condition.
141-5866 Pump Group Gear (4)
Order Pump and Gasket for Transmission and Torque
Converter Pump.
124-7692 Power Train Ar
5T-1033 Shaft Gp Drive (A) Pump
Order complete.
8X-0249 Shaft Gp Drive (Main)
Order completed
8X-0466 Mounting Gp Bevel Gear
New seals and shims required.
135-0472 Pump Gp Lines & (H)
D & A, inspect, reseal as needed.
(not used at fFreeport)
124-7721 Housing Gp Rear Axle
D & A, inspect, new Bearings Shims, Seals, repair or
replace worn parts.
124-8506 Converter Gp Torque
New Torque Converter Housing with integral Sump and
lager Screens. Same basic Torque Converter Group.
125-7162 Guard Gp Drive Shaft
Use old parts. Repair if required.
169-1479 Lines Gp Filter5
Order complete except Guard As is same and can be
reused.
135-0471 Gear Gp Differential and Bevel
Partial D & A, inspect, set Backlash and new Seals as
required.
124-7686 Platform Ar
2A-6547 Tread Gp Safety
Clean, inspect and replace as required.
8X-2838 Lines Gp Filter & (Steering)
Replace Filter Element, Hose As and Seals.
8X-2839 Mounting Gp Hydraulic Tank (Steering)
Replace complete, except shield.
8X-2840 Tank Gp Air
Replace complete except Reservoir and Hold Down.
8X-2846 Lubrication Gp Auto
Order complete group.
9G-9288 Covers Gp Protection
OK Use all old components.
6E-0918 Tank Gp Filter & (Steering)
D & A modify to accept V.I.M.S. sensors and reseal.
131-3210 Wiring Gp RH Platform
Order complete group (all new V.I.M.S.)
5
Note A: Bolts in critical areas that have been assembled and disassembled for several times
should be replaced.

Page 7 of 8
 8X-0264 Platform Gp RH
Modify inboard rear Platform Mounting by moving
Mounting hole forward 65mm to conform with new main
Frame Mtg. location.
9Y-8918 Tank Gp Expansion (A)
With use of old Radiator, Freeport will use old
Expansion Tanks and modify Lines Gp Water to install
properly.
(Add sight gage to Tank)
MANDATORY ATTACHMENT
105-2272 Drive Gp-Fan
Part of Engine Basic Ar.
156-6240. (Freeport Configuration)
9Y-8919 Exhaust Ar-Muffler
Piping and Muffler will be inspected and evaluated for
reuse.
137-0034 Seat Gp-(ISRI)
Being purchased as part of complete Cab from CAT.
174-6571 Seat Gp-Companion
Being purchased as part of complete Cab from CAT.
131-7956 Tank Gp-Fuel
Tank assembly will be modified to accommodate new
Fuel Level .
(parts of V.I.M.S. update)
102-1698 Starting Ar-Air
8X-6531 Control Gp-Air Start (Chassis)
Order complete group, Hose As & Valves.
8X-2858 Lines Gp-Air Start (RH Platform)
Order complete group.
9Y-0646 Starting Motor Gp-Air Turbin
Order complete group.
102-1702 Wiring Gp-Air Start (RH Platform)
Order complete group.
ATTACHMENT
143-2514 Clean-Out Gp-Cab
Being purchased as part of complete Cab from CAT.
199-4385 Visor Gp-Cab
Being purchased as part of complete Cab from CAT.
117-0447 Prelube Gp-Engine (Air Start)
Order complete group.
Hose As, Motor and Harnesses.

Page 8 of 8