BEFORE OPERATION

Operation and Maintenance

Manual Excerpt

2010 Caterpillar
All Rights Reserved

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November 2010

Operation and
Maintenance
Manual
784C and 785C Off-Highway
Truck/Tractor
1HW1-Up (Machine)
APX1-Up (Machine)
2PZ1-Up (Machine)

SAFETY.CAT.COM

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45
Operation Section
Before Operation

Operation Section

Machine Access System

Specifications

Before Operation

The machine access system has been designed to

meet the intent of the technical requirements in ISO
2867 Earth-moving Machinery Access Systems.
The access system provides for operator access to
the operator station and to conduct the maintenance
procedures described in Maintenance section.

i04027420

Mounting and Dismounting

SMCS Code: 7000

i01999151

Daily Inspection
SMCS Code: 1000; 7000
For maximum service life of the machine, make a
thorough walk-around inspection before you mount
the machine. Make a complete counterclockwise
circle of the machine.
Look around the machine and under the machine.
Inspect the condition of all major components.
Check all grease fittings. Look for the following
discrepancies:
Illustration 47

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loose bolts

Use steps and handholds whenever you mount

the machine. Use steps and handholds whenever
you dismount the machine. Before you mount the
machine, clean the step and the handholds. Inspect
the step and handholds. Make all necessary repairs.

trash buildup

Face the machine whenever you mount the machine

and whenever you dismount the machine. Maintain a
three-point contact with the step and with handholds.

cracks in the frame

Note: Three-point contact can be two feet and one

hand. Three-point contact can also be one foot and
two hands.
Do not mount a moving machine. Do not dismount a
moving machine. Never jump off the machine. Do
not try to mount the machine when you carry tools
or supplies. Do not try to dismount the machine
when you are carrying tools or supplies. Use a hand
line to pull equipment onto the platform. Do not
use any controls as handholds when you enter the
operator compartment or when you exit the operator
compartment.

oil, coolant, or fuel leaks

broken parts or worn parts

Remove any trash and any debris. Report any

abnormalities to the shop. Make any necessary
repairs before you operate the machine.
Note: If the machine has not been operated for more
than 48 hours, qualified personnel should complete a
service inspection before you operate the machine.

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Operation Section
Before Operation

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g00658921

Illustration 48
(A) Ladders and lights
(B) Warning light
(C) Ground level controls
(D) Engine
(E) Torque converter and transmission
hydraulic systems
(F) Fuel tank

(G) Hoist cylinders

(H) Tires
(I) Frame and body
(J) Suspension cylinders
(K) Rear axle hydraulic system
(L) Hoist and brake hydraulic systems
(M) Air system

(N) Steering system

(O) Automatic lubrication system
(P) Engine air filters
(Q) Rollover protective structure
(R) Cab
(S) Expansion tank

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47
Operation Section
Before Operation

(A) Inspect the ladders. Inspect the lights for broken

lamps, lenses and proper operation. Replace
broken lamps and lenses.

Illustration 51

g00663888

(5) Dipstick
Illustration 49

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(1) Warning light

(B) Inspect warning light (1).

(D) Inspect the engine. Use dipstick (5) to check the

oil level in the oil sump for the engine. Check
for oil leaks, coolant leaks, exhaust leaks, and
compressed air leaks. Check the belts of the
engine for proper tension and for good condition.
(E) Inspect the hydraulic system for the torque
converter and for the transmission. Check for
leaks from the torque converter and from the
transmission. Check worn hoses and damaged
lines. Repair any leaks, worn hoses and damaged
lines.

Illustration 50

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(2) Cover
(3) Cover
(4) Cover

(C) Inspect the ground level controls. Make sure

that cover (2) for the engine shutdown switch
and cover (3) for the battery disconnect switch
are down. Inspect cover (4) on the RS-232
connection for the VIMS.

Illustration 52

g00663889

(6) Fuel tank

(7) Truck body

(F) Inspect fuel tank (6). Make sure that the filler cap
is installed correctly. Check the level in fuel tank
(6). Check the welds and mounting brackets for
fuel tank (6). Look for any leaks or damage to
fuel tank (6).
(G) Inspect the hoist cylinders. Look for leaks,
cracking, or marks on the chrome.

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Operation Section
Before Operation

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(H) Inspect tires for cuts, gouges and proper inflation.

Remove large rocks from the treads. Look for
abnormal wear or uneven wear that may indicate
mechanical problems elsewhere. Make sure that
you check the inside of the tire for damage or
for wear. Inspect the tire treads for damage. If
necessary, repair the tires.
Look for damaged rims. Replace any missing valve
caps. Check the wheel bearing for bolts that are
loose or missing.

(K) Inspect the hydraulic system for the rear axle.

Check the level in sight gauge (9). Look for leaks
around filter (8) for the rear axle. Inspect the
lights for damage.
Note: Correct oil levels are critical in the rear axle
housing. Check the oil level prior to operation. If you
add oil, allow sufficient time for the oil to fill all of the
compartments in the final drive housing and in the
differential housing.

Note: Rust behind a bolt may indicate that the bolt is

loose. Shiny metal areas around a bolt may indicate
that the bolt is loose.
Remove any objects that are wedged between the
dual tires. Make sure that the rock ejectors swing
freely.
(I) Inspect truck body (7) and the frame. Check the
frame for cracks or damage. Inspect the dump
body for damage, wear or distortion. Check for
uneven wear of the body support pads.
(J) Inspect all of the suspension cylinders for leaks.
Repair any leaks in the suspension cylinders.
Check for the following conditions. If any of
these conditions are present, see Operation and
Maintenance Manual, Suspension Cylinder Check for further instructions.

The chrome has been wiped off and the whole

length of the chrome is used during normal
operation.

The VIMS will display the service code for

collapsed suspension cylinders.

The ride is harsh and the suspension cylinders

extend fully when the truck is empty.

Illustration 54

g00648831

(10) Upper sight gauge for the hoist, torque converter, and brake
tank
(11) Upper sight gauge for the transmission tank

(L) Inspect the hydraulic system for the hoist and

for the brakes. Check for leaks, worn hoses and
damaged lines. Repair any leaks, worn hoses
and damaged lines.
Check the level in the hoist, the torque converter
and the brake tank on upper sight gauge (10).
Check the level in the transmission tank on upper
sight gauge (11). Make sure that the filler caps are
installed. Inspect the tank covers for damaged bolts,
loose bolts or missing bolts. Tighten loose bolts and
replace missing bolts. Check the welds and mounting
brackets for the hydraulic tank. Inspect the tank for
leaks or for damage. If necessary, make repairs.
(M) Inspect the air system. Drain the moisture and
sediment from the air tanks. Check for leaks.

Illustration 53
(8) Rear axle oil filter
(9) Sight gauge

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Illustration 55

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Operation Section
Before Operation

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(12) Upper sight gauge

(N) Inspect the steering hydraulic system for leaks,

worn hoses and damaged lines. If necessary,
repair leaks, worn hoses and damaged lines.
Inspect the steering cylinders and the steering
tie rods.
Check the level in the steering hydraulic tank on
upper sight gauge (12). Inspect the tank cover for
damaged bolts, loose bolts, or missing bolts. Check
the welds for the tank. If necessary, make repairs.

Illustration 57

g00647965

Rollover Protective Structure (ROPS)

(Q) Inspect the Rollover Protective Structure (ROPS)

for cracks in welds, castings or any metal
section on the ROPS. Check mounting bolts
and mounting pads for damage. Consult your
Caterpillar dealer for necessary repairs.
(R) Inspect the cab. Check the level in the washer
fluid bottle. Check the VIMS for diagnostic codes.
Correct any discrepancies.
(S) Inspect the expansion tank and the cooling
systems for leaks, worn hoses and debris. Repair
any leaks and damaged hoses. Remove any
debris that could block the air flow through the
radiator.

Illustration 56

g00648974

(13) Level gauge

(14) Tank

(O) Inspect the automatic lubricant reservoir. Check

the level gauge (13) on the reservoir. Inspect the
tank (14) for leaks. Check all the grease fittings.
(P) Check the engine air filter service indicators.
Check the engine air precleaners for accumulated
debris. If necessary, empty the precleaners. See
this Operation and Maintenance Manual, Engine
Air Precleaner - Clean.