Armado 784 785C

785C Off-Highway Truck APX00001-UP (MACHINE) POWERED BY 3512B En...
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Product: TRUCK
Model: 785C TRUCK APX
Configuration: 785C Off-Highway Truck APX00001-UP (MACHINE)
POWERED BY 3512B Engine
Special Instruction
Assembly Procedures for 784C Tractors and 785C Off-Highway Trucks{7000, 7960}
Media Number -REHS0877-03 Publication Date -2005/06/01 Date Updated -2005/06/30
i02112968
Assembly Procedures for 784C Tractors and 785C Off-

Highway Trucks{7000, 7960}
SMCS - 7000; 7960
Tractor:
784C (S/N: 2PZ1-105)
Off-Highway Truck:
785C (S/N: APX180-450)
785C HAA (S/N: 5AZ264-399)
Introduction
This publication contains the necessary procedures for the field assembly of the 785C Off-Highway
Trucks and the 784C Tractors. This publication also contains the commissioning procedures for the
785C Off-Highway Trucks and the 784C Tractors.
Note: The photographs in this publication are for illustrative purposes. Some photographs may not
be in sequence for illustrative purposes. The differences in the machines are noted in the assembly
procedures.
The suggested tools and equipment should be present before assembly. If the recommended tools
and equipment are not present, assembly will be more difficult and more time will be necessary to
complete the assembly.
Do not perform any procedures or order any parts until this publication is read thoroughly. Do not
perform any procedures or order any parts until you understand the information in this publication.
After assembly is complete, prepare the machine for use. The Operations and Maintenance Manual
shows the preparation of the machine. Use the Parts Manual and the Service Manual with this
Special Instruction.
The 785C HAA Off-Highway Truck uses a 3516B Engine. The larger engine is for use in high
altitude applications. High altitude applications include areas of the world that are 3048 m (10,000
ft) above sea level. The horsepower of the standard 3512B Engine begins to decrease at altitudes that
are above 3048 m (10,000 ft). The 3516B Engine is able to maintain 1081 kW (1450 hp) up to an
altitude of 4877 m (16,000 ft). The front of the truck has been modified in order to accept the
Firmado digitalmente por Martin
Martin Gajardo Gonzalez
Nombre de reconocimiento (DN):
CN = Martin Gajardo Gonzalez, C =
Gajardo CL, O = Finning Sudamerica, OU =
Centro Servicios La Negra
Gonzalez Ubicación: Antofagasta
Fecha: 2006.11.06 14:57:14 -04'00'
https://sis2001.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 06/11/2006
785C Off-Highway Truck APX00001-UP (MACHINE) POWERED BY 3512B En...Página 2 de 220
additional length of the 3516B Engine. Minor modifications were made to the components that
follow: frame, hood, oil lines, fuel lines, air circuits and water circuits. Differences in assembly
procedures are noted.
Table 1
Referenced Publications
Sales Model Service Publication Media Number
Parts Manual SEPB2789
784C
Service Manual SENR1485
(S/N: 2PZ1-UP)
Operation and Maintenance Manual SEBU7173
Parts Manual SEBP3021
785C
(S/N: APX180-UP)
Parts Manual SEPB2788
785C HAA
(S/N: 5AZ264-UP)
Do not attempt to assemble this machine until you read and you
understand the assembly instructions.
Improper assembly procedures could result in injury or death.
NOTICE
Do not allow any dirt or foreign material to get into the hydraulic
system during assembly, connection of lines, when components are
filled with fluid, or during any maintenance operation.
Note: After assembly of the truck is complete, prepare the truck for use. The suspension cylinders
must be charged. The air should be purged from the brake system. This is shown in the Operations
and Maintenance Manual. Use the Parts Manual and the Service Manual with this Special
Instruction.
Note: Clean all of the mating surfaces. Deburr all of the mating surfaces. Chase all of the tapped
holes that are used for mounting purposes. Remove the paint from all contacting surfaces. This is
necessary for a good solid joint.
Parts List
Table 2
Required Parts for Installation of the 6G-9380 Rear Axle Housing or the 118-3810 Rear
Axle Housing
Qty Part Number Description
20 2H-1618 Bolt
20 5T-1352 Spacer
4 2N-2486 Bolt
Table 3
Required Parts for Installation of the 8X-9485 Front Suspension Gp or the 5T-0883 Front
Suspension Gp or the 193-6340 Front Suspension Gp
2 1U-4605 Front Suspension Gp (1)
2 6E-6070 Front Suspension Gp (2)
2 231-0342 Front Suspension Gp (3)
20 4H-6511 Bolt
20 5T-1352 Spacer
2 5T-3581 Key
20 4K-0684 Hard Washer
20 7H-7539 Full Nut
8 8F-1692 Bolt
8 5T-4896 Spacer
8 3S-6162 Hard Washer
8 8H-3390 Full Nut
16 127-7050 Shim
(1) This part is part of 5T-0883 Front Suspension Gp .
(2) This part is part of 8X-9485 Front Suspension Gp .
(3) This part is part of 193-6340 Front Suspension Gp .
Table 4
Required Parts for Installation of the 8W-4447 Transmission Oil Lines or the 170-3582
Transmission Oil Lines
1 4J-0522 O-Ring Seal

Table 5
Required Parts for Installation of the 156-7139 Service Brake Lines Gp or the 156-7140
Service Brake Lines Gp and Installation of the 154-3760 Traction Control Gp
2 6V-9746 O-Ring Seal
Table 6
Required Parts for Installation of the 8W-4442 Service Brake Lines Gp

4 5T-0967 Block
4 5T-0968 Block
8 8T-2501 Bolt
8 8T-4896 Hard Washer
1 5T-9053 Plate (LH)
1 5T-0965 Plate (RH)
2 9C-4937 Breather As
7K-1181 Cable Strap
Table 7
Required Parts for Installation of the 2A-6729 Automatic Lubrication Gp or the 164-4667
Automatic Lubrication Gp
1 178-6919 Lubrication Pump
1 5T-9441 Hose
1 6J-7929 Hose
7 4K-8864 Clip
7 5M-3062 Bolt
Table 8
Required Parts for Installation of the 163-4538 Hydraulic Oil Cooler Lines Gp or the 170-
3580 Hydraulic Oil Cooler Lines Gp or the 159-2170 Hydraulic Oil Cooler Lines Gp
2 3S-5468 Hose
8 8T-4984 Hose Clamp
2 2A-7208 Tube As (1)
2 5T-4675 Tube As (2)
4 006-8352 O-Ring Seal

1 2A-7209 Tube As (1)
1 5T-4674 Tube As (2)
4 6V-8519 Half Clamp

4 8T-8917 Bolt
4 7X-0550 Hard Washer
1 2A-7207 Tube As (1)
1 5T-4673 Tube As (2)
(1) This part is part of 163-4538 Hydraulic Oil Cooler Lines Gp . This part is used on the 784C Tractors.
(2) This part is part of 170-3580 Hydraulic Oil Cooler Lines Gp and 159-2170 Hydraulic Oil Cooler Lines Gp . This
part is used on the 785C and the 785C HAA Off-Highway Trucks.
Table 9
Required Parts for Installation of the 187-1796 Ladder Gp or the 187-1798 Ladder Gp
Item Qty Part Number Description
1 152-0543 Ladder Assembly (1)
1
1 4S-7530 Hose (3)
2
1 7D-4958 Hose (2) (4)
3 2 4V-0661 Mount
4 2 1A-5822 Bolt
5 3 7D-1649 Washer
6 2 6V-8188 Nut
7 2 2S-1654 Washer
1 5T-8269 Plate (1)
8
1 156-9192 Plate (2)
9 1 0S-1595 Bolt
10 1 187-0425 Ladder Assembly (5)
11 (6) 9D-4721 Rail

12 1 165-0192 Plate (2)
13 2 189-5526 Handhold (2)
14 1 156-8124 Pipe (2)
15 2 9P-2950 Handhold
16 8 5P-2228 Bolt
17 8 5P-1076 Hard Washer
18 2 153-1315 Handhold
19 16 8T-4896 Hard Washer
20 8 6V-8801 Nut
21 8 4L-9337 Bolt
22 4 117-1944 Plate
23 24 1D-4692 Bolt
25 24 1K-6872 Locknut
Belt As
4 114-8725 (7)
26
Belt As
4 156-9195 (8)
27 12 4V-9804 Plate
28 6 4V-9810 Step As
(1) This part is part of 187-1796 Ladder Gp .
(3) This part is part of 144-4180 Air Horn Gp .
(5) This part is part of 187-1796 Ladder Gp and part of 187-1798 Ladder Gp .
(6) Two units of this part are used in 187-1796 Ladder Gp . Only one unit of this part is used in 187-1798 Ladder Gp .

Table 10
Required Parts for Installation of the 8W-4439 Fender Gp or the 152-4633 Fender Gp or the
179-3492 Fender Gp
1 8W-4817 Fender Assembly
1 157-8059 Plate (1)
1 157-8062 Plate (1)
1 8W-6383 Guard
1 8W-6062 Deflector
1 8W-0568 Plate As (2)
1 8W-0571 Plate (2)
1 5T-4039 Brace (3)
2 0S-1595 Bolt (3)
2 8T-8917 Bolt (1)
2 5P-8245 Hard Washer (3)
2 8T-4223 Hard Washer (1)
(1) This part is part of 152-4633 Fender Gp . This part is used on 785C HAA Off-Highway Trucks.
(2) This part is part of 152-4633 Fender Gp or the 179-3492 Fender Gp .
(3) This part is part of one of the following groups: 152-0530 Catwalk , 152-3833 Catwalk , 159-3494 Catwalk and
159-3974 Catwalk .
Table 11
Required Parts for Installation of 5T-3205 Rear View Mirror Gp

1 6V-6962 Mirror
2 6V-6961 Knob
2 8D-8011 Plate
2 5P-9865 Mirror Spacer
3 2K-4973 Locknut
2 8T-2502 Bolt
2 6V-8801 Nut
1 5P-6872 Mirror
Table 12
Required Parts for Installation of 8W-1923 Rear View Mirror Gp

1 8T-2287 Mirror
Table 13

1 6V-8285 Mirror As
1 8T-2287 Mirror
Table 14
Required Parts for Installation of the 6G-9260 Steering Link

2 135-5268 Steering Arm (1)
12 2H-3758 Bolt (2)
12 4K-0684 Hard Washer (2)
(1) When the machine is shipped, this part is attached to the chassis.
(2) When the machine is shipped, this part is attached to the front suspension cylinder.
Table 15
Required Parts for Installation of the 163-7223 Cab Mounting Gp or the 163-7224 Cab
Mounting Gp
1 5T-7218 Support
22 1F-7464 Bolt
22 5P-8250 Washer
1 2A-7040 Support (1)
1 5T-7370 Support (2)
40 163-0042 Cab Mount

8 163-3127 Sleeve
6 163-0365 Sleeve
6 163-0364 Sleeve
4 5T-9893 Shim
4 5T-9894 Shim
8 6V-2624 Bolt
20 5T-5807 Retainer
6 1D-4649 Bolt
6 1K-9420 Bolt
(1) This part is part of 163-7223 Cab Mounting Gp . This part is used on the 784C Tractors.
(2) This part is part of 163-7224 Cab Mounting Gp .
Table 16
Required Parts for Installation of the 115-9184 Fuel Tank Gp or the 115-9185 Fuel Tank Gp

1 8W-3602 Mud Flap
5 4L-6454 Bolt
5 8T-2561 Washer
5 6V-8801 Nut
Table 17
Required Parts for Installation of the 2A-6726 Fuel Line or the 153-2077 Fuel Line or the
173-9469 Fuel Line
1 6V-8358 Ball Valve
2 3D-2824 O-Ring Seal
1 030-7950 Elbow
1 9L-5254 Elbow
6 4L-6454 Bolt (1)
785C Off-Highway Truck APX00001-UP (MACHINE) POWERED BY 3512B ... Página 10 de 220
1 116-2041 Guard (1)
(1) The part is attached to the fuel tank group.
Table 18
Required Parts for Installation of the 5T-3214 Truck Hood Gp or the 152-3390 Truck Hood
Gp or the 163-0931 Truck Hood Gp
1 5T-4228 Rail
Table 19
Required Parts for Installation of the 5T-3220 Platform Gp

Qty Part Numbers Description
1 7I-5397 Platform
Table 20
Required Parts for Installation of the 6I-2971 Air Lines or the 147-0834 Air Lines or the
178-2226 Air Lines
1 178-2227 Air Cleaner Gp
10 137-8292 Clamp
4 164-4867 Elbow
2 178-1168 Tube
1 178-2222 Tube
2 7C-2985 Elbow
4 133-5940 Clamp
2 178-1167 Tube
2 4P-5104 Elbow
2 119-6298 Clamp
1 2V-0146 Hose As
1 184-7686 Elbow
1 178-1166 Tube
5 6V-8801 Nut
8 5P-1075 Hard Washer
2 9X-2494 U-Bolt
1 5M-3062 Bolt
1 4W-9923 Plate
1 4L-6454 Bolt
1 4D-7388 Clip
2 7W-7417 Service Indicator
2 0A-2926 Nipple
2 3B-6552 Elbow
2 139-2480 Hose
2 5P-9085 Clip
2 8T-9371 Bolt
1 5P-2299 Flared Plug
Table 21
Required Parts for Installation of the 141-7131 Pressure Sensor and Mounting Gp or the
147-0835 Pressure Sensor and Mounting Gp
2 9X-0262 Adapter
2 161-9926 Pressure Sensor
1 4P-8134 Clip
2 130-5300 Clip
2 4L-6454 Bolt
3 6V-8801 Nut
1 133-5933 Bracket
1 3S-2093 Cable Strap
Table 22
Required Parts for the Installation of the 1W-5254 Air Cleaner Gp or the 147-0832 Air
Cleaner Gp or the 178-2227 Air Cleaner Gp
2 7W-7417 Service Indicator
2 0A-2926 Nipple
2 160-9808 Block
2 3B-6552 Elbow
1 156-6271 Air Cleaner
1 156-6272 Air Cleaner
38 7X-0343 Bolt
38 8T-4122 Washer
4 156-6273 Bracket
2 9B-7237 Bolt
2 156-6274 Bracket
2 163-1802 Clip
2 139-2480 Hose
2 8B-4884 Elbow
2 7W-0629 Filter Adapter
2 5T-6459 Elbow (1)
4 141-7148 Clamp (1)
(1) This part is from the air lines group.
Table 23
Required Parts for Installation of the 156-9341 Steering Tank and Filter Gp
1 155-4127 Steering Tank and Filter Gp
1 1U-8331 Steering Tank Conversion Group
Table 24
Required Parts for Installation of the 151-8727 Steering Lines Gp or the 176-6393 Steering
Lines Gp

2 5K-9090 O-Ring Seal
1 151-8726 Tube
1 151-8724 Tube
1 151-8725 Tube
1 151-8723 Tube
1 2G-8874 Clamp
1 2G-8875 Clamp
2 0S-0509 Bolt
2 5M-2894 Hard Washer
1 150-9037 Bar
2 5K-9090 O-Ring Seal
1 2G-8895 Bracket
4 0L-1351 Bolt
1 6G-8532 Guard
Table 25
Required Parts for Installation of the 174-0912 Service Brake Control Gp or the 170-3641
Service Brake Control Gp
2 188-0750 Hose (1)
1 8W-4372 Hose
1 6D-7953 Hose
(1) The 785C HAA Off-Highway Truck only requires one hose.
Table 26
Required Parts for the Installation of the 172-0214 Exhaust Pipe Gp

2 2W-9766 Seal Ring
2 4W-0221 Pipe
2 2W-8851 Seal Ring
1 4W-0225 Elbow
1 2W-9067 Sleeve
1 4W-0223 Elbow
4 5S-7382 Bolt
Table 27

4 2W-8851 Seal Ring
1 2W-9078 Pipe
1 153-7472 Elbow
1 153-7471 Elbow
1 2W-9067 Sleeve
1 4W-0223 Elbow
4 5S-7382 Bolt
Table 28

2 6G-7031 Elbow
16 7K-1270 Washer
8 0S-1589 Bolt
4 1D-5117 Jam Nut
4 4B-3586 Setscrew
5T-8038 Tube As
8 0S-1566 Bolt
1 8X-0480 Plate
1 8X-0484 Plate
8 2D-5238 Taperlock Stud
2 6G-7038 Seal Ring
2 5T-3369 Piston
2 5T-2762 Spring
2 5T-3367 Elbow
6 9D-2836 Lock
12 0L-1351 Bolt
8 7X-0448 Nut
Table 29
Required Parts for the Installation of the 174-9332 Muffler Gp

2 5T-6927 Bracket
16 5S-7379 Bolt
4 5T-6928 Strap
1 5T-7938 Tube As
2 4N-9330 Clamp
3 5P-2424 Bolt
7 1K-6872 Locknut
1 2W-3773 Muffler Assembly
8 5S-7383 Bolt
8 2K-4973 Locknut
1 5T-6978 Plate
1 8W-4382 Extension Pipe
1 2W-6737 Muffler Assembly
2 5T-4278 Strap
1 1W-1305 Clamp
1 8W-4381 Extension Pipe
Table 30
Required Parts for the Installation of the 5T-3218 Heater Lines Gp or the 152-4637 Heater
Lines Gp
2 6P-8855 Spacer
10 9X-2488 Hose Clamp
9 6D-1641 Clip
1 0T-0102 Bolt
Table 31
Required Parts for Installation of the 170-3601 Chassis Wiring and Lighting Gp or the 186-
6583 Battery and Wiring Gp
2 115-2422 Battery
2 9D-6635 Battery Hold-Down Assembly
1 5K-3294 Clip
1 9M-4995 Clip
1 5S-7379 Bolt
1 117-5883 Cable
Table 32
Required Parts for the Installation of the 6G-9270 Front Wheel Group or the 8X-9487 Front
Wheel Group

2 5T-9790 Tire Valve Gp (1)
2 6G-1546 O-Ring Seal (1)
2 8W-0331 Swivel Connector (1)
6 8W-3891 Flange Nut

84 5P-8250 Washer
84 2J-3507 Full Nut
(1) The tire valve group is a part of the 230-0098 Demountable Rim Gp or the 232-1332 Demountable Rim Gp .
Table 33
Required Parts for the Installation of the 140-7626 Rear Wheel and the 230-0098
Demountable Rim Gp
12 8W-3891 Flange Nut
168 5P-8250 Washer
168 2J-3507 Full Nut
8 6J-0427 Spacer
2 8X-2627 Bracket
8 1D-4566 Bolt
Table 34
Required Parts for Installation of the 154-3756 Body Mounting Gp

2 5T-5984 Plate
1 5T-5986 Mud Flap
2 6G-9705 Strip
53 0S-1588 Bolt
48 6V-8801 Nut
10 0L-1351 Bolt
1 5T-5987 Mud Flap

2 5T-5985 Plate
1 5T-5989 Mud Flap
2 6G-9704 Strip
1 5T-5988 Mud Flap
1 105-4727 Mud Flap
1 8X-5421 Plate
2 8W-8679 Pin
2 6G-9697 Washer
1 8W-2896 Washer
2 8W-8677 Plate
4 0S-1585 Bolt
Table 35
Required Parts for the Installation of the Shims for the Body
2 8W-4348 Shoe
18 6G-9711 Shim
6 5T-3750 Plate
8 6G-9547 Pad
24 7D-1649 Hard Washer
6 1A-1460 Bolt
18 9S-1366 Bolt
18 1D-4719 Full Nut
Table 36
Required Parts for the Installation of the Rock Ejectors

2 112-6212 Ejector
2 6G-7773 Pin
4 3B-4647 Cotter Pin
1 112-6180 Plate Assembly
1 112-6181 Plate Assembly
Table 37
Required Parts for the Installation of the 6G-9560 Hoist Cylinder and Mounting Gp
2 6G-9692 Pin
4 6G-9696 Spacer
2 6G-9691 Bar
4 0S-1585 Bolt
Table 38
Required Parts for the Installation of the 144-4146 Truck Body Retaining Cable Gp
1 159-2512 Cable
1 105-0314 Coupler
2 1D-4643 Bolt
2 5P-8250 Washer
2 2H-3794 Locknut
1 8W-0109 Plate
1 2B-0974 Clevis Pin
1 3B-4617 Cotter
Table 39
Required Parts for Installation of the 3T-4411 Flood Lamp Gp

1 3T-4411 Flood Lamp Gp
Table 40
Required Parts for Installation of the 5T-4463 Hydraulic Tank Mounting

16 4L-6454 Bolt
14 6V-8801 Nut
16 8T-2561 Washer
2 8T-9101 Bolt
2 105-2200 Mud Flap
1 105-2201 Mud Flap
1 105-2204 Support
1 105-2205 Support
1 105-4620 Support
Table 41
Required Parts for the Installation of the 154-9041 Film Gp or the 162-2755 Film Gp
1 100-5615 Film
3 131-5415 Film
1 100-8733 Film (1)
1 100-8728 Film (1)
1 154-9042 Film (1)
1 162-2756 Film (2)
1 154-9043 Film
1 100-8726 Film (LH)
1 100-8727 Film (RH)
1 154-9045 Film (LH)
1 154-9044 Film (RH)
(1) Only used on the 784C Tractors and the 785C Off-Highway Trucks
(2) Only used on the 785C HAA Off-Highway Trucks
Machine Specifications
Table 42
Item Specifications
Empty weight
103,375 kg (227,900 lb)
Wheel base
5.2 m (17.0 ft)
Length
11.02 m (36.2 ft)
Ground to top of canopy

5.94 m (19.5 ft)
Ground to upper edge of body

5.56 m (18.25 ft)
Turning radius
30.2 m (99.2 ft)
Width of body assembly

6.78 m (22.25 ft)
Approximate Weights
Personal injury or death can result from lifting a heavy assembly.
The heavy assembly can fall if using an incorrect hoist to lift the load.
Be sure the hoist has the correct capacity to lift a heavy assembly.
Approximate weight of the assembly is given below.
Personal injury or death can result from improper lifting or blocking.
When a hoist or jack is used to lift any part or component, stand clear
of the area. Be sure the hoist or jack has the correct capacity to lift a
component. Install blocks or stands before performance of any work
under a heavy component.
Approximate weights of the components are shown. Clean all surfaces

where parts are to be installed.
Table 43
Module Weight
Truck frame module

30670 kg (67620 lb)
Rear axle housing with final drives

16601 kg (36600 lb)
Front suspension cylinder, wheel and brake assembly

3578 kg (7890 lb)
Tire and Rim

3332 kg (7345 lb)
Hoist cylinder
835 kg (1840 lb)
Body pivot pin

39 kg (86 lb)
Fuel tank
681 kg (1500 lb)
Right side platform assembly

380 kg (840 lb)
Dual slope body, side boards, tail extension, and partial liner
24,790 kg (54,650 lb)
Flat Floor Body with partial liner

25,790 kg (56,860 lb)
Body Side
6,530 kg (14,400 lb)
Front Cab Support

173 kg (380 lb)
Rear Cab Support

225 kg (495 lb)
Ejector Assembly
115 kg (255 lb)
Cab
1814 kg (4000 lb)
Necessary Hoist Capacity

In order to remove the truck frame from the trailer, one hoist with a minimum capacity of 54430 kg
(120000 lb) is needed. As an alternative, you can use two hoists in order to remove the truck frame
from the trailer. Each hoist should have a minimum capacity of 27240 kg (60050 lb).
Specifications for Cables, Chains, and Lifting Devices
Use approved cables, chains, and lifting devices in order to lift components. Refer to the
manufacturer's literature in order to determine the application when you select the items that follow:
cable, chain and lifting devices. When you lift a component, the lift angle is critical. Refer to the
Illustration that follows in order to see the effect of the lift angle on the working load limit.
Illustration 1 g00629745
Lift angles for lifting slings.
(A) The load capacity is 100 percent of the working load limit for the sling.
(B) The load capacity is 86 percent of the working load limit for the sling.
(C) The load capacity is 70 percent of the working load limit for the sling.
(D) The load capacity is 50 percent of the working load limit for the sling.
Necessary Equipment and Supplies for Assembly

The following supplies and equipment are used for the assembly:
z Obtain six barrels of TDTO or TO-4 oil for the systems that follow: the hoist, the torque
converter and the brakes. Each barrel should have a capacity of 208 L (55 US gal). SAE
viscosity grade 10 is recommended. Refer to the Operation and Maintenance Manual for more
details.
z Obtain two barrels of TDTO for the transmission and for the drive train. Each barrel should
have a capacity of 208 L (55 US gal). Ambient temperatures that are extreme may require a
different oil viscosity. Refer to Service Manual, SEBU6250, "Caterpillar Machine Lubricant
Recommendations". Refer to the Operation and Maintenance Manual for more details.
z Obtain one barrel of TDTO or TO-4 oil for the steering system. The barrel should have a
capacity of 208 L (55 US gal). Refer to the Operation and Maintenance Manual for more
details.
z Cables, straps, and chains that have adequate load limits
z Various shackles that should have a working load limit of 27240 kg (60053 lb)
z Obtain steel rod that is 88.9 mm (3.50 inches) in diameter. The steel rod should be at least
4191 mm (165.0 inches) long.
z Obtain one portable air compressor. The air compressor should have enough capacity in order
to operate two 25.4 mm (1 inch) impact air guns. The air compressor should have a minimum
capacity of 3 CM (100 CFM).
z Obtain 24 hardwood blocks that are 203 mm (8.0 inches) tall. The blocks should be 203 mm
(8.0 inches) wide. The blocks should be 914 mm (36.0 inches) long.
z Obtain two stepladders that are 1.8 m (6 ft) tall.
z Obtain two stepladders that are 3.6 m (12 ft) tall.
z Obtain 94 m (308 ft) of rope that is 19 mm (0.75 inch) in diameter. When you install the body
on the chassis, use the rope in order to guide the body into position.
z Obtain 20 nitrogen bottles that are T-size. The nitrogen is used to inflate the tires. The nitrogen
is used to charge the suspension cylinders.
z Obtain one lift truck that can lift 6810 kg (15000 lb).
z Four 7X-1062 Ether Cylinders
z Paint spray gun
z Obtain two 1U-9204 Lever Pullers .
z Obtain three 138-7573 Link Brackets , three 138-7575 Link Brackets , and three 138-7574
Link Brackets .
z Four metal stands. The metal stands support the truck body before the truck body is installed
to the truck frame.
z Obtain 4C-4188 Paint Remover . The 4C-4188 Paint Remover is used to clean the parts on the
truck.
z 5P-0960 Molybdenum Grease
z Obtain 9S-3263 Thread Lock Compound . The 9S-3263 Thread Lock Compound is used on
the bolts that secure the platform.
z Obtain 1U-6396 O-Ring Assembly Compound .
z 5P-3413 Pipe Sealant
Required Tools
The following tools are required for the assembly:
z Use a 6V-6080 Torque Multiplier Gp in order to tighten the components that follow: the bolts
for the front suspension cylinder, steering arm mounting nuts, ballstud nuts and wheel rim
mounting nuts.
z Use a 6V-7820 Torque Multiplier Gp in order to tighten the rear axle housing nuts.
z Use a 8T-9293 Torque Wrench with the torque multipliers.
z Use a 162-8718 Torque Wrench to torque the ROPS cab mounting bolts.
z Use a 9U-6566 Socket (47.62 mm (1.875 inch)) to tighten the bolts that secure the components
that follow: the ROPS, the upper front suspension and the steering arm .
z Use a 9U-6560 Socket (38.1 mm (1.50 inch)) to tighten the ROPS cab mount bolts, and the
front suspension cylinder cap mounting bolts.
z Use a 9U-6548 Socket (19.05 mm (.750 inch)) to tighten the bolts that secure the right side
platform.
z Use a 0V-0455 Open End Wrench (47.62 mm (1.875 inch)) to tighten the upper bolts that
secure the front suspension cylinders.
z Use a 132-8232 Power Pack and a 132-8119 Hydraulic Torque Wrench with a capacity of
4200 N·m (3100 lb ft) in order to tighten the lower bolts that secure the front suspension
cylinders.
z Use a 8F-2239 Open End Wrench (50.8 mm (2.28 inch)) to tighten the lower bolts that secure
the front suspension cylinders .
z Use a air regulated 8T-5230 Torque Wrench Gp with a capacity of 300 N·m (220 lb ft).
z Use a 8T-5183 Drive Extension with the 8T-5230 Torque Wrench Gp .
z Use a 8T-5182 Socket (38.1 mm (1.50 inch)) to install the rim nuts.
z Have a 5S-6076 Extension .
z Have a 2P-8261 Adapter .
z Have a 6V-3146 Extension .
z Have a 6V-4170 Adapter .
z Use a 175-5507 Nitrogen Charging Group for the front suspension cylinders.
z Use a FT-1975 Gauge Block for charging the front suspension cylinders.
z Use a 9U-5617 Oil Refill Pump for charging the suspension cylinders with oil.
z Use a 6V-4040 Inflation Group to inflate the tires.
z Remove the head from the 8T-6624 Bolts in order to make two 30 mm (1.20 inch) metric
guide pins.
z 1 1/4 X 7 thread tap
z 1 X 14 thread tap
z 1 x 8 thread tap
z 3/4 x 10 thread tap
z Use a pair of 6V-0006 Pliers to install the connector for the Traction Control System.
z Apply 4C-5593 Anti-Seize Compound to threads.
z Apply 4C-5599 Anti-Seize Compound to threads.
Torque Specifications
z Tighten the rear axle housing bolts to a torque of 1800 ± 200 N·m (1325 ± 150 lb ft).
z Tighten the 44 bolts that secure the rear wheel mounting ring to a torque of 1150 ± 150 N·m
(850 ± 110 lb ft).
z Tighten the 90 bolts that mount the front wheel rim to a torque of 1150 ± 150 N·m (850 ± 110
lb ft).
z Tighten the 210 nuts that mount the rear wheel rim to a torque of 1150 ± 150 N·m (850 ± 110
lb ft).
z Tighten the upper 20 bolts and nuts that mount the front suspension cylinder to a torque of
1825 ± 175 N·m (1350 ± 130 lb ft).
z Tighten the lower eight bolts and eight nuts that mount the front suspension cylinder to a
torque of 2700 ± 275 N·m (1990 ± 200 lb ft).
z Tighten the eight bolts that secure the bearing cap on the front suspension cylinder to a torque
of 875 ± 100 N·m (645 ± 75 lb ft).
z Tighten the 12 bolts that mount the front steering arm to a torque of 1800 ± 200 N·m (1330 ±
150 lb ft).
z Tighten the 20 cab mounting bolts to a torque of 1904 ± 68 N·m (14052 ± 50 lb ft).
z Tighten the 22 cab support mounting bolts to a torque of 900 ± 100 N·m (665 ± 75 lb ft).
z Tighten the eight fuel tank bolts to a torque of 460 ± 60 N·m (339 ± 44 lb ft).
z Tighten the four fuel tank caps to a torque of 800 ± 100 N·m (590 ± 74 lb ft).
z Tighten the bolts for the right side platform assembly to a torque of 370 ± 50 N·m (270 ± 35 lb
ft).
Assembly Tips
Note: Follow the table of contents for the assembly sequence of the truck.
The assembly of the truck requires four mechanics for a total of 150 hours. Two crane operators are
required for a total of 24 hours until the major components are installed.
Before you unload the chassis and related components, read the information that follows in order to
make the job easier.
z In order to assemble the machine, select an area that is smooth and flat. The area should be 25
m (80 ft) wide and 30 m (100 ft) long. The area should drain well. Place the chassis in the
center of the area.
z When you unload components, place the components near the chassis. however, keep an area
around the chassis clear in order to position the cranes for lifting the components.
z Open all the boxes and inspect the contents.
z Organize components and hardware in order to help reduce lost hardware and speed assembly.
z Do not open plastic bags of hardware. The plastic bags are marked with yellow labels that are
printed with the group part number. Individual components are marked with yellow labels that
are printed with the component part number and the group part number. Move each plastic bag
of hardware to the chassis when the corresponding component is installed.
When you remove the chassis from the tractor-trailer, place wooden supports under the chassis.
Place wooden supports at the front of the chassis and place wooden supports at the rear of the
chassis.
Note: Use hardwood blocks that are 203 mm (8.0 inches) high and 914.4 mm (36 inches) long. Stack
the hardwood blocks in pairs until the height of the hardwood blocks is 607 mm (24.0 inches).
Illustration 2 g
Chassis and component layout for assembly of the 785C Off-Highway Truck
View of the chassis on a trailer
View of the chassis on a trailer
View of the components on a trailer
View of the components on a trailer
View of the lifting bar
View of proper blocking
View of the rear axle on a trailer
View of the air cleaners, the hood rail, the RH platform, the steering hydraulic tank, and a box of parts
View of the fuel tank
View of the cab
Install the 6G-9380 Rear Axle Housing or the 118-3810 Rear
Axle Housing
Table 44
Required Parts for Installation of the 6G-9380 Rear Axle Housing or the 118-3810 Rear
Axle Housing
1 20 2H-1618 Bolt
2 20 5T-1352 Spacer
3 4 2N-2486 Bolt
1. Place the axle and transmission assembly near the truck frame. Block up the transmission.
View of the shipping brackets on the chassis
2. Remove the shipping brackets from the rear struts.
3. Remove the paint and clean the mounting areas on the A-frame.
View of the mounting surface on the axle housing
4. Remove the paint and clean the mounting area on the axle housing.
View of the mounting area on the drive shaft slip joint
5. Remove the paint and clean the mounting area on the drive shaft slip joint at the transmission.
View of the lower mounting bracket for the rear suspension cylinder
6. Remove the guard over the pin in the lower right suspension cylinder. Retain the guard and the
existing mounting hardware.
View of the lower bracket for mounting the rear suspension cylinder
7. Remove the two existing plates and the existing hardware.
8. Remove the paint from each of the two pins.
View of the axle and transmission assembly
9. Remove the two existing pins.
View of the guard for the drive shaft slip joint
10. Remove the existing hardware in order to remove the guard for the drive shaft slip joint.
Retain the guard and the existing hardware for the drive shaft slip joint.
11. Remove the paint and clean the mounting area on the drive shaft slip joint.
12. Align the 8X-0473 Drive Shaft Slip Joint to the torque converter. Install four 2N-2486 Bolts .
Note: Tighten the bolts to a torque of 550 ± 20 N·m (406 ± 15 lb ft).
Note: Secure the 8X-0473 Drive Shaft Slip Joint with a prybar during the torque sequence.
View of mounting bracket for the lateral control rod
13. Remove the existing hardware and the existing washer. Retain the washer and the hardware.
14. Slide the existing pin out of the bore, as shown.
15. Align the rear axle group with the frame assembly.
16. Lift the rear axle group into position at the truck frame.
(1) 2H-1618 Bolt
(2) 5T-1352 Spacer
17. Use 20 2H-1618 Bolts (1) and 20 5T-1352 Spacers (2) in order to secure the rear axle housing
to the a-frame assembly. Tighten the bolts with an air wrench. The bolts will be tightened to
the final torque later.
18. Align the rear suspension cylinders with the axle housing.
19. Slide the previously removed pins into position. Use the previously existing hardware in order
to secure the two pins into position.
(1) 2H-1618 Bolt
(2) 5T-1352 Spacer
20. Tighten the 20 2H-1618 Bolts (1) that secure the axle housing to the A-frame to a torque of
1800 ± 200 N·m (1325 ± 150 lb ft).
Note: Prior to the installation, apply 4C-5591 Anti-Seize Compound to the pin.
21. Lift the lateral control rod into position. Slide the existing pin into position. Secure the pin
with the previously removed plate and the previously removed hardware.
View of the drive shaft slip joint
22. Align the drive shaft slip joint to the transmission. Use the existing hardware in order to
connect the drive shaft slip joint to the transmission. Tighten the bolts to a torque of 550 ± 20
N·m (405 ± 15 lb ft).
View of the guard for the drive shaft slip joint
23. Use the previously removed hardware in order to install the guard for the drive shaft slip joint
that was previously removed.
Install the 5T-0883 Front Suspension Gp or the 8X-9485 Front

Suspension Gp or install the 193-6340 Front Suspension Gp
Table 45
Required Parts for Installation of the 5T-0883 Front Suspension Gp or the 8X-9485 Front
Suspension Gp or the 193-6340 Front Suspension Gp
2 1U-4605 Front Suspension Gp (1)
1 2 6E-6070 Front Suspension Gp (2)
2 231-0342 Front Suspension Gp (3)
2 20 4H-6511 Bolt
3 20 5T-1352 Spacer
4 2 5T-3581 Key
5 20 4K-0684 Hard Washer
6 20 7H-7539 Full Nut
7 8 8F-1692 Bolt
8 8 5T-4896 Spacer
9 8 3S-6162 Hard Washer
10 8 8H-3390 Full Nut
11 16 127-7050 Shim
(1) This part is part of 5T-0883 Front Suspension Gp .

(2) This part is part of 8X-9485 Front Suspension Gp .
(3) This part is part of 193-6340 Front Suspension Gp .
Note: The hardware that is needed to install the front suspension cylinder is located on the same
shipping pallet as the front suspension cylinder.
View of the front suspension gp
1. Remove the six existing bolts, washers, and spacers from the mounting surface for the steering
arm.
(1) Front Suspension Gp
(A) Nut
2. Remove nuts (A) that secure Front Suspension Gp (1) to the shipping pallet.
3. Clean the shipping grease and the paint from the bearing mounting at the top of the suspension
cylinder.
4. Clean the shipping grease and the paint from the surfaces for mounting the tire rim.
View of the front suspension gp
5. Clean the shipping grease and the paint from the mounting surface at the back of the
suspension cylinder. Clean the bolt holes. Make sure that the spot faces are clean. A clean
surface ensures proper torque values.
View of the bearing cap
6. Remove the existing bearing caps. Retain the existing bearing caps and existing hardware.
(B) Shipping bracket
7. Support the steering arms. Remove the shipping bracket (B) from the mounting flange for the
front suspension cylinder.
8. Clean the shipping grease and the paint from the mounting flanges for the front suspension
cylinders. Clean the grease and paint from the spot faces on the back of the mounting flanges.
Deburr any sharp edges.
(2) 4H-6511 Bolt
(3) 5T-1352 Spacer
9. Insert ten 4H-6511 Bolts (2) through ten 5T-1352 Spacers (3). Insert the bolts and the spacers
through the upper bolt holes in the mounting flanges for the suspension cylinders.
(4) 5T-3581 Key
10. Insert a clean 5T-3581 Key (4) into the keyway of each the mounting flange for the suspension
cylinder. Align the bolt holes.
11. Install the previously removed bearing cap on the end of the Front Suspension Gp (1).
Note: The lockring on the bearing cap should face downward. Place the fitting for the grease
line toward the rear of the machine.
Note: A 148-0357 Strut Lifting Gp can be used to install the Front Suspension Gp.
12. Position one Front Suspension Gp (1) at the mounting flange on each side of the machine.
Note: The ports for the brake oil cooler lines should face to the rear of the machine.
(2) 4H-6511 Bolt
(3) 5T-1352 Spacer
(5) 4K-0684 Hard Washer
(6) 7H-7539 Full Nut
(7) 8F-1692 Bolt
(8) 5T-4896 Spacer
(9) 3S-6162 Hard Washer
(10) 8H-3390 Full Nut
13. Push ten 4H-6511 Bolts (2) through the upper bolt holes in the suspension cylinder. Secure the
suspension cylinder with ten 4K-0684 Hard Washers (5) and ten 7H-7539 Full Nuts (6) on the
upper bolts. Use an air wrench to tighten the bolts and the nuts.
Note: The nuts will be tightened to a final torque later. The nuts should be facing outward
from the machine.
14. Insert four 8F-1692 Bolts (7) through four 5T-4896 Spacers (8) and then insert the bolts
through the four lower bolt holes. Push the bolts through the bolt holes in the suspension
cylinder.
15. Secure the four lower bolts with four 3S-6162 Hard Washers (9) and four 8H-3390 Full Nuts
(10). Use an air wrench to tighten the bolts and the nuts.
Note: The nuts will be tightened to a final torque later. The nuts should be facing outward
from the machine.
16. Tighten ten 7H-7539 Full Nuts (6) to a final torque of 1825 ± 175 N·m (1350 ± 130 lb ft).
17. Tighten four 8H-3390 Full Nuts (10) to a final torque of 2700 ± 275 N·m (2000 ± 200 lb ft).
(11) 127-7050 Shim
18. Install 127-7050 Shims (11) behind the bearing cap at the top of each suspension cylinder. Use
enough shims to eliminate any gap.
View of the bearing cap at the suspension cylinder
19. Use the previously removed hardware in order to install the bearing cap to the frame assembly
at each suspension cylinder.
20. Repeat Steps 1 through 19 for the suspension cylinder on the other side of the machine.
Install the 8W-4447 Transmission Oil Lines or the 170-3582

Table 46
Required Parts for Installation of the 8W-4447 Transmission Oil Lines or the 170-3582
1 1 4J-0522 O-Ring Seal
1. Remove the covers from the ports at the transmission. Remove the caps from the hoses.
View of the transmission
(1) 4J-0522 O-Ring Seal
2. Install one 4J-0522 O-Ring Seal (1) into the existing 8W-4958 Hose .
3. Use the existing hardware in order to connect the existing 8W-4958 Hose to the transmission
lube port.
5. Use the existing hardware in order to connect the existing 8W-4965 Hose to the port of the
transmission for the transmission charge pump.
7. Use the existing hardware in order to connect the existing 8W-4966 Hose to the port of the
transmission for the transmission cooler.
8. Install one 4J-0527 O-Ring Seal (3) to the existing 164-2488 Hose .
9. Use the existing hardware in order to connect the existing 164-2488 Hose to the port of the
transmission for the transmission scavenge pump.
10. Connect the existing 4D-4791 Hose to the transmission.
Note: The opposite end of the existing 4D-4791 Hose attaches at the hydraulic tank.
11. Connect the existing 8W-5061 Hose to the port at the transmission control.
Note: The opposite end of the existing 8W-5061 Hose attaches at the torque converter lockup
clutch valve.
12. Connect the existing 8W-3187 Hose to the port that is above the port for the transmission
lubrication.
Note: The opposite end of the existing 8W-3187 Hose attaches at the torque converter lockup
clutch and synchronizing valve.
Install the 156-7139 Service Brake Lines Gp or the 156-7140

Service Brake Lines Gp and Install the 154-3760 Traction
Control Gp
Table 47
Required Parts for Installation of the 156-7139 Service Brake Lines Gp or the 156-7140
Service Brake Lines Gp and Installation of the 154-3760 Traction Control Gp
1 2 6V-9746 O-Ring Seal
View of the air/hydraulic cylinder
1. Attach the existing 8W-3191 Hose Assembly to the air/hydraulic cylinder, as shown.
View of the TCS valve
(1) 6V-9746 O-Ring Seal
2. Remove the two caps that cover the hose connections at the TCS valve.
3. Install one 6V-9746 O-Ring Seal (1) into the end of the existing 8W-5160 Hose Assembly .
Connect the existing hose to the port at the right side of the TCS valve, as shown.
View of the TCS valve
4. Install one 6V-9746 O-Ring Seal (1) into the end of the existing 8W-5159 Hose Assembly .
Connect the existing hose to the port at the left side of the TCS valve, as shown.
View of the front of the A-frame
5. Use the existing hardware to secure the existing 8W-3191 Hose Assembly at the front of the
A-frame.
View of the A-frame
6. Use the existing hardware to secure the existing 8W-5159 Hose Assembly to the A-frame.
View of the A-frame
7. Use the existing hardware to secure the existing 8W-5160 Hose Assembly and the existing
8W-3191 Hose Assembly to the A-frame.
Install the 8W-4442 Service Brake Lines Gp

Table 48
Required Parts for Installation of the 8W-4442 Service Brake Lines Gp

1 4 5T-0967 Block
2 4 5T-0968 Block
3 8 8T-2501 Bolt
5 1 5T-9053 Plate (LH)
6 1 5T-0965 Plate (RH)
7 2 9C-4937 Breather As
8 7K-1181 Cable Strap
Note: Before you operate the machine, purge all air from the brake lines after the brake lines
are installed.
View of the ports for the brake cooling lines
1. At each side of the machine, slide the existing hose through the hole in the bracket behind the
ports for the brake cooling lines. Attach the service brake line to the service brake port.
View of the ports for rear brake cooling
(1) 5T-0967 Block
(2) 5T-0968 Block
(3) 8T-2501 Bolt
(4) 8T-4896 Hard Washer
2. Use a 5T-0967 Block (1), a 5T-0968 Block (2), two 8T-2501 Bolts (3), and two 8T-4896 Hard
Washers (4) to secure the service brake line to the bracket at each side of the machine.
View of the ports for rear brake cooling
(1) 5T-0967 Block
(2) 5T-0968 Block
(3) 8T-2501 Bolt
(5) 5T-9053 Plate
3. At each side of the machine, remove the existing bolt and the washer from either side of the
brake purging screw above the parking brake port. Use the bolts and washers to secure a 5T-
9053 Plate (5) to each brake anchor on the left side of the machine.
Note: Use 5T-0965 Plate (6) on the right side of the machine.
4. Attach the existing 8W-5189 Hose to the parking brake port on the right side. Attach the
existing 8W-5188 Hose to the parking brake port on the left side.
5. Use one 5T-0967 Block (1), one 5T-0968 Block (2), two 8T-2501 Bolts (3), and two 8T-4896
Hard Washers (4) to secure the two existing parking brake lines to 5T-9053 Plate (5) on the
left side of the machine.
6. Use one 5T-0967 Block (1), one 5T-0968 Block (2), two 8T-2501 Bolts (3), and two 8T-4896
Hard Washers (4) to secure the two existing parking brake lines to the 5T-0965 Plate (6) on
the right side of the machine.
View of ports at the rear of the front strut
(7) 9C-4937 Breather Assembly
(8) 7K-1181 Cable Strap
7. Use the existing hardware in order to install 9C-4937 Breather Assembly (7). Install 9C-4937
Breather Assembly (7) to the mounting area that is located at the rear of the front strut.
8. Repeat Step 7 for the right side of the machine.
9. Attach one end of the existing 4D-6885 Hose to the port in the spindle on the right side. Attach
the other end of the existing 4D-6885 Hose to the 9C-4937 Breather Assembly (7). As needed,
secure the 4D-6885 Hose with 7K-1181 Cable Straps (8) .
10. Attach one end of the existing 9D-0771 Hose to the port in the spindle on the left side. Attach
the other end of the existing 4D-6885 Hose to the 9C-4937 Breather Assembly (7). As needed,
secure the 4D-6885 Hose with 7K-1181 Cable Straps (8) .
Install the 2A-6729 Automatic Lubrication Gp or 164-4667

Connect the Lubrication Lines at the Rear Axle
View of automatic lubrication solenoid valves
1. Use the existing hardware in order to install the existing automatic lubrication solenoid valves.
View of the lower eye of the rear suspension cylinder
2. Connect the existing 5N-5646 Hose to the lower cylinder eye of each rear suspension cylinder.
Note: For the 784C Tractors, connect the existing 5T-5760 Hose to the lower cylinder eye of
the rear suspension cylinder on the left side. Connect the existing 5T-4374 Hose to the lower
cylinder eye of the rear suspension cylinder on the right side.
View of mounting bracket for the rear suspension cylinder
3. Connect the existing 5T-4374 Hose to the lower pin for the left rear suspension cylinder.
Connect the existing 5N-5646 Hose to the lower pin for the right rear suspension cylinder.
Note: For the 784C Tractors, connect the existing 5N-5646 Hose to each lower pin for the rear
suspension cylinders.
View of the lateral control rod
4. Connect the existing 5T-4375 Hose to the lateral control rod at the frame.
View of the lateral control rod
5. Connect the existing 5T-4373 Hose to the lateral control rod at the axle housing.
Complete the Installation of the Lubrication Lines
Table 49
Required Parts for Installation of the 2A-6729 Automatic Lubrication Gp or the 164-4667
1 1 178-6919 Lubrication Pump
2 1 5T-9441 Hose
3 1 6J-7929 Hose
5 7 4K-8864 Clip
6 7 5M-3062 Bolt
(1) 178-6919 Lubrication Pump
(2) 5T-9441 Hose
(3) 6J-7929 Hose
1. Use the existing hardware to install the 178-6919 Lubrication Pump (1) on the platform.
Note: Apply 5P-3413 Pipe Sealant to the threads.
2. Attach the existing 5T-9441 Hose (2) to the lubrication pump. Attach the existing 6J-7929
Hose (3) to the lubrication pump.
View of the bearing cap at the suspension cylinder
3. Connect the existing 5T-4382 Hoses to the existing connector that is in each bearing cap on
the top of each of the front suspension cylinders.
View of the front suspension cylinder
4. Connect the existing 8N-1701 Hoses to the existing elbow that is on the side of each of the
front suspension cylinders.
Note: The Steps that follow are for the 785C Off-Highway Trucks with a body that is
installed.
View of the pivot for the body
5. Connect the existing 8N-1701 Hoses to the existing elbows at each of the pivots for the body.
View of the hoist cylinder
6. Connect the existing 5T-4386 Hoses to the existing elbow that is in the left side hoist cylinder.
7. Connect the existing 161-9116 Hose As to the existing elbow that is in the right side hoist
cylinder.
(5) 4K-8864 Clip
(6) 5M-3062 Bolt
8. Use seven 4K-8864 Clips (5), seven 5M-3062 Bolts (6), and seven 8T-4896 Hard Washers (4)
to secure the lubrication line along each rail of the truck body.
Install the 163-4538 Hydraulic Oil Cooler Lines Gp , the 170-

3580 Hydraulic Oil Cooler Lines Gp , or the 159-2170
Hydraulic Oil Cooler Lines Gp
Table 50
Required Parts for Installation of the 163-4538 Hydraulic Oil Cooler Lines Gp or the 170-
3580 Hydraulic Oil Cooler Lines Gp or the 159-2170 Hydraulic Oil Cooler Lines Gp
2 2 3S-5468 Hose
3 8 8T-4984 Hose Clamp
2 2A-7208 Tube As (1)
4
2 5T-4675 Tube As (2)
5 4 006-8352 O-Ring Seal

1 2A-7209 Tube As (1)
7
1 5T-4674 Tube As (2)
8 4 6V-8519 Half Clamp

9 4 8T-8917 Bolt
10 4 7X-0550 Hard Washer
1 2A-7207 Tube As (1)
11
1 5T-4673 Tube As (2)
(1) This part is part of 163-4538 Hydraulic Oil Cooler Lines Gp . This part is used on the 784C Tractors.
(2) This part is part of 170-3580 Hydraulic Oil Cooler Lines Gp and 159-2170 Hydraulic Oil Cooler Lines Gp . This
part is used on the 785C and the 785C HAA Off-Highway Trucks.
Install the Front Brake Oil Cooler Lines
View of front brake oil cooler lines
1. Install one 4J-0524 O-Ring Seal (1) into each of the two existing hose assemblies. Connect the
existing hose assemblies to the existing flange with the existing hardware, as shown.
2. Repeat Step 1 for the other side of the machine.
Install the Rear Brake Oil Cooler Lines
View of rear brake oil cooler lines
1. Remove the caps from the oil cooler lines.
View of front brake oil cooler lines
(2) 3S-5468 Hose
(3) 8T-4984 Hose Clamp
(4) Tube As
2. Use a 3S-5468 Hose (2) and four 8T-4984 Hose Clamps (3) to secure the opposite end of each
Tube As (4) to the tube on the A-frame.
3. Use the existing clamps and existing hardware to secure Tube As (4) .
(4) Tube As
(5) 006-8352 O-Ring Seal
4. Install one 006-8352 O-Ring Seal (5) in the flanged end of each Tube As (4). Use the existing
hardware to connect one end of the tube assembly to the rear brake assembly.
5. Repeat Step 2 through Step 4 for the other side of the machine.
View of rear of machine
6. Remove the shipping covers and wire ties from the two existing hose assemblies at the rear of
the machine.
7. Install one 4J-0527 O-Ring Seal (6) in the end of each of the two existing hose assemblies.
Use the existing hardware to secure the end of each one of the existing hose assemblies to the
tube at each side of the rear axle housing.
Install the 187-1796 Ladder Gp or the 187-1798 Ladder Gp

Table 51
Required Parts for Installation of the 187-1796 Ladder Gp or the 187-1798 Ladder Gp
1
1 4S-7530 Hose (3)
2
1 7D-4958 Hose (2) (4)
3 2 4V-0661 Mount
4 2 1A-5822 Bolt
5 3 7D-1649 Washer
6 2 6V-8188 Nut
7 2 2S-1654 Washer
1 5T-8269 Plate (1)
8
1 156-9192 Plate (2)
9 1 0S-1595 Bolt
10 1 187-0425 Ladder Assembly (5)
11 (6) 9D-4721 Rail
12 1 165-0192 Plate (2)
13 2 189-5526 Handhold (2)
14 1 156-8124 Pipe (2)
15 2 9P-2950 Handhold
16 8 5P-2228 Bolt
18 2 153-1315 Handhold
20 8 6V-8801 Nut
21 8 4L-9337 Bolt
22 4 117-1944 Plate
23 24 1D-4692 Bolt
25 24 1K-6872 Locknut
Belt As
4 114-8725 (7)
26
Belt As
4 156-9195 (8)
27 12 4V-9804 Plate
28 6 4V-9810 Step As
(5) This part is part of 187-1796 Ladder Gp and part of 187-1798 Ladder Gp .
(6) Two units of this part are used in 187-1796 Ladder Gp . Only one unit of this part is used in 187-1798 Ladder Gp .
(1) 152-0543 Ladder Assembly
(2) 4S-7530 Hose
Note: Apply 5P-3413 Pipe Sealant to the threads on the fitting.
1. Attach 4S-7530 Hose (2) to the fitting on the back of the air horn that is attached to 152-0543
Ladder Assembly (1) .
Note: For the 785C HAA Off-Highway Trucks, attach 7D-4958 Hose (2) to the fitting on the
back of the air horn that is attached to 156-9183 Ladder Assembly (1) .
(3) 4V-0661 Mount
(A) Bracket
2. Install 4V-0661 Mount (3) in the bracket (A) on the frame.
View of the left front of the machine
3. Position 152-0543 Ladder Assembly (1) on the front of the machine at the left side. Slide the
hose from the air horn between the cab floor and the support arm. Use the existing hardware to
secure the top of the ladder to the machine. After the other fasteners are installed, tighten the
bolts to a final torque of 105 ± 20 N·m (75 ± 15 lb ft).
Note: For the 785C HAA Off-Highway Trucks, use 156-9183 Ladder Assembly (1) .
(3) 4V-0661 Mount
(4) 1A-5822 Bolt
(5) 7D-1649 Washer
(6) 6V-8188 Nut
(7) 2S-1654 Washer
(A) Bracket
4. Install 1A-5822 Bolt (4) with 7D-1649 Washer (5) through the ladder and through 4V-0661
Mount (3) in bracket (A) on the frame. Install 6V-8188 Nut (6) with 2S-1654 Washer (7) on
1A-5822 Bolt (4) .
View of left side fender
5. Use the existing hardware to secure the ladder to the left side fender, as shown.
(3) 4V-0661 Mount
(4) 1A-5822 Bolt
(5) 7D-1649 Washer
(6) 6V-8188 Nut
(7) 2S-1654 Washer
(8) 5T-8269 Plate
(9) 0S-1595 Bolt
6. Install 4V-0661 Mount (3) in 5T-8269 Plate (8). Use one 1A-5822 Bolt (4), one 7D-1649
Washer (5), one 2S-1654 Washer (7), and one 6V-8188 Nut (6) to secure 5T-8269 Plate (8) to
the ladder. Use one 7D-1649 Washer (5) and one 0S-1595 Bolt (9) to secure the opposite end
of 5T-8269 Plate (8) to the boss on the machine.
Note: Use 156-9192 Plate (8) for the 785C HAA Off-Highway Trucks.
(11) 9D-4721 Rail
7. For the 784C Tractor and the 785C Off-Highway Truck, use the existing hardware in order to
install 187-0425 Ladder Assembly (10) and two 9D-4721 Rails (11) .
(11) 9D-4721 Rail
(12) 165-0192 Plate
(13) 189-5526 Handhold
(14) 156-8124 Pipe
8. For the 785C HAA Off-Highway Truck, use the existing hardware to secure 187-0425 Ladder
Assembly (10). Use the existing hardware to secure 165-0192 Plate (12) to the air cleaners.
Use the existing hardware to secure two 189-5526 Handholds (13) at the frame and at 165-
0192 Plate (12) .
9. For the 785C HAA Off-Highway Truck, use the existing hardware in order to secure 156-8124
Pipe (14) at the right side of the machine, as shown. Use the existing hardware in order to
secure one 9D-4721 Rail (11) on the right side of the machine, as shown.
Illustration 98
(15) 9P-2950 Handhold
(16) 5P-2228 Bolt
(17) 5P-1076 Hard Washer
(18) 153-1315 Handhold
(20) 6V-8801 Nut
(21) 4L-9337 Bolt
10. Install one 9P-2950 Handhold (15) on the left side of the vehicle by using two 5P-2228 Bolts
(16) and two 5P-1076 Hard Washers (17). Install one 153-1315 Handhold (18) on the left side
of the vehicle by using two 5P-2228 Bolts (16) and two 5P-1076 Hard Washers (17) .
11. The ladder assemblies that will be attached to the bottom of the front bumper have been
preassembled prior to shipment. Install one ladder assembly on the left side of the vehicle by
using: four 4L-9337 Bolts (21), eight 8T-4896 Hard Washers (19) and four 6V-8801 Nuts
(20) .
Note: The ladder assembly consists of the following components: two 117-1944 Plates (22),
two Belt As (26), three 4V-9810 Step As (28), six 4V-9804 Plates (27), twelve 1D-4692 Bolts
(23), twelve 8T-4223 Hard Washers (24) and twelve 1K-6872 Locknuts (25) .
12. Repeat Step 10 through Step 11 for the right side of the vehicle.
Install the 8W-4439 Fender Gp , the 152-4633 Fender Gp , or

the 179-3492 Fender Gp
Table 52
Required Parts for Installation of the 8W-4439 Fender Gp or the 152-4633 Fender Gp or the
179-3492 Fender Gp
1 1 8W-4817 Fender Assembly
2 1 157-8059 Plate (1)
3 1 157-8062 Plate (1)
4 1 8W-6383 Guard
5 1 8W-6062 Deflector
6 1 8W-0568 Plate As (2)
7 1 8W-0571 Plate (2)
8 1 5T-4039 Brace (3)
2 0S-1595 Bolt (3)
9
2 8T-8917 Bolt (1)
2 5P-8245 Hard Washer (3)
10
(1) This part is part of 152-4633 Fender Gp . This part is used on 785C HAA Off-Highway Trucks.
(2) This part is part of 152-4633 Fender Gp or the 179-3492 Fender Gp .
(3) This part is part of one of the following groups: 152-0530 Catwalk , 152-3833 Catwalk , 159-3494 Catwalk and
159-3974 Catwalk .
Note: Place the cab on stands in order to install the fender.
Note: You can apply the film before the cab is installed on the truck.
(1) 8W-4817 Fender
1. Use the existing hardware to install 8W-4817 Fender (1) along the front edge.

View of fender
(1) 8W-4817 Fender
2. Use the existing hardware to secure the vertical inside edge of 8W-4817 Fender (1) to the
machine.
Note: Refer to the Steps that follow for 785C HAA Off-Highway Trucks.

(1) 8W-4817 Fender
(2) 157-8059 Plate
a. When you install 8W-4817 Fender (1), also install 157-8059 Plate (2). Secure the
vertical, inside edge of the fender to the plate by using the existing hardware.
b. Use the existing hardware in order to secure the inside vertical edge of 157-8059 Plate
(2) to the machine.
Note: Perform Step 2.c and Step 2.d after the right side platform is installed.

(3) 157-8062 Plate
c. Use the existing hardware in order to secure 157-8062 Plate (2) to the right side
platform.
d. Use the existing hardware in order to secure the inside vertical edge of 157-8062 Plate
(3) to the machine.
Illustration 103
View of front left side of truck

Section (B-B)
(4) 8W-6383 Guard
3. Use the existing hardware to install 8W-6383 Guard (4) at the side of the cab, as shown.
Note: Make sure that the bend faces downward. Make sure that the bend faces to the outside.

View (C-C)

View of the rear of the cab
(4) 8W-6383 Guard
4. Use the existing hardware in order to secure the 8W-6383 Guard (4) behind the cab, as shown.
Note: Perform Step 5 after the right side platform is installed.

View (A-A)
(5) 8W-6062 Deflector

View of deflector
(5) 8W-6062 Deflector
5. Use the existing hardware in order to install 8W-6062 Deflector (5), as shown.
Note: Refer to Step 6 and Step 7 for the 785C Off-Highway Trucks and for the 785C HAA
Off-Highway Trucks.

(6) 8W-0568 Plate
(7) 8W-0571 Plate
6. Use the existing hardware in order to install 8W-0568 Plate (6) to the rear cab support.
7. Use the existing hardware in order to connect 8W-0571 Plate (7) to the 8W-0568 Plate (6) and
to the bracket that is at the rear of the cab.

(8) 5T-4039 Brace
(9) 0S-1595 Bolt
8. Use two 0S-1595 Bolts (9) and two 5P-8245 Hard Washers (10) in order to install 5T-4039
Brace (8), as shown.
Note: For the 785C HAA Off-Highway Trucks that are equipped with dual slope bodies, use
two 8T-8917 Bolts (9) and two 8T-4223 Hard Washers (10) in order to install 5T-4039 Brace
(8), as shown.
Install the Rear View Mirrors

Install the 5T-3205 Rear View Mirror Gp
Note: The 5T-3205 Rear View Mirror Gp is for the 785C Off-Highway Trucks and for the 785C
HAA Off-Highway Trucks that are equipped with dual slope bodies.
Table 53
Required Parts for Installation of 5T-3205 Rear View Mirror Gp

1 1 6V-6962 Mirror
2 2 6V-6961 Knob
3 2 8D-8011 Plate
4 2 5P-9865 Mirror Spacer
5 3 2K-4973 Locknut
6 2 8T-2502 Bolt
7 2 6V-8801 Nut
9 1 5P-6872 Mirror
Note: The mirrors and the necessary hardware are shipped in the cab.
(1) 6V-6962 Mirror
(2) 6V-6961 Knob
(3) 8D-8011 Plate
(4) 5P-9865 Spacer
(5) 2K-4973 Locknut
(6) 8T-2502 Bolt
(7) 6V-8801 Nut
1. Use the components that follow in order to install 6V-6962 Mirror (1) : two 6V-6961 Knobs
(2), two 8D-8011 Plates (3), two 5P-9865 Spacers (4), two 2K-4973 Locknuts (5), two 8T-
2502 Bolts (6), two 6V-8801 Nuts (7) and two 8T-4896 Hard Washers (8) .
Note: Tighten two 2K-4973 Locknuts (5). Loosen the two locknuts by 1 1/2 revolutions.

(9) 5P-6872 Mirror
2. Use the existing hardware to install 5P-6872 Mirror (9) onto the existing bracket.
3. Adjust the mirrors and tighten the mirrors.
Install the 8W-1923 Rear View Mirror Gp
Note: The 8W-1923 Rear View Mirror Gp is for the 785C Off-Highway Trucks and for the 785C
HAA Off-Highway Trucks that are equipped with dual slope bodies.
Table 54

1 1 8T-2287 Mirror

(1) 8T-2287 Mirror
1. Use the existing hardware in order to install 8T-2287 Mirror (1) to the handhold on the RH
platform.
2. Adjust the mirror and tighten the mirror.
Note: The mirror and the necessary hardware are shipped in the cab.
Install the 8W-7903 Rear View Mirror Gp
Note: The 8W-7903 Rear View Mirror Gp is for the 784C Tractors and for the 785C Off-Highway
Trucks that are equipped with flat floor bodies.
Table 55

1 1 6V-8285 Mirror As
2 1 8T-2287 Mirror
Note: The mirrors and the necessary hardware are shipped in the cab.

(1) 6V-8285 Mirror As

(1) 6V-8285 Mirror As
1. Use the existing hardware in order to install 6V-8285 Mirror As (1), as shown.
Note: It will be easier to install the mirror when the cab is on the ground.

(2) 8T-2287 Mirror As
3. Use the existing hardware in order to install 8T-2287 Mirror As (2), as shown.
Note: Do not tighten the bolts.
Install the 6G-9260 Steering Link

Table 56
Required Parts for Installation of the 6G-9260 Steering Link

1 2 135-5268 Steering Arm (1)
2 12 2H-3758 Bolt (2)
3 12 4K-0684 Hard Washer (2)
(1) When the machine is shipped, this part is attached to the chassis.
(2) When the machine is shipped, this part is attached to the front suspension cylinder.
1. Clean the mounting surface at the bottom of each front suspension cylinder.

(1) 135-5268 Steering Arm
(2) 2H-3758 Bolt
(3) 4K-0684 Hard Washer
2. Clean the mounting surface on each 135-5268 Steering Arm (1) .
3. Use the previously removed six 2H-3758 Bolts (2) and six 4K-0684 Hard Washers (3) to
secure each steering arm to the front suspension cylinder.
4. Tighten 12 2H-3758 Bolts (2) to a torque of 1800 ± 200 N·m (1325 ± 150 lb ft).
5. Tighten the four nuts that secure the steering arms to a torque of 2060 ± 100 N·m (1520 ± 75
lb ft).
Install the 163-7223 Cab Mounting Gp or the 163-7224 Cab

Mounting Gp
Table 57
Required Parts for Installation of the 163-7223 Cab Mounting Gp or the 163-7224 Cab
Mounting Gp
Items Qty Part Number Description
1 1 5T-7218 Support
2 22 1F-7464 Bolt
3 22 5P-8250 Washer
1 2A-7040 Support (1)
4
1 5T-7370 Support (2)
5 40 163-0042 Cab Mount

6 8 163-3127 Sleeve
7 6 163-0365 Sleeve
8 6 163-0364 Sleeve
9 4 5T-9893 Shim
10 4 5T-9894 Shim
11 8 6V-2624 Bolt
12 20 5T-5807 Retainer
13 6 1D-4649 Bolt
14 6 1K-9420 Bolt
(1) This part is part of 163-7223 Cab Mounting Gp . This part is used on the 784C Tractors.
(2) This part is part of 163-7224 Cab Mounting Gp .
1. Clean the grease and the paint from the mounting surfaces of the two supports. Deburr the
mounting surfaces of the two supports.

View of the frame
2. Remove the shipping covers from the frame. Remove the lifting eye from the front of the
frame.
3. Clean the grease and the paint from the mounting surfaces on the frame.

(1) 5T-7218 Support
(2) 1F-7464 Bolt
(3) 5P-8250 Washer
4. Position 5T-7218 Support (1) at the front of the truck frame. The approximate weight of 5T-
7218 Support (1) is 175 kg (386 lb).
5. Secure 5T-7218 Support (1) to the frame with ten 1F-7464 Bolts (2) and ten 5P-8250 Washers
(3). Tighten the bolts to a torque of 900 ± 100 N·m (665 ± 75 lb ft).

(2) 1F-7464 Bolt
(3) 5P-8250 Washer
(4) 5T-7370 Support
6. Position 5T-7370 Support (4) at the rear of the truck frame. The approximate weight of 5T-
7370 Support (4) is 225 kg (495 lb).
Note: Use 2A-7040 Support (4) for the 784C Tractors.
7. Secure 5T-7370 Support (4) to the frame with 12 1F-7464 Bolts (2) and 12 5P-8250 Washers

(5) 163-0042 Cab Mount
(6) 163-3127 Sleeve
8. Install eight 163-0042 Cab Mounts (5) and four 163-3127 Sleeves (6) into the four holes that
are in the front support arm.

(5) 163-0042 Cab Mount
(6) 163-3127 Sleeve
9. Install eight 163-0042 Cab Mounts (5) and four 163-3127 Sleeves (6) into the four holes that
are at the front of the machine frame.

(5) 163-0042 Cab Mount
(7) 163-0365 Sleeve
10. Install 12 163-0042 Cab Mounts (5) and six 163-0365 Sleeves (7) into the six holes toward the
rear of the machine frame.

(5) 163-0042 Cab Mount
() 163-0364 Sleeve
11. Install 12 163-0042 Cab Mounts (5) and six 163-0364 Sleeves (8) into the six holes in the rear
support arm.
12. Lift the cab assembly into position above the cab supports. The approximate weight of the cab
assembly is 1816 kg (4000 lb).

View of the path of the hydraulic hoses
Note: When you position the cab assembly, guide the hoses in order to prevent damage.

(9) 5T-9893 Shim
(10) 5T-9894 Shim
13. Place the cab assembly on the supports. Use 5T-9893 Shims (9) or 5T-9894 Shims (10) to
level the cab assembly. The bottom of the cab assembly should rest against the supports within
a tolerance of 0.75 mm (0.030 inch).

(1) 5T-7218 Support
(11) 6V-2624 Bolt
(12) 5T-5807 Retainer
Note: Apply 9S-3263 Thread Lock Compound to the threads of 6V-2624 Bolts (11) prior to
installation.
14. Secure the front of the cab assembly to 5T-7218 Support (1) with eight 6V-2624 Bolts (11)
and eight 5T-5807 Retainers (12). Tighten the bolts to a torque of 1904 ± 68 N·m (1405 ± 50
lb ft).
785C Off-Highway Truck APX00001-UP (MACHINE) POWERED BY 3512... Página 100 de 220

(2) 5T-7370 Support
(12) 5T-5807 Retainer
(13) 1D-4649 Bolt
(14) 1K-9420 Bolt
Note: Apply 9S-3263 Thread Lock Compound to the threads of 1D-4649 Bolts (13) before
you install the bolts.
15. Secure the cab assembly to the cab mount on the frame assembly with six 1D-4649 Bolts (13)
and six 5T-5807 Retainers (12). Tighten the bolts to a torque of 1904 ± 68 N·m (1405 ± 50 lb
ft).
Note: Apply 9S-3263 Thread Lock Compound to the threads of 1K-9420 Bolts (14) before
you install the bolts.
16. Secure the cab to 5T-7370 Support (2) with six 1K-9420 Bolts (14) and six 5T-5807 Retainers
Install the 115-9184 Fuel Tank Gp or the 115-9185 Fuel Tank

Gp
Table 58
Required Parts for Installation of the 115-9184 Fuel Tank Gp or the 115-9185 Fuel Tank Gp

1 1 8W-3602 Mud Flap
2 5 4L-6454 Bolt
3 5 8T-2561 Washer
4 5 6V-8801 Nut
1. Remove the paint and clean the mounting surfaces on the upper tank mounts and on the lower
tank mounts.
2. Remove the paint from the two pipes that project from the sides of the fuel tank. Clean the
pipes. Remove the paint from the lower mount on the fuel tank. Clean the lower mount on the
fuel tank.
Illustration 133
Mounts for the fuel tank
(A) Measurement of the tank mount on the frame assembly
(B) Measurement of the tank mount on the fuel tank
3. Measure the diameter of the tank mounts that are on the frame assembly. Record the
measurement (A). Remove the existing caps, the existing shims and the existing hardware.
4. Measure the diameter of the tank mounts that are on the side of the fuel tank. Record
measurement (B) .
5. Calculate the thickness (C) of the shim pack that is required.
Subtract distance (B) from distance (A). This is equal to distance (C). Distance (C) should
have a tolerance of + 0.00 mm - 0.12 mm (+ .000 inch - .005 inch).
Note: Place an equal amount of previously removed shims on each side of the previously
removed caps.
6. Position the fuel tank at the side of the frame. Use the previously removed hardware in order
to install the previously removed caps and the shim packs that were calculated in Step 5.
Tighten the bolts to a torque of 370 ± 50 N·m (275 ± 35 lb ft).
Note: For the 784C Tractors, tighten the existing bolts to a torque of 450 ± 25 N·m (330 ± 20
lb ft).

View of the lower mount for the fuel tank
7. Use the existing hardware to secure the fuel tank to the lower mount, as shown.

(1) 8W-3602 Mud Flap
(2) 4L-6454 Bolt
(3) 8T-2561 Washer
(4) 6V-8801 Nut
8. Use five 4L-6454 Bolts (2), five 8T-2561 Washers (3), and five 6V-8801 Nuts (4) to secure
8W-3602 Mud Flap (1) at the bottom of the fuel tank.

(D) Hose
9. Remove hose (D) and the attached hardware from the vent on the fuel tank.

(E) Vent
10. Use the existing hose clamp to secure the existing hose assembly to vent (E) .
Install the 2A-6726 Fuel Line , the 153-2077 Fuel Line , or the
173-9469 Fuel Line
Table 59
Required Parts for Installation of the 2A-6726 Fuel Line or the 153-2077 Fuel Line or the
173-9469 Fuel Line
1 1 6V-8358 Ball Valve

2 2 3D-2824 O-Ring Seal
3 1 030-7950 Elbow
4 1 9L-5254 Elbow
5 6 4L-6454 Bolt (1)
6 6 8T-4896 Hard Washer (1)
7 1 116-2041 Guard (1)
(1) The part is attached to the fuel tank group.

View of the fuel lines
1. Remove the wire tie and the caps from the fuel lines.

(A) Plug
2. Remove plugs (A) from the back side of the fuel tank.

(1) 6V-8358 Ball Valve
(2) 3D-2824 O-Ring Seal
(3) 030-7950 Elbow
3. Use one 3D-2824 O-Ring Seal (2) to install 6V-8358 Ball Valve (1) in the large port on the
back side of the fuel tank.
4. Use one 3D-2824 O-Ring Seal (2) to install 030-7950 Elbow (3) in 6V-8358 Ball Valve (1) .
5. Attach the fuel line for the engine to 030-7950 Elbow (3) .

(4) 9L-5254 Elbow
6. Install 9L-5254 Elbow (4) in the small port on the back side of the fuel tank.
Note: Apply 5P-3413 Pipe Sealant to the threads of the elbow.
7. Attach the fuel return line to 9L-5254 Elbow (4) .

View of wiring harness for the fuel sensor
8. Remove the wire tie from the wiring harness for the fuel sensor.

(5) 4L-6454 Bolt
(7) 116-2041 Guard
9. In order to remove 116-2041 Guard (7), remove the six 4L-6454 Bolts (5) and six 8T-4896
Hard Washers (6) .

(B) Guard
10. Slide the wiring harness through guard (B) on the bottom of the fuel tank.

View of the fuel tank sensor
11. Connect the wiring harness to the fuel tank sensor at the bottom of the fuel tank.
12. Use six 4L-6454 Bolts (5) and six 8T-4896 Hard Washers (6) to install 116-2041 Guard (7) .
Install the 5T-3214 Truck Hood Gp , the 152-3390 Truck Hood

Gp , or the 163-0931 Truck Hood Gp
Table 60
Required Parts for Installation of the 5T-3214 Truck Hood Gp or the 152-3390 Truck Hood
Gp or the 163-0931 Truck Hood Gp
1 1 5T-4228 Rail

(1) 5T-4228 Rail
1. Use the existing hardware in order to install 5T-4228 Rail (1) to the truck hood.
Install the 5T-3220 Platform Gp

Table 61
Required Parts for Installation of the 5T-3220 Platform Gp

Item Qty Part Numbers Description
1 1 7I-5397 Platform

View of the platform
1. Remove the lifting bracket from the front mounting location for the right side platform.
Remove the tie-wraps from the wiring harness.
2. Remove the paint from the mounting locations on the platform and on the machine. Clean the
mating surfaces.

(1) 7I-5397 Platform
3. Lift 7I-5397 Platform (1) into position at the right side of the truck.

View of the right side platform
4. Use the existing hardware to secure the right side platform at the front support. Tighten the
bolts to a torque of 370 ± 50 N·m (275 ± 35 lb ft).

(C) Bolt
5. Use the existing hardware to secure the right side platform at the rear support. Tighten the
bolts to a torque of 370 ± 50 N·m (275 ± 35 lb ft).
Note: Loosen two bolts (C) in the support arm for the rear platform in order to align the four
bolts. After you tighten four bolts, tighten bolts (C) to a torque of 370 ± 50 N·m (270 ± 35 lb
ft).

View of the signal lamps
6. Connect the existing wiring harness to the existing signal lamps, as shown. Secure the wiring
harness with the existing clips and bolts.
Install the 6I-2971 Air Lines , the 147-0834 Air Lines , or the
178-2226 Air Lines
Table 62
Required Parts for Installation of the 6I-2971 Air Lines or the 147-0834 Air Lines or the
178-2226 Air Lines
Items Qty Part Number Description
1 1 178-2227 Air Cleaner Gp
2 10 137-8292 Clamp
3 4 164-4867 Elbow
4 2 178-1168 Tube
5 1 178-2222 Tube
6 2 7C-2985 Elbow
7 4 133-5940 Clamp
8 2 178-1167 Tube
9 2 4P-5104 Elbow
10 2 119-6298 Clamp
11 1 2V-0146 Hose As
12 1 184-7686 Elbow
13 1 178-1166 Tube
14 5 6V-8801 Nut
16 2 9X-2494 U-Bolt
17 1 5M-3062 Bolt
19 1 4W-9923 Plate
20 1 4L-6454 Bolt
21 1 4D-7388 Clip
22 2 7W-7417 Service Indicator
23 2 0A-2926 Nipple
24 2 3B-6552 Elbow
25 2 139-2480 Hose
26 2 5P-9085 Clip
27 2 8T-9371 Bolt
28 1 5P-2299 Flared Plug

(1) 178-2227 Air Cleaner Gp
1. Attach a suitable lifting device to 178-2227 Air Cleaner Gp (1) .

2. Use the existing hardware to install 178-2227 Air Cleaner Gp (1) onto the rear hood.

View of the turbocharger housing
3. Remove the shipping cover from the right side turbocharger housing.
4. Apply 207-1601 Rubber Lubricant to the inside of the elbows in order to ease installation. For
vehicles that are being used in Europe, Africa or the Middle East (EAME) use 207-1600
Rubber Lubricant . Do not use any other type of lubricant, including oils, greases or vaseline.
Illustration 157
(2) 137-8292 Clamp As
(3) 164-4867 Elbow
(4) 178-1168 Tube
(5) 178-2222 Tube
(6) 7C-2985 Elbow
(7) 133-5940 Clamp As
(8) 178-1167 Tube
(9) 4P-5104 Elbow
(10) 119-6298 Clamp As
(11) 2V-0146 Hose As
(12) 184-7686 Elbow
(13) 178-1166 Tube
Note: Leave all of the clamps loose until all of the parts have been assembled.
5. Slide one 119-6298 Clamp As (10) onto one end of one 4P-5104 Elbow (9). Slide the end of
4P-5104 Elbow (9) with 119-6298 Clamp As (10) onto the inlet side of the turbocharger
housing on the right side of the engine.
6. Slide one 133-5940 Clamp As (7) onto 4P-5104 Elbow (9) .
7. Slide one 178-1167 Tube (8) into 4P-5104 Elbow (9) .
8. Slide one 133-5940 Clamp As (7) onto one end of one 7C-2985 Elbow (6). Slide that end of
7C-2985 Elbow (6) over 178-1167 Tube (8) .
9. Slide one 137-8292 Clamp As (2) onto the other end of 7C-2985 Elbow (6) .
10. Repeat Steps 5 through 9 for the left side.
11. Slide one 178-1166 Tube (13) into 7C-2985 Elbow (6) on the right side of the machine. Orient
178-1166 Tube (13), as shown.
12. Slide one 178-2222 Tube (13) into 7C-2985 Elbow (6) on the left side of the machine. Orient
178-2222 Tube (13), as shown.
13. Slide one 137-8292 Clamp As (2) onto one end of 164-4867 Elbow (3). Slide that end of 164-
4867 Elbow (3) onto 178-1166 Tube (13) .
14. Slide one 137-8292 Clamp As (2) onto the other end of 164-4867 Elbow (3). Slide one 178-
1168 Tube (4) into 164-4867 Elbow (2) .
15. Slide one 137-8292 Clamp As (2) onto one end of 164-4867 Elbow (3). Slide that end of 164-
4867 Elbow (3) onto 178-1166 Tube (13) .
16. Slide one 137-8292 Clamp As (2) onto the other end of 164-4867 Elbow (3). Slide that end of
164-4867 Elbow (3) onto the outlet side of the appropriate air cleaner.
17. Repeat Steps 13 through 16 for the left side.
18. Remove the existing plug that is in the port of 178-1166 Tube (13) .
19. Install one 184-7686 Elbow (12), as shown.
20. Connect the existing 2V-0146 Hose As (11) to 184-7686 Elbow (12) .

(14) 6V-8801 Nut
(16) 9X-2494 U-Bolt
21. Use two 6V-8801 Nuts (14), two 5P-1075 Hard Washers (15), and two 9X-2494 U-Bolts (16)
to secure each vertical air cleaner support to the existing supports.
Note: The vertical air cleaner tubes may need to be raised or lowered in order to keep the
horizontal air cleaner tubes parallel to the rear hood.

(A) Raised indicator
22. Check all of the tubes and the elbows for clearance. Make sure that raised indicator (A) on the
metal tube touches the elbow. Tighten all of the clamps to a torque of 13 ± 4 N·m (115 ± 35 lb
in).
(14) 6V-8801 Nut
(17) 5M-3062 Bolt
(19) 4W-9923 Plate
(20) 4L-6454 Bolt
(21) 4D-7388 Clip
(B) Hose
23. Install one 4D-7388 Clip (21) on hose (B) .
24. Use one 4L-6454 Bolt (20), two 8T-4896 Hard Washers (18), and one 6V-8801 Nut (14) to
attach 4W-9923 Plate (19) to 4D-7388 Clip (21) .
25. Use one 5M-3062 Bolt (17) and one 8T-4896 Hard Washer (18) to secure 4W-9923 Plate (19)
to the existing platform.

View of air cleaner assembly
26. Remove the shipping plugs and caps from the air cleaner assemblies.

(22) 7W-7417 Service Indicator
(C) Mounting bracket
27. Install one 7W-7417 Service Indicator (22) in the top of mounting bracket (C) that is located
on each air cleaner.

(23) 0A-2926 Nipple
(24) 3B-6552 Elbow
(C) Mounting bracket
28. Install one 0A-2926 Nipple (23) into each 3B-6552 Elbow (24) .
29. Install 3B-6552 Elbow (24) into the bottom of mounting bracket (C) that is located on each air
cleaner.

(24) 3B-6552 Elbow
(25) 139-2480 Hose
30. Install the fixed end of one 139-2480 Hose (25) into each 3B-6552 Elbow (24) .

(25) 139-2480 Hose
(26) 5P-9085 Clip
(27) 8T-9371 Bolt
31. Use one 5P-9085 Clip (26), one 8T-4896 Hard Washer (18), and one 8T-9371 Bolt (27) to
secure 139-2480 Hose (25) to each air cleaner.

(25) 139-2480 Hose
(D) Fitting
32. Install the swivel end of each 139-2480 Hose (25) into existing fitting (D) that is on each air
cleaner.
Install the 141-7131 Pressure Sensor and Mounting Gp or the

Table 63
Required Parts for Installation of the 141-7131 Pressure Sensor and Mounting Gp or the
1 2 9X-0262 Adapter
2 2 161-9926 Pressure Sensor
3 1 4P-8134 Clip
4 2 130-5300 Clip
5 2 4L-6454 Bolt
7 3 6V-8801 Nut
8 1 133-5933 Bracket
9 1 3S-2093 Cable Strap

(A) Wire tie
1. Remove wire tie (A) from the existing wiring harness for the sensor.
2. Remove the shipping plug from the port for the sensor that is in right side 178-1166 Tube .

(1) 9X-0262 Adapter
3. Install 9X-0262 Adapter (1) in right side 178-1166 Tube .

(1) 9X-0262 Adapter
(2) 161-9926 Pressure Sensor
4. Install 161-9926 Pressure Sensor (2) on 9X-0262 Adapter (1). Tighten the adapter to a torque
of 10 ± 2 N·m (88 ± 17 lb in).

(2) 161-9926 Pressure Sensor
(B) Wiring harness
5. Connect 161-9926 Pressure Sensor (2) to the existing plug for wiring harness (B) .
6. Repeat Step 1 through Step 5 for the left side.

(8) 133-5933 Bracket
(C) Bolt
7. Remove the existing bolt at position (C) on the right side of the engine.
8. Use the existing bolt to install 133-5933 Bracket (8) at position (C) on the engine.

(3) 4P-8134 Clip
(4) 130-5300 Clip
(5) 4L-6454 Bolt
(7) 6V-8801 Nut
(9) 3S-2093 Cable Strap
9. Use one 4L-6454 Bolt (5), two 8T-4896 Hard Washer (6), and one 6V-8801 Nut (7) to secure
4P-8134 Clip (3) to 133-5933 Bracket (8) .
10. Use one 4L-6454 Bolt (5), two 8T-4896 Hard Washer (6), and one 6V-8801 Nut (7) to secure
130-5300 Clip (4) to 133-5933 Bracket (8) .
11. Secure the connector for the sensor to 130-5300 Clip (4) .
12. Use a 3S-2093 Cable Strap (9) to secure the wiring harness to the 4P-8134 Clip (3) .

(4) 130-5300 Clip
(7) 6V-8801 Nut
(E) Mounting bracket
13. Use one 8T-4896 Hard Washer (6) and one 6V-8801 Nut (7) to secure one 130-5300 Clip (4)
to the bolt for mounting bracket (D) of the dipstick.
14. Secure the connector for the sensor to 130-5300 Clip (4) .
Install the 1W-5254 Air Cleaner Gp , the 147-0832 Air Cleaner

Gp , or the 178-2227 Air Cleaner Gp
Table 64
Required Parts for the Installation of the 1W-5254 Air Cleaner Gp or the 147-0832 Air
Cleaner Gp or the 178-2227 Air Cleaner Gp
1 2 7W-7417 Service Indicator
2 2 0A-2926 Nipple
3 2 160-9808 Block
4 2 3B-6552 Elbow
5 1 156-6271 Air Cleaner
6 1 156-6272 Air Cleaner
7 38 7X-0343 Bolt
8 38 8T-4122 Washer
9 4 156-6273 Bracket
11 2 9B-7237 Bolt
12 2 156-6274 Bracket
13 2 163-1802 Clip
14 2 139-2480 Hose
15 2 8B-4884 Elbow
16 2 7W-0629 Filter Adapter
17 2 5T-6459 Elbow (1)
18 4 141-7148 Clamp (1)
(1) This part is from the air lines group.
1. Remove 156-6271 Air Cleaner (5) and remove 156-6272 Air Cleaner (6) from the box.
Prepare the air cleaners for installation.
2. Use two 9B-7237 Bolts (11) and two 5P-1075 Hard Washers (10) to secure one 156-6274
Bracket (12) to each air cleaner.
(7) 7X-0343 Bolt
(8) 8T-4122 Washer
(9) 156-6273 Bracket
3. Use eight 7X-0343 Bolts (7) and eight 8T-4122 Washers (8) to secure two 156-6273 Brackets
(9) to each air cleaner.

(7) 7X-0343 Bolt
(8) 8T-4122 Washer
4. Use a suitable lifting device to position 156-6271 Air Cleaner (5) at the left side of the hood.
Use ten 7X-0343 Bolts (7) and ten 8T-4122 Washers (8) to secure the air cleaner to the hood.
Note: The weight of 156-6271 Air Cleaner (5) is 50 kg (110 lb).
5. Remove the shipping cover from the air inlet tube at the rear of the hood.

(17) 5T-6459 Elbow
(18) 141-7148 Clamp
6. Use two 141-7148 Clamps (18) to secure one 5T-6459 Elbow (17) between the air cleaner and
the air inlet tube at the hood.

(1) 7W-7417 Service Indicator
(2) 0A-2926 Nipple
(3) 160-9808 Block
(4) 3B-6552 Elbow
(7) 7X-0343 Bolt
(8) 8T-4122 Washer
(13) 163-1802 Clip
(14) 139-2480 Hose
(15) 8B-4884 Elbow
7. Use 0A-2926 Nipple (2) to connect 7W-7417 Service Indicator (1) to 160-9808 Block (3) .
8. Install 3B-6552 Elbow (4) in 160-9808 Block (3) .
9. Install 8B-4884 Elbow (15) in each air cleaner assembly.
10. Use 139-2480 Hose (14) to connect 8B-4884 Elbow (15) at the air cleaner to 3B-6552 Elbow
(4) in 160-9808 Block (3) .
11. Use one 163-1802 Clip (13), one 7X-0343 Bolt (7), and one 8T-4122 Washer (8) to secure
139-2480 Hose (14) .

(5) 156-6271 Air Cleaner
(6) 156-6272 Air Cleaner
12. Repeat Step 4 through Step 11 in order to install 156-6272 Air Cleaner (6) on the right side of
the hood.
Install the 156-9341 Steering Tank and Filter Gp

Table 65
Required Parts for Installation of the 156-9341 Steering Tank and Filter Gp
1 1 155-4127 Steering Tank and Filter Gp
2 1 1U-8331 Steering Tank Conversion Group

(1) 155-4127 Steering Tank and Filter Gp
(2) 1U-8331 Steering Tank Conversion Group
1. Use a suitable lifting device to position the 155-4127 Steering Tank and Filter Gp (1) on the
platform.
Note: The weight of the tank is approximately 105 kg (230 lb).
2. Remove the shipping plugs from the mounting strips for the tank. Use the existing hardware to
secure the 155-4127 Steering Tank and Filter Gp (1) on the platform.
3. Remove the shipping plug from the oil port at the bottom of the tank. Install the 1U-8331
Steering Tank Conversion Group (2) in the port.
Note: Apply 5P-3413 Pipe Sealant to the threads.
Install the 151-8727 Steering Lines Gp or the 176-6393 Steering

Lines Gp
Table 66
Required Parts for Installation of the 151-8727 Steering Lines Gp or the 176-6393 Steering
Lines Gp
1 2 5K-9090 O-Ring Seal
2 1 151-8726 Tube
3 1 151-8724 Tube
4 1 151-8725 Tube
6 1 151-8723 Tube
7 1 2G-8874 Clamp
8 1 2G-8875 Clamp
9 2 0S-0509 Bolt
10 2 5M-2894 Hard Washer
11 1 150-9037 Bar
12 2 5K-9090 O-Ring Seal
14 1 2G-8895 Bracket
15 4 0L-1351 Bolt
17 1 6G-8532 Guard


(A) Shipping plug
1. Remove four shipping plugs (A) from the elbows on the steering metering pump. Loosen the
elbows in order to ease the installation of the tube assemblies.
Note: Tighten the elbows after you install the tube assemblies.

(1) 5K-9090 O-Ring Seal
(2) 151-8726 Tube
(3) 151-8724 Tube
(5) 151-8725 Tube
(6) 151-8723 Tube
Note: Apply 1U-6396 O-Ring Assembly Compound to all O-rings.
2. Install one 5K-9090 O-Ring Seal (1) in 151-8726 Tube (2). Attach 151-8726 Tube (2) to the
upper right elbow on the steering valve.
3. Install one 5K-9090 O-Ring Seal (1) in 151-8724 Tube (3). Attach 151-8724 Tube (3) to the
lower right elbow on the steering valve.
4. Install one 6V-9746 O-Ring Seal (4) in 151-8725 Tube (5). Attach 151-8725 Tube (5) to the
upper left elbow on the steering valve.
5. Install one 6V-9746 O-Ring Seal (4) in 151-8723 Tube (6). Attach 151-8723 Tube (6) to the
lower left elbow on the steering valve.
Note: All four tube assemblies should exit below the cab.

(7) 2G-8874 Clamp
(8) 2G-8875 Clamp
(9) 0S-0509 Bolt
(10) 5M-2894 Hard Washer
(11) 150-9037 Bar
6. Use one 2G-8874 Clamp (7), one 2G-8875 Clamp (8), two 0S-0509 Bolts (9), and two 5M-
2894 Hard Washers (10) to secure the four tube assemblies to the 150-9037 Bar (11) .
7. Tighten the four elbows on the steering valve.

View of the frame
8. Use the existing clamps to attach the four existing steering lines to the frame. Put the large
hose with the shortest end fitting in the top clamp and put the large hose with the longest end
fitting in the bottom clamp.
(12) 5K-9090 O-Ring Seal
9. Remove the shipping covers from the steering lines. Use two 5K-9090 O-Ring Seals (12) and
two 6V-9746 O-Ring Seals (13) to replace the seals in the steering lines.
10. Connect the steering lines to the tube assemblies under the cab. Refer to the illustration above.

(14) 2G-8895 Bracket
(15) 0L-1351 Bolt
11. Remove the shipping plug from the mount at the frame. Use one 0L-1351 Bolt (15) and one
5M-2894 Hard Washer (16) to secure 2G-8895 Bracket (14) to the frame.
(15) 0L-1351 Bolt
(17) 6G-8532 Guard
12. Use three 0L-1351 Bolts (15) and three 5P-1075 Hard Washers (16) to secure 6G-8532 Guard
(17) .

13. Install one 6V-8398 O-Ring Seal (18) into the existing hose assembly. Connect the existing
hose assembly.

14. Install one 4J-0527 O-Ring Seal (19) into each of the two existing hose assemblies. Use the
existing hardware to connect the two existing hose assemblies, as shown.
15. Use the existing clamps to secure the hoses.
Install the 174-0912 Service Brake Control Gp or the 170-3641

Table 67
Required Parts for Installation of the 174-0912 Service Brake Control Gp or the 170-3641
1 2 188-0750 Hose (1)
2 1 8W-4372 Hose
3 1 6D-7953 Hose
(1) The 785C HAA Off-Highway Truck only requires one hose.

View of wire tie-wraps
1. Remove the wire tie-wraps that secure the air lines for shipping. Remove the caps from the air
tank and from the air lines.
Illustration 193
Top view of service brake system
(1) 188-0750 Hose
(2) 8W-4372 Hose
(3) 6D-7953 Hose

(1) 188-0750 Hose
2. Connect the two existing 188-0750 Hoses (1) to the tee fitting and the elbow fitting at the front
of the air tank. The existing 188-0750 Hoses (1) are from the air dryers.
Note: For 785C HAA Off-Highway Trucks, only one 188-0750 Hose (1) comes from the air
dryer. Attach the hose to the elbow at the front of the air tank.

(2) 8W-4372 Hose
(3) 6D-7953 Hose
3. Connect the existing 8W-4372 Hose (2) to the fitting that is toward the outside of the truck at
the back of the air tank. The existing 8W-4372 Hose (2) is from the relay near the
air/hydraulic cylinders.
4. Connect the 6D-7953 Hose (3) to the fitting that is toward the inside of the truck at the back of
the air tank. The 6D-7953 Hose (3) is from port 1 at the side of the cab.
Install the 172-0214 Exhaust Pipe Gp or the 172-0215 Exhaust

Pipe Gp
Install the 172-0214 Exhaust Pipe Gp
Table 68

1 2 2W-9766 Seal Ring
2 2 4W-0221 Pipe
4 1 4W-0225 Elbow
5 1 2W-9067 Sleeve
6 1 4W-0223 Elbow
8 4 5S-7382 Bolt
Illustration 196
(1) 2W-9766 Seal Ring
(2) 4W-0221 Pipe
(4) 4W-0225 Elbow
(5) 2W-9067 Sleeve
(6) 4W-0223 Elbow
(8) 5S-7382 Bolt
1. Remove the shipping cover from the elbow on the right side of the engine.
2. Install one 2W-9766 Seal Ring (1) to the existing elbow on the turbocharger. Compress 2W-
9766 Seal Ring (1) while you install one 4W-0221 Pipe (2) to the elbow.
3. Install one 2W-8851 Seal Ring (3) to 4W-0221 Pipe (2). Compress 2W-8851 Seal Ring (3)
while you install 4W-0225 Elbow (4) to 4W-0221 Pipe (2) .
4. Remove the shipping cover from the elbow on the left side of the engine.
5. Install one 2W-9766 Seal Ring (1) to the existing elbow on the turbocharger. Compress 2W-
9766 Seal Ring (1) while you install one 4W-0221 Pipe (2) to the elbow.
6. Install 2W-9067 Sleeve (5) in the exhaust tube.
7. Install one 2W-8851 Seal Ring (3) to 4W-0221 Pipe (2). Compress 2W-8851 Seal Ring (3)
while you install 4W-0223 Elbow (6) to 4W-0221 Pipe (2) .
8. Use four 8T-4896 Hard Washers (7) and four 5S-7382 Bolts (8) to secure 4W-0223 Elbow (6)
to the frame.
Table 69

2 1 2W-9078 Pipe
3 1 153-7472 Elbow
4 1 153-7471 Elbow
5 1 2W-9067 Sleeve
6 1 4W-0223 Elbow
8 4 5S-7382 Bolt
Illustration 197
(2) 2W-9078 Pipe
(3) 153-7472 Elbow
(4) 153-7471 Elbow
(5) 2W-9067 Sleeve
(6) 4W-0223 Elbow
(8) 5S-7382 Bolt
2. Install one 2W-8851 Seal Ring (1) on the elbow. Compress 2W-8851 Seal Ring (1) while you
install 2W-9078 Pipe (2) on the elbow.
3. Install one 2W-8851 Seal Ring (1) on 2W-9078 Pipe (2). Compress 2W-8851 Seal Ring (1)
while you install 153-7472 Elbow (3) on 2W-9078 Pipe (2) .
5. Install one 2W-8851 Seal Ring (1) on the elbow. Compress 2W-8851 Seal Ring (1) while you
install 153-7471 Elbow (4) on the elbow.
6. Install 2W-9067 Sleeve (5) in the exhaust tube.
7. Install one 2W-8851 Seal Ring (1) on 153-7471 Elbow (4). Compress 2W-8851 Seal Ring (1)
while you install 4W-0223 Elbow (6) on 153-7471 Elbow (4) .
8. Use four 8T-4896 Hard Washers (7) and four 5S-7382 Bolts (8) to secure 4W-0223 Elbow (6)
to the frame.

Table 70

1 2 6G-7031 Elbow
2 16 7K-1270 Washer
4 8 0S-1589 Bolt
5 4 1D-5117 Jam Nut
6 4 4B-3586 Setscrew
7 5T-8038 Tube As
8 8 0S-1566 Bolt
9 1 8X-0480 Plate
10 1 8X-0484 Plate
11 8 2D-5238 Taperlock Stud
12 2 6G-7038 Seal Ring
13 2 5T-3369 Piston
14 2 5T-2762 Spring
15 2 5T-3367 Elbow
16 6 9D-2836 Lock
18 12 0L-1351 Bolt
19 8 7X-0448 Nut
Illustration 198
(1) 6G-7031 Elbow
(2) 7K-1270 Washer
(4) 0S-1589 Bolts
(5) 1D-5117 Jam Nut
(6) 4B-3586 Setscrew
(7) 5T-8038 Tube As
(8) 0S-1566 Bolts
(9) 8X-0480 Plate
(10) 8X-0484 Plate
(11) 2D-5238 Taperlock Stud
(12) 6G-7038 Seal Ring
(13) 5T-3369 Piston
(14) 5T-2762 Spring
(15) 5T-3367 Elbow
(16) 9D-2836 Lock
(18) 0L-1351 Bolt
(19) 7X-0448 Nut
1. Install one 6G-7031 Elbow (1) to the existing 8W-9626 Bracket with the following
components: eight 7K-1270 Washers (2), eight 5P-8247 Hard Washers (3) and four 0S-1589
Bolts (4) .
2. Install two 1D-5117 Jam Nuts (5) and two 4B-3586 Setscrews (6) to 6G-7031 Elbow (1) .
3. Tighten the exhaust clamp from the elbow to the existing 8W-9620 Tube As .
4. Install 5T-8038 Tube As (7) to the frame.
5. Install one 6G-7031 Elbow (1) to the frame with the following components: eight 7K-1270
Washers (2), eight 5P-8247 Hard Washers (3) and four 0S-1589 Bolts (4) .
6. Install two 1D-5117 Jam Nuts (5) and two 4B-3586 Setscrews (6) to 6G-7031 Elbow (1) .
7. Use four 0S-1566 Bolts (8) to secure 8X-0480 Plate (9) to the truck body.
8. Use four 0S-1566 Bolts (8) to secure 8X-0484 Plate (10) to the truck body.
9. Install four 2D-5238 Taperlock Studs (11) to 8X-0480 Plate (9) and to 8X-0484 Plate (10) .
10. Install one 6G-7038 Seal Ring (12) to 5T-3369 Piston (13).
11. Install one 5T-2762 Spring (14) to 5T-3367 Elbow (15) .
12. Install 5T-3369 Piston (13) to 5T-3367 Elbow (15). Compress 5T-2762 Spring (14) and install
the following components: three 9D-2836 Locks (16), six 5P-1075 Hard Washers (17) and six
0L-1351 Bolts (18) .
13. Repeat Steps 10 through 12 for the other 5T-3369 Piston (13) and 5T-3367 Elbow (15) .
14. Install one 5T-3367 Elbow (15) to 8X-0480 Plate (9) with the following components: four 7K-
1270 Washers (2), four 5P-8247 Hard Washers (3) and four 7X-0448 Nuts (19) .
15. Install one 5T-3367 Elbow (15) to 8X-0484 Plate (10) with the following components: four
7K-1270 Washers (2), four 5P-8247 Hard Washers (3) and four 7X-0448 Nuts (19) .
Install the 174-9332 Muffler Gp

Table 71
Required Parts for the Installation of the 174-9332 Muffler Gp

1 2 5T-6927 Bracket
3 16 5S-7379 Bolt
4 4 5T-6928 Strap
5 1 5T-7938 Tube As
6 2 4N-9330 Clamp
7 3 5P-2424 Bolt
9 7 1K-6872 Locknut
10 1 2W-3773 Muffler Assembly
11 8 5S-7383 Bolt
12 8 2K-4973 Locknut
13 1 5T-6978 Plate
14 1 8W-4382 Extension Pipe
15 1 2W-6737 Muffler Assembly
16 2 5T-4278 Strap
17 1 1W-1305 Clamp
18 1 8W-4381 Extension Pipe
Illustration 199
(1) 5T-6927 Bracket
(3) 5S-7379 Bolt
(4) 5T-6928 Strap
(5) 5T-7938 Tube As
(6) 4N-9330 Clamp
(7) 5P-2424 Bolt
(9) 1K-6872 Locknut
(10) 2W-3773 Muffler Assembly
(11) 5S-7383 Bolts
(12) 2K-4973 Locknut
(13) 5T-6978 Plate
(14) 8W-4382 Extension Pipe
(15) 2W-6737 Muffler Assembly
(16) 5T-4278 Strap
(17) 1W-1305 Clamp
(18) 8W-4381 Extension Pipe
1. Install two 5T-6927 Brackets (1) to the frame with eight 5P-1075 Hard Washers (2) and eight
5S-7379 Bolts (3) .
2. Install two 5T-6928 Straps (4) to two 5T-6927 Brackets (1) with four 5P-1075 Hard Washers
(2) and four 5S-7379 Bolts (3) .
3. Install 5T-7938 Tube As (5) to the frame.
4. Slide the following components over the end of 2W-3773 Muffler Assembly (10) : 4N-9330
Clamp (6), 5P-2424 Bolt (7), two 8T-4223 Hard Washers (8) and 1K-6872 Locknut (9).
Note: Apply a thin coat of 4C-5590 Anti-Seize Compound to the end of 2W-3773 Muffler
Assembly (10) before installation.
Note: Lubricate 8T-4223 Hard Washers (8) and threads of 5P-2424 Bolt (7) before
installation.
5. Use a suitable lifting device in order to install 2W-3773 Muffler Assembly (7) to the end of
5T-7938 Tube As (5) .
6. Use two 5T-6928 (4), eight 5S-7383 Bolts (11), and eight 2K-4973 Locknuts (12) to secure
2W-3773 Muffler Assembly (7) to two 5T-6927 Brackets (1). Tighten 4N-9330 Clamp (6) to a
torque of 60 ± 12 N·m (45 ± 10 lb ft).
7. Install 5T-6978 Plate (13) to 2W-3773 Muffler Assembly (7) and to the frame with two 5P-
1075 Hard Washers (2) and two 5S-7379 Bolts (3).
8. Slide the following components over the end of 8W-4382 Extension Pipe (14) : 4N-9330
Clamp (6), 5P-2424 Bolt (7), two 8T-4223 Hard Washers (8) and 1K-6872 Locknut (9) .
Note: Apply a thin coat of 4C-5590 Anti-Seize Compound to the end of 8W-4382 Extension
Pipe (14) before installation.
installation.
9. Install 8W-4382 Extension Pipe (14) to 2W-3773 Muffler Assembly (7). Tighten 4N-9330
Clamp (6) to a torque of 60 ± 12 N·m (45 ± 10 lb ft).
10. Use a suitable lifting device in order to install 2W-6737 Muffler Assembly (15) to the end of
the exhaust elbow.
11. Use the following components to secure 2W-6737 Muffler Assembly (15) to the frame: two
5T-4278 Straps (16), four 8T-4223 Hard Washers (8) and four 1K-6872 Locknuts (9). Tighten
the exhaust clamp when 2W-6737 Muffler Assembly (15) is in place.
12. Slide the following components over the end of 8W-4381 Extension Pipe (18) : 1W-1305
Clamp (17), 5P-2424 Bolt (7), two 8T-4223 Hard Washers (8) and 1K-6872 Locknut (9) .
Note: Apply a thin coat of 4C-5590 Anti-Seize Compound to the end of 8W-4381 Extension
Pipe (18) before installation.
installation.
13. Install 8W-4381 Extension Pipe (18) to 2W-6737 Muffler Assembly (15). Tighten 4N-9330
Clamp (6) to a torque of 60 ± 12 N·m (45 ± 10 lb ft).
Connect Air Lines and Wire Harnesses to the Cab

View of the cab
1. Remove all of the tape and all of the plugs from the cab.
2. Remove the caps from the air lines and from the wire harnesses.

View of the right side of the cab
(1) Main air supply to the cab
(2) Air supply to the air start control valve
(3) Air line for the parking brake control
(4) Air line for the service brake control
(5) Air line for the diverter valve control
(6) Air line for the automatic retarder control
(7) Air line for the automatic lubrication (if equipped)
(A) Transmission wiring harness
(B) Battery wiring harness
(C) Wiring harness
(D) Chassis 2 wiring harness
(E) Engine wiring harness
Note: The air lines and the wire harnesses are connected on the right side of the cab. Each
opening in the plate at the cab has an identification number. The air lines are marked with
numbers that correspond. Match the numbers in order to connect the air lines. The openings
for the electrical plugs are not marked. Be sure to count the number of pins in each electrical
connections and connect the electrical connector to the correct electrical plug in the cab.
3. Connect the air lines to the correct places on the cab.
4. Connect the wire harnesses to the correct places on the cab.

View of the cab
5. Use tie straps to secure the air lines and the wire harnesses.
Install the 5T-3218 Heater Lines Gp or the 152-4637 Heater

Lines Gp
Table 72
Required Parts for the Installation of the 5T-3218 Heater Lines Gp or the 152-4637 Heater
Lines Gp
1 2 6P-8855 Spacer
2 10 9X-2488 Hose Clamp

3 9 6D-1641 Clip
5 1 0T-0102 Bolt

View of the underside of the cab
1. Remove the wire ties from the heater hoses that are under the cab.

(1) 6P-8855 Spacer
(2) 9X-2488 Hose Clamp
2. Connect the heater hoses under the cab and on the frame with two 6P-8855 Spacers (1) and
eight 9X-2488 Hose Clamps (2). Tighten the hose clamps to a torque of 4.5 ± 0.5 N·m (40 ±
4.5 lb in).

(3) 6D-1641 Clip
(5) 0T-0102 Bolt
3. Secure the heater hoses to the frame with the following components: one 6D-1641 Clip (3),
one 5M-2894 Hard Washer (4) and one 0T-0102 Bolt (5)
Install the 144-4180 Air Horn Gp or the 144-4182 Air Horn Gp

(1) Hose assembly
(2) Fitting
1. Remove the caps from the air hose assemblies.
2. Connect hose assembly (1) to fitting (2) .
Note: Apply 5P-3413 Pipe Sealant to the threads of fitting (2) .
Connect the Air Conditioner Lines

1. Remove the shipping covers and wire ties from the air conditioner lines.

2. Connect air conditioning lines. Trim the drain tubes. Secure the drain tubes with a wire tie.
Install the 170-3601 Chassis Wiring and Lighting Gp or the

186-6583 Battery and Wiring Gp
Table 73
Required Parts for Installation of the 170-3601 Chassis Wiring and Lighting Gp or the 186-
6583 Battery and Wiring Gp

1 2 115-2421 Battery (1)
2 2 9D-6635 Battery Hold-Down Assembly
3 1 5K-3294 Clip
4 1 9M-4995 Clip
6 1 5S-7379 Bolt
7 1 117-5883 Cable
(1) This battery is shipped dry. The dealer will be required to procure battery acid.

1. Remove the caps from the two wiring harnesses.

2. Connect the two wiring harnesses to the front of the cab. Secure the two wiring harnesses to
the bottom of the cab.

View of the left side fender
3. Connect the parking lights and the turn signal lights on the left side fender to the wiring
harness at the electrical connections.

View of the underside of the right side platform
4. Connect the wiring harness for the right side platform to the wiring harness at the electrical
connections.

View of the front strut

View of the front strut
5. Connect the sensor for the Truck Payload Measurement System on the front struts to the
wiring harness at the electrical connections.

View of the underside of the right side platform
6. Remove the wire ties from the harness.
7. Route the harness into the battery compartment.

(1) 115-2422 Battery
(2) 9D-6635 Battery Hold-Down Assembly
(3) 5K-3294 Clip
8. Place two 115-2422 Batteries (1) into the battery compartment. Refer to the illustration above.
9. Remove the nuts. Install two 9D-6635 Battery Hold-Down Assemblies (2) to 115-2422
Batteries (1).
10. Secure the positive battery cable to 9D-6635 Battery Hold-Down Assembly (2) with 5K-3294
Clip (3). Install the nuts. Tighten the nuts to a torque of 20 ± 4 N·m (180 ± 35 lb in).

(4) 9M-4995 Clip
(6) 5S-7379 Bolt
(7) 117-5883 Cable
11. Use 9M-4995 Clip (4), 8T-4896 Hard Washer (5), and 5S-7379 Bolt (6) to secure the positive
battery cable to the frame.
12. Install 117-5883 Cable (7) to 115-2422 Batteries (1). Attach 117-5883 Cable (7). Refer to the
illustration above.
13. Secure the positive battery cable on the positive battery post.
14. Secure the negative battery cable on the negative battery post.
Install the 6G-9270 Front Wheel Group or the 8X-9487 Front

Wheel Group
Table 74
Required Parts for the Installation of the 6G-9270 Front Wheel Group or the 8X-9487 Front
Wheel Group
1 2 5T-9790 Tire Valve Gp (1)
2 2 6G-1546 O-Ring Seal (1)
3 2 8W-0331 Swivel Connector (1)
4 6 8W-3891 Flange Nut

5 84 5P-8250 Washer
6 84 2J-3507 Full Nut
(1) The group is part of the 230-0098 Demountable Rim Gp or part of the 232-1332 Demountable Rim Gp .
1. Make sure that all the paint, all the grease, and all the burrs has been removed from the wheel
studs and the mating surfaces.
Note: Use 4C-4188 Paint Remover to remove the paint. Use 4C-4079 Brake and Electrical
Cleaner in order to clean the mating surfaces.
2. Install six clevis assemblies and two lifting cables to the frame assembly. Refer to the
illustration above.
3. Attach a suitable crane to the front of the truck. Raise the front of the truck enough to install
the front tires.
Note: Leave the hoist attached to the front of the truck while the front tires are being installed.

(1) 5T-9790 Tire Valve Group
(2) 6G-1546 O-Ring Seal
(3) 8W-0331 Swivel Connector
Note: Typically, the shop or a tire servicing person installs the rim assembly.
4. Use the following parts to assemble the rims to the front tires: two 5T-9790 Tire Valve Groups
(1), two 6G-1546 O-Ring Seals (2) and two 8W-0331 Swivel Connectors (3). Before you
continue, ensure that the pattern for the threads is oriented to the desired position. Inflate the
tire with dry nitrogen to the correct operating pressure.
Note: Refer to the Operation and Maintenance Manual, "Tire Inflation Information".
5. Use a tire handler in order to install each tire and rim on the wheel on each side of the truck.

(4) 8W-3891 Flange Nut
(5) 5P-8250 Washer
(6) 2J-3507 Full Nut
6. Install three 8W-3891 Flange Nuts (4) on the three longest studs.
7. Install 42 5P-8250 Washers (5) and 42 2J-3507 Full Nuts (6) on the remainder of the studs.
Note: Tighten 8W-3891 Flange Nuts (4) and 2J-3507 Full Nuts (5) to a torque of 1150 ± 150
N·m (850 ± 110 lb ft).
8. Repeat Step 6 through Step 7 for the other side of the truck.
Front Wheel Alignment

Typical top view of the steering linkage
(1) Clamps on left side tie bar
(2) Clamps on right side tie bar
(B) Distance between the front tires at the back
(F) Distance between the front tires at the front
Procedure
1. Lift the front of the truck until the front wheels are off the ground and the strut rods in the
suspension cylinders are fully extended.
2. Move the wheels to a straight ahead position.
3. Measure distance (F) between the front tires. Mark the measurement locations of distance (F)
on each tire.
4. Rotate the tires by 180 degrees.
5. Measure distance (B) between the marks that were made in Step 3.
6. Use Table 75 to determine the correct toe-out when the front wheels are off the ground.
Table 75
Model Correct Toe-Out

784C (B) = (F) - 164.6 mm (6.48 inch)
785C (B) = (F) - 48.5 mm (1.91 inch)
7. Use the following procedure to adjust the tie rods in order to get the correct toe-out with the
front wheels off the ground:
a. Loosen clamps (1) and (2) .
b. Turn each tie rod by the same number of turns in order to get the correct toe-out.
Note: After adjustment, the tie rods must be of equal length.
Note: Use the following procedure to align the tie rod with the clamp assembly. Failure to correctly
locate the clamp assembly on the tie rod could shorten the service life of the tie rod assembly.
Clamp Positioning

View A-A
(3) Tie rod
(4) Clamp assembly
(A) 6.350 ± 1.530 mm (0.25 ± 0.06 inch)
1. Position the clamp assembly (4) on the tie rod (3). Refer to Illustration 227.

(3) Tie rod
(4) Clamp assembly
(5) Nut
2. Align the open portion of the clamp assembly (4) with one of the slots in tie rod (3). Refer to
Illustration 228.
3. Tighten nut (5) .
Reference: Refer to Specifications, "Steering Linkage and Cylinder Mounting" for additional
information.
Note: When the adjustment is correct, there will be a front wheel toe-in when the truck is in normal
operation with correctly charged suspension cylinders.
Install the 230-0098 Demountable Rim Gp or the 232-1332

Demountable Rim Gp
Table 76
Required Parts for the Installation of the 230-0098 Demountable Rim Gp or the 232-1332
Demountable Rim Gp
1 2 5T-9796 Connector
2 4 5T-9790 Tire Valve Gp
3 4 6G-1546 O-Ring Seal
4 2 176-7282 Extension
5 180 5P-8250 Washer (1)
6 180 2J-3507 Full Nut (1)
7 2 229-9388 Plate
8 2 229-9386 Plate
9 2 229-9387 Plate
10 6 6V-8188 Nut
11 4 1S-0996 Clip
12 2 5P-2228 Bolt
14 4 1K-3113 Spacer
15 4 7X-0336 Bolt
1 230-1131 Hose As (2)
16
1 8X-2659 Hose As (3)
17 8 6J-0427 Spacer
18 2 8X-2627 Bracket
20 8 1D-4566 Bolt
(1) Part of the 142-5135 Rear Wheel or part of the 140-7626 Rear Wheel
(2) Part of the 230-0098 Demountable Rim Gp
(3) Part of the 232-1332 Demountable Rim Gp

View of the tire ring on the final drive

View of the ring after removal from the final drive
1. Remove the existing rings, washers, and nuts from the wheel assembly. Save the components
for assembly purposes.
2. Raise the rear of the truck enough to install the rear wheels.
Note: Leave the hoist attached to the rear of the truck until the tires are installed.

(1) 5T-9796 Connector
(2) 5T-9790 Tire Valve Gp
(3) 6G-1546 O-Ring Seal
(4) 176-7282 Extension
Note: Typically, the shop or the tire servicing person will install the rim assembly.
3. Install the following parts when you prepare the inner rim: one 5T-9796 Connector (1), one
5T-9790 Tire Valve Gp (2) and one 6G-1546 O-Ring Seal (3) .
4. Repeat Step 3 for the remaining inner rim.
5. Install the following parts when you prepare the outer rim: one 5T-9790 Tire Valve Gp (2),
one 6G-1546 O-Ring Seal (3) and one 176-7282 Extension (4) .
6. Repeat Step 5 for the remaining outer rim.
7. Make sure that all the paint, all the grease, and all the burrs has been removed from the wheel
studs and the mating surfaces.
Note: Use 4C-4188 Caterpillar Paint and Decal Remover in order to remove the paint. Use
4C-4079 Brake and Electrical Cleaner in order to clean the mating surfaces.
8. Use a tire handler to install the inner rear wheel.

(5) 5P-8250 Washer
9. Install 45 5P-8250 Washers (5) and 45 2J-3507 Full Nuts (6) to the existing studs.
Note: Tighten 2J-3507 Full Nuts (6) to a torque of 1150 ± 150 N·m (850 ± 110 lb ft).
10. Repeat Steps 7 through 9 for the other inner tire and rim.
Illustration 235
View of the rear rim
(1) 5T-9796 Connector
(7) 229-9388 Plate
(8) 229-9386 Plate
(9) 229-9387 Plate
(10) 6V-8188 Nut
(11) 1S-0996 Clip
(12) 5P-2228 Bolt
(14) 1K-3113 Spacer
(15) 7X-0336 Bolt
(16) Hose As
11. Attach one end of hose assembly (16) to the 5T-9796 Connector (1) that is located on the inner
rim. Route the hose assembly through the two 1S-0996 Clips (11) .
12. Assemble one 1S-0996 Clip (11) to 229-9386 Plate (8) by using: one 5P-2228 Bolt (12), two
8T-4223 Hard Washers (13) and one 6V-8188 Nut (10). Assemble the other 1S-0996 Clip (11)
to the 229-9386 Plate (8). Use the mounting hardware that is mentioned in Step 13. Refer to
Illustration 235.
13. Assemble one 229-9386 Plate (8) to the rear rim by using: one 229-9388 Plate (7) and one
229-9387 Plate (9). Secure the plates by using: two 7X-0336 Bolts (15), four 8T-4223 Hard
Washers (13), two 1K-3113 Spacers (14) and two 6V-8188 Nuts (10) .
14. Repeat Steps 11 through 13 for the other inner tire and rim.

(5) 5P-8250 Washer
15. Install the rings that were removed in Step 1 to the tire and rim. Install 45 5P-8250 Washers
(5) and 45 2J-3507 Full Nuts (6) .
Note: Tighten 2J-3507 Full Nuts (6) to a torque of 1150 ± 150 N·m (850 ± 110 lb ft).

View of the outer tire and the rim
16. Use a tire handler in order to install the outer tire and rim on the truck.
Note: Align the valve stem on the tire and rim with the valve stem extension.
Note: Tie a piece of wire around the valve stem extension. When you are installing the outer
tire and rim, pull the valve stem extension through the tire and rim.

View of outer tire and rim
17. Install the washers and the bolts that were removed in Step 1.

View of the outer tire and the rim
18. Remove one of the brass nuts from each of the valve stems.

(17) 6J-0427 Spacer
(18) 8X-2627 Bracket
(20) 1D-4566 Bolt
19. Install the following components to outer rear wheel: four 6J-0427 Spacers (17), one 8X-2627
Bracket (18), four 5P-8245 Hard Washer (19) and four 1D-4566 Bolts (20) .
20. Insert the valve extensions through 8X-2627 Brackets (18). Install the brass nuts that were
removed in Step 18.
21. Repeat Steps 15 through 20 for the other outer rear wheel.
Install the 154-3756 Body Mounting Gp
Table 77
Required Parts for Installation of the 154-3756 Body Mounting Gp

1 2 5T-5984 Plate
2 1 5T-5986 Mud Flap
3 2 6G-9705 Strip
4 53 0S-1588 Bolt
5 48 6V-8801 Nut
7 10 0L-1351 Bolt
8 1 5T-5987 Mud Flap
9 2 5T-5985 Plate
10 1 5T-5989 Mud Flap
11 2 6G-9704 Strip
12 1 5T-5988 Mud Flap
13 1 105-4727 Mud Flap
14 1 8X-5421 Plate
16 2 8W-8679 Pin
17 2 6G-9697 Washer
18 1 8W-2896 Washer
19 2 8W-8677 Plate
21 4 0S-1585 Bolt
Illustration 241
View of left side of body
(1) 5T-5984 Plate
(2) 5T-5986 Mud Flap
(3) 6G-9705 Strip
(4) 0S-1588 Bolt
(5) 6V-8801 Nuts
(7) 0L-1351 Bolts
(9) 5T-5985 Plate
(10) 5T-5989 Mud Flap
(11) 6G-9704 Strip
(12) 5T-5988 Mud Flap
(13) 105-4727 Mud Flap
(14) 8X-5421 Plate

(1) 5T-5984 Plate
(3) 6G-9705 Strip
(4) 0S-1588 Bolt
(5) 6V-8801 Nut
1. Attach 5T-5984 Plate (1) to 5T-5986 Mud Flap (2) with the following components: 6G-9705
Strip (3), nine 0S-1588 Bolts (4) and nine 6V-8801 Nuts (5) .
2. Install 5T-5984 Plate (1) to the front of the body on the right side with five 5P-1075 Hard
Washers (6) and five 0L-1351 Bolts (7) .
Note: The bend of 5T-5984 Plate (1) must go toward the rear of the dump body.

(1) 5T-5984 Plate
(3) 6G-9705 Strip
(4) 0S-1588 Bolt
(5) 6V-8801 Nut
3. Install 5T-5984 Plate (1) to the front of the body on the left side with five 5P-1075 Hard
Washers (6) and five 0L-1351 Bolts (7) .
Note: The bend of 5T-5984 Plate (1) must go toward the rear of the dump body.
(4) 0S-1588 Bolt
(5) 6V-8801 Nut
(9) 5T-5985 Plate
(10) 5T-5989 Mud Flap
(11) 6G-9704 Strip
Strip (11), ten 0S-1588 Bolts (4) and ten 6V-8801 Nuts (5) .
5. Install 5T-5985 Plate (9) to the middle of the body on the right side with ten 6V-8801 Nuts
(5), ten 5P-1075 Hard Washers (6), and ten 0L-1351 Bolts (7) .

(4) 0S-1588 Bolt
(5) 6V-8801 Nut
(9) 5T-5985 Plate
(11) 6G-9704 Strip
(12) 5T-5988 Mud Flap
Strip (11), ten 0S-1588 Bolts (4) and ten 6V-8801 Nuts (5) .
7. Install 5T-5984 Plate (1) to the middle of the body on the left side with ten 6V-8801 Nuts (5),
ten 5P-1075 Hard Washers (6), and ten 0L-1351 Bolts (7) .
8. Attach 8X-5421 Plate (14) and 105-4727 Mud Flap (13) to the truck body with five 0S-1588
Bolts (4) and five 5M-2894 Hard Washer (15) .
Installation of the Rock Guard to the Truck Body

View of the rock guard
1. Attach a temporary lifting eye to the rock guard.
2. With a suitable hoist, position the rock guard to the truck body, as shown. The weight of the
rock guard is 24 kg (53 lb).
3. Weld the rock guard to the truck body. Refer to Illustration 248 and refer to Table 78.
Table 78
Weld Tolerances
Weld Description
W1
4 mm (0.16 inch) Bevel Groove Weld
The fillet Weld is
W2 4 mm (0.16 inch) wide by
25 mm (0.1 inch) long.
4. Remove the lifting eye from the rock guard. Clean the area and paint the area.
Installation of the Truck Body to the Frame
1. Remove all of the paint, grease, and burrs from the truck frame and from the truck body.

(16) 8W-8679 Pin
2. Fit both of the 8W-8679 Pins (16) to the truck body.
3. Use a suitable crane and a suitable lifting device to position the truck body to the truck frame.
4. Align the pivot pin bores of the truck body and the pivot pin bores of the truck frame.

(16) 8W-8679 Pin
(17) 6G-9697 Washer
(18) 8W-2896 Washer
5. Install both of the 8W-8679 Pins (16) through the outer ear of the truck body.
Note: Lubricate both of the pins with 4C-5590 Anti-Seize Compound before installation.
6. Install two 6G-9697 Washers (17) between the outer ear of the truck body and the truck frame.
Note: If 6G-9697 Washer (17) does not fit, insert one 8W-2896 Washer (18). 8W-2896
Washer (18) is 4 mm (0.16 inch) thinner than 6G-9697 Washer (17) .
7. Drive 8W-8679 Pins (16) through the pivot pin bores of the truck body and of the truck frame.

(16) 8W-8679 Pin
(19) 8W-8677 Plate
(21) 0S-1585 Bolt
8. Use the following components in order to secure 8W-8679 Pins (16) in place: two 8W-8677
Plates (19), four 5P-8245 Hard Washers (20) and four 0S-1585 Bolts (21 )

View of the body position sensor
9. Remove the wire tie from the arm of the body position sensor. Attach the arm of the body
position sensor to the boss on the truck body.
Install the Shims for the Body
Table 79
Required Parts for the Installation of the Shims for the Body
1 2 8W-4348 Shoe
2 18 6G-9711 Shim
3 6 5T-3750 Plate
4 8 6G-9547 Pad
5 24 7D-1649 Hard Washer
6 6 1A-1460 Bolt
7 18 9S-1366 Bolt
8 18 1D-4719 Full Nut
1. Raise the truck body and connect the retaining cable of the truck body.

(1) 8W-4348 Shoe

(1) 8W-4348 Shoe
(2) 6G-9711 Shim
(3) 5T-3750 Plate
(4) 6G-9547 Pad
(5) 7D-1649 Hard Washer
(6) 1A-1460 Bolt
2. Use the following method to calculate the number of 6G-9711 Shims (2) or 5T-3750 Plates (3)
that are required for each 6G-9547 Pad (4) :
a. Make sure that the truck is parked on a level surface. Disconnect the retaining cable and
lower the truck body to the frame rails.
b. Use the center mounting block on the truck in order to mark the locations for the pad
assemblies on the frame rails.
c. Raise the truck body and connect the retaining cable.
d. Place one 6G-9711 Shim (2) and one 6G-9547 Pad (4) at each of the three locations that
are marked on the frame rails.
e. Disconnect the retaining cable and lower the truck body.
f. Add shims at any of the pads that are loose. Add enough shims in order to eliminate all
of the gaps.
g. Tilt each 8W-4348 Shoe (1) until the shoe is parallel with the body.
h. Measure the gap between the shoe and the body.
i. Measure a pad and add enough shims in order to obtain a thickness that is 1.5 mm
(0.060 inch) thicker than the gap between the body and the shoe.
3. Raise the body approximately 200 mm (8.0 inch). Place blocking material between the body
and the frame rails.

(2) 6G-9711 Shim
(3) 5T-3750 Plate
(4) 6G-9547 Pad
(5) 7D-1649 Hard Washer
(6) 1A-1460 Bolt
(7) 9S-1366 Bolt
4. Use three 7D-1649 Hard Washers (5) and three 1A-1460 Bolts (6) to install 6G-9711 Shims
(2), 5T-3750 Plate (3), and 6G-9547 Pad (4) on each 8W-4348 Shoe (1) .
5. Use three 7D-1649 Hard Washers (5), three 9S-1366 Bolt (7), and three 1D-4719 Full Nut (8)
to install 6G-9711 Shims (2), 5T-3750 Plate (3), and 6G-9547 Pad (4) at each location on the
frame rail.
Install the Rock Ejectors
Table 80
Required Parts for the Installation of the Rock Ejectors

1 2 112-6212 Ejector
2 2 6G-7773 Pin
3 4 3B-4647 Cotter Pin
4 1 112-6180 Plate Assembly
5 1 112-6181 Plate Assembly

(1) 112-6212 Ejector
(2) 6G-7773 Pin
(3) 3B-4647 Cotter Pin
1. Use a suitable lifting device to position 112-6212 Ejector (1) to the truck body.
2. Use one 6G-7773 Pin (2) and two 3B-4647 Cotter Pins (3) to secure 112-6212 Ejector (1) to
the truck body. Bend cotter pins (3) with pliers in order to keep pin (2) in place.
3. Lower the ejector between the tires. Check the clearance on both sides of the ejector.
Note: If the rock ejector brackets have not been installed, the following steps are for the
installation of the rock ejector brackets.
Note: The rock ejector brackets should be installed after the body has been installed.
4. Attach a string and a plumb bob to the center of the mounting pin bore in the rock ejector
bracket. Position the rock ejector bracket on the bottom of the truck body. The string should be
centered between the two tires. Check the distance that separates the string and the wheels in
order to prevent the ejectors from striking the wheels. The ejectors that are installed should be
centered in the forward position, in the rear position, and in the side position.
Illustration 257
(A) 1125 ± 3 mm (44 ± 0.12 inch)
5. Use weld (W1) to secure 112-6180 Plate Assembly (4) to the bottom of the right side of the
body. Refer to Illustration 257 and refer to Table 81.
Table 81
Weld Tolerances
Weld Description
The fillet weld is
W1 10 mm (0.40 inch) with a
1.5 mm (0.06 inch) penetration in four places.
6. Repeat Step 4 and Step 5 for the other side of the truck body.
Install the 6G-9560 Hoist Cylinder and Mounting Gp

Table 82
Required Parts for the Installation of the 6G-9560 Hoist Cylinder and Mounting Gp
1 2 6G-9692 Pin
2 4 6G-9696 Spacer
3 2 6G-9691 Bar
5 4 0S-1585 Bolt
1. Make sure that all the paint, all the grease, and all the burrs has been removed from the hoist
cylinders, the truck body, and the mating surfaces.
Note: Use 4C-4188 Paint and Decal Remover in order to remove the paint. Use 4C-4079
Brake and Electrical Cleaner in order to clean the mating surfaces.

(1) 6G-9692 Pin
2. Install one 6G-9692 Pin (1) in the outer ear of the truck body.
Note: Apply 4C-5590 Anti-Seize Compound to 6G-9692 Pin (1) before installation.
3. Before you remove the shipping brackets from the hoist cylinders, use a suitable lifting device
in order to stabilize the hoist cylinders.
4. Remove the shipping brackets from the hoist cylinders.
5. Use a suitable lifting device in order to align the pin bores of the truck body and of the hoist
cylinders.

(1) 6G-9692 Pin
(2) 6G-9696 Spacer
(3) 6G-9691 Bar
(5) 0S-1585 Bolt
6. Complete the installation of 6G-9692 Pin (1) with the following components: two 6G-9696
Spacers (2), 6G-9691 Bar (3), two 5P-8245 Hard Washers (4) and two 0S-1585 Bolts (5) .
Note: 6G-9696 Spacers (2) between the hoist cylinder and the outer ear of the truck body.
7. Repeat Steps 1 through 6 for the other hoist cylinder.
Install the 144-4146 Truck Body Retaining Cable Gp

Table 83
Required Parts for the Installation of the 144-4146 Truck Body Retaining Cable Gp
1 1 159-2512 Cable
2 1 105-0314 Coupler
3 2 1D-4643 Bolt
4 2 5P-8250 Washer
5 2 2H-3794 Locknut
6 1 8W-0109 Plate
7 1 2B-0974 Clevis Pin
9 1 3B-4617 Cotter
(1) 159-2512 Cable
(2) 105-0314 Coupler
(3) 1D-4643 Bolts
(4) 5P-8250 Washer
(5) 2H-3794 Locknut
1. Install one end of 159-2512 Cable (1) around 105-0314 Coupler (2). Attach 105-0314 Coupler
(2) to the truck body with the following components: two 1D-4643 Bolts (3), two 5P-8250
Washers (4) and two 2H-3794 Locknuts (5) .

(6) 8W-0109 Plate
(7) 2B-0974 Clevis Pin
(9) 3B-4617 Cotter
2. Install 8W-0109 Plate (6) to the truck body with the following components: 2B-0974 Clevis
Pin (7), 5P-8247 Hard Washer (8) and 3B-4617 Cotter (9) .

(1) 159-2512 Cable
3. Secure 159-2512 Cable (1) to the truck body, as shown.
Install the 3T-4411 Flood Lamp Gp

Table 84
Required Parts for Installation of the 3T-4411 Flood Lamp Gp

1 1 3T-4411 Flood Lamp Gp
Note: When the cab is shipped, the flood lamp is stored in the back of the cab.

(1) 3T-4411 Flood Lamp Gp
1. To ensure that you have an adequate surface for ground, clean the paint from the mounting of
the flood lamp.
2. Remove the tape that covers the mounting holes at the top of the cab. Pull the wiring from the
opening in the cab.
3. Connect the wire harness from the cab to the wire harness of 3T-4411 Flood Lamp Gp (1) .
4. Use the existing hardware to install 3T-4411 Flood Lamp Gp (1) .
Install the 5T-4463 Hydraulic Tank Mounting

Table 85
Required Parts for Installation of the 5T-4463 Hydraulic Tank Mounting

1 16 4L-6454 Bolt
2 14 6V-8801 Nut
3 16 8T-2561 Washer
4 2 8T-9101 Bolt
5 2 105-2200 Mud Flap
6 1 105-2201 Mud Flap
7 1 105-2204 Support
8 1 105-2205 Support
9 1 105-4620 Support

(A) Bolt
(B) Bolt
(C) Bolt
(D) Bolt
(1) 4L-6454 Bolt
(2) 6V-8801 Nut
(3) 8T-2561 Washer
(4) 8T-9101 Bolt
(5) 105-2200 Mud Flap
(6) 105-2201 Mud Flap
(7) 105-2204 Support
(8) 105-2205 Support
(9) 105-4620 Support
1. Remove the existing two bolts (A) from the hydraulic tank.
2. Use the two bolts (A) to attach 105-2205 Support (8) to the hydraulic tank.
3. Use four 4L-6454 Bolts (1), four 8T-2561 Washers (3), and four 6V-8801 Nuts (2) to secure
one 105-2200 Mud Flap (5) to 105-2205 Support (8) .
4. Loosen the two existing bolts (C) on the hydraulic tank.
Note: Do not remove the bolts (C) in order to prevent the sight glass from falling to the bottom
of the hydraulic tank.
5. Slide 105-2204 Support (7) over the existing bolts (C). Tighten the bolts in order to secure the
support to the hydraulic tank.
6. Use four 4L-6454 Bolts (1), four 8T-2561 Washers (3), and four 6V-8801 Nuts (2) to secure
one 105-2200 Mud Flap (5) to 105-2204 Support (7) .
7. Remove the two existing bolts (D) from the hydraulic tank. Remove the three existing bolts
(B) from the hydraulic tank.
8. Use bolts (B) to secure 105-4620 Support (9) to the hydraulic tank.
Note: Install the bolts in the three original holes.
9. Install two 8T-9101 Bolts (4) in 105-4620 Support (9) .
Note: The two 8T-9101 Bolts (4) replace bolts (D) .
10. Use eight 4L-6454 Bolts (1), eight 8T-2561 Washers (3), and six 6V-8801 Nuts (2) to secure
one 105-2201 Mud Flap (6) to the 105-4620 Support (9) .
Install the 154-9041 Film Gp or the 162-2755 Film Gp

Table 86
Required Parts for the Installation of the 154-9041 Film Gp or the 162-2755 Film Gp
1 1 100-5615 Film
2 3 131-5415 Film
3 1 100-8733 Film (1)
4 1 100-8728 Film (1)
1 154-9042 Film (1)
5
1 162-2756 Film (2)
6 1 154-9043 Film
7 1 100-8726 Film (LH)
8 1 100-8727 Film (RH)
9 1 154-9045 Film (LH)
10 1 154-9044 Film (RH)
(1) Only used on the 784C Tractors and the 785C Off-Highway Trucks
(2) Only used on the 785C HAA Off-Highway Trucks
Note: The film groups are shipped in the cab assembly.

(1) 100-5615 Film
(2) 131-5415 Film
(3) 100-8733 Film
(4) 100-8728 Film
(5) 154-9042 Film
(6) 154-9043 Film

(7) 100-8726 Film
(8) 100-8727 Film
(9) 154-9045 Film
(10) 154-9044 Film
Illustration 269
(1) 100-5615 Film
(2) 131-5415 Film
(3) 100-8733 Film
(4) 100-8728 Film
(5) 154-9042 Film
(6) 154-9043 Film
(7) 100-8726 Film
(8) 100-8727 Film
(9) 154-9045 Film
(10) 154-9044 Film
(A) 65 ± 5 mm (2.6 ± 0.2 inch)
(B) 350 mm (13.8 inch)
(C) 25 ± 1 mm (1.0 ± 0.04 inch)
(D) 35 ± 1 mm (1.4 ± 0.04 inch)
(E) 200 ± 1 mm (7.9 ± 0.04 inch)
(F) 300 mm (11.8 inch)
(G) 52 ± 1 mm (2.0 ± 0.04 inch)
(H) 155 mm (6.1 inch)
1. Install 100-5615 Film (1) and three 131-5415 Films (2) on the front of the canopy.
2. Install 154-9045 Film (9) to the left side of the truck body. Install 154-9044 Film (10) on the
right side of the truck body.
Note: Center the films in the available spaces.
3. Install 100-8727 Film (8) on the side of the right front fender. Install 100-8726 Film (7) on the
side of the left front fender.
Note: The films must be installed on the sides of the front fenders before the films are
installed on the front of the front fenders.
4. Install 154-9042 Film (5) on the front of the right front fender for the 784C Tractor and for the
785C Off-Highway Truck. Install 162-2756 Film (5) on the front of the right front fender for
the 785C HAA Off-Highway Truck. Install 154-9043 Film (6) on the front of the left front
fender. Install 100-8728 Film (4) and 100-8733 Film (3) on the front of the right front fender
for the 784C Tractor and for the 785C Off-Highway Truck.
Note: Align the red stripes on the front and on the side of the front fenders.
Perform the Commissioning Procedure for the Machine

Check all of the fluid levels. The fluids should be properly filled before the commissioning
procedures begin. Refer to Operation and Maintenance Manual, SEBU6250, "Caterpillar Machine
Fluids Recommendations" for the appropriate fluid for each system.
z Verify the integrity of the air intake system. Refer to Service Magazine, SEPD0635,
"Procedure to Test the Air Induction System".
z The engine crankcase contains 204 L (54 US gal) of oil for the 784C Tractor and for the 785C
Off-Highway Truck. The engine crankcase contains 291 L (77 US gal) of oil for the 785C
HAA Off-Highway Truck.
z The coolant system contains 390 L (103 US gal) of coolant for the 784C Tractor and for the
785C Off-Highway Truck. The coolant system contains 435 L (115 US gal) of coolant for the
785C HAA Off-Highway Truck.
z The hoist, torque converter, and brake tank contains 421 L (112 US gal) of oil.
z The hydraulic tank for the transmission contains 83 L (22 US gal) of oil.
z The hydraulic tank for the steering system contains 91 L (25 US gal) of oil. DO NOT attempt
to fill this tank while the engine is running. Fill the steering hydraulic tank when the engine is
OFF.
z Air pressure can be taken from the line for the air start tank.
z The steering pressure tap for standby pressure is on the right side on the inside of the frame.
This is close to the rear engine mount.
z The steering pressure tap for standby cut in pressure and the cut out pressure is on the left side
of the bottom of the steering valve.
z The pressure tap for the torque converter outlet pressure is located on the valve body that is
below the lockup valve.
z The torque converter lockup switch is located on the lockup valve on the rear of the converter
housing.
z The pressure tap for the transmission charge pump is located on the right side of the transfer
gear case on the transmission.
z The pressure tap for the lube oil of the transmission is on the right side of the transfer gear
case that is located on the transmission.
z The pressure tap for the hoist is located on the hoist pump on the inside of the right hand
frame.
z Two pressure taps for the TCS are located on the TCS valve. The valve is located on the right
side of the frame. The right hand wheel is located on the rear port.
z The pressure tap for the towing motor is located on the top left side of the differential housing.
z The brake retraction motor has the same tap as the towing motor.
z Look for all parts that are damaged or parts that are missing.
z Look for loose connections, loose fasteners, and loose joints.
z Look for leaks underneath the truck.
z Use the Service Manual to correct any problems.
Check the Configuration of the Electronic Control Modules

(ECM)
Reference: Service Manual, SENR9122, "Electronic Programmable Transmission Control
(EPTCII)"Service Manual, SENR1503, "769D, 771D, 773D, 775D, 784C, 785C, 789C, and 793C
Off-Highway Truck/Tractors Brake Electronic Control System"Systems Operation, RENR2630,
"Off-Highway Truck/Tractors Vital Information Management System (VIMS)" Testing and
Adjusting Troubleshooting, RENR2631, "Off-Highway Truck/Tractors Vital Information
Management System (VIMS)".
This section contains assembly checks and functional checks of the systems. Perform the checks
before you deliver the machine to the customer.
1. Connect a laptop computer to the Caterpillar Diagnostic Connector on the fuse panel behind
the operator seat. The laptop computer should have 139-4166 Data Link Cable As , 7X-1700
Communication Adapter , 7X-1425 Data Link Cable , and a NEXG4523 Service Program
Module.
2. In order to power the electrical system of the truck, perform the steps that follow:
a. Connect the batteries.
b. Turn the battery disconnect switch ON.
c. Turn the manual engine shutdown switch OFF.
d. Turn the key of the machine ON.
e. DO NOT START THE TRUCK.
Note: When the key is in the ON position, the VIMS System will perform a four second
to six second self test. Disregard the VIMS self test at this time.
3. Start the Electronic Technician (ET). The Electronic Technician (ET) lists all of the electronic
control modules for the machine. There will be at least an "ENGINE CONTROL", "POWER
TRAIN CONTROL", and a "BRAKE CONTROL". If the truck has the Automatic Retarder
Control (ARC), the ET screen should show the features.
4. The Electronic Technician (ET) should display the truck model for each control. Make sure
that the model is correct for each control.
5. Choose the "ENGINE CONTROL". Next, choose "CONFIGURATION".
6. Change the "EQUIPMENT IDENTIFICATION NUMBER" in order to correspond to the PIN

of the truck. If you select a new setting, select "ENTER". This confirms the change.
7. Check the "ENGINE SERIAL NUMBER". The "ENGINE SERIAL NUMBER" must match
the engine serial number that is on the engine. If you select a new setting, select "ENTER".
This confirms the change.
8. Adjust the "FUEL RATIO CONTROL", if necessary. The air/fuel ratio is adjustable. The
range is -25 to 25. The factory default is 0. If you select a new setting, select "ENTER". This
confirms the change.
9. Check the "FAN CONTROL" setting. On a truck that is equipped with a variable speed fan,
the "FAN CONTROL" must be on. On a truck that is equipped with a fan speed that is fixed,
the "FAN CONTROL" should be off. If you select a new setting, select "ENTER". This
10. Check the "ETHER CONTROL" setting. Set the "ETHER CONTROL" to the ON position. If
you select a new setting, select "ENTER". This confirms the change.
11. Check the "OIL RENEWAL CONTROL" setting. On a truck that is equipped with the oil
renewal system, the "OIL RENEWAL CONTROL" must be set to ON. After you set the
engine oil renewal solenoid to ON, the "OIL TO FUEL" ratio must be set to ON. After you set
the engine oil renewal solenoid to ON, the "OIL TO FUEL" ratio should be set. The "OIL TO
FUEL" is adjustable in a range from -50 to 50. The factory default is 10. If you select a new
setting, select "ENTER". This confirms the change.
12. Check the "ENGINE OIL PRELUBE" setting. On a truck that is equipped with the engine
prelube system, "ENGINE OIL PRELUBE" must be ON. If you select a new setting, select
"ENTER". This confirms the change.
13. Check the "COOL CYLINDER CUT-OUT". If you select a new setting, select "ENTER".
14. Check the "SHUTTER CONTROL" setting. On a truck that is equipped with an attachment
shutter, "SHUTTER CONTROL" must be ON.
15. Return to the engine control screen. Select "ACTIVE CODES". Select the "INCLUDE ALL
ECM'S" button. The button is at the bottom of the screen. If "NO ACTIVE CODES" appears,
then continue. Refer to Systems Operation, RENR2630, "Off-Highway Truck/Tractors Vital
Information Management System (VIMS)" and Testing and Adjusting Troubleshooting,
RENR2631, "Off-Highway Truck/Tractors Vital Information Management System (VIMS)".
This will help to resolve the active faults.
Note: A password that was assigned by the factory clears the events that are logged on the
engine ECM. This is the only way to clear the events from the engine ECM.
16. Return to the engine control screen and select "LOGGED CODES". Select the button at the
bottom of the screen "INCLUDE ALL ECM'S". Clear all codes that are logged. Refer to
Systems Operation, RENR2630, "Off-Highway Truck/Tractors Vital Information Management
System (VIMS)" and Testing and Adjusting Troubleshooting, RENR2631, "Off-Highway
Truck/Tractors Vital Information Management System (VIMS)". This will help to resolve the
active faults.
17. Return to the engine control screen and select "DIAGNOSTICS" and "EVENTS". Select the
button at the bottom of the screen "INCLUDE ALL ECM'S". Clear all of the codes that are
logged. Refer to Systems Operation, RENR2630, "Off-Highway Truck/Tractors Vital
Information Management System (VIMS)" and Testing and Adjusting Troubleshooting,
RENR2631, "Off-Highway Truck/Tractors Vital Information Management System (VIMS)".
Note: A password that was assigned by the factory clears the events that are logged on the
engine ECM. This is the only way to clear the events from the engine ECM.
18. Return to the engine control screen and select "SERVICE", "CALIBRATIONS", and
"INJECTOR CODES CALIBRATION". Select "PRINT" at the bottom of the screen. Select a
print destination.
Note: Step 18 provides a record of the injector code for each cylinder. The codes may
accidentally change. The injector codes are stamped on the injector. If an injector is changed,
the new injector code must be updated in the engine ECM.
19. The engine prelube and the ether control can be tested without starting the engine. The engine
prelube and the ether control can be tested.
a. Return to the engine control screen and select "DIAGNOSTICS" and "OVERRIDE
PARAMETERS". Select "START AID" and "CHANGE". The ether solenoids will
energize. Select "CHANGE" again. The feature will turn OFF.
b. Return to the engine control screen and select "DIAGNOSTICS" and "OVERRIDE
PARAMETERS". Select "ENGINE PRELUBE" and "CHANGE". The prelube motor
will energize. Select "CHANGE" again. The prelube motor will de-energize.
20. Return to the ET menu. Select "DATA LINK", "SELECT ECM", "POWER TRAIN
CONTROL", and "CONFIGURATION". On the configuration screen, check and adjust the
following parameters. Refer to Service Manual, SENR9122, "Electronic Programmable
Transmission Control (EPTCII)".
a. The "EQUIPMENT NUMBER" and the customer number should match. Make the
changes to the numbers, as needed. If you select a new setting, select "ENTER". This
b. Check the "TRANSMISSION SERIAL NUMBER". "TRANSMISSION SERIAL

NUMBER" should match the transmission serial number on the transmission. If you
select a new setting, select "ENTER". This confirms the change.
c. Check the "TRANSMISSION MAXIMUM GEAR" setting. The transmission maximum

gear setting is adjustable from four to six. If you select a new setting, select "ENTER".
d. Check the "BODY UP GEAR LIMIT" setting. The body up gear limit is adjustable from
one to four. If you select a new setting, select "ENTER". This confirms the change.
21. Return to the Electronic Technician screen. Select "DATA LINK", "SELECT ECM",
"BRAKES", "AUTO RETARDER", and "CONFIGURATION". From the configuration
screen, check and adjust the following parameters. Refer to Service Manual, SENR1503,
"769D, 771D, 773D, 775D, 784C, 785C, 789C, and 793C Off-Highway Truck/Tractors Brake
Electronic Control System".
b. Check the "TRANSMISSION SERIAL NUMBER". The "TRANSMISSION SERIAL

NUMBER" should match the transmission serial number on the transmission. If you
select a new setting, select "ENTER". This confirms the change.
c. Check the "TRANSMISSION MAXIMUM GEAR" setting. The maximum transmission

gear selection is adjustable from four to six. If you select a new setting, select
"ENTER". This confirms the change.
d. Check the "BODY UP GEAR LIMIT" setting. The body up gear limit is adjustable from
one to four. If you select a new setting, select "ENTER". This confirms the change.
22. Return to the Electronic Technician screen. Select "DATA LINK", "SELECT ECM",
"BRAKES", "AUTO RETARDER", and "CONFIGURATION". From the configuration
screen, check and adjust the following parameters. Refer to Service Manual, SENR1503,
"769D, 771D, 773D, 775D, 784C, 785C, 789C, and 793C Off-Highway Truck/Tractors Brake
Electronic Control System".
b. Check the "DESIRED ENGINE AUTO RETARDER SPEED". The engine automatic
retarder speed that is desired is adjustable from 1850 RPM to 1950 RPM. If you select a
new setting, select "ENTER". This confirms the change.
c. Use the VIMS keypad module. Enter "8378" and press "OK". This will initiate the
"VIMS SELF TEST". Refer to "VIMS Self Test" in the Operations and Maintenance
Manual.
d. With the laptop computer that is connected to the diagnostic port, continue to the next
step. Use the laptop computer again after the engine has been started.
Prepare to Start the Engine
1. Verify that the fluid levels are at a safe level.
2. Disable the engine at ground level. The engine should be shut off, so the engine will not start.
3. Prime the pump drive housing and the hoist pump with 3P-0659 Oil or crank the engine.
Crank the engine over two times for 15 seconds, while the engine is locked out. This will fill
the compartments with oil.
4. Start the engine. Verify that the pressures are safe for operation. Run the engine until normal
operation temperatures are reached. All the fluid levels should be adjusted, as required. Run
the engine for 5 seconds for the first two starts. Check and fill the hydraulic transmission, the
steering, the radiator, and the engine, as needed. Restart the engine and check for leaks. Run
the engine for 30 seconds and then run the engine for 60 seconds. Check the ground for leaks.
5. Refer to Systems Operation, RENR2630, "Off-Highway Truck/Tractors Vital Information

Management System (VIMS)" and Testing and Adjusting Troubleshooting, RENR2631, "Off-
Highway Truck/Tractors Vital Information Management System (VIMS)" for additional
information. There are three levels of warning categories. With a warning category 1, the
appropriate alert indicator will flash. With a warning category 2, the appropriate alert indicator
and the action lamp will flash. With a warning category 3, the appropriate alert indicator and
the action lamp will flash and the action alarm will sound intermittently.
{ The coolant temperature is a warning category 2.
{ The coolant flow is a warning category 3.
{ The engine oil pressure is a warning category 3.
{ The brake air pressure is a warning category 3.
{ The transmission oil filter is a warning category 2.
{ The converter or return oil temperature is a warning category 2.
{ The brake ON is a warning category 1 or a warning category 3.
{ The alternator is a warning category 1.
{ The fuel level is a warning category 1 with a 10 second delay.
{ The steering is a warning category 3.
6. Disconnect the cable, the adapter, and the module that is running the Electronic Technician
(ET) from the laptop computer. Connect a 127-9797 Cable to the RS-232 port on the laptop
computer. Connect the other end of the 127-9797 Cable to the diagnostic port in the panel
behind the operator's seat. Observe the gauges, the warning lights, and the service lights with
the laptop computer during the truck operation.
7. The low brake pressure indicator causes the alert indicator to flash. The VIMS Message Center
should provide the following instruction: "Do Not Move Machine". This message is on display
until the starting and service reservoir is charged to one-half of the maximum operating
pressure. If the parking brake switch is turned off and the correct air pressure is not attained,
the warning horn will sound.
8. Take notes on all of the events that are recorded on the message center. Resolve the events
before you proceed.
9. Start VIMS-PC software. Use VIMS-PC software to clear all faults that are logged on VIMS
memory.
Note: The logged events cannot be cleared when you are using the VIMS Keypad module.
10. Select "VIMS-PC COMMUNICATE" from the "VIMS-PC" group. Refer to Testing and
Adjusting Troubleshooting, RENR2631, "Off-Highway Truck/Tractors Vital Information
Management System (VIMS)", "Downloading Data From The Machine".
11. Select "DATA" and "DOWNLOAD DATA". Choose a destination and select "STANDARD
DATA". Then select "OK".
Note: Remove faults that are logged on the VIMS memory.
12. The yellow light should activate when the retarder is engaged.
13. The engine should be at normal operation temperature and the transmission should be in
neutral. Check the "HIGH" idle speeds (1935 ± 10 RPM) and the LOW idle speeds (700 ± 10
RPM). The RPM ranges cannot be changed.
Note: The automatic elevated low idle is activated after ten minutes of engine operation. The
low idle comes up gradually at the rate of 33 RPM per second. The transmission should be in
"NEUTRAL" and the parking brake should be ON. Do NOT depress the pedal for
engagement.
Note: After the activation of the elevated idle, the operator may reset the 10 minute delay by
pushing the throttle pedal to more than 25% of the pedal's travel. If the coolant temperature
rises above 70 °C (158 °F) engine speed returns to low idle.
14. Push the ground level shutdown switch. This shuts down the engine. The steering accumulator
tanks will not drain. Wait for 5 seconds. Turn the key to the off position. Listen for the tanks to
drain. The steering accumulator pressure drops to zero before you start the truck.
At operating temperature, the steering oil is hot and under pressure.

Hot oil can cause burns.
To prevent possible personal injury, release the pressure in the steering

system before the lines are disconnected or removed.
15. Bring the air pressure governor to the proper level for a maximum pressure of 827 ± 34 kPa
(120 ± 5 psi). Purge the air pressure to 455 kPa (66 psi). A warning category 3 occurs at 455
kPa (66 psi).
16. Check the air dryer. The air dryer should expel air at 827 kPa (120 psi).
17. The dryer should have 24 Volts or more.
18. The hoist pressure for the 785C is 17225 + 700 - 0 kPa (2500 + 100 - 0 psi).
Note: The power down pressure for the 785C is 3450 + 350 - 0 kPa (500 + 50 - 0 psi) at high
idle. The system should recover to full pressure within 1 second.
19. Check the hoist pressure. Hoist pressure occurs when you power up or you power down the
body. When the system is in the middle detent the system pressure is zero.
20. The transmission does not shift into reverse with the hoist lever that is raised. The truck must
be shifted to the forward gears with the hoist lever that is raised.
21. The cut in pressure for the steering system is 16470 ± 350 kPa (2390 ± 50 psi).
22. The cut out pressure for the steering system is 18300 ± 350 kPa (2655 ± 50 psi).
23. The low pressure standby for the steering system is between 2070 kPa (300 psi) and 3600 kPa
(525 psi).
24. The lube oil pressure for the transmission at LOW idle is 4 kPa (0.6 psi). The lube oil pressure
for the transmission at HIGH idle is 140 kPa (20 psi) to 205 kPa (30 psi).
25. The minimum oil pressure for the transmission charge pump at LOW idle is 2515 kPa (365
psi). The maximum oil pressure for the transmission charge pump at HIGH idle is 3175 kPa
(460 psi).
26. The oil pressure for the torque converter lockup is 2135 ± 70 kPa (310 ± 10 psi) when the
engine is operating at 1300 RPM or higher.
27. The maximum pressure for the torque converter outlet is 345 kPa (50 psi) to 585 kPa (85 psi)
at 1640 ± 65 RPM.
28. As the shift cane moves through each gear, the indicator will flash the correct gear. As the
gears shift the engine speed increases. This indicates that the throttle control shifting chip is
programmed.
29. Properly control the throttle shifting through all of the gears. As you shift up and down the
brakes must be off.
30. Check the downshift inhibitor. At HIGH idle, shift the transmission from sixth gear through all
of the gears to first gear. The transmission should not downshift.
31. Check the reverse shift inhibitor. With the transmission in first gear and travel speed at 10
mph, shift the shift cane into reverse. The transmission will shift into NEUTRAL. The
transmission will shift into reverse at 3 mph.
32. Check the transmission neutralizer switch. The engine will start in neutral only. Try to start the
engine in first gear and reverse.
33. With the engine that is turned off, shut the cab doors and windows. Engage the retarder and
apply the secondary brake and the foot brake. Listen for air leaks. Watch the air gauge for a
drop after the initial drop from the brake engagements. The pressure should remain at 3.5 kPa
(0.51 psi) per minute. Hold the engagement for 3 minutes. The maximum drop in air pressure
is 10 kPa (1.45 psi).
34. Test the air system overnight. Leave the truck shut down overnight. The air tank should
contain 827 kPa (120 psi). The air tank should contain enough air. The engine should start the
next morning. The truck requires 518 kPa (75 psi) to start the engine.
35. Check the pressure for the TCS system. There should be 4700 ± 200 kPa (680 ± 30 psi).
Note: When the retarder is on and the Traction Control System switch is on, the pressure
drops off on the left side and the pressure then drops off on the right side.
36. The parking brake indicator must flash when the parking brake is engaged.
37. A warning category 3 will activate when the following conditions occur:
{ The engine is running.
{ The transmission is in forward or reverse.
{ The parking brake is ON.
Note: Trucks that are operating with a VIMS system need ground speed to activate the
warning.
38. The parking brake warning light flashes when the secondary brake is engaged. A warning
category 3 will activate when the following conditions occur:
{ The engine is running.
{ The transmission is in forward or reverse.
{ The parking brake is ON.
Note: Trucks that are operating with a VIMS system need ground speed to activate the
warning.
39. Check the towing motor. The motor should have a minimum of 3790 kPa (550 psi).
40. The current draw for the towing motor should be 12 to 22 amperes at high pressure. You
should be able to hear the motor when the switch is on.
41. The brake retract pressure is 4700 ± 200 kPa (680 ± 30 psi).
Activate the Hoist Controls for the Truck Body
The truck might appear to have a problem with the body hoist controls. The 184-4671 Software
Group will set the parameters for the hoist system.
Note: ET Software must be used to set these parameters on all trucks.
Note: On the 2.4 ET Software, when the parameters are not visible or accessible on the configuration
screen, disconnect the connection and reconnect the connection. This establishes the communication
to the transmission control, until the parameters appear.
Note: On the 3.0 ET Software, the parameters appear clearly on the configuration screen.
Note: On the 3.1 ET Software, the figures will appear on the configuration.
Adjustment of the Hoist Lower Valve (A Programmable Parameter)
The hoist lower valve command is adjustable. This compensates for the differences in the valves.
The adjustment range is -5 to +5 with zero as the default. A positive adjustment factor will increase
the lower valve command. This causes the body to come down harder. A negative adjustment factor
will decrease the lower valve command. This causes the body to come down softer.
The adjustment for the hoist lower valve may not be available on earlier ECM systems. The
adjustment range may be from 0 to 10 with 5 as the default on some early ECM systems.
Note: When the adjustment for the hoist lower valve is set too high, too much oil can be diverted to
the hoist system while the hoist system is in float mode. This causes the brake oil to heat up faster.
Retarding capability is also decreased. To set the adjustment for the hoist lower valve, follow the
procedure below.
1. Raise the body of the truck and connect the truck body retaining cable.
2. Place a 6V-7830 Tetragauge or place a 3.45 MPa (500 psi) gauge with a hose extension on the
outlet port of the hoist pump.
Note: Disconnect the truck body retaining cable and lower the body to the frame.
3. While the body is down, place the hoist lever in hold.
4. Enter the configure parameter screen through the service menu in the Electronic Technician.
5. Change the adjustment for the hoist lower valve to a setting that is desired from -5 to 5. The
procedure begins at 0. Adjust the settings in increments of 1 in the positive position or in the
negative position.
Note: If you are using a 3.45 MPa (500 psi) gauge, remove the gauge from the extension.
6. Raise the body to the middle position.
7. Lower the body to the frame.
8. If a 6V-7830 Tetragauge is not installed, shut off the engine and install a 3.45 MPa (500 psi)
gauge. Start the engine and run the engine to high idle. Cycle the hoist lever to the body float
position and the hold position. Do not power down or raise the bed if you are using a 3.45
MPa (500 psi) gauge. Damage may occur to the gauge.
9. With the engine that is running, place the hoist lever in the body float position.
10. Run the engine to high idle. Verify that the pressure at the hoist outlet port is less than 1723
kPa (250 psi).
Note: When the pressure is greater than 1724 kPa (250 psi), the adjustment is set too high. This
causes too much oil to be diverted to the hoist valve. This causes the brake oil to overheat when the
body is in the body float position. Lower the adjustment for the hoist lower valve and repeat Step 4
through Step 10. This lowers the pressure below 1724 kPa (250 psi).
Note: The pressure can be checked after each resetting of the adjustment in ET. Cycle the hoist lever
from the hold position to the body float position. If you change the adjustment setting and there is no
corresponding pressure setting, cycle the lever again. A change will occur in the settings between 2
and 5.
Enable the Hoist System (A Programmable Parameter)
All the trucks that are shipped from the factory with the 184-4671 Software Group and without the
truck bodies have a hoist enable parameter that is set to a value of 2. Parameter Value 2 is a test
mode. Parameter Value 2 will prevent the hoist cylinders from being activated by accident. After the
body is installed, change the Parameter Value to 1. The hoist system should function properly. When
the hoist system does not work, check the items below.
1. Verify that the hoist system is enabled in the Configurable Parameters Screen through the
service menu in the Electronic Technician.
Table 87
Hoist Enable Parameter

Parameter
Description
Value
The hoist system is not installed.
The hoist lever does not function.
0
No diagnostics will be logged on the hoist lever. No diagnostics will be
logged on the solenoids.
1 The hoist system is installed and the hoist system is enabled.
The hoist system is installed but the hoist system is disabled in the
HOLD position.
2 The solenoids and the hoist lever have diagnostics, but the hoist lever is
ignored.
The solenoids are kept in hold.
2. Disconnect the Electronic Technician and then reconnect the line when the hoist enable status
does not appear on the configuration screen. The hoist enable parameter flexes with the 3.0 ET
Software when the parameter connects. On certain occasions, the flexed parameters are missed
by the Electronic Technician at the time of connection.
Note: 3.1 ET Software has this parameter that is standard on the configuration screen.
3. If the hoist enable status does not change, check the following items:
{ The engine should not be running.
{ The truck should not be moving.
{ Transmission Output Speed needs to be zero in order to change the parameter.
{ The engine causes the TOS signal to fluctuate, and this keeps the parameter from
changing.
Note: Press the F5 button in order to go directly to the configuration screen on the Electronic
Technician.
Body Down Snub Function (A Non-programmable Parameter)
The body down snub function cushions the shock when the body hits the bed of the truck. When the
body is lowered, the body up switch detects the proximity of the body to the rail of the truck. The
ECM will go into snub mode.
When the operator's request is less than the snub mode, the ECM will use the operator's request. This
ensures that the snub function will never cause the body to go down faster than the hoist lever
modulation (operator's request).
The body snub function will be cancelled as the operator moves the hoist lever out of the body float
position or the body lower position. The body snub function will not start, until the body goes above
the body up switch activation level.
Seat Controls
1. Check the following adjustments:
{ The distance from the front of the seat to the rear of the seat is 150 mm (6 inch).
{ The height is 75 mm (3 inch).
{ Adjust the weight for the suspension to the correct ride position.
{ The seat cushion has two positions.
{ The back cushion has three positions.
Seat Belt
1. Adjust the seat belt to the proper length.
2. Fasten the seat belt buckle around the lap. The length of the belt may not slip.
3. The belt should unlatch.
Instrument Panel
1. Turn the ignition key to the ON position. This supplies the power to the electrical circuits in
the cab. The dome lights and the windshield wipers can be checked.
2. Turn the key to the START position. This activates the starting motor. The diesel engine starts.
After the engine starts, release the key to the ON position.
3. Turn the ignition switch to the OFF position. The engine should stop. The electrical circuits in
the cab should de-energize. The instrument panel lights, the headlights, and the taillights
remain on.
Climate Control
1. Pressurize the cab:
{ Turn the ignition key to the ON position.
{ Turn the switch for the blower to the LOW position.
{ Turn the blower switch to the HIGH position.
{ There should be an audible sound.
2. Check the heater:
{ Start the engine.
{ The lines for the heater valves should be open.
{ Turn on the heat control. The air should be warm.
3. Check for air flow:
{ Turn the fan control switch to the LOW position or the HIGH position.
{ Check for air flow from the dash assembly and from the seat supports.
Windshield Wipers
1. Turn the ignition key to the ON position. Turn the wiper switch to the three positions. The
three positions are OFF, LOW, and HIGH. The front wipers and the rear wipers must operate
in both modes.
2. Depress the wiper switches. This will activate the windshield washers.
3. Turn the switches to the OFF position. The front wiper arms and the rear wiper arms should
return to the proper position.
Running Lights
1. The ignition switch should be in the OFF position. Push the three position switch from the
OFF position to the middle position. The instrument panel lights and the taillights should be
on.
2. Push the switch to the up position. The front headlights should be on.
Flood Lights
1. Turn the ignition key to the ON position.
2. Push the switch from the OFF position to the ON position. The lights will be activated.
Flood Lights (Auxiliary)
1. Turn the ignition key to the OFF position. Push the switch for the access ladder to the opposite
direction. The lamps for the access ladder should be on.
Check the switches in the cab and at ground level.
2. Push the switch for the engine compartment at ground level. The switch is in the bumper
assembly. The lamps in the engine compartment should be on.
Dome Lights
2. Turn the switch for the dome light ON and OFF.
Cigar Lighter
2. Push the cigar lighter inward. The cigar lighter should pop out.
Machine Horns
The ignition switch should be in the OFF position. Press the horn. The horn should sound.
Machine Operation
1. Operate the machine for a minimum of 15 minutes. Operate the machine in all gears and
perform steering maneuvers. Perform braking operations. Operate the implement systems
while you are operating the truck.
2. Correct any problems:
{ Harsh Braking
{ Jerky steering
{ Unusual noises
Rear Axle Hydraulic System
The truck comes from the factory with a 40 micron filter element for the rear axle lubrication and the
filtration system. The filter element is inside of the 132-2820 Filter Assembly . The filter is mounted
on the rear differential. Operate the truck for 8 hours with the 40 micron filter element. Install a 4T-
3131 Filter Element after the clean up period. The filter element is a 13 micron filter element.
Check the Service Brake Discs
Refer to the Air System and Brakes Testing and Adjusting, "Service Brake Discs - Check". Also,
refer to Guideline for Reusable Parts and Salvage, SEBF8095, "Service Brakes for Off-Highway
Trucks and Tractors" in order to determine the service intervals. Record all data in the Air System
and Brakes Testing and Adjusting, "Worksheets".
Transmission and Torque Converter Filters
The filter elements for the 6I-8073 Transmission Charge Filter and the 4T-4760 Torque Converter
Charge Filter should be changed after 8 hours of operation. Install the 4T-3131 Filter Element in the
6I-8073 Transmission Charge Filter . Install the 1R-0741 Filter Element into the 4T-4760 Torque
Converter Charge Filter . Install the 126-7840 Filter Assembly .
Checks Before the Delivery of the 784C Tractor or of the 785C Off-Highway Truck
The page that is following is a list of assembly checks and systems checks that are recommended. Do
this checklist before the truck is delivered to the customer. Do all of the checks and verify that the
systems function properly.
Refer to the Air System and Brakes Testing and Adjusting, "Service Brake Discs – Check". Also,
refer to Guideline for Reusable Parts and Salvage, SEBF8095, "Service Brakes for Off-Highway
Trucks and Tractors" in order to determine the service intervals. Record all data in the Air System
and Brakes Testing and Adjusting, "Worksheets".
Use the Service Manual and use the Operation and Maintenance Manual in order to correct any
system problems before you deliver the truck.
After you complete the final check, please sign your name and the name of the dealer.
Make copies of the check procedure. Mail the copies to the following address:
Caterpillar Inc.
Attention: MCE Product Support
784C Tractor and 785C Off-Highway Trucks
N. 27th and Pershing Road
Decatur, IL 62525
Dealer:____________________
Customer:____________________
Product Identification Number:____________________
1. Before you start the engine, make sure that all fluid compartments are full. Also, make sure
that all pump case drains are full.
2. Check that the system pressures are set correctly.
{ Pump
{ YES ____ NO ____
{ Brake
{ YES ____ NO ____
{ Steering Pressure
{ YES ____ NO ____
{ Transmission
{ YES ____ NO ____
{ Torque Converter
{ YES ____ NO ____
{ Differential
{ YES ____ NO ____
3. Check the machine lights.
{ Operational
{ YES ____ NO ____
{ Cab and Dash
{ YES ____ NO ____
4. Check the controls in the cab.
{ Check if the cab door opens. Check if the cab door closes.
{ YES ____ NO ____
{ Check if the Operation and Maintenance Manual is in the literature pouch on the back of
the operator's seat.
{ YES ____ NO ____
{ Check if the horn functions.
{ YES ____ NO ____
{ Check if the windshield wipers and washers function.
{ YES ____ NO ____
{ Check if the seat belts operate.
{ YES ____ NO ____
{ Check if the fan switch operates.
{ YES ____ NO ____
{ Check if the heater functions.
{ YES ____ NO ____
{ Check if the air conditioner functions.
{ YES ____ NO ____
{ Check the test light. The test light is for the EMS.
{ YES ____ NO____
{ Check if the hour meter operates.
{ YES ____ NO ____
{ Check if the implements operate:
{ Hoist
{ YES ____ NO ____
{ Steering Action
{ YES ____ NO ____
{ Check if the steering column functions.
{ YES ____ NO ____
{ Check if the parking brake functions.
{ YES ____ NO ____
5. Check if all fluid levels are full.
{ YES ____ NO ____
6. Correct any unusual noises or unusual leaks.
{ YES ____ NO ____
7. Check if all lubrication lines are filled with grease.
{ YES ____ NO ____
8. Check if all quality requirements are fulfilled. Check if all variances have been corrected.
{ YES ____ NO ____
9. Check if the backup alarms function.
{ YES ____ NO ____
10. Check if the machine is repainted to the factory specifications.
{ YES ____ NO ____
11. Check if there was damage to the machine from shipment.
{ YES ____ NO ____
12. Check if all required parts were shipped with the machine.
{ YES ____ NO ____
13. Sign your name in the space below.
{ Hydraulic
{
{ Electrical
{
{ Structural
{
{ Other
14. Comments
Predelivery Worksheet
Table 88
Date Employee I.D. Model Serial Number Hours Inspector Name
Note: All safety product improvement programs (PIP) must be completed.
Table 89
Service Points
Visual After
and Fluid Levels Operation
Inspection Operation
_ Oil _ Air Cleaner

_ Coolant Indicator
_ Fuel _ V- Belt
_ Batteries OVC Tension
> (12.45) _ _ Leaks - Oil,
VDC1 _ VDC2 Air, Fuel,
_ Priming Pump
_ Air Filters Coolant
_ Paint _ Governor Control
_ Drain Water _ Friction on
Engine (1) (2) _ Outside _ Air Compressor
from Fuel Tank Hoses
Damage _ Smoke Color
_ Drain Water _ Friction on
_ Unusual Noise
Separator Wires
_ Open Coolant _ Loose Wire
conditioner Connections
Valves _ Loose or
_ Grease Fittings Lost Fasteners
_ Transmission
_ Differential
_ Final Drives
_ Transmission - Each
_ Tire Pressure
Gear
_ Paint _ Grease Fittings _ Leaks - Oil
_ Neutral Start
_ Outside _ Front & Rear _ Loose or lost
Power Train _ Transmission Lever
Damage Axle Bolt Fasteners
Lock
_ Tires - Cuts, Torques _ Tires - Cuts,
_ Back - Up Alarm
gouges _ Front & Rear Gouges
_ Neutralizer Valve
Universal
_ Unusual Noise
Torques
_ Wheel to Rim
Torques
_ Steering
_ Brake Fluid _ Leaks - Oil,
_ Retarder
_ Paint _ Drain Water Air
Steering and _ Service Brakes
_ Outside from Air Tank _ Loose or
Brakes _ Parking Brakes
Damage _ Grease Fittings Lost Fasteners
_ Air Dryer
_ Unusual Noise
_ Sheet Metal
_ Loose or
_ Grease Fittings _ Enclosure Doors -
Chassis Lost Fasteners
_ Paint Locks and Latches
_ Welds
_ Damage
_ Hydraulic Tank _ Leaks - Oil
_ Controls
_ Cylinder _ Friction or
Hydraulic _ Too much Drift
Rods _ Grease Fittings Lost Fasteners
_ Unusual Noise
_ Grease Fittings _ Welds

_ Paint
_ Body Pads _ Loose or
Truck Body _ Damage _ Body Positions
_ Retention Lost Fasteners
_ Liners
Cable _ Damage
_ Disconnect Switch
_ VIMS
_ Hoist Control
_ Horn
_ Operation
_Seat Belts
Guide
_ Seat Adjustments
_ Maintenance
_ All Switches &
Guide
Controls
_ Windshield _ Parts Book
_ Doors and Windows
_ Sheet Metal Washer _ Seat Cover
_ Locks and Latches
_ Air Filters _ Steps & Grab
Cab _ Mirrors Adjustment
_ Paint _ Grease Fittings Irons
_ windshield Wipers
_ Glass _ Torque on _ Loose or
_ Windshield Washers
ROPS Support Lost Fasteners
_ Heater
_ Loose Wire
_ Air
Connections
Conditioner/Pressurizer
_ Leaks -
Lights - Outside and Cab
Water
_ Gauges
_ Unusual Noise
_ Steering Column
Adjustment
_ Attachment
_ Special
Fluid Levels _ Warning
Assembly
_ Charge on Fire _ Attachments Plates
Parts
Misc. and Suppression _ Engine Shutdown _ Decals
_ S/N Plates
Attachments System Switch _ Leaks
_ Correct
_ Grease Fittings _ Fire Suppression Test _ Loose or
Attachments
_ Automatic Switch Lost Fasteners
_ Hand Tools
Lubrication
_ Paint
System
(1) If the machine was in storage, the engine needs pressure lubrication before the engine is started.
(2) For cold weather operation, refer to Operation and Maintenance Manual, 5338.
Copyright 1993 - 2006 Caterpillar Inc. Mon Nov 6 12:05:54 UTC-0400 2006
All Rights Reserved.
Private Network For SIS Licensees.

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785C Off-Highway Truck APX00001-UP (MACHINE) POWERED BY 3512B En...

Assembly Procedures for 784C Tractors and 785C Off-

Improper assembly procedures could result in injury or death.

2 6E-6070 Front Suspension Gp (2)

2 231-0342 Front Suspension Gp (3)

1 4J-0522 O-Ring Seal

Required Parts for Installation of the 8W-4442 Service Brake Lines Gp

2 5T-4675 Tube As (2)

4 006-8352 O-Ring Seal

1 5T-4674 Tube As (2)

4 6V-8519 Half Clamp

1 5T-4673 Tube As (2)

1 4S-7530 Hose (3)

11 (6) 9D-4721 Rail

13 2 189-5526 Handhold (2)

14 1 156-8124 Pipe (2)

(7) This part is part of 187-1796 Ladder Gp .

1 157-8062 Plate (1)

1 8W-0571 Plate (2)

1 5T-4039 Brace (3)

2 0S-1595 Bolt (3)

2 8T-8917 Bolt (1)

2 5P-8245 Hard Washer (3)

2 8T-4223 Hard Washer (1)

Required Parts for Installation of 5T-3205 Rear View Mirror Gp

Required Parts for Installation of 8W-1923 Rear View Mirror Gp

Required Parts for Installation of 8W-7903 Rear View Mirror Gp

Required Parts for Installation of the 6G-9260 Steering Link

12 2H-3758 Bolt (2)

12 4K-0684 Hard Washer (2)

1 5T-7370 Support (2)

40 163-0042 Cab Mount

Qty Part Number Description

6 8T-4896 Hard Washer (1)

1 116-2041 Guard (1)

(1) The part is attached to the fuel tank group.

Required Parts for Installation of the 5T-3220 Platform Gp

4 141-7148 Clamp (1)

(1) This part is from the air lines group.

Qty Part Number Description

Required Parts for the Installation of the 172-0214 Exhaust Pipe Gp

Required Parts for the Installation of the 172-0215 Exhaust Pipe Gp

Required Parts for the Installation of the 173-8432 Exhaust Pipe Gp

Required Parts for the Installation of the 174-9332 Muffler Gp

Qty Part Number Description

2 6G-1546 O-Ring Seal (1)

2 8W-0331 Swivel Connector (1)

6 8W-3891 Flange Nut

Required Parts for Installation of the 154-3756 Body Mounting Gp

1 5T-5987 Mud Flap

Required Parts for the Installation of the Rock Ejectors

Required Parts for Installation of the 3T-4411 Flood Lamp Gp

Required Parts for Installation of the 5T-4463 Hydraulic Tank Mounting

1 100-8728 Film (1)

1 154-9042 Film (1)

1 162-2756 Film (2)

Ground to top of canopy

Ground to upper edge of body

Width of body assembly

Personal injury or death can result from lifting a heavy assembly.

Personal injury or death can result from improper lifting or blocking.

Approximate weights of the components are shown. Clean all surfaces

Truck frame module