785D Off-Highway Truck MSY00001-UP (MACHINE) POWERED BY 3512C Engi...

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Product: TRUCK
Model: 785D TRUCK MSY
Configuration: 785D Off-Highway Truck MSY00001-UP (MACHINE) POWERED BY 3512C Engine

Special Instruction
Caterpillar Off-Highway Truck (777, 785, 789, 793, and 797) Technician Checklist
Differential Removal and Installation Checklist{0372, 0374, 3258, 3258}
Media Number -REHS9021-00 Publication Date -02/07/2013 Date Updated -02/07/2013

i05345991

Caterpillar Off-Highway Truck (777, 785, 789, 793, and 797)

Technician Checklist
Differential Removal and Installation Checklist{0372, 0374,
3258, 3258}
SMCS - 0372-010; 0374-010; 3258-010

OEM:
CAT WDS (S/N: M6J1-UP)
Off-Highway Truck/Tractor:
777 (S/N: 84A1-UP)
777B (S/N: 4YC1-UP)
777C (S/N: 4XJ1-UP)
777D (S/N: AGC1-UP; FKR1-UP; 3PR1-UP; 2YW1-UP; AGY1-UP)
777F (S/N: WTK1-UP; JRP1-UP; JXP1-UP)
777G (S/N: T5A1-UP; TNM1-UP; RDR1-UP; T4Y1-UP)
785 (S/N: 8GB1-UP)
785B (S/N: 6HK1-UP)
785C (S/N: 1HW1-UP; APX1-UP; 5AZ1-UP)
785D (S/N: DMC1-UP; MSY1-UP)
789 (S/N: 9ZC1-UP)
789B (S/N: 7EK1-UP)
789C (S/N: 2BW1-UP)
789D (S/N: SPD1-UP; SHH1-UP)
793 (S/N: 3SJ1-UP)
793B (S/N: 1HL1-UP)
793C (S/N: CBR1-UP; 4AR1-UP; ATY1-UP; 4GZ1-UP)
793D (S/N: FDB1-UP)
793F Series AC (S/N: EMD1-UP)
793F (S/N: SND1-UP; SSP1-UP; RBT1-UP)
797 (S/N: 5YW1-UP)
797B (S/N: JSM1-UP)
797F (S/N: LAJ1-UP; WSP1-UP)

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Introduction
These checks are required for component removal and installation. Initial check after completion.

Note: Service literature procedures, specific to the model and serial number, must be used in this
process. The checklist does not substitute procedures for the procedures given in the service
literature.

Table 1
Customer Name/ Machine Unit Machine Serial Machine Service Work Order
Location Number Number Meter Hours Number
/

Table 2
Differential
Differential Differential Differential Differential
Installed
Removed Removed Installed Installed
Source/Rebuilder (2)
Sequence # CID (1) # Sequence # CID (1) #

(1)
CID (Component Identification) is the number assigned to the component by the user/dealer.
(2)
Suorce/Rebuilder is either NEW, REMAN, DLR (Dealer Rebuilt), or CUST (Customer Rebuilt).

Checklist
Table 3

1. Record Complaint:

2. Pre-repair contamination control.

High-pressure wash the rear half of the truck to remove all
A. dirt/debris.
Keep the work area clean and the floor dry - contain all fluid
B. spills.
Cover components with plastic or keep in containers until
C. installation to keep clean.
Verify new parts cleanliness. Assure that they are cleaned
D. and capped/ protected against dirt.

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3. Investigate differential history or failure cause, if appropriate.

Question the operator on application, operating conditions,
A.
and history. Review SOS history.
Review VIMS, EPTC2, or ET for detected fault information
B.
- record the work order folder.
Take SOS Sample refer to: Contamination Control
Guidelines, SEBF8482, "Obtaining Oil Sample for
C. Analysis". Drain the engine and related power train oil
reservoirs and visually check oil for water, coolant, or debris
contaminants.

D.
Inspect the magnetic drain plugs. Save any debris.
Remove/inspect system filters/screens and save any
E.
contamination evidence.

If the differential failed generating metal debris, then remove, clean, and
inspect / repair the wheel stations. Use the Caterpillar R&I checklists as
4. needed..

Cover and cap all cleaned and reused components/lines until installed to
prevent dirt entry.
Cover all removed component cores with plastic sheets until shipping covers
5. are available.

Inspect drive shaft splines and U-joints for wear/damage. Reference

SEBF8126, Guidelines for Reusable Parts, Universal Joints & Drive Shafts.
6. Spline tooth wear limit is 0.2 mm (0.008 inch).

Inspect axle shaft splines, traction aid gear, axle thrust wear surface, and final
7. drive hubcap thrust plate for damage and excessive wear.

Inspect differential mounting area and machine frame for wear, stripped
threads, cracks, or deformation.
8. Repair/replace and paint as needed.

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Remove and clean rear axle filtration system. Inspect and clean or replace
system hoses and tubes. Refer to Tool Operating Manual, NEHS0643, "Using
the 233-7191, 233-7192, 233-7193 and 265-4959 hose cleaning groups" and
Contamination Control Guidelines, SEBF8485, "Cleaning Fluid-Carrying
Hose and Tube Assemblies In Shop and Field Applications". Use new clamps
9. (torque to spec), o-ring seals, and gaskets.

Inspect the differential filter bypass and bypass indicator for correct
operation.
Inspect both the rear axle filter bypasses and bypass indicators for correct
10. operation.

11. Remove differential thrust pin and inspect for damage.

Thoroughly clean axle housing and mounting surface with a high

pressure/temperature wash.
Pay close attention to cavities in rear axle housing which may collect debris.
Use lint free shop towels in cleaning and checking the cleanliness of the rear
12. axle housing.

Supervisor sign-off required.

Inspect/replace the electrical connectors and harnesses for loose pins,

brittleness, and fatigue. Replace the differential/wheel station wire harness
13. every rebuild life cycle.

Install new or rebuilt lube oil pump and cooler. Verify correct operation of
rear axle motor drive pump, hydraulic motor, and lube oil pump (no warning
14. override logged, etc.)

Clean/protect all mounting surfaces and exposed cavities of the replacement

15. differential.

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16. Transfer all covers/plugs to the removed component cores and pack into
shipping containers to prevent damage and dirt entry. Tag with completed Cat
dealer core tag.

17. Install thrust pin - set clearance.

Clearance Specification Actual

Thrust Pin Setting

Use new bolts/u-joints to install the main drive shaft. Existing bolts cannot be
18. reused:

Bolt Torque Specification Actual

Main Shaft U-Joint

Differential
filter #:
__________
Install 6-micron clean-up filters for transmissions and
dealer rebuilt differentials. Install 40 micron clean-up filters Transmission
for new components. Use the clean-up filters for at least 8 filter #:
19. hours operation time. __________

Fill wheel stations and the axle housing with oil. Wait 10 minutes and check
20. oil level.

Perform the Transmission Oil Change Refill & Start-up Procedure to prevent
21. pump cavitation. Use oil meeting ISO --/16/13 cleanliness level.

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p y
loop filtration may be required to achieve ISO cleanliness Transmission
level of --/18/15 refer to Contamination Control Guidelines, test #:
SEBF8438, "Procedure for Filtering Off-Highway Truck __________
Rear Axle Oil" and Contamination Control Guidelines,
SEBF8454, "Procedure for Filtering Off-Highway Truck Axle test #:
(769-777) Rear Axle Oil". Attach particle count printouts. __________
22.

Break-in and Warm-up Procedure:

1) Operate in fourth gear or lower, until oil is at 180°F.
23. 2) Run truck to 60-75% load and limit speed to 4th gear for 15-20 minutes.

Differential
filter #:
__________
After 8 hours of operation without bypassing filters, inspect
the clean-up filters, install new standard filters final drive Wheel station
filters, and a new 13 micron (non-standard) differential filter #:
filter. __________
After 8 hours of operation, inspect the magnetic plug and check component
and related systems for leaks.
After one running shift and within 24 clock hours of installation, take a power
train system oil sample. Send the sample to the Cat dealer with this checklist,
completed, and signed.
After one running shift, and within 24 clock hours of installation, take an oil
sample from the differential and each wheel group. Send the samples to the
24. Cat dealer, along with this checklist, completed and signed.

Technician
Name: Signature: Date:

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