784C and 785C Off-Highway Trucks Machine Systems Caterpillar

Installation Procedure

Note: The Duo-Cone seals must be installed correctly. Refer to Disassembly and Assembly, "Duo-Cone Seals - Install".

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Illustration 1	g06356602

1. Install seal (22). Use Tooling (E) to install Duo-Cone seal (21).
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   Illustration 2	g01737493

2. Install retainer (20).
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   Illustration 3	g01737461

3. Raise the temperature of bearing cone (19). Install bearing cone (19).
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   Illustration 4	g01737413

4. Lower the temperature of bearing cup (18). Install bearing cup (18). Ensure that bearing cup (18) is seated correctly.
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   Illustration 5	g01737393

5. Install O-ring seal (17). Install retainer (16). Install bolts (15).
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   Illustration 6	g01737374

6. Use Tooling (F) to install Duo-Cone seal (14).
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   Illustration 7	g01737333

7. Turn over wheel assembly (12). Lower the temperature of bearing cup (13). Install bearing cup (13). Ensure that bearing cup (13) is seated correctly.
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   Illustration 8	g01737181

8. Use Tooling (C) and a suitable lifting device to install wheel assembly (12). The weight of wheel assembly (12) is approximately 640 kg (1410 lb).
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   Illustration 9	g01738815

9. Install bearing cone (11). Do not install the shims now.

10. Use the following steps to perform the preferred bearing preload procedure.
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    Illustration 10	g01739255

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    Illustration 11	g01739256

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    NOTICE
    Failure to follow the recommended procedure or the specified tooling that is required for the procedure could result in damage to components. To avoid component damage, follow the recommended procedure using the recommended tools.

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    NOTICE
    Do not use an impact wrench to tighten or loosen the bolts on the bearing preload adjuster. The vibration of an impact tool can damage the digital indicators and/or cause incorrect indicator readings. Always use hand tools to tighten or loosen the bolts on the bearing preload adjuster.

    1. Use Tooling (H) to adjust the wheel bearing preload. Refer to Tool Operating Manual, NEHS0920, "200–4532 Front Wheel Bearing Preload Adjuster for 785, 789, and 793 Off-Highway Trucks".

    2. Use a suitable lifting device to position the preload adjuster of Tooling (H) onto the base plate of Tooling (H). The weight of the preload adjuster is approximately 150 kg (330 lb). The weight of the base plate is approximately 191 kg (420 lb).

    3. Apply Tooling (G) onto the bolts of Tooling (H). Install the bolts . Tighten the bolts to a torque of 271 N·m (200 lb ft) in a diagonal pattern by one quarter turn at a time.
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       Illustration 12	g01739276

    4. Set the dial indicators of Tooling (H) to read zero.
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       Illustration 13	g01739294

    5. Loosen the bolts of Tooling (H) by one quarter turn at a time in a diagonal pattern. Loosen until all the bolts are no longer threaded into the base plate of Tooling (H).

    6. Clean the threads that are in the spindle. Ensure that the spindle is free of burrs. Use a suitable lifting device to install the preload adjuster of Tooling (H) onto the spindle. The weight of the preload adjuster is approximately 150 kg (330 lb).

    7. Install the bolts. Tighten the bolts to a torque of 271 N·m (200 lb ft) in a diagonal pattern by one quarter turn at a time.

    8. Use Tooling (A) to release the parking brake. Do not exceed 4137 kPa (600 psi).

    9. Rotate the wheel by a minimum of three revolutions.

    10. Record the measurement from each of the dial indicators of Tooling (H) and average the measurements. Record the average measurement as Dimension (X).
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        Illustration 14	g01739256

    11. Use a suitable lifting device to remove the preload adjuster of Tooling (H). The weight of the preload adjuster is approximately 150 kg (330 lb).
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        Illustration 15	g01738831

    12. Install a number of shims (10) that is equal to Dimension (X).

    13. Apply Tooling (G) onto new bolts (8). Install retainer (9) and new bolts (8). Tighten new bolts (8) to a torque of 250 ± 14 N·m (184 ± 10 lb ft).
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        Illustration 16	g01737113

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        Illustration 17	g01737035

    14. Remove Tooling (A).

        Note: Relieve the pressure in the parking brake before Tooling (A) is removed. Failure to remove the pressure could result in injury or death to personnel in the area.

11. Use the following steps to perform the alternate bearing preload procedure.
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    Illustration 18	g01738573

    1. Use Tooling (J) to measure the thickness of retainer (9) at three locations. Average the three measurements and record the result as Dimension (X). Install retainer (9). Install four new bolts (8) that are equally spaced. Tighten bolts (8) to a torque of 80 N·m (59 lb ft).

    2. Use Tooling (A) to release the parking brake. Do not exceed 4137 kPa (600 psi).

    3. Rotate the wheel by two revolutions. Tighten bolts (8) to a torque of 80 N·m (59 lb ft). Rotate the wheel by two revolutions. Tighten bolts (8) to a torque of 80 N·m (59 lb ft). Rotate the wheel by two revolutions. Use Tooling (K) to measure the distance from the top of the retainer to the end of the spindle at three locations. Average the three measurements and record the result as Dimension (Y). Subtract Dimension (X) from Dimension (Y) and record the result as Dimension (Z).

       Note: The factory retainer will have only two holes.

    4. Remove bolts (8) and retainer (9).
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       Illustration 19	g01738831

    5. Install a number of shims (10) that is equal to Dimension (Z) plus an additional 0.34 mm (0.0134 inch).

    6. Apply Tooling (G) onto new bolts (8). Install retainer (9) and new bolts (8). Tighten new bolts (8) to a torque of 250 ± 14 N·m (184 ± 10 lb ft).
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       Illustration 20	g01737113

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       Illustration 21	g01737035

    7. Remove Tooling (A).

       Note: Relieve the pressure in the parking brake before Tooling (A) is removed. Failure to remove the pressure could result in injury or death to personnel in the area.

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    Illustration 22	g01737115

12. Install O-ring seal (7). Install cover (6). Apply Tooling (G) onto bolts (5). Install bolts (5).
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    Illustration 23	g01737114

13. Install O-ring seals (4).
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    Illustration 24	g01737093

14. Position manifolds (3). Install bolts (2) and bolts (1).

End By:

1. Install the wheel, the brake, and the suspension cylinder.