Caterpillar Certified Rebuild Upgrade (CCRU) For 785 and 785B Off-Highway Trucks{7000} Caterpillar

Off-Highway Truck:

785 (S/N: 8GB244-UP)

785B (S/N: 6HK1-UP)

Introduction

This Special Instruction provides the procedure in order to complete a Caterpillar Certified Rebuild Upgrade (CCRU) on a 785 or 785B Off-Highway Truck. The CCRU procedure involves upgrading a 785 or 785B to include the improved functionality of a 785C while rebuilding the machine per the Caterpillar Certified Rebuild (CCR) process. The upgrade includes a 3512B engine with Tier 1 emissions and VIMS electronics

Reference Disassembly and Assembly Manual, Parts Manual, and Operation and Maintenance Manual.

Registering CCRU Machines

Register the machine for CCRU via the standard CCR registration process.

Required Parts

Note: The required parts are subject to some change. Refer to TMI for the most recent required parts list.

Note: If you are required to fabricate a part, ensure that all fabricated parts are deburred. Use caution when deburring parts. Avoid excessive grinding and notches.

Table 1

Required Parts
Sales Model	Arrangement	Engine
785	446-9422	373-9862 Engine Ar  (1) 10R-6700 Engine Ar  (2)
785B	446-9423

( 1 )	New engine
( 2 )	Reman engine

Component Upgrades

When performing the CCRU, some components may be reused after performing required updates detailed below, including the frame and other major structures. Replace any components that are not reworked per the instructions below or do not pass reusability guidelines to fulfill 785C parts list. Additional components may be reusable depending on specific machine build configuration and/or service parts. Serviceable part numbers not common with the 785C CCR parts list are not acceptable for reuse unless specified in the upgrade instructions below. Refer to 785C CCR Documentation REYD1846 and Parts Book CCRC3021.

Refer to the CCRU website. The link to the website is:

https://dealer.cat.com/cda/layout?m=20009&x=7

Note: Update instructions cover all 785 8GB and 785B 6HK machines, later machines may already include some of the required component updates listed below. Compare as-built configuration (not latest service part) to 785C parts list.

Frame Upgrade

Recondition the machine frame per CCR documentation. Update clipping and mounting hardware per the prints below to fulfill 171-7851 Frame As and 7I-5073 Tube As . Most original mounting hardware will be reused, but remove original mounting hardware that interferes with attachment of new mounting hardware. Refer to the following documentation for frame reconditioning:

• Special Instruction, REHS0452, "Weld Repair Procedure for Field Retrofit of Large Off-Highway Truck Frame Superstructure"

• Reuse And Salvage Guidelines, SEBF8879, "Repair/Replace Large OHT Body Pivot Bores and Suspension Bores"

• Special Instruction, REHS0541, "Procedure for the Inspection, Repair, and Component Replacement on the Frames of Certain Off-Highway Trucks and Tractors"

Fabricated Frame Parts

Illustration 1	g03397185
3V-0966 Bar

ASTM A36

SAE Grades 1008 through 1025

Illustration 2	g03382461
6S-4806 Lug

ASTM A36

SAE Grades 1008 through 1025

Illustration 3	g03382474
7G-7118 Plate

ASTM A36

SAE Grades 1008 through 1025

Illustration 4	g03397183
7T-2406 Boss

ASTM A36

SAE Grades 1008 through 1025

Illustration 5	g03382495
8S-0349 Strip

ASTM A36

SAE Grades 1008 through 1025

Illustration 6	g03397188
8W-2844 Block

ASTM A108 Grade 1018

ASTM A576 Grade 1018

ASTM A36/A36M

AS/NZS 1442 Grade 1020 and 1022

AS/NZS 3678 Grade 250

AS/NZS 3679.1 Grade 250 and 300

Illustration 7	g03382431
8X-6083 Block

ASTM A108 Grade 1018

ASTM A576 Grade 1018

ASTM A36/A36M

AS/NZS 1442 Grade 1020 and 1022

AS/NZS 3678 Grade 250

AS/NZS 3679.1 Grade 250 and 300

Illustration 8	g03397598
103-5702 Plate As (1) 1F-0748 Weld Nut

Cold Rolled Strip: ASTM A109/A109M - Temper No. 4 or 5

Cold Rolled Sheet: ASTM A1008/A1008M - Designations CS (Grade A, B, or C) and DS (Grade A or B)

Hot Rolled Sheet: ASTM A1011/A1011M - Designations CS (Grade A, B, or C) and DS (Grade A or B)

Heavy Thickness Coils: ASTM A1018/A1018M - Designations CS (Grade A, B, 1007, 1008, 1009, 1010, or 1012), and DS (Grade A, B, 1006, or 1006A)

Hot Rolled Sheet: ASTM A1011/A1011M - Designation CS (Grade D) ASTM A510/A510M - Grades SAE 1006, 1008, 1010, and 1012

Illustration 9	g03397784
Plate 1

Illustration 10	g03397785
Plate 2

Illustration 11	g03397192
114-8129 Bracket As (2) Plate 1 (3) Plate 2 (4) 1F-0750 Weld Nuts (5) 9F-6445 Weld Nuts

Illustration 12	g03397268
159-8644 Plate

ASTM A36

SAE Grades 1008 through 1025

Illustration 13	g03397269
159-8645 Plate

ASTM A36

SAE Grades 1008 through 1025

Illustration 14	g03397271
159-8646 Plate

ASTM A36

SAE Grades 1008 through 1025

Illustration 15	g03397196
159-8643 Plate As (6) 159-8644 Plate (7) 159-8645 Plate (8) 159-8646 Plate

Illustration 16	g03397275
2H-1795 Plate

ASTM A36

SAE Grades 1008 through 1025

Illustration 17	g03397278
5P-2330 Gusset

ASTM A36

SAE Grades 1008 through 1025

Illustration 18	g03397279
171-7690 Plate

ASTM A36

SAE Grades 1008 through 1025

Illustration 19	g03397198
174-4318 Support As (4) 1F-0750 Weld Nuts (9) 2H-1795 Plate (10) 5P-2330 Gusset (11) 171-7690 Support As

Illustration 20	g03397283
142-5746 Gusset

ASTM A36

SAE Grades 1008 through 1025

Illustration 21	g03397285
171-0800 Support

Cold Rolled Strip: ASTM A109/A109M - Temper No. 4 or 5

Cold Rolled Sheet: ASTM A1008/A1008M - Designations CS (Grade A, B, or C) and DS (Grade A or B)

Hot Rolled Sheet: ASTM A1011/A1011M - Designations CS (Grade A, B, or C) and DS (Grade A or B)

Heavy Thickness Coils: ASTM A1018/A1018M - Designations CS (Grade A, B, 1007, 1008, 1009, 1010, or 1012), and DS (Grade A, B, 1006, or 1006A)

Hot Rolled Sheet: ASTM A1011/A1011M - Designation CS (Grade D) ASTM A510/A510M - Grades SAE 1006, 1008, 1010, and 1012

Illustration 22	g03397286
185-2295 Block

ASTM A108 Grade 1018

ASTM A576 Grade 1018

ASTM A36/A36M

AS/NZS 1442 Grade 1020 and 1022

AS/NZS 3678 Grade 250

AS/NZS 3679.1 Grade 250 and 300

Illustration 23	g03397200
178-3068 Support As (12) 142-5746 Gusset (13) 171-0800 Support (14) 185-2295 Block (15) 8D-3508 Boss

Illustration 24	g03414660
210-8624 Plate

ASTM A36

SAE Grades 1008 through 1025

Illustration 25	g03397201
231-8820 Plate

ASTM A36

SAE Grades 1008 through 1025

Illustration 26	g03382481
240-8944 Plate

ASTM A36

SAE Grades 1008 through 1025

Illustration 27	g03382485
296-6845 Plate

ASTM A36

SAE Grades 1008 through 1025

Illustration 28	g03397205
365-6190 Plate

ASTM A36

SAE Grades 1008 through 1025

Illustration 29	g03382836
391-2902 Plate

ASTM A108 Grade 1018

ASTM A576 Grade 1018

ASTM A36/A36M

AS/NZS 1442 Grade 1020 and 1022

AS/NZS 3678 Grade 250

AS/NZS 3679.1 Grade 250 and 300

Illustration 30	g03397208
391-2900 Plate As (16) 391-2902 Plate (17) 8T-5912 Weld Nut

Illustration 31	g03397220
432-2651 Plate

ASTM A656/A656M Grade 50

ASTM A1011/A1011M Grade 45, Grade SS 50, HSLAS 50 and HSLAS-F 50

ASTM A572 Grade 42 and Grade 50

ASTM A1018/A1018M Grade HSLAS 45/50 and HSLAS-F 50

AS 3678 Grade 350

AS 3679 Grade 350

Illustration 32	g03397209
432-2650 Plate As (18) 432-2651 Plate (19) 8T-5911 Weld Nuts

Illustration 33	g03397221
439-1754 Plate

ASTM A656/A656M Grade 80

Illustration 34	g03397263
103-2003 Boss

ASTM A36

SAE Grades 1008 through 1025

Illustration 35	g03397265
439-2607 Gusset

ASTM A656/A656M Grade 50

ASTM A1011/A1011M Grade 45, Grade SS 50, HSLAS 50 and HSLAS-F 50

ASTM A572 Grade 42 and Grade 50

ASTM A1018/A1018M Grade HSLAS 45/50 and HSLAS-F 50

AS 3678 Grade 350

AS 3679 Grade 350

Illustration 36	g03397223
439-1755 Plate As (15) 8D-3508 Boss (20) 439-1754 Plate (21) 103-2003 Boss (22) 439-2607 Gusset

Illustration 37	g03397225
100-4750 Block

ASTM A36

SAE Grades 1008 through 1025

Illustration 38	g03397231
2A-7041 Plate

ASTM A656/A656M Grade 50

ASTM A1011/A1011M Grade 45, Grade SS 50, HSLAS 50 and HSLAS-F 50

ASTM A572 Grade 42 and Grade 50

ASTM A1018/A1018M Grade HSLAS 45/50 and HSLAS-F 50

AS 3678 Grade 350

AS 3679 Grade 350

Illustration 39	g03397235
3G-9123 Block

ASTM A36

SAE Grades 1008 through 1025

Illustration 40	g03397236
5C-6406 Bar

ASTM A36

SAE Grades 1008 through 1025

Illustration 41	g03397246
5T-6229 Block

ASTM A108 Grade 1018

ASTM A576 Grade 1018

ASTM A36/A36M

AS/NZS 1442 Grade 1020 and 1022

AS/NZS 3678 Grade 250

AS/NZS 3679.1 Grade 250 and 300

Illustration 42	g03397247
5T-7927 Block

ASTM A36

SAE Grades 1008 through 1025

Illustration 43	g03397249
6G-5095 Block

ASTM A108 Grade 1018

ASTM A576 Grade 1018

ASTM A36/A36M

AS/NZS 1442 Grade 1020 and 1022

AS/NZS 3678 Grade 250

AS/NZS 3679.1 Grade 250 and 300

Illustration 44	g03397250
6W-0484 Angle

Cold Rolled Strip: ASTM A109/A109M - Temper No. 4 or 5

Cold Rolled Sheet: ASTM A1008/A1008M - Designations CS (Grade A, B, or C) and DS (Grade A or B)

Hot Rolled Sheet: ASTM A1011/A1011M - Designations CS (Grade A, B, or C) and DS (Grade A or B)

Heavy Thickness Coils: ASTM A1018/A1018M - Designations CS (Grade A, B, 1007, 1008, 1009, 1010, or 1012), and DS (Grade A, B, 1006, or 1006A)

Hot Rolled Sheet: ASTM A1011/A1011M - Designation CS (Grade D) ASTM A510/A510M - Grades SAE 1006, 1008, 1010, and 1012

Illustration 45	g03382475
7G-8263 Plate

ASTM A36

SAE Grades 1008 through 1025

Illustration 46	g03405558
7I-5073 Tube As

Frame Upgrades

Illustration 47	g03412716
Rear left-hand view of the frame (14) 150-3980 Bar (24) 296-6845 Plate (50) 8P-8308 Plate (52) 9D-5568 Boss (54) 9D-5659 Boss

Illustration 48	g03412717
Front left-hand view of the frame (31) 038-2091 Bar (52) 9D-5568 Boss (54) 9D-5659 Boss (56) 9D-6168 Boss

Illustration 49	g03412718
Front right-hand view of the frame (28) 391-2900 Plate As (30) 439-1755 Plate As (38) 5B-1983 Boss (40) 5H-9394 Boss (52) 9D-5568 Boss (54) 9D-5659 Boss

Illustration 50	g03412719
Rear right-hand view of the frame (6) 8W-2844 Block (47) 8D-3508 Boss (54) 9D-5659 Boss

Illustration 51	g03412721
Top view of the frame (3) 7G-7118 Plate (12) 114-8129 Bracket As (29) 432-2650 Plate As (53) 9D-5571 Boss (54) 9D-5659 Boss (55) 9D-6166 Boss

Illustration 52	g03413257
Top view of the frame (10) 103-4393 Bracket (13) 135-7459 Plate (32) 100-4750 Block (54) 9D-5659 Boss (56) 9D-6168 Boss

Illustration 53	g03413627
Top view of the bumper (43) 5V-5790 Block (54) 9D-5659 Boss (55) 9D-6166 Boss

Illustration 54	g03412722
Top view of the frame (2) 6S-4806 Lug (8) 9D-3446 Step (9) 9G-0028 Boss As (18) 178-3068 Support As (38) 5B-1983 Boss (54) 9D-5659 Boss (55) 9D-6166 Boss (56) 9D-6168 Boss

Illustration 55	g03412723
Front view of strut area (7) 8X-6083 Block (27) 386-3002 Support As (33) 138-1219 Collar (34) 2A-7041 Plate (41) 5T-6229 Block (51) 9D-5567 Boss (52) 9D-5568 Boss (53) 9D-5571 Boss (54) 9D-5659 Boss (56) 9D-6168 Boss

Illustration 56	g03414286
Front view of strut area (52) 9D-5568 Boss (54) 9D-5659 Boss (56) 9D-6168 Boss

Illustration 57	g03412725
Front left-hand view (31) 038-2091 Bar (42) 5T-7927 Block (51) 9D-5567 Boss (52) 9D-5568 Boss (54) 9D-5659 Boss (55) 9D-6166 Boss (56) 9D-6168 Boss

Illustration 58	g03413828
Front right-hand view (51) 9D-5567 Boss (54) 9D-5659 Boss (55) 9D-6166 Boss (56) 9D-6168 Boss

Illustration 59	g03413829
Front view (55) 9D-6166 Boss

Illustration 60	g03412727
Inside left-hand frame view (47) 8D-3508 Boss (51) 9D-5567 Boss (54) 9D-5659 Boss (55) 9D-6166 Boss (56) 9D-6168 Boss

Illustration 61	g03413831
Inside left-hand frame view (9) 9G-0028 Boss As (22) 257-6883 Plate (54) 9D-5659 Boss (55) 9D-6166 Boss (56) 9D-6168 Boss

Illustration 62	g03412729
Inside left-hand rail (5) 8S-0349 Strip (9) 9G-0028 Boss As (19) 210-8624 Plate (54) 9D-5659 Boss (55) 9D-6166 Boss (56) 9D-6168 Boss

Illustration 63	g03413911
Inside left-hand rail (21) 240-8944 Plate (54) 9D-5659 Boss (55) 9D-6166 Boss (56) 9D-6168 Boss

Illustration 64	g03412730
Inside right-hand rail (16) 171-7851 Frame As (54) 9D-5659 Boss (55) 9D-6166 Boss

Illustration 65	g03414186
Inside right-hand rail (54) 9D-5659 Boss

Illustration 66	g03412732
Inside right-hand frame view (4) 7T-2406 Boss (9) 9G-0028 Boss As (17) 174-4318 Support As (23) 258-7114 Plate As (39) 5C-6406 Bar (46) 7G-8263 Plate

Illustration 67	g03414234
Inside right-hand frame view (45) 6W-0484 Angle (54) 9D-5659 Boss

Illustration 68	g03414236
Inside right-hand frame view (6) 8W-2844 Block (54) 9D-5659 Boss

Frame Support Upgrade

Illustration 69	g03405461
127-0960 Boss

Carbon Steel, MIN 3:1 rolling reduction ratio

Illustration 70	g03405517
8W-4590 Plate

ASTM A36

SAE Grades 1008 through 1025

Illustration 71	g03405464
142-5747 Plate

ASTM A36

SAE Grades 1008 through 1025

Illustration 72	g03405465
171-7692 Plate

ASTM A108 Grade 1018

ASTM A576 Grade 1018

ASTM A36/A36M

AS/NZS 1442 Grade 1020 and 1022

AS/NZS 3678 Grade 250

AS/NZS 3679.1 Grade 250 and 300

Illustration 73	g03414583
171-7691 Support As (1) 127-0960 Boss (2) 8D-3508 Boss (3) 1F-0748 Weld Nut (4) 3R-4850 Block (5) 8F-9836 Boss (6) 142-5747 Plate (7) 171-7692 Plate

Illustration 74	g03414592
171-7691 Support As (8) 9F-6445 Weld Nuts (9) 1F-0750 Weld Nuts (10) 3H-4776 Boss (11) 8W-4590 Plate (12) 9F-2978 Weld Nut

Rear Axle Housing Upgrade

ReferenceSpecial Instruction, REHS6075, "Procedure to Install the Rear Axle Lubrication Filter Retrofit Kit on the 785C and the 789C Off-Highway Trucks"

Recondition the rear axle housing and support per CCR documentation. Update mounting hardware, add cooling and filtration functionality to the rear axle housing per the prints below to fulfill 310-8650 Rear Axle Housing As and 8X-8919 Support As .Refer to Special Instruction, SEHS9984, "Special Instruction For Rear Axle Lubrication, Cooling And Filtration Retrofit For 785 And 785B Off-Highway Trucks" for additional rework instructions. Rear axle filtration retrofit kit is required. Refer to IRM PELJ1406 "Rear Axle Filtration Retrofit Kit for 785C and 789C Off-Highway Trucks for alternate filter mounting option.

Rear Axle Fabricated Parts

Illustration 75	g03407035
142-5694 Block

ASTM A36

SAE Grades 1008 through 1025

Illustration 76	g03407037
149-9899 Bracket

ASTM A36

SAE Grades 1008 through 1025

Illustration 77	g03407038
Plate 0007

ASTM A108 Grade 1018

ASTM A576 Grade 1018

ASTM A36/A36M

AS/NZS 1442 Grade 1020 and 1022

AS/NZS 3678 Grade 250

AS/NZS 3679.1 Grade 250 and 300

Illustration 78	g03407039
Plate 0008

ASTM A108 Grade 1018

ASTM A576 Grade 1018

ASTM A36/A36M

AS/NZS 1442 Grade 1020 and 1022

AS/NZS 3678 Grade 250

AS/NZS 3679.1 Grade 250 and 300

Illustration 79	g03407130
Plate 0009

ASTM A108 Grade 1018

ASTM A576 Grade 1018

ASTM A36/A36M

AS/NZS 1442 Grade 1020 and 1022

AS/NZS 3678 Grade 250

AS/NZS 3679.1 Grade 250 and 300

Illustration 80	g03407131
Plate 0010

ASTM A108 Grade 1018

ASTM A576 Grade 1018

ASTM A36/A36M

AS/NZS 1442 Grade 1020 and 1022

AS/NZS 3678 Grade 250

AS/NZS 3679.1 Grade 250 and 300

Illustration 81	g03407132
Plate 0004

ASTM A108 Grade 1018

ASTM A576 Grade 1018

ASTM A36/A36M

AS/NZS 1442 Grade 1020 and 1022

AS/NZS 3678 Grade 250

AS/NZS 3679.1 Grade 250 and 300

Rear Axle Upgrade

Illustration 82	g03407146
Rear view

Illustration 83	g03407765
side view

Illustration 84	g03407766
Detail A

Illustration 85	g03407775
Detail B

Illustration 86	g03407776
Section C-C

Illustration 87	g03407777
Section D-D

Fabricated Rear Axle Support Parts

Illustration 88	g03407795
8X-8919 (1) 5T-7553 Block (2) 8X-5951 Bracket As (3) 328-9070 Bracket As (4) 351-2804 Bracket As (5) 355-5216 Plate (6) 355-5217 Plate (7) 109-2979 Boss (8) 4D-6293 Boss (9) 5H-9394 Boss (10) 6J-9944 Lug (11) 7J-7778 Lug (12) 8D-3508 Boss (13) 9V-8296 Block

Illustration 89	g03408604
8X-8919 view A-A (3) 328-9070 Bracket As (14) 8W-2837 Block

Illustration 90	g03411317
8X-8919 (12) 8D-3508 Boss

Illustration 91	g03414694
5T-7553 Block

ASTM A108 Grade 1018

ASTM A576 Grade 1018

ASTM A36/A36M

AS/NZS 1442 Grade 1020 and 1022

AS/NZS 3678 Grade 250

AS/NZS 3679.1 Grade 250 and 300

Illustration 92	g03408960
8W-2837 Block

ASTM A108 Grade 1018

ASTM A576 Grade 1018

ASTM A36/A36M

AS/NZS 1442 Grade 1020 and 1022

AS/NZS 3678 Grade 250

AS/NZS 3679.1 Grade 250 and 300

Illustration 93	g03408961
9V-8296 Block

ASTM A36

SAE Grades 1008 through 1025

Illustration 94	g03408974
109-2979 Boss

ASTM A108 Grade 1018

ASTM A576 Grade 1018

ASTM A36/A36M

AS/NZS 1442 Grade 1020 and 1022

AS/NZS 3678 Grade 250

AS/NZS 3679.1 Grade 250 and 300

Illustration 95	g03395206
4E-2543 Bracket

ASTM A36

SAE Grades 1008 through 1025

Illustration 96	g03408975
328-9070 Bracket As (15) 4E-2543 Bracket (16) 8T-3490 Weld Nut

Illustration 97	g03408979
351-2803 Bracket

Cold Rolled Strip: ASTM A109/A109M - Temper No. 4 or 5

Cold Rolled Sheet: ASTM A1008/A1008M - Designations CS (Grade A, B, or C) and DS (Grade A or B)

Hot Rolled Sheet: ASTM A1011/A1011M - Designations CS (Grade A, B, or C) and DS (Grade A or B)

Heavy Thickness Coils: ASTM A1018/A1018M - Designations CS (Grade A, B, 1007, 1008, 1009, 1010, or 1012), and DS (Grade A, B, 1006, or 1006A)

Hot Rolled Sheet: ASTM A1011/A1011M - Designation CS (Grade D) ASTM A510/A510M - Grades SAE 1006, 1008, 1010, and 1012

Illustration 98	g03408977
351-2804 Bracket As (16) 8T-3490 Weld Nut (17) 351-2803 Bracket

Illustration 99	g03395228
355-5216 Plate

Cold Rolled Strip: ASTM A109/A109M - Temper No. 4 or 5

Cold Rolled Sheet: ASTM A1008/A1008M - Designations CS (Grade A, B, or C) and DS (Grade A or B)

Hot Rolled Sheet: ASTM A1011/A1011M - Designations CS (Grade A, B, or C) and DS (Grade A or B)

Heavy Thickness Coils: ASTM A1018/A1018M - Designations CS (Grade A, B, 1007, 1008, 1009, 1010, or 1012), and DS (Grade A, B, 1006, or 1006A)

Hot Rolled Sheet: ASTM A1011/A1011M - Designation CS (Grade D) ASTM A510/A510M - Grades SAE 1006, 1008, 1010, and 1012

Illustration 100	g03395243
355-5217 Plate

Cold Rolled Strip: ASTM A109/A109M - Temper No. 4 or 5

Cold Rolled Sheet: ASTM A1008/A1008M - Designations CS (Grade A, B, or C) and DS (Grade A or B)

Hot Rolled Sheet: ASTM A1011/A1011M - Designations CS (Grade A, B, or C) and DS (Grade A or B)

Heavy Thickness Coils: ASTM A1018/A1018M - Designations CS (Grade A, B, 1007, 1008, 1009, 1010, or 1012), and DS (Grade A, B, 1006, or 1006A)

Hot Rolled Sheet: ASTM A1011/A1011M - Designation CS (Grade D) ASTM A510/A510M - Grades SAE 1006, 1008, 1010, and 1012

Hydraulic Upgrade

Recondition the main hydraulic tank per CCR documentation and complete modifications per the prints below to fulfill 161-0537 Tank and 105-2496 Cover .

Hydraulic Tank Upgrades

Illustration 101	g03395276
(1) 161-0540 Plate (2) 166-8629 Plate As

Illustration 102	g03408411
Block 1

ASTM A36

SAE Grades 1008 through 1025

Illustration 103	g03408413
Plate 1

ASTM A36

SAE Grades 1008 through 1025

Illustration 104	g03408415
Plate 2

ASTM A36

SAE Grades 1008 through 1025

Illustration 105	g03388582
(3) Block 1 (4) Plate 1 (5) Plate 2

Illustration 106	g03410455
105-2496 Cover

Steering Tank Upgrade

Recondition the steering tank and cover per CCR documentation and complete modifications per the prints below to fulfill 167-8106 Hydraulic Tank As and 155-4128 Cover As .

Illustration 107	g03405973
155-4128 Cover As (1) 5J-3306 Fitting (2) 6J-4022 Fitting (3) 9R-2613 Weld Boss

Illustration 108	g03405991
Side view of the 167-8106 Hydraulic Tank As (4) 4J-5050 Boss

Illustration 109	g03405993
Front view of the 167-8106 Hydraulic Tank As (5) 8T-6462 Weld Boss

Hood Upgrade

Recondition hood panel per CCR documentation and complete modifications per the print below to fulfill 163-0932 Hood As .

Illustration 110	g03408983
163-0932 Hood As (1) 161-4162 Plate (2) 290-2349 Plate (3) 310-1504 Channel (4) 314-8013 Channel (5) 1F-0748 Weld Nuts (6) 9F-2978 Weld Nuts

Fabricated Hood Parts

Illustration 111	g03408982
290-2351 Channel

Cold Rolled Strip: ASTM A109/A109M - Temper No. 4 or 5

Cold Rolled Sheet: ASTM A1008/A1008M - Designations CS (Grade A, B, or C) and DS (Grade A or B)

Hot Rolled Sheet: ASTM A1011/A1011M - Designations CS (Grade A, B, or C) and DS (Grade A or B)

Heavy Thickness Coils: ASTM A1018/A1018M - Designations CS (Grade A, B, 1007, 1008, 1009, 1010, or 1012), and DS (Grade A, B, 1006, or 1006A)

Hot Rolled Sheet: ASTM A1011/A1011M - Designation CS (Grade D) ASTM A510/A510M - Grades SAE 1006, 1008, 1010, and 1012

Illustration 112	g03410585
310-1504 Channel

Cold Rolled Strip: ASTM A109/A109M - Temper No. 4 or 5

Cold Rolled Sheet: ASTM A1008/A1008M - Designations CS (Grade A, B, or C) and DS (Grade A or B)

Hot Rolled Sheet: ASTM A1011/A1011M - Designations CS (Grade A, B, or C) and DS (Grade A or B)

Heavy Thickness Coils: ASTM A1018/A1018M - Designations CS (Grade A, B, 1007, 1008, 1009, 1010, or 1012), and DS (Grade A, B, 1006, or 1006A)

Hot Rolled Sheet: ASTM A1011/A1011M - Designation CS (Grade D) ASTM A510/A510M - Grades SAE 1006, 1008, 1010, and 1012

Illustration 113	g03410586
314-8013 Channel

Cold Rolled Strip: ASTM A109/A109M - Temper No. 4 or 5

Cold Rolled Sheet: ASTM A1008/A1008M - Designations CS (Grade A, B, or C) and DS (Grade A or B)

Hot Rolled Sheet: ASTM A1011/A1011M - Designations CS (Grade A, B, or C) and DS (Grade A or B)

Heavy Thickness Coils: ASTM A1018/A1018M - Designations CS (Grade A, B, 1007, 1008, 1009, 1010, or 1012), and DS (Grade A, B, 1006, or 1006A)

Hot Rolled Sheet: ASTM A1011/A1011M - Designation CS (Grade D) ASTM A510/A510M - Grades SAE 1006, 1008, 1010, and 1012

Illustration 114	g03410593
161-4162 Plate

Cold Rolled Strip: ASTM A109/A109M - Temper No. 4 or 5

Cold Rolled Sheet: ASTM A1008/A1008M - Designations CS (Grade A, B, or C) and DS (Grade A or B)

Hot Rolled Sheet: ASTM A1011/A1011M - Designations CS (Grade A, B, or C) and DS (Grade A or B)

Heavy Thickness Coils: ASTM A1018/A1018M - Designations CS (Grade A, B, 1007, 1008, 1009, 1010, or 1012), and DS (Grade A, B, 1006, or 1006A)

Hot Rolled Sheet: ASTM A1011/A1011M - Designation CS (Grade D) ASTM A510/A510M - Grades SAE 1006, 1008, 1010, and 1012

Platform Upgrade

Recondition platform per CCR documentation and complete modifications per the prints below to fulfill 7I-5397 Support As .

Fabricated Platform Parts

Illustration 115	g03410597
8W-0522 Channel

Cold Rolled Strip: ASTM A109/A109M - Temper No. 4 or 5

Cold Rolled Sheet: ASTM A1008/A1008M - Designations CS (Grade A, B, or C) and DS (Grade A or B)

Hot Rolled Sheet: ASTM A1011/A1011M - Designations CS (Grade A, B, or C) and DS (Grade A or B)

Heavy Thickness Coils: ASTM A1018/A1018M - Designations CS (Grade A, B, 1007, 1008, 1009, 1010, or 1012), and DS (Grade A, B, 1006, or 1006A)

Hot Rolled Sheet: ASTM A1011/A1011M - Designation CS (Grade D) ASTM A510/A510M - Grades SAE 1006, 1008, 1010, and 1012

Illustration 116	g03410599
8W-9619 Plate

Cold Rolled Strip: ASTM A109/A109M - Temper No. 4 or 5

Cold Rolled Sheet: ASTM A1008/A1008M - Designations CS (Grade A, B, or C) and DS (Grade A or B)

Hot Rolled Sheet: ASTM A1011/A1011M - Designations CS (Grade A, B, or C) and DS (Grade A or B)

Heavy Thickness Coils: ASTM A1018/A1018M - Designations CS (Grade A, B, 1007, 1008, 1009, 1010, or 1012), and DS (Grade A, B, 1006, or 1006A)

Hot Rolled Sheet: ASTM A1011/A1011M - Designation CS (Grade D) ASTM A510/A510M - Grades SAE 1006, 1008, 1010, and 1012

Illustration 117	g03407033
173-6564 Plate

Cold Rolled Strip: ASTM A109/A109M - Temper No. 4 or 5

Cold Rolled Sheet: ASTM A1008/A1008M - Designations CS (Grade A, B, or C) and DS (Grade A or B)

Hot Rolled Sheet: ASTM A1011/A1011M - Designations CS (Grade A, B, or C) and DS (Grade A or B)

Heavy Thickness Coils: ASTM A1018/A1018M - Designations CS (Grade A, B, 1007, 1008, 1009, 1010, or 1012), and DS (Grade A, B, 1006, or 1006A)

Hot Rolled Sheet: ASTM A1011/A1011M - Designation CS (Grade D) ASTM A510/A510M - Grades SAE 1006, 1008, 1010, and 1012

Illustration 118	g03410601
387-7537 Plate

ASTM A656/A656M Grade 50

ASTM A1011/A1011M Grade 45, Grade SS 50, HSLAS 50 and HSLAS-F 50

ASTM A572 Grade 42 and Grade 50

ASTM A1018/A1018M Grade HSLAS 45/50 and HSLAS-F 50

AS 3678 Grade 350

AS 3679 Grade 350

Other Components

Refer to the table below for additional parts that may be reused after reconditioning. Refer to reusability guidelines.

Illustration 119	g03406043
300-2141 Fender As (1) 173-6564 Plate (2) 8X-7422 Boss

Illustration 120	g03406036
300-2141 Fender As (3) 4D-6293 Boss

Illustration 121	g03407033
173-6564 Plate

Cold Rolled Strip: ASTM A109/A109M - Temper No. 4 or 5

Cold Rolled Sheet: ASTM A1008/A1008M - Designations CS (Grade A, B, or C) and DS (Grade A or B)

Hot Rolled Sheet: ASTM A1011/A1011M - Designations CS (Grade A, B, or C) and DS (Grade A or B)

Heavy Thickness Coils: ASTM A1018/A1018M - Designations CS (Grade A, B, 1007, 1008, 1009, 1010, or 1012), and DS (Grade A, B, 1006, or 1006A)

Hot Rolled Sheet: ASTM A1011/A1011M - Designation CS (Grade D) ASTM A510/A510M - Grades SAE 1006, 1008, 1010, and 1012

Reusable Parts

Table 2

Reusable Parts List
Qty	Part Number
5T-3280 Service and Parking Brake Gp
2	9D-6125 Adapters
16	0S-1588 Bolts
70	0S-1625 Bolts
66	2J-3505 Full Nuts
8	6M-9155 Pins
2	9D-7367 Pistons  (1)
2	9D-7849 Pistons
4	9S-4190 O-Ring Plugs
10	5P-4282 Taperlock Studs
8X-8365 High Speed Oil Change Gp
1	1P-7919 Male Coupler  (1)
1	6B-8129 Pipe Nipple
1	002-5743 Elbow
1	030-7965 Elbow  (1)
235-5741 Service Brake Control Gp
1	2D-8910 Elbow
1	5T-9733 Bracket
1	7D-5208 Fitting
1	7D-5207 Plug
2	5M-6213 Pipe Plugs
5T-6942 Protection Cap Gp
1	5T-0016 Transmission Cover
1	1L-5072 Dowel
1	9M-7394 Lever
6G-8390 Vandalism Protection Gp
1	1L-5072 Dowel
1	9M-7394 Lever
1	5D-1901 Washer
9G-9288 Protection Cap Gp
1	5D-1911 Hydraulic Cap Cover
1	1L-5072 Dowel
1	9M-7394 Lever
164-4884 Cowling Gp
2	8w-3872 Guards
179-3492 Fender Gp
1	8W-0571 Plate
1	8W-0568 Plate As
170-3597 Frame Gp
4	1D-4586 Bolts
2	1D-4637 Bolts
8	2A-1538 Bolts
2	5T-1351 Brackets
1	5T-8945 Bracket As
1	5T-8963 Bracket As
1	5T-3462 Cover
3	5T-3190 Guards
5	5T-6321 Plates
4	5T-1353 Spacers
163-0931 Truck Hood Gp
1	7P-8992 Handhold
1	5T-6399 Plate As
1	5T-4228 Rail As
4	8H-5305 Washers
144-4180 Air Horn Gp
2	4M-5282 Bolts  (1)
1	6V-8918 Bolt  (1)
1	5D-7133 Bracket  (1)
2	5D-7132 Clamps  (1)
1	5D-6998 Air Horn Gp
1	4M-5280 Plated Full Nut  (1)
2	6V-8185 Nuts  (1)
1	8T-4224 Hard Washer  (2)
187-1796 Ladder Gp
1	5T-8066 Brace
1	5T-8245 Ladder As
1	5T-8217 Plate
1	5T-8269 Plate
2	5T-8218 Plate As
2	2S-1654 Washers
4	7X-0618 Hard Washers  (1)
4	8T-4222 Plated Washers  (1)
170-3603 Air Conditioner Lines Gp
1	7X-3187 Bolt  (1)
1	8T-8917 Bolt  (1)
1	6V-1867 Clip
1	6V-1868 Clip
1	5P-4107 Washer  (1)
1	5P-4106 Nut  (1)
1	7X-0575 Hard Washer  (1)
173-9469 Fuel Lines Gp
1	9L-5254 Elbow
2	001-6301 Elbows
1	030-7965 Elbow  (1)
5T-3218 Heater Lines Gp
2	6P-8855 Tubes
6G-9260 Steering Link Gp
2	0S-1756 Bolts  (1)
1	9F-2247 Pipe Plug
6V-1970 Literature Gp
1	7F-3400 Polyethylene Bag  (2)
2	5P-8500 Keys
310-1730 Automatic Lubrication Gp
1	5T-2125 Angle  (1)
1	3B-7262 Pipe Nipple  (1)
1	8W-3085 Plate  (1)
163-7224 Cab Mounting Gp
6	1D-4649 Bolts  (1)
20	5T-5807 Retainers  (1)
193-6347 Cab Mounting Gp
22	1F-7464 Bolts
1	5T-7218 Support As
22	5P-8250 Washers
5T-4463 Hydraulic Tank Mounting Gp
2	6G-5293 Caps
5T-3220 Platform Gp
2	7F-5227 Bolts
1	5T-0087 Plate As
2	2G-8742 Hard Washers
6G-9270 Front Wheel Group
24	0S-1595 Bolts
84	8X-2560 Studs  (1)
6	8X-2561 Studs  (1)
2	5T-6062 Covers
6	8W-3891 Flange Nuts  (1)
84	2J-3507 Full Nuts  (1)
2	8X-2634 Front Wheels  (1)
365-4228 Chassis Wiring Gp
1	5P-9617 Adapter  (2)
1	6V-8918 Bolt  (1)
137-6648 Ether Starting Aid Gp
2	8T-4137 Bolts  (1)
4	8T-4200 Bolts  (1)
4W-4033 Refrigerant Condenser and Mounting Gp
1	8N-7486 Condenser Assembly  (1)
2	4W-4085 Plates  (1)
175-5210 Engine Oil Filler Gp
2	4H-7993 Clips
170-3577 Water Lines Gp
1	6V-9872 Connector
2	9B-7237 Bolts  (2)
1	2W-1389 Bonnet
2	2W-7390 Bracket As
3	6V-5040 Clips
3	6V-5039 Clips
1	2W-7393 Tube
170-3578 Water Lines Gp
4	8T-4222 Washers  (1)
7C-2655 Engine Support Gp  (1)
8	1B-7709 Bolts  (1)
4	3B-2968 Bolts  (1)
6	2N-5006 Bolts  (1)
6	5P-8086 Bolts  (1)
2	8W-0587 Caps  (1)
4	2J-3506 Full Nuts  (1)
2	3K-9770 Full Nuts  (1)
8	4K-0367 Full Nuts  (1)
2	7W-0659 Mounting Plates  (1)
2	7W-3495 Sleeves  (1)
2	4K-0684 Hard Washers  (1)
16	5P-8247 Hard Washers  (1)
8	5P-8248 Hard Washers  (1)
6	5P-8250 Washers  (1)
6	5P-8839 Hard Washers  (1)
365-4229 Traction Control Gp
1	8T-8917 Bolt  (1)
235-5741 Service Brake Control Gp
1	2D-8910 Elbow
2	9B-7237 Bolts  (2)
1	5T-9733 Bracket
1	7D-5208 Fitting
1	7D-5207 Plug
2	5M-6213 Pipe Plugs
5T-6942 Protection Cap Gp
1	5T-0016 Transmission Cover
1	9M-7394 Lever  (2)
6G-8390 Vandalism Protection Gp
1	9M-7394 Lever  (2)
1	1M-8649 Retaining Ring
1	5D-1901 Washer
6G-9570 Steering Cylinder and Mounting Gp
2	1U-3182 Steering Cylinder Gp
4	5T-6503 Plugs
309-9645 Hoist Cylinder and Mounting Gp
2	6G-9691 Bars
6	1D-4615 Bolts
2	6G-8208 Covers
2	6G-8221 Retainers
4	6G-9696 Spacers
365-4240 Brake Lines Gp
1	8W-3711 Bracket
1	5T-0965 Plate
1	5T-9053 Plate
365-4230 Service Brake Lines Gp
1	8W-1767 Junction Block
2	4L-6459 Bolts
2	8W-4733 Brackets
2	8W-3406 Air/Hydraulic Cylinder Gp  (2)
1	5T-1086 Plate
1	5T-1060 Brake Release Pump and Motor Gp
4	5M-1932 Taperlock Studs
170-3580 Hydraulic Oil Cooler Lines Gp
4	5T-7492 Angles
1	8T-2441 Clip
1	8T-2442 Clip
8	6V-1543 Half Clamps
2	5T-6742 Elbows
1	8W-4043 Plate
2	3S-5468 Hoses
1	5T-6778 Manifold
2	5T-4675 Tube As
2	8W-4289 Tube As
176-6393 Steering Lines Gp
2	8D-7296 Junction Blocks
2	1D-4707 Bolts
2	4F-5192 Bolts
2	5S-7383 Bolts  (1)
1	2G-8874 Clamp
1	2G-8875 Clamp
1	6D-0837 Elbow
1	8W-5161 Manifold
365-4225 Torque Converter Filter and Lines Gp
2	0T-0055 Bolts  (2)
7	0T-0065 Bolts
4	1B-4367 Bolts
1	8L-5008 Pipe Elbow
1	8W-2692 Flange
1	3P-0348 Relief Valve Gp
1	3P-0349 Relief Valve Gp  (1)
365-4234 Transmission Oil Lines Gp
2	8W-2691 Angles
1	8T-8917 Bolt  (1)
1	6V-1867 Clip
1	6V-1868 Clip
1	8W-0304 Manifold
1	8W-2612 Tube As
1	8W-2655 Tube As
6T-6148 Gear Pump and Drive Gp
1	9G-9621 Oil Pump Drive Gear
1	6T-6147 Gear Pump Gp
309-9641 Hydraulic Pump and Mounting Gp
1	2A-6546 Pump Drive Gp  (1)
156-9341 Steering Tank and Filter Gp
1	6V-0301 Adapter
5T-3230 Drive Shaft Guard Gp
1	2A-7238 Guard As  (1)
1	2A-7241 Guard As  (1)
310-6715 Axle and Mounting Gp
1	6G-6407 Axle Shaft
1	6G-6408 Axle Shaft
130-6634 Differential and Bevel Gear Gp
1	6V-9001 Elbow
7	0T-0102 Bolts  (1)
1	5T-5966 Bearing Cage
1	5T-5967 Bearing Cage
1	6V-0457 Bearing Cone
1	8M-3391 Cover
1	5T-8684 Differential Ring Gear
1	7D-3029 Thrust Pin
2	5T-5921 Plates
24	7D-3504 Taperlock Studs  (1)
365-4223 Rear Axle Housing Gp
6	0L-1178 Bolts
1	003-2143 Elbow
1	5T-5974 Plate
1	5T-5975 Plate As
365-4239 Service Brake Lines Gp
2	8W-0222 Adapters
1	5T-9142 Block
4	5P-2566 Bolts
1	8T-8917 Bolt
4	4K-5175 Bolts
365-4224 Oil Cooler Lines Gp
4	6G-7602 Manifolds
2	5T-0966 Plates
1	5T-4673 Tube As
1	5T-4674 Tube As
8W-4451 Pump Drive Shaft Gp
8	0L-0478 Bolts
8X-0498 Drive Shaft Gp
8	2N-2486 Bolts
365-4222 Axle Housing Support Gp
6	1D-4626 Bolts  (1)
20	2H-1618 Bolts  (1)
1	8X-0573 Pin  (1)
1	8X-0585 Plate  (1)
1	8W-9826 Ring  (1)
20	5T-1352 Spacers  (2)
1	8X-0572 Thrust Washer  (1)

( 1 )	Only used on 785B
( 2 )	Only used on 785

Complete CCR

After updating the components listed above, perform a 785C CCR per the CCR documentation. Install retrofit 250-6900 Cab Ar and new engine 373-9862 Engine Ar or reman option 10R-6700 Engine Ar . Any components not updated and reconditioned must be fulfilled by new or remanufactured components to satisfy the 785C parts list. Refer to 785C CCR Documentation REYD1846 and Parts Book CCRC3021.

CCRU Identification

After completing the 785C CCR, apply machine model decals displaying the original machine model 785 or 785B. Install the CCRU Serial Number Plate with the issued CCRU serial number and Caterpillar Rebuild Upgrade Machine decals per the CCR decal application guidelines.