Usage:
Introduction
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Do not attempt to assemble this machine until you read and understand the assembly procedure. Improper procedures could result in injury or death. |
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Before unloading the 789 Chassis and components, read the following suggestions, which will make the assembly easier.
Previous assembly experience has shown that choosing the correct area is the first step to a smooth, quick assembly.
NOTE: The last two pages of this instruction contain a check list that must be completed and returned to Caterpillar Inc.
Preparation Before Assembly of Machine
A flat, smooth, well-drained area 30.5 m × 24.5 m (100 ft. wide × 80 ft. long) is needed. Use the center of the area to set the chassis.
Keep the area around the chassis free for the movement of the cranes.
As the components are unloaded, set them in a position near the chassis; but not in the way of the cranes. They will not have to be handled again except for installation on the chassis.
Set the large wooden boxes of smaller components, sheet metal, mud flaps, and hardware aside and out of the way. Open the boxes to familiarize yourself with there contents.
Do not open the bags of hardware. The bags are well marked as to where the contents are used. Place all the bagged hardware in one of the large wooden boxes close to the machine area.
As the components are installed, remove the bagged hardware marked for that components from the box.
By organizing the hardware as described, the risk of lost hardware is reduced, as well as the time spent searching for parts.
Included in this Special Instruction is a list of tools and equipment recommended for assembly of the truck.
This equipment and tools should be readily available at the assembly site.
The use of these suggestions, the tools and equipment recommended, and a thorough understanding of the Special Instruction will help ensure a smooth, organized assembly.
Reference: Parts Manual, Operation & Maintenance Manual, Tool Guide, 789 Truck Service Manual Modules SENR3334, SENR3436, SENR4733 and SENR4724, and Special Instruction SMHS7867.
NOTE: After assembly of the truck is complete, suspension cylinders must be charged (if not charged at the factory) and the air purged from the brake system. Get the truck ready for use as shown in the Operation and Maintenance Guide. Use the Parts Book and the Service Manual along with this instruction.
| NOTICE |
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Do not let any dirt or foreign material get into the hydraulic system. |
| NOTICE |
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Clean all surfaces and remove burrs from all areas where parts are to be installed. Use solvent (initially) and 4C4204 Cleaner for final cleaning. |
Weights (approximate)
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When a hoist is used to lift any part or assembly, stand clear of the area. Be sure the hoist has the capacity to lift a heavy assembly. Approximate weights of the components and assemblies are given below. |
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Chassis module as shipped ... 42 676 kg (94,000 lb)
Cab assembly ... 1 725 kg (3800 lb)
Front strut, wheel and brake assembly (each) ... 4 758 kg (10,480 lb)
Final drive, wheel and brake assembly (each) ... 5 571 kg (12,270 lb)
Tire and rim assembly (standard) each ... 3 738 kg (8,233 lb)
Tire and rim assembly (attachment) each ... 4 502 kg (9,917 lb)
Body and canopy assembly (standard) ... 25 044 kg (55,222 lb)
Body equipped with liners - add approximately ... 9106 kg (20,033 lb)
Body and canopy assembly (heavy duty) ... 26 307 kg (57,875 lb)
Body and canopy assembly (taconite) ... 24 056 kg (52,987 lb)
Hoist cylinder (each) ... 908 kg (2,000 lb)
Axle (heaviest) ... 249 kg (548 lb)
Body pivot pin (each) ... 41 kg (90 lb)
Fuel tank ... 900 kg (1,980 lb)
Air tank ... 161 kg (354 lb)
Steering tank ... 100 kg (222 lb)
Right platform and steering tank ... 600 kg (1,320 lb)
Specifications
Empty weight ... 113 152 kg (250,000 lb)
Wheel base ... 5 700 mm (224.4 in)
Length ... 12 177 mm (479.4 in)
Ground to top of canopy ... 5 928 mm (233.4 in)
Turning radius ... 27.5 m (90 ft 3 in)
Ground to upper edge of body (36 x 51 tires installed) ... 5 304 mm (208.8 in)
Outside of body assembly to center of body ... 3220 mm (126.75 in)
Torque Specifications
Rear axle housing mounting bolts 86 ... 1825 ± 175 N·m (1350 ± 130 lb ft)
Rear axle housing cover mounting nuts 20 ... 55 ± 10 N·m (40 ± 8 lb ft)
Wheel rim mounting nuts all ... 1125 ± 100 N·m (830 ± 75 lb ft)
Front suspension cylinder mounting bolts/nuts 24 ... 1825 ± 175 N·m (1350 ± 130 lb ft)
Front suspension cylinder mounting bolts/nuts 8 ... 4000 ± 500 N·m (2950 ± 370 lb ft)
Front suspension cylinder cap mounting bolts 8 ... 875 ± 100 N·m (645 ± 75 lb ft)
Front steering arm mounting bolts 16 ... 1632 ± 50 N·m (1200 ± 37 lb ft)
Steering cylinder mounting nuts 4 ... 2550 ± 100 N·m (1887 ± 75 lb ft)
Tie rod end mounting nuts ballstuds ... 2550 ± 100 N·m (1887 ± 75 lb ft)
Cab support mounting bolts 25 ... 875 ± 100 N·m (648 ± 75 lb ft)
Necessary Hoist Capacity
Chassis assembly (less cab, platform, etc.).
To remove the chassis assembly from the lowboy trailer, two hoists with 36 320 kg (80,000 lb) capacity are needed.
With the differential housing on supports, one hoist with 36 320 kg (80,000 lb) capacity is needed to lift the chassis at the front lifting points.
With the front frame crossmember on supports, one hoist with 36 320 kg (80,000 lb) is needed to lift the chassis at the rear lifting points.
Necessary Tools and Use
- 1 - 1U8848 Axle Installation Tool2P2506 Lubricant (Anti-seize)9S3263 Sealant - Thread Lock
Used on platform mounting bolts 10 mm (3/8 in) 5P3520 Spanner Wrench
Used to hold steering arm and steering cylinder ballstuds during torque. 1 - 6V6080 Torque Multiplier (18.5 to 1 power ratio)
Used to tighten: Front Strut Mounting Nuts (2 3/16 in); Steering Tie Rod Ball Joint Nuts (3 1/2 in);ROPS Cab Mounting Bolts (1 7/8 in)1 - 6V7820 Torque Multiplier (6 to 1 power ratio)
Used to tighten: Rear Axle Housing to Differential Housing nuts and bolts (1 1/2 in); Wheel Rim Mounting Nuts (1 1/2 in)1 - 6V7915 Torque Wrench
Used: With 6V6080 and 6V4085 Torque Multiplier 1 - 6V7916 Torque Wrench
Used to tighten: ROPS Cab Mounting Bolts (1 7/8 in) 1 - 6V4154 Box Wrench (1 1/2 in)
Part of Torque Extension Arrangement, includes 6V4170 Adapter and 6V3146 Extension
Extension: Used to tighten final drive bolts and front strut top bolts
- 1 - 6V3146 Extension handle 1 - 5S6084 Socket (3 1/2 in)1 - 6V4170 Adapter (3/4 in square drive)1 - 2P8261 Adapter (3/4 in x 1 in)1 - 8H8537 Socket (1 1/2 in)
Used to tighten: Rear Axle Housing and Front Strut Assembly 1 - 5S6076 Extension, 25 x 457 mm (1.0 in x 18 in)
Used with 2P2336 Socket and 2P2338 Socket 1 - 2P2336 Socket (1 7/8 in)
Used to tighten ROPS Cab bolts and front strut mounting nuts to correct torque 1 - 2P2338 Socket (2 3/16 in)
Used to tighten Front Strut nuts to correct torque 1 - Nitrogen charging kit to charge suspension cylinders (if necessary)3 - 3/4 in x 10, 203 mm (8.0 inches long) threaded rod or bolts
Used to install lift cylinder bearings if they were removed for shipping 1 - 7H1680 Volume Compressor
Hand operated oil pump to oil charge suspension cylinders 1 - 6V4040 Nitrogen Tire Inflation Group
Used to correctly inflate tires with nitrogen 1 - 8T5230 Air Regulated Controlled Torque Wrench, 300 N·m (220 lb ft) capacity1 - 8T5183 Extension, 19 x 406 mm (.75 in x 16 in)
Used with air controlled torque wrench (wheel mounting nut) 1 - 8T5182 Socket (1 1/2 in)
Used with 19 x 406 mm (.75 in x 16 in) extension 1 - 8T3196 Slug Wrench (offset box, 1 7/8 in)
Used to hold front suspension cylinder mounting nuts during torque 1 - 1 1/4 in x 7 Tap
Necessary Equipment for Assembly
- 2 - 36 320 kg (80,000 lb) cranes
Cables and/or chains of adequate capacity: * Single - 23 653 kg (52,100 lb)* 25 mm (1.0 in) diameter chain double - 40 860 kg (90,000 lb)* Double - 23 653 kg (52,100 lb)* Shackles - 44 mm (1.75 in) = 27 240 kg (60,000 lb) minimum load* 3 - 208 liter (55 gal.) barrels of final drive oil GO - SAE 80W90 (see Operation and Maintenance Manual)* 2 - 208 liter (55 gal) barrels of CD/T0-2 SAE 10 hydraulic oil
Portable air compressor. This compressor must have enough capacity to operate two 25 mm (1.0 in) impact air guns at the same time. Minimum air compressor capacity 3 M3 (100 cfm) minimum * 6 or more 101 x 203 x 406 mm (4.0 x 8.0 x 16.0 in) hardwood blocks* 2 - 1.83 m (6 ft) step ladders and 2 - 3.66 m (12 ft) step ladders* 94 m (308 ft) of 13 or 19 mm (.50 or .75 in) rope to help guide the body into position when installing on the chassis* Cleaning solvent (initial cleaning of mounting surfaces)* 4C4204 Cleaner (final cleaning of mounting surfaces)* Nitrogen, approximately 20-T sized bottles (337 ft3), or equivalent (for tire inflation and suspension cylinder charging)* Lift truck with the capacity to lift approximately 6810 kg (15,000 lb)* 4 - 7 x 1062 Ether bottles
Tire Inflation Pressure and Mounting
NOTE: Valve stem connections and extensions must be installed at initial mounting and inflation of the tire. See the topics entitled "Installation of Front Tires and Rims" and "Installation of Rear Tires and Rims".
NOTE: The "R" in tire size denotes radial construction.
Chassis Lifting Points
1. When lifting the chassis assembly, make lifting connections at locations (A) and (B).
2. Use cables or chains around the rear of the chassis at locations (C) and (D) as shown.
Chassis Support
1. Place supports under the front and rear of the truck chassis.
NOTE: Make sure that there will be enough clearance to install the rear tires and rims.
2. To install the front strut and rear wheel assemblies only, with the strut completely retracted, 457 mm (18 in) in height is needed. Tires and rims can be installed later.
3. To install the front tires rims, 1524 mm (60 in) in height is needed.
4. To install the rear tires and rims, 1372 mm (54 in) in height is needed.
Installation of Front Step Assemblies
Install front step assemblies (1) and (2) with bolts and washers.
Installation of Final Drive, Wheel and Brake Assembly
1. Remove skid plate (1), spacers and shipping cover (2) from the differential housing, both sides.
2. Remove shipping cover (3) from both axle housings.
3. Clean all mounting surfaces and remove burrs, where parts are to be installed, both sides.
4. Position axle housing with Automatic Electronic Traction Aid (AETA) Speed Sensor towards the rear, Install axle housing (4) with a 5P9519, O-ring Seal, bolts and washers at location (A), both sides.
5. Tighten bolts (5) to a torque of 1825 ± 175 N·m (1350 ± 130 lb ft), both sides.
NOTE: If equipped with AETA do not install the guard until all bolts (5) have been tightened to their correct torque.
6. If equipped with an AETA, connect the wire to the sensor as shown.
8. Tighten the bolts to a torque of 1825 ± 175 N·m (1350 ± 130 lb ft).
9. Install a clip at location (B) with a bolt and washer.
10. Install 8X2277 Plate (9) with 2J2555 Bolts and 5D0764 Washers. Fasten 8X2278 Plate Assembly (10) to the plate with 0S1585 Bolts and 5P8245 Washers, both sides.
11. Tighten the bolts to a torque of 1825 ± 175 N·m (1350 ± 130 lb ft).
Installation of Front Suspension Cylinders (Struts)
1. Remove bolts and spacers. Keep the bolts, as these are needed for installation.
2. Remove the spacers and cover (1) and bracket (2). Keep the hardware, as it is needed for installation.
3. Clean all mounting surfaces and remove any burrs, where parts are to be installed.
4. Install 5T6255 Key (3) as shown, both sides.
5. Install suspension cylinder (4) with the steering arm mounting surface towards the rear of the chassis.
NOTE: Make sure 5T6255 Key is in the correct location.
6. Install twelve 5P5769 Bolts (5) with 5T1352 Spacers (6), 4K0684 Washers and 7H7539 Nuts (7). The nuts go towards the outside.
7. Install four 2D7687 Bolts (8) with 5T4896 Spacers (9), 3S6162 Washers and 8H3390 Nuts (10) in the bottom four holes. The nuts go towards the outside.
8. Install strut cap (11) on suspension cylinder (4) with the locking ring down.
NOTE: Before installing the R.H. suspension cylinder, make sure that the strut cap is installed on the suspension cylinder.
10. Tighten bolts (5) to a torque of 1825 ± 175 N·m (1350 ± 130 lb ft) and bolts (8) to a torque of 4000 ± 500 N·m (2950 ± 370 lb ft).
11. Tighten strut cap bolts (12) to a torque of 875 ± 100 N·m (648 ± 75 lb ft).
12. Connect grease line (13) with clip (14), each side.
NOTE: If the truck is equipped with a payload monitor, connect wire (15) to the sensor located under guard assembly (16).
13. If the ballstuds for the steering cylinders and tie rod ends were removed, clean the tapers and put 2P2506 Lubricant on the ballstud tapers.
14. Install steering arm (17) with eight 3R2300 Bolts and tighten to a torque of 1632 ± 50 N·m (1208 ± 40 lb ft), each arm.
15. Install steering cylinder (18) and tie rod (19) as shown (both sides) with the open side of the clamps to the rear. Adjust both tie rods to a 1689 mm (66.5 in) dimension from grease fitting to grease fitting.
NOTE: A ratchet puller (as shown) can be used to align the steering cylinder and tie rod ends with the steering arm.
16. Remove plug (20) and the snap ring from each ballstud that has to be tightened.
17. Install nuts (21) and using the spanner wrench as shown, tighten the nuts to a torque of 2550 ± 100 N·m (1887 ± 75 lb ft).
18. Again, install plug (20) and the snap ring in each ballstud from which they were removed.
19. Install the hydraulic steering lines with O-ring seals, bolts and washers, both cylinders.
20. Connect grease lines at locations (A), (B), (C), (D), (E), (F) and (G).
NOTE: Refer to Service Brake Lines Group and Brake Oil Cooler Lines Group in the Parts Manual for additional information on how to connect the following lines.
21. Remove all plates that cover the openings. Install brake oil cooler manifold (22) on the front brake housing with O-ring seals, bolts and washers, both sides.
22. Connect brake oil cooler lines (23) and (24) with O-ring seals, flanges, bolts and washers, each side.
23. Connect service brake line (25) at location (H) as shown, each side.
24. Clip service brake line (25) at location (J) as shown, each side.
25. Connect parking brake line (26) as shown with clamp (27), both sides.
26. Clip parking brake line (26) at location (K) as shown, each side.
27. Remove plug (27) from the front brake housing.
28. Install 7B4115 Nipple, 081104 Reducer, 5H4778 Elbow and connect 5D7464 Hose Assembly (29). Connect 3D7587 Elbow, 9M8662 Coupling and 4H6112 Breather (28) as shown, both sides.
Installation of Front Tires and Rims
| NOTICE |
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Make sure that all grease, burrs, nicks, etc. are removed from the wheel and rim mounting surfaces. Use solvent for initial cleaning and 4C4204 Cleaner for final cleaning. Failure to do so may cause damage to the wheel and rim. |
NOTE: Before mounting a front tire and rim on the wheel, make sure that a 8W0331 Connector (45°) and a valve assembly are installed at initial mounting and inflation of the tire.
1. Raise the front of the truck approximately 1524 mm (60.0 in) and support with blocks or stands.
NOTE: Keep the hoist attached to the front of the truck until the tires and rims are installed.
2. Install tire and rim (1) with washers and nuts (2), each side.
3. Tighten rim mounting nuts (2) to a torque of 1125 ± 100 N·m (830 ± 75 lb ft).
4. Inflate the tires with nitrogen. (See Tire Inflation Pressure and Mounting chart).
Front Wheel Alignment and Suspension Cylinder Adjustment
Check and adjust front wheel alignment as follows.
1. Lift the front of the truck until the front wheels are off the ground and the suspension cylinders are fully extended.
NOTE: The front suspension cylinders can be charged at this time with nitrogen. Charge the front cylinders with nitrogen to 1668 kPa (242 psi), this will give the correct dimension with the body installed on the machine on level ground; or see the topic entitled "Dimensions and Charging Pressures for Front and Rear Suspension Cylinders".
2. Move the wheels to a straight ahead position.
3. Measure the distance between the front tires at location (A).
4. Mark location (A) on each tire and rotate 180°.
5. Again, measure distance (B) between the same marks.
6. The correct toe-out for the front wheels (with the suspension cylinder fully extended) is obtained when distance (B) at the back of the tires is 48.5 mm (1.91 in) less than distance (A) at the front of the tires.
7. If it is necessary to adjust the tie rods to get the correct toe-out, loosen clamps (1) on the left side and clamps (2) on the right side. Turn each tie rod the same number of turns to get the correct toe-out measurement.
8. After adjustment, the tie rods must be equal length.
9. Remove the stands or blocks and lower the front of the truck to the ground.
Installation of Rear Ladder Assembly
Install rear ladder assembly (1) with bolts and washers.
Installation of Cab Assembly
1. Remove lifting bracket (1) and the shipping cover from the frame. Clean the frame and support mounting surfaces. The hardware from the lifting bracket will be used for mounting the cab.
NOTE: Clean the threads in the cab mounting surfaces with a 1 1/4 in - 7 tap.
3. Tighten support mounting bolts to a torque of 875 ± 100 N·m (648 ± 75 lb ft).
4. Install four 5T5804 Sleeves (4) shortest sleeve, and eight 5T5803 Rubber Mounts (5) at locations (A) and (B) as shown, cab front mounting surfaces.
5. Install six 5T8643 Sleeves (6) longest sleeve, and twelve 5T5803 Rubber Mounts (7) at location (C), cab rear mounting surface - inside.
6. Install six 5T5805 Sleeves (8) middle size sleeves, and twelve 5T5803 Rubber Mounts (9) at location (D), cab rear mounting surface - outside.
NOTE: Put 9S3263 Sealant (Thread Lock) on all bolts that are used to mount the platform assemblies.
7. Install platform assemblies (10) and (11).
8. Install handrail assemblies (12), (13), and (14). The left hand rear view mirror may be installed at this time. Refer to Rear View Mirror Group in the Parts Manual.
9. Install flood lamp (15), handhold (16) and hood latch assembly (17).
10. If the truck is equipped with a payload monitor, connect wiring harness (18) to harness (19) and wiring harness (20) to harness (21).
11. Install two 9G9150 Clips (22) with a bolt and washer as shown.
NOTE: Make sure green lamp assembly (23) is towards the front.
12. Install the lamp assemblies on the side of the cab with bolts and washers.
13. Clean the cab mounting surfaces and cab support assemblies.
14. Put the cab in position on supports (2) and (3).
NOTE: Use 5T9893 Shims (front) and 5T9894 Shims (rear) as necessary between the cab and either front or rear support to achieve a flatness within 0.75 mm (.03 in) with the cab.
15. Install eight 6H1628 Bolts (24), six 1K9418 Bolts (25) and six 1D4649 Bolts (26) with 5T5807 Retainers.
16. Tighten cab mounting bolts to a torque of 1904 ± 68 N·m (1409 ± 50 lb ft).
Air Hose and Electrical Connections
1. The plate for the air hose connections is located at the right rear of the cab.
2. Each opening in plate (A) has an identification number as shown. Each air hose also has an identification tag with a corresponding number.
3. Connect each air hose to the opening with the same number on the plate. (See following hose identification).
- * 1 Main air supply and air compressor governor line.
- * 2 Air supply to air start control valve.
- * 3 Parking brake control valve air line.
- * 4 Service brake control valve air line.
- * 5 No connection.
- * 6 Governor control chamber to governor control valve line.
- * 7 Automatic lubrication supply air line (if equipped).
- * 2 Air supply to air start control valve.
4. Connect four cannon plugs (8).
5. Connect tachometer cable (9). Install window washer hose (10) at location (B).
6. Connect body hoist control rod (11) to lever (12).
7. Connect payload monitor (if equipped) wiring (13) and (14) and install two clips with a bolt and washer. (This material is shipped in rear compartment behind the cab.)
8. Connect fire suppression hose (15) if equipped.
9. Open the air cleaner access panel on the front of the cab and position window washer hose (16) as shown.
10. Run the hose down along the right side of the cab to the washer bottle and connect it at location (C).
11. Install three 4D7794 Clips (17) with bolts and washers.
12. Close the access panel on the front of the cab.
13. Install windshield wiper arm and blade (18).
Installation and Connection of Steering Lines and Hoses
1. Remove the panel from the front of the cab.
7. Fasten the five steering lines to 5T6852 Bar with two 5T6867 Clamps (6) and one 9S1350 Clip (7) with bolts and washers.
8. Connect cab wiring as shown and install two 9G9154 Clips (8) with a bolt and washer.
9. Connect air horn hose (9) with a clip as shown.
10. Connect heater hoses (10) and (11) (from the cab) to hoses (12) and (13) on the chassis with spacers and clamps.
11. Open the heater valves on the engine.
12. Connect air conditioner hoses (14) and (15) (from the cab) to hoses (16) and (17) on the chassis.
13. Connect steering hoses (18), (19), (20), (21) and (22) from the steering control valve to tubes (1), (2), (3), (4) and (5). The ends of the tubes and hoses are numbered for correct connections.
14. Install clamps (23) and (24).
15. Install 6G8532 Guard Assembly (25) with bolts and washers.
16. Install the panel on the front of the cab.
NOTE: Guard (25) and the front panel should be installed later, so a check for leaks can be made after start up.
Installation of Platform and Fenders
1. Install the left hand ladder assembly (1) with bolts and washers, do not tighten the bolts at this time.
2. Install a 7G6276 Plate between bracket (2) and the ladder at location (A) with a 9S1366 Bolt, 5P1076 Washer and a 1D4719 Nut.
3. Install support assembly (3) with bolts and washers, do not tighten the bolts.
NOTE: If desired, the air cleaners can be installed on the fenders before the fenders are installed on the machine. See the topic entitled Installation of Air Cleaners and Air Lines.
4. Install fender assembly (4) with bolts and washers.
5. Install 8W2025 Brace (5) as shown. Connect parking and turn signal wiring harness (6) [located inside of rubber hose] to wiring harness (7).
6. Install clamps (8) and clip (9) with a bolt and washer.
7. All bolts can now be tightened.
8. Install right fender assembly (10) ... ... with a 8W4926 Plate at location (B) as shown.
9. Connect parking and turn signal wiring harness (11) [located inside of rubber hose] to the wiring harness on the chassis.
10. Install a clip at location (C) with a bolt and washer.
11. Connect wire (12) from the chassis to the disconnect switch and wire (13) from the disconnect switch to the battery.
12. Put wire (14) through the opening and install clips (15) and (16).
NOTE: Refer to Lighting and Wiring Group in the Parts Manual for more details.
13. Put payload monitor wire (17) through the opening with 8K1433 Grommet (18) and install 9M8406 Clip (19).
14. Connect wire (17) to the wires on the lamp assemblies (20) and install two 9G9150 Clips.
15. Install lamp assemblies (20) [green lamp towards the rear] with bolts and washers.
Installation of Handrails
1. Install handrail (1).
2. Install handrail (2).
3. Install handrail (3) if removed for shipment.
4. Install battery door latch assembly (4) with U - bolts, nuts and washers.
Installation of Mirrors
Install right hand and ...
... left hand mirrors as shown.
Installation of Air Cleaners and Air Lines
4. Connect hose assembly (3) to indicator mounting block (5) as shown, each side.
5. Remove protective covering, loosen clamp (6) and slide air tube (7) out towards the air cleaner.
6. Align tube (7) with tube (8) and install elbow (9) with four 5P4869 Clamps (10). Do not tighten clamps at this time.
NOTE: The elbows should be at room temperature for ease of installation.
7. Install 7N5008 Hose (11) between tubes (7) and (12) with four 5P0600 Clamps (13). Do not tighten the clamps.
9. All clamps can now be tightened.
10. Repeat the same procedure for the other side.
Installation of Hydraulic Steering Tank
NOTE: Steering tank mounting hardware may be stored (for shipment) on the platform.
2. Connect hydraulic steering line (2) to the oil filter. Connect hydraulic steering lines (3) and (4) with O - ring seals, flanges and bolts.
Installation of Air Start Tank (if removed for shipment)
1. Install the air start tank with U - bolts (1). Make sure drain tube (2) is through the opening in the fender.
2. Connect hose (3) from the air start motor to the air start tank.
3. Connect hose (4) from the tank to the drain valve and hose (5) from the brake relay valve to the tank.
4. Connect hose (6) from the air dryer to the tank and hose (7) from the number one port on the side of the cab.
5. Install a rubber grommet at location (A) to protect the hoses from wear during operation.
6. Install plastic straps as necessary to hold the hoses in position.
Installation of Automatic Lubrication Group (if equipped)
NOTE: Bolts and washers may have be stored (for shipment) on the platform.
2. Connect air line (2) from the junction block on the frame to the lubrication pump.
3. Connect air line (3) from port number seven on the side of the cab to the lubrication pump as shown.
4. Install plastic straps as necessary to hold the hoses in position.
Installation of Exhaust Mufflers
The 789 truck comes equipped with either dual mufflers or dual body heat.
Dual Mufflers
1. Install exhaust elbow and pipe assembly (1).
2. Install muffler assembly (2) with clamps (3), brackets (4), bolts, washers and nuts.
3. Install exhaust pipe extension (5) with clamp (6).
4. Install bracket assembly (7).
5. Install plate assembly (8), muffler assembly (9), bracket assembly (10), pipe extension (11) with clamps (12) and (13), bolts, washers and nuts. Tighten the bolt in clamp (13) to a torque of 25 ± 7 N·m (19 ± 5 lb ft).
Dual Body Heat
1. Install pipe assembly (1) and elbow assembly (2).
2. Install bracket assembly (3) and tube assembly (4) to the frame.
3. Fasten elbow (5) to the bracket assembly.
4. Fasten elbow (6) to the frame.
Installation of Fuel Tank
1. Clean the fuel tank mounting surfaces on the chassis and ... ... on the tank.
2. Bolt the caps to the frame brackets and measure their vertical diameter. Measure the diameter of the pipe assembly on the tank. Subtract the bracket diameter from the pipe diameter. This will give you the shim thickness needed.
3. Put the fuel tank in position on the chassis.
5. Install four 5D5654 Mountings (3) in bracket (4) as shown.
7. Remove plugs (6) and (7) from the fuel tank.
8. Install 6V8358 Valve Assembly (8), 307944 Elbow (9) with a 3D2824 Seal and connect fuel supply line (10) to the fuel tank.
9. Install 9L5254 Elbow (11) and connect fuel return line (12) to the fuel tank.
Installation of Rear Brake Lines
NOTE: Only the left side is shown in this procedure. The same procedure is used for the right side.
1. Install brake oil cooler line (1) with clamp (2) to the axle housing with O - ring seal, flanges, lockwashers bolts.
2. Connect brake oil cooler line (3) to line (1) with O - ring seal, flanges, bolts and washers.
3. Connect hose assembly (4), the service brake line, to the axle housing with a 6V8624 Elbow and a 2M9780 Seal.
4. Install clip (5).
5. Install brake oil cooler line (6) with hose (7), clamps (8) and clamps (9) to the axle housing with O - ring seal, flanges, bolts and washers.
NOTE: It may be necessary to loosen clamps (9) so that brake oil cooler lines can be moved closer together to accommodate rubber hose clamps (8).
6. Connect hose assembly (10), the parking brake line, to the axle housing with 6V8721 Elbow and a 2M9780 Seal.
7. Connect hose assembly (11), the service brake bleed line, to the axle housing with 2M9780 Elbow and a 6V8721 Seal.
8. See Brake System Bleeding Procedure (removing air).
Installation of Rear Tires and Rims
| NOTICE |
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Check the coolant and oil levels in the engine, hydraulic tank, etc. (except differential and final drive). |
Make sure that all grease, burrs, nicks, etc. are removed from the wheel and rim mounting surfaces. Use solvent for initial cleaning and 4C4204 Cleaner for final cleaning. Failure to do so may cause damage to the wheel and rim.
NOTE: Before installation of the rear tires and rims, start the truck and check for any leaks, etc. Purge (remove trapped air) from the brake lines. If the truck can be operated, this will make installation of rear tires and rims easier. With the parking brake released (all air removed), the rear wheels can be turned by hand to align the wheel studs with the holes in the rim.
Inside Rear Tires and Rims
1. Raise the rear of the truck high enough to provide the clearance needed to install the rear tires and rims. Support with blocks or stands.
NOTE: The hoist MUST be attached to the rear of the truck until the tires and rims are installed.
2. Remove rim ring (1) from the wheel assembly, both sides.
NOTE: Before installing the inside rear tire and rim, mark the wheel assembly with chalk at the four bolt hole locations (where the valve stem extension guard mounts). This mark will make it easier to align the tires and rims on the wheel for location of the valve stem extension.
NOTE: Do not use any lubrication on the nuts or washers and make sure all mating surfaces are clean and dry.
3. Install inside tire and rim (2) [with the valve stem to the outside] with nuts and washers. Tighten rim mounting nuts to a torque of 1125 ± 100 N·m (830 ± 75 lb ft).
4. Install hose assembly guard (3) with four bolts and lockwashers.
5. Install protective guards (5) with bolts as shown.
6. Make sure protective guard (5) is flat against the rim as they can be installed either way, depending on tire and rim size.
NOTE: Attach a wire to the valve to pull it through the valve stem opening in the outside rim.
| NOTICE |
|---|
If the truck is to be operated without the outside rear tire, install and torque all 1D4635 Bolts to hold the final drive to the wheel. |
Outside Rear Tires and Rims
NOTE: Do not use any lubrication on the nuts or washers and make sure all mating surfaces clean and dry.
1. Install ring (1) on the outside tire and rim as shown.
NOTE: Make sure to align valve stem openings (7) as shown.
2. Tighten the ring mounting nuts to a torque of 1125 ± 100 N·m (830 ± 75 lb ft).
37 X 57 Tubeless Tires
(9) 5T9790 Tire Valve Group. (10) 8W0331 Swivel Connector. (11) 8X2659 Hose Assembly. (12) 8X2658 Valve Extension. (13) 5P8245 Washer. (14) 1D4566 Bolt. (15) 6J0247 Spacer. (16) 8X2627 Plate.
36 X 51 Tubeless Tires
(9) 5T9790 Tire Valve Group. (10) 8W0331 Swivel Connector. (13) 5P8245 Washer. (14) 1D4566 Bolt, (15) 6J0247 Spacer. (16) 8X2627 Plate. (17) 8W3433 Hose Assembly. (18) 5T9796 Connector. (19) 5T9789 Valve Extension.
NOTE: Before mounting outside tires and rims, make sure a 8W0331 Swivel Connector is installed at initial mounting and inflation of the tire.
3. Install outside tire and rim (20) with bolts, nuts and washers (with the valve stem to the outside).
NOTE: Do not use any lubrication on the nuts or washers.
4. Tighten rim mounting bolts to a torque of 1125 ± 100 N·m (830 ± 75 lb ft).
5. Install bracket (16) with spacers (15), bolts (14) and washers (13).
Installation of Rear Axles
NOTE: To make installation of the rear axles easier, start the engine and release the parking brakes (see Brake System Air Removal Procedure). This will release the rear wheels so they can be turned to align the axle splines during installation of the axles.
1. Loosen cover (1) both sides.
2. Remove cover assembly (8) both sides.
3. Remove adapter (2) from axle (3) both sides.
4. Install axle (3), long axle on the left side, using 1U8848 Axle Installation Tool (4)
NOTE: If equipped with AETA, be sure to align the timing bracket on the shaft ...
... with notches in the timing gear before installing the axles.
5. Use a bar through openings (A) to help align the axle into the differential.
6. Install adapter (2) and snap ring (5) both sides.
7. Final drive failure can occur due to the stack-up tolerances of all the internal components. Check the dimension as shown in the illustration above. If the dimension is not within tolerance, check the assembly procedure for any error.
8. Tighten cover (1) both sides.
9. Use grease (lubriplate) to hold thrust washer (6) in position on dowels (7) when installing cover assembly (8).
NOTE: If the thrust washer slips off the dowels, damage to the axle housing can occur during operation of the truck.
10. Install cover assembly (8) with O-ring seal, nuts and lockwashers (both sides).
NOTE: Make sure the covers fit correctly before tightening the nuts.
11. Tighten nuts (9) to a torque of 55 ± 10 N·m (40 ± 8 lb ft).
12. Lift the rear of the truck, and remove the blocks or stands.
13. Lower the truck to the ground.
Installation of Hoist Cylinders (if removed for shipment)
NOTE: When installing a hoist cylinder, use a nylon strap around the cylinder so it will hang at an angle. This will allow the cylinder to clear the hydraulic and/or fuel tank during installation.
NOTE: Make sure oil ports on both cylinders are towards the front of the truck.
1. Install retainer (1) over the hoist cylinder trunnion.
2. Install bearing assembly (2) with the snap ring towards the outside.
3. Install a hose clamp around the bearing to help hold it together during installation of the cylinder.
4. Install three [3/4 - 10] rods 8 inches long (3), in retainer (1). Install hoist cylinder (4).
5. Use nuts and washers to pull the cylinder onto the bearing as shown.
NOTE: Make sure the cylinder is started on the bearing straight. Remove the hose clamp as the cylinder is going onto the bearing.
6. Remove Allen plugs (5) from cylinder, where plugs are outside.
7. Install unions (6) with 3D2824 O-rings, nipples (7) and cap assemblies (8) as shown.
8. Install cover (9) with three bolts (10) and washers, both sides.
9. Connect hoist cylinder hydraulic hoses (11) with seals, flanges and bolts, both sides.
10. Connect grease lines (12), both cylinders.
11. Fill the hydraulic tank (see the Operation and Maintenance Manual).
Brake System Bleeding Procedure (removing air)
|
Put blocks in front of and behind the wheels to make sure the machine does not move while the parking brakes are OFF. |
|
| NOTICE |
|---|
Check the coolant and all fluid levels in the engine, hydraulic tank, etc. (except the differential and final drive). |
Fill the compartments - See the Operation and Maintenance Manual.
Before the bleed valves for the hydraulic brakes on each wheel can be used to remove air from the oil in the system, the makeup oil tank for the hydraulic brakes must be full and the air pressure system must have more than 550 kPa (80 psi).
Use a section of hose on the brake bleed valves and a bucket to contain the oil when bleeding the service brakes.
Service Brakes
NOTE: It may be easier and necessary to open fittings starting at the master cylinder and working towards the brakes - very necessary on the front brakes.
1. Start the truck and check for any oil leaks.
2. Move parking brake valve (1) to the ON position.
3. To make sure the makeup oil tank is full of oil, operate the engine at high idle for 20 seconds between each brake application.
4. Depress and hold the brake pedal down ...
at the same time, hold and open bleed valve (3). Hold the bleed valve open until there is a constant flow of oil.
5. Close bleed valve and release the service brake pedal. Do this procedure for each wheel.
NOTE: This machine is equipped with a master cylinder overstroke indicator. When this indicator (located on the dash) comes ON and the parking brake is OFF, it indicates low fluid level, air in the hydraulic circuit or leakage in the fluid lines.
Stop the machine and investigate the cause. Do not operate the machine until the cause has been corrected. The switch, located on the roto chamber, must be manually reset before the indicator will go out.
Parking Brake
With the engine operating, activate parking brake valve (1) ON and OFF as many times as necessary to purge the system of air. The parking brake will release when all the air is removed.
Transmission Neutralizer
|
The transmission on this machine will neutralize when the transmission shift lever is in reverse and the hydraulic control lever is in either raise or lower position. The neutralizer will not stop the vehicle from rolling. Use the brakes to stop. |
|
Adjustment of hoist control linkage (1) or ...
... the cable and neutralizer switch (2), located behind the operators seat, may be necessary if:
- * The transmission does not go from REVERSE to NEUTRAL when the control lever for the body is moved to either RAISE or LOWER position.* If the transmission will not go into REVERSE when the body is down.
1. To adjust the switch, put the yoke in a position so that the neutralizer switch is activated only in the RAISE and LOWER position of the hoist control lever.
2. Make sure the hoist control linkage is correctly adjusted before adjustment of the switch.
NOTE: Refer to the Service Manual if necessary to adjust the hoist control linkage.
Differential and Final Drive Fill Procedure
1. Position the final drive so that drain plug (2) is located half way between the top and bottom. Remove drain plug (2).
2. Loosen cover (1).
3. Fill the differential and final drive through opening (A) until oil runs out the drain plug opening in the final drive. The fill quantity is approximately 583 L (151 gal).
NOTE: Oil fill will be slow. Refer to the Operation & Maintenance Manual for the correct type and quantity.
4. Tighten cover (1) and install drain plug (2).
5. Check the oil level after a few hours of operation to make sure it is full.
Installation of Body Assembly
Remove the plates from the lifting eyes located on the outer side of the body, each side.
Remove lifting eyes as follows:
- * Three from the canopy.* Two from the inside of the front wall.* Two from the floor (inside).* Four from the underside of the body.
Check the body pivot pin bores and hoist cylinder pin bores with there respective pins before the body is raised into position.
NOTE: Rear lifting cables should be approximately 102 to 152 mm (4.0 to 6.0 in) longer then the front cables.
1. Lift body assembly (1) into position on the truck chassis.
2. Install pivot pins (2), with washers (3) between the body and the frame at two locations, as shown above.
3. Install plates (4) with three OS1585 Bolts (5) and 5P8245 Washers (each pin).
4. Connect the grease fitting lines.
5. Cut hoist cylinder restraining brackets from frame and grind the weld area smooth.
NOTE: Connect the first hoist cylinder that starts to rise when the hoist lever is moved to the raised position.
* Make sure the grease fitting is towards the front of the truck.
6. Use a hoist to raise the body assembly.
7. Put blocks between the body rails and the frame.
8. Install a 6G9696 Spacer (6) on each side of the hoist cylinder bearing as shown.
9. Use a tag wire at three locations to hold the spacers in position.
10. With a ratchet puller, align hoist cylinder (7) bores with the bores in the body.
11. Raise hoist cylinders (7) until the pin bores are in alignment.
13. Connect the grease fitting lines.
14. Put the truck on a level surface. Raise the body to a position where the body rails and the frame are parallel.
15. Measure actual rail-to-rail distance [nominal distance between rails is 42 mm (1.65 in)].
16. Place the pad assemblies (eight) on top of main frame, and use shims as necessary to produce zero clearance between the rails.
17. Raise the body and install (four) pads (11) and shims on the body with bolts, washers and nuts (each rail). Lower the body.
18. With the body down and resting on the main frame rail pads, put a pad (12) on each support (13) without shims.
19. Measure the clearance between the pad and body, and install 6G9711 Shims (14) as necessary to produce zero clearance. Add one shim to make a 1.5 mm (.06 in) compression on each pad (12).
20. Tack weld body guide (15) in position as shown on each frame plate (16) with a 10 mm (.39 in) space for clearance between the guide and the front body rail.
21. Make a 8 mm (.31 in) fillet weld at locations (B) on each guide and 6 mm (.24 in) bevel groove weld at location (C) on each guide.
22. Make a 10 mm (.39 in) bevel groove weld followed by a 10 mm (.39 in) fillet weld at location (D) on each guide.
23. Install rock ejector (17) with guards, pins and cotter pins (both sides).
24. Install baffles (18) on the right side with the angles towards the front, with plates, bolts, lockwashers and nuts.
25. Install baffles (19) on the left side with angles toward the rear; with plates, bolts, lockwashers and nuts.
Body Exhaust
1. Bolt plate assemblies (20) and (21) to the body assembly.
2. Install four 2D9345 Studs (23) in the truck body at location (E).
3. Assemble exhaust pipe extensions (22) with springs, bolts and locks as shown.
4. Fasten exhaust extensions (22) to the plate assemblies, with four 7K1270 Washers, 5P8247 Washers and 1D4720 Nuts.
5. With the body in the down position, loosen four bolts (25), and adjust bolts (26) to get the dimension shown at location (F).
6. Tighten bolts (25) and the lock nuts on bolts (26).
7. Insert coupler (27) through one end of cable assembly (28). Install coupler (27) on the truck body with two 1D4643 Bolts (29), two 2H3794 Nuts and 5P8250 Washers.
8. Install 8W0109 Plate (30) with a 2B0974 Clevis Pin (31), a 5P8247 Washer and a 3B4617 Cotter Pin.
9. Store the body lock cable in the position shown in the upper photo.
Dimension and Charging Pressures for Front and Rear Suspension Cylinders
| NOTICE |
|---|
Make sure the suspension cylinders are charged with oil before charging with nitrogen. See Service Manual SENR3420 for the complete operation, testing and adjusting procedure. |
1. Raise the front of the truck and install a FT1975 Gauge at location (A), each side.
2. Charge the front cylinders with nitrogen to 2200 kPa (320 psi). This will give the 265 mm (10.43 in) dimension with the body installed and the machine on level ground.
3. With the body installed and the machine on level ground, charge the rear cylinders until the 1177 mm (46.33 in) dimension is obtained.
Recommendations for Assembly Check Before Delivery of The Truck
The following is a list of recommended assembly checks and system functional checks before delivery of the truck to the customer. Please do all the checks and mark the list YES (system functioned properly) NO (system malfunction).
Use the Service Manual if needed to correct the problem of a system malfunction before delivery.
After the check list is completed;
* Clean the truck and paint all exposed areas.
* Sign your name and the name of the dealer.
Please tear out and mail to:
Caterpillar Inc.27th and Pershing St.
Decatur, IL. 62525
Att: Product Quality - Off Highway Trucks
Customer;____________________
Product Identification No:____________________
- 1. Check to make sure all hydraulic systems are full and all pumps primed prior to starting the engine. YES____________________NO____________________
- 2. Remove trapped air from the rear and front service brake systems, retarder system and parking brake. YES____________________NO____________________
- 3. Check parking brake release pump and electric motor. YES____________________NO____________________
- 4. Check steering system:
- * With the engine stopped the steering tank should be filled to the FULL mark of the top sight glass. YES____________________NO____________________* After starting the engine, the steering tank oil level should drop to the FULL mark of the bottom sight glass. YES____________________NO____________________* With the engine stopped (stop the engine with the ground level shut down) steer from left to right. YES____________________NO____________________* With the engine stopped and key switch OFF, steering accumulators will discharge and oil will be at upper sight glass of steering tank. YES____________________NO____________________
- 5. Vehicle Lights (function):
- * Headlamps (low and high beam). YES____________________NO____________________* Turn signals and emergency flasher. YES____________________NO____________________* Back-up lights. YES____________________NO____________________* Brake lights. YES____________________NO____________________* Ladder access light. YES____________________NO____________________* Engine compartment light. YES____________________NO____________________* Cab and dash lights. YES____________________NO____________________
- 6. Cab:
- * Both right and left doors open and close from the inside of the cab. YES____________________NO____________________* Operation and Maintenance Manual is in the literature pouch located on the back of the operator's seat. YES____________________NO____________________* Horn function. YES____________________NO____________________* Switch park brake valve to ON ... the BRAKE ON light on the EMS panel will come on. YES____________________NO____________________* Windshield wiper function/washer function. YES____________________NO____________________* Check seat belts. YES____________________NO____________________* Check function of back-up alarm. YES____________________NO____________________* With hoist lever in raise position, machine will not move in reverse. YES____________________NO____________________* Check heater (if equipped). YES____________________NO____________________* Check air conditioner (if equipped). YES____________________NO____________________* Check EMS light and test switch. YES____________________NO____________________* Check low air pressure EMS light, cab dash low air pressure light, and low air pressure warning buzzer. YES____________________NO____________________* Check engine coolant temperature gauge. YES____________________NO____________________* Check converter/retarder temperature. YES____________________NO____________________* Check hour meter (electrical). YES____________________NO____________________ * Check tachometer. YES____________________NO____________________* Check air pressure gauge. YES____________________NO____________________
- 7. Check to make sure left and right mirrors are installed. YES____________________NO____________________
- 8. Mud flaps, body down indicator and guard rails are installed. YES____________________NO____________________
- 9. With the engine operating at 1200 rpm, shift lever in first - gear and air pressure at 795 - 830 kPa (115 - 120 psi):
- * Machine does not move with retarder applied. YES____________________NO____________________* Machine does move with service brake pedal applied. YES____________________NO____________________* Machine does move with secondary brake applied. YES____________________NO____________________* Machine does not move with park lever applied. YES____________________NO____________________
The above procedure confirms brake actuation.
- 10. With the transmission in gear and parking brake on, the warning horn will sound. This is normal.
- 11. Check Automatic Electronic Traction Aid (AETA) if equipped. YES____________________NO____________________
- 12. Check all fluid levels - mainly final drive and differential (both sides). YES____________________NO____________________
- 13. After the completed truck has been checked and all adjustments made, it shall be road tested for the length of time necessary to check the operation of complete unit. YES____________________NO____________________
- 14. There shall be no unusual noises and oil leaks.
- 15. All quality requirements such as function and appearance must be fulfilled. All variances are to be corrected prior to releasing the vehicle to the customer. YES____________________NO____________________
- 2. Remove trapped air from the rear and front service brake systems, retarder system and parking brake. YES____________________NO____________________
Name of person making final check:
Dealer Name: