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

Wheel, Brake and Suspension (Front) - Install

Usage:

785C 1HW

Installation Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	148-0357	Lifting Gp	1
A	7X-0427	Bolt (1 1/4 - 7 )	8
B	138-7574	Link Bracket	2
C	1P-0520	Driver	1

Note: Cleanliness is an important factor. Before the installation procedure, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble.

Check all of the O-ring seals and the components for wear or damage. Replace the components, if necessary.

Lubricate all of the O-ring seals lightly with the lubricant that is being sealed.

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Illustration 1	g00502952

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Illustration 2	g00502951

Use Tooling (C) in order to install bearing (30) in cap (22) .

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Illustration 3	g00502948

Install lockring (29) onto cap (22) .

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Illustration 4	g00502944

Install cap (22) onto suspension cylinder (1) .
Note: Position cap (22) so that lockring (29) is facing suspension cylinder (1) .

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Illustration 5	g00502943

Install front axle (15) and brake assembly (10) onto suspension cylinder (1) . Refer to Disassembly and Assembly, "Front Axle - Install".

Position Tooling (B) onto the wheel assembly. Position a suitable lifting device around suspension cylinder (1) . Secure the lifting device to a hoist. The weight of suspension cylinder (1) , brake assembly (10) , and front axle (15) as a unit is 3574 kg (7880 lb).

Raise suspension cylinder (1) , brake assembly (10) , and front axle (15) as a unit to a vertical position.
Note: While suspension cylinder (1) , brake assembly (10) , and front axle (15) are maneuvered as a unit, use the forks from a suitable lift truck in order to stabilize Tooling (A) .

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Illustration 6	g00502892

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Illustration 7	g00502894

When suspension cylinder (1) , brake assembly (10) , and front axle (15) is in the vertical position, remove two cotter pins (X) from Tooling (A) .

Lift suspension cylinder (1) , brake assembly (10) , and front axle (15) as a unit. Rotate suspension cylinder (1) , brake assembly (10) , and front axle (15) as a unit to the vertical position.

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Illustration 8	g00503123

Lower suspension cylinder (1) , brake assembly (10) , and front axle (15) onto the base of Tooling (A) as a unit. Install eight bolts (Y) and the washers onto the base of Tooling (A) . Remove Tooling (B) and the lifting device.

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Illustration 9	g00502887

Install key (28) onto the frame assembly.

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Illustration 10	g00502884

Use a suitable lift truck and Tooling (A) in order to position suspension cylinder (1) , brake assembly (10) , and front axle (15) for installation.

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Illustration 11	g00502883

Install four new bolts (26) , the nuts and washers in order to align suspension cylinder (1) with key (28) .

When suspension cylinder (1) is aligned with key (28) , install the remaining six new bolts (26) , nuts and washers. Tighten six bolts (26) to a torque of 1825 ± 175 N·m (1346 ± 129 lb ft).

Install four new bolts (27) , the nuts and washers. Tighten four bolts (27) to a torque of 2700 ± 275 N·m (1991.4 ± 202.8 lb ft).

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Illustration 12	g00502863

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Illustration 13	g00502867

Remove Tooling (A) from front axle (15) .

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Illustration 14	g00502841

Note: If the engine has been removed for service, the engine and the tube assembly must be installed before installing shim pack (25) . The machine frame must be evenly supported on each side using two jacks under the main frame before installing shim pack (25) .

Measure the gap from frame assembly to cap (22) . Install shim pack (25) (not shown) that is equal to the measured gap. Install four bolts (24) and washers in order to install cap (22) to the frame assembly.
Note: Do not force the shims into the gap between cap (22) and the truck frame. Use enough shims in order to assemble a shim pack that places cap (22) in compression rather than with tension.

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Illustration 15	g00502838

Connect hose assembly (23) to cap (22) .

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Illustration 16	g00502836

Connect wire harness (21) to payload pressure sensor (20) at the electrical connection.

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Illustration 17	g00502834

Connect hose assembly (19) to suspension cylinder (1) .

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Illustration 18	g00502833

Use two bolts (18) and the washers in order to install bracket assembly (17) and hose assembly (16) as a unit to brake assembly (10) . Tighten two bolts (18) to a torque of 310 ± 25 N·m (229 ± 18 lb ft).

Connect hose assembly (16) to brake assembly (10) .

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Illustration 19	g00502832

Connect hose assembly (14) to front axle (15) .

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Illustration 20	g00502830

Install six bolts (13) and the washers in order to install tube assembly (12) to brake assembly (10) .

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Illustration 21	g00502827

Connect hose assembly (11) to brake assembly (10) .

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Illustration 22	g00502795

Use a suitable lifting sling and a hoist in order to position steering link (7) , steering cylinder assembly (4) , and steering arm (6) as a unit for installation. The weight of steering link (7) , steering cylinder assembly (4) , and steering arm (6) as a unit is 363 kg (800 lb).

Use six bolts (5) and the washers in order to install steering arm (6) . Tighten six bolts (5) to a torque of 1800 ± 200 N·m (1327.6 ± 147.5 lb ft).

Connect hose assemblies (2) and (3) .

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Personal injury or death can result from air in the oil for the brake hydraulic system.
Air in the system can prevent complete brake application and it is possible that the wheels on the machine can not be stopped.

Air must not be in the oil for the brake hydraulic system to function properly.

Remove the air from the service and parking brakes. Refer to Testing and Adjusting, SENRU1494, "Brake System Air - Purge" for the correct procedure.

Fill the hydraulic tank with hydraulic oil to the correct level. Refer to Operation and Maintenance Manual, SEBU7173, "Hoist, Torque Converter an Brake Tank Oil - Change" for the proper procedure.

Charge the suspension cylinder with oil and nitrogen. Refer to Testing and Adjusting, SENR1496, "Suspension Cylinder (Front) - Purge and Charge" for the correct procedure.

End By: Install the front tire and rim. Refer to Disassembly and Assembly, "Tire and Rim (Front) - Remove and Install".