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

Installation Procedure

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.

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

2. Lubricate all of the O-ring seals lightly with the lubricant that is being sealed.
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   Illustration 1	g00506224

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   Illustration 2	g00506225

3. Use a suitable lifting sling and a hoist in order to position suspension cylinder (1) in the horizontal position, as shown. The weight of suspension cylinder (1) is 400 kg (880 lb).

4. Install pin (23) (not shown) and plate (22) in order to install suspension cylinder (1).

5. Install plate (25). Install six bolts (24) and the washers. Tighten six bolts (24) to a torque of 370 ± 50 N·m (272.9 ± 36.9 lb ft).

6. Connect hose assembly (20) and (21).
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   Illustration 3	g00506325

7. Raise suspension cylinder (1) to the vertical position.

8. Prior to the installation of the charging valve, remove the plugs from pressure ports (19).
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   Illustration 4	g00506202

9. Use four bolts (17) in order to install charging valve (18) and the O-ring seals.
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   Illustration 5	g00506201

10. Use two bolts (15) and the washers in order to install plate (16).
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    Illustration 6	g00506200

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    Illustration 7	g00506199

11. Align suspension cylinder (1) and install pin (14) and plate (13).
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    Illustration 8	g00506198

12. Install plate (11) at the top of suspension cylinder (1). Install six bolts (12) and the washers. Tighten six bolts (12) to a torque of 370 ± 50 N·m (272.9 ± 36.9 lb ft).
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    Illustration 9	g00506196

13. Remove the lifting sling from suspension cylinder (1).
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    Illustration 10	g00506181

14. Connect wire harness (10) to payload pressure sensor (9) at the electrical connection.
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    Illustration 11	g00506180

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    Illustration 12	g00506179

15. Connect hose assemblies (8) and (7).
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    Illustration 13	g00506169

16. Use two bolts (5) and the washers in order to install guard (6).

17. Charge suspension cylinder (1). Refer to Suspension Cylinder Systems Operation/Testing and Adjusting, SENR1496, "Suspension Cylinder (Rear) - Purge and Charge" for the correct procedure.
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    Illustration 14	g00506168

18. Remove the blocking from frame assembly (3) and A-frame (4).
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    Illustration 15	g00506167

19. Install suspension cover (2) and the hose clamp on suspension cylinder (1).

    Note: The seam of suspension cover (2) should be positioned toward the centerline of the truck.

End By:

1. Remove the wheel chocks. Refer to Disassembly and Assembly, "Wheel Chocks - Remove and Install".