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.

Note: Apply 5P-3413 Pipe Sealant to the threads of all pipe connections.

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	g00517844

3. Inspect mounts (49) and sleeves (48) for wear or damage. If it is necessary, install two mounts (49) and sleeve (48) into each of the four bores of support (50) .

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Illustration 2	g00517843

4. Inspect mounts (51) and sleeves (52) for wear or damage. If it is necessary, install two mounts (51) and sleeve (52) into each of the four bores of the inside front mounting surface.

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Illustration 3	g00517840

5. Inspect mounts (54) and sleeves (55) for wear or damage. If it is necessary, install two mounts (54) and sleeve (55) into each of the six bores of support (53) .

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Illustration 4	g00517838

6. Inspect mounts (56) and sleeves (57) for wear or damage. If it is necessary, install two mounts (56) and sleeve (57) into each of the six bores of the inside rear mounting surface.

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Illustration 5	g00522561

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Illustration 6	g00518019

7. Attach a suitable lifting device and a hoist to cab (40) . Use the hoist in order to remove cab (40) from Tooling (B) (not shown) or the equivalent. The weight of cab (40) is 1814 kg (4000 lb).

Note: Ensure that all of the hoses, the hose assemblies, and wire harnesses are out of the way as the cab is positioned.

8. Position cab (40) onto the frame assembly. Use a feeler gauge to measure the gap from cab (40) to the frame assembly. Use shims (47) in order to obtain a total gap dimension of less than 0.75 mm (0.03 inch).

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Illustration 7	g00522559

Note: Before you install the cab mounting bolts, apply 9S-3263 Thread Lock Compound to the threads.

Note: Inspect bolts (46) that were removed in the removal procedure for wear or damage. If it is necessary, replace the worn or damaged bolts that were removed with new bolts (46) . If bolts (46) are not worn or damaged, they can be reused.

9. Install four bolts (46) and the washers to the inside front cab mounts. Tighten four bolts (46) to a torque of 1904 ± 68 N·m (1404.3 ± 50.2 lb ft).

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Illustration 8	g00522552

Note: Before you install the cab mounting bolts, apply 9S-3263 Thread Lock Compound to the threads.

Note: Inspect bolts (45) that were removed in the removal procedure for wear or damage. If it is necessary, replace the worn or damaged bolts that were removed with new bolts (45) . If bolts (45) are not worn or damaged, they can be reused.

10. Install four bolts (45) and the washers to the outside front cab mounts. Tighten four bolts (45) to a torque of 1904 ± 68 N·m (1404.3 ± 50.2 lb ft).

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Illustration 9	g00522508

Note: Before you install the cab mounting bolts, apply 9S-3263 Thread Lock Compound to the threads.

Note: Inspect bolts (44) that were removed in the removal procedure for wear or damage. If it is necessary, replace the worn or damaged bolts that were removed with new bolts (44) . If bolts (44) are not worn or damaged, they can be reused.

11. Install six bolts (44) and the washers to the inside rear cab mounts. Tighten the six bolts (44) to a torque of 1904 ± 68 N·m (1404.3 ± 50.2 lb ft).

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Illustration 10	g00522504

Note: Before you install the cab mounting bolts, apply 9S-3263 Thread Lock Compound to the threads.

Note: Inspect bolts (43) that were removed in the removal procedure for wear or damage. If it is necessary, replace the worn or damaged bolts that were removed with new bolts (43) . If bolts (43) are not worn or damaged, they can be reused.

12. Install six bolts (43) and the washers to the outside rear cab mounts. Tighten six bolts (43) to a torque of 1904 ± 68 N·m (1404.3 ± 50.2 lb ft).

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Illustration 11	g00522502

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Illustration 12	g00575554

13. Remove the lifting device from cab (40) .

14. Install two bolts (41) , the hard washers, the plate, and the nuts in order to connect deflector (42) to the frame assembly.

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Illustration 13	g00522497

15. Install four bolts (39) and the washers in order to connect ladder assembly (38) to the cab.

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Illustration 14	g00575406

16. Use four bolts (37) and the washers in order to install plate (36) and the air horn to the ladder assembly.

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Illustration 15	g00522489

17. Connect hose assembly (35) .

18. Connect hose assembly (34) .

19. Connect hose assembly (33) .

20. Connect hose assembly (32) .

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Illustration 16	g00522482

21. Connect hose assembly (31) .

22. Connect hose assembly (30) .

23. Connect hose assembly (29) .

24. Connect hose assembly (28) .

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Illustration 17	g00522476

25. Use bolt (27) and the washer in order to connect ground strap (26) to the cab.

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Illustration 18	g00522409

26. Connect wire harness (25) to the cab at the electrical connection.

27. Connect wire harness (24) to the cab at the electrical connection.

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Illustration 19	g00522407

28. Use Tool (A) in order to connect wire harness (23) to the cab at the electrical connection.

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Illustration 20	g00522405

29. Connect wire harness (22) to the cab at the electrical connection.

30. Connect wire harness (21) to the cab at the electrical connection.

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Illustration 21	g00522390

31. Install four bolts (20) and the washer in order to connect the fender assembly to the ladder assembly.

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Illustration 22	g00522367

32. Connect wire harness (19) at the electrical connection.

33. Connect wire harness (18) at the electrical connection.

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Illustration 23	g00522362

34. Tighten two screws (not shown) in order to connect wire harness (17) .

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Illustration 24	g00522358

35. Connect wire harness (16) at the electrical connection.

36. Connect wire harness (15) at the electrical connection.

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Illustration 25	g00522353

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Illustration 26	g00522356

37. Tighten two hose clamps in order to connect two hoses (12) and (13) , as shown.

    Note: Open the valves on the engine after two hoses (12) and (13) are connected.

38. Use one bolt (14) and the washer in order to install the clamp.

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Illustration 27	g00522349

39. Connect hose assembly (11) at the air conditioner quick disconnect.

40. Connect hose assembly (10) at the air conditioner quick disconnect.

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Illustration 28	g00522338

41. Connect wire harness (9) at the electrical connection.

42. Connect wire harness (8) at the electrical connection.

43. Connect hose assembly (7) .

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Illustration 29	g00522287

44. Connect hose assembly (6) .

45. Connect hose assembly (5) .

46. Connect hose assembly (4) .

47. Connect hose assembly (3) .

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Illustration 30	g00522283

48. Use three bolts (1) and the washers in order to install cover (2) to the frame assembly.

49. Refill the steering hydraulic tank with the correct hydraulic oil. Refer to Operation and Maintenance Manual, "Steering System Oil - Change" for the correct procedure.

50. Charge the pressure in the air tanks. Refer to Operation and Maintenance Manual, "Starting with an External Air Supply" for the correct procedure.

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Personal injury can result from contact with refrigerant. Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury. Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant. Always use precaution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated area. Personal injury or death can result from inhaling refrigerant through a lit cigarette. Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death. Do not smoke when servicing air conditioners or wherever refrigerant gas may be present. Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system.

51. Charge the air conditioning system. Refer to Air Conditioning and Heating Testing and Adjusting, SENR5664, "Refrigerant System - Charge" for the correct procedure.

End By:

1. Remove the retaining cable. Refer to Disassembly and Assembly, "Truck Body Retaining Cable - Remove and Install".
2. Remove the wheel chocks. Refer to Disassembly and Assembly, "Wheel Chocks (Front and Rear) - Remove and Install".