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Product: TRUCK
Model: 789C TRUCK 2BW
Configuration: 789C Truck 3516 Engine 2BW00001-UP (MACHINE)
Special Instruction
789C Off-Highway Truck Assembly Procedure{7000, 7006, 7960}
Media Number -REHS0878-11
Introduction
This special instruction contains the necessary procedures for the field assembly of 789C S/N:2BW303,306-UP
Off-Highway Trucks. This publication also contains the necessary commissioning procedures.
Note: The photographs in this publication are for illustrative purposes. Some photographs may not be in sequence
for illustrative purposes.
The shipping configuration consists of the rear axle housing that has the transmission and final drives that are
attached. The rear axle group is not connected to the chassis.
The suggested tools and equipment should be present before assembly. If the recommended tools and equipment are
not present, assembly will be more difficult and more time will be necessary to complete the assembly.
Do not perform any procedures or order any parts until you read this publication. Do not perform any procedures or
order any parts until you understand this publication thoroughly.
All of the parts that are contained within the shipping boxes will be identified with a white label. DO NOT
REMOVE THE WHITE LABELS FROM THE PARTS UNTIL THE PARTS ARE READY FOR
INSTALLATION. The white label identifies the part number and the group number for that particular part. When
you unpack the shipping containers, organize the parts by the group number or by the next level part number
("N/L"). This manual is organized by the assembly of the groups.
Tighten all of the fasteners to standard torque for that particular thread. Unless otherwise specified, do not use
thread lock or thread lubricant. A tightening specification is provided only when a special torque is required. The
following items are examples of fasteners that require special tightening specifications:
torque turn
thread lock
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Page 2 of 347
anti-seize
After assembly is complete, prepare the machine for use. The Operations and Maintenance Manual, SEBU7174
shows the preparation of the machine. Use the Parts Manual, SEBP2790 and the Service Manual, SENR1515 with
this special instruction.
ReferenceParts Manual, SEBP2790, "789C S/N:2BW1-UP" Off-Highway Trucks
ReferenceOperations and Maintenance Manual, SEBU7174, "789C S/N:2BW1-UP" Off-Highway Trucks
ReferenceService Manual, SENR1515, "789C S/N:2BW1-UP" Off-Highway Trucks
ReferenceTesting and Adjusting, SENR1502, "784C, 785C, 785D, 789C, 793C and 793D Off-Highway
Truck/Tractors Power Train Electronic Control System "
Do not attempt to assemble this machine until you read and you
understand the assembly instructions.
Improper assembly procedures could result in injury or death.
The space between the body and the frame becomes a zero clearance
area when the body is lowered. Failure to install the retaining cable can
result in injury or death to personnel working in this area.
NOTICE
Do not allow any dirt or foreign material to get into the hydraulic
system during assembly, connection of lines, when components are
filled with fluid, or during any maintenance operation.
Note: After assembly of the truck is complete, the suspension cylinders must be charged. The air should be purged
from the brake system. This is shown in the Operations and Maintenance Manual. Use the Parts Manual and the
Service Manual with this special instruction.
NOTICE
Clean all surfaces and remove burrs from all areas where parts are to
be installed. Chase all tapped holes used for mounting purposes.
Remove the paint from all contacting surfaces. Clean surfaces are
necessary for a good solid joint.
Parts List
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Table 1
Parts that are Needed for Installation of 5T-4465 Front Suspension Gp or 193-6343 Front Suspension Gp
Qty
Part Number
4T-5182 (1)
Front Suspension
229-2379 (2)
Front Suspension
2D-7687
Bolt
3S-6162
Hard Washer
5T-4896
Spacer
8H-3390
Full Nut
5T-6255
Key
5T-5202
Cap
24
5P-5769
Bolt
24
4K-0684
Hard Washer
24
5T-1352
Spacer
24
7H-7539
Full Nut
16
117-4935
Plate
1D-4639
Bolt
5P-8250
Washer
(1)
(2)
Part Name
Table 2
Parts that are Needed for Installation of the 5T-4462 Steering Link Group
Qty
Part Number
Part Name
16
3R-2300
Bolt
16
4K-0684
Hard Washer
3J-6899
Locknut
Table 3
Parts that are Needed for Installation 5T-4474 Rear Axle Housing Group
Qty
Part Number
8X-0465 (1)
Part Name
Slip Joint
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(1)
2N-2486 (1)
Bolt
20
2H-1618
Bolt
20
5T-1352
Spacer
Page 4 of 347
Table 4
Parts that are Needed for Installation of 241-7846 Service Brake Lines Gp
Qty
Part Number
Part Name
8W-3191
Hose
6V-9746
O-Ring Seal
8W-3723 (1)
Hose
114-2891 (1)
Hose
5P-7466
Clip
5P-7467
Clip
5P-8112 (1)
Grommet
8T-8917 (1)
Bolt
8T-4223 (1)
Hard Washer
5M-1932
Taperlock Stud
6V-8188
Nut
7G-3832
Grommet
7G-3833
Clip
7G-3834
Clip
5P-1076
Hard Washer
(1)
Table 5
Parts that are Needed for Installation of 170-3583 Transmission Oil Lines
Qty
Part Number
Part Name
8W-3358
Hose
1P-4582
Half Flange
4J-0527 (1)
O-Ring Seal
5P-2566
Bolt
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8T-4122
Washer
8W-3353
Hose
1P-4579 (1)
Half Flange
4J-0524 (1)
O-Ring Seal
8T-9389
Bolt
12
8T-4223
Hard Washer
8W-3354
Hose
160-4960
Hose
1P-4585
Half Flange
2H-6338
O-Ring Seal
7X-0347
Bolt
172-4613
Connector
4D-4791
Hose
8W-3707
Hose
8W-3708
Hose
(1)
Page 5 of 347
Table 6
Parts that are Needed for Installation of 8X-8270 Automatic Lubrication Gp at the Rear Axle
Qty
Part Number
Part Name
8T-9377
Bolt
6V-8801
Nut
5P-1075
Hard Washer
8W-4532
Hose As
2N-1287
Flared Elbow
5N-5646
Hose
5T-5760
Hose
4K-8864
Clip
9X-8250
Clip
5M-3062
Bolt
6K-1972
Flared Elbow
3P-1823
Pipe Adapter
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5T-5760
Hose
13
8T-4896
Hard Washer
5T-4381
Hose
Page 6 of 347
Table 7
Parts That Are Needed for Installation of 162-2634 Hydraulic Oil Cooler Lines
Qty
Part Number
Part Name
165-4931
Elbow Gp
148-8339
Connector
6V-0852
Dust Cap
5T-7618
Tube Assembly
3S-7594
Hose
5P-0598
Clamp
5P-1935
Seal
7X-0325
Bolt
8T-4223
Hard Washer
Table 8
Parts That Are Needed for Installation of 241-7845 Service Brake Lines Gp
Qty
Part Number
Part Name
148-8345
Connector
5T-0967
Block
5T-0968
Block
8T-2501
Bolt
8T-4896
Hard Washer
5T-9053
Plate
7X-0353
Bolt
5T-0965
Plate
3S-9175
Elbow
8T-4122
Hard Washer
5J-0541
Hose
9D-0771
Hose
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1S-0996
Clip
9C-4937
Breather As
7K-1181
Cable Strap
Page 7 of 347
Table 9
Parts That Are Needed for Installation of 133-3418 Fuel Tank Gp or 133-3419 Fuel Tank Gp
Qty
Part Number
150-9548 (1)
151-3177 (2)
Fuel Tank As
8X-2232
Shim Pack
8W-3602
Mud Flap
8T-2561
Washer
4L-6454
Bolt
6V-8801
Nut
145-2817
9M-7958
Hose Clamp
6V-8400
O-Ring Seal
(1)
(2)
Part Name
Table 10
Parts that are Needed for Installation of 5T-4483 Fuel Lines Group
Qty
Part Number
Part Name
9L-5254
Elbow
030-7944
Elbow
6V-8358
Ball Valve
Table 11
Parts that are Needed for Installation of 5T-4463 Hydraulic Tank Mounting Group
Qty
Part Number
Part Name
105-2200
Mud Flap
16
4L-6454
Bolt
16
8T-2561
Washer
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16
6V-8801
Nut
105-2204
Support
105-2205
Support
105-2201
Mud Flap
105-4620
Support
8T-9101
Bolt
Page 8 of 347
Table 12
Parts That Are Needed for Installation of 145-3418 Ladder Group
Qty
Part Number
Part Name
8W-0671
Ladder Assembly
24
8T-4896
Hard Washer
8T-2502
Bolt
5P-1075
Hard Washer
4L-6454
Bolt
5T-8218
Plate
5T-8220
Baffle
149-6884
Ladder Assembly
38
8T-4223
Hard Washer
5P-2566
Bolt
6V-8188
Nut
8T-8917
Bolt
8T-4835
Bolt
8W-2025
Brace
4L-9337
Bolt
6V-8801
Nut
9P-2950
Handhold
5P-1076
Hard Washer
5P-2228
Bolt
153-1315
Handhold
Table 13
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Part Number
Part Name
14
7D-1649
Washer
0S-1595
Bolt
5T-6403
Fender
0S-1621
Bolt
8W-4808
Support
8W-7900
Guard
8W-6382
Plate
5T-6553
Plate
26
5P-1075
Hard Washer
9B-7237
Bolt
15
1D-4717
Nut
8T-2502
Bolt
8W-7788
Strip
5S-7379
Bolt
8W-6063
Strip
4L-6454
Bolt
8W-7899
Guard
6H-1717
Bolt
8T-4223
Hard Washer
6V-8188
Nut
8W-0571
Plate
0S-1594
Bolt
5M-2894
Hard Washer
6V-8801
Nut
8W-0568
Plate
Table 14
Parts that are Needed for Installation of 277-0628 Brace for the 5T-1070 Fender Group
Qty
1
Pt. No.
277-0629
Description
Plate
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277-0628
Brace
4V-0661
Mount
6J-9944
Boss
8T-4223
Hard Washer
7X-0326
Bolt
6V-8188
Nut
7X-0590
Hard Washer
8T-8917
Bolt
5P-1076
Hard Washer
278-0773
Block (1)
(1)
Table 15
Parts That Are Needed for Installation of 6I-2972 Air Cleaner Group
Qty
Part Number
Part Name
5K-3772
Hose Assembly
3B-6493
Pipe Elbow
175-5251
Air Cleaner
16
8T-4122
Washer
16
7X-0344
Bolt
0A-2926
Nipple
7W-7417
Service Indicator
3B-6552
Elbow
Table 16
Parts that are Needed for Installation of 8W-7903 Rear View Mirror Group
Qty
Part Number
Part Name
3B-4605
Cotter
8W-7904
Tube Assembly
7X-0326
Bolt
8T-4223
Hard Washer
7D-9969
Support
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8T-2287
Mirror
5S-7379
Bolt
5P-1075
Hard Washer
6V-8285
Mirror
8W-7901
Bracket
6V-8801
Nut
4L-6454
Bolt
8T-4896
Hard Washer
Table 17
Parts that are Needed for Installation of 159-2489 Rear View Mirror Group
Qty
Part Number
Part Name
3B-4605
Cotter
159-4795
Tube
7X-0326
Bolt
8T-4223
Hard Washer
7D-9969
Support
8T-2287
Mirror
5S-7379
Bolt
5P-1075
Hard Washer
134-0987
Bracket
8Y-6989
Mirror
137-2129
Bracket
134-0989
Block
8T-4186
Bolt
18
8T-4121
Hard Washer
8T-4137
Bolt
8T-4136
Bolt
Table 18
Parts that are Needed for Installation of 174-9334 Muffler Gp
Qty
Part Number
Part Name
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5T-7766
Bracket
8T-4223
Hard Washer
5P-2566
Bolt
4W-0969
Muffler Assembly
5T-7768
Strap
4L-9337
Bolt
2K-4973
Locknut
8X-6607
Bracket
8T-9384
Bolt
5T-7823
Plate
10
8T-4896
Hard Washer
4L-6454
Bolt
5T-7770
Plate
4W-1814
Clamp
5S-7383
Bolt
8X-6605
Extension Pipe
6N-9298
Clamp
5P-2424
Bolt
1K-6872
Locknut
5T-7824
Clamp
5C-6565
Bolt
6V-8188
Nut
2V-8169
Plate
7X-0345
Bolt
5T-8049
Strap
4W-0532
Muffler Assembly
5T-8050
Strap
8W-4954
Plate
5P-1075
Hard Washer
9B-7237
Bolt
6V-8801
Nut
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(1)
8X-6606
Extension Pipe
1W-4161 (1)
C-Clamp
7C-3337 (1)
Elbow
2W-8851 (1)
Seal Ring
2W-9078 (1)
Pipe
7C-3338 (1)
Elbow
7C-3339 (1)
Elbow
7C-3336 (1)
Pipe
Table 19
Parts that are Needed for Installation of 5T-4464 Platform Group
Qty
Part Number
Part Name
7I-5493
Support
12
4L-6454
Bolt
14
8T-4896
Hard Washer
8X-7007
Rail
5P-8248
Hard Washer
1A-8063
Bolt
2S-7593
Hard Washer
8S-9092
Bolt
8W-4926
Plate
5P-2228
Bolt
8T-4223
Hard Washer
Table 20
Parts that are Needed for Installation of 156-9342 Steering Tank Group
Qty
Part Number
Part Name
155-6660
8T-4223
Hard Washer
5C-6565
Bolt
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Table 21
Parts that are Needed for Installation of the Cab Mounting Gp
Qty
Part Number
5T-6076 (2)
Support Assembly
25
5P-8250 (2)
Washer
25
1F-7464 (2)
Bolt
228-3732 (2)
Support
163-3127 (1)
Sleeve
40
163-0042 (1)
Cab Mount
163-0364 (1)
Sleeve
164-4411 (1)
Sleeve
20
5T-5807 (1)
Retainer
6V-2624 (1)
Bolt
5T-9893 (1)
Shim
5T-9894 (1)
Shim
6B-0388 (1)
Bolt
1K-9420 (1)
Bolt
(2)
(1)
Part Name
Table 22
Parts That Are Needed for Installation of 150-8726 Steering Lines Group
Qty
Part Number
Part Name
148-8340
Connector
148-8364
Elbow
148-8361
Elbow
150-8708
Tube
150-8709
Tube
150-8723
Tube
150-8710
Tube
150-8713
Tube
0T-0102
Bolt
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5M-2894
Hard Washer
9S-1350
Clip
5T-6867
Cup
0S-0509
Bolt
150-9037
Bar
6V-8398
O-Ring Seal
6V-8397
O-Ring Seal
0L-1351
Bolt
2G-8895
Bracket
6G-8532
Guard
9L-9132
Washer
6V-9746
O-Ring Seal
Table 23
Parts that are Needed for Installation of 5T-4484 Heater Lines Group
Qty
Part Number
Part Name
6P-8855
Spacer
9X-2488
Hose Clamp
6D-1641
Clip
8T-4896
Washer
5S-7379
Bolt
Table 24
Parts that are Needed for Installation of the Truck Hood Group
Qty
Part Number
5P-1075 (1)
Hard Washer
5S-7379 (1)
Bolt
211-9141 (2)
Rail As
12
8T-4896 (2)
Hard Washer
12
4L-6454 (2)
Bolt
(1)
(2)
Part Name
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Table 25
Parts that are Needed for Installation of 144-4141 Air Lines Group (If Equipped)
Qty
Part Number
Part Name
6I-0982
Tube
4P-5212
Hose
7N-5008
Hump Hose
233-8484
Clamp
16
240-2651
Clamp
233-8482
Clamp
1W-6903
Hump Hose
5T-6459
Elbow
233-8485
Clamp
Table 26
Parts that are Needed for Installation of 249-0316 Air Lines Group (If Equipped)
Qty
Part Number
Part Name
7E-7790
Hose
16
233-8485
Clamp
249-3766
Tube
5T-7874
Strap
0S-1595
Bolt
5P-8245
Hard Washer
5T-7874
Strap
9S-8752
Full Nut
0S-1571
Bolt
5T-6459
Elbow
Table 27
Parts That Are Needed for Installation of Tires and Rims 229-9389 Demountable Rim Gp
Qty
Part Number
Part Name
138-7582
Demountable Rim
8W-0338
O-Ring Seal
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(1)
8W-0331
Swivel Connector
5T-9790
Tire Valve
18
8W-3891 (1)
Flange Nut
304
5P-8250 (1)
Washer
304
2J-3507 (1)
Full Nut
230-1132
Hose As
261-3036
Plate
1S-0996
Clip
1B-4287
Washer
8T-4244
Nut
8T-4223
Hard Washer
261-3244
Pipe
261-3243
Spacer
8T-5001
Bolt
8T-5041
Bolt
176-7281
Extension
8X-2627
Bracket
1D-4566
Bolt
5P-8245
Hard Washer
6J-0427
Spacer
Table 28
Parts that are Needed for Installation of 125-6229 Body and Canopy Assembly
Qty
Part Number
Part Name
8W-3667
Guard Assembly
114-5012
Guard Assembly
8X-6394
Plate Assembly
112-6185
Plate Assembly
112-6184
Plate Assembly
Table 29
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Part Number
Part Name
155-3637
155-3636
131-5415
Film
100-5615
Film
Table 30
Parts that are Needed for Installation of 154-3757 Body Mounting Group
Qty
Part Number
Part Name
10
0L-1351
Bolt
24
5P-1075
Hard Washer
5T-7228
Plate
59
0S-1588
Bolt
54
6V-8801
Nut
6G-9704
Strip
5T-5989
Mud Flap
5T-5988
Mud Flap
5T-7255
Plate
5T-7352
Strip
5T-7274
Mud Flap
5T-7275
Mud Flap
5M-2894
Hard Washer
8X-5421
Plate
105-4727
Mud Flap
8W-8679
Pin
1H-9456
Bolt
5P-8247
Hard Washer
8W-9373
Cover
6G-9697
Washer
8W-2896
Washer
8W-8677
Plate
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0S-1585
Bolt
5P-8245
Hard Washer
10
322-0363
Pad As
24
6G-9711
Shim
5T-3750
Plate
25
9S-1366
Bolt
30
7D-1649
Washer
24
1F-7958
Full Nut
6G-7773
Pin
3B-4647
Cotter Pin
227-5875
Ejector
8X-6365
Baffle
8X-6366
Plate
9B-7237
Bolt
Table 31
Parts that are Needed for Installation of 5T-4469 Hoist Cylinder and Mounting
Qty
Part Number
Part Name
239-5505
Pin
6G-9696
Spacer
6G-9691
Bar
5P-8245
Hard Washer
0S-1585
Bolt
Table 32
Parts that are Needed for Installation of 5T-6046 Retaining Cable Gp (If Equipped) or 144-4147 Retaining
Cable Gp (If Equipped)
Qty
Part Number
Part Name
1D-4643
Bolt
5P-8250
Washer
2H-3794
Locknut
105-0314
Coupler
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6G-9703
Cable
145-9033
Cable
2B-0974
Clevis Pin
5P-8247
Hard Washer
3B-4617
Cotter
8W-0109
Plate
Table 33
Parts that are Needed for Installation of 8X-8270 Automatic Lubrication Group
Qty
Part Number
Part Name
351-2414
Lubrication Pump
17
8T-4896
Hard Washer
0S-1594
Bolt
8L-6557
Connector
9L-5125
Elbow
14
4K-8864
Clip
14
5M-3062
Bolt
2N-1287
Flared Elbow
Table 34
Parts that are Needed for the Installation of 3Z-4942 Fast Fill Service Center Group (If Equipped)
Qty
Part Number
Part Name
3B-7255
Reducing Bushing
2N-8037
Elbow
1Q-5485
Flange
032-4814
Elbow
3K-0360
O-Ring Seal
0S-1588
Bolt
0L-1351
Bolt
7X-0772
Hard Washer
2G-8992
Clamp
4L-6454
Bolt
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5M-2894
Hard Washer
Table 35
Parts that are Needed for Installation of 230-7213 Lighting Wiring Gp and 147-3533 Wiring and Lighting
Gp
Qty
Part Number
Part Name
9G-9152
Clip
11
8T-4896
Hard Washer
11
5M-3062
Bolt
4D-7794
Clip
4L-6454
Bolt
6V-8801
Nut
8M-2770
Clip
5P-0562
Lockwire
135-0428
Signal Lamp
7S-4346
Screw
9F-5599
Lockwasher
4B-2049
Nut
1S-0994
Clip
5S-7379
Bolt
5P-1075
Hard Washer
7D-4092
Clip
9G-9154
Clip
3T-0050
Clip
40
3S-2093
Cable Strap
1H-3244
Lockwasher
3T-4411
Flood Lamp
5T-1680
Plate
117-5883
Cable
9M-4995
Clip
3M-7212
Battery Terminal
9G-9150
Clip
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5P-9297
Clip
3T-3048
Clip Assembly
Table 36
Parts that are Needed for Installation of 115-6488 Payload Signal Lamp Group
Qty
Part Number
Part Name
9G-9150
Clip
8T-4896
Hard Washer
5M-3062
Bolt
8K-1433
Grommet
Approximate Weights
Table 37
Module
Weight
Air Cleaner
62 kg (137 lb)
34 kg (75 lb)
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Cab Assembly
Cab Support (front)
Cab Support (rear)
Rear Axle Housing and Transmission
Front Suspension Cylinder, Wheel, and Brake Assembly
Fuel Tank
Hoist Cylinder
Top Mounting Pin for the Hoist Cylinder
Mirror Guards
Right Side Platform Assembly
Rim
Rock Ejector
Mounting Bracket for the Rock Ejector
Safety Cable
Steering Arm
Steering Hydraulic Tank
Tire
Assembled Truck Body
Hinge Pin for the Truck Body
Truck Frame Module At Shipment
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Specifications
Table 38
Areas that are Measured
Empty weight
Wheel Base
Length
Ground to top of canopy
Ground to upper edge of body
Machine clearance turning circle
Width of body assembly
Width of truck frame at rear tires
Specifications
130933 kg (288660 lb)
5690 mm (224 inch)
12167 mm (479 inch)
6147 mm (242 inch)
5207 mm (205 inch)
30.2 m (99 ft)
7671 mm (302 inch)
6934 mm (273 inch)
Torque Specifications
Tighten the 20 cab mounting bolts to a torque value of 1900 70 Nm (1397 50 lb ft).
Tighten the 25 cab support mounting bolts to a torque value of 900 100 Nm (662 75 lb ft).
Tighten the 100 nuts that mount the front wheel rim to a torque value of 1150 150 Nm (845 110 lb ft).
Tighten the six lower bolts that mount the fuel tank to a torque value of 450 50 Nm (330 35 lb ft).
Tighten the two bolts that mount the bracket to the fuel tank to a torque value of 370 50 Nm (272 35 lb
ft).
Tighten the four bolts for the fuel tank cap to a torque value of 450 25 Nm (330 20 lb ft).
Tighten the 114 ring nuts that mount the rear outer wheel to a torque value of 1150 150 Nm (845 110 lb
ft).
Tighten the 100 bolts and the 100 nuts that mount the rear outer wheel rim to a torque value of 1150 150
Nm (845 110 lb ft).
Tighten the 16 bolts that mount the front support of the right side platform to a torque value of 370 50 Nm
(272 35 lb ft).
Tighten the 12 bolts that mount the rear support of the right side platform to a torque value of 215 40 Nm
(158 30 lb ft).
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Tighten the 16 bolts that mount the steering arm to a torque value of 1632 50 Nm (1200 35 lb ft).
Tighten the eight strut mounting bolts for the top bearings to a torque value of 900 100 Nm (661 75 lb ft).
Tighten the top 24 strut mounting bolts to a torque value of 2300 300 Nm (1691 220 lb ft).
Tighten the lower eight strut mounting bolts to a torque value of 4000 500 Nm (2941 365 lb ft).
Tighten the ball stud at the tie rod end to a torque value of 2550 100 Nm (1875 75 lb ft).
Tighten the 20 bolts that secure the axle housing to the A-frame to a torque value of 1800 250 Nm (1325
185 lb ft).
Illustration 1
g00629745
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(B) The load capacity is 86 percent of the working load limit for the sling.
(C) The load capacity is 70 percent of the working load limit for the sling.
(D) The load capacity is 50 percent of the working load limit for the sling.
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One portable air compressor - The air compressor should have enough capacity in order to operate two 25.4 mm
(1 inch) impact air guns. The air compressor should have a minimum capacity of 3 CM (100 CFM).
At least 24 hardwood blocks that are 203 mm (8.0 inch) tall - The blocks should be 203 mm (8.0 inch) wide. The
blocks should be 914 mm (36.0 inch) long.
At least 94 m (308 ft) of rope that is 19 mm (0.75 inch) in diameter - When you install the body on the chassis,
use the rope in order to guide the body into position.
Four metal stands - The metal stands support the truck body before the truck body is installed to the truck frame.
4C-4204 Paint Remover - The solvent cleans the parts on the truck.
9S-3263 Thread Sealant - Use thread sealant on the bolts that secure the platform.
Nitrogen bottles - Use 20 nitrogen bottles that are T-size in order to inflate the tires and charge the suspension
cylinders.
207-1600 Rubber Lubricant - 207-1600 Rubber Lubricant is used in EAME only.
Required Tools
Use a 8T-9293 Torque Wrench (12.7 mm (0.50 inch)) and a 6V-6080 Torque Multiplier in order to assemble
the following items: strut mounting bolts, strut mounting bearings, steering arm, tie rod ballstuds, wheel rim
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mounting nuts, mounting rings for the outside rear tires, cab support mounting bolts and cab mounting bolts.
Use the 6V-6080 Torque Multiplier in order to tighten the components that follow: the bolts for the front
suspension cylinder, steering arm mounting nuts, ball stud nuts and wheel rim mounting nuts. The 6V-6080
Torque Multiplier provides an 18.5 to 1 mechanical advantage.
Use a 9U-5089 Wheel Nut Socket (57.1 mm (2.25 inch)) to assemble the bottom bolts for the mounting struts.
Use a 8F-2239 Wrench to hold the bolts.
Use the 9U-6566 Socket (47.62 mm (1.875 inch)) to tighten the bolts that secure the components that follow:
the ROPS, the upper front suspension and the steering arm.
Use an 0V-0455 Open End Wrench (47.62 mm (1.875 inch)) to hold the upper bolts that secure the front
suspension cylinders.
Use the 9U-6560 Socket (38.1 mm (1.50 inch)) to tighten the ROPS cab mount bolts, mounting bolts for the
bearing cap for the front suspension cylinder, and the wheel rim mounting nuts.
Use a 4C-3386 Spanner Wrench in order to assemble the ball stud for the tie rod.
Use a 5S-6084 Socket (88.9 mm (3.50 inch)) to tighten the ball stud.
Use a 8T-0447 Dial Caliper in order to determine the shims that are required in order to mount the top of the
fuel tank.
Use a 162-8718 Torque Wrench in order to assemble the mounting bolts for the fuel tank and the mounting
bolts for the right side platform.
Have a 5S-6076 Extension in order to assemble the mounting nuts for the wheel rim.
Use 6V-0006 Connector Pliers in order to connect the wiring harness to the TCS sensor.
Use a 175-5507 Nitrogen Charging Group and a 175-7410 Auxiliary Fitting Group in order to charge the
suspension cylinders.
Have an FT-1975 Gauge Block for charging the front suspension cylinders.
Use a 9U-5617 Oil Refill Group for charging the suspension cylinders with oil.
Use a 139-4166 Data Link Cable and a 171-4400 Communication Adapter Group in the commissioning
procedure.
Use a 8T-5182 Socket (38.1 mm (1.50 inch)) to install the rim nuts.
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Illustration 2
g00760043
1. Unload the truck frame and the shipping crates on a flat, smooth, drained area 30.5 m (100 ft) by 24.5 m (80
ft). The area is needed for assembly of the truck.
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Illustration 3
g01065495
789C Off-Highway Truck chassis on a truck trailer
2. Set the truck frame in the center of the area. Keep the area around the truck frame free so the cranes can be
positioned for proper lifting.
Illustration 4
Lifting diagram
g00436898
The lifting diagram is located on the left frame rail. The left frame rail is located forward of the mounting bracket for the fuel tank.
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Illustration 5
Typical front lifting location of the chassis
g00718780
3. Unload the components from the trailer. Use a crane and a suitable lifting device in order to prepare the front
of the 789C chassis for removal from the truck trailer. The lifting device should have two 3.5 m (11.5 ft)
chains. The lifting device must be rated at 36320 kg (80000 lb). In the shipping configuration, the chassis
weighs approximately 39920 kg (88000 lb).
NOTICE
Failure to use a suitable two-way lifting device or lifting device without
a suitable spreader may result in damage to the front of the truck
chassis.
Illustration 6
View of the rear lifting location
g00760116
4. In order to prepare the rear of the 789C chassis for removal from the trailer, use the following items: a second
crane, a steel bar and a suitable lifting device. Install the steel bar through the future location of the hinge
pins. Connect a two-way lifting device to each end of the steel bar. The lifting device should have two 3.5 m
(11.5 ft) chains. The bar must be made of solid steel. The bar should have a 88.9 mm (3.5 inch) diameter. The
bar should be 4.2 m (165 inch) long. The lifting device must be rated at 36320 kg (80000 lb).
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Illustration 7
g00718782
Illustration 8
g00718783
View of the proper lifting procedure for the 789C Truck
5. Use both cranes in order to lift the chassis from the trailer. Drive the trailer forward. The frame is ready to be
blocked.
Illustration 9
View of the frame that is blocked
g00718788
6. Use hardwood blocks that are 203 mm (8 inch) by 203 mm (8 inch) to block the front of the frame. Stack the
hardwood blocks alternately. Use suitable metal stands to block the rear of the chassis. Place the stands under
the lower cross-tube at the supports for the hoist cylinder.
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Illustration 10
View of the frame that is blocked
g00678801
7. Once the blocking is in place, slowly shift the weight of the chassis to the blocking. If the blocking appears to
be adequately supporting the weight of the chassis, remove the cranes.
Illustration 11
g01065497
Illustration 12
g01065498
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Illustration 13
g01065499
8. Use a suitable lift truck or a suitable crane in order to unload the remaining three trucks.
Illustration 14
g00718790
Illustration 15
g01065500
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Illustration 16
g01065501
Illustration 17
g01065502
Illustration 18
g01065503
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Illustration 19
g01065504
Illustration 20
g01065506
Illustration 21
g01065507
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Illustration 22
g01065508
View of the components that are being unloaded and positioned
Illustration 23
g00718795
12. Set four large wooden boxes of smaller components and the hardware in front of the chassis. Open the boxes
in order to become familiar with the contents of each box.
NOTICE
Do not open the contents of the plastic part bags until parts are ready
for assembly. Once the bags are opened and the parts are removed, the
identity of the part number and the next group level may be lost. Both
of these numbers are necessary in order to facilitate the assembly of
the truck.
13. Organize the hardware by the next group level. Do not open the bags of hardware.
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Qty
Part Number
4T-5182 (1)
Front Suspension Gp
229-2379 (2)
Front Suspension Gp
2D-7687
Bolt
3S-6162
Hard Washer
5T-4896
Spacer
8H-3390
Full Nut
5T-6255
Key
5T-5202
Cap
24
5P-5769
Bolt
24
4K-0684
Hard Washer
10
24
5T-1352
Spacer
11
24
7H-7539
Full Nut
12
16
117-4935
Plate
13
1D-4639
Bolt
14
5P-8250
Washer
(1)
(2)
Illustration 24
Part Name
g01065699
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Note: The brake cooling ports must be oriented toward the back of the brake assembly. The weight of the
complete assembly is 4960 kg (10920 lb).
1. Use a clevis assembly and a hoist in order to rotate the housing assembly of the front suspension cylinder.
Refer to Illustration 24.
2. Use 4C-4204 Paint Remover in order to clean the shipping grease or clean the paint from the mounting flange
of the front suspension cylinder. Clean the bolt holes. Make sure that the spot faces are clean. Clean surfaces
ensure proper torque values.
Illustration 25
g00710015
3. Use 4C-4204 Paint Remover in order to clean the shipping grease or paint from the top bearing mount for the
front suspension cylinder.
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Illustration 26
(2) 2D-7687 Bolt
g01065706
4. Remove the straps in order to reposition the hose assemblies (B) for the service and parking brakes.
Reposition the hose assemblies (B) in order to prepare for the installation of the front suspension cylinder.
5. Disconnect grease line (D) from the ball stud for the steering cylinder. Disconnect grease line (D) from the
ball stud for the tie rod.
NOTICE
Failure to disconnect grease lines (D) in the previous step before
proceeding will result in damage to the grease lines.
6. Support the steering arm. Remove the following items: four 2D-7687 Bolts (2), four 3S-6162 Hard Washers
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(3), four 5T-4896 Spacers (4) and four 8H-3390 Nuts (5). Lower the steering arm. Save the fasteners for
installation of the suspension cylinder.
7. Remove shipping bracket (C) from the steering arm and discard shipping bracket (C) .
8. Use 4C-4204 Paint Remover in order to clean the top mounting surface (A) and the main mounting surface
(E) for the front suspension cylinder. Clean mounting surface (A) and mounting surface (E) to bright metal.
Remove the four plastic plugs in the tapped holes in mounting surface (A) .
Illustration 27
g01065710
9. Use 4C-4204 Paint Remover to clean the grease and paint from the spot faces on the back of the mounting
flanges on mounting surface (E). Deburr any sharp edges.
Illustration 28
(6) 5T-6255 Key
g01065712
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Illustration 29
(1) 4T-5182 Front Suspension Gp
g01078334
NOTICE
Assemble 5T-5202 Cap (2) so the retaining ring is positioned below the
bearing.
11. Install 5T-5202 Cap (2) on the end of 4T-5182 Front Suspension Gp (1) (If Equipped) or 229-2379 Front
Suspension Gp (1). Refer to the arrows.
Note: There may not be sufficient space in order to install the bearing after the suspension cylinder is bolted
to the frame.
Illustration 30
g01065713
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Illustration 31
(1) 4T-5182 Front Suspension Gp
g01065714
12. Use a suitable lifting strap and a crane in order to position 4T-5182 Front Suspension Gp (1) (If Equipped) or
229-2379 Front Suspension Gp (1) (If Equipped). Refer to Illustration 32 for the correct position. Adjust the
lifting strap until the mounting flange of the front suspension cylinder can be positioned squarely against the
mounting flange of the frame.
Illustration 32
g01065722
13. Position the front suspension group against the mounting flange on the frame.
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Illustration 33
g00718195
Illustration 34
g00718196
Illustration 35
g00718197
14. Use a suitable crane and a lever puller in order to align the mounting bolt holes.
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Illustration 36
(3) 2D-7687 Bolt
g01065724
15. Install the following items: four 2D-7687 Bolts (3), four 3S-6162 Washers (4), four 5T-4896 Spacers (5) and
four 8H-3390 Nuts (6). Place 5T-4896 Spacers (5) on 2D-7687 Bolts (3). Install the bolts and the spacers to
the mounting flange from the inside of the frame.
Note: Check the alignment of the mounting holes for the top bearing prior to tightening 2D-7687 Bolts (3) .
16. Install the following items: 12 5P-5769 Bolts (8), 12 4K-0684 Hard Washers (9), 12 5T-1352 Spacers (10)
and 12 7H-7539 Full Nuts (11). Place 5T-1352 Spacers (10) on 5P-5769 Bolts (8). Install the bolts (8) and the
spacers (10) to the mounting flange from the inside of the frame.
17. Tighten 2D-7687 Bolts (3) to a torque value of 4000 500 Nm (2940 365 lb ft). Tighten 5P-5769 Bolts (8)
to a torque value of 2300 300 Nm (1690 220 lb ft).
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Illustration 37
(12) 117-4935 Plate
g01065728
18. Align the holes for the top bearing cap. Install 117-4935 Plates (12). Install as many plates between the top
bearing and the frame as possible without driving plates by force.
NOTICE
Do not drive 117-4935 Plates (12) between bearing cap assembly and
truck frame.
Illustration 38
(13) 1D-4639 Bolt
g01065729
Note: Remove the plug for the grease line in order to fit a socket onto 1D-4639 Bolt (13) .
19. Install four 1D-4639 Bolts (13) and four 5P-8250 Washers (14) through the upper bearing housing. Tighten
1D-4639 Bolts (13) to a torque value of 900 100 Nm (660 75 lb ft).
Illustration 39
g01065735
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21. Repeat Step 1 through Step 20 for the other front suspension group.
Qty
Part Number
16
3R-2300
Bolt
16
4K-0684
Hard Washer
3J-6899
Locknut
Illustration 40
Part Name
g01065690
1. On each suspension cylinder, remove the eight existing bolts, washers, and spacers from the mounting surface
for the steering arm.
Illustration 41
g01066831
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Illustration 42
g01066832
2. Use 4C-4204 Paint Remover in order to clean the steering arm mounting surfaces to bright metal. Remove
any nicks or burrs on the mounting surfaces.
Illustration 43
g01066834
3. Use a suitable crane in order to support the right side steering arm. The steering arm assembly weighs
approximately 280 kg (617 lb).
Illustration 44
g00714628
4. Use 1U-9200 Lever Puller Hoist in order to rotate the front suspension cylinder rod. Rotate the front
suspension cylinder rod in order to align the front spindle with the steering arm.
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Illustration 45
(1) 3R-2300 Bolt
g01066841
5. Install eight 3R-2300 Bolts (1) and eight 4K-0684 Washers (2) .
Illustration 46
g00714631
Illustration 47
g01066841
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Illustration 48
(A) Paper Tube
g01066843
(B) Cap
9. Remove paper tube (A) and cap (B) from the ball stud.
10. Use a suitable crane in order to support the tie rod.
Illustration 49
g01076226
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Illustration 50
g01066846
11. Use 4C-4204 Paint Remover in order to clean the ball stud. Use 4C-4204 Paint Remover in order to clean the
center steering arm bore. Refer to the arrow in Illustration 50.
12. Apply 5P-3931 Anti-Seize Compound to the taper of the ball stud and threads. Refer to the arrows in
Illustration 49.
Illustration 51
(3) 3J-6899 Locknut
g01078339
13. Apply 5P-3931 Anti-Seize Compound to the face of 3J-6899 Locknut (3). Refer to the arrow in Illustration
51.
14. Install 3J-6899 Locknut (3) .
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Illustration 52
g00714640
Illustration 53
g00714642
16. Use a 4C-3386 Spanner Wrench in order to hold the ball stud. Hold the ball stud while you tighten Locknut
(3) .
Illustration 54
g01066849
17. Tighten 3J-6899 Locknut (3) to a torque value of 2550 100 Nm (1875 74 lb ft).
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Parts that Are Needed for Installation of Rear Axle Housing and Transmission
(1)
Item
Quantity
Part Number
Part Name
8X-0465 (1)
Slip Joint
2N-2486 (1)
Bolt
20
2H-1618
Bolt
20
5T-1352
Spacer
Illustration 55
g00679501
1. Place the axle and transmission assembly near the truck frame. Block up the transmission.
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Illustration 56
g00715774
2. Remove the guard from the left side of the rear axle housing. Remove the guard on the right side of the rear
axle housing.
Illustration 57
(A) Pin
g01149552
(B) Bolts
(C) Hard Washers
(D) Plate
3. Remove six bolts (B), six hard washers (C), and plate (D) that retains pin (A) in the axle housing.
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Illustration 58
(A) Pin
g01149556
4. Remove pins (A) from the axle housing. Use 4C-4204 Paint and Decal Remover to remove the paint from
pins (A) .
Illustration 59
g01066021
Illustration 60
g01066023
6. Remove the paint and clean the mounting area on the A-frame.
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Illustration 61
g00679529
7. Use 4C-4204 Paint and Decal Remover to remove the paint and clean the mounting areas on the rear axle
housing.
Illustration 62
(E) Bolts
g01149996
(F) Washers
(G) Guard
8. Remove five bolts (E) and washers (F) that secure guard (G). Clean the transmission drive shaft.
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Illustration 63
(1) 8X-0465 Slip Joint
g01150020
Note: Hold the drive shaft with a prybar during the torque sequence.
9. Align 8X-0465 Slip Joint (1) to the transmission. Install the four 2N-2486 Bolts (2). Tighten the 2N-2486
Bolts (2) to a torque of 550 20 Nm (405 15 lb ft).
Illustration 64
(E) Bolts
g01149996
(F) Washers
(G) Guard
10. Reinstall guard (E) with five bolts (F) and washers (G) .
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Illustration 65
g01150034
Illustration 66
g01066030
11. Remove shipping plate (J) on the drive shaft yoke at the transmission. Discard shipping plate (J) .
Illustration 67
(K) Pin
g01150124
12. Use 4C-4204 Paint and Decal Remover to remove paint from pin (K) .
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Illustration 68
(K) Pin
g01150174
(L) Bolt
(M) Hard Washer
(N) Full Nut
(P) Washers
13. Remove bolt (L), hard washer (M), full nut (N), and two washers (P) that secure pin (K) in the rear cross-tube.
Illustration 69
(K) Pin
g01150191
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Illustration 70
(R) Control Rod
g01150201
Illustration 71
(R) Control Rod
g01150210
15. Support control rod (R) with wood blocks in order to raise control rod (R) away from the rear axle assembly.
Illustration 72
g01066077
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Illustration 73
(K) Pin
g01150376
Note: Apply anti-seize grease to the pin. Apply anti-seize grease to the bore.
17. Slide pin (K) back into position.
Illustration 74
(L) Bolt
g01150433
18. Install bolt (L), hard washer (M), full nut (N), and two washers (P) that secure pin (K). Tighten bolt (L) to a
torque of 620 80 Nm (455 60 lb ft).
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Illustration 75
(3) 2H-1618 Bolts
g01150442
19. Apply 9S-3263 Thread Lock Compound to the 20 2H-1618 Bolts (3). Install 20 2H-1618 Bolts (3) and 20
5T-1352 Spacers (4). This will secure the A-frame to the rear axle housing. Tighten the 20 2H-1618 Bolts (3)
that secure the rear axle housing to the A-frame. Tighten the 20 bolts to a torque of 1800 200 Nm (1330
150 lb ft).
Illustration 76
g01066087
20. Remove the links in the chains that were used to secure the A-frame.
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Illustration 77
g00679680
21. Align the rear struts with the rear axle housing.
Illustration 78
(B) Bolts
g01150493
(C) Washers
(D) Plates
Illustration 79
Location of the lubrication fittings on the lower rear strut pin
g01076090
Note: Make sure that the lubrication fittings on the pins face toward the rear of the machine. The lubrication
fittings should be on the horizontal center line of the bore. Refer to figure 79.
22. Install the following items: pins (A), plates (D), 12 washers (C) and 12 bolts (B). Tighten bolts (B) to a torque
of 370 50 Nm (270 35 lb ft).
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Illustration 80
g00715774
23. If the guards are removed, reinstall the guards over the pins.
Illustration 81
(S) Bolts
g01150855
(T) Washers
(U) Guard
24. Remove five bolts (S) and washers (T) that secure guard (U). Clean the transmission drive shaft.
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Illustration 82
(1) 8X-0465 Slip Joint
g01150858
Note: Hold the drive shaft with a prybar during the torque sequence.
25. Align 8X-0465 Slip Joint (1) to the transmission. Install four 2N-2486 Bolts (2). Tighten 2N-2486 Bolts (2) to
a torque of 550 20 Nm (405 15 lb ft).
Illustration 83
(S) Bolts
g01150855
(T) Washers
(U) Guard
26. Reinstall guard (U) with five bolts (S) and washers (T) .
Parts that Are Needed for Installation of 241-7846 Service Brake Lines Gp
Item
Quantity
Part Number
Part Name
8W-3191
Hose
6V-9746
O-Ring Seal
8W-3723 (1)
Hose
114-2891 (1)
Hose
5P-7466
Clip
5P-7467
Clip
5P-8112 (1)
Grommet
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8T-8917 (1)
Bolt
8T-4223 (1)
Hard Washer
10
5M-1932
Taperlock Stud
11
6V-8188
Nut
12
7G-3832
Grommet
13
7G-3833
Clip
14
7G-3834
Clip
15
5P-1076
Hard Washer
(1)
Illustration 84
g01066552
(A) Cap on the hose connection to the master cylinder
1. Remove cap (A) that covers the hose connections for the master cylinders.
Illustration 85
(1) 8W-3191 Hose
g01066550
2. Attach the end of the 8W-3191 Hose (1) to the master cylinders.
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Illustration 86
(B) Cap on TCS valve
g01066555
3. Remove cap (B) and cap (C) that covers the hose connections at the TCS valve.
Illustration 87
(2) 6V-9746 O-Ring Seal
g01066556
4. Use a 6V-9746 O-Ring Seal (2) when you are connecting 8W-3723 Hose (3). Connect the end of the 8W3723 Hose (3) to the port at the right side of the TCS valve.
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Illustration 88
(2) 6V-9746 O-Ring Seal
g01066556
5. Use a 6V-9746 O-Ring Seal (2) when you are connecting 114-2891 Hose (4). Connect the end of the 1142891 Hose (4) to the port at the left side of the TCS valve.
Illustration 89
g01066618
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Illustration 90
(1) 8W-3191 Hose
g01066619
6. Use the following components to secure the 114-2891 Hose (4) to the A-frame: two 5P-7466 Clips (5), two
5P-7467 Clips (6), two 5P-8112 Grommets (7), two 8T-8917 Bolts (8) and two 8T-4223 Hard Washers (9) .
7. Use the components that follow to secure the 8W-3723 Hose (3) and the 8W-3191 Hose (1) to the A-frame:
four 5M-1932 Taperlock Studs (10), four 5P-1076 Hard Washers (15), four 6V-8188 Nuts (11), two 7G-3832
Grommets (12), two 7G-3833 Clips (13) and two 7G-3834 Clips (14) .
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Parts that Are Needed for Installation of 170-3583 Transmission Oil Lines
Item
Quantity
Part Number
Part Name
8W-3358
Hose
1P-4582
Half Flange
4J-0527 (1)
O-Ring Seal
5P-2566
Bolt
8T-4122
Washer
8W-3353
Hose
1P-4579 (1)
Half Flange
4J-0524 (1)
O-Ring Seal
8T-9389
Bolt
10
12
8T-4223
Hard Washer
11
8W-3354
Hose
12
160-4960
Hose
13
1P-4585
Half Flange
14
2H-6338
O-Ring Seal
15
7X-0347
Bolt
16
172-4613
Connector
17
4D-4791
Hose
18
8W-3707
Hose
19
8W-3708
Hose
(1)
1. Remove the covers from the ports at the transmission. Remove the caps from the hoses.
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Illustration 91
(1) 8W-3358 Hose
g00759681
2. Use the following components to attach the 8W-3358 Hose (1) to the transmission lubrication port: two 1P4582 Half Flanges (2), one 4J-0527 O-Ring Seal (3), four 5P-2566 Bolts (4) and four 8T-4223 Washers (10) .
Illustration 92
(6) 8W-3353 Hose
g00759680
3. Use the following components to attach the 8W-3353 Hose (6) to the port of the transmission for the
transmission charge pump: two 1P-4579 Half Flanges (7), one 4J-0524 O-Ring Seal (8), four 8T-9389 Bolts
(9) and four 8T-4223 Hard Washers (10) .
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Illustration 93
(7) 1P-4579 Half Flanges
g00759679
4. Use the components that follow to attach the 8W-3354 Hose (11) to the port of the transmission for the
transmission cooler: two 1P-4579 Half Flanges (7), one 4J-0524 O-Ring Seal (8), four 8T-9389 Bolts (9) and
four 8T-4223 Hard Washers (10) .
Illustration 94
(5) 8T-4122 Hard Washers
g00759677
5. Use the components that follow to attach the 160-4960 Hose (12) to the port of the transmission for the
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transmission scavenge pump: two 1P-4585 Half Flanges (13), one 2H-6338 O-Ring Seal (14), four 7X-0347
Bolts (15) and four 8T-4122 Hard Washers (5) .
Illustration 95
(16) 172-4613 Connector
g00759676
6. Use a 172-4613 Connector (16) in order to attach 4D-4791 Hose (17) to the transmission. 4D-4791 Hose (17)
comes from the hydraulic tank.
Illustration 96
(18) 8W-3707 Hose
g00759674
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Illustration 97
(18) 8W-3707 Hose
g00759672
7. Connect the 8W-3707 Hose (18) to the port at the transmission control. 8W-3707 Hose (18) comes from the
torque converter lockup clutch and synchronizing valve.
Illustration 98
(19) 8W-3708 Hose
g00759671
8. Connect the 8W-3708 Hose (19) to the port that is above the port for the transmission lubrication. 8W-3708
Hose (19) comes from the torque converter lockup clutch and synchronizing valve.
Quantity
Part Number
Part Name
8T-9377
Bolt
6V-8801
Nut
5P-1075
Hard Washer
8W-4532
Hose As
2N-1287
Flared Elbow
5N-5646
Hose
5T-5760
Hose
4K-8864
Clip
9X-8250
Clip
10
5M-3062
Bolt
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11
6K-1972
Flared Elbow
12
3P-1823
Pipe Adapter
13
5T-5760
Hose
14
13
8T-4896
Hard Washer
15
5T-4381
Hose
Illustration 99
(1) 8T-9377 Bolts
g01066642
1. Place the lubrication injector bank in position at the rear axle housing. Use six 8T-9377 Bolts (1), six 6V8801 Nuts (2) and 12 8T-4896 Hard Washers (14) to attach the lubrication injector bank to the rear axle
housing.
Illustration 100
(4) 8W-4532 Hose
g01076176
2. Install the 8W-4532 Hose (4) to the junction block. The 8W-4532 Hose (4) is the supply line for lubrication.
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Illustration 101
(5) 2N-1287 Flared Elbow
g00759635
3. Use a 2N-1287 Flared Elbow (5) to attach a 5T-5760 Hose (7) to the lower cylinder eye of each rear
suspension cylinder.
Illustration 102
(3) 5P-1075 Hard Washer
g00759633
4. Use the following components to secure each 5N-5760 Hose (7) to the rear axle housing: 4K-8864 Clip (8),
5M-3062 Bolt (10) and 5P-1075 Hard Washer (3). Use 9X-8250 Clip (9) to secure the 8W-4532 Hose (4) to
the rear axle housing at the left side of the machine.
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Illustration 103
(6) 5N-5646 Hose
g00759632
5. Use a 6K-1972 Flared Elbow (11) and a 3P-1823 Pipe Adapter (12) to attach one 5N-5646 Hose (6) to each
lower pin for the rear suspension cylinders.
Illustration 104
(8) 4K-8864 Clip
g00759626
6. Use a 4K-8864 Clip (8) and the existing bolt to secure each hose for the lower pins of the rear suspension
cylinders.
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Illustration 105
(5) 2N-1287 Flared Elbow
g00759622
Illustration 106
(8) 4K-8864 Clip
g00759620
7. Use a 2N-1287 Flared Elbow (5) to attach a 5T-5760 Hose (13) to the control rod at the frame. Use one 4K8864 Clip (8), one 5M-3062 Bolt (10), and one 8T-4896 Hard Washer (14) to secure the 5T-5760 Hose (13)
at the opposite end of the control rod.
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Illustration 107
(5) 2N-1287 Flared Elbow
g00759617
8. Use a 2N-1287 Flared Elbow (5) to attach a 5T-4381 Hose (15) to the control rod at the axle housing.
Connect the Wiring Harness for the Rear Axle and Transmission
Assembly
Illustration 108
g00760780
1. Unwrap the differential oil filter and the harness for the traction control system. Route the harness along the
inside of the A-frame at the right side of the machine. Connect the six pin connector and the eight pin
connector at the front chassis harness. Secure the harness with the existing bolts and clips.
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Illustration 109
(A) Bolt
g00760782
(B) Guard
(C) Lead
2. Remove two bolts (A) that secure guard (B) over the transmission speed sensor. Connect lead (C) from the
transmission wiring harness to the transmission speed sensor. Install guard (B). Secure lead (C) with the
existing bolt and clamp.
Illustration 110
(D) Lead
g00760793
3. Connect lead (D) from the transmission wiring harness to the gear position switch at the transmission. Secure
lead (D) with the existing clip and bolt.
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Illustration 111
Cover on three solenoids on the transmission.
g01076214
Illustration 112
(E) Upshift solenoid
g00760804
4. Connect the three leads from the transmission wiring harness to the three solenoids. The three solenoids are
located under the step at the top of the transmission. The three leads have the following labels: upshift,
downshift and lockup clutch. Refer to Illustration 112 in order to make sure that the leads are connected to the
appropriate solenoids.
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Illustration 113
(H) Lead
g00760810
5. Connect the long lead (H) from the rear chassis harness for VIMS to the oil temperature sensor at the top of
the axle housing at the left side of the machine.
Qty
Part Number
165-4931
Elbow Gp
148-8339
Connector
6V-0852
Dust Cap
5T-7618
Tube Assembly
3S-7594
Hose
5P-0598
Clamp
5P-1935
Seal
7X-0325
Bolt
8T-4223
Hard Washer
Illustration 114
Part Name
g01068173
1. Remove the following items for each hose connection: four bolts, four washers, two split flanges, cap and Oring seal. Refer to the arrows. Retain the hardware for installation of the hose assembly for the front oil
cooler.
NOTICE
Prevent contamination of the hydraulic system when hose assemblies
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2. Repeat Step 1 for the second connection to the hose assembly to the brake oil cooler.
Illustration 115
(A) Caps
g01068174
Illustration 116
(B) Hose assembly
g01068175
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Illustration 117
g00744325
3. Remove caps (A) from hose assembly (B) and hose assembly (C). Make sure that O-ring seal (D) is still in the
proper position. Use the hardware that was removed in Step 1 and Step 2 in order to connect hose assembly
(B) and hose assembly (C) to the front brake.
Note: Inspect O-ring seals (D) for wear or damage. If necessary, replace O-ring seals (D) with 4J-0524 ORing Seal . Apply 1U-6396 O-Ring Assembly Compound to O-ring seals prior to assembly.
4. Repeat Step 1 through Step 3 for the other front service brake.
Illustration 118
g01068451
(E) Hose assembly that returns cooling oil from the rear service brake
5. Remove the clamp assembly. Refer to the arrow. Save the hardware for installation of the hose assembly for
the rear oil cooler.
6. Remove the cap from tube assembly (E) .
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Illustration 119
g00744329
7. Remove the following items: three bolts, three washers, the plate and the O-ring seal.
Illustration 120
(1) 165-4931 Elbow Gp
g01068452
8. Install an oil sampling fitting in each of the oil cooler tubes. Install one 165-4931 Elbow Gp (1) in each oil
cooler tube assembly. Install one 148-8339 Connector (2) on each 165-4931 Elbow Gp (1). Install one 6V0852 Dust Cap (3) on each fitting (2) .
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Illustration 121
(4) 5T-7618 Tube Assembly
g01068457
9. Connect 5T-7618 Tube Assembly (4) to the return hose assembly for the hydraulic oil tank by using 3S-7594
Hose (5) and four 5P-0598 Clamps (6). Leave 5P-0598 Clamps (6) loose until the opposite end of 5T-7618
Tube Assembly (4) is connected.
Illustration 122
(7) 5P-1935 Seal
g01068458
Illustration 123
g01068471
Proper routing of rear cooling line for the right side of the truck
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Illustration 124
g01068472
Proper routing of rear cooling line for the left side of the truck
10. Connect the remaining end of 5T-7618 Tube Assembly (4) by using the following items: 5P-1935 Seal (7),
three 7X-0325 Bolts (8) and three 8T-4223 Hard Washers (9) .
Note: Inspect 5P-1935 Seal (7) for wear or damage. If necessary, replace 5P-1935 Seal (7) with a new part.
Apply 1U-6396 O-Ring Assembly Compound to the seals prior to assembly.
Illustration 125
g01068462
Illustration 126
g01068463
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Illustration 127
g01068460
12. Remove the following items: Two half flanges, cap, O-ring seal, four washers and four bolts. Refer to the
arrows. Save the hardware for installation of the hose assembly for the rear oil cooler.
Illustration 128
g01068467
13. Use the hardware that was removed in step 12 in order to connect the hose assembly.
14. Repeat step 5 through step 13 in order to install the other rear cooling oil lines.
Quantity
Part Number
Part Name
148-8345
Connector
5T-0967
Block
5T-0968
Block
8T-2501
Bolt
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8T-4896
Hard Washer
5T-9053
Plate
7X-0353
Bolt
8T-4122
Hard Washer
5T-0965
Plate
10
3S-9175
Elbow
11
5J-0541
Hose
12
9D-0771
Hose
13
1S-0996
Clip
14
9C-4937
Breather As
15
7K-1181
Cable Strap
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Illustration 129
g01068616
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Note: Before you operate the machine, purge all air from the brake lines after the lines are installed.
Note: Refer to Systems Operation/Testing and Adjusting Air System and Brakes, "Brake System Air - Purge"
for information regarding purging brake lines.
1. Remove the shipping plug from the parking brake port and the service brake port in each brake anchor. The
service brake port is marked with an "S" that is cast in the brake anchor. The parking brake port is marked
with a "P" that is cast in the brake anchor.
2. Remove the caps from the service brake line and from the parking brake line at each side of the machine.
3. Install one 148-8345 Connector (1) in the service brake port and in the parking brake port in each brake
anchor.
Illustration 130
(1) 148-8345 Connector
g01068620
(A) Hose
4. At each side of the machine, slide the existing Hose (A) through the hole in the bracket behind the ports for
the brake cooling lines. Attach the service brake line to the 148-8345 Connector (1) at each service brake port.
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Illustration 131
(2) 5T-0967 Block
g01068701
5. Use block (2), block (3), two bolts (4), and two hard washers (5) to secure the service brake line. Secure the
service brake line to the bracket at each side of the machine.
Illustration 132
(1) 148-8345 Connector
g01068635
6. At each side of the machine, connect the parking brake line (B) to the 148-8345 Connector (1) at the parking
brake port.
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Illustration 133
(2) 5T-0967 Block
g01068627
7. At the right side of the machine, use two bolts (7) and two hard washers (8) to secure the plate (9) above the
parking brake port.
Illustration 134
(6) 5T-9053 Plate
g01068632
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8. At the left side of the machine, use two bolts (7) and two hard washers (8) to secure the plate (6) above the
parking brake port.
Illustration 135
(2) 5T-0967 Block
g01068636
9. Use a block (2), a block (3), two bolts (4), and two hard washers (5) to secure the parking brake line to the
plate at each side of the machine.
Illustration 136
g01068637
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Illustration 137
(10) 3S-9175 Elbow
g01068638
11. Install a 3S-9175 Elbow (10) in each spindle. Apply 5P-3413 Pipe Sealant to the external threads of the 3S9175 Elbow (10) prior to assembly.
Illustration 138
(10) 3S-9175 Elbow
g01068640
12. At each side of the machine, attach the existing vent line from the breather to the 3S-9175 Elbow (10). The
5J-0451 Hose (11) is for the right side. The 9D-0771 Hose (12) is for the left side.
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Illustration 139
(12) 9D-0771 Hose
g01068642
13. By using clip (13), the existing bolt, and the existing washer, attach hose (11) on the right side and hose (12)
on the left side.
14. Attach 9C-4937 Breather As (14) to the end of the vent line on each side of the truck.
Illustration 140
(15) 7K-1181 Cable Straps
g01068650
15. Use 7K-1181 Cable Straps (15) to secure the vent lines.
Qty
Part Number
Part Name
150-9548 (1)
151-3177 (2)
8X-2232
Shim Pack
8W-3602
Mud Flap
8T-2561
Washer
4L-6454
Bolt
6V-8801
Nut
145-2817
9M-7958
Hose Clamp
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(1)
(2)
6V-8400
O-Ring Seal
Illustration 141
g00940921
(1) 150-9548 Fuel Tank Assembly (If Equipped)
1. Remove either the 150-9548 Fuel Tank Assembly (1) (If Equipped) or the 151-3177 Fuel Tank As (1) (If
Equipped) from the shipping pallet.
Illustration 142
(A) Front top mount for the fuel tank
g01071485
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Illustration 143
g01076732
150-9548 Fuel Tank As (1) mounting on chassis
(C) Bottom mount for the fuel tank
(D) Nuts
Illustration 144
g01071486
151-3177 Fuel Tank As (1) mounting on chassis
(C) Bottom mount for the fuel tank
(D) Nuts
(E) Additional mounting point for fuel tank
2. Remove two nuts (D) from bottom mount (C). Disassemble the hardware from bottom mount (C). For 1513177 Fuel Tank As , disassemble the hardware from mounting point (E) for the fuel tank. Retain all hardware.
Note: 150-9548 Fuel Tank As (1) has two lower mounting points. 151-3177 Fuel Tank As (1) has three lower
mounting points.
NOTICE
Mating surfaces of the mounting flanges must be cleaned to bright
metal and free of nicks and burrs to produce joints with the desired
structural properties.
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3. Disassemble the upper mounts for the fuel tank on the chassis. Use 4C-4204 Paint Remover to remove the
shipping grease or paint from the front fuel tank mounting (A) and rear fuel tank mounting (B). The mating
surfaces of these mounts must be cleaned to bright metal and free of nicks and burrs.
4. Reassemble the upper mounts for the fuel tank on the chassis.
Illustration 145
(A) Typical front mount for the fuel tank
g01071505
5. Use 8T-0447 Dial Caliper As to measure dimension (F) at the front and rear fuel tank mounting. Record these
dimensions for use later in this procedure.
6. Remove the following parts from the front fuel tank mounting (A) : two existing bolts, two washers and cap.
Repeat for the existing rear fuel tank mounting (B) .
Illustration 146
g00720498
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7. Use 4C-4204 Paint Remover to remove the shipping grease or paint from the front fuel tank mounting and
rear fuel tank mounting. The mating surfaces of these mounts must be cleaned to bright metal and free of
nicks and burrs.
Illustration 147
(G) Dimension
g01071512
8. Use an outside micrometer to measure dimension (G) at the front and rear fuel tank mounting.
9. Subtract dimension (G) from dimension (F) in order to calculate the maximum shim thickness. The minimum
allowable shim thickness is equal to 0.12 mm (0.005 inch) less than the maximum shim thickness. Repeat this
calculation for the remaining fuel tank mounting. Use 8X-2232 Shim Pack (3) to obtain the required shim for
the front and rear mounts.
Illustration 148
(1) 150-9548 Fuel Tank Assembly
g00940928
10. Use a suitable crane to lift 150-9548 Fuel Tank Assembly (1) or 151-3177 Fuel Tank As (1). The Fuel Tank
Assembly weighs approximately 900 kg (1982 lb).
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Illustration 149
(2) 8X-2232 Shim Pack
g01071529
11. Position 150-9548 Fuel Tank Assembly (1) or 151-3177 Fuel Tank As (1) on the front and rear fuel tank
mounting.
12. Assemble the appropriate number of 8X-2232 Shim Packs (2) that was determined in Step 9. Then, replace
the existing cap (A), two washers, and two bolts. Tighten the bolts to a torque of 450 25 Nm (331 18 lb
ft).
Illustration 150
(2) 8X-2232 Shim Pack
g01071530
13. Assemble the appropriate number of 8X-2232 Shim Packs (2) that was determined in Step 9 and replace the
existing cap (B), two washers, and two bolts. Tighten the bolts to a torque value of 450 25 Nm (331 18 lb
ft).
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Illustration 151
Mount for 150-9548 Fuel Tank As
g01071531
(D) Nut
(I) Bolts
14. Assemble the lower mount (C) for the fuel tank by sliding bolt (H) through the hole and tightening nut (D).
Repeat for the remaining mounts. Tighten the two bolts (I) to a torque value of 370 50 Nm (272 37 lb ft).
Illustration 152
(3) 8W-3602 Mud Flap
g01071535
15. Assemble the 8W-3602 Mud Flap (3) by using five 8T-2561 Washers (4), five 4L-6454 Bolts (5), and five
6V-8801 Nuts (6). Tighten 4L-6454 Bolts (5) to a torque value of 47 9 Nm (35 7 lb ft).
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Illustration 153
g01071538
(7) 145-2817 O-Ring Face Seal Hose Assembly
(8) 9M-7958 Hose Clamp
16. Use a 9M-7958 Hose Clamp (8) to secure the 145-2817 O-Ring Face Seal Hose Assembly (7) to fitting on the
fuel tank.
Illustration 154
g01071539
(7) 145-2817 O-Ring Face Seal Hose Assembly
(9) 6V-8400 O-Ring Seal
17. Connect the 145-2817 O-Ring Face Seal Hose Assembly (7) to the Elbow by using an 6V-8400 O-Ring Seal
(9) .
Qty
Part Number
Part Name
9L-5254
Elbow
030-7944
Elbow
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6V-8358
Illustration 155
Rear view of the fuel tank
Ball Valve
g01069293
1. Remove the two caps from the hose assemblies. Remove the two plugs from the fuel tank.
2. Assemble 9L-5254 Elbow (1). Apply 5P-3413 Pipe Sealant to the external tapered threads of the elbow prior
to installation.
3. Connect hose assembly (A) to 9L-5254 Elbow (1). Apply 5P-3413 Pipe Sealant to the external tapered
threads prior to installation.
4. Assemble 6V-8358 Ball Valve (3) to the fuel tank. Connect 030-7944 Elbow (2) to 6V-8358 Ball Valve (3).
Apply 5P-3413 Pipe Sealant to the external tapered threads prior to installation.
5. Connect hose assembly (B) to 030-7944 Elbow (2). Apply 5P-3413 Pipe Sealant to the external tapered
threads prior to installation.
Qty
Part Number
Part Name
105-2200
Mud Flap
16
4L-6454
Bolt
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16
8T-2561
Washer
16
6V-8801
Nut
105-2204
Support
105-2205
Support
105-2201
Mud Flap
105-4620
Support
8T-9101
Bolt
Illustration 156
(A) Remove the bolts prior to installation of the guards.
g01069341
(B) Do not remove these bolts. Loosen the bolts approximately 8 mm (0.3 inch).
Illustration 157
g01069345
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2. Assemble the 105-2200 Flap (1) to 105-2204 Support (5) by using the following items: four 4L-6454 Bolts
(2), four 8T-2561 Washers (3) and four 6V-8801 Nuts (4). Tighten 4L-6454 Bolts (2) to a torque value of 47
9 Nm (35 7 lb ft).
3. Install the 105-2204 Support Assembly (5) and tighten two bolts (B). Tighten bolts (B) to a torque value of 47
9 Nm (35 7 lb ft).
Illustration 158
(1) 105-2200 Mud Flap
g01069348
4. Assemble the 105-2200 Flap (1) to 105-2205 Support (6) by using the following items: four 4L-6454 Bolts
(2), four 8T-2561 Washers (3) and four 6V-8801 Nuts (4). Tighten 4L-6454 Bolts (2) to a torque value of 47
9 Nm (35 7 lb ft).
5. Use two bolts (A) in order to secure the 105-2205 Support Assembly (6) to the hydraulic tank. Tighten bolts
(A) to a torque value of 47 9 Nm (35 7 lb ft).
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Illustration 159
(2) 4L-6454 Bolt
g01069351
6. Assemble the 105-2201 Flap (7) to 105-4620 Support (8) by using the following items: eight 4L-6454 Bolts
(2), eight 8T-2561 Washers (3) and six 6V-8801 Nuts (4). Tighten 4L-6454 Bolts (2) to a torque value of 47
9 Nm (35 7 lb ft).
7. Install the 105-4620 Support Assembly (8) by using three bolts (A). Tighten bolts (A) and two 8T-9101 Bolts
(9) to a torque value of 47 9 Nm (35 7 lb ft).
Qty
Part Number
Part Name
8W-0671
Ladder Assembly
24
8T-4896
Hard Washer
8T-2502
Bolt
5P-1075
Hard Washer
4L-6454
Bolt
5T-8218
Plate
5T-8220
Baffle
149-6884
Ladder Assembly
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38
8T-4223
Hard Washer
10
5P-2566
Bolt
11
6V-8188
Nut
12
8T-8917
Bolt
13
8T-4835
Bolt
14
8W-2025
Brace
15
4L-9337
Bolt
16
6V-8801
Nut
17
9P-2950
Handhold
18
5P-1076
Hard Washer
19
5P-2228
Bolt
20
153-1315
Handhold
Illustration 160
(1) 8W-0671 Ladder Assembly
g00720478
1. Use eight 8T-4896 Hard Washers (2) and eight 8T-2502 Bolts (3) to assemble 8W-0671 Ladder Assembly (1)
to the truck frame.
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Illustration 161
(4) 5P-1075 Hard Washer
g01071068
2. Use the following parts to assemble 5T-8220 Baffle (7) to 149-6884 Ladder As (8) : 5T-8218 Plate (6), three
5P-1075 Hard Washers (4) and three 4L-6454 Bolts (5) .
Illustration 162
(8) 149-6884 Ladder Assembly
g01071070
3. Use a suitable crane to position the 149-6884 Ladder Assembly (8). The 149-6884 Ladder Assembly (8)
weighs approximately 36 kg (79 lb).
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Illustration 163
(8) 149-6884 Ladder Assembly
g01071072
4. Assemble 149-6884 Ladder Assembly (8) by using the following parts: four 5P-2566 Bolts (10), eight 8T4223 Hard Washers (9) and four 6V-8188 Nuts (11). Leave 5P-2566 Bolts (10) loose at this time.
Illustration 164
(9) 8T-4223 Hard Washer
g01071073
5. Install three 8T-8917 Bolts (12) and three 8T-4223 Hard Washers (9) into the top of 149-6884 Ladder As (8).
8T-8917 Bolts (12) and 8T-4223 Hard Washers (9) hold 149-6884 Ladder As (8) to the frame.
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Illustration 165
(8) 149-6884 Ladder Assembly
g01071090
6. Use the following parts to assemble 8W-2025 Brace (14) to 149-6884 Ladder Assembly (8) : 8T-8917 Bolt
(12), 8T-4835 Bolt (13), 6V-8188 Nut (11) and three 8T-4223 Hard Washers (9) .
Illustration 166
(4) 5P-1075 Hard Washer
g01071091
7. Use the following parts to assemble 5T-8220 Baffle (7) on the right side: 5T-8218 Plate (6), three 5P-1075
Hard Washers (4) and three 4L-6454 Bolts (5) .
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Illustration 167
g01071095
Illustration 168
(2) 8T-4896 Hard Washer
g01071096
8. Assemble the step assembly on the right side by using the following parts: four 4L-9337 Bolts (15), eight 8T4896 Hard Washers (2) and four 6V-8801 Nuts (16) .
Illustration 169
g01071105
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9. Assemble 9P-2950 Handhold (17) by using two 5P-1076 Hard Washers (18) and two 5P-2228 Bolts (19).
Assemble 153-1315 Handhold (20) by using two 5P-1076 Hard Washers (18) and two 5P-2228 Bolts (19) .
10. Repeat Step 8 and Step 9 on the other side of the truck chassis.
Qty
Part Number
Part Name
14
7D-1649
Washer
0S-1595
Bolt
5T-6403
Fender
0S-1621
Bolt
8W-4808
Support
8W-7900
Guard
8W-6382
Plate
5T-6553
Plate
26
5P-1075
Hard Washer
10
9B-7237
Bolt
11
15
1D-4717
Nut
12
8T-2502
Bolt
13
8W-7788
Strip
14
5S-7379
Bolt
15
8W-6063
Strip
16
4L-6454
Bolt
17
8W-7899
Guard
18
6H-1717
Bolt
19
8T-4223
Hard Washer
20
6V-8188
Nut
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21
8W-0571
Plate
22
0S-1594
Bolt
23
5M-2894
Hard Washer
24
6V-8801
Nut
25
8W-0568
Plate
Note: The following procedure is most easily completed before the cab assembly is assembled to the truck chassis.
The cab assembly must be 1220 mm (48 inch) above the ground in order to complete this procedure while the cab
assembly is located on stands.
Illustration 170
(1) 7D-1649 Washer
g00714498
Illustration 171
(1) 7D-1649 Washer
g00714501
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1. Position 5T-6403 Fender Assembly (3) by using the following items: ten 7D-1649 Washers (1), five 0S-1595
Bolts (2) and five 0S-1621 Bolts (4) .
Illustration 172
(1) 7D-1649 Washer
g01070257
2. Assemble the 8W-4808 Support Assembly (5) by using four 7D-1649 Washers (1) and four 0S-1621 Bolts
(4) .
Illustration 173
(6) 8W-7900 Guard
g00714506
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Illustration 174
(6) 8W-7900 Guard
g00714507
Illustration 175
(6) 8W-7900 Guard
g00714508
(B) Cab
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Illustration 176
Section B-B
g00714512
3. Assemble 8W-7900 Guard (6) by using the following items: 8W-7788 Strip (13), nine 5P-1075 Washers (9)
and nine 5S-7379 Bolts (14) .
Note: Do not tighten 5S-7379 Bolts (14) at this time.
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Illustration 177
(7) 8W-6382 Plate
g00714515
4. Assemble 8W-6382 Plate (7) by using the following items: six 5P-1075 Washers (9), two 9B-7237 Bolts (10),
two 8T-2502 Bolts (12) and four 1D-4717 Nuts (11) .
5. Assemble 5T-6553 Plate (8) by using the following items: two 5P-1075 Washers (9), two 8T-2502 Bolts (12)
and two 1D-4717 Nuts (11) .
Illustration 178
(9) 5P-1075 Hard Washer
g00714518
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Illustration 179
(9) 5P-1075 Hard Washer
g00714519
6. Assemble 8W-7899 Guard (17) to the right side platform by using the following items: 8W-6063 Strip (15),
nine 5P-1075 Washers (9), nine 4L-6454 Bolts (16) and nine 1D-4717 Nuts (11) .
Illustration 180
g00761885
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7. Assemble 8W-0568 Plate (25) by using the following parts: four 0S-1594 Bolts (22), eight 5M-2894 Hard
Washers (23) and four 6V-8801 Nuts (24) .
8. Assemble 8W-0571 Plate (21) by using the following parts: two 6H-1717 Bolts (18), four 8T-4223 Hard
Washers (19) and two 6V-8188 Nuts (20) .
(1)
Item
Qty
Pt. No.
Description
277-0629
Plate
277-0628
Brace
4V-0661
Mount
6J-9944
Boss
8T-4223
Hard Washer
7X-0326
Bolt
6V-8188
Nut
7X-0590
Hard Washer
8T-8917
Bolt
10
5P-1076
Hard Washer
11
278-0773
Block (1)
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Illustration 181
5T-6403 Fender As
g01302508
(4) Boss
1. Remove 5V-8305 Boss . Weld Boss (4) to 5T-6403 Fender As in the same location. Refer to Illustration 181
and Table 53 for the weld specifications.
Table 53
Weld Specifications
Item
Description
W1
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Illustration 182
(11) Block
g01302538
2. Fabricate block (11). Carbon steels that can be used to fabricate block (11) are listed below in Table 54. Refer
to Illustration 182 and Table 55 for dimensions. Drill two holes that are 11 mm (0.433 inch) in diameter at the
locations that are shown. Tap the holes to 1/2-13-2B thread.
Table 54
Grade of Steel
"BS 4360 Grade 40B"
"ASTM A36"
"SAE Grades 1008 through 1025"
"DIN 17100 Grade USt 37-2"
"AFNOR A35-501Q Grade E2402"
"JIS G4051 Grade S20C"
"JIS G3505 SWRM15 through 22"
"JIS G3505 SWRM10"
Table 55
Fabricated Dimensions for 278-0773 Block
Item
A
B
C
D
E
F
G
Dimensions
70 mm (2.76 inch)
36 mm (1.42 inch)
20 mm (0.79 inch)
40 mm (1.57 inch)
17 mm (0.67 inch)
25 mm (0.98 inch)
80 mm (3.15 inch)
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Illustration 183
(11) Block
g01303632
Illustration 184
Location of block (11)
g01312062
3. Locate block (11). Refer to Illustration 184 and Table 56 for dimensions.
Table 56
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Dimensions
468 5 mm (18.43 0.20 inch)
304 5 mm (11.97 0.20 inch)
Illustration 185
Weld specifications for block (11)
g01303854
4. Weld block (11) to 5T-6197 Pedestal . Refer to Illustration 185 and Table 57 for the weld specifications.
Table 57
Weld Specifications
Item
Description
W2
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Illustration 186
(1) Plate
g01304646
(2) Brace
(5) Hard Washer
(9) Bolt
5. Use hard washers (5) and bolts (9) in order to attach plate (1) to block (11) .
Note: Do not tighten bolts (9) fully at this time.
Illustration 187
g01304652
(1) Plate
(2) Brace
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(3) Mount
(6) Bolt
(7) Nut
(8) Hard Washer
(10) Hard Washer
(11) Block
6. First, insert mount (3) into plate (1). Next, insert bolt (6) into hard washer (10), brace (2), hard washer (8),
mount (3), and hard washer (8). Screw nut (7) onto bolt (6) .
Note: Do not tighten nut (7) fully at this time.
Illustration 188
(2) Brace
g01304705
(4) Boss
(9) Bolt
(10) Hard Washer
7. Insert bolt (9) into hard washer (10), the other end of brace (2), and boss (4). Next, screw bolt (9) into boss
(4) .
Note: Adjust brace (2) in order to achieve the proper fit. Then tighten all of the nuts and bolts which are
associated with brace (2) and plate (1) .
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Parts That Are Needed for Installation of 6I-2972 Air Cleaner Group
Item
Qty
Part Number
5K-3772
Hose Assembly
3B-6493
Pipe Elbow
175-5251
Air Cleaner
16
8T-4122
Washer
16
7X-0344
Bolt
0A-2926
Nipple
7W-7417
Service Indicator
3B-6552
Elbow
Illustration 189
(1) 5K-3772 Hose Assembly
Part Name
g00720433
1. Assemble 3B-6493 Pipe Elbow (2) and 5K-3772 Hose Assembly (1) to each 175-5251 Air Cleaner (3). The
175-5251 Air Cleaner weighs approximately 62 kg (137 lb).
2. Remove two bolts (A) .
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Illustration 190
g00720434
Illustration 191
(3) 175-5251 Air Cleaner
g01070059
3. Use a suitable crane to position 175-5251 Air Cleaner (3) against the left fender. Assemble using eight 8T4122 Washers (4) and eight 7X-0344 Bolts (5) .
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Illustration 192
(1) 5K-3772 Hose Assembly
g01070064
4. Assemble 3B-6552 Elbow (8) to the block. Connect 5K-3772 Hose Assembly (1) to 3B-6552 Elbow (8) .
5. Assemble 0A-2926 Nipple (6) to the block.
6. Assemble 7W-7417 Service Indicator (7) to 0A-2926 Nipple (6) .
Illustration 193
(3) 175-5251 Air Cleaner
g01070065
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Illustration 194
(1) 5K-3772 Hose Assembly
g01070126
7. Use seven 8T-4122 Washers (4) and seven 7X-0344 Bolts (5) in order to assemble 175-5251 Air Cleaner (3)
against the right fender.
Illustration 195
(B) Battery compartment door
g01070130
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Illustration 196
(4) 8T-4122 Washer
g01070131
Qty
Part Number
Part Name
3B-4605
Cotter
8W-7904
Tube Assembly
7X-0326
Bolt
8T-4223
Hard Washer
7D-9969
Support
8T-2287
Mirror
5S-7379
Bolt
5P-1075
Hard Washer
6V-8285
Mirror
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10
8W-7901
Bracket
11
6V-8801
Nut
12
4L-6454
Bolt
13
8T-4896
Hard Washer
Note: The following procedure is most easily completed before the right side platform is assembled to the
truck chassis.
Illustration 197
(1) 3B-4605 Cotter
g01078487
1. Assemble 8W-7904 Tube (2) by using the following items: two 7D-9969 Supports (5), two 7X-0326 Bolts (3)
and two 8T-4223 Hard Washers (4) .
Illustration 198
(1) 3B-4605 Cotter
g00721782
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Illustration 199
(6) 8T-2287 Mirror
g01078488
3. Assemble 8T-2287 Mirror (6) by using two 5S-7379 Bolts (7) and two 5P-1075 Hard Washers (8) .
4. Adjust 8T-2287 Mirror (6) to the desired position. Tighten the 7X-0326 Bolts (3) .
Illustration 200
Rear side of 6V-8285 Mirror (9)
g01070266
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Illustration 201
(7) 5S-7379 Bolt
g01070267
5. Assemble two 8W-7901 Brackets (10) to 6V-8285 Mirror (9) by using the following items: two 4L-6454
Bolts (12), four 8T-4896 Hard Washers (13) and two 6V-8801 Nuts (11). Fasten this assembly to the rail by
using two 5S-7379 Bolts (7) and two 5P-1075 Hard Washers (8) .
6. Adjust 6V-8285 Mirror (9) to the desired position. Tighten 5S-7379 Bolts (7) .
Qty
Part Number
Part Name
3B-4605
Cotter
159-4795
Tube
7X-0326
Bolt
8T-4223
Hard Washer
7D-9969
Support
8T-2287
Mirror
5S-7379
Bolt
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5P-1075
Hard Washer
134-0987
Bracket
10
8Y-6989
Mirror
11
137-2129
Bracket
12
134-0989
Block
13
8T-4186
Bolt
14
18
8T-4121
Hard Washer
15
8T-4137
Bolt
16
8T-4136
Bolt
Note: The following procedure is most easily completed before the right side platform is assembled to the
truck chassis.
Illustration 202
(1) 3B-4605 Cotter
g00721781
1. Assemble 159-4795 Tube (2) by using the following items: two 7D-9969 Supports (5), two 7X-0326 Bolts (3)
and two 8T-4223 Hard Washers (4) .
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Illustration 203
(1) 3B-4605 Cotter
g00721782
Illustration 204
(6) 8T-2287 Mirror
g00721783
3. Assemble 8T-2287 Mirror (6) by using two 5S-7379 Bolts (7) and two 5P-1075 Hard Washers (8) .
4. Adjust 8T-2287 Mirror (6) to the desired position. Tighten the 7X-0326 Bolts (3) .
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Illustration 205
g00749841
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Illustration 206
View A-A
g00749844
5. Assemble 137-2129 Bracket (11) to the rail by using eight 8T-4137 Bolts (15) and eight 8T-4121 Hard
Washers (14) .
6. Assemble 8Y-6989 Mirror (10) to 134-0987 Bracket (9) by using three 8T-4136 Bolts (16) and six 8T-4121
Hard Washers (14). Position this assembly on the 137-2129 Bracket (11). Fasten the assembly with the
following items: two 134-0989 Blocks (12), four 8T-4186 Bolts (13) and four 8T-4121 Hard Washers (14) .
7. Adjust 8Y-6989 Mirror (10) to the desired position. Tighten 8T-4186 Bolts (13) .
Qty
Part Number
Part Name
5T-7766
Bracket
8T-4223
Hard Washer
5P-2566
Bolt
4W-0969
Muffler Assembly
5T-7768
Strap
4L-9337
Bolt
2K-4973
Locknut
8X-6607
Bracket
8T-9384
Bolt
10
5T-7823
Plate
11
10
8T-4896
Hard Washer
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(1)
12
4L-6454
Bolt
13
5T-7770
Plate
14
4W-1814
Clamp
15
5S-7383
Bolt
16
8X-6605
Extension Pipe
17
6N-9298
Clamp
18
5P-2424
Bolt
19
1K-6872
Locknut
20
5T-7824
Clamp
21
5C-6565
Bolt
22
6V-8188
Nut
23
2V-8169
Plate
24
7X-0345
Bolt
25
5T-8049
Strap
26
4W-0532
Muffler Assembly
27
5T-8050
Strap
28
8W-4954
Plate
29
5P-1075
Hard Washer
30
9B-7237
Bolt
31
6V-8801
Nut
32
8X-6606
Extension Pipe
33
1W-4161 (1)
C-Clamp
34
7C-3337 (1)
Elbow
35
2W-8851 (1)
Seal Ring
36
2W-9078 (1)
Pipe
37
7C-3338 (1)
Elbow
38
7C-3339 (1)
Elbow
39
7C-3336 (1)
Pipe
Note: Step 1 through Step 7 of the following procedure is most easily completed before the right side platform is
assembled to the truck chassis.
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Illustration 207
(1) 5T-7766 Bracket
g01070661
1. Assemble 5T-7766 Bracket (1) to the right side platform by using four 8T-4223 Hard Washers (2) and four
5P-2566 Bolts (3). Tighten 5P-2566 Bolts (3) to a torque value of 60 12 Nm (44 9 lb ft).
Illustration 208
(4) 4W-0969 Muffler Assembly
g01070666
2. Assemble 4W-0969 Muffler Assembly (4) by using the following items: 5T-7768 Strap (5), four 4L-9337
Bolts (6) and four 2K-4973 Locknuts (7). Apply 5P-3931 Anti-Seize Compound to 4L-9337 Bolts (6) prior to
assembly. The 4W-0969 Muffler Assembly (4) weighs approximately 19 kg (42 lb). Tighten 4L-9337 Bolts
(6) to a torque value of 25 6 Nm (18 4 lb ft).
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Illustration 209
(2) 8T-4223 Hard Washer
g01070667
3. Assemble 8X-6607 Bracket (8) by using two 8T-4223 Hard Washers (2) and two 8T-9384 Bolts (9). Tighten
8T-9384 Bolts (9) to a torque value of 105 20 Nm (77 15 lb ft).
Illustration 210
(10) 5T-7823 Plate
g01070668
4. Assemble 5T-7823 Plate (10) by using two 8T-4896 Hard Washers (11) and two 4L-6454 Bolts (12). Tighten
4L-6454 Bolts (12) to a torque value of 47 9 Nm (35 7 lb ft).
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Illustration 211
(7) 2K-4973 Locknut
g01070670
5. Assemble 5T-7770 Plate (13) by using the following items: 4W-1814 Clamp (14), 5S-7383 Bolt (15) and 2K4973 Locknut (7). Apply 5P-3931 Anti-Seize Compound to 5S-7383 Bolt (15) prior to assembly. Tighten 5S7383 Bolt (15) to a torque value of 25 6 Nm (18 4 lb ft).
Illustration 212
(16) 8X-6605 Extension Pipe
g01070672
6. Assemble 8X-6605 Extension Pipe (16) by using the following items: 6N-9298 Clamp (17), 5P-2424 Bolt
(18) and 1K-6872 Locknut (19). Apply 5P-3931 Anti-Seize Compound to 5P-2424 Bolt (18) prior to
assembly. Tighten 5P-2424 Bolt (18) to a torque value of 60 12 Nm (44 9 lb ft).
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Illustration 213
(2) 8T-4223 Hard Washer
g01070841
Illustration 214
(2) 8T-4223 Hard Washer
g01070674
7. Assemble 5T-7824 Clamp (20) by using the following items: two 5C-6565 Bolts (21), four 8T-4223 Washers
(2), two 6V-8188 Nuts (22), 5P-2424 Bolt (18) and 1K-6872 Locknut (19). Apply 5P-3931 Anti-Seize
Compound to 5P-2424 Bolt (18) prior to assembly. Tighten 5P-2424 Bolt (18) to a torque value of 60 12
Nm (44 9 lb ft). Tighten 5C-6565 Bolt (21) to a torque value of 105 20 Nm (77 15 lb ft).
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Illustration 215
(A) Bolts
g01070676
(B) Cover
Illustration 216
g00721964
9. Use a suitable scraper in order to clean the mounting flange on the beam.
Illustration 217
g01070679
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Illustration 218
g00721967
10. Assemble the lower muffler assembly to the truck chassis by using four 2V-8169 Plates (23) and four 7X0345 Bolts (24). Tighten 7X-0345 Bolts (24) to a torque value of 115 20 Nm (85 15 lb ft).
Illustration 219
(2) 8T-4223 Hard Washer
g01070688
11. Assemble 5T-8049 Strap (25) by using two 8T-4223 Hard Washers (2) and two 5P-2566 Bolts (3). Repeat for
remaining 5T-8049 Straps (25). Tighten 5P-2566 Bolts (3) to a torque value of 105 20 Nm (77 15 lb ft).
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Illustration 220
(25) 5T-8049 Strap
g01070697
12. Position 4W-0532 Muffler Assembly (26) on 5T-8049 Strap (25). The 4W-0532 Muffler Assembly (26)
weighs approximately 21 kg (46 lb).
Illustration 221
(7) 6N-9298 Clamp
g01070726
13. Assemble 5T-8050 Strap (27) by using the following items: two 8T-4896 Hard Washers (11), two 5S-7383
Bolts (15) and two 2K-4973 Locknuts (7). Apply 5P-3931 Anti-Seize Compound to 5S-7383 Bolts (15) prior
to assembly. Tighten 5S-7383 Bolts (15) to a torque value of 25 6 Nm (18 4 lb ft). Repeat for remaining
5T-8050 Strap (27) .
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Illustration 222
(25) 5T-8049 Strap
g01070754
14. Assemble 8W-4954 Plate (28) to 5T-8049 Strap (25) by using the following items: four 5P-1075 Hard
Washers (29), two 9B-7237 Bolts (30) and two 6V-8801 Nuts (31). Repeat for remaining 8W-4954 Plate
(28). Tighten 9B-7237 Bolts (30) to a torque value of 47 9 Nm (35 7 lb ft).
Illustration 223
g01070757
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15. Assemble 8X-6606 Extension Pipe (32) by using the following items: 6N-9298 Clamp (17), 5T-7824 Clamp
(20), two 5P-2424 Bolts (18), two 1K-6872 Locknuts (19), two 5C-6565 Bolts (21), four 8T-4223 Hard
Washers (2) and two 6V-8188 Nuts (22). Apply 5P-3931 Anti-Seize Compound to 5P-2424 Bolts (18) and to
5C-6565 Bolts (21) prior to assembly. Tighten 5P-2424 Bolts (8) and 5C-6565 Bolts (21) to a torque value of
60 12 Nm (44 9 lb ft).
Illustration 224
(A) Shipping covers
g01151256
(B) Clamp
16. Remove the shipping covers (A). Retain both clamps (B) .
Illustration 225
g01151268
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17. Install 7C-3337 Elbow (34) to the exhaust port on the engine. Use the existing clamp (B) to secure 7C-3337
Elbow (34) in place. Tighten clamp (B) to a torque value of 15 3 Nm (11 2 lb ft).
Note: Do not overtighten clamp (B) .
Illustration 226
(34) 7C-3337 Elbow
g01070774
18. Place 2W-8851 Seal Ring (35) in the groove on the end of 7C-3337 Elbow (34) .
19. Slip 2W-9078 Pipe (36) over 2W-8851 Seal Ring (35) and onto 7C-3337 Elbow (34) .
20. Place 2W-8851 Seal Ring (35) in the groove on the end of 2W-9078 Pipe (36) and slip 7C-3338 Elbow (37)
over 2W-8851 Seal Ring (35) and 2W-9078 Pipe (36) .
21. Attach the end of 7C-3338 Elbow (37) to 4W-0532 Muffler As (26) with 1W-4161 Clamp (33). Tighten 1W4161 Clamp (33) to a torque value of 15 3 Nm (11 2 lb ft).
Note: Do not overtighten 1W-4161 Clamp (33) .
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Illustration 227
(C) Cover
g01070792
(D) Bolt
(E) Washer
22. Remove cover (C) from the frame by removing four bolts (D) and four washers (E). Retain bolts (D) and
washers (E) .
Illustration 228
(26) 4W-0532 Muffler As
g01151268
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23. Install 7C-3339 Elbow (38) on the exhaust port of the engine. Use the existing clamp (B) to secure 7C-3339
Elbow (38) in place. Tighten clamp (B) to a torque value of 15 3 Nm (11 2 lb ft).
Note: Do not overtighten clamp (B) .
24. Place 2W-8851 Seal Ring (35) in the groove on the end of 7C-3339 Elbow (38) and slip 2W-9078 Pipe (36)
over 2W-8851 Seal Ring (35) and 7C-3339 Elbow (38) .
25. Place 2W-8851 Seal Ring (35) in the groove on the end of 2W-9078 Pipe (36) and slip 7C-3336 Pipe (39)
over 2W-8851 Seal Ring (35) and 2W-9078 Pipe (36) .
26. Use four bolts (D) and four washers (E) to secure 7C-3336 Pipe (39) to the frame. Tighten bolts (D) .
Qty
Part Number
Part Name
7I-5493
Support
12
4L-6454
Bolt
14
8T-4896
Hard Washer
8X-7007
Rail
5P-8248
Hard Washer
1A-8063
Bolt
2S-7593
Hard Washer
8S-9092
Bolt
8W-4926
Plate
10
5P-2228
Bolt
11
8T-4223
Hard Washer
Note: Step 1 through 3 of the following procedure are most easily completed before the right side platform is
assembled to the truck chassis.
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Illustration 229
(1) 7I-5493 Support Assembly
g00715112
1. Use a suitable crane in order to remove 7I-5493 Support Assembly (1) from the shipping pallet. Set the 7I5493 Support Assembly (1) aside. The 7I-5493 Support Assembly (1) weighs approximately 761 kg (1677
lb).
2. Use a suitable crane in order to remove the remaining miscellaneous components from the shipping pallet.
3. Replace the 7I-4593 Support Assembly (1) on the shipping pallet and disconnect the crane.
Illustration 230
(1) 7I-5493 Support Assembly
g00715114
4. Use 4C-4204 Paint Remover in order to clean the shipping grease or paint from the mounting flanges of the
right front fender. Refer to the arrows. The mating surfaces of these mounting flanges must be cleaned to
bright metal and free of nicks and burrs.
NOTICE
Mating surfaces of these mounting flanges must be cleaned to bright
metal and free of nicks and burrs to produce joints with the desired
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structural properties.
5. Use 12 4L-6454 Bolts (2) and 12 8T-4896 Hard Washers (3) in order to assemble 8X-7007 Rail Assembly
(4) .
Illustration 231
Front mounting flange for the RH platform
g01070959
6. Use a suitable crane in order to support the weight of the shipping bracket (A). Remove the following items:
eight bolts (B), two bolts (C) and shipping bracket (A). The shipping bracket (A) weighs approximately 41 kg
(91 lb).
7. Use 4C-4204 Paint Remover in order to clean the shipping grease or paint from the front mounting flange of
the right side platform. The mating surfaces of this flange must be cleaned to bright metal and free of nicks
and burrs.
Illustration 232
Rear mounting flange for the RH platform
g01070967
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Illustration 233
Rear mounting flange for the RH platform
g00715122
8. Use 4C-4204 Paint Remover in order to clean the shipping grease or paint from the rear mounting flange of
the right side platform. The mating surfaces of this flange must be cleaned to bright metal and free of nicks
and burrs.
Illustration 234
RH platform
g00715125
9. Use a suitable crane and a three-point connection to the right side platform in order to lift the right-hand
platform. Adjust the position of the platform until the mounting flanges of the right side platform can be
positioned against the truck chassis.
Note: A portion of the 2W-3700 Muffler Group and the 159-2489 Rear View Mirror Group have been
assembled. These components are more easily assembled while the right side platform is on the ground.
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Illustration 235
RH platform
g00715126
10. Position the right side platform against the mounting flanges and align the holes in the mounting flanges.
Illustration 236
(5) 5P-8248 Hard Washer
g01070969
11. Assemble eight 5P-8248 Washers (5) and eight 1A-8063 Bolts (6). Do not tighten the eight 1A-8063 Bolts (6)
at this time.
Illustration 237
g01070972
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Top three 8S-9092 Bolts (8) for rear mounting point on platform.
Illustration 238
g01070973
Bottom three 8S-9092 Bolts (8) for rear mounting point on platform.
(7) 2S-7593 Hard Washer
(8) 8S-9092 Bolt
12. Assemble six 2S-7593 Hard Washers (7) and six 8S-9092 Bolts (8). Use a suitable torque wrench in order to
tighten the 8S-9092 Bolts (8) to a torque value of 215 40 Nm (158 29 lb ft) and tighten the 1A-8063
Bolts (6) to a torque value of 370 50 Nm (272 36 lb ft).
Illustration 239
(9) 8W-4926 Plate
g01070977
13. Use three 8T-4223 Hard Washers (11) and three 5P-2228 Bolts (10) in order to assemble 8W-4926 Plate (9) .
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Parts that are Needed for Installation of 156-9342 Steering Tank Group
Item
Qty
Part Number
Part Name
155-6660
8T-4223
Hard Washer
5C-6565
Bolt
1. Use a suitable crane in order to position 155-6660 Steering Tank and Filter Group (1) on the right platform.
Illustration 240
(1) 155-6660 Steering Tank and Filter Gp
g01070014
Illustration 241
(1) 155-6660 Steering Tank and Filter Gp
g01070015
2. Use nine 8T-4223 Hard Washers (2) and nine 5C-6565 Bolts (3) in order to assemble 155-6660 Steering
Tank and Filter Gp (1) to the truck chassis.
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Qty
Part Number
5P-6076 (1)
Support Assembly
25
5P-8250 (1)
Washer
25
1F-7464 (1)
Bolt
228-3732 (1)
Support
163-3127 (2)
Sleeve
40
163-0042 (2)
Cab Mount
163-0364 (2)
Sleeve
164-4411 (2)
Sleeve
20
5T-5807 (2)
Retainer
10
6V-2624 (2)
Bolt
11
5T-9893 (2)
Shim
12
5T-9894 (2)
Shim
13
6B-0388 (2)
Bolt
14
1K-9420 (2)
Bolt
(1)
(2)
Illustration 242
Part Name
g01071172
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1. Use a suitable crane in order to support the weight of the shipping bracket (A). Remove the following items:
four bolts (B), four washers and shipping bracket (A). Shipping bracket (A) weighs approximately 36 kg (79
lb).
Illustration 243
g01071173
Illustration 244
g01071174
2. Remove the 25 plugs from the mounting flanges on the front and rear cab support assemblies. Refer to the
arrows.
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Illustration 245
g00718019
3. Use 4C-4204 Paint Remover in order to clean the shipping grease or paint from the mounting flanges of the
front and rear cab support assemblies. Mating surfaces of these mounting flanges must be cleaned to bright
metal and free of nicks and burrs.
NOTICE
Using 4C-4204 Paint Remover , clean the shipping grease or paint from
the mounting flanges of the front and rear cab support assemblies.
Mating surfaces of these mounting flanges must be cleaned to bright
metal and free of ticks and burrs.
Illustration 246
(1) 5T-6076 Support Assembly
g00718021
4. Use 4C-4204 Paint Remover in order to clean the shipping grease or paint from the mounting flange of 5T6076 Support (1) .
5. Use a suitable crane in order to position 5T-6076 Support (1) against the front mounting flange. The 5T-6076
Support (1) weighs approximately 169 kg (373 lb).
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Illustration 247
(2) 5P-8250 Washer
g00718023
6. Assemble 11 5P-8250 Washers (2) and 11 1F-7464 Bolts (3). Tighten 1F-7464 Bolts (3) to a torque value of
900 100 Nm (662 74 lb ft).
Illustration 248
(2) 5P-8250 Washer
g00718024
7. Use 4C-4204 Paint Remover in order to clean the shipping grease and paint from the mounting flange of 2283732 Support (4) .
Note: A portion of the 5T-1070 Fender Gp should be assembled. This component is more easily assembled
on the ground.
8. Use a suitable crane in order to position 228-3732 Support (4) against the rear mounting flange. The 228-3732
Support (4) weighs approximately 232 kg (511 lb).
9. Assemble 14 5P-8250 Washers (2) and 14 1F-4764 Bolts (3). Tighten 1F-7464 Bolt (3) to a torque value of
900 100 Nm (662 74 lb ft).
Note: A thin wall socket may be required to torque the bottom row of 1F-7464 Bolts (3) .
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Illustration 249
(5) 163-3127 Sleeve
g00718025
10. Assemble a 163-3127 Sleeve (5) in each of eight 163-0042 Cab Mounts (6). Assemble eight mount
assemblies to the front cab support.
Illustration 250
(6) 163-0042 Cab Mount
g00718026
11. Assemble a 163-0364 Sleeve (7) in each of the six 163-0042 Cab Mounts (6). Assemble the six mount
assemblies to the outer rear cab support.
12. Assemble a 164-4411 Sleeve (8) in each of the six 163-0042 Cab Mounts (6). Assemble the six mount
assemblies to the inner rear cab support.
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Illustration 251
g00718028
Illustration 252
g00718030
13. Use a suitable crane and a three-point connection to the cab assembly in order to lift the cab assembly. The
cab assembly weighs approximately 1725 kg (3800 lb).
Illustration 253
g00718031
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Illustration 254
g00718032
14. Position the cab assembly on the front cab support assembly and the rear cab support assembly. Be careful not
to damage the following lines groups: steering, heating and air conditioning. Refer to the arrows in Illustration
254.
Illustration 255
(11) 5T-9893 Shim
g00718033
15. Check the four mounting points for the cab for flatness. If necessary, use 5T-9893 Shim (11) and 5T-9894
Shim (12) in order to level the cab assembly. A flatness of 0.75 mm (0.030 inch) is required.
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Illustration 256
(6) 163-0042 Cab Mount
g00718034
16. Assemble the following items: eight 163-0042 Cab Mounts (6), eight 5T-5807 Retainers (9) and eight 6V2624 Bolts (10). Apply 4C-4030 Thread Lock Compound to 6V-2624 Bolts (10) prior to installation. Do not
tighten 6V-2624 Bolts (10) at this time.
Illustration 257
(6) 163-0042 Cab Mount
g00718035
17. Assemble the following items: six 163-0042 Cab Mounts (6), six 5T-5807 Retainers (9) and six 6B-0388
Bolts (13). Apply 4C-4030 Thread Lock Compound to 6B-0388 Bolts (13) prior to installation. Tighten 6B0388 Bolts (13) to a torque value of 1904 68 Nm (1400 50 lb ft).
18. Assemble the following items: six 163-0042 Cab Mounts (6), six 5T-5807 Retainers (9) and six 1K-9420
Bolts (14). Apply 4C-4030 Thread Lock Compound to 1K-9420 Bolts (14) prior to installation. Tighten 1K9420 Bolts (14) to a torque value of 1904 68 Nm (1400 50 lb ft).
19. Tighten 6V-2624 Bolts (10) to a torque value of 1904 68 Nm (1400 50 lb ft).
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Illustration 258
View of the cab
g00741273
1. Remove all of the tape and all of the plugs from the cab.
2. Remove the caps from the air lines and from the wire harnesses.
3. Complete Step 3.a through Step 3.f if the machine is equipped with Caterpillar Integrated Object Detection
System (CIODS).
Illustration 259
View of the right side of the cab
g02352164
a. Remove ten bolts (A) and ten washers (B) that secure plate (C) to the side of the cab. Retain the
hardware.
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Illustration 260
View from the right side of the cab
g02352162
c. Insert the harness assemblies (D) for the cameras through the top hole in plate (C) .
Illustration 261
g02358238
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d. Secure harness assemblies (D) to plate (C) by using grommet assembly (E). Tighten grommet assembly
(E) to a torque of 20 2 Nm (175 17.5 lb in).
Note: Grommet assembly (E) is shipped attached to harness assemblies (D) .
e. Connect harness assemblies (D) to harness assemblies (F) that are located in the cab. Refer to Table 65
and Illustration 260 to help connect the harness assemblies.
Table 65
Video Cables to Display
Cable Color
Front
Red
Right
Blue
Rear
Green
Left
Yellow
Illustration 262
g02352173
f. Secure plate (C) that was removed in Step 3.b to the side of the cab by using the ten bolts (A) and ten
washers (B) that were removed in Step 3.a.
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Illustration 263
View of the right side of the cab
g02350946
(1) Main air supply and the line for the air compressor governor
(2) Air supply to air start control valve
(3) Air line for the parking brake control valve
(4) Air line for the service brake control valve
(5) Air line for the automatic lubrication system
(6) Air line for the brake diverter valve
(7) Air line for the automatic retarder control valve
(G) Battery wiring harness
(H) Transmission wiring harness
(J) Camera wiring harness
(K) CIODS radar wiring harness
(L) Chassis 1 Wiring harness
(M) Engine wiring harness
(N) Chassis 2 wiring harness
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Note: The air lines and the wire harnesses are connected on the right side of the cab. Each opening in the
plate at the cab has an identification number. The air lines are marked with numbers that correspond. Match
the numbers in order to connect the air lines. The openings for the electrical plugs are not marked. Be sure to
count the number of pins in each electrical connections and connect the electrical connector to the correct
electrical plug in the cab.
Illustration 264
g02352142
Illustration 265
g00741279
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6. Use tie straps to secure the air lines and the wire harnesses.
Qty
Part Number
Part Name
148-8340
Connector
148-8364
Elbow
148-8361
Elbow
150-8708
Tube
150-8709
Tube
150-8723
Tube
150-8710
Tube
150-8713
Tube
0T-0102
Bolt
10
5M-2894
Hard Washer
11
9S-1350
Clip
12
5T-6867
Clamp
13
0S-0509
Bolt
14
150-9037
Bar
15
10
6V-8398
O-Ring Seal
16
6V-8397
O-Ring Seal
17
0L-1351
Bolt
18
2G-8895
Bracket
19
6G-8532
Guard
20
9L-9132
Washer
21
6V-9746
O-Ring Seal
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Illustration 266
g00721597
1. Remove the eight bolts and the eight washers that secure the panel on the left side of the cab.
Illustration 267
View of the hand metering unit
g01067645
2. Remove the five plastic caps (A) from the ports of the hand metering unit.
NOTICE
Prevent contamination of the steering system when hose assemblies
and components are removed from the machine. Contamination of the
steering system with foreign material will reduce the service life of the
components.
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Illustration 268
(1) 148-8340 Connector
g01067646
Illustration 269
(B) Rear Port "T"
g01067648
3. Install a 148-8340 Connector (1) in rear port "T" (B) of the hand metering unit and rear port "L" (C) of the
hand metering unit.
Note: Apply steering oil to the O-rings.
4. Install a 148-8364 Elbow (2) in front port "P" (D) of the hand metering unit and front port "R" (E) of the hand
metering unit.
Note: Apply steering oil to the O-rings.
5. Install a 148-8361 Elbow (3) in side port "LS" (F) of the hand metering unit.
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Illustration 270
(4) 150-8708 Tube
g01067649
6. Connect the 150-8708 Tube (4) to rear port "T" (B) of the hand metering unit.
7. Connect the 150-8709 Tube (5) to front port "P" (D) of the hand metering unit.
8. Connect the 150-8723 Tube (6) to front port "R" (E) of the hand metering unit.
9. Connect the 150-8710 Tube (7) to side port "LS" (F) that is located on the side of the hand metering unit.
10. Connect the 150-8713 Tube (8) to rear port "L" (C) of the hand metering unit.
Illustration 271
g01067657
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11. Assemble 150-9037 Bar (14) by using two 5T-6867 Clamps (12), two 0S-0509 Bolts (13), and two 5M-2894
Hard Washers (10) .
12. Assemble 9S-1350 Clip (11) on 150-9037 Bar (14) by using 0T-0102 Bolt (9) and 5M-2894 Hard Washer
(10) .
13. Remove the five caps from the tube assemblies.
Illustration 272
(15) 6V-8398 O-Ring Seals
g01067659
14. Install four 6V-8398 O-Ring Seals (15) and one 6V-8397 O-Ring Seal (16) on the tube assemblies. Apply
steering oil to O-ring seals (15) and (16) .
Illustration 273
(G) Typical location of tags
g01067661
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15. Connect five hose assemblies to the respective tube assemblies. The tags for the hose assembly must match up
with the tags for the tube assembly in order to obtain the proper installation. For example, connect the tube
assembly with tag "G" to the hose assembly with tag "G". For an example of the location of the tags, refer to
callout (G) in Illustration 273.
Illustration 274
g00721607
Illustration 275
(H) Straps
g01067684
16. Remove two sets of hose clamps and one clip from the frame. Position four hose assemblies in the clamps and
assemble to the frame. Position one hose assembly in the remaining clip. Tighten nuts to a torque of 35 5
Nm (26 4 lb ft).
17. If necessary, secure the hose assemblies with straps (H) .
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Illustration 276
(10) 5M-2894 Hard Washer
g01067664
18. Install 2G-8895 Bracket (18) by using 0L-1351 Bolt (17) and 5M-2894 Hard Washer (10) .
Illustration 277
(17) 0L-1351 Bolts
g01067665
19. Install 6G-8532 Guard (19) by using three 0L-1351 Bolts (17) and three 9L-9132 Washers (20) .
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Illustration 278
(21) 6V-9746 O-Ring Seal
g01151834
(J) Plate
(K) Half Flange
(L) O-Ring Seal
(M) Half Flange
(N) O-Ring Seal
(P) Plate
(R) Bolt
(S) Hard Washer
20. Remove the cap from the filter assembly. Also, remove the cap from the hose assembly. Connect hose
assembly to filter assembly by using 6V-9746 O-Ring Seal (21) .
Illustration 279
g01151924
"Tank" port and "Pump" port on the steering tank before the steering lines are connected.
(J) Plate
(M) Half Flange
(P) Plate
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(R) Bolt
(S) Hard Washer
21. Remove eight bolts (R), eight hard washers (S), plate (J), plate (P), and two half flanges (M). Remove covers
from the "TANK" port and from the "PUMP" port of the steering tank. Save the hardware that is removed.
The hardware will be used during the installation of the hose assemblies to the tank and to the pump.
Illustration 280
(J) Plate
g01151963
22. Install the hose assembly from the steering tank to the steering pump by reusing the following parts: O-ring
seal (N), two half flanges (M), four hard washers (S), plate (J) and four bolts (R). Inspect O-ring seal (N). If
necessary, replace the O-ring seal.
23. Install the hose assembly from the steering solenoid and relief valve to the steering tank by reusing the
following parts: O-ring seal (L), two half flanges (K), four hard washers (S), plate (P) and four bolts (R).
Inspect O-ring seal (L). If necessary, replace the O-ring seal.
Qty
Part Number
Part Name
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6P-8855
Spacer
9X-2488
Hose Clamp
6D-1641
Clip
8T-4896
Washer
5S-7379
Bolt
Illustration 281
(1) 6P-8855 Spacer
g01071303
2. Inside the engine compartment, connect heater hose assembly by using 6P-8855 Spacer (1) and four 9X-2488
Hose Clamps (2) .
3. Repeat Step 2 for the remaining heater hose assembly.
Illustration 282
g01071305
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4. Secure the two heater hose assemblies under the cab by using the following items: 6D-1641 Clip (3), 8T-4896
Hard Washer (4) and 5S-7379 Bolt (5) .
Illustration 283
g01071318
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Illustration 284
(A) Hose assembly
g01071319
1. Remove the cap. Connect hose assembly (A) to the dryer. Prior to assembly, lubricate the O-ring seals with
9U-7551 Air Conditioner Lubricant .
Note: When you connect hose assembly (A), inspect the O-ring seals. If necessary, replace the O-ring seals
with new parts.
2. Remove the cap. Connect hose assembly (B). Prior to assembly, lubricate the O-ring seals with 9U-7551 Air
Conditioner Lubricant .
Note: When you connect hose assembly (B), inspect the O-ring seals. If necessary, replace the O-ring seals
with new parts.
Illustration 285
g00745260
1. Remove the strap from the hose assembly. The strap is located at the loose end of the hose assembly.
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Illustration 286
g01071707
2. Remove the cap from the loose end of the hose assembly. Route the hose assembly to the fitting next to the
front cab support on the bottom of the cab.
Illustration 287
g01071708
3. Connect the loose end of the hose assembly to the fitting. Refer to the arrow.
Parts that are Needed for Installation of the Truck Hood Group
Item
Qty
Part Number
Part Name
5P-1075 (1)
Hard Washer
5S-7379 (1)
Bolt
211-9141 (2)
Rail As
12
8T-4896 (2)
Hard Washer
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12
4L-6454 (2)
(1)
(2)
Illustration 288
(1) 5P-1075 Hard Washer
Bolt
g01071721
1. Use two 5P-1075 Hard Washers (1) and two 5S-7379 Bolts (2) in order to install the hood latch mechanism.
Refer to the arrows.
2. The position of the hood latch mechanism will need adjustment until these conditions exist:
Illustration 289
g01071752
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Illustration 290
(3) 211-9141 Rail As
g01071748
3. Using ten 8T-4896 Hard Washers (4) and 10 4L-6454 Bolts (5) assemble 211-9141 Rail (3) .
Installation of 5T-1017 Air Starting Control Gp Group and Lines for the
Air Tank
Illustration 291
(A) Hose assembly
g01071792
1. Remove the shipping cap from the elbow and hose assembly (A). Apply 5P-3413 Pipe Sealant to the external
threads of the connection. Assemble hose assembly (A) to the air reservoir.
2. Apply 5P-3413 Pipe Sealant to the external threads of the connection of hose assembly (B) and hose
assembly (C). Assemble hose assembly (B) and hose assembly (C) to the air reservoir.
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Illustration 292
(D) Hose assembly
g01071796
3. Thread hose assembly (D) and hose assembly (E) through the grommet. Apply 5P-3413 Pipe Sealant to the
external threads of the connection of hose assembly (D) and hose assembly (E). Assemble hose assembly (D)
and hose assembly (E) to the air reservoir.
Qty
Part Number
Part Name
6I-0982
Tube
4P-5212
Hose
7N-5008
Hump Hose
233-8484
Clamp
16
240-2651
Clamp
233-8482
Clamp
1W-6903
Hump Hose
5T-6459
Elbow
233-8485
Clamp
Note: The following procedure illustrates the installation of the air lines group for the one side of the truck. The
other side of the truck uses identical parts in the same sequence.
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Illustration 293
(1) 6I-0982 Tube
g00723125
Illustration 294
(A) Bolts
g01152357
(B) Nuts
(C) Strap
1. Remove the following items: two bolts (A), two nuts (B) and strap (C). Position 6I-0982 Tube (1). Install the
following items: two bolts (A), two nuts (B) and strap (C). Do not tighten the bolts at this time.
Illustration 295
g01152363
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(A) Bolts
(B) Nuts
(C) Strap
Illustration 296
(1) 6I-0982 Tube
g00723131
2. Align 6I-0982 Tube (1) with the existing tube assemblies. Refer to the arrows. Secure strap (C) by tightening
bolts (A) to a torque value of 25 7 Nm (18 5 lb ft).
Illustration 297
(1) 6I-0982 Tube
g00723132
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Illustration 298
(2) 4P-5212 Hose
g00723134
Illustration 299
(2) 4P-5212 Hose
g01072632
Note: Assemble each pair of clamps by rotating the clamps until the t-bolts are located 180 90 degrees from
each other. Do not orient the t-bolts less than 90 degrees from each other.
Note: Apply either 207-1601 Rubber Lubricant or 207-1600 Rubber Lubricant for EAME only to the inside
of 4P-5212 Hose (2) before assembly.
3. Assemble four 240-2651 Clamps (5) and 4P-5212 Hose (2). The torque on the 240-2651 Clamps is 7.5 1
Nm (66 9 lb in).
Note: Assemble each pair of clamps so that the bolts are located 180 from each other.
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Illustration 300
(1) 6I-0982 Tube
g00723133
Illustration 301
(3) 7N-5008 Hump Hose
g01072637
Note: Apply either 207-1601 Rubber Lubricant or 207-1600 Rubber Lubricant for EAME only to the inside
of 7N-5008 Hump Hose (3) before assembly.
4. Assemble four 233-8484 Clamps (4) with a torque of7.5 1 Nm (66 9 lb in)and 7N-5008 Hump Hose (3) .
Note: Assemble each pair of clamps so that the bolts are located 180 from each other.
5. Position four 233-8484 Clamps (4) and tighten to a torque value of 7.5 1 Nm (66 9 lb in).
6. Position four 240-2651 Clamps (5) and tighten to a torque value of 7.5 1 Nm (66 9 lb in).
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Illustration 302
(6) 233-8482 Clamp
g01072640
Note: Apply either 207-1601 Rubber Lubricant or 207-1600 Rubber Lubricant for EAME only to the inside
of 1W-6903 Hump Hose (7) before assembly.
7. Assemble four 233-8482 Clamps (6) and 1W-6903 Hump Hose (7). Position two 233-8482 Clamps (6) and
tighten to a torque value of 7.5 1 Nm (66 9 lb in). Do not tighten the remaining 233-8482 Clamps (6)
until the remaining 6I-0982 Tube (1) is assembled.
Note: Assemble each pair of 233-8482 Clamps (6) so that the bolts are located 180 from each other.
Illustration 303
(8) 5T-6459 Elbow
g01072642
8. Assemble four 233-8485 Clamps (9) and 5T-6459 Elbow (8). Position four 233-8485 Clamps (9) and tighten
to a torque value of 7.5 1 Nm (66 9 lb in).
Note: Assemble each pair of 233-8485 Clamps (9) so that the bolts are located 180 from each other.
9. Repeat Step 1 through Step 8 for the left side of the truck.
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Table 70
Parts that are Needed for Installation of 249-0316 Air Lines Group (If Equipped)
Item
Qty
Part Number
Part Name
7E-7790
Hose
16
233-8485
Clamp
249-3766
Tube
5T-7874
Strap
0S-1595
Bolt
5P-8245
Hard Washer
5T-7874
Strap
9S-8752
Full Nut
0S-1571
Bolt
10
5T-6459
Elbow
Note: The following procedure illustrates the installation of the air lines group for the one side of the truck. The
other side of the truck uses identical parts in the same sequence.
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Illustration 304
(1) 7E-7790 Hose
g01072782
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Illustration 305
View A-A
g01072798
4. Use two 0S-1595 Bolts (5) and two 5P-8245 Hard Washers (6) to install 5T-7873 Bracket As (4) to the
chassis. Tighten 0S-1595 Bolts (5) to a torque of 105 15 Nm (75 11 lb ft). Place 249-3766 Tube (3) on
5T-7873 Bracket As (4) .
5. Use two 9S-8752 Full Nuts (8) and two 0S-1571 Bolts (9) to install 5T-7874 Strap (7). Tighten 0S-1571 Bolts
(9) to a torque of 25 7 Nm (18 5 lb ft).
6. Tighten four 233-8485 Clamps (2) from step 2 to a torque of 7.5 1 Nm (66 9 lb in).
Note: Apply either 207-1601 Rubber Lubricant or 207-1600 Rubber Lubricant for EAME only to the inside
of 5T-6459 Elbow (10) before assembly.
7. Assemble 5T-6459 Elbow (10) and four 233-8485 Clamps (2). Tighten four 233-8485 Clamps (2) to a torque
of 7.5 1 Nm (66 9 lb in).
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Note: Assemble each pair of 233-8485 Clamps (2) so that the bolts are located 180 from each other.
Breathing ether vapors or repeated contact of ether with skin can cause
personal injury. Personal injury may occur from failure to adhere to
the following procedures.
Use ether only in well ventilated areas.
Do not smoke while changing ether cylinders.
Use ether with care to avoid fires.
Do not store replacement ether cylinders in living areas or in the
operator's compartment.
Do not store ether cylinders in direct sunlight or at temperatures above
49 C (120 F).
Discard cylinders in a safe place. Do not puncture or burn cylinders.
Keep ether cylinders out of the reach of unauthorized personnel.
Illustration 306
g01071334
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(1)
Item
Qty
Part Number
Part Name
138-7582
Demountable Rim
8W-0338
O-Ring Seal
8W-0331
Swivel Connector
5T-9790
Tire Valve
18
8W-3891 (1)
Flange Nut
304
5P-8250 (1)
Washer
304
2J-3507 (1)
Full Nut
230-1132
Hose As
261-3036
Plate
10
1S-0996
Clip
11
1B-4287
Washer
12
8T-4244
Nut
13
8T-4223
Hard Washer
14
261-3244
Pipe
15
261-3243
Spacer
16
8T-5001
Bolt
17
8T-5041
Bolt
18
176-7281
Extension
19
8X-2627
Bracket
20
1D-4566
Bolt
21
5P-8245
Hard Washer
22
6J-0427
Spacer
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Illustration 307
(1) 138-7582 Demountable Rim
g00721711
1. Assemble 138-7582 Demountable Rim (1) to the front tire by using the following parts: 8W-0338 O-Ring
Seal (2), 5T-9790 Tire Valve (4) and 8W-0331 Swivel Connector (3). Before continuing, ensure that the
thread pattern is oriented to the desired position. Inflate the tire with dry nitrogen to operating pressure. Refer
to Operation and Maintenance Manual, SEBU7174, "Tire Inflation Information".
Note: The process of assembling tires to the rim is performed by a tire servicing person.
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Illustration 308
g00721712
Illustration 309
g01069579
2. Use 4C-6796 Mineral Spirits and 4C-4204 Paint Remover to clean the wheel mounting flange and studs to
bright metal. Remove any nicks or burrs on the mounting flange.
NOTICE
Removal of paint and burrs is necessary to obtain and maintain the
fastener torque.
Illustration 310
g00721717
3. Use 4C-4204 Paint Remover to clean the wheel mounting flange of the rim to bright metal. Remove any nicks
or burrs on the mounting flange.
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Illustration 311
g00721718
4. Position the tire assembly next to the wheel by using a tire handler. The weight of the tire and rim assembly is
approximately 3923 kg (8649 lb).
Illustration 312
g00721719
5. Raise the front of the 789C truck chassis in order to install the front wheel assemblies. Use a suitable crane to
raise the front of the truck. Also, use a two-way lifting device that consists of two 6 m (19.7 ft) lifting straps
or lifting cables. Use a lifting device that is rated for 36320 kg (80,072 lb). The truck chassis weighs
approximately 44492 kg (98,088 lb).
Illustration 313
g00721721
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Illustration 314
g00940929
6. Use a tire handler to position the tire on the wheel. Align the wheel studs with the bolt pattern in the rim.
Illustration 315
g00721723
Illustration 316
(5) 8W-3891 Flange Nut
g00721725
7. Use a tire handler to retain the tire assembly. Assemble three 8W-3891 Flange Nuts (5) on the three longer
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wheel studs.
8. Assemble 51 5P-8250 Washers (6) and 51 2J-3507 Full Nuts (7). Tighten the nuts with an air wrench.
9. Remove the tire handler and use a suitable torque wrench to tighten 8W-3891 Flange Nuts (5) and 2J-3507
Full Nuts (7). Tighten 8W-3891 Flange Nuts (5) and 2J-3507 Full Nuts (7) to a torque of 1150 150 Nm
(847 111 lb ft).
10. Repeat Step 1 through Step 9 for the opposite side of the truck.
Illustration 317
g00721726
11. Measure the front wheel toe-in. If necessary, adjust the front wheel toe-in. Refer to ""Front Wheel
Alignment" ". Remove the crane and remove the lifting device after adjusting the front wheel toe-in.
Illustration 318
Typical top view of the steering linkage
g01302534
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1. While the strut rods in the suspension cylinders are fully extended, move the wheels to a straight ahead
position.
2. Measure the distance between the front wheels at location (A) .
3. Mark location (A) at each tire. Rotate the tires by 180 degrees.
4. Measure the distance at location (D) between the same marks.
5. Refer to Table 72 in order to determine the correct toe-out when the front wheels are off the ground.
Table 72
Correct Toe-Out
D = A - 48.5 mm (1.91 inch)
6. If the difference that was found in the previous step is not correct, adjust each link assembly by the same
number of turns.
Note: After the adjustment has been made, the tie rods must be of equal length.
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Illustration 319
View A-A
g00928723
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Illustration 320
Side view of the clamp assembly
g00928726
8. Align the open portion of clamp assembly (F) with one of the slots in tie rod (E) .
9. Tighten the nut to a torque value of 583 27 Nm (430 20 lb ft).
Note: When the adjustment is correct, there will be a front wheel toe-in when the truck is in normal operation
with correctly charged suspension cylinders.
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Illustration 321
(1) 138-7582 Demountable Rim
g00721727
1. Assemble 138-7582 Demountable Rim (1) to the inside rear tire by using the following parts: 8W-0338 ORing Seal (2), 5T-9790 Tire Valve (4), 8W-0331 Swivel Connector (3) and 230-1132 Hose As (8). Before
continuing, ensure that the thread pattern is oriented to the desired position. Inflate the tire with dry nitrogen
to operating pressure. Refer to Operation and Maintenance Manual, "Tire Inflation Information".
Note: The process of assembling tires to the rim is performed by a tire servicing person.
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Illustration 322
g00940930
Illustration 323
g00940931
2. In order to install the rear tires, raise the rear of the chassis by using a suitable crane, steel bar, and a suitable
lifting device. Install the steel bar through the openings for the hinge pins. Connect a two-way lifting device
to each end of the bar. Use a lifting device that is made of two 3.5 m (11.5 ft) chains. The bar must have the
following characteristics: solid steel, approximately 76 mm (3 inch) in diameter and 2.44 m (8.00 ft) long.
The lifting device must be rated for 36320 kg (80,072 lb).
Illustration 324
g01069590
3. Use 4C-6796 Mineral Spirits and 4C-4204 Paint Remover to clean the wheel mounting flange and studs to
bright metal. Remove any nicks or burrs on the mounting flange.
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4. Remove the following parts: two 9B-7237 Bolts (9), two 4L-6454 Bolts (11), four 5P-1075 Hard Washers
(10) and 104-7783 Clamp (12) .
Illustration 325
g00721732
5. Use 4C-4204 Paint Remover to clean the wheel mounting flange of the inside rear tire assembly to bright
metal. Remove any nicks or burrs on the mounting flange. Refer to the arrow in the above picture.
Illustration 326
(A) Bolts
g01069591
(B) Washers
(C) Ring
6. Remove 57 bolts (A) and 57 washers (B) in order to remove ring (C) .
7. Remove ring (C) .
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Illustration 327
g01069593
Illustration 328
g01069594
Illustration 329
g01069595
8. Use a tire handler to position the inside rear tire on the wheel. Align the wheel studs with the bolt pattern in
the rim. Align the valve on the rim with the two holes on the flange of the rear axle. Refer to the arrows in the
above picture.
Note: The lockring on the rim should face out toward the center of the wheel.
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Illustration 330
(5) 8W-3891 Flange Nut
g00721736
9. Use a tire handler to retain the tire assembly. Assemble three 8W-3891 Flange Nuts (5) on the three longer
wheel studs.
10. Assemble 51 5P-8250 Washers (6) and 51 2J-3507 Full Nuts (7). Tighten nuts with an air wrench.
11. Remove the tire handler and use a suitable torque wrench to tighten 8W-3891 Flange Nuts (5) and 2J-3507
Full Nuts (7). Tighten 8W-3891 Flange Nuts (5) and 2J-3507 Full Nuts (7) to a torque value of 1150 150
Nm (847 111 lb ft).
Illustration 331
(14) 261-3244 Pipe
g01069623
12. Place 261-3244 Pipes (14) into the holes in the cast rib.
13. Place 261-3243 Spacers (15) on either sides of the rib on 261-3244 Pipes (14).
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Illustration 332
(8) 230-1132 Hose As
g01154435
14. Identify the thick cross section of the cast rib. Place 261-3036 Plate (9) with legs toward the cast rib. Make
sure that the wider edge of 261-3036 Plate (9) is positioned toward the thicker side of the rib.
15. Place 230-1132 Hose As (8) in 261-3036 Plate (9). Attach 230-1132 Hose As (8) to 261-3036 Plate (9) with
1S-0996 Clip (10). In order to install one side of 261-3036 Plate (9) onto the cast rib, place 8T-5001 Bolt (16)
through the following items: 1B-4287 Washer (11), 261-3243 Spacer (15), 261-3244 Pipe (14), 261-3243
Spacer (15), 1S-0996 Clip (10), 261-3036 Plate (9) and 8T-4223 Hard Washer (13). Screw 8T-4244 Nut (12)
on the end of 8T-5001 Bolt (16) .
Illustration 333
g01154436
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Illustration 334
(12) 8T-4244 Nut
g01154437
16. In order to install the other side of 261-3036 Plate (9) onto the cast rib, place 8T-5041 Bolt (17) through the
following items: 1B-4287 Washer (11), 261-3243 Spacer (15), 261-3244 Pipe (14), 261-3243 Spacer (15), 1S0996 Clip (10), 261-3036 Plate (9) and 8T-4223 Hard Washer (13). Screw 8T-4244 Nut (12) on the end of
8T-5041 Bolt (17) .
17. Tighten both 8T-4244 Nuts (12) .
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Illustration 335
(1) 138-7582 Demountable Rim
g01069669
18. Assemble 138-7582 Demountable Rim (1) to the outside rear tire by using the following parts: 8W-0338 ORing Seal (2), 5T-9790 Tire Valve (4) and 176-7281 Valve Extension (15). Before continuing, make sure that
the thread pattern is oriented to the desired position. Inflate the tire with dry nitrogen to operating pressure.
Refer to Operation and Maintenance Manual, SEBU7174, "Tire Inflation Information".
Note: The process of assembling tires to the rim is usually performed by a tire servicing person.
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Illustration 336
g01069676
19. Use 4C-4204 Paint Remover to clean the wheel mounting flange of the outside rear wheel to bright metal.
Remove any nicks or burrs on the mounting flange.
20. Use 4C-4204 Paint Remover to clean the rim mounting flange of the outside rear tire assembly to bright
metal. Remove any nicks or burrs on the mounting flange.
Illustration 337
(C) Ring
g01069679
21. Use 4C-4204 Paint Remover to clean the mounting flange of the inside of ring (C) to bright metal. Remove
any nicks or burrs on the mounting flange.
22. Use a suitable hoist to position ring (C). Assemble enough 5P-8250 Washers (6) and 2J-3507 Full Nuts (7) in
order to retain the ring when the tire assembly is turned over. Tighten 2J-3507 Full Nuts (7) by hand.
Illustration 338
g00721744
23. Use a suitable tire handler to turn the tire assembly to the other side.
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Illustration 339
(5) 8W-3891 Flange Nut
g00721745
Illustration 340
g00721746
24. Assemble the remaining 50 5P-8250 Washers (6) and 50 2J-3507 Full Nuts (7). Install three 8W-3891 Flange
Nuts (5) on the three longer wheel studs.
25. Use a suitable torque wrench to tighten the 2J-3507 Full Nuts (7) and the 8W-3891 Flange Nuts (5). Tighten
2J-3507 Full Nuts (7) and the 8W-3891 Flange Nuts (5) to a torque of 1150 150 Nm (847.2 111 lb ft).
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Illustration 341
g00721747
26. Connect a suitable piece of wire to the hose assembly on the inside tire that is used in order to inflate the tire.
Refer to the arrow in the above photograph.
27. Use a suitable tire handler to position the outside rear tire approximately 30.4 cm (12 inch) from the wheel.
Align the hose assembly for the inside tire to the hole in the rim on the outside tire. Once the hose assembly is
aligned, position the outside rear tire on the rear wheel.
Illustration 342
(A) Bolts
g01069681
(B) Washers
Illustration 343
g01078571
28. Use a tire handler to retain the tire assembly. Assemble 57 washers (B) and 57 bolts (A) in order to retain the
outside tire assembly. Remove the tire handler. Tighten the bolts to a torque of 1150 150 Nm (847.2 111
lb ft). Refer to the arrows in the above photograph in order to remove the wire.
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Illustration 344
(19) 8X-2627 Bracket
g01069684
Illustration 345
View of bracket with valve stem on the rear, outside tire
g01069688
29. Assemble 8X-2627 Bracket (19) by using the following parts: four 6J-0427 Spacers (22), four 1D-4566 Bolts
(20) and four 5P-8245 Hard Washers (21) .
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Illustration 346
g00721754
30. Repeat Step 1 through Step 29 for the opposite side of the truck.
31. Remove the crane, the lifting device, and the bar.
Qty
Part Number
Part Name
8W-3667
Guard Assembly
114-5012
Guard Assembly
8X-6394
Plate Assembly
112-6185
Plate Assembly
112-6184
Plate Assembly
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Illustration 347
g00714909
Illustration 348
(1) 8W-3667 Guard
g00714910
Illustration 349
(1) 8W-3667 Guard
g00714912
1. Use a suitable lift truck in order to position the 8W-3667 Guard (1) on the truck body. The 8W-3667 Guard
(1) weighs approximately 72 kg (159 lb). The 8W-3667 Guard (1) will be positioned from the two clips.
Refer to the arrows in Illustration 349 for the location of the clips.
2. After positioning 8W-3667 Guard (1), mark the location of the weld and remove 8W-3667 Guard (1) .
3. Prepare 8W-3667 Guard (1) for installation. Use 4C-4204 Paint Remover in order to clean the mounting
surface. The mating surface must be free of nicks and burrs.
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Illustration 350
(1) 8W-3667 Guard
Illustration 351
(1) 8W-3667 Guard
g00714914
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Illustration 352
Section A-A
g00714917
Table 74
Welding Dimensions
Weld
Specification
4 mm (0.16 inch) fillet weld
W1
25 mm (0.98 inch) to
75 mm (2.95 inch) skip weld.
W2
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Illustration 353
(1) 8W-3667 Guard
g00714918
5. After installation of 8W-3667 Guard (1), prepare the welded connection for paint.
Illustration 354
g00714919
Illustration 355
g00714920
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Illustration 356
(2) 114-5012 Guard
Illustration 357
(2) 114-5012 Guard
g01071856
g01078875
7. Use a suitable lift truck in order to position one of 114-5012 Guards (2) on the truck body. 114-5012 Guards
(2) weigh approximately 42 kg (93 lb).
8. After positioning 114-5012 Guard (2), mark the location of the weld and remove 114-5012 Guard (2) .
9. Prepare 114-5012 Guard (2) for installation. Use 4C-4204 Paint Remover in order to clean the mounting
surface. The mating surface must be free of nicks and burrs.
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Illustration 358
(2) 114-5012 Guard
g01078876
10. Position and weld 114-5012 Guard (2) to the truck body.
Table 75
Welding Dimensions
Weld
Specification
4 mm (0.16 inch) fillet weld
W1
25 mm (0.98 inch) to
75 mm (2.95 inch) skip weld.
W2
11. After installation of 114-5012 Guard (2), prepare the welded connection for paint.
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Illustration 359
g00714920
Illustration 360
(E) 1150 5 mm (45.3 0.2 inch)
g01078892
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Illustration 361
Section B-B
g01077162
Table 76
Welding Dimensions
Weld
Specification
W3
8. Prepare 8X-6394 Plate Assembly (3) for installation. Use 4C-4204 Paint Remover in order to clean the
mounting surface. The mounting surface must be free of nicks and burrs.
Note: The 8X-6394 Plate Assembly (3) is most accurately located after the truck body has been installed.
9. Weld 8X-6394 Plate Assembly (3) to the truck frame.
10. After installation of 8X-6394 Plate Assembly (3), prepare the welded connection for paint.
11. Use 4C-4200 Paint in order to touch up the weld.
Illustration 362
g00714925
12. Use a plumb bob in order to transfer the midpoint between the tires to the truck body. Mark this point on the
truck body.
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Illustration 363
(4) 8X-6394 Plate Assembly
g00714927
13. Use a lift truck in order to position 112-6185 Plate Assembly (4) against the truck body. Center the plate
assembly on the mark that was made in Step 12.
Illustration 364
(4) 112-6185 Plate Assembly
g01077170
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Illustration 365
Section G-G
g01077172
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Illustration 366
Section H-H
g01077173
Table 77
Welding Dimensions
Weld
W4
Specification
10 mm (0.4 inch) fillet weld with
1.5 mm (0.06 inch) penetration
14. Prepare 112-6185 Plate Assembly (4) for installation. Use 4C-4204 Paint Remover in order to clean the
mounting surface. The mounting surface must be free of nicks and burrs.
15. Weld 112-6185 Plate Assembly (4) to the truck frame.
16. After installation of 112-6185 Plate Assembly (4), prepare the welded connection for paint.
17. Use 4C-4200 Paint in order to touch up the weld.
18. Repeat Steps 12 through 17 for the 112-6184 Plate Assembly (5) on the right side of the truck body.
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Table 78
Parts that are Needed for Installation of 155-3633 Film Group
Item
Qty
Part Number
Part Name
155-3637
Film (LH)
155-3636
Film (RH)
131-5415
Film
100-5615
Film
Note: The following procedure is most easily completed before the truck body is assembled to the truck
chassis.
Illustration 367
(1) 155-3637 Film
Illustration 368
g00722967
g00722969
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1. Prepare for installation of 155-3637 Film (1). Use a suitable cleaner in order to remove the dirt and the oil
from the painted surface.
2. Apply 155-3637 Film (1) carefully to the truck body. Install the film by beginning at one end.
3. Remove any trapped air under the film by using the following items: soap, water and a plastic scraper. After
the trapped air has been removed, the mechanic will remove the paper cover.
Illustration 369
(2) 155-3636 Film
Illustration 370
(2) 155-3636 Film
g00722970
g00722972
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Illustration 371
(3) 131-5415 Film
g00722974
Illustration 372
(3) 131-5415 Film
g00722975
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Illustration 373
(3) 131-5415 Film
g00722976
5. Repeat Step 1 through Step 3 for three 131-5415 Film (3) and one 100-5615 Film (4) .
Refer to 5T-6046 Retaining Cable Gp for a truck with a dual slope body.
Refer to 144-4147 Retaining Cable Gp for a truck with a flat floor body.
Table 79
Parts that are Needed for Installation of 5T-6046 Retaining Cable Gp or 144-4147 Retaining Cable Gp
Item
Qty
Part Number
1D-4643
Bolt
5P-8250
Washer
2H-3794
Locknut
105-0314
Coupler
6G-9703 (1)
Cable
145-9033 (2)
Cable
2B-0974
Clevis Pin
5P-8247
Hard Washer
3B-4617
Cotter
8W-0109
Plate
(1)
(2)
Part Name
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Illustration 374
(1) 1D-4643 Bolt
g01054947
1. Use two people to position either 6G-9703 Cable (5) (If Equipped) or 145-9033 Cable (5) (If Equipped). Use
the following items to assemble either 6G-9703 Cable (5) (If Equipped) or 145-9033 Cable (5) (If Equipped):
105-0314 Coupler (4), two 1D-4643 Bolts (1), two 5P-8250 Washers (2) and two 2H-3794 Locknuts (3). The
cables weigh approximately 35 kg (79 lb).
Illustration 375
(5) 6G-9703 Cable
g01054950
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2. Use the following items to assemble 8W-0109 Plate (9) : 2B-0974 Clevis Pin (6), 5P-8247 Hard Washer (7)
and 3B-4617 Cotter (8) .
3. Store either 6G-9703 Cable (5) (If Equipped) or 145-9033 Cable (5) (If Equipped) by positioning the loose
end of the cable against the truck body and latching with the 8W-0109 Plate (9) .
Qty
Part Number
Part Name
10
0L-1351
Bolt
24
5P-1075
Hard Washer
5T-7228
Plate
59
0S-1588
Bolt
54
6V-8801
Nut
6G-9704
Strip
5T-5989
Mud Flap
5T-5988
Mud Flap
5T-7255
Plate
10
5T-7352
Strip
11
5T-7274
Mud Flap
12
5T-7275
Mud Flap
13
5M-2894
Washer
14
8X-5421
Plate
15
105-4727
Mud Flap
16
8W-8679
Pin
17
1H-9456
Bolt
18
5P-8247
Hard Washer
19
8W-9373
Cover
20
6G-9697
Washer
21
8W-2896
Washer
22
8W-8677
Plate
23
0S-1585
Bolt
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24
5P-8245
Hard Washer
25
10
322-0363
Pad As
26
25
6G-9711
Shim
27
5T-3750
Plate
28
24
9S-1366
Bolt
29
30
7D-1649
Washer
30
24
1F-7958
Full Nut
31
6G-7773
Pin
32
3B-4647
Cotter Pin
33
227-5875
Ejector
34
8X-6365
Baffle
35
8X-6366
Plate
36
9B-7237
Bolt
Illustration 376
g00723467
1. Position the truck body at a suitable location for assembly of the mud flaps. The weight of the assembled
truck body is 44230 kg (97510 lb).
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Illustration 377
(1) 0L-1351 Bolt
g00723478
Illustration 378
g01077196
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2. Use five 0L-1351 Bolts (1) and five 5P-1075 Hard Washers (2) in order to assemble 5T-7228 Plate (3) to the
mounting location of the front, right mud flap.
3. Use the following items in order to assemble 5T-5989 Mud Flap (7) to 5T-7228 Plate (3) : ten 0S-1588 Bolts
(4), ten 6V-8801 Nuts (5) and 6G-9704 Strip (6) .
Illustration 379
(1) 0L-1351 Bolt
g01077197
4. Use five 0L-1351 Bolts (1) and five 5P-1075 Hard Washers (2) in order to assemble 5T-7228 Plate (3) to the
mounting location of the front, left mud flap.
5. Use the following items in order to assemble 5T-5988 Mud Flap (8) to 5T-7228 Plate (3) : ten 0S-1588 Bolts
(4), ten 6V-8801 Nuts (5) and 6G-9704 Strip (6) .
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Illustration 380
(2) 5P-1075 Hard Washer
g00723482
Illustration 381
g01072030
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6. Assemble 5T-7255 Plate (9) to the mounting location of the right, rear mud flap by using the following items:
five 0S-1588 Bolts (4), five 5P-1075 Hard Washers (2) and five 6V-8801 Nuts (5) .
7. Assemble 5T-7274 Mud Flap (11) to 5T-7255 Plate (9) by using the following items: 12 0S-1588 Bolts (4),
12 6V-8801 Nuts (5) and 5T-7352 Strip (10) .
Illustration 382
(2) 5P-1075 Hard Washer
g00723483
8. Assemble 5T-7255 Plate (9) to the mounting location of the left, rear mud flap by using the following items:
five 0S-1588 Bolts (4), five 5P-1075 Hard Washers (2) and five 6V-8801 Nuts (5) .
9. Assemble 5T-7275 Mud Flap (12) to 5T-7255 Plate (9) by using the following items: 12 0S-1588 Bolts (4),
12 6V-8801 Nuts (5) and 5T-7352 Strip (10) .
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Illustration 383
(4) 0S-1588 Bolt
g00723484
Illustration 384
(4) 0S-1588 Bolt
g00723485
10. Assemble 105-4727 Mud Flap (15) by using the following items: five 0S-1588 Bolts (4), five 5N-2894
Washers (13) and 8X-5421 Plate (14) .
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Illustration 385
g00723487
11. Clean the bores for the truck body hinge. Refer to the arrows. Remove the following items: paint, grease and
burrs.
Illustration 386
g00723489
12. Partially assemble two 8W-8679 Pins (16) in preparation for installation of the truck body to the chassis.
Slide the pin into the first bore at each side of the truck. Slide in the pin from the outside of the truck body.
Illustration 387
g00723490
13. Clean the bores for the body hoist. Refer to the arrows. Remove the following items: paint, grease and burrs.
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14. Assemble pin assemblies in preparation for installation of the truck body to the chassis. Refer to the arrows.
Illustration 388
(17) 1H-9456 Bolt
g00723492
15. Install 8W-9373 Cover (19) by using four 1H-9456 Bolts (17) and four 5P-8247 Hard Washers (18). Repeat
for the remaining 8W-9373 Cover (19) .
Illustration 389
g00723493
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Illustration 390
(A) Location of lifting points
g01790134
16. Use a suitable crane and use a lifting device in order to prepare the front of the 789C truck body for
installation on the truck chassis. Use a two-way lifting device for lifting the front of the truck body. The
lifting device must be made from two 6 m (19.7 ft) straps or two 6 m (19.7 ft) cables. Connect the straps or
connect the cables to the truck body at locations (A). The lifting device must be rated at 36320 kg (80071.8
lb). The truck body weighs approximately 44492 kg (98000.0 lb).
17. Use a second crane or a second lifting device in order to lift the rear of the 789C truck body in order to
prepare the 789C truck body for installation on the truck chassis. Connect a two-way lifting device that is
made from two 3.5 m (11.5 ft) chains that are connected to each end of the bar. When the front of the truck
body is lifted, use a two-way lifting device. The two-way lifting device must be made from either two 6 m
(19.7 ft) straps or two 6 m (19.7 ft) cables.
18. Tie a tag line to the truck body in order to allow a mechanic to pull on the truck body from the side while the
mechanic is installing the hinge pins.
Illustration 391
g00723501
19. Lower the truck body in order to align the bores for the hinge pins.
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Illustration 392
(16) 8W-8679 Pin
g00723502
Illustration 393
(16) 8W-8679 Pin
g00723503
20. Assemble one 6G-9697 Washer (20) at the location of each hinge pin. Do not drive the 6G-9697 Washer (20)
in place. If 6G-9697 Washer (20) cannot be assembled, replace 6G-9697 Washer (20) with a 8W-2896
Washer (21) .
21. Finish installation of two 8W-8679 Pins (16). The 8W-8679 Pin (16) weighs approximately 41 kg (90 lb).
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Illustration 394
(22) 8W-8677 Plate
g00723504
Illustration 395
g00723505
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22. Use two 0S-1585 Bolts (23) and two 5P-8245 Hard Washers (24) to assemble 8W-8677 Plate (22). Repeat for
the remaining hinge pin.
Illustration 396
Right-hand view
g01811034
(B) Rockers
(C) Body rail
(D) Frame rail
(25) Rocker pads
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25. Raise the dump body and install the proper safety device in order to secure the dump body in the RAISE
position.
Illustration 397
g01790315
26. Remove bolt (E) and washer (F) in three places. Retain the hardware. Add required shims (26) and/or plate
(27) between the top of rocker (B) and rocker pads (25) .
27. Install the hardware that was retained from Step 26 in order to secure rocker pads (25), shim (26) and/or plate
(27) .
Note: Tighten the bolts to a torque of 100 20 Nm (74 15 lb ft).
28. Remove the safety device. Repeat Step 23 through Step 27 until both of the rocker pads come into contact
with the body at the same time.
29. Raise or lower the body in order to bring the body and frame rails parallel to each other.
30. Measure the distance between body rail (C) and frame rail (D) at the front of the body and at the rear of the
body. Ensure that the distance is the same at the front of the body and at the rear of the body.
Illustration 398
g01790316
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Illustration 399
g01790317
31. Install one pad (25) and the required shims (26) and/or plates (27) in four places. Install three bolts (28), three
washers (29) and three nuts (30) in four places in order to secure the pads and shims. Evenly tighten bolts (28)
to a torque of 105 20 Nm (80 15 lb ft).
Note: Block the body in position when you install the shims and pads.
32. Repeat Step 31 for the other side.
33. Remove the block and lower the body to the DOWN position.
34. Measure the gap between the rocker pads (25) and the body. Add equal amounts of shim (26) and/or plates
(27) to each side in order to take up the gap. Refer to Step 24 for the proper procedure to add shims (26) or
plates (27) .
35. Raise and lower the body in order to make sure that all mounted pads have even contact with the frame.
Illustration 400
(31) 6G-7773 Pin
g01072033
36. Use a suitable crane in order to position 227-5875 Ejector (33). The 227-5875 Ejector (33) weighs
approximately 50 kg (110 lb).
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37. Assemble 6G-7773 Pin (31) and two 3B-4647 Cotter Pins (32) .
38. Repeat Step 36 and Step 37 for the opposite side of the truck.
Illustration 401
(2) 5P-1075 Hard Washer
g01072034
39. Assemble 8X-6365 Baffle (34) by using the following items: two 8X-6366 Plates (35), four 9B-7237 Bolts
(36) and four 5P-1075 Hard Washers (2) .
Qty
Part Number
Part Name
239-5505
Pin
6G-9696
Spacer
6G-9691
Bar
5P-8245
Hard Washer
0S-1585
Bolt
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Illustration 402
(1) 239-5505 Pin
g01072042
1. Use a suitable crane and a suitable lifting device to lift the front of the 789C truck body for installation on the
hoist cylinder. Use a two-way lifting device that is made of two 6 m (19.7 ft) straps or two 6 m (19.7 ft)
cables when the front of the truck body is lifted. The lifting device must be rated at 36320 kg (80000 lb). The
truck body weighs approximately 44492 kg (98000 lb).
The space between the body and the frame becomes a zero clearance
area when the body is lowered. Failure to install the retaining cable can
result in injury or death to personnel working in this area.
2. Use a suitable chain in order to support the weight of the hoist cylinder. The hoist cylinder weighs
approximately 833 kg (1836 lb).
Illustration 403
g00940935
3. Cut the shipping bracket from the truck frame. Remove the shipping bracket from the hoist cylinder. After the
shipping bracket has been removed, grind the frame flush and repair the paint by using 4C-4200 Paint .
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Illustration 404
g00940936
4. Use the hydraulics on the truck to extend the hoist cylinder and align the bore of the bracket on the body with
the bore of the cylinder bearing.
Illustration 405
(1) 239-5505 Pin
g01077204
Illustration 406
(2) 6G-9696 Spacer
g01077205
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Illustration 407
(1) 239-5505 Pin
g00723561
6. Align 6G-9696 Spacer (2) with the hoist bearing cylinder. Drive 239-5505 Pin (1) half of the way through the
hoist bearing cylinder.
Illustration 408
(2) 6G-9696 Spacer
g00723563
Illustration 409
g00723564
7. Align the second 6G-9696 Spacer (2) at the opposite side of the hoist cylinder. Drive the 239-5505 Pin (1)
into position.
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Illustration 410
(3) 6G-9691 Bar
g00723565
8. Assemble the following items: 6G-9691 Bar (3), two 5P-8245 Hard Washers (4) and two 0S-1585 Bolts (5) .
9. Repeat Step 1 through Step 8 for the remaining hoist cylinder.
Qty
Part Number
Part Name
351-2414
Lubrication Pump
17
8T-4896
Hard Washer
0S-1594
Bolt
8L-6557
Connector
9L-5125
Elbow
14
4K-8864
Clip
14
5M-3062
Bolt
2N-1287
Flared Elbow
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Illustration 411
Typical view
g00723573
Illustration 412
Typical view
g00723575
1. Use a suitable crane to position 351-2414 Lubrication Pump (1) on the truck chassis.
2. Use three 0S-1594 Bolt (3) and three 8T-4896 Hard Washer (2) to assemble 351-2414 Lubrication Pump (1) .
3. Remove two caps and connect hose assembly (A) .
4. Remove two caps and connect hose assembly (B) .
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Illustration 413
View of the left, front suspension cylinder
g00723578
Illustration 414
(4) 8L-6557 Connector
g00723579
5. Remove the bearing cap plug for the grease line. Install 8L-6557 Connector (4) .
6. Remove the cap and connect the existing hose assembly to 8L-6557 Connector (4) .
Illustration 415
g00723581
View of the rear side of the left, front suspension cylinder
(5) 9L-5125 Elbow
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Illustration 416
g00723582
View of the front side of the left, front suspension cylinder
9. Inspect front side of the suspension cylinder. The two relief plugs should be located on the front side of the
suspension cylinder.
10. Repeat Step 5 through Step 9 for the right side of the truck.
Illustration 417
g00723583
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Illustration 418
(5) 9L-5125 Elbow
g00723584
Illustration 419
(2) 8T-4896 Hard Washer
g00723587
14. Raise the truck body and install the truck body retaining cable.
The space between the body and the frame becomes a zero clearance
area when the body is lowered. Failure to install the retaining cable can
result in injury or death to personnel working in this area.
15. Position the hose assembly along the inside of the frame rail of the body. Assemble the following items:
seven 4K-8864 Clips (6), seven 8T-4896 Hard Washers (2) and seven 5M-3062 Bolts (7) .
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Illustration 420
(8) 2N-1287 Flared Elbow
g00723588
16. Remove the plug and assemble 2N-1287 Flared Elbow (8) to the top hoist cylinder bearing.
17. Remove the cap and connect the existing hose assembly to 2N-1287 Flared Elbow (8) .
18. Repeat Step 16 through Step 17 for the right side of the truck.
19. Remove the truck body retaining cable. Lower the truck body.
Qty
Part Number
Part Name
3B-7255
Reducing Bushing
2N-8037
Elbow
1Q-5485
Flange
032-4814
Elbow
3K-0360
O-Ring Seal
6V-3822
Bolt
0L-1351
Bolt
7X-0772
Hard Washer
2G-8992
Clamp
10
4L-6454
Bolt
11
5M-2894
Hard Washer
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Illustration 421
(1) 3B-7255 Reducing Bushing
g01072137
Illustration 422
g01072139
4. Remove the existing adapter and the gasket on the steering tank. Retain the gasket.
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Illustration 423
(3) 1Q-5485 Flange
g01072141
5. Install 3K-0360 O-Ring Seal (5) on 032-8414 Elbow (4). Install 032-8414 Elbow (4) in 1Q-5485 Flange (3).
Use two 6V-3822 Bolts (6) to install the gasket and 1Q-5485 Flange (3) onto the steering tank.
6. Attach the hose assembly to 032-8414 Elbow (4) .
Illustration 424
(7) 0L-1351 Bolt
g01072151
7. Use four 0L-1351 Bolts (7) and four 7X-0772 Hard Washers (8) to attach the box to the fuel tank.
Illustration 425
g01072152
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8. Use 4L-6454 Bolt (10), 5M-2894 Hard Washer (11), and 2G-8992 Clamp (9) to secure the hoses to the side
of the fuel tank.
Illustration 426
(9) 2G-8992 Clamp
g01072156
9. Use 4L-6454 Bolt (10), 5M-2894 Hard Washer (11), and 2G-8992 Clamp (9) to secure the hoses to the rear
of the fuel tank.
Qty
Part Number
Part Name
9G-9152
Clip
11
8T-4896
Hard Washer
11
5M-3062
Bolt
4D-7794
Clip
4L-6454
Bolt
6V-8801
Nut
8M-2770
Clip
5P-0562
Lockwire
135-0428
Signal Lamp
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10
7S-4346
Screw
11
9F-5599
Lockwasher
12
4B-2049
Nut
13
1S-0994
Clip
14
5S-7379
Bolt
15
5P-1075
Hard Washer
16
7D-4092
Clip
17
9G-9154
Clip
18
3T-0050
Clip
19
40
3S-2093
Cable Strap
20
1H-3244
Lockwasher
21
3T-4411
Flood Lamp
22
5T-1680
Plate
23
117-5883
Cable
24
9M-4995
Clip
25
3M-7212
Battery Terminal
26
9G-9150
Clip
27
5P-9297
Clip
28
3T-3048
Clip Assembly
Illustration 427
g00723596
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1. Connect the wiring harness to the VIMS pressure sensor that is located on the left strut.
2. Use 5M-3062 Bolt (3) and 8T-4896 Hard Washer (2) to assemble 9G-9152 Clip (1). Assemble the Sure-Seal
connection to 9G-9152 Clip (1) .
3. Use the existing bolt and washer to secure the wiring harness to 4D-7794 Clip (4) .
4. Repeat Step 1 through Step 3 for the left side of the truck.
Illustration 428
Front view of the fuel tank
g00940939
Illustration 429
g01072398
5. Remove the following items from the VIMS fuel level sensor: the existing six bolts, six washers and the
guard.
6. Pull the harness through the guard on the bottom of the fuel tank.
7. Connect the harness to the VIMS fuel level sensor. Replace the following items that were removed in Step 5:
the guard, washers and bolts.
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Illustration 430
Rear view of the fuel tank
g00723600
8. Secure the wiring harness with the following items: 4D-7794 Clip (4), 5M-3062 Bolt (3) and 8T-4896 Hard
Washer (2) .
Illustration 431
(9) 135-0428 Signal Lamp
g00723605
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Illustration 432
(11) 9F-5599 Lockwasher
g00723606
9. Assemble 135-0428 Signal Lamp (9) by using the following items: three 7S-4346 Screws (10), three 9F-5599
Lockwashers (11) and three 4B-2049 Nuts (12) .
10. Repeat Step 9 for the remaining 135-0428 Signal Lamp (9) .
11. Connect a wiring harness to each 135-0428 Signal Lamp (9) .
Illustration 433
(2) 8T-4896 Hard Washer
g00723608
12. Secure the wiring harness with the following items: 5P-9297 Clip (27), 5M-3062 Bolt (3) and 8T-4896 Hard
Washer (2) .
13. Use the following items to secure three cables and a wiring harness: 9M-4995 Clip (24), 9G-9150 Clip (26),
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Illustration 434
(2) 8T-4896 Hard Washer
g00723609
14. Use the following items to secure the wiring harness: four 1S-0994 Clip (13), four 5M-3062 Bolts (3) and
four 8T-4896 Hard Washers (2) .
Illustration 435
(14) 5S-7379 Bolt
g00723612
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Illustration 436
(14) 5S-7379 Bolt
g00723614
15. Remove the strap. Route the hose. Connect the existing left signal lamp to the wiring harness on the chassis.
16. Secure the hose with the following items: three 7D-4092 Clips (16), three 5P-1075 Hard Washers (15) and
three 5S-7379 Bolts (14) .
Illustration 437
g00723617
17. Remove the strap. Route the wiring harness above the front cab support.
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Illustration 438
(2) 8T-4896 Hard Washer
g00723619
18. Use 5M-3062 Bolt (3) and 8T-4896 Hard Washer (2) to assemble 9G-9154 Clip (17) and 3T-0050 Clip (18) .
Illustration 439
g00723621
19. Connect the wiring harness from the chassis to the front of the cab. Secure the connections in the 9G-9154
Clip (17) and 3T-0050 Clip (18). Refer to the arrows.
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Illustration 440
(19) 3S-2093 Cable Strap
g00723623
20. Use as many 3S-2093 Cable Strap (19) as required in order to secure the harnesses.
Illustration 441
g01072400
21. Remove the six bolts that secure the cover to the back of the cab.
Illustration 442
g01072401
22. Remove the light assembly from the back of the cab.
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23. Reposition the cover on the back of the cab. Reinstall the six bolts for the cover on the back of the cab.
Illustration 443
g01072405
Illustration 444
(14) 5S-7379 Bolt
g00723624
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Illustration 445
(2) 8T-4896 Hard Washer
g00723626
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Illustration 446
g00764688
32. Use the existing bolt and the existing washer to connect the arm for the body position sensor to the truck
body.
Note: The body position sensor will be calibrated later in the assembly procedure.
Qty
Part Number
Part Name
9G-9150
Clip
8T-4896
Hard Washer
5M-3062
Bolt
8K-1433
Grommet
Note: The following procedure can only be completed after the 5T-4464 Platform Group and the 147-3533 Wiring
and Lighting Group have been assembled to the truck chassis.
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Illustration 447
Illustration 448
(1) 9G-9150 Clip
g01072446
g00723267
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Illustration 449
(4) 8K-1433 Grommet
g00723268
(D) Screw
(E) Red lamp
(F) Green lamp
1. The wiring harness must be extended from the right side of the platform. Then extend the wiring harness
through the platform and extend the wiring harness into the right side payload signal lamp. Assemble 8K1433 Grommet (4) to the right side platform at the point of intersection between the wiring harness and the
platform.
2. Remove the four existing screws and the existing lamp assembly. Retain the four screws and retain the lamp
assembly for the later assembly.
3. Use 8T-4896 Hard Washers (2) and 5M-3062 Bolts (3) to assemble two 9G-9150 Clips (1) .
4. Connect two Sure-seal connectors from the signal lamps to the wiring harness. Assemble the Sure-seal
connectors to the clips.
5. Replace the lamp assembly and the four screws.
Note: Position the green lamp (F) forward of the red lamp (E) .
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Illustration 450
g01072491
228-0937 Monitor Wiring Group (PAYLOAD CONTROL SYSTEM) (LAMPS) (If Equipped)
Illustration 451
g01072493
230-1478 Monitor Wiring Group (PAYLOAD CONTROL SYSTEM) (DISPLAY) (If Equipped)
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Illustration 452
Wiring harness connection on platform
g01072494
Illustration 453
Wiring harness connection on frame
g01072500
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Illustration 454
View A-A of wiring harness connection on frame
g01072501
(A) Wiring harness connection for 228-0937 Monitor Wiring Group (PAYLOAD CONTROL SYSTEM) (LAMPS)
(B) Wiring harness connection for 230-1478 Monitor Wiring Group (PAYLOAD CONTROL SYSTEM) (DISPLAY)
1. Connect the wiring harness connector on the platform to the wiring harness connector on the frame. Connect
228-0937 Monitor Wiring Group (PAYLOAD CONTROL SYSTEM) (LAMPS) (If Equipped) to wiring
harness connection (A). Connect 230-1478 Monitor Wiring Group (PAYLOAD CONTROL SYSTEM)
(DISPLAY) (If Equipped) to wiring harness connection (B) .
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Illustration 455
View of the object detection locations
g02338357
ReferenceRefer to Special Instruction, KENR8668 for the orientation of the radar. The radar orientation is critical
for the operation of the object detection system.
Safety Information
Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you
understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools.
Failure to follow these procedures can result in personal injury. The following procedures should also be observed.
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs.
A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in
order to perform these functions properly.
Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not
heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible
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Illustration 456
Typical view
g01947953
(1) Pin
(2) Cable
1. Raise the truck body and install the retaining cable (2) for the truck body.
Refer to Illustration 456.
2. Set the parking brake.
3. Turn the key start switch and the disconnect switch to the OFF position.
Required Parts
Table 86
Parts for the 359-4262 Sensor Wiring Gp (OBJECT DETECTION)
Qty
Part Number
Description
10
7K-1181
Cable Strap
153-9480
Angle As
360-1914
Sensor Harness As
361-6815
Sensor Harness As
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130-5300
Clip
130-5301
Clip
147-0385
Clip
4D-9517
Clip
10
4K-8864
Clip
5S-7379
Bolt
7C-8246
Spacer
8T-4121
Hard Washer
8T-4136
Bolt
8T-4195
Bolt
Table 87
Part Number
Description
7K-1181
Cable Strap
144-4613
Angle As
153-9480
Angle As
305-3747
Plate As
305-3748
Plate As
312-4475
Bracket
336-6684
Camera Gp
348-9537
Plate As
119-5708
Clip
147-0385
Clip
219-6485
Flood Lamp Gp
4D-7735
Clip
4D-7794
Clip
4L-6454
Bolt
6V-3265
Clip
6V-8801
Nut
17
7X-7729
Washer
8M-2773
Clip
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19
8T-4121
Hard Washer
10
8T-4133
Nut
14
8T-4136
Bolt
8T-4137
Bolt
8T-4896
Hard Washer
8T-6466
Bolt
9X-8256
Washer
Table 88
Part Number
Description
347-7917
347-7919
348-8759
Bracket
348-8760
Bracket
348-8765
Clamp Bracket
349-4915
Bracket
360-3866
Plate As
360-3872
Mount As
363-7065
Plate As
363-8578
363-9147
Sensor Wiring Gp
198-4778
Hard Washer
5P-1076
Hard Washer
16
6V-7744
Locknut
112
7X-7729
Washer
16
8T-4121
Hard Washer
16
8T-4133
Nut
8T-4136
Bolt
32
8T-4137
Bolt
8T-4183
Bolt
36
8T-4186
Bolt
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12
8T-4195
Bolt
8T-4196
Bolt
8T-4956
Bolt
Table 89
Part Number
Description
352-5603
Bracket As
355-9048
Monitor Display Gp
362-0881
362-2231
Bracket As
096-6166
Hard Washer
6V-4248
Bolt
8T-4121
Hard Washer
9X-2045
Screw
Table 90
Part Number
Description
n/a (1)
Cover
n/a (1)
Bolt
n/a (1)
Camera
n/a (1)
Bolt
n/a (1)
Nut
n/a (1)
Nut
305-3748
Plate As
n/a (1)
Camera Harness
348-9537
Plate As
8T-6466
Bolt
18
7X-7729
Washer
8T-4133
Nut
312-4475
Bracket
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2
(1)
305-3747
Plate As
Table 91
Required Parts for Assembling the Radar Boxes to the Brackets (Front and Rear)
Qty
Part Number
Description
347-7919
348-8760
Bracket
32
8T-4137
Bolt
32
7X-7729
Washer
347-7917
348-8759
Bracket
Table 92
Part Number
Description
347-7919 (1)
347-7917 (2)
347-7919 (3)
347-7917 (4)
360-3872
Mount As
360-1914
8T-4195
Bolt
16
8T-4121
Hard Washer
147-0385
Clip
7K-1181
Cable Strap
8T-4956
Bolt
5P-1076
Hard Washer
130-5301
Clip
348-8765
Clamp Bracket
8T-4196
Bolt
16
8T-4186
Bolt
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32
7X-7729
Washer
16
6V-7744
Locknut
8T-4136
Bolt
8M-2773
Clip
(1)
(2)
(3)
(4)
Table 93
Required Parts for Installation of the Left Side Hardware
Qty
Part Number
Description
363-7065
Plate As
8T-4195
Bolt
11
8T-4121
Hard Washer
363-8578
8T-4183
Bolt
198-4778
Hard Washer
305-3747
Plate As
8T-4136
Bolt
153-9480
Angle As
4L-6454
Bolt
8T-4896
Hard Washer
6V-8801
Nut
144-4613
Angle As
219-6485
Flood Lamp Gp
247-4285
Bolt
8T-4224
Hard Washer
6V-9189
Locknut
8T-4137
Bolt
6V-3265
Clip
4D-7735
Clip
147-0385
Clip
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7K-1181
Cable Strap
Table 94
Part Number
Description
363-7065
Plate As
8T-4195
Bolt
8T-4121
Hard Washer
363-8578
8T-4183
Bolt
198-4778
Hard Washer
305-3747
Plate As
8T-4136
Bolt
219-6485
Flood Lamp Gp
247-4285
Bolt
8T-4224
Hard Washer
6V-9189
Locknut
144-4613
Angle As
119-5708
Clip
8T-4137
Bolt
6V-3265
Clip
4D-7735
Clip
7K-1181
Cable Strap
Table 95
Part Number
Description
360-3866
Plate As
8T-4136
Bolt
48
7X-7729
Washer
349-4915
Bracket
20
8T-4186
Bolt
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8T-4195
Bolt
361-6815
Sensor Harness As
10
4K-8864
Clip
8T-4121
Hard Washer
7C-8246
Spacer
130-5300
Clip
5S-7379
Bolt
153-9480
Angle As
347-7919
347-7917
16
8T-4133
Nut
4D-9517
Clip
7K-1181
Cable Strap
Table 96
Part Number
Description
355-9048
Monitor Display Gp
362-2231
Bracket As
352-5603
Bracket As
n/a (1)
Bolts
096-6166
Hard Washer
6V-4248
Bolt
8T-4121
Hard Washer
9X-2045
Screw
(1)
Bolts (4) should be shipped already attached to monitor display group (1)
Qty
Part Number
Description
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n/a (1)
Cover
n/a (1)
Bolt
n/a (1)
Camera
n/a (1)
Bolt
n/a (1)
Nut
n/a (1)
Nut
305-3748
Plate As
n/a (1)
Camera Harness
348-9537
Plate As
10
8T-6466
Bolt
11
18
7X-7729
Washer
12
8T-4133
Nut
13
312-4475
Bracket
14
305-3747
Plate As
(1)
Note: An arrow is located at the top of the camera lens which indicates the up direction of the camera. The camera
that is going to be installed on the rear of the truck needs to have this arrow installed facing up.
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Illustration 457
(1) Cover
g02352341
(2) Bolt
(3) Camera
(4) Bolt
(5) Nut
(6) Nut
1. Assemble the four cameras with the parts that are supplied with the cameras.
Refer to Illustration 457.
Note: Do not tighten the nuts (6). The nuts will be used in the following procedure in order to attach the
camera to the brackets for the camera.
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Illustration 458
View of the front and side cameras
g02338576
Illustration 459
View of the rear camera
g02339320
2. Route the camera harness and the connector through the hole that is provided in the 305-3748 Plate As (7)
and the 348-9537 Plate As (9). Place the grommet that is provided on the harness for the camera through the
hole. Repeat this procedure for all the cameras.
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Illustration 460
View of the front and side cameras
g02339362
(4) Bolt
(6) Nut
(7) 305-3748 Plate As
Illustration 461
View of the rear camera
g02339361
(4) Bolt
(6) Nut
(9) 348-9537 Plate As
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3. Use bolts (4) and nuts (6) to secure the 336-6684 Camera Groups to plate assemblies (7) and plate assembly
(9) .
Front Camera
Illustration 462
Camera assembled to the front bracket
g02339462
1. Mount the assembled camera group and plate assembly (7) to bracket (13) by using three bolts (10), six
washers (11), and three nuts (12) .
Side Cameras
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Illustration 463
Side camera and plate assembly
g02339472
1. For the two side cameras, mount the camera group and plate assembly (7) to plate assembly (14) by using six
bolts (10), 12 washers (11), and six nuts (12) .
Qty
Part Number
Description
347-7919
348-8760
Bracket
32
8T-4137
Bolt
32
7X-7729
Washer
347-7917
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348-8759
Bracket
Note: Mounting location is important. Each radar box must be mounted in the designated location that is labeled on
the harness connector for each box.
The sensors for the Caterpillar Object Detection System are assembled before shipping. Use the following
procedure in order to assemble the mounting brackets to the radar boxes.
Note: Inspect the grommet on the bottom of the radar box to ensure that the sealant has not been disturbed during
shipment. If the seal is not intact, use silicone sealant in order to seal the grommet.
Mount the Front and Rear 347-7919 Object Detection Sensors (Black Sensors) to the Brackets
Illustration 464
g02199974
Upper front and rear radar boxes (black sensor) and bracket
(1) 347-7919 Object Detection Sensor Gp
(2) 348-8760 Bracket
(3) 8T-4137 Bolts
(4) 7X-7729 Hard Washers
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Illustration 465
g02199994
Lower front and rear radar boxes (white sensor) and bracket
(3) 8T-4137 Bolts
(4) 7X-7729 Hard Washers
(5) 347-7917 Object Detection Sensor Gp
(6) 348-8759 Bracket
Qty
Part Number
Description
347-7919 (1)
347-7917 (2)
347-7919 (3)
347-7917 (4)
360-3872
Mount As
360-1914
8T-4195
Bolt
16
8T-4121
Hard Washer
147-0385
Clip
10
7K-1181
Cable Strap
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11
8T-4956
Bolt
12
5P-1076
Hard Washer
13
130-5301
Clip
14
348-8765
Clamp Bracket
15
8T-4196
Bolt
16
16
8T-4186
Bolt
17
32
7X-7729
Washer
18
16
6V-7744
Locknut
19
8T-4136
Bolt
20
8M-2773
Clip
(1)
(2)
(3)
(4)
ReferenceRefer to Special Instruction, KENR8668 for the orientation of the radar. The radar orientation is critical
for the operation of the object detection system.
Illustration 466
Front radar boxes
g02199675
(1) 347-7919 Object Detection Sensor Gp with 327-5293 Object Detection Sensor Gp
(2) 347-7917 Object Detection Sensor Gp with 321-0902 Object Detection Sensor Gp
(3) 347-7919 Object Detection Sensor Gp with 321-0903 Object Detection Sensor Gp
(4) 347-7917 Object Detection Sensor Gp with 321-0902 Object Detection Sensor Gp
Each radar box has a specific mounting location. The radar sensors have individual part numbers located on the
harnesses at the bottom of the box.
Installation of the Box Group for the Object Detection (Front)
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Note: Ensure that the correct radar box is located in the correct position. Refer to Illustration 466.
Illustration 467
View of the rear of 360-3872 Mount As (5)
g02358296
1. Secure harness assembly (6) to the back of mount assembly (5) by using four bolts (7), four washers (8), four
clips (9), and one cable strap (10) .
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Illustration 468
(A) Harness assembly
g02358303
2. Secure mount assembly (5) to the front bumper by using eight bolts (11) and eight hard washers (12) .
3. Secure harness assembly (6) to the front bumper by using one clip (13) and the hardware from Step 2.
4. Connect harness assembly (A) to harness assembly (6) .
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Illustration 469
(5) 360-3872 Mount As
g02339537
5. Install four clamp brackets (14) to mount assembly (5) by using eight bolts (15), and eight washers (8) .
Illustration 470
(1) 347-7919 Object Detection Sensors
g02339677
6. Secure sensors (1) and (2), and box groups (3) and (4) to clamp brackets (14) by using 16 bolts (16), 32
washers (17), and 16 locknuts (18) .
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Illustration 471
g02358419
View of the rear of the front sensor mount assembly
(6) 360-1914 Sensor Harness As (RADAR, FRONT)
(10) 7K-1181 Cable Strap
Illustration 472
g02352880
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1. Secure the front camera that was previously assembled to the top of the cowling group by using four bolts
(19) and four washers (10) .
2. Secure the harness assembly for the camera to the top of the machine by using one clip (20), and the existing
bolt and washer.
3. Connect existing harness assembly (B) to the harness assembly for the camera assembly.
Qty
Part Number
Description
363-7065
Plate As
8T-4195
Bolt
11
8T-4121
Hard Washer
363-8578
8T-4183
Bolt
198-4778
Hard Washer
305-3747
Plate As
8T-4136
Bolt
153-9480
Angle As
10
4L-6454
Bolt
11
8T-4896
Hard Washer
12
6V-8801
Nut
13
144-4613
Angle As
14
219-6485
Flood Lamp Gp
15
247-4285
Bolt
16
8T-4224
Hard Washer
17
6V-9189
Locknut
18
8T-4137
Bolt
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19
6V-3265
Clip
20
4D-7735
Clip
21
147-0385
Clip
22
7K-1181
Cable Strap
ReferenceRefer to Special Instruction, KENR8668 for the orientation of the radar. The radar orientation is critical
for the operation of the object detection system.
Installation of the Box Group for the Object Detection (Left Hand Side)
Illustration 473
(1) 363-7065 Plate As
g02340316
1. Secure plate assembly (1) to the side of the left-hand walkway by using four bolts (2) and four hard washers
(3) .
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Illustration 474
(1) 363-7065 Plate As
g02340376
2. Secure box group (4) to plate assembly (1) by using four bolts (5) and four washers (6) .
Installation of Camera Group (Left Hand Side)
Illustration 475
g02352899
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1. Secure plate assembly (7) to the left-hand walkway by using four bolts (8) and four washers (3) .
Illustration 476
(7) 305-3747 Plate As
g02352900
2. Secure one angle assembly (9) to plate assembly (7) by using one bolt (10), two washers (11), and one nut
(12) .
Installation of the Lamp Group (Left Hand Side)
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Illustration 477
(7) 305-3747 Plate As
g02352908
1. Secure one flood lamp group (14) to plate assembly (7) by using one bolt (15), two washers (16), and one
locknut (17). Insert one angle assembly (13) between flood lamp group (14) and plate assembly (7). Refer to
Illustration 477 for the orientation of angle assembly (13) .
Note: Tighten bolt (15) to a maximum of 20 Nm (175 lb in).
Connect the Harness Assemblies (Left Hand Side)
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Illustration 478
(A) Bolt
g02352966
(B) Washer
(C) Plate
(4) 363-8578 Object Detection Box Gp
1. Remove four bolts (A) and four washers (B) that secure plate (C) to box group (4). Retain the hardware.
2. Remove plate (C). Retain all the hardware.
Illustration 479
g02352911
(D) Bolt
(E) Washer
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3. Secure the top of harness assembly (F) by using existing bolt (D), existing washer (E), and one clip (21) .
4. Secure the middle of harness assembly (F) to angle assembly (13) by using one bolt (18), one washer (3), and
one clip (19) .
5. Secure the bottom of harness assembly (F) by using existing bolt (8), existing washer (3), and one clip (20) .
6. Secure harness assembly (H) to angle assembly (9) by using one bolt (10), one washer (11), and one clip (21).
7. Secure harness assembly (H) to the top of box group (4) by using two cable straps (22) .
8. Connect cable assembly (G) to harness assembly (F) .
9. Connect the one end of harness assembly (H) to the side of box group (4) .
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Illustration 480
(H) 361-0194 Sensor Harness As
g02353007
10. Connect the other end of harness assembly (H) to the back of the flood lamp group.
11. Install plate (C) that was removed in Step 1 by using the hardware that was removed in Step 1. Refer to
Illustration 478.
Qty
Part Number
Description
363-7065
Plate As
8T-4195
Bolt
8T-4121
Hard Washer
363-8578
8T-4183
Bolt
198-4778
Hard Washer
305-3747
Plate As
8T-4136
Bolt
219-6485
Flood Lamp Gp
10
247-4285
Bolt
11
8T-4224
Hard Washer
12
6V-9189
Locknut
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13
144-4613
Angle As
14
119-5708
Clip
15
8T-4137
Bolt
16
6V-3265
Clip
17
4D-7735
Clip
18
7K-1181
Cable Strap
ReferenceRefer to Special Instruction, KENR8668 for the orientation of the radar. The radar orientation is critical
for the operation of the object detection system.
Installation of the Box Group for the Object Detection (Right Hand Side)
Illustration 481
(1) 363-7065 Plate As
g02341761
1. Secure plate assembly (1) to the side of the right-hand platform by using four bolts (2) and four washers (3) .
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Illustration 482
(1) 363-7065 Plate As
g02341778
2. Secure box group (4) to plate assembly (1) by using four bolts (5) and four washers (6) .
Installation of the Camera Group (Right Hand Side)
Illustration 483
g02353025
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1. Secure plate assembly (7) to the right-hand platform by using four bolts (8) and four washers (3) .
Installation of the Lamp Group (Right Hand Side)
Illustration 484
(7) 305-3747 Plate As
g02353026
1. Secure one flood lamp group (9) to plate assembly (7) by using one bolt (10), two washers (11), and one
locknut (12). Insert one bracket (13) between flood lamp group (9) and plate assembly (7). Refer to
Illustration 484 for the orientation of bracket (13) .
Note: Tighten bolt (10) to a maximum of 20 Nm (175 lb in).
Connect the Harness Assemblies (Right Hand Side)
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Illustration 485
(A) Bolt
g02353042
(B) Washer
(C) 283-0657 Cable As
(D) Harness assembly for the 336-6684 Camera Gp
(3) 8T-4121 Hard Washer
(7) 305-3747 Plate As
(8) 8T-4136 Bolt
(13) 144-4613 Angle As
(14) 119-5708 Clip
(15) 8T-4137 Bolt
(16) 6V-3265 Clip
(17) 4D-7735 Clip
1. Secure the top of harness assembly (D) by using existing bolt (A), existing washer (B), and one clip (14) .
2. Secure the middle of harness assembly (D) to angle assembly (13) by using one bolt (15), one washer (3), and
one clip (16) .
3. Secure the bottom of harness assembly (D) by using existing bolt (8), existing washer (3), and one clip (17) .
4. Connect cable assembly (C) to harness assembly (D) .
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Illustration 486
(4) 363-8578 Object Detection Box Gp
g02353068
(E) Bolt
(F) Washer
(G) Plate
5. Remove four bolts (E) and four washers (F) that secure plate (G) to the top of box group (4). Retain the
hardware.
6. Remove plate (G) from the top of box group (4). Retain plate (G) .
Illustration 487
g02353072
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7. Connect one end of harness assembly (H) to the back of lamp group (9) .
8. Connect the other end of harness assembly (H) to the side of box group (4) .
9. Secure harness assembly (H) to the top of box group (4) by using two cable straps (18) .
Illustration 488
(4) 363-8578 Object Detection Box Gp
g02353068
(E) Bolt
(F) Washer
(G) Plate
10. Secure plate (G) to box group (4) by using four bolts (E) and four washers (F) .
Note: Bolts (E), washers (F), and plate (G) were removed in Step 5 and Step 6.
Qty
Part Number
Description
360-3866
Plate As
8T-4136
Bolt
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48
7X-7729
Washer
349-4915
Bracket
20
8T-4186
Bolt
8T-4195
Bolt
361-6815
Sensor Harness As
10
4K-8864
Clip
8T-4121
Hard Washer
10
7C-8246
Spacer
11
130-5300
Clip
12
5S-7379
Bolt
13
153-9480
Angle As
14
347-7919
15
347-7917
16
16
8T-4133
Nut
17
4D-9517
Clip
18
7K-1181
Cable Strap
Illustration 489
g02341820
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1. Secure two plate assemblies (1) to the rear of the frame by using eight bolts (2) and eight washers (3) .
Note: Existing hardware may be required to secure plate assemblies (1) to the top of the frame.
Illustration 490
(1) 360-3866 Plate As
g02349906
2. Secure two brackets (4) to two plate assemblies (1) by using four bolts (5) and four washers (3) .
3. Secure two brackets (4) to the rear of the frame by using four bolts (6) and four washers (3) .
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Illustration 491
(1) 360-3866 Plate As
g02358516
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Illustration 492
View of the rear of the frame
g02354198
6. Secure harness assembly (7) to the rear of the machine by using one angle assembly (13), one bolt (12), one
washer (9), and one clip (8) .
Illustration 493
g02353856
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7. Secure two object detection box groups (14) to the top of the rear frame by using eight bolts (5), 16 washers
(3), and eight nuts (16) .
8. Secure two object detection box groups (15) to the rear frame by using eight bolts (5), 16 washers (3), and
eight nuts (16) .
Illustration 494
(7) 361-6815 Sensor Harness As
g02358761
9. Connect harness assembly (7) to the box group (14) and box group (15) on the right-hand side.
10. Secure harness assembly (7) to the side of box group (15) on the right-hand side by using one clip (17) and
the existing bolt and washer.
11. Secure harness assembly (7) to the bottom of box group (14) and box group (15) by using two cable straps
(18) .
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Illustration 495
(7) 361-6815 Sensor Harness As
g02358972
12. Connect harness assembly (7) to the box group (14) and box group (15) on the left-hand side.
13. Secure harness assembly (7) to the side of box group (15) on the left-hand side by using one clip (17) and the
existing bolt and washer.
14. Secure harness assembly (7) to the bottom of box group (14) and box group (15) by using two cable straps
(18) .
Installation of the Camera Group (Rear)
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Illustration 496
(A) Rear camera assembly
g02353900
1. Secure rear camera assembly (A) that was previously assembled to the rear of the frame by using two bolts
(2) and two washers (9) .
Connect the Harness Assemblies (Rear)
Illustration 497
(A) Rear camera assembly
g02358977
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1. Connect harness assembly (B) to harness assembly for the rear camera assembly (A) .
2. Secure excess slack from the harness assembly from rear camera assembly (A) to the box for camera group by
using one cable strap (18) .
Qty
Part Number
Description
355-9048
Monitor Display Gp
362-2231
Bracket As
352-5603
Bracket As
n/a (1)
Bolts
096-6166
Hard Washer
6V-4248
Bolt
8T-4121
Hard Washer
9X-2045
Screw
(1)
Bolts (4) should be shipped already attached to monitor display group (1)
Illustration 498
g02350914
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(4) Bolts
(5) 096-6166 Hard Washer
(6) 6V-4248 Bolt
(7) 8T-4121 Hard Washer
1. Attach monitor display group (1) to bracket assembly (2) by using four bolts (4) and four washers (5) .
Note: Bolts (4) should be shipped already attached to monitor display group (1) .
2. Attach bracket assembly (2) to bracket assembly (3) by using two bolts (6) and two washers (7) .
Illustration 499
(3) 352-5603 Bracket As
g02350921
3. Secure bracket assembly (3) to the top of the cab by using two screws (8) .
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Illustration 500
Typical view of the sensor harness assemblies
g02284713
Illustration 501
g02350926
4. Connect the three 319-6830 Sensor Harness As 12-pin connectors to the corresponding connectors on the
back of monitor display group (1). The video cable connects to the green connector. The 12-pin connector
with two wires connects to the black connector and the 12-pin connector with five wires connects to the gray
connector.
Required Material
Communication Adapter
Software
Table 104
Part Number
361-8176
System
Caterpillar Integrated Object Detection System
Notes
Radar and Camera
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362-3942
Cameras only
Perform the following procedure in order to flash program the ECM. The ECM is flashed in order to upgrade the
software. Flash programming of the ECM must be done if the ECM has been replaced. Caterpillar Electronic
Technician (Cat ET) contains the program WinFlash. WinFlash is used in order to load the software into the ECM.
The following procedure is used in order to flash the software into the display.
Procedure
1. Ensure that the key start switch and the disconnect switch are in the OFF position.
2. Disconnect the center 12-pin connector from the display.
3. Connect the 345-7489 Monitor Harness As between the system harness for the display and the center
connector on the display.
4. Connect the 7X-1425 Data Link Cable As between the 7X-1700 Communication Adapter Gp and Cat ET.
5. Connect the 139-4166 Data Link Cable As between the 7X-1700 Communication Adapter Gp and the
diagnostic connector of the 345-7489 Monitor Harness As .
6. Turn power back on to the display.
7. Use WinFlash in order to load the software.
8. Disconnect the 345-7489 Monitor Harness As from the system harness for the display and the center
connector on the display.
9. Connect the 12-pin connector of the system harness to the center connector of the display.
10. Turn the disconnect switch and the key start switch to the ON position.
11. Verify that the display turns on and the Caterpillar Integrated Object Detection system starts.
Note: Refer to Special Instruction, REHS5191 regarding information for the CIODS.
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1. For the correct type of fluid and the correct amount of fluid, refer to Operation and Maintenance Manual,
SEBU7174, "789C Off-Highway Truck". Refer to the following items: "Cooling System Specifications",
"Fuel Specifications", "Lubricant Specifications", "Lubricant Viscosities" and "Refill Capacities".
2. Check the oil level in the differential housing and the final drives. Refer to the following items: "Lubricant
Viscosities", "Refill Capacities" and "Differential and Final Drive Oil - Change".
3. Check the oil level of the front wheel. If necessary, remove the cap and add oil. Replace the cap. Repeat for
the remaining front wheel.
4. Fill the transmission with oil. Check the oil level of the transmission. If necessary, remove the cap and add oil
until the oil level reaches the center of the lower sight glass. Replace the cap.
5. Check the oil level of the engine. If necessary, remove the cap and add oil until the oil level reaches the full
mark on the dipstick. Replace the cap.
6. Check the coolant level for the jacket water. If necessary, remove the cap and add coolant until the indicator
is between the red and the green range. Replace the cap.
7. Check the coolant level for the aftercooler. If necessary, remove the cap and add coolant until the indicator is
between the red and the green range. Replace the cap.
8. Fill the steering system with the oil that is recommended for this application. Remove the filler cap. Fill the
steering system until the oil level reaches the center of the upper sight gauge. Replace the cap.
9. With the oil that is recommended for this application, fill the following systems: hoist, brake and torque
converter. Remove the cap from the hydraulic tank. Add oil until the level reaches the center of the upper
sight gauge. Replace the cap on the hydraulic tank.
10. Fill the fuel tank with the fuel that is recommended for this application. Remove the filler cap and add fuel
until the fuel level reaches the fill opening. Replace the cap.
11. Check the joints of the drive shaft for proper assembly. If necessary, grease the joints.
12. Fill the Autolube Reservoir and the Autolube System. Fill the reservoir with the recommended grease for the
specific application. Remove the top assembly of the reservoir. Fill the reservoir until the reservoir is 75%
full. Replace the top assembly. Use a grease gun in order to fill the individual hose assemblies from the
reservoir to the three lube injector manifolds. Fill the hose assemblies from the lube injector to the bearing.
Fill individual circuits until the grease is observed at each bearing.
Note: The lube injectors are factory installed and the lube injectors should not require any adjustments in the
field.
13. Assemble two 7X-1062 Ether Cylinder Assembly . Refer to Operation and Maintenance Manual, SEBU7174,
"789C Off-Highway Truck", "Ether Starting Aid Cylinder - Replace".
14. Fill the reservoir for the front window washer. Refer to Operation and Maintenance Manual, SEBU7174,
"789C Off-Highway Truck", "Window Washer - Fill".
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NOTICE
Each filler opening is sealed with a reusable plug. Do not remove these
plugs until you are ready to fill the battery with electrolyte. These are
maintenance free batteries and the filler plugs do not need to be
removed for electrolyte level maintenance inspection.
1. Mark the cable connections to each battery. Disconnect the cable connections to each battery.
2. Remove all of the filler plugs. Fill each cell to the proper level with battery grade sulfuric acid of 1.265
specific gravity. Batteries and acid must be at a temperature of 16 C (61 F) to 38 C (100 F) at the time of
the filling. Install the filler caps and tighten to a torque value of 3.4 1.1 Nm (30 10 lb in).
3. Use a 4C-4911 Battery Load Tester and a 8T-0900 Ammeter in order to apply a load of 375 A to the battery
for 15 seconds. Disconnect the battery load tester.
4. Use a 6V-7070 Digital Multimeter in order to measure the voltage and record the voltage across the battery.
5. If the voltage that was recorded in Step 4 was 9.0 V or higher, the battery is ready for service.
6. If the voltage that was recorded in Step 4 was less than 9.0 V, charge the battery at a rate of 40 amp for 20
minutes. Use the 4C-4925 Portable Battery Charger .
7. If the battery required a booster charge in Step 6, repeat Step 3 through Step 5. If the recorded battery voltage
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after the second load test is less than 9.0 V, the battery must be replaced.
8. Repeat Step 1 through Step 7 for the remaining battery.
9. Remove all of the test equipment. Connect the battery cables.
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Note: A factory assigned password clears events that are logged on the engine ECM. This is the only way to
clear the events from the engine ECM.
16. Return to the engine control screen and select "LOGGED CODES". Select the button at the bottom of the
screen "INCLUDE ALL ECM'S". Clear all codes that are logged. Refer to Service Manual, RENR2630, "OffHighway Truck/Tractor Vital Information Management System (VIMS) - Systems Operation".
17. Return to the engine control screen and select "DIAGNOSTICS" and "EVENTS". Select the button at the
bottom of the screen "INCLUDE ALL ECM'S". Clear all of the codes that are logged. Refer to Service
Manual, RENR2630, "Off-Highway Truck/Tractor Vital Information Management System (VIMS) - Systems
Operation".
Note: A factory assigned password clears events that are logged on the engine ECM. This is the only way to
clear the events from the engine ECM.
18. Return to the engine control screen and select "SERVICE", "CALIBRATIONS", and "INJECTOR CODES
CALIBRATION". Select "PRINT" at the bottom of the screen. Select a print destination.
Note: Step 18 provides a record of the injector code for each cylinder. The codes may accidentally change.
The injector codes are stamped on the injector. If an injector is changed, the new injector code must be
updated in the engine ECM.
19. The engine prelube and the ether control can be tested without starting the engine. The engine prelube and the
ether control can be tested.
a. Return to the engine control screen and select "DIAGNOSTICS" and "OVERRIDE PARAMETERS".
Select "START AID" and "CHANGE". The ether solenoids will energize. Select "CHANGE" again in
order to turn off the feature.
b. Return to the engine control screen and select "DIAGNOSTICS" and "OVERRIDE PARAMETERS".
Select "ENGINE PRELUBE" and "CHANGE". The prelube motor will energize. Select "CHANGE"
again. The prelube motor will de-energize.
20. Return to the ET menu. Select "DATA LINK", "SELECT ECM", "POWER TRAIN CONTROL", and
"CONFIGURATION". On the configuration screen, check and adjust the following parameters. Refer to
Service Manual, SENR9122, "Electronic Programmable Transmission Control (EPTCII)".
a. The "EQUIPMENT NUMBER" and the customer number should match. Change the numbers, as
needed. If you select a new setting, select "ENTER". This confirms the change.
b. Check the "TRANSMISSION SERIAL NUMBER". "TRANSMISSION SERIAL NUMBER" should
match the transmission serial number on the transmission. If you select a new setting, select "ENTER".
This confirms the change.
c. Check the "TRANSMISSION MAXIMUM GEAR" setting. The transmission maximum gear setting is
adjustable from four to six. If you select a new setting, select "ENTER". This confirms the change.
d. Check the "BODY UP GEAR LIMIT" setting. The body up gear limit is adjustable from one to four. If
you select a new setting, select "ENTER". This confirms the change.
21. Return to the Electronic Technician (ET) menu. Select "DATA LINK", "SELECT ECM", "BRAKES",
"AUTO RETARDER", and "CONFIGURATION". From the configuration screen, check and adjust the
following parameters. Refer to Service Manual, SENR1503, "769D, 771D, 773D, 775D, 784C, 785C, 789C,
and 793C Off-Highway Truck/Tractors Brake Electronic Control System".
a. The "EQUIPMENT NUMBER" and the customer number should match. Change the numbers, as
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needed. If you select a new setting, select "ENTER". This confirms the change.
b. Check the "DESIRED ENGINE AUTO RETARDER SPEED". The engine automatic retarder speed
that is desired is adjustable from 1850 RPM to 1950 RPM. If you select a new setting, select "ENTER".
This confirms the change.
c. Use the VIMS keypad module. Enter "8378" and press "OK". This will initiate the "VIMS SELF
TEST". Refer to "VIMS Self Test" in the Operations and Maintenance Manual.
d. With the laptop computer that is connected to the diagnostic port, continue to the next step. Use the
laptop computer again after the engine has been started.
When the parking brakes are released manually, the machine has no
brakes.
To avoid possible personal injury, the tires must be blocked securely
before the parking brakes are manually released.
4. Perform a walk around inspection. Make sure that the wheels are chocked. Make sure that all fluids are at safe
levels. Adjust the rear view mirrors. Adjust the seat belts. Make sure that all personnel are clear of the
machine. Refer to Operation and Maintenance Manual, SEBU7174, "789C Off-Highway Truck", "Before
Starting Engine".
5. Prime the pump drive housing and the hoist pump with 3P-0659 Oil or crank the engine. Crank the engine
over two times for 15 seconds, while the engine is locked out. This will fill the compartments with oil.
6. Make sure that the body is down. Place the body position control in the FLOAT position.
7. Engage the parking brake. Place the transmission shift lever in the NEUTRAL position. Refer to Operation
and Maintenance Manual, SEBU7174, "789C Off-Highway Truck", "Starting the Engine".
8. Place the starting aid switch in the AUTOMATIC position. The fuel system should not require priming.
However, if you must prime the fuel system refer to Operation and Maintenance Manual, SEBU7174, "789C
Off-Highway Truck", "Fuel System Prime".
9. Position one mechanic on the ground in order to observe levels of the fluid tank. The mechanic should also
watch for fluid leaks. Place the engine shutdown switch in the ON position.
10. Start the engine. Verify that the pressures are safe for operation. Run the engine for 5 seconds for the first two
starts. Check and fill the hydraulic tank, the transmission, the steering, the radiator, and the engine, as needed.
Restart the engine and check for leaks. Run the engine for 30 seconds and then run the engine for 60 seconds.
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Check the ground for leaks. Run the engine until normal operation temperatures are reached. All the fluid
levels should be adjusted, as required.
11. The engine should be at normal operation temperature and the transmission should be in neutral. Check the
"HIGH" idle speeds (1960 40 RPM) and the "LOW" idle speeds (700 15 RPM). The RPM ranges cannot
be changed.
Note: 10 minutes after the engine starts the automatic elevated low idle will become active. The low idle
comes up gradually at the rate of 33 RPM per second. The transmission should be in "NEUTRAL" and the
parking brake should be ON. Do NOT depress the pedal for engagement.
Note: After the activation of the elevated idle speed, the operator may reset the 10 minute delay by tapping
the throttle pedal to more than 1/4 of the pedal's travel. If the coolant temperature rises above 70 C (158 F),
then the engine speed will return to low idle.
12. Bring the air pressure governor to the proper level for a maximum pressure of 827 34 kPa (120 5 psi).
Purge the air pressure to 455 kPa (66 psi). A Level 3 warning should occur at 455 kPa (66 psi).
13. Check the air dryer. The air dryer should expel air at 827 kPa (120 psi).
14. The dryer should have 24 V or more.
Running Check
1. Refer to Service Manual, RENR2630, "Off-Highway Truck/Tractor Vital Information Management System
(VIMS) - Systems Operation" for additional information. There are three levels of warnings. One red light
signals a level one warning. Two red lights signal that there is a level two warning. Two red lights and an
audible alarm signal the level three warning.
The brake ON is 1 or 3.
The alternator is 1.
The steering is 3.
2. Disconnect the cable, the adapter, and the module that is running the Electronic Technician (ET) from the
laptop computer. Connect a 127-9797 Cable to the RS-232 port on the laptop computer. Connect the other
end of the 127-9797 Cable to the diagnostic port in the panel behind the operator's seat. Observe the gauges,
the warning lights, and the service lights with the laptop computer during the truck operation.
3. The low brake pressure indicator causes the alert indicator to flash. The VIMS Message Center should
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provide the following instruction: "Do Not Move Machine". This message is on display until the starting and
service reservoir is charged to one-half of the maximum operating pressure. If the parking brake switch is off,
the warning horn will sound before the tank pressure is one-half of maximum operating pressure.
4. Take notes on all of the events that are recorded on the message center. Resolve the events before you
proceed.
5. Start VIMS-PC software. Use VIMS-PC software to clear all faults that are logged on VIMS memory.
Note: The logged events cannot be cleared when you are using the VIMS Keypad module.
6. Select "VIMS-PC COMMUNICATE" from the "VIMS-PC" group. Refer to Service Manual, RENR2630,
"Off-Highway Truck/Tractor Vital Information Management System (VIMS) - Systems Operation",
"Downloading Data From The Machine".
7. Select "DATA" and "DOWNLOAD DATA". Choose a destination and select "STANDARD DATA". Then
select "OK".
Note: Remove faults that are logged on the VIMS memory.
Functional Checks
1. The yellow light should activate when the retarder is engaged.
2. Test the service brakes.
a. Make sure that the body is down.
b. Place the hoist lever in the FLOAT position.
c. Place the transmission gear selector in NEUTRAL.
d. Place the parking brake switch in the ON position.
Note: The parking brake indicator should flash when the parking brake is engaged.
e. Start the engine. Allow the air system to reach full operating pressure.
f. Apply the service brake. Move the transmission gear selector to the FIRST GEAR position.
g. Move the parking brake switch to the OFF position.
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h. Accelerate the engine to 1200 RPM. The truck should not move.
i. Decelerate the engine to LOW IDLE. Move the transmission gear selector to the NEUTRAL position.
Place the parking brake switch in the ON position.
j. If necessary, service the service brakes. Make sure that the service brakes are functioning properly
before you continue with the commissioning procedure.
3. Test the secondary brakes.
a. Make sure that the body is down.
b. Place the hoist lever in the FLOAT position.
c. Place the transmission gear selector in NEUTRAL.
d. Place the parking brake switch in the ON position.
e. Start the engine. Allow the air system to reach full operating pressure.
f. Apply the secondary brake. Move the transmission gear selector to the FIRST GEAR position.
g. Move the parking brake switch to the OFF position.
h. Accelerate the engine to 1200 RPM. The truck should not move.
i. Decelerate the engine to LOW IDLE. Move the transmission gear selector to the NEUTRAL position.
Place the parking brake switch in the ON position.
j. If necessary, service the secondary brakes. Make sure that the secondary brakes are functioning
properly before you continue with the commissioning procedure.
4. Test the parking brake.
a. Make sure that the body is down.
b. Place the hoist lever in the FLOAT position.
c. Place the transmission gear selector in NEUTRAL.
d. Place the parking brake switch in the ON position.
e. Start the engine. Allow the air system to reach full operating pressure.
f. Move the transmission gear selector to the FIRST GEAR position.
g. Accelerate the engine to 1200 RPM. The truck should not move.
h. Decelerate the engine to LOW IDLE. Move the transmission gear selector to the NEUTRAL position.
i. If necessary, service the parking brakes. Make sure that the parking brakes are functioning properly
before you continue with the commissioning procedure.
5. Test the brake retract switch.
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a. Position the truck on a slight grade. Move the parking brake switch to the ON position. Stop the engine.
b. Depress the service brake pedal and release the service brake pedal several times until the pressure in
the air system is released.
c. Raise the cover of the brake retract switch. Hold the switch in the ON position. The truck should begin
to roll. After the truck is rolling, release the switch to the OFF position. Refer to Operation and
Maintenance Manual, "Brake Release Switch".
Note: Do not hold the brake retract switch for more than 15 to 20 seconds.
d. If the truck did not roll, service the brake retract system.
6. With the engine that is turned off, shut the cab doors and windows. Engage the retarder and apply the
secondary brake and the foot brake. Listen for air leaks. Watch the air gauge for a drop after the initial drop
from the brake engagements. The pressure should remain at 3.5 kPa (0.51 psi) per minute. Hold the
engagement for 3 minutes. The maximum drop in air pressure is 10 kPa (1.45 psi).
7. Test the air system overnight. Leave the truck shutdown overnight. The air tank should contain 827 kPa (120
psi). The air tank should retain enough air. The engine should start the next morning. The truck requires 518
kPa (75 psi) to start the engine.
8. Test the steering system.
a. Position the truck on a surface that is flat and level.
b. Check the oil level in the steering hydraulic tank. When the engine is off, the oil level should be in the
green area of the upper sight gage.
c. Make sure that the body is down.
d. Place the hoist lever in the FLOAT position.
e. Place the transmission gear selector in NEUTRAL.
f. Place the parking brake switch in the ON position.
g. Start the engine. Allow the steering system to reach full operating pressure and temperature.
Note: The oil level should be in the green area of the lower sight gage.
h. Place the parking brake switch in the OFF position. Place the operator key switch in the OFF position.
The steering accumulators should discharge. The steering pressure should drop to zero.
i. Start the engine. Allow the steering accumulators to reach full charge. Place the shutdown engine
switch in the OFF position. The steering pressure should not drop. Release all brakes. Steer the machine
from right stop to left stop in order to check the secondary steering function. The truck must be able to
steer from stop to stop.
j. Continue to steer the truck until the level three warning activates. The warning will activate when
steering pressure drops below 1900 kPa (275 psi).
k. If the truck is not able to steer from stop to stop, service the secondary steering system.
9. Test the AETA system.
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a. Position the truck in an area so that the truck can turn in complete circles.
b. Turn the steering wheel all the way to the left. With the engine at LOW IDLE, drive the machine in a
complete circle. While you turn, lift the cover of the AETA test switch and place the switch in the ON
position. Refer to Operation and Maintenance Manual, SEBU7174, "Traction Control System (TCS) Switch". The machine should slow down gradually.
c. While you continue to turn, place the AETA test switch in the OFF position. The machine speed should
increase.
d. Stop the truck.
e. Repeat the test while you turn in the opposite direction.
f. If the AETA system does not function properly, service the AETA system before you continue.
10. Check the transmission neutralizer switch. The engine will start in neutral only. Try to start the engine in first
gear and reverse.
11. Test the transmission neutralizer.
a. Make sure that the truck body is down. Start the truck.
b. Place the transmission gear selector in the REVERSE position.
c. Raise the truck body. The transmission should automatically shift to NEUTRAL.
d. The transmission will stay in NEUTRAL until the body is lowered and the transmission gear selector is
placed in NEUTRAL.
e. If the transmission neutralizer does not function properly, service the transmission neutralizer before
you continue.
12. Test the transmission gear selector. As you move the selector through the gear ranges the indicator should
flash the correct gear.
13. Check the downshift inhibitor. With the engine at HIGH IDLE and the machine in SIXTH gear, move the
transmission gear selector down one gear at a time to FIRST gear. The transmission should not downshift.
14. Test the backup alarm.
a. Make sure that the truck body is down. Make sure that the hoist lever is in the FLOAT position and that
the parking brake switch is ON. Start the truck.
b. Place the transmission gear selector in the REVERSE position.
c. The backup alarm should sound immediately.
d. If the backup alarm does not function properly, service the backup alarm before you continue.
15. Check the reverse shift inhibitor. When the truck is traveling in FIRST gear at a speed of 10 mph, place the
transmission gear selector in REVERSE. The transmission will shift to NEUTRAL. The transmission will
shift into REVERSE at 3 mph.
16. Test the pressures in Chart 105.
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Table 105
Commissioning Specifications
Description
Specification
Actual
Comments
710 20 rpm
1935 30 rpm
35 30 kPa (5 4 psi)
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Note: On the 3.0 ET Software, the parameters appear clearly on the configuration screen.
Note: On the 3.1 ET Software, the figures will appear on the configuration.
Adjustment for the Hoist Lower Valve (A Parameter that Can Be Set)
Lowering the hoist is adjustable. This compensates for the differences in the valves. The adjustment range is -5 to
+5 with zero as the default. A positive adjustment factor will increase the lower valve command. This causes the
body to come down harder. A negative adjustment factor will decrease the lower valve command. This causes the
body to come down softer.
The adjustment for the Hoist Lower Valve may not be available on earlier ECM systems. The adjustment range may
be from 0 to 10 with 5 as the default on some early ECM systems.
Note: When the adjustment for the Hoist Lower Valve is set too high, too much oil can be diverted to the hoist
system while the hoist system is in float mode. This causes the brake oil to heat up faster. Retarding capability is
also decreased. To set the adjustment for the Hoist Lower Valve, follow the procedure below.
1. Raise the body of the truck and retain the body.
2. Place a 6V-7830 Tetragauge or place a 3.45 MPa (500 psi) gauge with a hose extension on the outlet port of
the hoist pump.
Note: Remove the retainer for the body and lower the body to the frame.
3. While the body is down, place the hoist lever in hold.
4. Enter the configure parameter screen through the service drop-down menu in the Electronic Technician.
5. Change the adjustment for the hoist lower valve to a setting that is desired from -5 to 5. The procedure begins
at 0. Adjust the settings in increments of 1 in the positive position or in the negative position.
Note: If you are using a 3.45 MPa (500 psi) gauge, remove the gauge from the extension.
6. Raise the body to the middle position.
7. Lower the body to the frame.
8. If a 6V-7830 Tetragauge is not installed, shut off the engine and install a 3.45 MPa (500 psi) gauge. Start the
engine and run the engine to high idle. Cycle the hoist lever to the body float position and the hold position.
Do not power down or raise the bed if you are using a 3.45 MPa (500 psi) gauge. Damage may occur to the
gauge.
9. With the engine that is running, place the hoist lever in the body float position.
10. Run the engine to high idle. Verify that the pressure at the hoist outlet port is less than 1723 kPa (250 psi).
Note: When the pressure is greater than 1724 kPa (250 psi), the adjustment is set too high. This causes too much oil
to be diverted to the hoist valve. This causes the brake oil to overheat when the body is in the body float position.
Lower the Adjustment for the Hoist Lower Valve and repeat Step 1 through Step 3. This lowers the pressure below
1724 kPa (250 psi).
Note: The pressure can be checked after each resetting of the adjustment in ET. Cycle the hoist lever from the hold
position to the body float position. If you change the adjustment setting and there is no corresponding pressure
setting, cycle the lever again. A change will occur in the settings between 2 and 5.
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Description
the hoist system is not installed, a hoist lever that will not function, no diagnostics will
be logged on the hoist lever or the solenoids
the hoist system is installed and enabled (normal operation)
the hoist system is installed but disabled (default), solenoids and the hoist lever have
diagnostics, but the hoist lever is ignored and the solenoids are kept in hold
2. Disconnect ET and then reconnect the line when the Hoist Enable Status does not appear on the configuration
screen. The hoist enable parameter flexes with the 3.0 ET Software when the parameter connects. On
occasion, ET misses the flexed parameters at connection time.
Note: 3.1 ET Software has this parameter standard on the configuration screen.
3. If the Hoist Enable Status does not change, check the following:
The engine causes the TOS signal to fluctuate. This keeps the parameter from changing.
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the snub function will never cause the body to go down faster than the hoist lever modulation (operator's request).
The body snub function will be cancelled as the operator moves the hoist lever out of the body float position or the
body lower position. The body snub function will not start, until the body goes above the body up switch activation
level.
Seat Controls
1. Check the following adjustments:
The linear motion from the front to the rear is 150 mm (6 inch).
Adjust the weight for the suspension to the correct ride position.
Seat Belt
1. Adjust the seat belt to the proper length.
2. Fasten the seat belt buckle around the lap. The length of the belt may not slip.
3. The belt should unlatch.
Instrument Panel
1. Turn the ignition key to the ON position. This supplies the power to the electrical circuits in the cab. The
dome lights and the front window wipers can be checked.
1. Turn the key to the START position. This activates the starting motor. The diesel engine starts. After the
engine starts, release the key to the ON position.
2. Turn the ignition switch to the OFF position. The engine should stop. The electrical circuits in the cab should
de-energize. The instrument panel lights, the headlights, and the taillights remain on.
Climate Control
1. To pressurize the cab, perform the following steps:
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Turn the fan control switch to the LOW position or the HIGH position.
Check for air flow from the dash assembly and from the seat supports.
Running Lights
1. The ignition switch should be in the OFF position. Push the three position switch from the OFF position to the
middle position. The instrument panel lights and the taillights should be on.
2. Push the switch to the up position. The front headlights should be on.
Flood Lights
1. Turn the ignition key to the ON position.
2. Push the switch from the OFF position to the ON position. The flood lights should be on.
Auxiliary Floodlights
1. Turn the ignition key to the OFF position. Push the switch for the access ladder to the opposite direction. The
lamps for the access ladder should be on.
Check the switches in the cab and at ground level.
2. Push the switch for the engine compartment at ground level. The switch is in the bumper assembly. The lamps
in the engine compartment should be on.
Dome Lights
1. Turn the ignition key to the ON position.
2. Turn the switch for the dome light ON and OFF.
Cigar Lighter
1. Turn the ignition key to the ON position.
2. Push the cigar lighter inward. The cigar lighter should pop out.
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Machine Horns
The ignition switch should be in the OFF position. Press the horn. The horn should sound.
Machine Operation
1. Operate the machine for a minimum of 15 minutes. Operate the machine in all gears and perform steering
maneuvers. Perform braking operations. Operate the implement systems while you are operating the truck.
2. Correct any problems:
Harsh Braking
Jerky steering
Unusual noises
Cleanout Filter
Standard Filter
Qty
132-8875
132-8875
Power train
1R-0773
1R-0773
4T-6915
4T-6915
139-1536
1R-0772
343-4465
343-4465 (1)
1R-0741 (2)
Transmission Charge
343-4465
343-4465 (1)
1R-0778 (2)
Transmission Lubrication
132-8875
1R-0773
(1)
Recommended
(2)
Acceptable
Note: Some systems utilize the same part number for the cleanout filters and the standard filters but the filters still
need to be replaced after 8 hours.
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element after eight hours of machine operation. Failure to change to a service element may result in clogging
of the filter.
Replace the 343-4465 Oil Filter Elements with a 343-4465 Oil Filter Element or a 1R-0741 Oil Filter Element
Assembly .
Note: The 343-4465 Oil Filter Element is recommended for replacement, however the 1R-0741 Oil Filter Element
Assembly is also an acceptable replacement.
Note: The 343-4465 Oil Filter Element is for power train use only and not approved for hydraulic
applications.
Contamination is one of the major causes of transmission control system failure. Some power train oil systems were
cleaned with fine cleanout filters, which frequently caused oil to bypass the filter. The use of clean out filters in
power train oil systems is no longer recommended. A new line of advanced efficiency Caterpillar transmission
filters have been introduced for use in power train application.
Hoist Pump
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Steering Pressure
Transmission Pressures
Differential
Operational
Access Ladder
Engine Compartment
Check if the cab door opens. Check if the cab door closes.
Check if the Operation and Maintenance Manual is in the literature pouch on the back of the operator
seat.
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Check the test light. The test light is for the EMS.
Hoist
Steering Action
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8. Check if all clean-out filters have been replaced as specified by assembly procedure.
9. Check if all quality requirements are fulfilled. Check if all variances have been corrected.
13. Check if all required parts are shipped with the machine.
Hydraulic
Electrical
Structural
Other
15. Comments
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Predelivery Worksheet
Table 108
Date
Employee I.D.
Model
Serial Number
Hours
Inspector Name
Power Train
Steering and
Brakes
Visual
Inspection
_ Paint
_ Outside
Damage
_ Oil
_ Coolant
_ Fuel
_ Batteries OVC >
(12.45) _ VDC1 _
VDC2
_ Air Filters
_ Drain Water from
Fuel Tank
_ Drain Water
Separator
_ Open Coolant
conditioner Valves
_ Grease Fittings
_ Priming Pump
_ Governor Control
_ Air Compressor
_ Smoke Color
_ Unusual Noise
_ Air Cleaner
Indicator
_ V-Belt Tension
_ Leaks (Oil, Air,
Fuel, Coolant)
_ Friction on
Hoses
_ Friction on
Wires
_ Loose Wire
Connections
_ Loose or Lost
Fasteners
_ Paint
_ Outside
Damage
_ Tires - Cuts,
gouges
_ Transmission
_ Differential
_ Final Drives
_ Tire Pressure
_ Grease Fittings
_ Front & Rear Axle
Bolt Torques
_ Front & Rear
Universal Torques
_ Wheel to Rim
Torques
_ Leaks (Oil)
_ Loose or lost
Fasteners
_ Tires - Cuts,
Gouges
_ Paint
_ Outside
Damage
_ Brake Fluid
_ Drain Water from
Air Tank
_ Grease Fittings
_ Steering
_ Retarder
_ Service Brakes
_ Parking Brakes
_ Air Dryer
_ Unusual Noise
Operation
After Operation
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Chassis
_ Sheet Metal
_ Paint
_ Damage
_ Loose or Lost
Fasteners
_ Welds
hydraulic
_ Controls
_ Too much Drift
_ Unusual Noise
_ Leaks - Oil
_ Friction or Lost
Fasteners
Truck Body
_ Paint
_ Damage
_ Liners
_ Grease Fittings
_ Body Pads
_ Retention Cable
_ Body Positions
_ Welds
_ Loose or Lost
Fasteners
_ Damage
_ Disconnect Switch
_ VIMS
_ Hoist Control
_ Horn
_Seat Belts
_ Seat Adjustments
_ All Switches & Controls
_ Doors and Windows
_ Locks and Latches
_ Mirror Adjustment
_ Front Window Wipers
_ Window Washers
_ Heater
_ (Air
Conditioner/Pressurizer)
Lights - Outside and Cab
_ Gauges
_ Unusual Noise
_ Steering Column
Adjustment
_ Attachments
_ Engine Shutdown Switch
_ Test Switch for Fire
Suppression
_ Grease Fittings
Cab
_ Sheet Metal
_ Paint
_ Glass
_ Front Window
Washer
_ Air Filters
_ Grease Fittings
_ Torque on ROPS
Support
Misc. and
Attachments
_ Special
Assembly Parts
_ S/N Plates
_ Correct
Attachments
_ Hand Tools
_ Paint
_ Attachment Fluid
Levels
_ Charge for Fire
Suppression System
_ Grease Fittings
_ Automatic
Lubrication System
(1)
If the machine was in storage, lubricate the engine before starting the engine.
(2)
_ Operation Guide
_ Maintenance
Guide
_ Parts Book
_ Seat Cover
_ Steps & Grab
Irons
_ Loose or Lost
Fasteners
_ Loose Wire
Connections
_ Leaks - Water
_ Warning Plates
_ Decals
_ Leaks
_ Loose or Lost
Fasteners
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