- Off-Highway Truck:
- 785 (S/N: 8GB244-UP)
- 785B (S/N: 6HK1-UP)
Introduction
This Special Instruction provides the procedure in order to complete a Caterpillar Certified Rebuild Upgrade (CCRU) on a 785 or 785B Off-Highway Truck. The CCRU procedure involves upgrading a 785 or 785B to include the improved functionality of a 785C while rebuilding the machine per the Caterpillar Certified Rebuild (CCR) process. The upgrade includes a 3512B engine with Tier 1 emissions and VIMS electronics
Reference Disassembly and Assembly Manual, Parts Manual, and Operation and Maintenance Manual.
Registering CCRU Machines
Register the machine for CCRU via the standard CCR registration process.
Required Parts
Note: The required parts are subject to some change. Refer to TMI for the most recent required parts list.
Note: If you are required to fabricate a part, ensure that all fabricated parts are deburred. Use caution when deburring parts. Avoid excessive grinding and notches.
Required Parts     | ||
Sales Model     | Arrangement     | Engine     |
785     | 446-9422     | 373-9862 Engine Ar (1) 10R-6700 Engine Ar (2)     |
785B     | 446-9423     |
( 1 ) | New engine |
( 2 ) | Reman engine |
Component Upgrades
When performing the CCRU, some components may be reused after performing required updates detailed below, including the frame and other major structures. Replace any components that are not reworked per the instructions below or do not pass reusability guidelines to fulfill 785C parts list. Additional components may be reusable depending on specific machine build configuration and/or service parts. Serviceable part numbers not common with the 785C CCR parts list are not acceptable for reuse unless specified in the upgrade instructions below. Refer to 785C CCR Documentation REYD1846 and Parts Book CCRC3021.
Refer to the CCRU website. The link to the website is:
https://dealer.cat.com/cda/layout?m=20009&x=7Note: Update instructions cover all 785 8GB and 785B 6HK machines, later machines may already include some of the required component updates listed below. Compare as-built configuration (not latest service part) to 785C parts list.
Frame Upgrade
Recondition the machine frame per CCR documentation. Update clipping and mounting hardware per the prints below to fulfill 171-7851 Frame As and 7I-5073 Tube As . Most original mounting hardware will be reused, but remove original mounting hardware that interferes with attachment of new mounting hardware. Refer to the following documentation for frame reconditioning:
- Special Instruction, REHS0452, "Weld Repair Procedure for Field Retrofit of Large Off-Highway Truck Frame Superstructure"
- Reuse And Salvage Guidelines, SEBF8879, "Repair/Replace Large OHT Body Pivot Bores and Suspension Bores"
- Special Instruction, REHS0541, "Procedure for the Inspection, Repair, and Component Replacement on the Frames of Certain Off-Highway Trucks and Tractors"
Fabricated Frame Parts
Illustration 1 | g03397185 |
3V-0966 Bar |
ASTM A36
SAE Grades 1008 through 1025
Illustration 2 | g03382461 |
6S-4806 Lug |
ASTM A36
SAE Grades 1008 through 1025
Illustration 3 | g03382474 |
7G-7118 Plate |
ASTM A36
SAE Grades 1008 through 1025
Illustration 4 | g03397183 |
7T-2406 Boss |
ASTM A36
SAE Grades 1008 through 1025
Illustration 5 | g03382495 |
8S-0349 Strip |
ASTM A36
SAE Grades 1008 through 1025
Illustration 6 | g03397188 |
8W-2844 Block |
ASTM A108 Grade 1018
ASTM A576 Grade 1018
ASTM A36/A36M
AS/NZS 1442 Grade 1020 and 1022
AS/NZS 3678 Grade 250
AS/NZS 3679.1 Grade 250 and 300
Illustration 7 | g03382431 |
8X-6083 Block |
ASTM A108 Grade 1018
ASTM A576 Grade 1018
ASTM A36/A36M
AS/NZS 1442 Grade 1020 and 1022
AS/NZS 3678 Grade 250
AS/NZS 3679.1 Grade 250 and 300
Illustration 8 | g03397598 |
103-5702 Plate As (1) 1F-0748 Weld Nut |
Cold Rolled Strip: ASTM A109/A109M - Temper No. 4 or 5
Cold Rolled Sheet: ASTM A1008/A1008M - Designations CS (Grade A, B, or C) and DS (Grade A or B)
Hot Rolled Sheet: ASTM A1011/A1011M - Designations CS (Grade A, B, or C) and DS (Grade A or B)
Heavy Thickness Coils: ASTM A1018/A1018M - Designations CS (Grade A, B, 1007, 1008, 1009, 1010, or 1012), and DS (Grade A, B, 1006, or 1006A)
Hot Rolled Sheet: ASTM A1011/A1011M - Designation CS (Grade D) ASTM A510/A510M - Grades SAE 1006, 1008, 1010, and 1012
Illustration 9 | g03397784 |
Plate 1 |
Illustration 10 | g03397785 |
Plate 2 |
Illustration 11 | g03397192 |
114-8129 Bracket As (2) Plate 1 (3) Plate 2 (4) 1F-0750 Weld Nuts (5) 9F-6445 Weld Nuts |
Illustration 12 | g03397268 |
159-8644 Plate |
ASTM A36
SAE Grades 1008 through 1025
Illustration 13 | g03397269 |
159-8645 Plate |
ASTM A36
SAE Grades 1008 through 1025
Illustration 14 | g03397271 |
159-8646 Plate |
ASTM A36
SAE Grades 1008 through 1025
Illustration 15 | g03397196 |
159-8643 Plate As (6) 159-8644 Plate (7) 159-8645 Plate (8) 159-8646 Plate |
Illustration 16 | g03397275 |
2H-1795 Plate |
ASTM A36
SAE Grades 1008 through 1025
Illustration 17 | g03397278 |
5P-2330 Gusset |
ASTM A36
SAE Grades 1008 through 1025
Illustration 18 | g03397279 |
171-7690 Plate |
ASTM A36
SAE Grades 1008 through 1025
Illustration 19 | g03397198 |
174-4318 Support As (4) 1F-0750 Weld Nuts (9) 2H-1795 Plate (10) 5P-2330 Gusset (11) 171-7690 Support As |
Illustration 20 | g03397283 |
142-5746 Gusset |
ASTM A36
SAE Grades 1008 through 1025
Illustration 21 | g03397285 |
171-0800 Support |
Cold Rolled Strip: ASTM A109/A109M - Temper No. 4 or 5
Cold Rolled Sheet: ASTM A1008/A1008M - Designations CS (Grade A, B, or C) and DS (Grade A or B)
Hot Rolled Sheet: ASTM A1011/A1011M - Designations CS (Grade A, B, or C) and DS (Grade A or B)
Heavy Thickness Coils: ASTM A1018/A1018M - Designations CS (Grade A, B, 1007, 1008, 1009, 1010, or 1012), and DS (Grade A, B, 1006, or 1006A)
Hot Rolled Sheet: ASTM A1011/A1011M - Designation CS (Grade D) ASTM A510/A510M - Grades SAE 1006, 1008, 1010, and 1012
Illustration 22 | g03397286 |
185-2295 Block |
ASTM A108 Grade 1018
ASTM A576 Grade 1018
ASTM A36/A36M
AS/NZS 1442 Grade 1020 and 1022
AS/NZS 3678 Grade 250
AS/NZS 3679.1 Grade 250 and 300
Illustration 23 | g03397200 |
178-3068 Support As (12) 142-5746 Gusset (13) 171-0800 Support (14) 185-2295 Block (15) 8D-3508 Boss |
Illustration 24 | g03414660 |
210-8624 Plate |
ASTM A36
SAE Grades 1008 through 1025
Illustration 25 | g03397201 |
231-8820 Plate |
ASTM A36
SAE Grades 1008 through 1025
Illustration 26 | g03382481 |
240-8944 Plate |
ASTM A36
SAE Grades 1008 through 1025
Illustration 27 | g03382485 |
296-6845 Plate |
ASTM A36
SAE Grades 1008 through 1025
Illustration 28 | g03397205 |
365-6190 Plate |
ASTM A36
SAE Grades 1008 through 1025
Illustration 29 | g03382836 |
391-2902 Plate |
ASTM A108 Grade 1018
ASTM A576 Grade 1018
ASTM A36/A36M
AS/NZS 1442 Grade 1020 and 1022
AS/NZS 3678 Grade 250
AS/NZS 3679.1 Grade 250 and 300
Illustration 30 | g03397208 |
391-2900 Plate As (16) 391-2902 Plate (17) 8T-5912 Weld Nut |
Illustration 31 | g03397220 |
432-2651 Plate |
ASTM A656/A656M Grade 50
ASTM A1011/A1011M Grade 45, Grade SS 50, HSLAS 50 and HSLAS-F 50
ASTM A572 Grade 42 and Grade 50
ASTM A1018/A1018M Grade HSLAS 45/50 and HSLAS-F 50
AS 3678 Grade 350
AS 3679 Grade 350
Illustration 32 | g03397209 |
432-2650 Plate As (18) 432-2651 Plate (19) 8T-5911 Weld Nuts |
Illustration 33 | g03397221 |
439-1754 Plate |
ASTM A656/A656M Grade 80
Illustration 34 | g03397263 |
103-2003 Boss |
ASTM A36
SAE Grades 1008 through 1025
Illustration 35 | g03397265 |
439-2607 Gusset |
ASTM A656/A656M Grade 50
ASTM A1011/A1011M Grade 45, Grade SS 50, HSLAS 50 and HSLAS-F 50
ASTM A572 Grade 42 and Grade 50
ASTM A1018/A1018M Grade HSLAS 45/50 and HSLAS-F 50
AS 3678 Grade 350
AS 3679 Grade 350
Illustration 36 | g03397223 |
439-1755 Plate As (15) 8D-3508 Boss (20) 439-1754 Plate (21) 103-2003 Boss (22) 439-2607 Gusset |
Illustration 37 | g03397225 |
100-4750 Block |
ASTM A36
SAE Grades 1008 through 1025
Illustration 38 | g03397231 |
2A-7041 Plate |
ASTM A656/A656M Grade 50
ASTM A1011/A1011M Grade 45, Grade SS 50, HSLAS 50 and HSLAS-F 50
ASTM A572 Grade 42 and Grade 50
ASTM A1018/A1018M Grade HSLAS 45/50 and HSLAS-F 50
AS 3678 Grade 350
AS 3679 Grade 350
Illustration 39 | g03397235 |
3G-9123 Block |
ASTM A36
SAE Grades 1008 through 1025
Illustration 40 | g03397236 |
5C-6406 Bar |
ASTM A36
SAE Grades 1008 through 1025
Illustration 41 | g03397246 |
5T-6229 Block |
ASTM A108 Grade 1018
ASTM A576 Grade 1018
ASTM A36/A36M
AS/NZS 1442 Grade 1020 and 1022
AS/NZS 3678 Grade 250
AS/NZS 3679.1 Grade 250 and 300
Illustration 42 | g03397247 |
5T-7927 Block |
ASTM A36
SAE Grades 1008 through 1025
Illustration 43 | g03397249 |
6G-5095 Block |
ASTM A108 Grade 1018
ASTM A576 Grade 1018
ASTM A36/A36M
AS/NZS 1442 Grade 1020 and 1022
AS/NZS 3678 Grade 250
AS/NZS 3679.1 Grade 250 and 300
Illustration 44 | g03397250 |
6W-0484 Angle |
Cold Rolled Strip: ASTM A109/A109M - Temper No. 4 or 5
Cold Rolled Sheet: ASTM A1008/A1008M - Designations CS (Grade A, B, or C) and DS (Grade A or B)
Hot Rolled Sheet: ASTM A1011/A1011M - Designations CS (Grade A, B, or C) and DS (Grade A or B)
Heavy Thickness Coils: ASTM A1018/A1018M - Designations CS (Grade A, B, 1007, 1008, 1009, 1010, or 1012), and DS (Grade A, B, 1006, or 1006A)
Hot Rolled Sheet: ASTM A1011/A1011M - Designation CS (Grade D) ASTM A510/A510M - Grades SAE 1006, 1008, 1010, and 1012
Illustration 45 | g03382475 |
7G-8263 Plate |
ASTM A36
SAE Grades 1008 through 1025
Illustration 46 | g03405558 |
7I-5073 Tube As |
Frame Upgrades
Illustration 47 | g03412716 |
Rear left-hand view of the frame (14) 150-3980 Bar (24) 296-6845 Plate (50) 8P-8308 Plate (52) 9D-5568 Boss (54) 9D-5659 Boss |
Illustration 48 | g03412717 |
Front left-hand view of the frame (31) 038-2091 Bar (52) 9D-5568 Boss (54) 9D-5659 Boss (56) 9D-6168 Boss |
Illustration 49 | g03412718 |
Front right-hand view of the frame (28) 391-2900 Plate As (30) 439-1755 Plate As (38) 5B-1983 Boss (40) 5H-9394 Boss (52) 9D-5568 Boss (54) 9D-5659 Boss |
Illustration 50 | g03412719 |
Rear right-hand view of the frame (6) 8W-2844 Block (47) 8D-3508 Boss (54) 9D-5659 Boss |
Illustration 51 | g03412721 |
Top view of the frame (3) 7G-7118 Plate (12) 114-8129 Bracket As (29) 432-2650 Plate As (53) 9D-5571 Boss (54) 9D-5659 Boss (55) 9D-6166 Boss |
Illustration 52 | g03413257 |
Top view of the frame (10) 103-4393 Bracket (13) 135-7459 Plate (32) 100-4750 Block (54) 9D-5659 Boss (56) 9D-6168 Boss |
Illustration 53 | g03413627 |
Top view of the bumper (43) 5V-5790 Block (54) 9D-5659 Boss (55) 9D-6166 Boss |
Illustration 54 | g03412722 |
Top view of the frame (2) 6S-4806 Lug (8) 9D-3446 Step (9) 9G-0028 Boss As (18) 178-3068 Support As (38) 5B-1983 Boss (54) 9D-5659 Boss (55) 9D-6166 Boss (56) 9D-6168 Boss |
Illustration 55 | g03412723 |
Front view of strut area (7) 8X-6083 Block (27) 386-3002 Support As (33) 138-1219 Collar (34) 2A-7041 Plate (41) 5T-6229 Block (51) 9D-5567 Boss (52) 9D-5568 Boss (53) 9D-5571 Boss (54) 9D-5659 Boss (56) 9D-6168 Boss |
Illustration 56 | g03414286 |
Front view of strut area (52) 9D-5568 Boss (54) 9D-5659 Boss (56) 9D-6168 Boss |
Illustration 57 | g03412725 |
Front left-hand view (31) 038-2091 Bar (42) 5T-7927 Block (51) 9D-5567 Boss (52) 9D-5568 Boss (54) 9D-5659 Boss (55) 9D-6166 Boss (56) 9D-6168 Boss |
Illustration 58 | g03413828 |
Front right-hand view (51) 9D-5567 Boss (54) 9D-5659 Boss (55) 9D-6166 Boss (56) 9D-6168 Boss |
Illustration 59 | g03413829 |
Front view (55) 9D-6166 Boss |
Illustration 60 | g03412727 |
Inside left-hand frame view (47) 8D-3508 Boss (51) 9D-5567 Boss (54) 9D-5659 Boss (55) 9D-6166 Boss (56) 9D-6168 Boss |
Illustration 61 | g03413831 |
Inside left-hand frame view (9) 9G-0028 Boss As (22) 257-6883 Plate (54) 9D-5659 Boss (55) 9D-6166 Boss (56) 9D-6168 Boss |
Illustration 62 | g03412729 |
Inside left-hand rail (5) 8S-0349 Strip (9) 9G-0028 Boss As (19) 210-8624 Plate (54) 9D-5659 Boss (55) 9D-6166 Boss (56) 9D-6168 Boss |
Illustration 63 | g03413911 |
Inside left-hand rail (21) 240-8944 Plate (54) 9D-5659 Boss (55) 9D-6166 Boss (56) 9D-6168 Boss |
Illustration 64 | g03412730 |
Inside right-hand rail (16) 171-7851 Frame As (54) 9D-5659 Boss (55) 9D-6166 Boss |
Illustration 65 | g03414186 |
Inside right-hand rail (54) 9D-5659 Boss |
Illustration 66 | g03412732 |
Inside right-hand frame view (4) 7T-2406 Boss (9) 9G-0028 Boss As (17) 174-4318 Support As (23) 258-7114 Plate As (39) 5C-6406 Bar (46) 7G-8263 Plate |
Illustration 67 | g03414234 |
Inside right-hand frame view (45) 6W-0484 Angle (54) 9D-5659 Boss |
Illustration 68 | g03414236 |
Inside right-hand frame view (6) 8W-2844 Block (54) 9D-5659 Boss |
Frame Support Upgrade
Illustration 69 | g03405461 |
127-0960 Boss |
Carbon Steel, MIN 3:1 rolling reduction ratio
Illustration 70 | g03405517 |
8W-4590 Plate |
ASTM A36
SAE Grades 1008 through 1025
Illustration 71 | g03405464 |
142-5747 Plate |
ASTM A36
SAE Grades 1008 through 1025
Illustration 72 | g03405465 |
171-7692 Plate |
ASTM A108 Grade 1018
ASTM A576 Grade 1018
ASTM A36/A36M
AS/NZS 1442 Grade 1020 and 1022
AS/NZS 3678 Grade 250
AS/NZS 3679.1 Grade 250 and 300
Illustration 73 | g03414583 |
171-7691 Support As (1) 127-0960 Boss (2) 8D-3508 Boss (3) 1F-0748 Weld Nut (4) 3R-4850 Block (5) 8F-9836 Boss (6) 142-5747 Plate (7) 171-7692 Plate |
Illustration 74 | g03414592 |
171-7691 Support As (8) 9F-6445 Weld Nuts (9) 1F-0750 Weld Nuts (10) 3H-4776 Boss (11) 8W-4590 Plate (12) 9F-2978 Weld Nut |
Rear Axle Housing Upgrade
ReferenceSpecial Instruction, REHS6075, "Procedure to Install the Rear Axle Lubrication Filter Retrofit Kit on the 785C and the 789C Off-Highway Trucks"
Recondition the rear axle housing and support per CCR documentation. Update mounting hardware, add cooling and filtration functionality to the rear axle housing per the prints below to fulfill 310-8650 Rear Axle Housing As and 8X-8919 Support As .Refer to Special Instruction, SEHS9984, "Special Instruction For Rear Axle Lubrication, Cooling And Filtration Retrofit For 785 And 785B Off-Highway Trucks" for additional rework instructions. Rear axle filtration retrofit kit is required. Refer to IRM PELJ1406 "Rear Axle Filtration Retrofit Kit for 785C and 789C Off-Highway Trucks for alternate filter mounting option.
Rear Axle Fabricated Parts
Illustration 75 | g03407035 |
142-5694 Block |
ASTM A36
SAE Grades 1008 through 1025
Illustration 76 | g03407037 |
149-9899 Bracket |
ASTM A36
SAE Grades 1008 through 1025
Illustration 77 | g03407038 |
Plate 0007 |
ASTM A108 Grade 1018
ASTM A576 Grade 1018
ASTM A36/A36M
AS/NZS 1442 Grade 1020 and 1022
AS/NZS 3678 Grade 250
AS/NZS 3679.1 Grade 250 and 300
Illustration 78 | g03407039 |
Plate 0008 |
ASTM A108 Grade 1018
ASTM A576 Grade 1018
ASTM A36/A36M
AS/NZS 1442 Grade 1020 and 1022
AS/NZS 3678 Grade 250
AS/NZS 3679.1 Grade 250 and 300
Illustration 79 | g03407130 |
Plate 0009 |
ASTM A108 Grade 1018
ASTM A576 Grade 1018
ASTM A36/A36M
AS/NZS 1442 Grade 1020 and 1022
AS/NZS 3678 Grade 250
AS/NZS 3679.1 Grade 250 and 300
Illustration 80 | g03407131 |
Plate 0010 |
ASTM A108 Grade 1018
ASTM A576 Grade 1018
ASTM A36/A36M
AS/NZS 1442 Grade 1020 and 1022
AS/NZS 3678 Grade 250
AS/NZS 3679.1 Grade 250 and 300
Illustration 81 | g03407132 |
Plate 0004 |
ASTM A108 Grade 1018
ASTM A576 Grade 1018
ASTM A36/A36M
AS/NZS 1442 Grade 1020 and 1022
AS/NZS 3678 Grade 250
AS/NZS 3679.1 Grade 250 and 300
Rear Axle Upgrade
Illustration 82 | g03407146 |
Rear view |
Illustration 83 | g03407765 |
side view |
Illustration 84 | g03407766 |
Detail A |
Illustration 85 | g03407775 |
Detail B |
Illustration 86 | g03407776 |
Section C-C |
Illustration 87 | g03407777 |
Section D-D |
Fabricated Rear Axle Support Parts
Illustration 88 | g03407795 |
(1) 5T-7553 Block (2) 8X-5951 Bracket As (3) 328-9070 Bracket As (4) 351-2804 Bracket As (5) 355-5216 Plate (6) 355-5217 Plate (7) 109-2979 Boss (8) 4D-6293 Boss (9) 5H-9394 Boss (10) 6J-9944 Lug (11) 7J-7778 Lug (12) 8D-3508 Boss (13) 9V-8296 Block |
Illustration 89 | g03408604 |
8X-8919 view A-A (3) 328-9070 Bracket As (14) 8W-2837 Block |
Illustration 90 | g03411317 |
(12) 8D-3508 Boss |
Illustration 91 | g03414694 |
5T-7553 Block |
ASTM A108 Grade 1018
ASTM A576 Grade 1018
ASTM A36/A36M
AS/NZS 1442 Grade 1020 and 1022
AS/NZS 3678 Grade 250
AS/NZS 3679.1 Grade 250 and 300
Illustration 92 | g03408960 |
8W-2837 Block |
ASTM A108 Grade 1018
ASTM A576 Grade 1018
ASTM A36/A36M
AS/NZS 1442 Grade 1020 and 1022
AS/NZS 3678 Grade 250
AS/NZS 3679.1 Grade 250 and 300
Illustration 93 | g03408961 |
9V-8296 Block |
ASTM A36
SAE Grades 1008 through 1025
Illustration 94 | g03408974 |
109-2979 Boss |
ASTM A108 Grade 1018
ASTM A576 Grade 1018
ASTM A36/A36M
AS/NZS 1442 Grade 1020 and 1022
AS/NZS 3678 Grade 250
AS/NZS 3679.1 Grade 250 and 300
Illustration 95 | g03395206 |
4E-2543 Bracket |
ASTM A36
SAE Grades 1008 through 1025
Illustration 96 | g03408975 |
328-9070 Bracket As (15) 4E-2543 Bracket (16) 8T-3490 Weld Nut |
Illustration 97 | g03408979 |
351-2803 Bracket |
Cold Rolled Strip: ASTM A109/A109M - Temper No. 4 or 5
Cold Rolled Sheet: ASTM A1008/A1008M - Designations CS (Grade A, B, or C) and DS (Grade A or B)
Hot Rolled Sheet: ASTM A1011/A1011M - Designations CS (Grade A, B, or C) and DS (Grade A or B)
Heavy Thickness Coils: ASTM A1018/A1018M - Designations CS (Grade A, B, 1007, 1008, 1009, 1010, or 1012), and DS (Grade A, B, 1006, or 1006A)
Hot Rolled Sheet: ASTM A1011/A1011M - Designation CS (Grade D) ASTM A510/A510M - Grades SAE 1006, 1008, 1010, and 1012
Illustration 98 | g03408977 |
351-2804 Bracket As (16) 8T-3490 Weld Nut (17) 351-2803 Bracket |
Illustration 99 | g03395228 |
355-5216 Plate |
Cold Rolled Strip: ASTM A109/A109M - Temper No. 4 or 5
Cold Rolled Sheet: ASTM A1008/A1008M - Designations CS (Grade A, B, or C) and DS (Grade A or B)
Hot Rolled Sheet: ASTM A1011/A1011M - Designations CS (Grade A, B, or C) and DS (Grade A or B)
Heavy Thickness Coils: ASTM A1018/A1018M - Designations CS (Grade A, B, 1007, 1008, 1009, 1010, or 1012), and DS (Grade A, B, 1006, or 1006A)
Hot Rolled Sheet: ASTM A1011/A1011M - Designation CS (Grade D) ASTM A510/A510M - Grades SAE 1006, 1008, 1010, and 1012
Illustration 100 | g03395243 |
355-5217 Plate |
Cold Rolled Strip: ASTM A109/A109M - Temper No. 4 or 5
Cold Rolled Sheet: ASTM A1008/A1008M - Designations CS (Grade A, B, or C) and DS (Grade A or B)
Hot Rolled Sheet: ASTM A1011/A1011M - Designations CS (Grade A, B, or C) and DS (Grade A or B)
Heavy Thickness Coils: ASTM A1018/A1018M - Designations CS (Grade A, B, 1007, 1008, 1009, 1010, or 1012), and DS (Grade A, B, 1006, or 1006A)
Hot Rolled Sheet: ASTM A1011/A1011M - Designation CS (Grade D) ASTM A510/A510M - Grades SAE 1006, 1008, 1010, and 1012
Hydraulic Upgrade
Recondition the main hydraulic tank per CCR documentation and complete modifications per the prints below to fulfill 161-0537 Tank and 105-2496 Cover .
Hydraulic Tank Upgrades
Illustration 101 | g03395276 |
(1) 161-0540 Plate (2) 166-8629 Plate As |
Illustration 102 | g03408411 |
Block 1 |
ASTM A36
SAE Grades 1008 through 1025
Illustration 103 | g03408413 |
Plate 1 |
ASTM A36
SAE Grades 1008 through 1025
Illustration 104 | g03408415 |
Plate 2 |
ASTM A36
SAE Grades 1008 through 1025
Illustration 105 | g03388582 |
(3) Block 1 (4) Plate 1 (5) Plate 2 |
Illustration 106 | g03410455 |
105-2496 Cover |
Steering Tank Upgrade
Recondition the steering tank and cover per CCR documentation and complete modifications per the prints below to fulfill 167-8106 Hydraulic Tank As and 155-4128 Cover As .
Illustration 107 | g03405973 |
155-4128 Cover As (1) 5J-3306 Fitting (2) 6J-4022 Fitting (3) 9R-2613 Weld Boss |
Illustration 108 | g03405991 |
Side view of the 167-8106 Hydraulic Tank As (4) 4J-5050 Boss |
Illustration 109 | g03405993 |
Front view of the 167-8106 Hydraulic Tank As (5) 8T-6462 Weld Boss |
Hood Upgrade
Recondition hood panel per CCR documentation and complete modifications per the print below to fulfill 163-0932 Hood As .
Illustration 110 | g03408983 |
163-0932 Hood As (1) 161-4162 Plate (2) 290-2349 Plate (3) 310-1504 Channel (4) 314-8013 Channel (5) 1F-0748 Weld Nuts (6) 9F-2978 Weld Nuts |
Fabricated Hood Parts
Illustration 111 | g03408982 |
290-2351 Channel |
Cold Rolled Strip: ASTM A109/A109M - Temper No. 4 or 5
Cold Rolled Sheet: ASTM A1008/A1008M - Designations CS (Grade A, B, or C) and DS (Grade A or B)
Hot Rolled Sheet: ASTM A1011/A1011M - Designations CS (Grade A, B, or C) and DS (Grade A or B)
Heavy Thickness Coils: ASTM A1018/A1018M - Designations CS (Grade A, B, 1007, 1008, 1009, 1010, or 1012), and DS (Grade A, B, 1006, or 1006A)
Hot Rolled Sheet: ASTM A1011/A1011M - Designation CS (Grade D) ASTM A510/A510M - Grades SAE 1006, 1008, 1010, and 1012
Illustration 112 | g03410585 |
310-1504 Channel |
Cold Rolled Strip: ASTM A109/A109M - Temper No. 4 or 5
Cold Rolled Sheet: ASTM A1008/A1008M - Designations CS (Grade A, B, or C) and DS (Grade A or B)
Hot Rolled Sheet: ASTM A1011/A1011M - Designations CS (Grade A, B, or C) and DS (Grade A or B)
Heavy Thickness Coils: ASTM A1018/A1018M - Designations CS (Grade A, B, 1007, 1008, 1009, 1010, or 1012), and DS (Grade A, B, 1006, or 1006A)
Hot Rolled Sheet: ASTM A1011/A1011M - Designation CS (Grade D) ASTM A510/A510M - Grades SAE 1006, 1008, 1010, and 1012
Illustration 113 | g03410586 |
314-8013 Channel |
Cold Rolled Strip: ASTM A109/A109M - Temper No. 4 or 5
Cold Rolled Sheet: ASTM A1008/A1008M - Designations CS (Grade A, B, or C) and DS (Grade A or B)
Hot Rolled Sheet: ASTM A1011/A1011M - Designations CS (Grade A, B, or C) and DS (Grade A or B)
Heavy Thickness Coils: ASTM A1018/A1018M - Designations CS (Grade A, B, 1007, 1008, 1009, 1010, or 1012), and DS (Grade A, B, 1006, or 1006A)
Hot Rolled Sheet: ASTM A1011/A1011M - Designation CS (Grade D) ASTM A510/A510M - Grades SAE 1006, 1008, 1010, and 1012
Illustration 114 | g03410593 |
161-4162 Plate |
Cold Rolled Strip: ASTM A109/A109M - Temper No. 4 or 5
Cold Rolled Sheet: ASTM A1008/A1008M - Designations CS (Grade A, B, or C) and DS (Grade A or B)
Hot Rolled Sheet: ASTM A1011/A1011M - Designations CS (Grade A, B, or C) and DS (Grade A or B)
Heavy Thickness Coils: ASTM A1018/A1018M - Designations CS (Grade A, B, 1007, 1008, 1009, 1010, or 1012), and DS (Grade A, B, 1006, or 1006A)
Hot Rolled Sheet: ASTM A1011/A1011M - Designation CS (Grade D) ASTM A510/A510M - Grades SAE 1006, 1008, 1010, and 1012
Platform Upgrade
Recondition platform per CCR documentation and complete modifications per the prints below to fulfill 7I-5397 Support As .
Fabricated Platform Parts
Illustration 115 | g03410597 |
8W-0522 Channel |
Cold Rolled Strip: ASTM A109/A109M - Temper No. 4 or 5
Cold Rolled Sheet: ASTM A1008/A1008M - Designations CS (Grade A, B, or C) and DS (Grade A or B)
Hot Rolled Sheet: ASTM A1011/A1011M - Designations CS (Grade A, B, or C) and DS (Grade A or B)
Heavy Thickness Coils: ASTM A1018/A1018M - Designations CS (Grade A, B, 1007, 1008, 1009, 1010, or 1012), and DS (Grade A, B, 1006, or 1006A)
Hot Rolled Sheet: ASTM A1011/A1011M - Designation CS (Grade D) ASTM A510/A510M - Grades SAE 1006, 1008, 1010, and 1012
Illustration 116 | g03410599 |
8W-9619 Plate |
Cold Rolled Strip: ASTM A109/A109M - Temper No. 4 or 5
Cold Rolled Sheet: ASTM A1008/A1008M - Designations CS (Grade A, B, or C) and DS (Grade A or B)
Hot Rolled Sheet: ASTM A1011/A1011M - Designations CS (Grade A, B, or C) and DS (Grade A or B)
Heavy Thickness Coils: ASTM A1018/A1018M - Designations CS (Grade A, B, 1007, 1008, 1009, 1010, or 1012), and DS (Grade A, B, 1006, or 1006A)
Hot Rolled Sheet: ASTM A1011/A1011M - Designation CS (Grade D) ASTM A510/A510M - Grades SAE 1006, 1008, 1010, and 1012
Illustration 117 | g03407033 |
173-6564 Plate |
Cold Rolled Strip: ASTM A109/A109M - Temper No. 4 or 5
Cold Rolled Sheet: ASTM A1008/A1008M - Designations CS (Grade A, B, or C) and DS (Grade A or B)
Hot Rolled Sheet: ASTM A1011/A1011M - Designations CS (Grade A, B, or C) and DS (Grade A or B)
Heavy Thickness Coils: ASTM A1018/A1018M - Designations CS (Grade A, B, 1007, 1008, 1009, 1010, or 1012), and DS (Grade A, B, 1006, or 1006A)
Hot Rolled Sheet: ASTM A1011/A1011M - Designation CS (Grade D) ASTM A510/A510M - Grades SAE 1006, 1008, 1010, and 1012
Illustration 118 | g03410601 |
387-7537 Plate |
ASTM A656/A656M Grade 50
ASTM A1011/A1011M Grade 45, Grade SS 50, HSLAS 50 and HSLAS-F 50
ASTM A572 Grade 42 and Grade 50
ASTM A1018/A1018M Grade HSLAS 45/50 and HSLAS-F 50
AS 3678 Grade 350
AS 3679 Grade 350
Other Components
Refer to the table below for additional parts that may be reused after reconditioning. Refer to reusability guidelines.
Illustration 119 | g03406043 |
300-2141 Fender As (1) 173-6564 Plate (2) 8X-7422 Boss |
Illustration 120 | g03406036 |
300-2141 Fender As (3) 4D-6293 Boss |
Illustration 121 | g03407033 |
173-6564 Plate |
Cold Rolled Strip: ASTM A109/A109M - Temper No. 4 or 5
Cold Rolled Sheet: ASTM A1008/A1008M - Designations CS (Grade A, B, or C) and DS (Grade A or B)
Hot Rolled Sheet: ASTM A1011/A1011M - Designations CS (Grade A, B, or C) and DS (Grade A or B)
Heavy Thickness Coils: ASTM A1018/A1018M - Designations CS (Grade A, B, 1007, 1008, 1009, 1010, or 1012), and DS (Grade A, B, 1006, or 1006A)
Hot Rolled Sheet: ASTM A1011/A1011M - Designation CS (Grade D) ASTM A510/A510M - Grades SAE 1006, 1008, 1010, and 1012
Reusable Parts
Reusable Parts List     | |
Qty     | Part Number     |
5T-3280 Service and Parking Brake Gp     | |
2     | 9D-6125 Adapters     |
16     | 0S-1588 Bolts     |
70     | 0S-1625 Bolts     |
66     | 2J-3505 Full Nuts     |
8     | 6M-9155 Pins     |
2     | 9D-7367 Pistons (1)     |
2     | 9D-7849 Pistons     |
4     | 9S-4190 O-Ring Plugs     |
10     | 5P-4282 Taperlock Studs     |
8X-8365 High Speed Oil Change Gp     | |
1     | 1P-7919 Male Coupler (1)     |
1     | 6B-8129 Pipe Nipple     |
1     | 002-5743 Elbow     |
1     | 030-7965 Elbow (1)     |
235-5741 Service Brake Control Gp     | |
1     | 2D-8910 Elbow     |
1     | 5T-9733 Bracket     |
1     | 7D-5208 Fitting     |
1     | 7D-5207 Plug     |
2     | 5M-6213 Pipe Plugs     |
5T-6942 Protection Cap Gp     | |
1     | 5T-0016 Transmission Cover     |
1     | 1L-5072 Dowel     |
1     | 9M-7394 Lever     |
6G-8390 Vandalism Protection Gp     | |
1     | 1L-5072 Dowel     |
1     | 9M-7394 Lever     |
1     | 5D-1901 Washer     |
9G-9288 Protection Cap Gp     | |
1     | 5D-1911 Hydraulic Cap Cover     |
1     | 1L-5072 Dowel     |
1     | 9M-7394 Lever     |
164-4884 Cowling Gp     | |
2     | 8w-3872 Guards     |
179-3492 Fender Gp     | |
1     | 8W-0571 Plate     |
1     | 8W-0568 Plate As     |
170-3597 Frame Gp     | |
4     | 1D-4586 Bolts     |
2     | 1D-4637 Bolts     |
8     | 2A-1538 Bolts     |
2     | 5T-1351 Brackets     |
1     | 5T-8945 Bracket As     |
1     | 5T-8963 Bracket As     |
1     | 5T-3462 Cover     |
3     | 5T-3190 Guards     |
5     | 5T-6321 Plates     |
4     | 5T-1353 Spacers     |
163-0931 Truck Hood Gp     | |
1     | 7P-8992 Handhold     |
1     | 5T-6399 Plate As     |
1     | 5T-4228 Rail As     |
4     | 8H-5305 Washers     |
144-4180 Air Horn Gp     | |
2     | 4M-5282 Bolts (1)     |
1     | 6V-8918 Bolt (1)     |
1     | 5D-7133 Bracket (1)     |
2     | 5D-7132 Clamps (1)     |
1     | 5D-6998 Air Horn Gp     |
1     | 4M-5280 Plated Full Nut (1)     |
2     | 6V-8185 Nuts (1)     |
1     | 8T-4224 Hard Washer (2)     |
187-1796 Ladder Gp     | |
1     | 5T-8066 Brace     |
1     | 5T-8245 Ladder As     |
1     | 5T-8217 Plate     |
1     | 5T-8269 Plate     |
2     | 5T-8218 Plate As     |
2     | 2S-1654 Washers     |
4     | 7X-0618 Hard Washers (1)     |
4     | 8T-4222 Plated Washers (1)     |
170-3603 Air Conditioner Lines Gp     | |
1     | 7X-3187 Bolt (1)     |
1     | 8T-8917 Bolt (1)     |
1     | 6V-1867 Clip     |
1     | 6V-1868 Clip     |
1     | 5P-4107 Washer (1)     |
1     | 5P-4106 Nut (1)     |
1     | 7X-0575 Hard Washer (1)     |
173-9469 Fuel Lines Gp     | |
1     | 9L-5254 Elbow     |
2     | 001-6301 Elbows     |
1     | 030-7965 Elbow (1)     |
5T-3218 Heater Lines Gp     | |
2     | 6P-8855 Tubes     |
6G-9260 Steering Link Gp     | |
2     | 0S-1756 Bolts (1)     |
1     | 9F-2247 Pipe Plug     |
6V-1970 Literature Gp     | |
1     | 7F-3400 Polyethylene Bag (2)     |
2     | 5P-8500 Keys     |
310-1730 Automatic Lubrication Gp     | |
1     | 5T-2125 Angle (1)     |
1     | 3B-7262 Pipe Nipple (1)     |
1     | 8W-3085 Plate (1)     |
163-7224 Cab Mounting Gp     | |
6     | 1D-4649 Bolts (1)     |
20     | 5T-5807 Retainers (1)     |
193-6347 Cab Mounting Gp     | |
22     | 1F-7464 Bolts     |
1     | 5T-7218 Support As     |
22     | 5P-8250 Washers     |
5T-4463 Hydraulic Tank Mounting Gp     | |
2     | 6G-5293 Caps     |
5T-3220 Platform Gp     | |
2     | 7F-5227 Bolts     |
1     | 5T-0087 Plate As     |
2     | 2G-8742 Hard Washers     |
6G-9270 Front Wheel Group     | |
24     | 0S-1595 Bolts     |
84     | 8X-2560 Studs (1)     |
6     | 8X-2561 Studs (1)     |
2     | 5T-6062 Covers     |
6     | 8W-3891 Flange Nuts (1)     |
84     | 2J-3507 Full Nuts (1)     |
2     | 8X-2634 Front Wheels (1)     |
365-4228 Chassis Wiring Gp     | |
1     | 5P-9617 Adapter (2)     |
1     | 6V-8918 Bolt (1)     |
137-6648 Ether Starting Aid Gp     | |
2     | 8T-4137 Bolts (1)     |
4     | 8T-4200 Bolts (1)     |
4W-4033 Refrigerant Condenser and Mounting Gp     | |
1     | 8N-7486 Condenser Assembly (1)     |
2     | 4W-4085 Plates (1)     |
175-5210 Engine Oil Filler Gp     | |
2     | 4H-7993 Clips     |
170-3577 Water Lines Gp     | |
1     | 6V-9872 Connector     |
2     | 9B-7237 Bolts (2)     |
1     | 2W-1389 Bonnet     |
2     | 2W-7390 Bracket As     |
3     | 6V-5040 Clips     |
3     | 6V-5039 Clips     |
1     | 2W-7393 Tube     |
170-3578 Water Lines Gp     | |
4     | 8T-4222 Washers (1)     |
7C-2655 Engine Support Gp (1)     | |
8     | 1B-7709 Bolts (1)     |
4     | 3B-2968 Bolts (1)     |
6     | 2N-5006 Bolts (1)     |
6     | 5P-8086 Bolts (1)     |
2     | 8W-0587 Caps (1)     |
4     | 2J-3506 Full Nuts (1)     |
2     | 3K-9770 Full Nuts (1)     |
8     | 4K-0367 Full Nuts (1)     |
2     | 7W-0659 Mounting Plates (1)     |
2     | 7W-3495 Sleeves (1)     |
2     | 4K-0684 Hard Washers (1)     |
16     | 5P-8247 Hard Washers (1)     |
8     | 5P-8248 Hard Washers (1)     |
6     | 5P-8250 Washers (1)     |
6     | 5P-8839 Hard Washers (1)     |
365-4229 Traction Control Gp     | |
1     | 8T-8917 Bolt (1)     |
235-5741 Service Brake Control Gp     | |
1     | 2D-8910 Elbow     |
2     | 9B-7237 Bolts (2)     |
1     | 5T-9733 Bracket     |
1     | 7D-5208 Fitting     |
1     | 7D-5207 Plug     |
2     | 5M-6213 Pipe Plugs     |
5T-6942 Protection Cap Gp     | |
1     | 5T-0016 Transmission Cover     |
1     | 9M-7394 Lever (2)     |
6G-8390 Vandalism Protection Gp     | |
1     | 9M-7394 Lever (2)     |
1     | 1M-8649 Retaining Ring     |
1     | 5D-1901 Washer     |
6G-9570 Steering Cylinder and Mounting Gp     | |
2     | 1U-3182 Steering Cylinder Gp     |
4     | 5T-6503 Plugs     |
309-9645 Hoist Cylinder and Mounting Gp     | |
2     | 6G-9691 Bars     |
6     | 1D-4615 Bolts     |
2     | 6G-8208 Covers     |
2     | 6G-8221 Retainers     |
4     | 6G-9696 Spacers     |
365-4240 Brake Lines Gp     | |
1     | 8W-3711 Bracket     |
1     | 5T-0965 Plate     |
1     | 5T-9053 Plate     |
365-4230 Service Brake Lines Gp     | |
1     | 8W-1767 Junction Block     |
2     | 4L-6459 Bolts     |
2     | 8W-4733 Brackets     |
2     | 8W-3406 Air/Hydraulic Cylinder Gp (2)     |
1     | 5T-1086 Plate     |
1     | 5T-1060 Brake Release Pump and Motor Gp     |
4     | 5M-1932 Taperlock Studs     |
170-3580 Hydraulic Oil Cooler Lines Gp     | |
4     | 5T-7492 Angles     |
1     | 8T-2441 Clip     |
1     | 8T-2442 Clip     |
8     | 6V-1543 Half Clamps     |
2     | 5T-6742 Elbows     |
1     | 8W-4043 Plate     |
2     | 3S-5468 Hoses     |
1     | 5T-6778 Manifold     |
2     | 5T-4675 Tube As     |
2     | 8W-4289 Tube As     |
176-6393 Steering Lines Gp     | |
2     | 8D-7296 Junction Blocks     |
2     | 1D-4707 Bolts     |
2     | 4F-5192 Bolts     |
2     | 5S-7383 Bolts (1)     |
1     | 2G-8874 Clamp     |
1     | 2G-8875 Clamp     |
1     | 6D-0837 Elbow     |
1     | 8W-5161 Manifold     |
365-4225 Torque Converter Filter and Lines Gp     | |
2     | 0T-0055 Bolts (2)     |
7     | 0T-0065 Bolts     |
4     | 1B-4367 Bolts     |
1     | 8L-5008 Pipe Elbow     |
1     | 8W-2692 Flange     |
1     | 3P-0348 Relief Valve Gp     |
1     | 3P-0349 Relief Valve Gp (1)     |
365-4234 Transmission Oil Lines Gp     | |
2     | 8W-2691 Angles     |
1     | 8T-8917 Bolt (1)     |
1     | 6V-1867 Clip     |
1     | 6V-1868 Clip     |
1     | 8W-0304 Manifold     |
1     | 8W-2612 Tube As     |
1     | 8W-2655 Tube As     |
6T-6148 Gear Pump and Drive Gp     | |
1     | 9G-9621 Oil Pump Drive Gear     |
1     | 6T-6147 Gear Pump Gp     |
309-9641 Hydraulic Pump and Mounting Gp     | |
1     | 2A-6546 Pump Drive Gp (1)     |
156-9341 Steering Tank and Filter Gp     | |
1     | 6V-0301 Adapter     |
5T-3230 Drive Shaft Guard Gp     | |
1     | 2A-7238 Guard As (1)     |
1     | 2A-7241 Guard As (1)     |
310-6715 Axle and Mounting Gp     | |
1     | 6G-6407 Axle Shaft     |
1     | 6G-6408 Axle Shaft     |
130-6634 Differential and Bevel Gear Gp     | |
1     | 6V-9001 Elbow     |
7     | 0T-0102 Bolts (1)     |
1     | 5T-5966 Bearing Cage     |
1     | 5T-5967 Bearing Cage     |
1     | 6V-0457 Bearing Cone     |
1     | 8M-3391 Cover     |
1     | 5T-8684 Differential Ring Gear     |
1     | 7D-3029 Thrust Pin     |
2     | 5T-5921 Plates     |
24     | 7D-3504 Taperlock Studs (1)     |
365-4223 Rear Axle Housing Gp     | |
6     | 0L-1178 Bolts     |
1     | 003-2143 Elbow     |
1     | 5T-5974 Plate     |
1     | 5T-5975 Plate As     |
365-4239 Service Brake Lines Gp     | |
2     | 8W-0222 Adapters     |
1     | 5T-9142 Block     |
4     | 5P-2566 Bolts     |
1     | 8T-8917 Bolt     |
4     | 4K-5175 Bolts     |
365-4224 Oil Cooler Lines Gp     | |
4     | 6G-7602 Manifolds     |
2     | 5T-0966 Plates     |
1     | 5T-4673 Tube As     |
1     | 5T-4674 Tube As     |
8W-4451 Pump Drive Shaft Gp     | |
8     | 0L-0478 Bolts     |
8X-0498 Drive Shaft Gp     | |
8     | 2N-2486 Bolts     |
365-4222 Axle Housing Support Gp     | |
6     | 1D-4626 Bolts (1)     |
20     | 2H-1618 Bolts (1)     |
1     | 8X-0573 Pin (1)     |
1     | 8X-0585 Plate (1)     |
1     | 8W-9826 Ring (1)     |
20     | 5T-1352 Spacers (2)     |
1     | 8X-0572 Thrust Washer (1)     |
( 1 ) | Only used on 785B |
( 2 ) | Only used on 785 |
Complete CCR
After updating the components listed above, perform a 785C CCR per the CCR documentation. Install retrofit 250-6900 Cab Ar and new engine 373-9862 Engine Ar or reman option 10R-6700 Engine Ar . Any components not updated and reconditioned must be fulfilled by new or remanufactured components to satisfy the 785C parts list. Refer to 785C CCR Documentation REYD1846 and Parts Book CCRC3021.
CCRU Identification
After completing the 785C CCR, apply machine model decals displaying the original machine model 785 or 785B. Install the CCRU Serial Number Plate with the issued CCRU serial number and Caterpillar Rebuild Upgrade Machine decals per the CCR decal application guidelines.