785G IV Off-Highway Truck Field Assembly Caterpillar

Parts and Specification Information

Illustration 1	g06163824

Illustration 2	g06163592

Illustration 3	g06163634

Illustration 4	g06163896

Note: Verify that all parts are shipped and undamaged for preparation of assembly. Missing or damaged parts can be ordered prior to assembly to avoid delays during assembly.

Installation Procedure

Start By:

1. Install the front suspension

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Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

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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.

Note: Remove all protective shipping covers, flanges, plugs, caps, clamps, cable straps, and material.

Note: Clean mounting and contact surfaces for major component installation free of wax, dirt, debris, paint, and grease.

Note: If necessary, chase unprotected threaded holes with an appropriately sized tap to remove paint, rust, or other debris.

Note: Unless otherwise specified, all torque requirements are Standard Torque values. Refer to the "General Information" section in this document for the correct torque values.

Note: Before tightening the cable straps (mounting hardware), remove the slack from the harness assembly(s) and allow adequate strain relief.

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Illustration 5	g06164649
(A) 4D-5768 Bolt (B) 2J-3505 Full Nut (C) 5P-8249 Hard Washer (D) 5T-0504 Washer (E) 5T-5947 Pin

1. Remove and retain bolt (A), nut (B), washer (C), two plates (D), and pin (E).
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   Illustration 6	g06164666

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   Illustration 7	g06164786
   (F) 456-8724 Rear Suspension Gp (T1) 1U-9202 Lever Puller Hoist Gp

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   NOTICE
   Before raising the rear struts, disconnect both of the rear strut sensors. Failure to disconnect the sensors may result in damage to the electrical connection of the sensor.

2. Attach a suitable lifting device onto rear suspension cylinder (F). Use the suitable lifting device to lift and rotate rear suspension cylinder (F). Use Tooling (T1) and a suitable lifting device to secure rear suspension cylinder (F) out of the way. The weight of rear suspension cylinder (F) is approximately 374 kg (825 lb). Repeat this step for the remaining rear suspension cylinder.
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   Illustration 8	g06164801
   (F) 456-8724 Rear Suspension Gp

3. Remove the suitable lifting device used to lift rear suspension cylinder (F). Repeat this step for the remaining rear suspension cylinder.
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   Illustration 9	g06164908

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   Illustration 10	g06164918
   (G) 2J-3507 Full Nut (H) 5P-8250 Washer (J) 208-8784 Plate

4. If it is necessary to adjust the angle of the transmission, remove and retain five nuts (G), five washers (H), and plate (J).. Repeat this step for the opposite side.

5. Install plate (J) at the desired position then install five washers (H), and five nuts (G). Repeat this step for the opposite side.
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   Illustration 11	g06165460
   (K) 8T-4139 Bolt (L) 8T-4223 Hard Washer (M) 372-7382 Guard As

6. Remove and retain two bolts (K), two washers (L), and guard assembly (M). Repeat this step for the opposite side.
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   Illustration 12	g06165468
   (N) 0L-1178 Bolt (P) 5P-8248 Hard Washer (R) 150-6310 Plate (S) 150-6308 Pin

7. Remove and retain four bolts (N), four washers (P), plate (R), and pin (S). Repeat this step for the opposite side.
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   Illustration 13	g06228689
   (T) 479-2171 Bolt As (V) 492-7238 Transmission Harness As (W) 8T-5005 Bolt (X) 8T-4121 Hard Washer (Y) 136-4992 Spacer (Z) 8T-1899 Clip (AA) 8T-1900 Clip (AB) 6V-1249 Grommet

8. Remove and retain two bolt assemblies (T), two bolts (W), two washers (X), two spacers (Y), clip (Z), clip (AA), and grommet (AB). Position harness assembly (V) out of the way.
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   Illustration 14	g06165822
   (AC) 8T-4136 Bolt (AD) 8T-4121 Hard Washer (AE) 394-0616 Plate As

9. Remove and retain five bolts (AC), five washers (AD), and plate assembly (AE).
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   Illustration 15	g06205952
   (AF) 216-4983 T Bolt Clamp (AG) 216-4983 T Bolt Clamp (AH) 6V-8519 Half Clamp (AJ) 3S-5468 Hose (AK) 3S-5468 Hose

10. Loosen four clamps (AF), four clamps (AG), and two clips (AH). Move hose (AJ) and (AK) out of the way.

    Note: Move hose (AJ) enough so that it does not interfere when installing the power train arrangement.

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    Illustration 16	g06165337

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    Illustration 17	g06165508

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    Illustration 18	g06205883

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    Illustration 19	g06165906
    (1) 416-5253 Power Train Ar (2) 5T-1352 Spacer (3) 2H-1618 Bolt (T2) 189-0408 Shackle As

11. Attach two of Tooling (T2) and suitable lifting devices onto power train arrangement (1). If necessary, attach an additional suitable lifting device onto the rear of power train arrangement (1) to be used to adjust the angle of the transmission.

12. Use Tooling (T2) and the suitable lifting device to move power train arrangement (1) into position under the frame. The weight of power train arrangement (1) is approximately 16783 kg (37000 lb).

13. Align the bolt pattern of power train arrangement (1) with the bolt pattern of the axle housing support. Install ten spacers (3) and ten bolts (2).

14. Install suitable cribbing to support the weight of power train arrangement (1). The weight of power train arrangement (1) is approximately 16783 kg (37000 lb).
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    Illustration 20	g06206136
    (AF) 216-4983 T Bolt Clamp (AJ) 3S-5468 Hose

15. Connect hose (AJ) and tighten four clamps (AF)
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    Illustration 21	g06165938
    ( A) 4D-5768 Bolt (B) 2J-3505 Full Nut (C) 5P-8249 Hard Washer (D) 5T-0504 Washer (E) 5T-5947 Pin (AL) 397-7413 Link Gp (T3) Loctite Graphite-50

16. Apply Tooling (T3) to the bearing bore of lateral control rod (AL) and pin (E). Attach a suitable lifting device onto lateral control rod (CC). The weight of lateral control rod (AL) is approximately 115 kg (254 lb).

17. Install pin (E), two washers (D), two hard washers (C), nut (B), and bolt (A).
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    Illustration 22	g06166318
    (F) 456-8724 Rear Suspension Gp (T1) 1U-9202 Lever Puller Hoist Gp

18. Attach a suitable lifting device onto rear suspension cylinder (F). Disconnect and remove Tooling (T1). Use the suitable lifting device to lower and rotate rear suspension cylinder (F). The weight of rear suspension cylinder (F) is approximately 374 kg (825 lb). Repeat this step for the remaining rear suspension cylinder.
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    Illustration 23	g06166362
    (F) 456-8724 Rear Suspension Gp (N) 0L-1178 Bolt (P) 5P-8248 Hard Washer (R) 150-6310 Plate (S) 150-6308 Pin (T3) Loctite Graphite-50

19. Apply Tooling (T3) to the suspension cylinder pin bores of the rear axle housing and pin (S). Position rear suspension (F). Install pin (S), plate (R), six washers (P), and six bolts (N). Repeat this step for the remaining rear suspension cylinder.
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    Illustration 24	g06205915
    (K) 8T-4139 Bolt (L) 8T-4223 Hard Washer (M) 372-7382 Guard As

20. Install guard assembly (M), two washers (L), and two bolts (K). Repeat this step for the opposite side.
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    Illustration 25	g06166378

21. Remove and discard four bolts (AM), four nuts (AN), eight washers (AP), and plate (AR). Repeat this step for the opposite side.
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    Illustration 26	g06166392

22. Cut and discard two brackets (AS) from the frame and the axle support housing. Clean and paint the affected areas. Repeat this step for the opposite side.

23. Remove Tooling (T1), (T2), all suitable lifting devices, and cribbing.
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    Illustration 27	g06206153

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    Illustration 28	g06206169
    (24) 3P-0653 O-Ring Seal (25) 8T-4223 Hard Washer (26) 7X-0325 Bolt (27) 442-8782 Tube As (AF) 216-4983 T Bolt Clamp (AG) 216-4983 T Bolt Clamp (AH) 6V-8519 Half Clamp (AK) 3S-5468 Hose

24. Install tube assembly (27), O-ring seal (24), three hard washers (25), and three bolts (26). Connect hose (AK). Tighten four clamps (AG) and two clips (AH).

Drive Shaft (Slip Joint) - Connect

Note: Prior to the drive shaft installation, ensure that the torque converter yoke and the transmission yoke are in phase with each other.

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Illustration 29	g06228795
(8) 2N-2486 Bolt (AT) 8X-0473 Slip Joint

1. Attach a suitable lifting device onto slip joint (AT). The weight of slip joint (AT) is approximately 130 kg (286 lb). Use the suitable lifting device to lift slip joint (AT). Remove the support block and extend slip joint (AT) to the transmission yoke.

2. Install four bolts (8).
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   Illustration 30	g06227839

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   Illustration 31	g06228780
   Tightening Sequence (8) 2N-2486 Bolt (AT) 8X-0473 Slip Joint

3. Use the following steps to connect the universal joint of slip joint (AT) to the transmission.

   1. Mate the key and the pilot diameter of the universal joint with the yoke of the transmission . Use a suitable rubber or wooden hammer to completely seat the universal joint.

   2. Tighten bolts (8) in the following sequence
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      Table 3

      Tightening Sequence	A	B
      	B	C
      	C	D

   3. Tighten bolts (8) to a torque of 550 ± 20 N·m (406 ± 15 lb ft) in an alternating (X) pattern.

   4. Tighten bolts (8), again, to a torque of 550 ± 20 N·m (406 ± 15 lb ft) in an alternating (X) pattern to ensure that the correct torque has been achieved.

Drive Shaft Guard Install

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Illustration 32	g06228820
(AC) 8T-4136 Bolt (AD) 8T-4121 Hard Washer (AE) 394-0616 Plate As

1. Install guard assembly (AE), five washers (AD), and five bolts (AC).
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   Illustration 33	g06229255
   (T) 479-2171 Bolt As (V) 492-7238 Transmission Harness As (W) 8T-5005 Bolt (X) 8T-4121 Hard Washer (Y) 136-4992 Spacer (Z) 8T-1899 Clip (AA) 8T-1900 Clip (AB) 6V-1249 Grommet

2. Position harness assembly (V). Install grommet (AB), clip (AA), clip (Z), two spacers (Y), two washers (X), two bolts (W), and two bolt assemblies (T).
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   Illustration 34	g06228862
   (4) 394-0618 Plate (5) 8T-4121 Hard Washer (6) 8T-4136 Bolt (7) 446-1439 Plate

3. Install plate (4), plate (7), eight hard washers (5), and eight bolts (6).

Power Train Lines and Wiring Connect

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Illustration 35	g06228910
(9) 479-2172 Bolt As (10) 5P-7466 Clip (11) 5P-8112 Grommet (12) 5P-7467 Clip (13) 390-9582 Transmission Harness As (V) 492-7238 Transmission Harness As (AV) 390-9616 Transmission Harness As

1. Install transmission harness assembly (13), two grommets (11), two clips (12), two clips (10), and two bolt assemblies (9). Connect transmission harness assembly (13) to transmission harness assembly (V) and transmission harness assembly (AV).
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   Illustration 36	g06229289
   (AW) 226-8797 Nut (AX) 329-3356 Nut (AY) 5P-1076 Hard Washer (AZ) 102-8873 Plate (BA) 117-4845 Clamp (BB) 422-1274 Block

2. Remove and retain two hex cap nuts (AW), two nuts (AX), two washers (AY), two plates (AZ), two clamps (BA), and two blocks (BB).
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   Illustration 37	g06231567
   () () () () ()

3. Remove and discard four bolts (BC), eight hard washers (BD), two half flanges (BE), and O-ring seal (BF). four nuts (BG), and cover (BH) from hose assembly (BJ).
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   Illustration 38	g06231571

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   Illustration 39	g06231574
   (14) 455-5892 Tube As (15) 9X-8257 Washer (16) 118-7313 Bolt (17) 124-1859 O-Ring Seal (18) 1P-4585 Half Flange (19) 8T-4193 Bolt (20) 6V-5040 Clip (21) 6V-5039 Clip (22) 5P-1076 Hard Washer (23) 8T-4139 Bolt

4. Install tube assembly (14), O-ring seal (17), two half flanges (18), four hard washers (15) and four bolts (16). Install O-ring seal (17), two half flanges (18), four hard washers (15) and four bolts (19). Install clip (20), clip (21), hard washer (22), and bolt (23).
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   Illustration 40	g06232591
   (AW) 226-8797 Nut (AX) 329-3356 Nut (AY) 5P-1076 Hard Washer (AZ) 102-8873 Plate (BA) 117-4845 Clamp (BB) 422-1274 Block

5. Install two hex cap nuts (AW), two nuts (AX), two washers (AY), two plates (AZ), two clamps (BA), and two blocks (BB).
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   Illustration 41	g06231606
   (BL) 329-3356 Nut (BK) 8T-4223 Hard Washer

6. Remove and retain nut (BL) and washer (BK).
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   Illustration 42	g06231998
   (BL) 329-3356 Nut (BK) 8T-4223 Hard Washer (BM) 455-5871 Hose As (BN) 420-4145 Hose As (10) 5P-7466 Clip (11) 5P-8112 Grommet (12) 5P-7467 Clip (10A) 5P-7462 Clip (11A) 6V-0683 Grommet (12A) 5P-7463

7. Connect hose assembly (BM) and hose assembly (BN). Install clip (10), grommet (11), clip (12), clip (10A), grommet (11A), clip (12A), hard washer (BK), and nut (BL).
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   Illustration 43	g06232113
   (BP) 8T-4648 Bolt (BR) 8T-4223 Hard Washer (BT) 1P-4579 Half Flange (BW) 234-3544 O-Ring Seal (BX) 455-5873 Hose As

8. Remove four bolts (BP), eight washers (BR), and four nuts (BS), two half flanges (BT), cover (BV), and O-ring seal (BW) from hose assembly (BX).

9. Discard four washers (BR), four nuts (BS), and cover (BV).

10. Retain four bolts (BP), four washers (BR), two half flanges (BT). and O-ring seal (BW).
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    Illustration 44	g06232109
    (BY) 390-9582 Transmission Harness As (BZ) 390-9616 Transmission Harness As (BP) 8T-4648 Bolt (BR) 8T-4223 Hard Washer (BT) 1P-4579 Half Flange (BW) 234-3544 O-Ring Seal (BX) 455-5873 Hose As

11. Connect harness assembly (BY) to harness assembly (BZ). Install clip (10). grommet (11), clip (12), and bolt assembly (9). Install O-ring seal (BW) onto hose assembly (BX). Position hose assembly (BX). Install two half flanges (BT), four hard washers (BR), and four bolts (BP).