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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 Publication Date -02/01/2011 Date Updated -02/01/2011
i04195649
789C Off-Highway Truck Assembly Procedure{7000, 7006, 7960}

SMCS - 7000-016; 7006-016; 7960-016
Off-Highway Truck/Tractor:
789C (S/N: 2BW303-303,306-UP)
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:
high/low tightening specification
torque turn
thread lock
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 14/02/2011
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
Table 1
Parts that are Needed for Installation of 5T-4465 Front Suspension Gp or 193-6343 Front Suspension Gp
Qty Part Number Part Name

2 4T-5182 (1) Front Suspension
2 229-2379 (2) Front Suspension
8 2D-7687 Bolt
8 3S-6162 Hard Washer
8 5T-4896 Spacer
8 8H-3390 Full Nut
2 5T-6255 Key
2 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
8 1D-4639 Bolt
8 5P-8250 Washer
(1) Part of 5T-4465 Front Suspension Gp
(2) Part of 193-6343 Front Suspension Gp
Table 2
Parts that are Needed for Installation of the 5T-4462 Steering Link Group
16 3R-2300 Bolt
16 4K-0684 Hard Washer
1 3J-6899 Locknut
Table 3
Parts that are Needed for Installation 5T-4474 Rear Axle Housing Group
1 8X-0465 (1) Slip Joint
8 2N-2486 (1) Bolt

20 2H-1618 Bolt
20 5T-1352 Spacer
(1) Part of 5T-8543 Drive Shaft
Table 4
Parts that are Needed for Installation of 241-7846 Service Brake Lines Gp
1 8W-3191 Hose
4 6V-9746 O-Ring Seal
1 8W-3723 (1) Hose
1 114-2891 (1) Hose
4 5P-7466 Clip
4 5P-7467 Clip
3 5P-8112 (1) Grommet
2 8T-8917 (1) Bolt
3 8T-4223 (1) Hard Washer
4 5M-1932 Taperlock Stud
4 6V-8188 Nut
2 7G-3832 Grommet
2 7G-3833 Clip
2 7G-3834 Clip
4 5P-1076 Hard Washer
(1) Part of 241-7847 Traction Control
Table 5
Parts that are Needed for Installation of 170-3583 Transmission Oil Lines
1 8W-3358 Hose
2 1P-4582 Half Flange
1 4J-0527 (1) O-Ring Seal
4 5P-2566 Bolt
4 8T-4122 Washer
1 8W-3353 Hose
4 1P-4579 (1) Half Flange
2 4J-0524 (1) O-Ring Seal
8 8T-9389 Bolt
12 8T-4223 Hard Washer
1 8W-3354 Hose
1 160-4960 Hose
2 1P-4585 Half Flange
1 2H-6338 O-Ring Seal
4 7X-0347 Bolt
1 172-4613 Connector
1 4D-4791 Hose
1 8W-3707 Hose
1 8W-3708 Hose
(1) Part of 5T-1027 Torque Converter Filter and Lines
Table 6
Parts that are Needed for Installation of 8X-8270 Automatic Lubrication Gp at the Rear Axle
6 8T-9377 Bolt
6 6V-8801 Nut
1 8W-4532 Hose As
4 2N-1287 Flared Elbow
2 5N-5646 Hose
2 5T-5760 Hose
5 4K-8864 Clip
1 9X-8250 Clip
3 5M-3062 Bolt
2 6K-1972 Flared Elbow
2 3P-1823 Pipe Adapter
1 5T-5760 Hose
1 5T-4381 Hose
Table 7
Parts That Are Needed for Installation of 162-2634 Hydraulic Oil Cooler Lines
4 165-4931 Elbow Gp
1 6V-0852 Dust Cap
2 5T-7618 Tube Assembly
2 3S-7594 Hose
8 5P-0598 Clamp
2 5P-1935 Seal
6 7X-0325 Bolt
Table 8
Parts That Are Needed for Installation of 241-7845 Service Brake Lines Gp
4 5T-0967 Block
4 5T-0968 Block
8 8T-2501 Bolt
1 5T-9053 Plate
4 7X-0353 Bolt
1 5T-0965 Plate
2 3S-9175 Elbow
1 5J-0541 Hose
1 9D-0771 Hose
2 1S-0996 Clip
2 9C-4937 Breather As
8 7K-1181 Cable Strap
Table 9
Parts That Are Needed for Installation of 133-3418 Fuel Tank Gp or 133-3419 Fuel Tank Gp
1 150-9548 (1) Fuel Tank Assembly
1 151-3177 (2) Fuel Tank As
4 8X-2232 Shim Pack
1 8W-3602 Mud Flap
5 8T-2561 Washer
5 4L-6454 Bolt
5 6V-8801 Nut
1 145-2817 O-Ring Face Seal Hose Assembly
1 9M-7958 Hose Clamp
(1) Part of 133-3418 Fuel Tank Gp
Table 10
Parts that are Needed for Installation of 5T-4483 Fuel Lines Group
1 9L-5254 Elbow
1 030-7944 Elbow
1 6V-8358 Ball Valve
Table 11
Parts that are Needed for Installation of 5T-4463 Hydraulic Tank Mounting Group
2 105-2200 Mud Flap
16 4L-6454 Bolt
16 8T-2561 Washer
16 6V-8801 Nut
1 105-2204 Support
1 105-2205 Support
1 105-2201 Mud Flap
1 105-4620 Support
2 8T-9101 Bolt
Table 12
Parts That Are Needed for Installation of 145-3418 Ladder Group

1 8W-0671 Ladder Assembly
8 8T-2502 Bolt
6 4L-6454 Bolt
2 5T-8218 Plate
2 5T-8220 Baffle
1 149-6884 Ladder Assembly
4 5P-2566 Bolt
5 6V-8188 Nut
4 8T-8917 Bolt
1 8T-4835 Bolt
1 8W-2025 Brace
8 4L-9337 Bolt
8 6V-8801 Nut
2 9P-2950 Handhold
8 5P-2228 Bolt
2 153-1315 Handhold
Table 13
Parts that are Needed for Installation of 5T-1070 Fender Group

14 7D-1649 Washer
5 0S-1595 Bolt
1 5T-6403 Fender
9 0S-1621 Bolt
1 8W-4808 Support
1 8W-7900 Guard
1 8W-6382 Plate
2 5T-6553 Plate
2 9B-7237 Bolt
15 1D-4717 Nut
4 8T-2502 Bolt
1 8W-7788 Strip
9 5S-7379 Bolt
1 8W-6063 Strip
9 4L-6454 Bolt
1 8W-7899 Guard
2 6H-1717 Bolt
2 6V-8188 Nut
1 8W-0571 Plate
4 0S-1594 Bolt
8 5M-2894 Hard Washer
4 6V-8801 Nut
1 8W-0568 Plate
Table 14
Parts that are Needed for Installation of 277-0628 Brace for the 5T-1070 Fender Group
Qty Pt. No. Description
1 277-0629 Plate
1 277-0628 Brace
1 4V-0661 Mount
1 6J-9944 Boss
1 7X-0326 Bolt
1 6V-8188 Nut
2 7X-0590 Hard Washer
3 8T-8917 Bolt
1 278-0773 Block (1)
(1) Fabricate this component.
Table 15
Parts That Are Needed for Installation of 6I-2972 Air Cleaner Group
2 5K-3772 Hose Assembly
2 3B-6493 Pipe Elbow
2 175-5251 Air Cleaner
16 8T-4122 Washer
16 7X-0344 Bolt
2 0A-2926 Nipple
2 7W-7417 Service Indicator
2 3B-6552 Elbow
Table 16
Parts that are Needed for Installation of 8W-7903 Rear View Mirror Group
2 3B-4605 Cotter
1 8W-7904 Tube Assembly
2 7X-0326 Bolt
2 7D-9969 Support
1 8T-2287 Mirror
4 5S-7379 Bolt
1 6V-8285 Mirror
2 8W-7901 Bracket
2 6V-8801 Nut
2 4L-6454 Bolt
Table 17
Parts that are Needed for Installation of 159-2489 Rear View Mirror Group
2 3B-4605 Cotter
1 159-4795 Tube
2 7X-0326 Bolt
2 7D-9969 Support
1 8T-2287 Mirror
2 5S-7379 Bolt
1 134-0987 Bracket
1 8Y-6989 Mirror
1 137-2129 Bracket
2 134-0989 Block
4 8T-4186 Bolt
8 8T-4137 Bolt
3 8T-4136 Bolt
Table 18
Parts that are Needed for Installation of 174-9334 Muffler Gp

1 5T-7766 Bracket
8 5P-2566 Bolt
1 4W-0969 Muffler Assembly
1 5T-7768 Strap
4 4L-9337 Bolt
9 2K-4973 Locknut
1 8X-6607 Bracket
2 8T-9384 Bolt
1 5T-7823 Plate
2 4L-6454 Bolt
1 5T-7770 Plate
1 4W-1814 Clamp
5 5S-7383 Bolt
1 8X-6605 Extension Pipe
2 6N-9298 Clamp
4 5P-2424 Bolt
4 1K-6872 Locknut
2 5T-7824 Clamp
4 5C-6565 Bolt
4 6V-8188 Nut
4 2V-8169 Plate
4 7X-0345 Bolt
2 5T-8049 Strap
1 4W-0532 Muffler Assembly
2 5T-8050 Strap
2 8W-4954 Plate
4 9B-7237 Bolt
4 6V-8801 Nut
1 8X-6606 Extension Pipe

1 1W-4161 (1) C-Clamp
1 7C-3337 (1) Elbow
4 2W-8851 (1) Seal Ring
2 2W-9078 (1) Pipe
1 7C-3338 (1) Elbow
1 7C-3339 (1) Elbow
1 7C-3336 (1) Pipe
(1) Part of 230-8139 Exhaust Pipe Gp
Table 19
Parts that are Needed for Installation of 5T-4464 Platform Group

1 7I-5493 Support
12 4L-6454 Bolt
1 8X-7007 Rail
8 1A-8063 Bolt
6 2S-7593 Hard Washer
6 8S-9092 Bolt
1 8W-4926 Plate
3 5P-2228 Bolt
Table 20
Parts that are Needed for Installation of 156-9342 Steering Tank Group
1 155-6660 Steering Tank and Filter Gp
9 5C-6565 Bolt
Table 21
Parts that are Needed for Installation of the Cab Mounting Gp

1 5T-6076 (2) Support Assembly
25 5P-8250 (2) Washer
25 1F-7464 (2) Bolt
1 228-3732 (2) Support
8 163-3127 (1) Sleeve
40 163-0042 (1) Cab Mount
6 163-0364 (1) Sleeve
6 164-4411 (1) Sleeve
20 5T-5807 (1) Retainer
8 6V-2624 (1) Bolt
4 5T-9893 (1) Shim
4 5T-9894 (1) Shim
6 6B-0388 (1) Bolt
6 1K-9420 (1) Bolt
(2) Part of 193-6348 Cab Mounting Gp
Table 22
Parts That Are Needed for Installation of 150-8726 Steering Lines Group
2 148-8364 Elbow
1 148-8361 Elbow
1 150-8708 Tube
1 150-8709 Tube
1 150-8723 Tube
1 150-8710 Tube
1 150-8713 Tube
1 0T-0102 Bolt

1 9S-1350 Clip
2 5T-6867 Cup
2 0S-0509 Bolt
1 150-9037 Bar
4 0L-1351 Bolt
1 2G-8895 Bracket
1 6G-8532 Guard
3 9L-9132 Washer
Table 23
Parts that are Needed for Installation of 5T-4484 Heater Lines Group
2 6P-8855 Spacer
8 9X-2488 Hose Clamp
1 6D-1641 Clip
1 8T-4896 Washer
1 5S-7379 Bolt
Table 24
Parts that are Needed for Installation of the Truck Hood Group
2 5P-1075 (1) Hard Washer
2 5S-7379 (1) Bolt
1 211-9141 (2) Rail As
12 8T-4896 (2) Hard Washer
12 4L-6454 (2) Bolt
(1) Part of 211-9145 Truck Hood Gp
(2) Part of 211-9143 Cowling Group
Table 25
Parts that are Needed for Installation of 144-4141 Air Lines Group (If Equipped)
2 6I-0982 Tube
2 4P-5212 Hose
2 7N-5008 Hump Hose
8 233-8484 Clamp
16 240-2651 Clamp
4 233-8482 Clamp
1 1W-6903 Hump Hose
2 5T-6459 Elbow
8 233-8485 Clamp
Table 26
2 7E-7790 Hose
16 233-8485 Clamp
2 249-3766 Tube
2 5T-7874 Strap
4 0S-1595 Bolt
2 5T-7874 Strap
4 9S-8752 Full Nut
4 0S-1571 Bolt
2 5T-6459 Elbow
Table 27
Parts That Are Needed for Installation of Tires and Rims 229-9389 Demountable Rim Gp
6 138-7582 Demountable Rim
6 8W-0338 O-Ring Seal
4 8W-0331 Swivel Connector

6 5T-9790 Tire Valve
18 8W-3891 (1) Flange Nut
304 5P-8250 (1) Washer
304 2J-3507 (1) Full Nut
2 230-1132 Hose As
2 261-3036 Plate
4 1S-0996 Clip
4 1B-4287 Washer
4 8T-4244 Nut
4 261-3244 Pipe
8 261-3243 Spacer
2 8T-5001 Bolt
2 8T-5041 Bolt
2 176-7281 Extension
2 8X-2627 Bracket
8 1D-4566 Bolt
8 6J-0427 Spacer
(1) Part of 5T-1023 Front Wheel Group
Table 28
Parts that are Needed for Installation of 125-6229 Body and Canopy Assembly
1 8W-3667 Guard Assembly
2 114-5012 Guard Assembly
1 8X-6394 Plate Assembly
1 112-6185 Plate Assembly
1 112-6184 Plate Assembly
Table 29
Parts that are Needed for Installation of 155-3633 Film Group

1 155-3637 Film (Left Side)
1 155-3636 Film (Right Side)
3 131-5415 Film
1 100-5615 Film
Table 30
Parts that are Needed for Installation of 154-3757 Body Mounting Group
10 0L-1351 Bolt
2 5T-7228 Plate
59 0S-1588 Bolt
54 6V-8801 Nut
2 6G-9704 Strip
1 5T-5989 Mud Flap
1 5T-5988 Mud Flap
2 5T-7255 Plate
2 5T-7352 Strip
1 5T-7274 Mud Flap
1 5T-7275 Mud Flap
1 8X-5421 Plate
1 105-4727 Mud Flap
2 8W-8679 Pin
8 1H-9456 Bolt
2 8W-9373 Cover
2 6G-9697 Washer
2 8W-2896 Washer
2 8W-8677 Plate
4 0S-1585 Bolt
10 322-0363 Pad As
24 6G-9711 Shim
8 5T-3750 Plate
25 9S-1366 Bolt
30 7D-1649 Washer
24 1F-7958 Full Nut
2 6G-7773 Pin
4 3B-4647 Cotter Pin
2 227-5875 Ejector
1 8X-6365 Baffle
2 8X-6366 Plate
4 9B-7237 Bolt
Table 31
Parts that are Needed for Installation of 5T-4469 Hoist Cylinder and Mounting
2 239-5505 Pin
4 6G-9696 Spacer
2 6G-9691 Bar
4 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)
2 1D-4643 Bolt
2 5P-8250 Washer
2 2H-3794 Locknut
1 105-0314 Coupler
1 6G-9703 Cable
1 145-9033 Cable
1 2B-0974 Clevis Pin
1 3B-4617 Cotter
1 8W-0109 Plate
Table 33
Parts that are Needed for Installation of 8X-8270 Automatic Lubrication Group
1 351-2414 Lubrication Pump
3 0S-1594 Bolt
2 8L-6557 Connector
4 9L-5125 Elbow
14 4K-8864 Clip
14 5M-3062 Bolt
2 2N-1287 Flared Elbow
Table 34
Parts that are Needed for the Installation of 3Z-4942 Fast Fill Service Center Group (If Equipped)
1 3B-7255 Reducing Bushing
1 2N-8037 Elbow
1 1Q-5485 Flange
1 032-4814 Elbow
1 3K-0360 O-Ring Seal
2 0S-1588 Bolt
4 0L-1351 Bolt
4 7X-0772 Hard Washer
2 2G-8992 Clamp
2 4L-6454 Bolt
Table 35
Parts that are Needed for Installation of 230-7213 Lighting Wiring Gp and 147-3533 Wiring and Lighting
Gp
1 9G-9152 Clip
11 5M-3062 Bolt
2 4D-7794 Clip
2 4L-6454 Bolt
2 6V-8801 Nut
2 8M-2770 Clip
2 5P-0562 Lockwire
2 135-0428 Signal Lamp
6 7S-4346 Screw
6 9F-5599 Lockwasher
6 4B-2049 Nut
4 1S-0994 Clip
8 5S-7379 Bolt
5 7D-4092 Clip
3 9G-9154 Clip
2 3T-0050 Clip
40 3S-2093 Cable Strap
3 1H-3244 Lockwasher
1 3T-4411 Flood Lamp
1 5T-1680 Plate
1 117-5883 Cable
2 9M-4995 Clip
1 3M-7212 Battery Terminal
1 9G-9150 Clip
1 5P-9297 Clip
1 3T-3048 Clip Assembly
Table 36
Parts that are Needed for Installation of 115-6488 Payload Signal Lamp Group
2 9G-9150 Clip
1 5M-3062 Bolt
1 8K-1433 Grommet
Approximate Weights
Personal injury or death can result from lifting a heavy assembly.
The heavy assembly can fall if using an incorrect hoist to lift the load.
Be sure the hoist has the correct capacity to lift a heavy assembly.
Approximate weight of the assembly is given below.
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.
Table 37
Module Weight
Air Cleaner 62 kg (137 lb)
Body pivot pin

34 kg (75 lb)
Cab Assembly 1920 kg (4250 lb)
Cab Support (front)

169 kg (372 lb)
Cab Support (rear)

232 kg (511 lb)
Rear Axle Housing and Transmission

20200 kg (44520 lb)
Front Suspension Cylinder, Wheel, and Brake Assembly

4960 kg (10920 lb)
Fuel Tank
1200 kg (2640 lb)
Hoist Cylinder
833 kg (1835 lb)
Top Mounting Pin for the Hoist Cylinder

15 kg (33 lb)
Mirror Guards
72 kg (159 lb)
Right Side Platform Assembly

761 kg (1676 lb)
Rim
1600 kg (3540 lb)
Rock Ejector
99 kg (218 lb)
Mounting Bracket for the Rock Ejector

38 kg (83 lb)
Safety Cable
35 kg (79 lb)
Steering Arm
280 kg (617 lb)
Steering Hydraulic Tank

100 kg (220 lb)
Tire
3178 kg (7000 lb)
Assembled Truck Body

44230 kg (97500 lb)
Hinge Pin for the Truck Body

41 kg (90 lb)
Truck Frame Module At Shipment

39920 kg (88000 lb)
Specifications
Table 38
Areas that are Measured Specifications
Empty weight
130933 kg (288660 lb)
Wheel Base
5690 mm (224 inch)
Length
12167 mm (479 inch)
Ground to top of canopy

6147 mm (242 inch)
Ground to upper edge of body

5207 mm (205 inch)
Machine clearance turning circle

30.2 m (99 ft)
Width of body assembly

7671 mm (302 inch)
Width of truck frame at rear tires

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).
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).
Specifications for Cables, Chains, and Lifting Devices
ReferenceService Magazine, SEPD0531 03 July, "Fabric Slings and Protective Sleeves Are Available for Lifting
Truck Bodies"
Use approved cables, chains, and lifting devices in order to lift components. Refer to the literature from the
manufacturer in order to determine the application when you select the items that follow: cable, chain and lifting
devices. When you lift a component, the lift angle is critical. Refer to the Illustration that follows in order to see the
effect of the lift angle on the working load limit.
Illustration 1 g00629745
Lift angles for lifting slings.
(A) The load capacity is 100 percent of the working load limit for the sling.
(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.
Necessary Hoist Capacity

Two hoists are needed to remove the truck frame from the trailer. One hoist with a 54430 kg (120,000 lb) capacity
and one hoist with a 36,290 kg (80,000 lb) is needed.
When the rear axle housing is on supports, a hoist with a 36,290 kg (80,000 lb) capacity is needed to lift the truck
frame at the front lifting points.
With the front crossmember on supports, one hoist with 54,430 kg (120,000 lb) capacity is needed to lift the truck
frame at the rear lifting points.
789C Assembly Tips

Note: Follow the table of contents for the assembly sequence of the truck.
1. The assembly of the 789C requires four mechanics for a total of 196 hours. Two crane operators are required
for a total of 24 hours until the major components are installed.
2. All of the parts that are contained within the shipping boxes will be identified with a yellow label. DO NOT
REMOVE THE YELLOW LABELS FROM THE PARTS UNTIL THE PARTS ARE READY FOR
INSTALLATION. The yellow 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.
3. Complete the assembly of components such as the cab, right side platform, and the body prior to assembling
the components to the truck. For example, before you assemble the cab to the truck, assemble as much of the
following items as possible: 150-8726 Steering Lines Group, 5T-1070 Fender Group and 159-2489 Rear
View Mirror Group.
4. After assembly is complete, prepare the machine for use. Refer to the commissioning procedure. In order to
perform the tests that are contained in the commissioning procedure, refer to the following service
information: Operations and Maintenance Manual, SEBU7174, Parts Manual, SEBP2790 and Service
Manual, SENR1515.
Necessary Equipment and Supplies for Assembly

The following items are necessary for assembly:
Six 208 L (55 US gal) barrels of hoist, converter, and brake oil (TDTO, TO-4). - SAE viscosity grade 10 is
recommended. Refer to the Operation and Maintenance Manual for more details.
One 133 L (35 US gal) barrel of steering oil - The steering oil should be of one of the following types: HYDO,
TDTO, DEO CF-4, API CF-4 and CE-compliant oils. Refer to the Operation and Maintenance Manual for more
details.
Several shackles - The shackles should have a working load limit of 27,240 kg (60,053 lb).
A steel rod that is 88.9 mm (3.50 inch) in diameter - The steel rod should be at least 4191 mm (165 inch) long.
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.
207-1601 Rubber Lubricant
Cables, straps, and chains that have adequate capacity
Two step ladders that are 1.8 m (6 ft) tall
Two step ladders that are 3.6 m (12 ft) tall
A lift truck that can lift 6810 kg (15,000 lb)
A paint spray gun
Two 7X-1062 Ether Cylinders
Two 1U-9204 Lever Pullers
Four 138-7573 Link Brackets
5P-0960 Molybdenum Grease
4C-5599 Anti-Seize Compound
2P-2506 Anti-Seize Compound
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
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 6V-4040 Tire Inflation Group to inflate the tires.
Use a 4C-4911 Battery Load Tester in order to test the batteries.
Use a 8T-0900 Ammeter in order to test the batteries.
Use a 6V-7070 Digital Multimeter in order to test batteries.
Use a 175-5507 Nitrogen Charging Group and a 175-7410 Auxiliary Fitting Group in order to charge the
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.
Have a 6V-3146 Extension Handle .
Have a 6V-4170 Adapter .
Prepare to Assemble the 789C Off-Highway Truck
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.
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.
Lifting diagram
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.
Typical front lifting location of the chassis
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.
View of the rear lifting location
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).
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.
View of the frame that is blocked
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.
View of the frame that is blocked
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.
8. Use a suitable lift truck or a suitable crane in order to unload the remaining three trucks.
View of the components that are being unloaded and positioned
9. Position the components near the truck chassis.
10. Use a suitable crane and a lift truck in order to position the cab on suitable stands. To assemble the right
fender and air cleaner to the cab, use 121.9 cm (48 inch) stands. The cab weighs approximately 1920 kg (4250
lb).
11. Once the front blocking is in place, slowly shift the weight of the cab to the stands. If stands appear to be
adequately supporting the weight of the cab, remove the cranes.
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.
Installation of 5T-4465 Front Suspension Gp or 193-6343 Front

Suspension Gp
Table 39
Parts that are Needed for Installation of 5T-4465 Front Suspension Gp or 193-6343 Front Suspension Gp
Item Qty Part Number Part Name

1 2 4T-5182 (1) Front Suspension Gp
1 2 229-2379 (2) Front Suspension Gp
2 8 2D-7687 Bolt
3 8 3S-6162 Hard Washer
4 8 5T-4896 Spacer
5 8 8H-3390 Full Nut
6 2 5T-6255 Key
7 2 5T-5202 Cap
8 24 5P-5769 Bolt
9 24 4K-0684 Hard Washer
10 24 5T-1352 Spacer
11 24 7H-7539 Full Nut
12 16 117-4935 Plate
13 8 1D-4639 Bolt
14 8 5P-8250 Washer
(1) Part of 5T-4465 Front Suspension Gp
(2) Part of 193-6343 Front Suspension Gp
(1) 4T-5182 Front Suspension Gp
(1) 229-2379 Front Suspension Gp
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.
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.
(2) 2D-7687 Bolt
(3) 3S-6162 Hard Washer
(4) 5T-4896 Spacer
(5) 8H-3390 Full Nut
(A) Top mounting surface for the upper bearing of the front suspension cylinder
(B) Hose assemblies for the service and parking brake
(C) Shipping bracket
(D) Grease lines
(E) Lower mounting surface for front suspension cylinder
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
(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) .
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.
(6) 5T-6255 Key
10. Install 5T-6255 Key (6) .
(7) 5T-5202 Cap
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.
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.
13. Position the front suspension group against the mounting flange on the frame.
14. Use a suitable crane and a lever puller in order to align the mounting bolt holes.
(3) 2D-7687 Bolt
(5) 5T-4896 Spacer
(6) 8H-3390 Full Nut
(8) 5P-5769 Bolt
(9) 4K-0684 Hard Washer
(10) 5T-1352 Spacer
(11) 7H-7539 Full Nut
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).
(12) 117-4935 Plate
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.
(13) 1D-4639 Bolt
(14) 5P-8250 Washer
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).
20. Connect the sensor for the front suspension group.
21. Repeat Step 1 through Step 20 for the other front suspension group.
Installation of 5T-4462 Steering Link Group

Table 40
Parts that are Needed for Installation of the 5T-4462 Steering Link Group
1 16 3R-2300 Bolt
2 16 4K-0684 Hard Washer
3 1 3J-6899 Locknut
1. On each suspension cylinder, remove the eight existing bolts, washers, and spacers from the mounting surface
for the steering arm.
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.
3. Use a suitable crane in order to support the right side steering arm. The steering arm assembly weighs
approximately 280 kg (617 lb).
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.
(1) 3R-2300 Bolt
(2) 4K-0684 Hard Washer
5. Install eight 3R-2300 Bolts (1) and eight 4K-0684 Washers (2) .
6. Remove the crane and remove 1U-9200 Lever Puller Hoist .
(1) 3R-2300 Bolt
(2) 4K-0684 Washer
7. Tighten 3R-2300 Bolts (1) to a torque value of 1632 50 Nm (1200 37 lb ft).
8. Repeat Step 2 through Step 7 for the other side.
(A) Paper Tube
(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.
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.
(3) 3J-6899 Locknut
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) .
15. Remove the retaining ring and the cap.
16. Use a 4C-3386 Spanner Wrench in order to hold the ball stud. Hold the ball stud while you tighten Locknut
(3) .
17. Tighten 3J-6899 Locknut (3) to a torque value of 2550 100 Nm (1875 74 lb ft).
Installation of 5T-4474 Rear Axle Housing Group

Refer to the 5T-4474 Rear Axle Housing .
Refer to either the 5T-4466 Rear Suspension Gp (If Equipped) or 193-6342 Rear Suspension Gp (If
Equipped).
Refer to the 5T-8543 Drive Shaft .
Refer to the 5T-1031 Drive Shaft Guard .
Table 41
Parts that Are Needed for Installation of Rear Axle Housing and Transmission
Item Quantity Part Number Part Name
1 1 8X-0465 (1) Slip Joint
2 8 2N-2486 (1) Bolt
3 20 2H-1618 Bolt
4 20 5T-1352 Spacer
(1) Part of 5T-8543 Drive Shaft
1. Place the axle and transmission assembly near the truck frame. Block up the transmission.
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.
(A) Pin
(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.
(A) Pin
4. Remove pins (A) from the axle housing. Use 4C-4204 Paint and Decal Remover to remove the paint from
pins (A) .
5. Remove the shipping brackets from the A-frame.
6. Remove the paint and clean the mounting area on the A-frame.
7. Use 4C-4204 Paint and Decal Remover to remove the paint and clean the mounting areas on the rear axle
housing.
(E) Bolts
(F) Washers
(G) Guard
8. Remove five bolts (E) and washers (F) that secure guard (G). Clean the transmission drive shaft.
(1) 8X-0465 Slip Joint
(H) Holes for 2N-2486 Bolts
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).
(E) Bolts
(F) Washers
(G) Guard
10. Reinstall guard (E) with five bolts (F) and washers (G) .
11. Remove shipping plate (J) on the drive shaft yoke at the transmission. Discard shipping plate (J) .
(K) Pin
12. Use 4C-4204 Paint and Decal Remover to remove paint from pin (K) .
(K) Pin
(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.
(K) Pin
(R) Control Rod
14. Remove pin (K) from the bore.
Note: The pin secures control rod (R) to the frame.
(R) Control Rod
15. Support control rod (R) with wood blocks in order to raise control rod (R) away from the rear axle assembly.
16. Lift the rear axle assembly to the frame assembly.
(K) Pin
(R) Control Rod
Note: Apply anti-seize grease to the pin. Apply anti-seize grease to the bore.
17. Slide pin (K) back into position.
(L) Bolt
(M) Hard Washer
(N) Full Nut
(P) Washers
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).
(3) 2H-1618 Bolts
(4) 5T-1352 Spacers
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).
20. Remove the links in the chains that were used to secure the A-frame.
21. Align the rear struts with the rear axle housing.
(B) Bolts
(C) Washers
(D) Plates
Location of the lubrication fittings on the lower rear strut pin
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).
23. If the guards are removed, reinstall the guards over the pins.
(S) Bolts
(T) Washers
(U) Guard
24. Remove five bolts (S) and washers (T) that secure guard (U). Clean the transmission drive shaft.
(1) 8X-0465 Slip Joint
(2) 2N-2486 Bolts
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).
(S) Bolts
(T) Washers
(U) Guard
26. Reinstall guard (U) with five bolts (S) and washers (T) .
Installation of 241-7846 Service Brake Lines Gp

Refer to 241-7847 Traction Control .
Table 42
Parts that Are Needed for Installation of 241-7846 Service Brake Lines Gp
1 1 8W-3191 Hose
2 4 6V-9746 O-Ring Seal
3 1 8W-3723 (1) Hose
4 1 114-2891 (1) Hose
5 4 5P-7466 Clip
6 4 5P-7467 Clip
7 4 5P-8112 (1) Grommet
8 2 8T-8917 (1) Bolt

9 3 8T-4223 (1) Hard Washer
10 4 5M-1932 Taperlock Stud
11 4 6V-8188 Nut
12 2 7G-3832 Grommet
13 2 7G-3833 Clip
14 2 7G-3834 Clip
15 4 5P-1076 Hard Washer
(1) Part of 241-7847 Traction Control
(A) Cap on the hose connection to the master cylinder
1. Remove cap (A) that covers the hose connections for the master cylinders.
(1) 8W-3191 Hose
2. Attach the end of the 8W-3191 Hose (1) to the master cylinders.
(B) Cap on TCS valve
(C) Cap on TCS valve
3. Remove cap (B) and cap (C) that covers the hose connections at the TCS valve.
(2) 6V-9746 O-Ring Seal
(3) 8W-3723 Hose
(4) 114-2891 Hose
4. Use a 6V-9746 O-Ring Seal (2) when you are connecting 8W-3723 Hose (3). Connect the end of the 8W-
3723 Hose (3) to the port at the right side of the TCS valve.
(3) 8W-3723 Hose
(4) 114-2891 Hose
5. Use a 6V-9746 O-Ring Seal (2) when you are connecting 114-2891 Hose (4). Connect the end of the 114-
2891 Hose (4) to the port at the left side of the TCS valve.
(1) 8W-3191 Hose
(3) 8W-3723 Hose
(4) 114-2891 Hose
(5) 5P-7466 Clips
(6) 5P-7467 Clips
(7) 5P-8112 Grommets
(8) 8T-8917 Bolts
(9) 8T-4223 Hard Washers
(10) 5M-1932 Taperlock Studs
(11) 6V-8188 Nuts
(12) 7G-3832 Grommets
(13) 7G-3833 Clips
(14) 7G-3834 Clips
(1) 8W-3191 Hose
(3) 8W-3723 Hose
(4) 114-2891 Hose
(5) 5P-7466 Clips
(6) 5P-7467 Clips
(7) 5P-8112 Grommets
(8) 8T-8917 Bolts
(10) 5M-1932 Taperlock Studs
(11) 6V-8188 Nuts
(12) 7G-3832 Grommets
(13) 7G-3833 Clips
(14) 7G-3834 Clips
(15) 5P-1076 Hard Washers
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) .
Installation of 170-3583 Transmission Oil Lines

Refer to the 5T-1027 Torque Converter Filter and Lines .
Table 43
Parts that Are Needed for Installation of 170-3583 Transmission Oil Lines
1 1 8W-3358 Hose
2 2 1P-4582 Half Flange
3 1 4J-0527 (1) O-Ring Seal
4 4 5P-2566 Bolt
5 4 8T-4122 Washer
6 1 8W-3353 Hose
7 4 1P-4579 (1) Half Flange
8 2 4J-0524 (1) O-Ring Seal
9 8 8T-9389 Bolt
10 12 8T-4223 Hard Washer
11 1 8W-3354 Hose
12 1 160-4960 Hose
13 2 1P-4585 Half Flange
14 1 2H-6338 O-Ring Seal
15 4 7X-0347 Bolt
16 1 172-4613 Connector
17 1 4D-4791 Hose
18 1 8W-3707 Hose
19 1 8W-3708 Hose
(1) Part of 5T-1027 Torque Converter Filter and Lines
1. Remove the covers from the ports at the transmission. Remove the caps from the hoses.
(1) 8W-3358 Hose
(2) 1P-4582 Half Flanges
(3) 4J-0527 O-Ring Seal
(4) 5P-2566 Bolts
(10) 8T-4223 Washers
2. Use the following components to attach the 8W-3358 Hose (1) to the transmission lubrication port: two 1P-
4582 Half Flanges (2), one 4J-0527 O-Ring Seal (3), four 5P-2566 Bolts (4) and four 8T-4223 Washers (10) .
(6) 8W-3353 Hose
(9) 8T-9389 Bolts
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) .
(9) 8T-9389 Bolts
(11) 8W-3354 Hose
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) .
(12) 160-4960 Hose
(14) 2H-6338 O-Ring Seal
(15) 7X-0347 Bolts
5. Use the components that follow to attach the 160-4960 Hose (12) to the port of the transmission for the
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) .
(16) 172-4613 Connector
(17) 4D-4791 Hose
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.
(18) 8W-3707 Hose
(18) 8W-3707 Hose
(19) 8W-3708 Hose
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.
(19) 8W-3708 Hose
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.
Connect the 8X-8270 Automatic Lubrication Group at the Rear Axle

Table 44
Parts that Are Needed for Installation of 8X-8270 Automatic Lubrication Group at the Rear Axle
1 6 8T-9377 Bolt
2 6 6V-8801 Nut
4 1 8W-4532 Hose As
5 4 2N-1287 Flared Elbow
6 2 5N-5646 Hose
7 2 5T-5760 Hose
8 5 4K-8864 Clip
9 1 9X-8250 Clip
10 3 5M-3062 Bolt
11 2 6K-1972 Flared Elbow

12 2 3P-1823 Pipe Adapter
13 1 5T-5760 Hose
15 1 5T-4381 Hose
(1) 8T-9377 Bolts
(2) 6V-8801 Nuts
(3) 5P-1075 Hard Washers
1. Place the lubrication injector bank in position at the rear axle housing. Use six 8T-9377 Bolts (1), six 6V-
8801 Nuts (2) and 12 8T-4896 Hard Washers (14) to attach the lubrication injector bank to the rear axle
housing.

(4) 8W-4532 Hose
2. Install the 8W-4532 Hose (4) to the junction block. The 8W-4532 Hose (4) is the supply line for lubrication.

(5) 2N-1287 Flared Elbow
(7) 5T-5760 Hose
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.

(3) 5P-1075 Hard Washer
(7) 5N-5760 Hose
(8) 4K-8864 Clip
(9) 9X-8250 Clip
(10) 5M-3062 Bolt
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.

(6) 5N-5646 Hose
(11) 6K-1972 Flared Elbow
(12) 3P-1823 Pipe Adapter
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.

(8) 4K-8864 Clip
6. Use a 4K-8864 Clip (8) and the existing bolt to secure each hose for the lower pins of the rear suspension
cylinders.

(13) 5T-5760 Hose

(8) 4K-8864 Clip
(10) 5M-3062 Bolt
(13) 5T-5760 Hose
(14) 8T-4896 Hard Washer
7. Use a 2N-1287 Flared Elbow (5) to attach a 5T-5760 Hose (13) to the control rod at the frame. Use one 4K-
8864 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.

(15) 5T-4381 Hose
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
Refer to the 186-6581 Harness .
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.

(A) Bolt
(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.

(D) Lead
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.

Cover on three solenoids on the transmission.

(E) Upshift solenoid
(F) Downshift solenoid
(G) Lockup clutch solenoid
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.

(H) Lead
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.
Installation of 162-2634 Hydraulic Oil Cooler Lines

Table 45
Parts That Are Needed for Installation of 162-2634 Hydraulic Oil Cooler Lines
1 4 165-4931 Elbow Gp
2 4 148-8339 Connector
3 4 6V-0852 Dust Cap
4 2 5T-7618 Tube Assembly
5 2 3S-7594 Hose
6 8 5P-0598 Clamp
7 2 5P-1935 Seal
8 6 7X-0325 Bolt
1. Remove the following items for each hose connection: four bolts, four washers, two split flanges, cap and O-
ring 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
and components are removed from the machine. Contamination of the

hydraulic system with foreign material will reduce the service life of
components.
2. Repeat Step 1 for the second connection to the hose assembly to the brake oil cooler.

(A) Caps

(B) Hose assembly
(C) Hose assembly
(D) O-Ring seal
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 O-
Ring 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.

(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) .
7. Remove the following items: three bolts, three washers, the plate and the O-ring seal.

(1) 165-4931 Elbow Gp
(2) 148-8339 Connector Assembly
(3) 6V-0852 Dust Cap
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 6V-
0852 Dust Cap (3) on each fitting (2) .

(4) 5T-7618 Tube Assembly
(5) 3S-7594 Hose
(6) 5P-0598 Clamp
(F) Clamp Assembly
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.

(7) 5P-1935 Seal
(8) 7X-0325 Bolt

Proper routing of rear cooling line for the right side of the truck

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.
11. Remove the tie-downs from the frame.
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.
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.
Installation of 241-7845 Service Brake Lines Gp

Table 46
Parts that Are Needed for Installation of the 241-7845 Service Brake Lines Gp
2 4 5T-0967 Block
3 4 5T-0968 Block
4 8 8T-2501 Bolt

6 1 5T-9053 Plate
7 4 7X-0353 Bolt
9 1 5T-0965 Plate
10 2 3S-9175 Elbow
11 1 5J-0541 Hose
12 1 9D-0771 Hose
13 2 1S-0996 Clip
14 2 9C-4937 Breather As
15 8 7K-1181 Cable Strap
Routing of the front brake lines
(1) 148-8345 Connector
(2) 5T-0967 Block
(3) 5T-0968 Block
(4) 8T-2501 Bolts
(6) 5T-9053 Plate
(7) 7X-0353 Bolt
(9) 5T-0965 Plate
(10) 3S-9175 Elbow
(11) 5J-0541 Hose
(12) 9D-0771 Hose
(13) 1S-0996 Clip
(14) 9C-4937 Breather As
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.

(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.

(2) 5T-0967 Block
(3) 5T-0968 Block
(4) 8T-2501 Bolt
(A) Brake hose
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.

(B) Parking brake line
6. At each side of the machine, connect the parking brake line (B) to the 148-8345 Connector (1) at the parking
brake port.

(2) 5T-0967 Block
(3) 5T-0968 Block
(4) 8T-2501 Bolt
(7) 7X-0353 Bolt
(9) 5T-0965 Plate
(10) 3S-9175 Elbow
(12) 5J-0451 Hose
(A) Brake hose
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.

(6) 5T-9053 Plate
(7) 7X-0353 Bolt
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.

(2) 5T-0967 Block
(3) 5T-0968 Block
(4) 8T-2501 Bolt
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.
10. Remove the shipping plug from each spindle.

(10) 3S-9175 Elbow
11. Install a 3S-9175 Elbow (10) in each spindle. Apply 5P-3413 Pipe Sealant to the external threads of the 3S-
9175 Elbow (10) prior to assembly.

(10) 3S-9175 Elbow
(12) 9D-0771 Hose
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.

(12) 9D-0771 Hose
(13) 1S-0996 Clip
(14) 9C-4937 Breather As
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.

(15) 7K-1181 Cable Straps
15. Use 7K-1181 Cable Straps (15) to secure the vent lines.
Installation of 133-3418 Fuel Tank Gp or 133-3419 Fuel Tank Gp

Table 47
Parts That Are Needed for Installation of 133-3418 Fuel Tank Gp or 133-3419 Fuel Tank Gp
1 1 150-9548 (1) Fuel Tank Assembly
1 1 151-3177 (2) Fuel Tank Assembly
2 4 8X-2232 Shim Pack
3 1 8W-3602 Mud Flap
4 5 8T-2561 Washer
5 5 4L-6454 Bolt
6 5 6V-8801 Nut
7 1 145-2817 O-Ring Face Seal Hose Assembly
8 1 9M-7958 Hose Clamp


(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.

(A) Front top mount for the fuel tank
(B) Rear top mount for the fuel tank
(C) Bottom mount for the fuel tank

150-9548 Fuel Tank As (1) mounting on chassis
(D) Nuts

151-3177 Fuel Tank As (1) mounting on chassis
(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 151-
3177 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.
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.

(A) Typical front mount for the fuel tank
(B) Typical rear mount for the fuel tank
(F) Dimension
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) .
789C Truck 3516 Engine 2BW00001-UP (MACHINE)(SEBP2790 - 126)/Basic Sear... Page 100 of 347
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.

(G) Dimension
(H) Fuel Tank Assembly
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.

(1) 150-9548 Fuel Tank Assembly
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).

(2) 8X-2232 Shim Pack
(A) Front mount for the fuel tank
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).

(2) 8X-2232 Shim Pack
(B) Rear mount for the fuel tank
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).

Mount for 150-9548 Fuel Tank As
(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).

(3) 8W-3602 Mud Flap
(4) 8T-2561 Washer
(5) 4L-6454 Bolt
(6) 6V-8801 Nut
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).

(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.

(7) 145-2817 O-Ring Face Seal Hose Assembly
17. Connect the 145-2817 O-Ring Face Seal Hose Assembly (7) to the Elbow by using an 6V-8400 O-Ring Seal
(9) .
Installation of 170-3600 Fuel Lines Group

Table 48
Parts that are Needed for Installation of 170-3600 Fuel Lines Group
1 1 9L-5254 Elbow
2 1 030-7944 Elbow
3 1 6V-8358 Ball Valve

Rear view of the fuel tank
(1) 9L-5254 Elbow
(2) 030-7944 Elbow
(3) 6V-8358 Ball Valve
(A) Fuel return line
(B) Fuel supply to engine
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.
Installation of 5T-4463 Hydraulic Tank Mounting Group

Table 49
Parts that are Needed for Installation of 5T-4463 Hydraulic Tank Mounting Group
1 2 105-2200 Mud Flap
2 16 4L-6454 Bolt
3 16 8T-2561 Washer
4 16 6V-8801 Nut
5 1 105-2204 Support
6 1 105-2205 Support
7 1 105-2201 Mud Flap
8 1 105-4620 Support
9 2 8T-9101 Bolt

(A) Remove the bolts prior to installation of the guards.
(B) Do not remove these bolts. Loosen the bolts approximately 8 mm (0.3 inch).
1. Remove seven bolts (A) and loosen two bolts (B) .
(1) 105-2200 Mud Flap
(2) 4L-6454 Bolt
(3) 8T-2561 Washer
(4) 6V-8801 Nut
(5) 105-2204 Support
(B) Bolts
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).

(1) 105-2200 Mud Flap
(2) 4L-6454 Bolt
(3) 8T-2561 Washer
(4) 6V-8801 Nut
(6) 105-2205 Support
(A) Bolts
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).

(2) 4L-6454 Bolt
(3) 8T-2561 Washer
(4) 6V-8801 Nut
(7) 105-2201 Mud Flap
(8) 105-4620 Support
(9) 8T-9101 Bolt
(A) Bolts
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).
Installation of 145-3418 Ladder Group

Table 50
Parts That Are Needed for Installation of 145-3418 Ladder Group

1 1 8W-0671 Ladder Assembly
3 8 8T-2502 Bolt
5 6 4L-6454 Bolt
6 2 5T-8218 Plate
7 2 5T-8220 Baffle
8 1 149-6884 Ladder Assembly

10 4 5P-2566 Bolt
11 5 6V-8188 Nut
12 4 8T-8917 Bolt
13 1 8T-4835 Bolt
14 1 8W-2025 Brace
15 8 4L-9337 Bolt
16 8 6V-8801 Nut
17 2 9P-2950 Handhold
19 8 5P-2228 Bolt
20 2 153-1315 Handhold

(1) 8W-0671 Ladder Assembly
(3) 8T-2502 Bolt
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.

(5) 4L-6454 Bolt
(6) 5T-8218 Plate
(7) 5T-8220 Baffle
(8) 149-6884 Ladder As
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) .

(8) 149-6884 Ladder Assembly
3. Use a suitable crane to position the 149-6884 Ladder Assembly (8). The 149-6884 Ladder Assembly (8)

(10) 5P-2566 Bolt
(11) 6V-8188 Nut
4. Assemble 149-6884 Ladder Assembly (8) by using the following parts: four 5P-2566 Bolts (10), eight 8T-
4223 Hard Washers (9) and four 6V-8188 Nuts (11). Leave 5P-2566 Bolts (10) loose at this time.

(12) 8T-8917 Bolt
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.

(11) 6V-8188 Nut
(12) 8T-8917 Bolt
(13) 8T-4835 Bolt
(14) 8W-2025 Brace
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) .

(5) 4L-6454 Bolt
(6) 5T-8218 Plate
(7) 5T-8220 Baffle
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) .

(15) 4L-9337 Bolt
(16) 6V-8801 Nut
8. Assemble the step assembly on the right side by using the following parts: four 4L-9337 Bolts (15), eight 8T-
4896 Hard Washers (2) and four 6V-8801 Nuts (16) .

(17) 9P-2950 Handhold
(19) 5P-2228 Bolt
(20) 153-1315 Handhold
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.
Installation of 5T-1070 Fender Group

Table 51
Parts that are Needed for Installation of 5T-1070 Fender Group

1 14 7D-1649 Washer
2 5 0S-1595 Bolt
3 1 5T-6403 Fender
4 9 0S-1621 Bolt
5 1 8W-4808 Support
6 1 8W-7900 Guard
7 1 8W-6382 Plate
8 2 5T-6553 Plate
10 2 9B-7237 Bolt
11 15 1D-4717 Nut
12 4 8T-2502 Bolt
13 1 8W-7788 Strip
14 9 5S-7379 Bolt
15 1 8W-6063 Strip
16 9 4L-6454 Bolt
17 1 8W-7899 Guard
18 2 6H-1717 Bolt
20 2 6V-8188 Nut
21 1 8W-0571 Plate
22 4 0S-1594 Bolt
23 8 5M-2894 Hard Washer
24 4 6V-8801 Nut
25 1 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.

(1) 7D-1649 Washer
(2) 0S-1595 Bolt
(3) 5T-6403 Fender Assembly

(1) 7D-1649 Washer
(3) 5T-6403 Fender Assembly
(4) 0S-1621 Bolt
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) .

(1) 7D-1649 Washer
(4) 0S-1621 Bolt
(5) 8W-4808 Support Assembly
2. Assemble the 8W-4808 Support Assembly (5) by using four 7D-1649 Washers (1) and four 0S-1621 Bolts
(4) .

(6) 8W-7900 Guard

(6) 8W-7900 Guard
(7) 8W-6382 Plate
(8) 5T-6553 Plate
(10) 9B-7237 Bolt
(11) 1D-4717 Nut
(12) 8T-2502 Bolt
(13) 8W-7788 Strip
(14) 5S-7379 Bolt

(6) 8W-7900 Guard
(B) Cab

Section B-B
(6) 8W-7900 Guard
(10) 9B-7237 Bolt
(13) 8W-7788 Strip
(B) Cab
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.

(7) 8W-6382 Plate
(8) 5T-6553 Plate
(10) 9B-7237 Bolt
(11) 1D-4717 Nut
(12) 8T-2502 Bolt
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) .

(15) 8W-6063 Strip
(16) 4L-6454 Bolt
(17) 8W-7899 Guard

(11) 1D-4717 Nut
(15) 8W-6063 Strip
(16) 4L-6454 Bolt
(17) 8W-7899 Guard
(C) Right side platform
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) .

(18) 6H-1717 Bolt
(20) 6V-8188 Nut
(21) 8W-0571 Plate
(22) 0S-1594 Bolt
(23) 5M-2894 Hard Washer
(24) 6V-8801 Nut
(25) 8W-0568 Plate
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) .
Installation of 277-0628 Brace for the 5T-1070 Fender Group

Note: S/N:2BW1-1129
Note: Refer to Special Instruction, REHS3392, "Field Installation of the Support for the Fender" for more
information.
Table 52
Parts that are Needed for Installation of 277-0628 Brace for the 5T-1070 Fender Group
Item Qty Pt. No. Description
1 1 277-0629 Plate
2 1 277-0628 Brace
3 1 4V-0661 Mount
4 1 6J-9944 Boss
6 1 7X-0326 Bolt
7 1 6V-8188 Nut
8 2 7X-0590 Hard Washer
9 3 8T-8917 Bolt
11 1 278-0773 Block (1)
(1) Fabricate this component.

5T-6403 Fender As
(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 3 mm (0.12 inch) fillet weld

Weld the boss all the way around.

(11) Block
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 Dimensions
A
70 mm (2.76 inch)
B
36 mm (1.42 inch)
C
20 mm (0.79 inch)
D
40 mm (1.57 inch)
E
17 mm (0.67 inch)
F
25 mm (0.98 inch)
G
80 mm (3.15 inch)

(11) Block

Location of block (11)
3. Locate block (11). Refer to Illustration 184 and Table 56 for dimensions.
Table 56
Location Dimensions for 278-0773 Block

Item Dimensions
H
468 5 mm (18.43 0.20 inch)
J
304 5 mm (11.97 0.20 inch)

Weld specifications for block (11)
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
6 mm (0.24 inch) fillet weld with

W2 1.5 mm (0.059 inch) root penetration
Weld the block on both sides.

(1) Plate
(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.
(1) Plate
(2) Brace
(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.

(2) Brace
(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) .
Installation of 6I-2972 Air Cleaner Group

Table 58
Parts That Are Needed for Installation of 6I-2972 Air Cleaner Group
1 2 5K-3772 Hose Assembly
2 2 3B-6493 Pipe Elbow
3 2 175-5251 Air Cleaner
4 16 8T-4122 Washer
5 16 7X-0344 Bolt
6 2 0A-2926 Nipple
7 2 7W-7417 Service Indicator
8 2 3B-6552 Elbow

(1) 5K-3772 Hose Assembly
(2) 3B-6493 Pipe Elbow
(3) 175-5251 Air Cleaner
(A) Bolts
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) .

(4) 8T-4122 Washer
(5) 7X-0344 Bolt
3. Use a suitable crane to position 175-5251 Air Cleaner (3) against the left fender. Assemble using eight 8T-
4122 Washers (4) and eight 7X-0344 Bolts (5) .

(6) 0A-2926 Nipple
(7) 7W-7417 Service Indicator
(8) 3B-6552 Elbow
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) .


(2) 3B-6493 Pipe Elbow
(4) 8T-4122 Washer
(5) 7X-0344 Bolt
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.

(B) Battery compartment door

(4) 8T-4122 Washer
(5) 7X-0344 Bolt
8. Open battery compartment door (B) .
9. Use one 8T-4122 Hard Washer (4) and one 7X-0344 Bolt (5) in order to assemble 175-5251 Air Cleaner Gp
(3) against the right fender.
10. Assemble 3B-6552 Elbow (8) to the block. Connect 5K-3772 Hose Assembly (1) to 3B-6552 Elbow (8) .
11. Assemble 0A-2926 Nipple (6) to the block.
12. Assemble 7W-7417 Service Indicator (7) to 0A-2926 Nipple (6) .
Installation of 8W-7903 Rear View Mirror Group

Note: The 8W-7903 Rear View Mirror Group is for trucks with a dual slope body.
Table 59
Parts that are Needed for Installation of 8W-7903 Rear View Mirror Group
1 2 3B-4605 Cotter
2 1 8W-7904 Tube Assembly
3 2 7X-0326 Bolt
5 2 7D-9969 Support
6 1 8T-2287 Mirror
7 4 5S-7379 Bolt
9 1 6V-8285 Mirror
10 2 8W-7901 Bracket
11 2 6V-8801 Nut
12 2 4L-6454 Bolt
Note: The following procedure is most easily completed before the right side platform is assembled to the
truck chassis.

(1) 3B-4605 Cotter
(2) 8W-7904 Tube
(3) 7X-0326 Bolt
(5) 7D-9969 Support
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) .

(1) 3B-4605 Cotter
2. Assemble two 3B-4605 Cotters (1) .

(6) 8T-2287 Mirror
(7) 5S-7379 Bolt
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) .

Rear side of 6V-8285 Mirror (9)
(10) 8W-7901 Bracket
(11) 6V-8801 Nut
(12) 4L-6454 Bolt

(7) 5S-7379 Bolt
(9) 6V-8285 Mirror
(10) 8W-7901 Bracket
(11) 6V-8801 Nut
(12) 4L-6454 Bolt
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) .
Installation of 159-2489 Rear View Mirror Group

Note: The 159-2489 Rear View Mirror Group is for trucks with a flat floor body.
Table 60
Parts that are Needed for Installation of 159-2489 Rear View Mirror Group
1 2 3B-4605 Cotter
2 1 159-4795 Tube
3 2 7X-0326 Bolt
5 2 7D-9969 Support
6 1 8T-2287 Mirror
7 2 5S-7379 Bolt

9 1 134-0987 Bracket
10 1 8Y-6989 Mirror
11 1 137-2129 Bracket
12 2 134-0989 Block
13 4 8T-4186 Bolt
15 8 8T-4137 Bolt
16 3 8T-4136 Bolt
Note: The following procedure is most easily completed before the right side platform is assembled to the
truck chassis.

(1) 3B-4605 Cotter
(2) 159-4795 Tube
(3) 7X-0326 Bolt
(5) 7D-9969 Support
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) .

(1) 3B-4605 Cotter
2. Assemble two 3B-4605 Cotters (1) .

(6) 8T-2287 Mirror
(7) 5S-7379 Bolt
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) .

View A-A
(9) 134-0987 Bracket
(10) 8Y-6989 Mirror
(11) 137-2129 Bracket
(12) 134-0989 Block
(13) 8T-4186 Bolt
(15) 8T-4137 Bolt
(16) 8T-4136 Bolt
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) .
Installation of 174-9334 Muffler Gp

Table 61
Parts that are Needed for Installation of 174-9334 Muffler Gp

1 1 5T-7766 Bracket
3 8 5P-2566 Bolt
4 1 4W-0969 Muffler Assembly
5 1 5T-7768 Strap
6 4 4L-9337 Bolt
7 9 2K-4973 Locknut
8 1 8X-6607 Bracket
9 2 8T-9384 Bolt
10 1 5T-7823 Plate
12 2 4L-6454 Bolt
13 1 5T-7770 Plate
14 1 4W-1814 Clamp
15 5 5S-7383 Bolt
16 1 8X-6605 Extension Pipe
17 2 6N-9298 Clamp
18 4 5P-2424 Bolt
19 4 1K-6872 Locknut
20 2 5T-7824 Clamp
21 4 5C-6565 Bolt
22 4 6V-8188 Nut
23 4 2V-8169 Plate
24 4 7X-0345 Bolt
25 2 5T-8049 Strap
26 1 4W-0532 Muffler Assembly
27 2 5T-8050 Strap
28 2 8W-4954 Plate
30 4 9B-7237 Bolt
31 4 6V-8801 Nut
32 1 8X-6606 Extension Pipe
33 1 1W-4161 (1) C-Clamp
34 1 7C-3337 (1) Elbow
35 4 2W-8851 (1) Seal Ring
36 2 2W-9078 (1) Pipe
37 1 7C-3338 (1) Elbow
38 1 7C-3339 (1) Elbow
39 1 7C-3336 (1) Pipe
(1) Part of 230-8139 Exhaust Pipe Gp
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.

(1) 5T-7766 Bracket
(3) 5P-2566 Bolt
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).

(4) 4W-0969 Muffler Assembly
(5) 5T-7768 Strap
(6) 4L-9337 Bolt
(7) 2K-4973 Locknut
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).

(8) 8X-6607 Bracket
(9) 8T-9384 Bolt
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).

(10) 5T-7823 Plate
(12) 4L-6454 Bolt
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).

(7) 2K-4973 Locknut
(13) 5T-7770 Plate
(14) 4W-1814 Clamp
(15) 5S-7383 Bolt
5. Assemble 5T-7770 Plate (13) by using the following items: 4W-1814 Clamp (14), 5S-7383 Bolt (15) and 2K-
4973 Locknut (7). Apply 5P-3931 Anti-Seize Compound to 5S-7383 Bolt (15) prior to assembly. Tighten 5S-
7383 Bolt (15) to a torque value of 25 6 Nm (18 4 lb ft).

(16) 8X-6605 Extension Pipe
(17) 6N-9298 Clamp
(18) 5P-2424 Bolt
(19) 1K-6872 Locknut
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).

(8) 8X-6607 Bracket
(21) 5C-6565 Bolt
(22) 6V-8188 Nut

(18) 5P-2424 Bolt
(20) 5T-7824 Clamp
(21) 5C-6565 Bolt
(22) 6V-8188 Nut
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).

(A) Bolts
(B) Cover
8. Remove bolts (A) and cover (B) .
9. Use a suitable scraper in order to clean the mounting flange on the beam.
(23) 2V-8169 Plate
(24) 7X-0345 Bolt
10. Assemble the lower muffler assembly to the truck chassis by using four 2V-8169 Plates (23) and four 7X-
0345 Bolts (24). Tighten 7X-0345 Bolts (24) to a torque value of 115 20 Nm (85 15 lb ft).

(3) 5P-2566 Bolt
(25) 5T-8049 Strap
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).

(25) 5T-8049 Strap
(26) 4W-0532 Muffler Assembly
12. Position 4W-0532 Muffler Assembly (26) on 5T-8049 Strap (25). The 4W-0532 Muffler Assembly (26)

(7) 6N-9298 Clamp
(15) 5S-7383 Bolt
(27) 5T-8050 Strap
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) .

(25) 5T-8049 Strap
(28) 8W-4954 Plate
(30) 9B-7237 Bolt
(31) 6V-8801 Nut
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).
(17) 6N-9298 Clamp
(18) 5P-2424 Bolt
(20) 5T-7824 Clamp
(21) 5C-6565 Bolt
(22) 6V-8188 Nut
(32) 8X-6606 Extension Pipe
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).

(A) Shipping covers
(B) Clamp
16. Remove the shipping covers (A). Retain both clamps (B) .

(26) 4W-0532 Muffler As
(33) 1W-4161 Clamp
(34) 7C-3337 Elbow
(36) 2W-9078 Pipe
(37) 7C-3338 Elbow
(38) 7C-3339 Elbow
(39) 7C-3336 Pipe
(B) Clamps
(D) Bolts
(E) Washers
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) .

(34) 7C-3337 Elbow
(35) 2W-8851 Seal Ring
(36) 2W-9078 Pipe
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 1W-
4161 Clamp (33) to a torque value of 15 3 Nm (11 2 lb ft).
Note: Do not overtighten 1W-4161 Clamp (33) .

(C) Cover
(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) .

(26) 4W-0532 Muffler As
(33) 1W-4161 Clamp
(34) 7C-3337 Elbow
(36) 2W-9078 Pipe
(37) 7C-3338 Elbow
(38) 7C-3339 Elbow
(39) 7C-3336 Pipe
(B) Clamps
(D) Bolts
(E) Washers
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) .
Installation of 5T-4464 Platform Group

Table 62
Parts that are Needed for Installation of 5T-4464 Platform Group

1 1 7I-5493 Support
2 12 4L-6454 Bolt
4 1 8X-7007 Rail
6 8 1A-8063 Bolt
7 6 2S-7593 Hard Washer
8 6 8S-9092 Bolt
9 1 8W-4926 Plate
10 3 5P-2228 Bolt
Note: Step 1 through 3 of the following procedure are most easily completed before the right side platform is
assembled to the truck chassis.

(1) 7I-5493 Support Assembly
1. Use a suitable crane in order to remove 7I-5493 Support Assembly (1) from the shipping pallet. Set the 7I-
5493 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.

(1) 7I-5493 Support Assembly
(2) 4l-6454 Bolt
(4) 8X-7007 Rail
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
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) .

Front mounting flange for the RH platform
(A) Shipping bracket
(B) Bolts
(C) Bolts
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.

Rear mounting flange for the RH platform

Rear mounting flange for the RH platform
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.

RH platform
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.

RH platform
10. Position the right side platform against the mounting flanges and align the holes in the mounting flanges.

(6) 1A-8063 Bolt
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.
Top three 8S-9092 Bolts (8) for rear mounting point on platform.

Bottom three 8S-9092 Bolts (8) for rear mounting point on platform.
(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).

(9) 8W-4926 Plate
(10) 5P-2228 Bolt
13. Use three 8T-4223 Hard Washers (11) and three 5P-2228 Bolts (10) in order to assemble 8W-4926 Plate (9) .
Installation of 156-9342 Steering Tank Group

Table 63
Parts that are Needed for Installation of 156-9342 Steering Tank Group
1 1 155-6660 Steering Tank and Filter Gp
3 9 5C-6565 Bolt
1. Use a suitable crane in order to position 155-6660 Steering Tank and Filter Group (1) on the right platform.

(1) 155-6660 Steering Tank and Filter Gp
(3) 5C-6565 Bolt

(1) 155-6660 Steering Tank and Filter Gp
(3) 5C-6565 Bolt
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.
Installation of the Cab Mounting Gp

Refer to 163-7225 Cab Mounting Gp .
Refer to 193-6348 Cab Mounting Gp .
Table 64
Parts that are Needed for Installation of the Cab Mounting Gp

1 1 5P-6076 (1) Support Assembly
2 25 5P-8250 (1) Washer
3 25 1F-7464 (1) Bolt
4 1 228-3732 (1) Support
5 8 163-3127 (2) Sleeve
6 40 163-0042 (2) Cab Mount
7 6 163-0364 (2) Sleeve
8 6 164-4411 (2) Sleeve
9 20 5T-5807 (2) Retainer
10 8 6V-2624 (2) Bolt
11 4 5T-9893 (2) Shim
12 4 5T-9894 (2) Shim
13 6 6B-0388 (2) Bolt
14 6 1K-9420 (2) Bolt
(A) Shipping Bracket
(B) Four bolts
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).
2. Remove the 25 plugs from the mounting flanges on the front and rear cab support assemblies. Refer to the
arrows.
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.

(1) 5T-6076 Support Assembly
4. Use 4C-4204 Paint Remover in order to clean the shipping grease or paint from the mounting flange of 5T-
6076 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).

(2) 5P-8250 Washer
(3) 1F-7464 Bolt
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).

(2) 5P-8250 Washer
(3) 1F-7464 Bolt
(4) 228-3732 Support
7. Use 4C-4204 Paint Remover in order to clean the shipping grease and paint from the mounting flange of 228-
3732 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) .

(5) 163-3127 Sleeve
(6) 163-0042 Cab Mount
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.

(6) 163-0042 Cab Mount
(7) 163-0364 Sleeve
(8) 164-4411 Sleeve
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.
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).
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.

(11) 5T-9893 Shim
(12) 5T-9894 Shim
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.

(6) 163-0042 Cab Mount
(9) 5T-5807 Retainer
(10) 6V-2624 Bolt
16. Assemble the following items: eight 163-0042 Cab Mounts (6), eight 5T-5807 Retainers (9) and eight 6V-
2624 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.

(6) 163-0042 Cab Mount
(9) 5T-5807 Retainer
(13) 6B-0388 Bolt
(14) 1K-9420 Bolt
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 6B-
0388 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 1K-
9420 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).
Connect Air Lines and Wire Harnesses to the Cab

View of the cab
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).

View of the right side of the cab
a. Remove ten bolts (A) and ten washers (B) that secure plate (C) to the side of the cab. Retain the
hardware.
b. Remove plate (C). Retain plate (C) .

View from the right side of the cab
c. Insert the harness assemblies (D) for the cameras through the top hole in plate (C) .
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 Video Cables to Camera Cable Color

1 Front Red
2 Right Blue
3 Rear Green
4 Left Yellow
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.

View of the right side of the cab
(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
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.
4. Connect the air lines to the correct places on the cab.
5. Connect the wire harnesses to the correct places on the cab.
View of the cab
6. Use tie straps to secure the air lines and the wire harnesses.
Installation of 150-8726 Steering Lines Group

Table 66
Parts That Are Needed for Installation of 150-8726 Steering Lines Group
2 2 148-8364 Elbow
3 1 148-8361 Elbow
4 1 150-8708 Tube
5 1 150-8709 Tube
6 1 150-8723 Tube
7 1 150-8710 Tube
8 1 150-8713 Tube
9 1 0T-0102 Bolt
11 1 9S-1350 Clip
12 2 5T-6867 Clamp
13 2 0S-0509 Bolt
14 1 150-9037 Bar
17 4 0L-1351 Bolt
18 1 2G-8895 Bracket
19 1 6G-8532 Guard
20 3 9L-9132 Washer
1. Remove the eight bolts and the eight washers that secure the panel on the left side of the cab.

View of the hand metering unit
(A) Plastic screw caps
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.

(2) 148-8364 Elbow
(3) 148-8361 Elbow

(B) Rear Port "T"
(C) Rear Port "L"
(D) Front Port "P"
(E) Front Port "R"
(F) Side Port "LS"
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.
5. Install a 148-8361 Elbow (3) in side port "LS" (F) of the hand metering unit.

(4) 150-8708 Tube
(5) 150-8709 Tube
(6) 150-8723 Tube
(7) 150-8710 Tube
(8) 150-8713 Tube
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.

(9) 0T-0102 Bolt
(11) 9S-1350 Clip
(12) 5T-6867 Clamp
(13) 0S-0509 Bolt
(14) 150-9037 Bar
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.

(15) 6V-8398 O-Ring Seals
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) .

(G) Typical location of tags
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.

(H) Straps
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) .

(17) 0L-1351 Bolt
(18) 2G-8895 Bracket
18. Install 2G-8895 Bracket (18) by using 0L-1351 Bolt (17) and 5M-2894 Hard Washer (10) .

(17) 0L-1351 Bolts
(19) 6G-8532 Guard
(20) 9L-9132 Washers
19. Install 6G-8532 Guard (19) by using three 0L-1351 Bolts (17) and three 9L-9132 Washers (20) .

(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) .

"Tank" port and "Pump" port on the steering tank before the steering lines are connected.
(J) Plate
(M) Half Flange
(P) Plate
(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.

(J) Plate
(K) Half Flange
(L) O-Ring Seal
(M) Half Flange
(N) O-Ring Seal
(P) Plate
(R) Bolt
(S) Hard Washer
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.
Installation of 5T-4484 Heater Lines Group

Table 67
Parts that are Needed for Installation of 5T-4484 Heater Lines Group
1 2 6P-8855 Spacer
2 8 9X-2488 Hose Clamp
3 1 6D-1641 Clip
4 1 8T-4896 Washer
5 1 5S-7379 Bolt
1. Remove the two caps from the heater hose assemblies.

(1) 6P-8855 Spacer
(2) 9X-2488 Hose Clamp
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.
(3) 6D-1641 Clip
(5) 5S-7379 Bolt
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) .
Installation of Air Conditioner Lines
Personal injury can result from contact with refrigerant.
Contact with refrigerant can cause frost bite. Keep face and hands away
to help prevent injury.
Protective goggles must always be worn when refrigerant lines are

opened, even if the gauges indicate the system is empty of refrigerant.
Always use precaution when a fitting is removed. Slowly loosen the

fitting. If the system is still under pressure, release it slowly in a well
ventilated area.
Personal injury or death can result from inhaling refrigerant through a

lit cigarette.
Inhaling air conditioner refrigerant gas through a lit cigarette or other

smoking method or inhaling fumes released from a flame contacting air
conditioner refrigerant gas, can cause bodily harm or death.
Do not smoke when servicing air conditioners or wherever refrigerant

gas may be present.
Use a certified recovery and recycling cart to properly remove the

refrigerant from the air conditioning system.

(A) Hose assembly
(B) Hose assembly
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.
Installation of 144-4183 Air Horn Group
1. Remove the strap from the hose assembly. The strap is located at the loose end of the hose assembly.
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.
3. Connect the loose end of the hose assembly to the fitting. Refer to the arrow.
Installation of the Truck Hood Group

Refer to 211-9145 Truck Hood Gp .
Refer to 211-9143 Cowling Group .
Table 68
Parts that are Needed for Installation of the Truck Hood Group
1 2 5P-1075 (1) Hard Washer
2 2 5S-7379 (1) Bolt
3 1 211-9141 (2) Rail As
4 12 8T-4896 (2) Hard Washer
5 12 4L-6454 (2) Bolt

(1) Part of 211-9145 Truck Hood Gp
(2) Part of 211-9143 Cowling Group

(2) 5S-7379 Bolt
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:
The hood lock latches easily.
The hood lock releases the rear hood assembly easily.

(3) 211-9141 Rail As
(5) 4L-6454 Bolt
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

(A) Hose assembly
(B) Hose assembly
(C) Hose assembly
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.

(D) Hose assembly
(E) Hose assembly
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.
Installation of 144-4141 Air Lines Group (If Equipped)

Table 69
1 2 6I-0982 Tube
2 2 4P-5212 Hose
3 2 7N-5008 Hump Hose
4 8 233-8484 Clamp
5 16 240-2651 Clamp
6 4 233-8482 Clamp
7 1 1W-6903 Hump Hose
8 2 5T-6459 Elbow
9 8 233-8485 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.

(1) 6I-0982 Tube

(A) Bolts
(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.

(1) 6I-0982 Tube
(A) Bolts
(B) Nuts
(C) Strap

(1) 6I-0982 Tube
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).

(1) 6I-0982 Tube
(2) 4P-5212 Hose

(2) 4P-5212 Hose
(3) 7N-5008 Hump Hose

(2) 4P-5212 Hose
(5) 240-2651 Clamp
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.

(1) 6I-0982 Tube

(4) 233-8484 Clamp
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).

(6) 233-8482 Clamp
(7) 1W-6903 Hump Hose
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.

(8) 5T-6459 Elbow
(9) 233-8485 Clamp
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).
9. Repeat Step 1 through Step 8 for the left side of the truck.
Installation of 249-0316 Air Lines Group (If Equipped)
Table 70
1 2 7E-7790 Hose
2 16 233-8485 Clamp
3 2 249-3766 Tube
4 2 5T-7874 Strap
5 4 0S-1595 Bolt
7 2 5T-7874 Strap
8 4 9S-8752 Full Nut
9 4 0S-1571 Bolt
10 2 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.

(1) 7E-7790 Hose
(2) 233-8485 Clamps
(3) 249-3766 Tube
(10) 5T-6459 Elbow
(A) Tube
1. Remove the cap from tube (A) .
of 7E-7790 Hose (1) before assembly.
2. Assemble one 7E-7790 Hose (1) and four 233-8485 Clamps (2) with a torque of 7.5 1 Nm (66 9 lb in).
3. Assemble 249-3766 Tube (3) to 7E-7790 Hose (1) .

View A-A
(4) 5T-7873 Bracket As
(5) 0S-1595 Bolt
(7) 5T-7874 Strap
(8) 0S-1571 Bolt
(9) 0S-1571 Bolt
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).
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).
Installation of the 7X-1062 Ether Cylinders
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.
1. Install two 7X-1062 Ether Cylinders .
Installation of 229-9389 Demountable Rim Gp

Refer to the 5T-1023 Front Wheel Group .
Table 71
Parts That Are Needed for Installation of 229-9389 Demountable Rim Gp

1 6 138-7582 Demountable Rim
2 6 8W-0338 O-Ring Seal
3 4 8W-0331 Swivel Connector
4 6 5T-9790 Tire Valve
5 18 8W-3891 (1) Flange Nut
6 304 5P-8250 (1) Washer
7 304 2J-3507 (1) Full Nut
8 2 230-1132 Hose As
9 2 261-3036 Plate
10 4 1S-0996 Clip
11 4 1B-4287 Washer
12 4 8T-4244 Nut
14 4 261-3244 Pipe
15 8 261-3243 Spacer
16 2 8T-5001 Bolt
17 2 8T-5041 Bolt
18 2 176-7281 Extension
19 2 8X-2627 Bracket
20 8 1D-4566 Bolt
22 8 6J-0427 Spacer
(1) Part of 5T-1023 Front Wheel Group
Install the Front Tires

(1) 138-7582 Demountable Rim
(2) 8W-0338 O-Ring Seal
(3) 8W-0331 Swivel Connector
(4) 5T-9790 Tire Valve
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.
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.
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.
4. Position the tire assembly next to the wheel by using a tire handler. The weight of the tire and rim assembly is
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).
6. Use a tire handler to position the tire on the wheel. Align the wheel studs with the bolt pattern in the rim.

(5) 8W-3891 Flange Nut
(6) 5P-8250 Washer
(7) 2J-3507 Full Nut
7. Use a tire handler to retain the tire assembly. Assemble three 8W-3891 Flange Nuts (5) on the three longer
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.
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.
Front Wheel Alignment

Typical top view of the steering linkage
(A) Distance between the front tires at the front
(B) Clamps on left side tie bar
(C) Clamps on right side tie bar
(D) Distance between the front tires at the back
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.

View A-A
(E) Tie rod
(F) Clamp assembly
(G) 6.350 1.530 mm (0.25 0.06 inch)
7. Position clamp assembly (F) on tie rod (E) .

Side view of the clamp assembly
(E) Tie rod
(F) Clamp assembly
(H) Nut
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.
Install the Rear Tires

(3) 8W-0331 Swivel Connector
(8) 230-1132 Hose As
1. Assemble 138-7582 Demountable Rim (1) to the inside rear tire by using the following parts: 8W-0338 O-
Ring 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.
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).
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.
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) .
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.

(A) Bolts
(B) Washers
(C) Ring
6. Remove 57 bolts (A) and 57 washers (B) in order to remove ring (C) .
7. Remove ring (C) .
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.

(6) 5P-8250 Washer
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).

(14) 261-3244 Pipe
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).

(8) 230-1132 Hose As
(9) 261-3036 Plate
(10) 1S-0996 Clip
(11) 1B-4287 Washer
(15) 261-3243 Spacer
(16) 8T-5001 Bolt
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) .
(8) 230-1132 Hose As
(9) 261-3036 Plate
(10) 1S-0996 Clip
(11) 1B-4287 Washer
(12) 8T-4244 Nut
(15) 261-3243 Spacer
(16) 8T-5001 Bolt
(17) 8T-5041 Bolt

(12) 8T-4244 Nut
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), 1S-
0996 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) .

(18) 176-7281 Valve Extension
18. Assemble 138-7582 Demountable Rim (1) to the outside rear tire by using the following parts: 8W-0338 O-
Ring 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.
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.

(C) Ring
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.
23. Use a suitable tire handler to turn the tire assembly to the other side.

(6) 5P-8250 Washer
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).
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.

(A) Bolts
(B) Washers
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.

(19) 8X-2627 Bracket
(20) 1D-4566 Bolt
(22) 6J-0427 Spacer

View of bracket with valve stem on the rear, outside tire
(19) 8X-2627 Bracket
(20) 1D-4566 Bolt
(22) 6J-0427 Spacer
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) .
30. Repeat Step 1 through Step 29 for the opposite side of the truck.
31. Remove the crane, the lifting device, and the bar.
Installation of 125-6229 Body and Canopy Assembly

Note: Be sure to remove all lifting eyes prior to the installation of the body and canopy to the chassis.
Table 73
Parts that are Needed for Installation of 125-6229 Body and Canopy Assembly
1 1 8W-3667 Guard Assembly
2 2 114-5012 Guard Assembly
3 1 8X-6394 Plate Assembly
4 1 112-6185 Plate Assembly
5 1 112-6184 Plate Assembly
Note: The 125-6229 Body and Canopy As is a dual slope body.
Note: Refer to the following procedure if the following items have not been assembled to the truck body: the
mounting brackets for the rock ejectors, right side muffler guard, left side mirror guard and body down
indicator brackets. Step 1 through Step 11 of the following procedure is most easily performed before the
truck body is installed. Step 12 through Step 18 of the following procedure is most easily performed after the
truck body has been installed.
Note: The rock ejector brackets and the guards are located in the body.

(1) 8W-3667 Guard

(1) 8W-3667 Guard
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.

(1) 8W-3667 Guard

(1) 8W-3667 Guard

Section A-A
(1) 8W-3667 Guard
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
4. Position and weld 8W-3667 Guard (1) to the truck body.

(1) 8W-3667 Guard
5. After installation of 8W-3667 Guard (1), prepare the welded connection for paint.
6. Use 4C-4200 Paint in order to touch up the area of the weld.

(2) 114-5012 Guard

(2) 114-5012 Guard
(A) 2514 mm (99.0 inch)
(B) 10 mm (0.4 inch)
(C) 161 mm (6.3 inch)
(D) 70 mm (2.8 inch)
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.

(2) 114-5012 Guard
10. Position and weld 114-5012 Guard (2) to the truck body.
Table 75
Welding Dimensions
Weld Specification

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.
12. Use 4C-4200 Paint in order to touch up the weld.
13. Repeat step 7 through step 12 in order to weld the other 114-5012 Guard (2) into position.

(E) 1150 5 mm (45.3 0.2 inch)

Section B-B
(3) 8X-6394 Plate Assembly
(F) 940 3 mm (37.0 0.1 inch)
Table 76
Welding Dimensions
Weld Specification
W3 3 mm (0.12 inch) fillet weld

Weld from location (D) to location (E).
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.
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.

(4) 8X-6394 Plate Assembly
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.

(4) 112-6185 Plate Assembly

Section G-G
(4) 112-6185 Plate Assembly

Section H-H
(G) 1226.5 3.0 mm (48.29 0.12 inch)
Table 77
Welding Dimensions
Weld Specification
10 mm (0.4 inch) fillet weld with

W4
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.
18. Repeat Steps 12 through 17 for the 112-6184 Plate Assembly (5) on the right side of the truck body.
Installation of 155-3633 Film Group
Table 78
Parts that are Needed for Installation of 155-3633 Film Group

1 1 155-3637 Film (LH)
2 1 155-3636 Film (RH)
3 3 131-5415 Film
4 1 100-5615 Film
Note: The following procedure is most easily completed before the truck body is assembled to the truck
chassis.

(1) 155-3637 Film
(1) 155-3637 Film
(A) The area between the ribs
(B) 25 1 mm (1.0 0.4 inch)
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.

(2) 155-3636 Film

(2) 155-3636 Film
(C) The area between the ribs
(D) 25 1 mm (1.0 0.4 inch)
4. Repeat Step 1 through Step 3 for 155-3636 Film (2) .

(3) 131-5415 Film

(3) 131-5415 Film

(3) 131-5415 Film
(4) 100-5615 Film
(E) 65 5 mm (2.5 0.2 inch)
5. Repeat Step 1 through Step 3 for three 131-5415 Film (3) and one 100-5615 Film (4) .
Installation of 5T-6046 Retaining Cable Gp or 144-4147 Retaining Cable

Gp
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
1 2 1D-4643 Bolt
2 2 5P-8250 Washer
3 2 2H-3794 Locknut
4 1 105-0314 Coupler
5 1 6G-9703 (1) Cable
5 1 145-9033 (2) Cable
6 1 2B-0974 Clevis Pin
8 1 3B-4617 Cotter
9 1 8W-0109 Plate
(1) Part of 5T-6046 Retaining Cable Gp
(2) Part of 144-4147 Retaining Cable Gp

(1) 1D-4643 Bolt
(2) 5P-8250 Washer
(3) 2H-3794 Locknut
(4) 105-0314 Coupler
(5) 6G-9703 Cable
(5) 145-9033 Cable
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).

(5) 6G-9703 Cable
(5) 145-9033 Cable
(6) 2B-0974 Clevis Pin
(8) 3B-4617 Cotter
(9) 8W-0109 Plate
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) .
Installation of 154-3757 Body Mounting Group

Table 80
Parts that are Needed for Installation of 154-3757 Body Mounting Group
1 10 0L-1351 Bolt
3 2 5T-7228 Plate
4 59 0S-1588 Bolt
5 54 6V-8801 Nut
6 2 6G-9704 Strip
7 1 5T-5989 Mud Flap
8 1 5T-5988 Mud Flap
9 2 5T-7255 Plate
10 2 5T-7352 Strip
11 1 5T-7274 Mud Flap
12 1 5T-7275 Mud Flap
13 5 5M-2894 Washer
14 1 8X-5421 Plate
15 1 105-4727 Mud Flap
16 2 8W-8679 Pin
17 8 1H-9456 Bolt
19 2 8W-9373 Cover
20 2 6G-9697 Washer
21 2 8W-2896 Washer
22 2 8W-8677 Plate
23 4 0S-1585 Bolt

25 10 322-0363 Pad As
26 25 6G-9711 Shim
27 8 5T-3750 Plate
28 24 9S-1366 Bolt
29 30 7D-1649 Washer
30 24 1F-7958 Full Nut
31 2 6G-7773 Pin
32 4 3B-4647 Cotter Pin
33 2 227-5875 Ejector
34 1 8X-6365 Baffle
35 2 8X-6366 Plate
36 4 9B-7237 Bolt
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).

(1) 0L-1351 Bolt
(3) 5T-7228 Plate
(4) 0S-1588 Bolt
(5) 6V-8801 Nut
(6) 6G-9704 Strip
(7) 5T-5989 Mud Flap
(1) 0L-1351 Bolt
(3) 5T-7228 Plate
(4) 0S-1588 Bolt
(5) 6V-8801 Nut
(6) 6G-9704 Strip
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) .

(1) 0L-1351 Bolt
(3) 5T-7228 Plate
(4) 0S-1588 Bolt
(5) 6V-8801 Nut
(6) 6G-9704 Strip
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) .

(4) 0S-1588 Bolt
(5) 6V-8801 Nut
(9) 5T-7255 Plate
(10) 5T-7352 Strip
(11) 5T-7274 Mud Flap
(12) 5T-7275 Mud Flap
(4) 0S-1588 Bolt
(5) 6V-8801 Nut
(6) 6G-9704 Strip
(9) 5T-7255 Plate
(10) 5T-7352 Strip
(11) 5T-7274 Mud Flap
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) .

(4) 0S-1588 Bolt
(5) 6V-8801 Nut
(9) 5T-7255 Plate
(10) 5T-7352 Strip
(12) 5T-7275 Mud Flap
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) .

(4) 0S-1588 Bolt
(14) 8X-5421 Plate
(15) 105-4727 Mud Flap

(4) 0S-1588 Bolt
(14) 8X-5421 Plate
(15) 105-4727 Mud Flap
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) .
11. Clean the bores for the truck body hinge. Refer to the arrows. Remove the following items: paint, grease and
burrs.
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.
13. Clean the bores for the body hoist. Refer to the arrows. Remove the following items: paint, grease and burrs.
14. Assemble pin assemblies in preparation for installation of the truck body to the chassis. Refer to the arrows.

(17) 1H-9456 Bolt
(19) 8W-9373 Cover
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) .

(A) Location of lifting points
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.
19. Lower the truck body in order to align the bores for the hinge pins.

(16) 8W-8679 Pin
(20) 6G-9697 Washer
(21) 8W-2896 Washer

(16) 8W-8679 Pin
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).

(22) 8W-8677 Plate
(23) 0S-1585 Bolt
(16) 8W-8679 Pin
(20) 6G-9697 Washer
(21) 8W-2986 Hose Assembly
(22) 8W-8677 Plate
(23) 0S-1585 Bolt
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.

Right-hand view
(B) Rockers
(C) Body rail
(D) Frame rail
(25) Rocker pads
23. Raise the dump body.
24. Lower the body slowly. If the body contacts both of the factory installed rocker pads on rockers (B) at the
same time, then go to Step 29. If the body does not contact both rocker pads (B) at the same time, then install
shims (26) under the rocker pads that need to be raised. Refer to Step 25 in order to install the shims.
Note: If the rocker pads need to be raised more than 8 mm (0.315 inch) then plate (27) should be used.
25. Raise the dump body and install the proper safety device in order to secure the dump body in the RAISE
position.
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.
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.

(31) 6G-7773 Pin
(32) 3B-4647 Cotter Pin
(33) 227-5875 Ejector
36. Use a suitable crane in order to position 227-5875 Ejector (33). The 227-5875 Ejector (33) weighs
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.

(34) 8X-6365 Baffle
(35) 8X-6366 Plate
(36) 9B-7237 Bolt
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) .
Installation of 5T-4469 Hoist Cylinder and Mounting

Table 81
Parts that are Needed for Installation of 5T-4469 Hoist Cylinder and Mounting
1 2 239-5505 Pin
2 4 6G-9696 Spacer
3 2 6G-9691 Bar
5 4 0S-1585 Bolt

(1) 239-5505 Pin
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).
2. Use a suitable chain in order to support the weight of the hoist cylinder. The hoist cylinder weighs
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 .
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.

(1) 239-5505 Pin
5. Apply 5P-3931 Anti-Seize Compound to 239-5505 Pin (1) .

(2) 6G-9696 Spacer

(1) 239-5505 Pin
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.

(2) 6G-9696 Spacer
7. Align the second 6G-9696 Spacer (2) at the opposite side of the hoist cylinder. Drive the 239-5505 Pin (1)
into position.

(3) 6G-9691 Bar
(5) 0S-1585 Bolt
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.
Installation of 8X-8270 Automatic Lubrication Group

Table 82
Parts that are Needed for Installation of 8X-8270 Automatic Lubrication Group
1 1 351-2414 Lubrication Pump
3 3 0S-1594 Bolt
4 2 8L-6557 Connector
5 4 9L-5125 Elbow
6 14 4K-8864 Clip
7 14 5M-3062 Bolt
8 2 2N-1287 Flared Elbow

Typical view
(1) 351-2414 Lubrication Pump

Typical view
(1) 351-2414 Lubrication Pump
(3) 0S-1594 Bolt
(A) Air line
(B) Grease line
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) .

View of the left, front suspension cylinder

(4) 8L-6557 Connector
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) .

View of the rear side of the left, front suspension cylinder
(5) 9L-5125 Elbow
7. Remove the plug and install 9L-5125 Elbow (5) .
8. Connect the existing hose assembly to 9L-5125 Elbow (5) .

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.

(5) 9L-5125 Elbow
11. Remove the plug and install 9L-5125 Elbow (5) .
12. Remove the cap and connect the existing hose assembly to 9L-5125 Elbow (5) .

(6) 4K-8864 Clip
(7) 5M-3062 Bolt
14. Raise the truck body and install the truck body retaining cable.
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) .

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) .
19. Remove the truck body retaining cable. Lower the truck body.
Installation of 3Z-4942 Fast Fill Service Center Group (If Equipped)

Table 83
Parts that are Needed for the Installation of 3Z-4942 Fast Fill Service Center Group (If Equipped)
1 1 3B-7255 Reducing Bushing
2 1 2N-8037 Elbow
3 1 1Q-5485 Flange
4 1 032-4814 Elbow
5 1 3K-0360 O-Ring Seal
6 2 6V-3822 Bolt
7 4 0L-1351 Bolt
8 4 7X-0772 Hard Washer
9 2 2G-8992 Clamp
10 2 4L-6454 Bolt

(1) 3B-7255 Reducing Bushing
(2) 2N-8037 Elbow
1. Remove the plug from the lubrication pump.
2. Install 3B-7255 Reducing Bushing (1). Install 2N-8037 Elbow (2) into 3B-7255 Reducing Bushing (1) .
3. Assemble the grease hose to 2N-8037 Elbow (2) .
4. Remove the existing adapter and the gasket on the steering tank. Retain the gasket.

(3) 1Q-5485 Flange
(4) 032-8414 Elbow
(5) 3K-0360 O-Ring Seal
(6) 6V-3822 Bolts
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) .

(7) 0L-1351 Bolt
(8) 7X-0772 Hard Washer
7. Use four 0L-1351 Bolts (7) and four 7X-0772 Hard Washers (8) to attach the box to the fuel tank.
(9) 2G-8992 Clamp
(10) 4L-6454 Bolt
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.

(9) 2G-8992 Clamp
(10) 4L-6454 Bolt
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.
Installation of 230-7213 Lighting and Wiring Group and 147-3533

Lighting and Wiring Group
Table 84
Parts that are Needed for Installation of 230-7213 Lighting and Wiring Group and 147-3533 Lighting and
Wiring Group
1 1 9G-9152 Clip
3 11 5M-3062 Bolt
4 2 4D-7794 Clip
5 2 4L-6454 Bolt
6 2 6V-8801 Nut
7 2 8M-2770 Clip
8 2 5P-0562 Lockwire
9 2 135-0428 Signal Lamp
10 6 7S-4346 Screw
11 6 9F-5599 Lockwasher
12 6 4B-2049 Nut
13 4 1S-0994 Clip
14 8 5S-7379 Bolt
16 5 7D-4092 Clip
17 3 9G-9154 Clip
18 2 3T-0050 Clip
19 40 3S-2093 Cable Strap
20 3 1H-3244 Lockwasher
21 1 3T-4411 Flood Lamp
22 1 5T-1680 Plate
23 1 117-5883 Cable
24 2 9M-4995 Clip
25 1 3M-7212 Battery Terminal
26 1 9G-9150 Clip
27 1 5P-9297 Clip
28 1 3T-3048 Clip Assembly
(1) 9G-9152 Clip
(3) 5M-3062 Bolt
(4) 4D-7794 Clip
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.

Front view of the fuel tank
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.

Rear view of the fuel tank
(3) 5M-3062 Bolt
(4) 4D-7794 Clip
8. Secure the wiring harness with the following items: 4D-7794 Clip (4), 5M-3062 Bolt (3) and 8T-4896 Hard
Washer (2) .

(9) 135-0428 Signal Lamp
(10) 7S-4346 Screw

(11) 9F-5599 Lockwasher
(12) 4B-2049 Nut
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) .

(3) 5M-3062 Bolt
(14) 5S-7379 Bolt
(24) 9M-4995 Clip
(25) 3M-7212 Battery Terminal
(27) 5P-9297 Clip
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),
5S-7379 Bolt (14) and 8T-4896 Hard Washer (2) .

(3) 5M-3062 Bolt
(13) 1S-0994 Clip
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) .

(14) 5S-7379 Bolt
(16) 7D-4092 Clip

(14) 5S-7379 Bolt
(16) 7D-4092 Clip
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) .
17. Remove the strap. Route the wiring harness above the front cab support.

(3) 5M-3062 Bolt
(17) 9G-9154 Clip
(18) 3T-0050 Clip
18. Use 5M-3062 Bolt (3) and 8T-4896 Hard Washer (2) to assemble 9G-9154 Clip (17) and 3T-0050 Clip (18) .
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.

(19) 3S-2093 Cable Strap
20. Use as many 3S-2093 Cable Strap (19) as required in order to secure the harnesses.
21. Remove the six bolts that secure the cover to the back of the cab.
22. Remove the light assembly from the back of the cab.
23. Reposition the cover on the back of the cab. Reinstall the six bolts for the cover on the back of the cab.
24. Remove the tape from the cab.

(14) 5S-7379 Bolt
(20) 1H-3244 Lockwasher
(21) 3T-4411 Flood Lamp
(22) 5T-1680 Plate
25. Assemble 5T-1680 Plate (22) to 3T-4411 Flood Lamp (21) .
26. Connect 3T-4411 Flood Lamp (21) to the cab harness. Use three 1H-3244 Lockwashers (20) and three 5S-
7379 Bolts (14) to secure 5T-1680 Plate (22) .

(3) 5M-3062 Bolt
(23) 117-5883 Cable
(24) 9M-4995 Clip
(25) 3M-7212 Battery Terminal
Batteries give off flammable fumes that can explode resulting in

personal injury.
Prevent sparks near the batteries. They could cause vapors to explode.
Do not smoke near batteries.
Electrolyte is an acid and can cause personal injury if it contacts skin or

eyes.
Always wear eye protection when starting a machine with jump start
cables.
Improper jumper cable connections can cause explosion resulting in

personal injury.
When using jumper cables, always connect positive(+) cable to positive

(+) terminal of battery connected to starter solenoid and negative(-)
cable from external source to engine block. Follow procedure in the
Operation and Maintenance Manual.
27. Assemble 117-5883 Cable (23) .
28. Connect the two cables to the positive battery terminal.
29. Connect the cable to the negative battery terminal.
30. Use the following items to secure the three cables: 9M-4995 Clip (24), 5M-3062 Bolt (3) and 8T-4896 Hard
Washer (2) .
31. Remove the existing nut and the existing washer. Secure the cable by using 3M-7212 Battery Terminal (25).
Replace the existing nut and the existing washer.
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.
Installation of 115-6488 Payload Signal Lamp Group

Note: This procedure is effective for (S/N: 2BW303,306-658).
Table 85
Parts that are Needed for Installation of 115-6488 Payload Signal Lamp Group
1 2 9G-9150 Clip
3 1 5M-3062 Bolt
4 1 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.

(1) 9G-9150 Clip
(3) 5M-3062 Bolt
(A) Wiring harness
(B) Signal lamp assembly

(4) 8K-1433 Grommet
(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 8K-
1433 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) .
Installation of 228-0937 Monitor Wiring Gp (PAYLOAD CONTROL

SYSTEM) (LAMPS) (If Equipped) and 230-1478 Monitor Wiring Gp
(PAYLOAD CONTROL SYSTEM) (DISPLAY) (If Equipped)
Note: This procedure is effective for (S/N: 2BW659-UP).
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.

228-0937 Monitor Wiring Group (PAYLOAD CONTROL SYSTEM) (LAMPS) (If Equipped)

230-1478 Monitor Wiring Group (PAYLOAD CONTROL SYSTEM) (DISPLAY) (If Equipped)

Wiring harness connection on platform

Wiring harness connection on frame

View A-A of wiring harness connection on frame
(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) .
Installation of the Caterpillar Integrated Object Detection System

(CIODS)
The information that is contained in this Special Instruction guides the user in the installation of the Caterpillar
Integrated Object Detection System for Off-Highway Trucks.
Do not perform any of the procedures until you have read the information in this publication.
ReferenceSpecial Instruction, REHS1841, "General Welding Procedures" for additional welding instructions.

View of the object detection locations
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
circumstance that might involve a potential hazard.
Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure that
any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.
Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication,
maintenance, or repair procedures used.
Prepare the Machine

Typical view
(1) Pin
(2) Cable
1. Raise the truck body and install the retaining cable (2) for the truck body.
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
1 153-9480 Angle As
1 360-1914 Sensor Harness As
1 130-5300 Clip
1 130-5301 Clip
4 147-0385 Clip
2 4D-9517 Clip
10 4K-8864 Clip
1 5S-7379 Bolt
1 7C-8246 Spacer
1 8T-4136 Bolt
7 8T-4195 Bolt
Table 87
Parts for the 320-6856 Object Detection Wiring Gp

2 144-4613 Angle As
2 153-9480 Angle As
2 305-3747 Plate As
3 305-3748 Plate As
1 312-4475 Bracket
4 336-6684 Camera Gp
1 348-9537 Plate As
1 119-5708 Clip
2 147-0385 Clip
2 219-6485 Flood Lamp Gp
2 4D-7735 Clip
1 4D-7794 Clip
2 4L-6454 Bolt
2 6V-3265 Clip
1 6V-8801 Nut
17 7X-7729 Washer
1 8M-2773 Clip

10 8T-4133 Nut
14 8T-4136 Bolt
3 8T-4137 Bolt
9 8T-6466 Bolt
8 9X-8256 Washer
Table 88
Parts for the 320-6857 Mounting Gp

4 347-7917 Object Detection Box Gp (RADAR)
4 348-8759 Bracket
4 348-8760 Bracket
4 348-8765 Clamp Bracket
4 349-4915 Bracket
2 360-3866 Plate As
1 360-3872 Mount As
2 363-7065 Plate As
2 363-8578 Object Detection Box Gp
1 363-9147 Sensor Wiring Gp
8 198-4778 Hard Washer
16 6V-7744 Locknut
112 7X-7729 Washer
16 8T-4133 Nut
8 8T-4136 Bolt
32 8T-4137 Bolt
8 8T-4183 Bolt
36 8T-4186 Bolt
12 8T-4195 Bolt
8 8T-4196 Bolt
8 8T-4956 Bolt
Table 89
Parts for the 362-0988 Monitor Display Gp

1 352-5603 Bracket As
1 355-9048 Monitor Display Gp
1 362-0881 Monitor Electronic Control Module
2 6V-4248 Bolt
2 9X-2045 Screw
Table 90
Required Parts for Assembling the Cameras to the Brackets

8 n/a (1) Cover
8 n/a (1) Bolt
4 n/a (1) Camera
8 n/a (1) Bolt
8 n/a (1) Nut
8 n/a (1) Nut
3 305-3748 Plate As
4 n/a (1) Camera Harness
1 348-9537 Plate As
9 8T-6466 Bolt
18 7X-7729 Washer
9 8T-4133 Nut
1 312-4475 Bracket
2 305-3747 Plate As
(1) Part of the 336-6684 Camera Gp
Table 91
Required Parts for Assembling the Radar Boxes to the Brackets (Front and Rear)
4 348-8760 Bracket
32 8T-4137 Bolt
32 7X-7729 Washer
4 348-8759 Bracket
Table 92
Required Parts for Installing the Front Hardware

1 347-7919 (1) Object Detection Box Gp
1 360-3872 Mount As
1 360-1914 Sensor Harness As (RADAR, FRONT)
4 8T-4195 Bolt
4 147-0385 Clip
8 8T-4956 Bolt
1 130-5301 Clip
4 348-8765 Clamp Bracket
8 8T-4196 Bolt
16 8T-4186 Bolt
32 7X-7729 Washer
16 6V-7744 Locknut
4 8T-4136 Bolt
1 8M-2773 Clip
(1) With 327-5293 Object Detection Sensor Gp
Table 93
Required Parts for Installation of the Left Side Hardware

1 363-7065 Plate As
4 8T-4195 Bolt
4 8T-4183 Bolt
1 305-3747 Plate As
8 8T-4136 Bolt
1 153-9480 Angle As
2 4L-6454 Bolt
1 6V-8801 Nut
1 144-4613 Angle As
1 247-4285 Bolt
1 6V-9189 Locknut
1 8T-4137 Bolt
1 6V-3265 Clip
1 4D-7735 Clip
2 147-0385 Clip
Table 94
Required Parts for Installation of the Right Side Hardware

1 363-7065 Plate As
4 8T-4195 Bolt
4 8T-4183 Bolt
1 305-3747 Plate As
6 8T-4136 Bolt
1 247-4285 Bolt
1 6V-9189 Locknut
1 144-4613 Angle As
1 119-5708 Clip
1 8T-4137 Bolt
1 6V-3265 Clip
1 4D-7735 Clip
Table 95
Required Parts for the Installation of the Rear Hardware

2 360-3866 Plate As
8 8T-4136 Bolt
48 7X-7729 Washer
2 349-4915 Bracket
20 8T-4186 Bolt
5 8T-4195 Bolt
10 4K-8864 Clip
1 7C-8246 Spacer
1 130-5300 Clip
1 5S-7379 Bolt
1 153-9480 Angle As
16 8T-4133 Nut
2 4D-9517 Clip
Table 96
Required Parts for Installation of the Hardware in the Cab

1 355-9048 Monitor Display Gp
4 n/a (1) Bolts
2 6V-4248 Bolt
2 9X-2045 Screw
(1) Bolts (4) should be shipped already attached to monitor display group (1)
Assemble the Camera Components
Assemble the Cameras to the Brackets
Table 97
Required Parts for Assembling the Cameras to the Brackets

Item Qty Part Number Description
1 8 n/a (1) Cover

2 8 n/a (1) Bolt
3 4 n/a (1) Camera
4 8 n/a (1) Bolt
5 8 n/a (1) Nut
6 8 n/a (1) Nut
7 3 305-3748 Plate As
8 4 n/a (1) Camera Harness
9 1 348-9537 Plate As
10 9 8T-6466 Bolt
11 18 7X-7729 Washer
12 9 8T-4133 Nut
13 1 312-4475 Bracket
14 2 305-3747 Plate As
(1) Part of the 336-6684 Camera Gp
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.

(1) Cover
(2) Bolt
(3) Camera
(4) Bolt
(5) Nut
(6) Nut
1. Assemble the four cameras with the parts that are supplied with the cameras.
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.

View of the front and side cameras
(7) 305-3748 Plate As
(8) Camera harness

View of the rear camera
(8) Camera harness
(9) 348-9537 Plate As
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.

View of the front and side cameras
(4) Bolt
(6) Nut
(7) 305-3748 Plate As

View of the rear camera
(4) Bolt
(6) Nut
(9) 348-9537 Plate As
3. Use bolts (4) and nuts (6) to secure the 336-6684 Camera Groups to plate assemblies (7) and plate assembly
(9) .
Front Camera

Camera assembled to the front bracket
(7) 305-3748 Plate As
(10) 8T-6466 Bolts
(11) 7X-7729 Hard Washers
(12) 8T-4133 Nuts
(13) 312-4475 Bracket
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

Side camera and plate assembly
(7) 305-3748 Plate As
(10) 8T-6466 Bolts
(12) 8T-4133 Nuts
(14) 305-3747 Plate As
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) .
Assemble the Radar Boxes to the Brackets
Table 98
Required Parts for Assembling the Radar Boxes to the Brackets (Front and Rear)
1 4 347-7919 Object Detection Box Gp (RADAR)
2 4 348-8760 Bracket
3 32 8T-4137 Bolt
4 32 7X-7729 Washer
6 4 348-8759 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

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
1. Locate all four 348-8760 Brackets (2) .
2. Use the 8T-4137 Bolts (3) and 7X-7729 Hard Washers (4) to mount the 348-8760 Brackets (2) to the 347-
7919 Object Detection Sensors (Black Sensors) (1). Refer to Illustration 464 to ensure the proper orientation
of the 348-8760 Brackets .
Mount the Front and Rear 347-7917 Object Detection Sensors (White Sensors) to the Brackets

Lower front and rear radar boxes (white sensor) and bracket
(3) 8T-4137 Bolts
(5) 347-7917 Object Detection Sensor Gp
(6) 348-8759 Bracket
1. Locate all four of the 348-8759 Brackets (6) .
2. Use the 8T-4137 Bolts (3) and 7X-7729 Hard Washers (4) to mount the 348-8759 Brackets (6) to the 347-
7917 Object Detection Sensors (White Sensors) (5). Refer to Illustration 465 to ensure the proper orientation
of the 348-8759 Brackets . Refer to Illustration 464 to ensure the proper orientation of the 348-8760
Brackets .
Installation of the Front Hardware
Table 99
Required Parts for Installing the Front Hardware

1 1 347-7919 (1) Object Detection Box Gp
5 1 360-3872 Mount As
6 1 360-1914 Sensor Harness As (RADAR, FRONT)
7 4 8T-4195 Bolt
9 4 147-0385 Clip
11 8 8T-4956 Bolt
13 1 130-5301 Clip
14 4 348-8765 Clamp Bracket
15 8 8T-4196 Bolt
16 16 8T-4186 Bolt
17 32 7X-7729 Washer
18 16 6V-7744 Locknut
19 4 8T-4136 Bolt
20 1 8M-2773 Clip

Front radar boxes
(1) 347-7919 Object Detection Sensor Gp with 327-5293 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)
Note: Ensure that the correct radar box is located in the correct position. Refer to Illustration 466.

View of the rear of 360-3872 Mount As (5)
(5) 360-3872 Mount As
(6) 360-1914 Sensor Harness As (RADAR, FRONT)
(7) 8T-4195 Bolt
(9) 147-0385 Clip
(10) 7K-1181 Cable Strap
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) .

(A) Harness assembly
(5) 360-3872 Mount As
(11) 8T-4956 Bolt
(13) 130-5301 Clip
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) .

(5) 360-3872 Mount As
(14) 348-8765 Clamp Bracket
(15) 8T-4196 Bolts
5. Install four clamp brackets (14) to mount assembly (5) by using eight bolts (15), and eight washers (8) .

(1) 347-7919 Object Detection Sensors
(2) 347-7917 Object Detection Box Gp
(3) 347-7919 Object Detection Sensors
(5) 360-3872 Mount As
(14) 348-8765 Clamp Bracket
(16) 8T-4186 Bolt
(17) 7X-7729 Washer
(18) 6V-7744 Locknut
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) .

View of the rear of the front sensor mount assembly
7. Connect sensor harness assembly (6) to the sensors.
8. Secure sensor harness assembly (6) to the bottom of the sensor box assemblies by using four cable straps
(10) .
Installation of Camera Group (Front)
View of the top of the cowling group
(B) Harness assembly
(19) 8T-4136 Bolt
(20) 8M-2773 Clip
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.
Installation of the Left Side Hardware
Table 100
Required Parts for Installation of the Left Side Hardware

1 1 363-7065 Plate As
2 4 8T-4195 Bolt
4 1 363-8578 Object Detection Box Gp
5 4 8T-4183 Bolt
6 4 198-4778 Hard Washer
7 1 305-3747 Plate As
8 8 8T-4136 Bolt
9 1 153-9480 Angle As
10 2 4L-6454 Bolt
12 1 6V-8801 Nut
13 1 144-4613 Angle As
14 1 219-6485 Flood Lamp Gp
15 1 247-4285 Bolt
17 1 6V-9189 Locknut
18 1 8T-4137 Bolt
19 1 6V-3265 Clip
20 1 4D-7735 Clip
21 2 147-0385 Clip
Installation of the Box Group for the Object Detection (Left Hand Side)

(1) 363-7065 Plate As
(2) 8T-4195 Bolt
1. Secure plate assembly (1) to the side of the left-hand walkway by using four bolts (2) and four hard washers
(3) .

(1) 363-7065 Plate As
(5) 8T-4183 Bolt
(6) 198-4778 Hard Washer
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)
(7) 305-3747 Plate As
(8) 8T-4136 Bolt
1. Secure plate assembly (7) to the left-hand walkway by using four bolts (8) and four washers (3) .

(7) 305-3747 Plate As
(9) 153-9480 Angle As
(10) 4L-6454 Bolt
(12) 6V-8801 Nut
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)

(7) 305-3747 Plate As
(13) 144-4613 Angle As
(14) 219-6485 Flood Lamp Gp
(15) 247-4285 Bolt
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)

(A) Bolt
(B) Washer
(C) Plate
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.
(D) Bolt
(E) Washer
(F) Harness assembly for the 336-6684 Camera Gp
(G) 274-4477 Cable As
(H) 361-0194 Sensor Harness As
(8) 8T-4136 Bolt
(9) 153-9480 Angle As
(10) 4L-6454 Bolt
(13) 144-4613 Angle As
(18) 8T-4137 Bolt
(19) 6V-3265 Clip
(20) 4D-7735 Clip
(21) 147-0385 Clip
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) .

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.
Installation of the Right Side Hardware
Table 101
Required Parts for Installation of the Right Side Hardware

1 1 363-7065 Plate As
2 4 8T-4195 Bolt
4 1 363-8578 Object Detection Box Gp
5 4 8T-4183 Bolt
7 1 305-3747 Plate As
8 6 8T-4136 Bolt
9 1 219-6485 Flood Lamp Gp
10 1 247-4285 Bolt
12 1 6V-9189 Locknut
13 1 144-4613 Angle As
14 1 119-5708 Clip
15 1 8T-4137 Bolt
16 1 6V-3265 Clip
17 1 4D-7735 Clip
Installation of the Box Group for the Object Detection (Right Hand Side)

(1) 363-7065 Plate As
(2) 8T-4195 Bolt
1. Secure plate assembly (1) to the side of the right-hand platform by using four bolts (2) and four washers (3) .

(1) 363-7065 Plate As
(5) 8T-4956 Bolt
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)
(7) 305-3747 Plate As
(8) 8T-4136 Bolt
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)

(7) 305-3747 Plate As
(10) 247-4285 Bolt
(13) 144-4613 Angle As
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)

(A) Bolt
(B) Washer
(C) 283-0657 Cable As
(D) Harness assembly for the 336-6684 Camera Gp
(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) .

(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) .

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) .

(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.
Installation of the Rear Hardware
Table 102
Required Parts for the Installation of the Rear Hardware

1 2 360-3866 Plate As
2 8 8T-4136 Bolt
3 48 7X-7729 Washer
4 2 349-4915 Bracket
5 20 8T-4186 Bolt
6 5 8T-4195 Bolt
7 1 361-6815 Sensor Harness As
8 10 4K-8864 Clip
10 1 7C-8246 Spacer
11 1 130-5300 Clip
12 1 5S-7379 Bolt
13 1 153-9480 Angle As
16 16 8T-4133 Nut
17 2 4D-9517 Clip
Install the Box Groups for the Object Detection (Rear)
(1) 360-3866 Plate As
(2) 8T-4136 Bolt
(3) 7X-7729 Washer
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.

(1) 360-3866 Plate As
(3) 7X-7729 Washer
(4) 349-4915 Bracket
(5) 8T-4186 Bolt
(6) 8T-4195 Bolt
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) .

(1) 360-3866 Plate As
(6) 8T-4195 Bolt
(7) 361-6815 Sensor Harness As
(8) 4K-8864 Clip
(10) 7C-8246 Spacer
(11) 130-5300 Clip
4. Connect harness assembly (7) to harness assembly (A) .
5. Secure harness assembly (7) to the top of the frame by using six clips (8) and one spacer (10). Secure harness
assembly (7) to two plate assemblies (1) by using three clips (8), three bolts (6), three washers (9), and one
clip (11) .
Note: Use the existing hardware in order to secure clips (8) to the top of the frame.

View of the rear of the frame
(8) 4K-8864 Clip
(12) 5S-7379 Bolt
(13) 153-9480 Angle As
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) .

(3) 7X-7729 Washer
(5) 8T-4186 Bolt
(16) 8T-4133 Nut
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) .

(17) 4D-9517 Clip
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) .

(17) 4D-9517 Clip
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)

(A) Rear camera assembly
(2) 8T-4136 Bolt
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)

(A) Rear camera assembly
(B) Harness assembly
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) .
Installation of the Hardware in the Cab
Table 103
Required Parts for Installation of the Hardware in the Cab

1 1 355-9048 Monitor Display Gp
2 1 362-2231 Bracket As
3 1 352-5603 Bracket As
4 4 n/a (1) Bolts
6 2 6V-4248 Bolt
8 2 9X-2045 Screw
(1) Bolts (4) should be shipped already attached to monitor display group (1)
(1) 355-9048 Monitor Display Gp
(2) 362-2231 Bracket As
(3) 352-5603 Bracket As
(4) Bolts
(6) 6V-4248 Bolt
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) .

(3) 352-5603 Bracket As
(8) 9X-2045 Screw
3. Secure bracket assembly (3) to the top of the cab by using two screws (8) .

Typical view of the sensor harness assemblies
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.
Flash the Caterpillar Integrated Object Detection System (CIODS)

Software onto the Display
The display is shipped with the application software installed. Use the following procedure in order to flash the
application software into the display.
Note: The software may need to be flashed.
Required Material
Caterpillar Electronic Technician CAT (ET)
Communication Adapter
345-7489 Monitor Harness As
Software
Table 104
Part Number System Notes

361-8176 Caterpillar Integrated Object Detection System Radar and Camera
362-3942 Caterpillar Integrated Object Detection System (Vision Only) 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.
Perform the Commissioning Procedure for the Machine

Note: The commissioning procedure frequently refers to the Operation and Maintenance Manual, SEBU7174,
"789C Off-Highway Truck" and the Service Manual, SENR1515, "789C Off-Highway Truck". Keep these manuals
available during the commissioning procedure.
Fill All Machine Fluid Compartments
NOTICE
Step 1 through Step 11 check and fill the fluid compartments of the
truck sufficiently to start the truck. This is an initial fill only. Only
after the engine is started and all machines systems have been
exercised can the fluid levels be adjusted to the normal operating
levels.
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".
Adjust the Tire Pressure
Adjust the tire pressure for each tire. If necessary, refer to Operation and Maintenance Manual, SEBU7174, "789C
Off-Highway Truck", "Tire Inflation Information".
Activate and Test the Batteries
Improper jumper cable connections can cause explosion resulting in

personal injury. Batteries may be located in separate compartments,
always connect positive (+) cable to positive (+) terminal of battery
connected to starter solenoid and negative () cable from external
source to engine block or frame.
Improper jump start cable connections can cause an explosion resulting

in personal injury.
Prevent sparks near the batteries. Sparks could cause vapors to

explode. Do not allow jump start cable ends to contact each other or the
engine.
Personal injury or death can result from working with batteries.
Electrolyte is an acid and can cause personal injury if it contacts skin or

eyes.
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
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.
Charge the Front and Rear Suspension Cylinders
Read all Warning labels on the suspension cylinders before servicing.
The vehicle must be on level ground before releasing the nitrogen

pressure.
Do not check the oil in the suspension cylinder until all of the nitrogen
pressure has been released.
Do not remove valves, covers or plugs from the cylinder unless the rod
is fully retracted and all of the nitrogen pressure has been released.
Do not stand under the machine during suspension cylinder charging,

discharging, or testing and adjusting procedures or while lifting or
lowering the machine. Sudden movement upward or downward can
cause the clearance above your head to change rapidly.
Failure to heed this Warning could lead to injury or death.
Refer to Special Instruction, SEHS9411, "Servicing the Suspension Cylinders for Off-Highway Trucks" for any
information concerning suspension cylinders. The Special Instruction includes tooling, pressures, and the correct
procedures for purging (oil and nitrogen) and charging (oil and nitrogen), that are used on all off-highway truck
Check the Configuration of the Electronic Control Modules (ECM's)

ReferenceService Manual, SENR9122, "Electronic Programmable Transmission Control (EPTCII)"Service
Manual, SENR1503, "769D, 771D, 773D, 775D, 784C, 785C, 789C, and 793C Off-Highway Truck/Tractors Brake
Electronic Control System"Service Manual, SENR2630, "Off-Highway Truck/Tractor Vital Information
Management System (VIMS) - Systems Operation"Service Manual, SENR2631, "Off-Highway Truck/Tractor Vital
Information Management System (VIMS) - Testing and Adjusting"
This section contains assembly checks and functional checks of systems. Perform the checks before you deliver the
machine to a customer.
1. Connect a laptop computer to the Caterpillar Diagnostic Connector on the fuse panel behind the operator seat.
The laptop computer should have 139-4166 Cable , 7X-1700 Communication Adapter , 7X-1425 Cable , and
a NEXG4523 Service Program Module.
2. In order to power the electrical system of the truck, perform the steps that follow:
a. Connect the batteries.
b. Turn the battery disconnect switch ON.
c. Turn the manual engine shutdown switch OFF.
d. Turn the key of the machine ON.
e. DO NOT START THE TRUCK.
Note: When the key is in the ON position, VIMS will perform a 4 to 6 second self test. Disregard the VIMS
self test at this time.
3. Start the Electronic Technician (ET). Electronic Technician (ET) lists all of the electronic control modules for
the machine. There will be at least an "ENGINE CONTROL", "POWER TRAIN CONTROL" and a
"BRAKE CONTROL". If the truck has the Automatic Retarder Control (ARC), the ET screen should show
the feature.
4. Electronic Technician (ET) should display the truck model for each control. Make sure that the model is
correct for each control.
5. Choose the "ENGINE CONTROL". Next, choose "CONFIGURATION".
6. Change the EQUIPMENT ID NUMBER in order to correspond to the PIN of the truck. If you select a new
setting, select "ENTER". This confirms the change.
7. Check the "ENGINE SERIAL NUMBER". The "ENGINE SERIAL NUMBER" must match the engine serial
number on the engine. If you select a new setting, select "ENTER". This confirms the change.
8. Adjust the "FUEL RATIO CONTROL", if necessary. The air/fuel ratio is adjustable. The range is -25 to 25.
The factory default is 0. If you select a new setting, select "ENTER". This confirms the change.
9. Check the "FAN CONTROL" setting. On a truck that is equipped with the variable speed fan, the "FAN
CONTROL" must be ON. On a truck that is equipped with a fixed speed fan, the " FAN CONTROL" should
be OFF. If you select a new setting, select "ENTER". This confirms the change.
10. Check the "ETHER CONTROL" setting. Set the "ETHER CONTROL" to the "ON" position. If you select a
new setting, select "ENTER". This confirms the change.
11. Check the "OIL RENEWAL CONTROL" setting. On a truck that is equipped with the oil renewal
attachment, the "OIL RENEWAL CONTROL" must be set to "ON". After you set the engine oil renewal
solenoid to "ON", the "OIL TO FUEL" ratio should be set. The "OIL TO FUEL" is adjustable in a range from
-50 to 50. The factory default is 10. If you select a new setting, select "ENTER". This confirms the change.
12. Check the "ENGINE OIL PRE-LUBE" setting. On a truck that is equipped with the engine pre-lube
attachment, "ENGINE OIL PRE-LUBE" must be ON. If you select a new setting, select "ENTER". This
confirms the change.
13. Check the "COOL CYLINDER CUT-OUT". If you select a new setting, select "ENTER". This confirms the
change.
14. Check the "SHUTTER CONTROL" setting. On a truck that is equipped with an attachment shutter,
"SHUTTER CONTROL" must be ON.
15. Return to the engine control screen. Select "ACTIVE CODES". Select the "INCLUDE ALL ECM'S" button.
The button is at the bottom of the screen. If "NO ACTIVE CODES" appears, then continue. Refer to Service
Manual, RENR2630, "Off-Highway Truck/Tractor Vital Information Management System (VIMS) - Systems
Operation". This will help to resolve the active faults.
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, "Off-
Highway 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
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.
Prepare to Start the Engine and Start the Engine
1. Verify that the fluid levels are at a safe level.
2. Disable the engine at ground level. The engine should be shut off, so the engine will not start.
3. Use an external supply of compressed air to charge the starting and service reservoirs. Charge the system
pressure to a maximum of 1034 kPa (150 psi). Refer to Operation and Maintenance Manual, SEBU7174,
"789C Off-Highway Truck", "Starting With An External Air Supply".
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.
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 coolant temperature is 2.
The coolant flow is 3.
The engine oil pressure is 3.
The brake air pressure is 3.
The transmission oil filter is 2.
The converter or return oil temperature is 2.
The brake ON is 1 or 3.
The alternator is 1.
The fuel level is 1 with a 10 second delay.
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
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.
Remove Air from the Brake System
1. Make sure that all the air that is trapped in the brake system is purged. Refer to Systems Operation/Testing
and Adjusting, SENR1528, "Brake System Air - Purge".
2. Remove the tire chocks.
Check the Service Brake Discs
Refer to the Air System and Brakes Testing and Adjusting, "Service Brake Discs Check". Also, refer to Guideline
for Reusable Parts and Salvage, SEBF8095, "Service Brakes for Off-Highway Trucks and Tractors" in order to
determine the service intervals. Record all data in the Air System and Brakes Testing and Adjusting, "Worksheets".
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.
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.
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.
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.
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.
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.
Table 105
Commissioning Specifications
Actual Comments
Description Specification
Engine Low Idle Speed 710 20 rpm : :

Engine High Idle Speed 1935 30 rpm : :
Brake Retract Pressure at High Idle 4685 207 kPa (680 30 psi) : :
Hoist Pressure (Raise) 18610 350 kPa (2700 50 : :

psi)
Hoist Pressure (Lower) 3275 175 kPa (475 25 psi) : :
Transmission Lubrication Pressure at Low Idle in

: :
NEUTRAL 35 30 kPa (5 4 psi)
Transmission Lubrication Pressure at High Idle in
: :
NEUTRAL 160 45 kPa (23 6 psi)
Transmission Charge Pressure at Low Idle 2480 kPa (360 psi) Minimum : :
Transmission Charge Pressure at High Idle 3203 kPa (465 psi) Maximum : :
Torque Converter Outlet Pressure at Low Idle : :

138 69 kPa (20 10 psi)
Torque Converter Outlet Pressure at High Idle : :

551 69 kPa (80 10 psi)
Pressure of the Torque Converter Lockup at 1300

2136 69 kPa (310 10 psi) : :
rpm
Activate the Hoist Controls for the Truck Body
The truck might appear to have a problem with the body hoist controls. The 184-4671 Software Group will set the
parameters for the hoist system.
Note: ET Software must be used to set these parameters on all trucks.
Note: On the 2.4 ET Software, when the parameters are not visible or accessible on the configuration screen,
disconnect the connection and reconnect the connection. This establishes the communication to the transmission
control, until the parameters appear.
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.
Hoist System Enable (A Parameter that Can Be Set)
All trucks that are shipped from the factory with the 184-4671 Software Group and without installed bodies have
this Hoist Enable Parameter set at a Value of 2. Parameter Value 2 is a test mode. Parameter Value 2 will prevent
the hoist cylinders from being activated by accident. After the body is installed, change the Parameter Value to 1.
The hoist system should function properly. When the hoist system does not work, check the items below.
1. Verify that the hoist system is enabled in the Configurable Parameters Screen through the service drop-down
menu in the Electronic Technician.
Table 106
Hoist Parameter Setting

Parameter
Description
Value
the hoist system is not installed, a hoist lever that will not function, no diagnostics will
0
be logged on the hoist lever or the solenoids
1 the hoist system is installed and enabled (normal operation)
the hoist system is installed but disabled (default), solenoids and the hoist lever have
2
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 should not be running.
The truck should not be moving.
The value of TOS needs to be zero in order to change the parameter.
The engine causes the TOS signal to fluctuate. This keeps the parameter from changing.
Note: Press the F5 button to go directly to the configuration screen on ET.
Calibrate the Body Position Sensor
Refer to Testing and Adjusting, SENR1502, "784C, 785C, 785D, 789C, 793C and 793D Off-Highway
Truck/Tractors Power Train Electronic Control System " for instructions on calibrating the body position sensor.
Body Snub Function (Not a Parameter that Can Be Set)
The body down snub function cushions the shock when the body hits the bed of the truck. The body up switch
detects when the body is close to the rail of the truck when the operator lowers the body. The ECM will go into snub
mode.
When the operator's request is less than the snub mode, the ECM will use the operator's request. This ensures that
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).
The height adjustment is 75 mm (3 inch).
Adjust the weight for the suspension to the correct ride position.
The seat cushion has two positions.
The back cushion has three positions.
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:
Turn the ignition key to the ON position.
Turn the switch for the blower to the LOW position.
Turn the blower switch to the HIGH position.
There should be an audible sound.
2. Check the heater:
Start the engine.
The lines for the heater valves should be open.
Turn on the heat control. The air should be warm.
3. Check for air flow:
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.
Front Window Wipers
1. Turn the ignition key to the ON position. Turn the wiper switch to the three positions. The three positions are
OFF, LOW, and HIGH. The front wipers and the rear wipers must operate in both modes.
2. Depress the wiper switches. This will activate the front window washers.
3. Turn the switches to the OFF position. The front wiper arms and the rear wiper arms should return to the
proper position.
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
2. Turn the switch for the dome light ON and OFF.
Cigar Lighter
2. Push the cigar lighter inward. The cigar lighter should pop out.
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
Replacing the Cleanout Filters
Cleanout filters are installed on some of the 789C hydraulic systems at the factory. It is necessary to replace all
cleanout filters with the standard filters that have been provided with the truck after the truck has been continuously
operated for eight hours. Failure to replace the cleanout filters with standard filters can cause a plugged filter
condition that causes the oil to bypass the filters. This will allow contaminated oil to enter the affected transmission,
the torque converter, steering, the hoist, or brake hydraulic systems.
Use the following chart for replacing the filters.
Table 107
Hydraulic System Cleanout Filter Standard Filter Qty

Parking Brake Release 132-8875 132-8875 1
Power train 1R-0773 1R-0773 1
Steering Case Drain 4T-6915 4T-6915 1
Steering Return Line 139-1536 1R-0772 1
343-4465 (1)
Torque Converter Charge 343-4465 2
1R-0741 (2)
343-4465 (1)
Transmission Charge 343-4465 2
1R-0778 (2)
Transmission Lubrication 132-8875 1R-0773 1
(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.
Transmission and Torque Converter Filters
The transmission system uses 343-4465 Oil Filter Elements , which have to be replaced by a service filter
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.
Check the Service Brake Discs
Refer to the Air System and Brakes Testing and Adjusting, "Service Brake Discs - Check". Also, refer to Guideline
for Reusable Parts and Salvage, SEBF8095, "Service Brakes for Off-Highway trucks and Tractors" in order to
determine the service intervals. Record all data in the Air System and Brakes Testing and Adjusting, "Worksheets".
Checks Before the Delivery of the 789C Truck
The page that follows is a list of assembly checks and systems checks that are recommended. Do this checklist
before the truck is delivered to the customer. Do all of the checks and verify that the systems function properly.
Use the Service Manual and use the Operation and Maintenance Manual in order to correct any system problems
before you deliver the truck.
After you complete the final check, sign your name and the name of the dealer.
Make copies of the check procedure. Mail the copies to the following address:
Caterpillar Inc.
Attention: MCE Product Support
789C Truck
N. 27th and Pershing Road
Decatur, IL 62525
Dealer:____________________
Customer:____________________
Product Identification Number:____________________
1. Before you start the engine, make sure that all hydraulic systems are full. Also, make sure that all pump case
drains are full.
2. Check that the system pressures are set correctly.
Hoist Pump
YES ____ NO ____
Brake Retract Pressure
YES ____ NO ____
Steering Pressure
YES ____ NO ____
Transmission Pressures
YES ____ NO ____
Torque Converter Pressures
YES ____ NO ____
Differential
YES ____ NO ____
3. Check the machine lights.
Operational
YES ____ NO ____
Cab and Dash
YES ____ NO ____
Access Ladder
YES ____ NO ____
Engine Compartment
YES ____ NO ____
4. Check the controls in the cab.
Check if the cab door opens. Check if the cab door closes.
YES ____ NO ____
Check if the Operation and Maintenance Manual is in the literature pouch on the back of the operator
seat.
YES ____ NO ____
Check if the horn functions.
YES ____ NO ____
Check if the front window wipers and washers function.
YES ____ NO ____
Check if the seat belts operate.
YES ____ NO ____
Check if the fan switch operates.
YES ____ NO ____
Check if the heater functions.
YES ____ NO ____
Check if the air conditioner functions.
YES ____ NO ____
Check the test light. The test light is for the EMS.
YES ____ NO____
Check if the hour meter operates.
YES ____ NO ____
Check if the implements operate:
Hoist
YES ____ NO ____
Steering Action
YES ____ NO ____
Check if the steering column functions.
YES ____ NO ____
Check if the parking brake functions.
YES ____ NO ____
5. Check if all fluid levels are full.
YES ____ NO ____
6. Correct any unusual noises or unusual leaks.
YES ____ NO ____
7. Check if all lubrication lines are filled with grease.
YES ____ NO ____
8. Check if all clean-out filters have been replaced as specified by assembly procedure.
YES ____ NO ____
9. Check if all quality requirements are fulfilled. Check if all variances have been corrected.
YES ____ NO ____
10. Check if the backup alarms function.
YES ____ NO ____
11. Check if the machine is repainted to the factory specifications.
YES ____ NO ____
12. Check if there was damage to the machine from shipment.
YES ____ NO ____
13. Check if all required parts are shipped with the machine.
YES ____ NO ____
14. Sign your name in the space below.
Hydraulic

Electrical

Structural

Other
15. Comments
Predelivery Worksheet
Table 108
Date Employee I.D. Model Serial Number Hours Inspector Name
Note: All safety product improvement programs (PIP) must be completed.
Table 109
Visual Service Points and After Operation

Operation
Inspection Fluid Levels
_ Oil
_ Air Cleaner
_ Coolant
Indicator
_ Fuel
_ V-Belt Tension
_ Batteries OVC >
_ Leaks (Oil, Air,
(12.45) _ VDC1 _
_ Priming Pump Fuel, Coolant)
VDC2
_ Paint _ Governor Control _ Friction on
_ Air Filters
Engine (1) (2) _ Outside _ Air Compressor Hoses
_ Drain Water from
Damage _ Smoke Color _ Friction on
Fuel Tank
_ Unusual Noise Wires
_ Drain Water
_ Loose Wire
Separator
Connections
_ Open Coolant
_ Loose or Lost
conditioner Valves
Fasteners
_ Grease Fittings
_ Transmission
_ Differential
_ Final Drives
_ Transmission - Each Gear
_ Paint _ Tire Pressure _ Leaks (Oil)
_ Neutral Start
_ Outside _ Grease Fittings _ Loose or lost
_ Transmission Lever Lock
Power Train Damage _ Front & Rear Axle Fasteners
_ Back - Up Alarm
_ Tires - Cuts, Bolt Torques _ Tires - Cuts,
_ Neutralizer Valve
gouges _ Front & Rear Gouges
_ Unusual Noise
Universal Torques
_ Wheel to Rim
Torques
_ Steering
_ Brake Fluid _ Retarder
_ Paint _ Leaks - Oil, Air
Steering and _ Drain Water from _ Service Brakes
_ Outside _ Loose or Lost
Brakes Air Tank _ Parking Brakes
Damage Fasteners
_ Grease Fittings _ Air Dryer
_ Unusual Noise
_ Sheet Metal _ Loose or Lost

_ Enclosure Doors - Locks
Chassis _ Paint _ Grease Fittings Fasteners
and Latches
_ Damage _ Welds
_ Controls _ Leaks - Oil
_ Cylinder Rods _ Hydraulic Tank
hydraulic _ Too much Drift _ Friction or Lost
_ Grease Fittings
_ Unusual Noise Fasteners
_ Welds
_ Paint _ Grease Fittings
_ Loose or Lost
Truck Body _ Damage _ Body Pads _ Body Positions
Fasteners
_ Liners _ Retention Cable
_ Damage
_ Disconnect Switch
_ VIMS
_ Hoist Control
_ Horn
_ Operation Guide
_Seat Belts
_ Seat Adjustments
_ Maintenance
_ All Switches & Controls
Guide
_ Front Window _ Doors and Windows
_ Parts Book
Washer _ Locks and Latches
_ Sheet Metal _ Seat Cover
_ Air Filters _ Mirror Adjustment
Cab _ Paint _ Steps & Grab
_ Grease Fittings _ Front Window Wipers
_ Glass Irons
_ Torque on ROPS _ Window Washers
_ Loose or Lost
Support _ Heater
Fasteners
_ (Air
_ Loose Wire
Conditioner/Pressurizer)
Connections
Lights - Outside and Cab
_ Leaks - Water
_ Gauges
_ Unusual Noise
_ Steering Column
Adjustment
_ Special _ Attachment Fluid
Assembly Parts Levels _ Warning Plates
_ Attachments
_ S/N Plates _ Charge for Fire _ Decals
Misc. and _ Engine Shutdown Switch
_ Correct Suppression System _ Leaks
Attachments _ Test Switch for Fire
Attachments _ Grease Fittings _ Loose or Lost
Suppression
_ Hand Tools _ Automatic Fasteners
_ Paint Lubrication System
(1) If the machine was in storage, lubricate the engine before starting the engine.
(2) For cold-weather operation, refer to Operation and Maintenance Manual, 5338.
Copyright 1993 - 2011 Caterpillar Inc. Mon Feb 14 18:54:16 UTC-0400 2011
All Rights Reserved.
Private Network For SIS Licensees.

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789C Truck 3516 Engine 2BW00001-UP (MACHINE)(SEBP2790 - 126)/Basic Search Page 1 of 347

789C Off-Highway Truck Assembly Procedure{7000, 7006, 7960}

high/low tightening specification

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

Improper assembly procedures could result in injury or death.

Qty Part Number Part Name

8 2N-2486 (1) Bolt

Parts That Are Needed for Installation of 145-3418 Ladder Group

Parts that are Needed for Installation of 5T-1070 Fender Group

Parts that are Needed for Installation of 174-9334 Muffler Gp

1 8X-6606 Extension Pipe

Parts that are Needed for Installation of 5T-4464 Platform Group

Parts that are Needed for Installation of the Cab Mounting Gp

3 5M-2894 Hard Washer

4 8W-0331 Swivel Connector

Parts that are Needed for Installation of 155-3633 Film Group

2 5M-2894 Hard Washer

Personal injury or death can result from lifting a heavy assembly.

Personal injury or death can result from improper lifting or blocking.

Approximate weights of the components are shown. Clean all surfaces

Body pivot pin

Cab Assembly 1920 kg (4250 lb)

Cab Support (front)

Cab Support (rear)

Rear Axle Housing and Transmission

Front Suspension Cylinder, Wheel, and Brake Assembly

Top Mounting Pin for the Hoist Cylinder

Right Side Platform Assembly

Mounting Bracket for the Rock Ejector

Steering Hydraulic Tank

Assembled Truck Body

Hinge Pin for the Truck Body

Truck Frame Module At Shipment

Areas that are Measured Specifications

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 for Cables, Chains, and Lifting Devices

Lift angles for lifting slings.

Necessary Hoist Capacity

789C Assembly Tips

Necessary Equipment and Supplies for Assembly

207-1600 Rubber Lubricant - 207-1600 Rubber Lubricant is used in EAME only.

207-1601 Rubber Lubricant

Cables, straps, and chains that have adequate capacity

Two step ladders that are 1.8 m (6 ft) tall

Two step ladders that are 3.6 m (12 ft) tall

A lift truck that can lift 6810 kg (15,000 lb)

A paint spray gun

Two 7X-1062 Ether Cylinders

Two 1U-9204 Lever Pullers

Four 138-7573 Link Brackets

Four 138-7575 Link Brackets

Four 138-7576 Link Brackets

Four 138-7574 Link Brackets