785D Off-Highway Truck MSY00001-UP (MACHINE) POWERED BY 3512C Engi...

Page 1 of 6

Shutdown SIS

Previous Screen

Product: TRUCK
Model: 785D TRUCK MSY
Configuration: 785D Off-Highway Truck MSY00001-UP (MACHINE) POWERED BY 3512C Engine

Special Instruction
Caterpillar Off-Highway Truck (777, 785, 789, 793, and 797) Technician Checklist
Final Drive Removal and Installation {0372, 0374, 4001, 4001, 4011, 4011, 4050,
4050}
Media Number -REHS9023-00 Publication Date -02/07/2013 Date Updated -02/07/2013

i05350010

Caterpillar Off-Highway Truck (777, 785, 789, 793, and 797)

Technician Checklist Final Drive Removal and Installation
{0372, 0374, 4001, 4001, 4011, 4011, 4050, 4050}
SMCS - 0372-010; 0374-010; 4001-010; 4011-010; 4050-010

OEM:
CAT WDS (S/N: M6J1-UP)
Off-Highway Truck/Tractor:
777 (S/N: 84A1-UP)
777B (S/N: 4YC1-UP)
777C (S/N: 4XJ1-UP)
777D (S/N: AGC1-UP; FKR1-UP; 3PR1-UP; 2YW1-UP; AGY1-UP)
777F (S/N: WTK1-UP; JRP1-UP; JXP1-UP)
777G (S/N: T5A1-UP; TNM1-UP; RDR1-UP; T4Y1-UP)
785 (S/N: 8GB1-UP)
785B (S/N: 6HK1-UP)
785C (S/N: 1HW1-UP; APX1-UP; 5AZ1-UP)
785D (S/N: DMC1-UP; MSY1-UP)
789 (S/N: 9ZC1-UP)
789B (S/N: 7EK1-UP)
789C (S/N: 2BW1-UP)
789D (S/N: SPD1-UP; SHH1-UP)
793 (S/N: 3SJ1-UP)
793B (S/N: 1HL1-UP)
793C (S/N: CBR1-UP; 4AR1-UP; ATY1-UP; 4GZ1-UP)
793D (S/N: FDB1-UP)
793F Series AC (S/N: EMD1-UP)
793F (S/N: SND1-UP; SSP1-UP; RBT1-UP)
797 (S/N: 5YW1-UP)
797B (S/N: JSM1-UP)
797F (S/N: LAJ1-UP; WSP1-UP)

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sis... 14/03/2022
785D Off-Highway Truck MSY00001-UP (MACHINE) POWERED BY 3512C Engi... Page 2 of 6

Introduction
These checks are required for component removal and installation. Initial check after completion.

Note: Service literature procedures, specific to the model and serial number, must be used in this
process. The checklist does not substitute procedures for the procedures given in the service
literature.

Table 1
Customer Name/ Machine Unit Machine Serial Machine Service Work Order
Location Number Number Meter Hours Number
/

Table 2
LH Final LH Final RH Final RH Final
Tracking Data Drive Drive Drive Drive
Removed Installed Removed Installed
Serial Number
CID Number (1)
Source/Rebuilder (2)

(1)
CID (Component Identification) is the number assigned to the component by the user/dealer.
(2)
Suorce/Rebuilder is either NEW, REMAN, DLR (Dealer Rebuilt), or CUST (Customer Rebuilt).

Checklist
Table 3

Record Complaint:
1.

2. Pre-repair contamination control.

High-pressure wash the rear half of the truck to remove all
A. dirt/debris.
Keep the work area clean and the floor dry - contain all fluid
B. spills.
C. Cover components with plastic or keep in containers until
installation to keep clean.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sis... 14/03/2022
785D Off-Highway Truck MSY00001-UP (MACHINE) POWERED BY 3512C Engi... Page 3 of 6

Verify new parts cleanliness. Assure that they are cleaned and
D. capped/ protected against dirt.

3. Investigate wheel history or failure cause, if appropriate.

Question the operator on application, operating conditions, and
A.
history. Review SOS history.
Review VIMS, EPTC2, or ET for detected fault information -
B.
record the work order folder.
Take SOS Sample refer to: Contamination Control Guidelines,
SEBF8482, "Obtaining Oil Sample for Analysis". Drain rear
C.
axle oil reservoirs and visually check oil for water or debris
contaminants. Save any debris.

D.
Inspect the magnetic drain plugs. Save any debris.
Remove/inspect system filters/screens and save any
E.
contamination evidence.

If a final drive failed generating metal/debris, remove, clean, and

inspect/repair both final drives and differential. Use the Caterpillar R& I
4. Checklists as needed.

If the repair on the removed final drive will not include a brake
5. repair/rebuild, perform a brake hold test before removal.
(check
Pass: Fail one)

6. Inspect the traction aid sensor group for reusability.

Cover and cap all cleaned and reused components/lines until installed to
prevent dirt entry.
Cover all removed component cores with plastic sheets until shipping
7. covers are available.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sis... 14/03/2022
785D Off-Highway Truck MSY00001-UP (MACHINE) POWERED BY 3512C Engi... Page 4 of 6

8. Inspect axle shaft splines, traction aid gear, axle thrust wear surface, and
final drive hubcap thrust plate for damage and excessive wear.

Inspect spindle mounting area and machine frame for wear, stripped
9. threads, cracks, or deformation. Repair/replace and paint as needed.

10. Remove and clean rear axle filtration system, if equipped.

Inspect and clean or replace system hoses/tubes. Clean with CAT hose
cleaner group. Refer to Tool Operating Manual, NEHS0643, "Using the
233-7191, 233-7192, 233-7193 and 265-4959 hose cleaning groups" and
Contamination Control Guidelines, SEBF8485, "Cleaning Fluid-Carrying
Hose and Tube Assemblies In Shop and Field Applications". Use new
11. clamps (torque to spec), o-ring seals, and gaskets.

Inspect the rear axle filter bypass and bypass indicator for correct operation.
12.

Differential Filter
Install 6-micron (for dealer rebuilt wheels), or 40- Number:
micron (for new/REMAN wheels) clean-up filters
in the rear axle lubrication circuit. Use these filters Wheel Station
13. for at least 8 hours of operation time. Filter Number:

Clean or replace all brake lines to maintain systems. Use new seals, hoses
14. & clamps.

15. Rebuild/replace brake slack adjuster for the installed final drive axle.

16. Thoroughly clean mounting surface on axle housing.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sis... 14/03/2022
785D Off-Highway Truck MSY00001-UP (MACHINE) POWERED BY 3512C Engi... Page 5 of 6

Clean or replace all brake lines to maintain systems. Use new seals, hoses
17. & clamps.

Inspect/replace electrical connectors and harnesses for loose pins,

18. brittleness, and fatigue.

Clean/protect all mounting surfaces and exposed cavities of the replacement

19. final drives(s).

Transfer all covers/plugs to the removed component cores and pack into
shipping containers to prevent damage and dirt entry. Tag with completed
20. Cat dealer core tag.

Fill both final drives and axle housing with oil meeting ISO --/16/13
21. cleanliness level. Wait 10 minutes and check oil level.

Check brake system pressures. Refer to procedures detailed in the Testing

22. and Adjusting manuals.

Parking Service Brakes Brake Cooling (Rear)

Brake and Retarder
System System Pressure Right Left Pressure
Pressure (Rear) Pressure

Spec.

Test
4000
Hour
Check

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sis... 14/03/2022
785D Off-Highway Truck MSY00001-UP (MACHINE) POWERED BY 3512C Engi... Page 6 of 6

23. Perform brake hold test. Test run truck and inspect for leaks..

Before releasing machine, test the torque converter system oil for
cleanliness. Kidney-loop filtration may be required to achieve ISO
cleanliness level of --/18/15 refer to Contamination Control Guidelines,
SEBF8438, "Procedure for Filtering Off-Highway Truck Rear Axle Oil".
24. Attach particle count printout and record highest test:____________.

After 8 hours of operation without bypassing filters, New filter part

inspect torque converter, clean-up filters, and install new number:
standard filters. __________
After 8 hours of operation, inspect the magnetic plug and check component
and related systems for leaks.
After one running shift and within 24 clock hours of installation, take an
SOS sample from both wheel stations and the differential. Send the sample
to the Cat dealer with this checklist, completed, and signed.
At 4,000 operating hours, perform tests in Step 22 and report the results to
25. the Cat dealer.

Technician
Name: Signature: Date:

Copyright 1993 - 2022 Caterpillar Inc. Mon Mar 14 12:23:05 EST 2022
All Rights Reserved.
Private Network For SIS Licensees.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sis... 14/03/2022