Cat 789C Off-Highway Truck Parts Manual – PDF DOWNLOAD

Description

Cat 789C Off-Highway Truck Parts Manual – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Cat 789C Off-Highway Truck Parts Manual – PDF DOWNLOAD

GENERAL INFORMATION A23
REPAIR ALTERNATIVES A42
SUPPLEMENTAL COOLANT
ADDITIVES A47
MAINTENANCE PARTS A52
INDEX A103
MACHINE ARRANGEMENT 1
CHASSIS AR 1
CHASSIS AR-EU 3
GENERAL AR 4
MACHINE AR-EU 6
ENGINE ARRANGEMENT 8
ENGINE AR 8
INSTALLATION AR-ENGINE 15
BASIC ENGINE 17
ADAPTER GP-FLYWHEEL HOUSING 17
AIR COMPRESSOR GP 18
BASE GP-VALVE COVER 22
BELT TIGHTENER GP 24
CAMSHAFT GP 26
COVER GP-CYLINDER BLOCK 28
COVER GP-FLYWHEEL HOUSING 30
COVER GP-FRONT HOUSING 31
COVER GP-VALVE MECHANISM 32
CRANKSHAFT GP 33
CYLINDER BLOCK AS 35
CYLINDER BLOCK GP 38
CYLINDER HEAD AS 43
CYLINDER HEAD GP 47
DAMPER GP 53
DRIVE AR-FAN 54
DRIVE GP-ACCESSORY 58
DRIVE GP-AUXILIARY 64
DRIVE GP-FAN 66
FLYWHEEL GP 78
GEAR GP-FRONT 80
GEAR GP-REAR 82
GUARD GP-BELT 84
HOUSING GP-FLYWHEEL 86
HOUSING GP-FRONT 88
LIFTING GP-ENGINE 89
MOUNTING GP-ALTERNATOR 90
PAN GP-OIL 92
PISTON & ROD GP 94
SEAL GP-CRANKSHAFT 96
SUPPORT GP-ENGINE 98
TRUNNION GP-ENGINE 100
VALVE MECHANISM GP 102
LUBRICATION SYSTEM 104
BREATHER GP 104
FILLER GP-ENGINE OIL 105
FILTER GP-ENGINE OIL 106
FUMES DISPOSAL GP 110
GAUGE GP-OIL LEVEL (DIPSTICK) 112
LINES GP-ENGINE OIL 114
LINES GP-FAN DRIVE 118
LINES GP-PRELUBRICATION 120
LINES GP-TURBOCHARGER OIL 122
METERING GP-OIL 130
OIL CHANGE GP-HIGH SPEED 132
PUMP GP-ENGINE OIL 134
PUMP GP-SCAVENGE 138
VALVE & MTG GP-FAN DRIVE 141
VALVE & MTG GP-OIL METERING 142
VALVE GP-SOLENOID 144
COOLING SYSTEM 147
CONNECTION GP-WATER 147
COOLER GP-ENGINE OIL 148
CORE AS-OIL COOLER 149
CORE GP-OIL COOLER 151
COVER GP-RADIATOR CAP 154
FAN GP-SUCTION 155
HOUSING & REGULATOR GP 156
INDICATOR GP-LIQUID LEVEL 157
LINES GP-AFTERCOOLER WATER 158
LINES GP-WATER 162
PUMP GP-AUXILIARY WATER 188
PUMP GP-WATER 192
RADIATOR GP 198
SHIELD GP-WATER MANIFOLD 208
VALVE GP-COOLANT SAMPLING 210
AIR INLET AND EXHAUST SYSTEM 211
AFTERCOOLER GP-TREATED
WATER 211
AFTERCOOLER GP-WATER 212
AIR CLEANER GP 213
EXHAUST AR-BODY 220
LINES GP-AIR 222
MANIFOLD GP-EXHAUST 228
MUFFLER GP 232
PIPE GP-EXHAUST 236
SHIELD GP-MANIFOLD 242
TURBOCHARGER GP 243
FUEL SYSTEM 245
CONTROL GP-ACCELERATOR 245
FASTENER GP-FUEL LINES 247
FILTER GP-FUEL 249
FILTER GP-PRIMARY FUEL 254
FILTER GP-WATER SEP & FUEL 255
HEATER GP-FUEL 256
SEBP2790-29 TABLE OF CONTENTS A1
TABLE OF CONTENTS
Name Page Name Page
INJECTOR GP-FUEL 258
LINES GP-FUEL 260
LINES GP-FUEL INJECTION 262
PUMP GP-FUEL INJECTION 274
PUMP GP-FUEL PRIMING 276
PUMP GP-FUEL TRANSFER 278
STRAINER GP-FUEL 284
TANK AS-FUEL 285
TANK GP-FUEL 288
ELECTRICAL AND STARTING SYSTEM 303
ALARM GP 303
ALTERNATOR GP-CHARGING 304
APPLICATION GP-MONITOR 306
BUFFER GP-SENSOR 308
CONTROL & MTG GP-ELECTRONIC 310
CONTROL & MTG GP-ENGINE ELEK 314
CONTROL GP-AIR STARTING 316
CONTROL GP-ELECTRONIC 322
CONTROL GP-ENG RATINGS ELEK 323
CONTROL GP-ENGINE ELECTRONIC 324
CONTROL GP-FAN 328
CONTROL GP-UNPROGRAMMED 329
ELECTRONICS GP-ENGINE RATINGS 332
ELECTRONICS GP-MACHINE 334
ELECTRONICS GP-MONITOR 335
ELECTRONICS GP-POWER TRAIN 336
HEATER GP-ENGINE OIL 338
HEATER GP-JACKET WATER 340
LAMP GP-DOME 341
LAMP GP-FLOOD 342
LAMP GP-HEAD 345
LAMP GP-PAYLOAD SIGNAL 347
LAMP GP-REAR 348
LAMP GP-SIGNAL 350
LUBRICATOR GP-AIR MOTOR 357
MODULE GP-VIDS/VIMS INTERFACE 359
MOTOR GP-PRELUBRICATION 361
PANEL GP-CIRCUIT BREAKER 362
SENSOR & MTG GP-PRESSURE 366
SENSOR GP-COOLANT LEVEL 367
SENSOR GP-FUEL LEVEL 368
SENSOR GP-POSITION 370
SENSOR GP-PRESSURE 379
SENSOR GP-SPEED 392
SENSOR GP-TEMPERATURE 398
SOFTWARE GP-MACHINE 401
SOFTWARE GP-MONITOR 402
SOFTWARE GP-POWER TRAIN 405
STARTING AID GP-ETHER 406
STARTING AR-AIR 412
STARTING AR-COLD WEATHER 416
STARTING MOTOR GP-AIR 418
SWITCH GP-BYPASS 429
SWITCH GP-DISCONNECT 431
SWITCH GP-FLOW 432
SWITCH GP-LIQUID LEVEL 434
SWITCH GP-MAGNETIC 435
SWITCH GP-START 439
THERMOCOUPLE GP 440
VALVE GP-SOLENOID 441
WIRING & LIGHTING GP 442
WIRING GP-CAB 518
WIRING GP-ENGINE 538
WIRING GP-JACKET WATER HEATER 558
POWER TRAIN 560
ACTUATOR GP-ROTARY 560
CASE & PARTS GP-PLANETARY 562
CONTROL GP-TRACTION 564
CONTROL GP-TRANSMISSION 568
CONTROL GP-TRANSMISSION HYD 572
COOLER GP-REAR AXLE OIL 579
COVER GP-SHIPPING 582
COVER GP-TRANSMISSION TANK
CAP 583
DIFFERENTIAL & BEVEL GEAR GP 584
DIFFERENTIAL GP 587
DRIVE GP-PUMP 588
FILTER & LINES GP-TORQUE CONV 592
FILTER GP-OIL 598
FINAL DRIVE GP 610
GEAR GP-TRANSFER 614
HOUSING GP-REAR AXLE 618
LINES GP-POWER TRAIN FILTER 626
LINES GP-TRANSMISSION OIL 628
PLANETARY GP-TRANSMISSION 656
POWER TRAIN AR 662
PUMP & LINES GP-REAR AXLE LUBE 664
PUMP GP-GEAR 666
RIM GP-DEMOUNTABLE 670
RIM GP-SINGLE 675
SCREEN GP-MAGNETIC 676
SHAFT GP-DRIVE 677
SLIP JOINT GP 678
TORQUE CONVERTER GP 680
TRANSMISSION AR 686
VALVE GP 687
VALVE GP-COOLER BYPASS 688
VALVE GP-FLOW CONTROL &
RELIEF 689
VALVE GP-LOCKUP CLUTCH & SYNC 692
VALVE GP-LUBE RELIEF 695
VALVE GP-PRESSURE CONTROL 696
VALVE GP-RELIEF 699
VALVE GP-SELECTOR & PRESS
CONT 702
VALVE GP-SOLENOID 704
VALVE GP-TRACTION CONTROL 708
WHEEL GP-REAR 710
A2 TABLE OF CONTENTS SEBP2790-29
TABLE OF CONTENTS
Name Page Name Page
FRAME AND BODY 718
BODY & CANOPY AS 718
CABLE GP-TRUCK BODY RETAINING 720
CATWALK GP 722
COWLING GP 726
EXTENSION AS 729
FENDER GP 732
FRAME AS 734
FRAME GP 746
GUARD GP-DRIVE SHAFT 749
GUARD GP-PLATFORM 750
GUARD GP-POWER TRAIN FILTER 751
HOOD GP-TRUCK 752
LADDER GP 756
LINER GP-BODY 758
LINER GP-EXTENSION 760
LUBRICATION GP-AUTOMATIC 762
MIRROR & CATWALK AR 774
MIRROR GP-REAR VIEW 776
MOUNTING AR-DUAL SLOPE BODY 781
MOUNTING AR-FLAT FLOOR BODY 782
MOUNTING GP-BODY 784
PLATFORM GP 788
PLATFORM GP-RH 790
PUMP GP-LUBRICATION 792
SIDEBOARD AS-BODY 798
SIDEWALL CAP AS-BODY 799
SUSPENSION GP-FRONT 800
SUSPENSION GP-REAR 808
TREAD GP-NONSKID 814
VALVE GP-LUBE DISTRIBUTION 815
BRAKING SYSTEM 819
AIR DRYER GP 819
BRAKE GP-SERVICE & PARKING 822
CONTROL GP-PARKING BRAKE 842
CONTROL GP-RETARDER 844
CONTROL GP-SERVICE BRAKE 846
CYLINDER GP-AIR 856
CYLINDER GP-AIR/HYDRAULIC 858
LINES GP-SERVICE BRAKE 860
PUMP GP-ELECTRIC DRIVE 886
SLACK ADJUSTER GP 888
TANK GP-AIR 892
TANK GP-BRAKE 895
VALVE & MTG GP-BRAKE 896
VALVE AS-CHECK 897
VALVE GP-AIR CONTROL 898
VALVE GP-BRAKE 902
VALVE GP-CHECK 906
VALVE GP-RELIEF 909
VALVE GP-SOLENOID 911
STEERING SYSTEM 913
ACCUMULATOR & MOUNTING GP 913
ACCUMULATOR GP-STEERING 914
CONVERSION GP-STEERING TANK 916
CYLINDER & MTG GP-STEERING 917
CYLINDER GP-STEERING 918
FILTER GP-OIL 919
LINES GP-STEERING 920
LINK GP-STEERING 938
PUMP & MTG GP-STEERING 940
PUMP GP-METERING 941
PUMP GP-PISTON 942
ROTATING GP-PUMP 944
STEERING COLUMN GP 945
STEERING GEAR GP 946
SWASHPLATE GP 948
TANK & FILTER GP-STEERING 950
TANK GP-STEERING 953
VALVE GP-ACCUMULATOR
CHARGING 954
VALVE GP-CHECK 955
VALVE GP-PRESS & FLOWCMPNSTR 956
VALVE GP-RELIEF 957
VALVE GP-SOLENOID 959
VALVE GP-SOLENOID & RELIEF 960
VALVE GP-STEERING 962
WHEEL GP-FRONT 964
HYDRAULIC SYSTEM 966
ACTUATOR GP-PILOT CONTROL 966
CONTROL GP-HOIST 968
CONTROL GP-HOIST ELECTRONIC 970
COVER GP-HYDRAULIC TANK CAP 972
CYLINDER & MTG GP-HOIST 974
CYLINDER GP-HOIST 976
HYDRAULIC AR 978
LINES GP-HOIST 980
LINES GP-HYDRAULIC OIL COOLER 992
MANIFOLD GP 1009
MOUNTING GP-HYDRAULIC TANK 1012
PUMP GP-GEAR 1014
SCREEN GP-HYDRAULIC 1026
SHAFT GP-PUMP DRIVE 1028
TANK GP-HYDRAULIC & TMSN 1030
UNIVERSAL JOINT GP-PUMP DRIVE 1041
VALVE & MTG GP-CONTROL 1042
VALVE GP-CONTROL 1044
VALVE GP-DIVERTER 1055
VALVE GP-RELIEF 1056
OPERATOR STATION 1058
ADJUSTER GP-SEAT 1058
AIR CONDITIONER GP 1064
ARMREST GP 1072
CAB AR-ROPS 1075
CAB GP-ROPS 1078
CLEANOUT GP-CAB 1089
SEBP2790-29 TABLE OF CONTENTS A3
TABLE OF CONTENTS
Name Page Name Page
COMPRESSOR GP-REFRIGERANT 1090
CONDENSER & MTG GPREFRIGERANT
DASH GP 1098
DOOR GP-CAB 1100
DOOR GP-LH 1110
EXTENSION GP-BACKREST 1113
HORN GP-AIR 1114
HOUSING GP-SEAT SUSPENSION 1116
INSTALLATION GP-RADIO 1119
LINES GP-AIR CONDITIONER 1120
LINES GP-HEATER 1126
LITERATURE GP 1127
MODULE GP-MESSAGE CENTER 1128
MOUNTING GP-CAB 1129
ODOMETER GP 1130
PAN GP-BACKREST 1133
PAN GP-SEAT 1136
PANEL GP-INSTRUMENT 1138
PANEL GP-SOUND SUPPRESSION 1156
RECLINER GP-SEAT 1158
SEAT BELT GP 1161
SEAT GP 1166
SEAT GP-ADJUSTABLE 1188
SEAT GP-COMPANION 1192
SEAT GP-SUSPENSION 1205
SUSPENSION GP-SEAT 1210
TANK GP-WINDOW WASHER 1216
VISOR GP-CAB 1217
WASHER GP-WINDOW 1220
WINDOW GP 1222
WIPER GP-WINDOW 1225
SERVICE EQUIPMENT AND SUPPLIES 1226
CHOCK GP-WHEEL 1226
FILM GP 1228
FILM GP-CAB 1231
PLATE & FILM GP 1232
PLATE-WARNING 1260
VALVE AS-TANK 1261
PART NUMBER INDEX B1

DESCRIPTION:

Cat 789C Off-Highway Truck Parts Manual – PDF DOWNLOAD

2BW1-Up (Machine)
7TR1-Up (Engine)
6LE1-Up (Transmission)
3LT1-Up (Torque Converter)
Powered By 3516 Engine

1. MACHINE IDENTIFICATION :

Caterpillar machines are identified by Product Identification Numbers (PIN). Some components included in a machine may be identified by Serial Numbers (S/N). Typical components that will be serialized include engines, transmissions, bulldozers, and rippers. The machine and engine are further identified by arrangement numbers and in some cases modification numbers.

• These numbers are shown on the product identification plate(s) and on the master plate in the operator’s compartment. Caterpillar dealers need all of these numbers to determine accurate parts identification. Effective First Quarter 2001 the Caterpillar Product Identification Number (PIN) changed from 8 to 17 characters.
• In an effort to provide uniform equipment identification, Caterpillar and other construction equipment manufacturers are moving to comply with the latest version of the product identification numbering standard.

Non-road machine PINs are defined by ISO 10261. The new PIN format will apply to all Caterpillar machines and generator sets. The PIN plates and frame marking will display the 17 character PIN. The new format will look like the following:

Where:

1. Caterpillar’s World Manufacturing Code (characters 1-3)
2. Machine Descriptor (characters 4-8)
3. Check Character (character 9)
4. Machine Indicator Section (MIS) or Product Sequence Number (characters 10-17). These were previously referred to as the Serial Number. Machines and generator sets produced before First Quarter 2001 will maintain their 8 character PIN format. Components such as engines, transmissions, axles, etc. and work tools will continue to use an 8 character Serial Number (S/N).

CAT 789C OFF-HIGHWAY TRUCK PARTS MANUAL – PDF DOWNLOAD:

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• This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
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