2003/06/09 Caterpillar

A New Body Down or Up Switch Is Now Used {7258, 7332}

Usage:

777D AGC

Off-Highway Truck: 769D (S/N: BBB1-UP) 771D (S/N: BCA1-UP) 773E (S/N: BDA1-UP) 775E (S/N: BEC1-UP) 777D (S/N: AGC1-UP) 777D HAA (S/N: AGY1-UP)

Service Magazine, SEPD0686, 09 June 2003, "A New Body Down or Up Switch No Longer Needs Adjustment". Disregard this article. The new switch does need to be adjusted. Refer to the information that follows.

Description of Change: A new switch and a new mounting group is now used.

Adaptable To: The new 215-6315 Switch Gp replaces the former 3E-0461 Electronic Control. The new switch is not a direct replacement.

The new switch and the new mounting group is effective with the following machines:

769D (S/N: BBB239-UP)
771D (S/N: BCA194-UP)
773D (S/N: BDA259-UP)
775D (S/N: BEC202-UP)
777D (S/N: AGC1240-UP)
777D HAA (S/N: AGY81-UP)

The new switch and the new mounting group are adaptable to all of the previous machines. Refer to the following information in order to replace the body down or up switch.

Parts List for the 769D and the 771D

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Illustration 1	g00996976
Body down or up switch for the 769D and 771D (1) 5P-1075 Hard Washer (2) 5S-7379 Bolt (3) 230-9204 Plate (4) 5P-4116 Hard Washer (5) 4M-6425 Bolt (6) 215-6315 Switch Gp (7) 8T-4896 Hard Washer (8) 230-9205 Plate As

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Table 1
769D/771D
Item	Qty	Part Number	Description
1	2	5P-1075	Hard Washer
2	4	5S-7379	Bolt
3	1	230-9204	Plate
4	2	5P-4116	Hard Washer
5	2	4M-6425	Bolt
6	1	215-6315	Switch Gp
7	2	8T-4896	Hard Washer
8	1	230-9205	Plate As

Parts List for the 773E and the 775E

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Illustration 2	g00996977
Body down or up switch for the 773E and 775E (9) 5P-1075 Hard Washer (10) 5S-7379 Bolt (11) 230-9204 Plate (12) 5P-4116 Hard Washer (13) 4M-6425 Bolt (14) 215-6315 Switch Gp (15) 8T-4896 Hard Washer (16) 230-9206 Plate As

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Table 2
773E/775E
Item	Qty	Part Number	Description
9	2	5P-1075	Hard Washer
10	4	5S-7379	Bolt
11	1	230-9204	Plate
12	2	5P-4116	Hard Washer
13	2	4M-6425	Bolt
14	1	215-6315	Switch Gp
15	2	8T-4896	Hard Washer
16	1	230-9206	Plate As

Parts List for the 777D

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Illustration 3	g00996979
Body down or up switch for 777D (17) 5P-1075 Hard Washer (18) 5S-7379 Bolt (19) 230-9204 Plate (20) 5P-4116 Hard Washer (21) 4M-6425 Bolt (22) 215-6315 Switch Gp (23) 230-9207 Plate As (24) 8T-4896 Hard Washer (25) 4L-6454 Bolt is only for the flat floor body. (26) 6V-8801 Nut (not shown) is only for the flat floor body. (27) 7V-0654 Block (not shown) is only for the dual slope body.

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Table 3
777D
Item	Qty	Part Number	Description
17	2	5P-1075	Hard Washer
18	6	5S-7379	Bolt ⁽¹⁾
19	1	230-9204	Plate
20	2	5P-4116	Hard Washer
21	2	4M-6425	Bolt
22	1	215-6315	Switch Gp
23	1	230-9207	Plate As
24	4	8T-4896	Hard Washer
25	4	4L-6454	Bolt ⁽²⁾
26	4	6V-8801	Nut ⁽²⁾
27	1	7V-0654	Block ⁽³⁾

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^( 1 )	Four of the bolts are used on the 777D with the dual slope body.
^( 2 )	This is used on the 777D with the flat floor body.
^( 3 )	This is used on the 777D with the dual slope body.

Installation on the 777D with the Flat Floor Body

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Illustration 4	g00996979
Body down or up switch for 777D with the flat floor body (17) 5P-1075 Hard Washer (18) 5S-7379 Bolt (19) 230-9204 Plate (20) 5P-4116 Hard Washer (21) 4M-6425 Bolt (22) 215-6315 Switch Gp (23) 230-9207 Plate As (24) 8T-4896 Hard Washer (25) 4L-6454 Bolt (26) 6V-8801 Nut (not shown)

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Illustration 5	g00999076
Mounting plate (D1) 10.5 mm (0.41 inch) diameter (H1) 65.0 mm (2.56 inch) (H2) 15.0 mm (0.59 inch) (H3) 40.0 mm (1.57 inch) (H4) 94.0 mm (3.70 inch) (L1) 25.0 mm (0.98 inch) (L2) 70.0 mm (2.76 inch) (L3) 95.0 mm (3.74 inch) (R1) 5.0 mm (0.20 inch) radius (T1) 10.0 mm (0.39 inch) thickness

Fabricate the mounting plate with the dimensions that are shown. Fabricate the mounting plate from 1008 steel.

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Illustration 6	g00999116
(L5) 507.0 ± 3.0 mm (19.96 ± 0.12 inch) (L6) 98.0 ± 3.0 mm (3.86 ± 0.12 inch) (W1) 10.0 mm (0.39 inch) fillet weld

Locate the mounting plate onto the pivot plate that is shown in Illustration 6. Dimension (L5) is from the center of the bore of the pivot to the center of hole in the mounting plate. Dimension (L5) is parallel to the bottom edge of the mounting plate. Dimension (L6) is perpendicular to the bottom edge of the mounting plate.

Tack weld the mounting plate onto the pivot plate.

Bolt plate assembly (23) to the mounting plate.

Bolt switch gp (22) to plate (19). Bolt the assembly to the frame.

Prior to welding the block onto the body, lower the body in order to verify the clearance of the plate assembly.

Weld (W1) 10.0 mm (0.39 inch) fillet weld onto both sides of the mounting plate.

Installation on the 777D with the Dual Slope Body

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Illustration 7	g00996979
Body down or up switch for 777D with the dual slope body (17) 5P-1075 Hard Washer (18) 5S-7379 Bolt (19) 230-9204 Plate (20) 5P-4116 Hard Washer (21) 4M-6425 Bolt (22) 215-6315 Switch Gp (23) 230-9207 Plate As (24) 8T-4896 Hard Washer (25) 7V-0654 Block (not shown)

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Illustration 8	g00998552
Front view of the body (25) 7V-0654 Block (26) Existing block (W2) 6.0 mm (0.25 inch) fillet weld

Note: In order to install the body down or up switch on the 777D with the dual slope body, an additional block must be welded to the body. 230-9207 Plate As will be used in order to locate 7V-0654 Block .

Bolt plate assembly (23) onto existing block (26) .

Locate block (25) toward the front of the machine from existing block (26) .

Bolt plate assembly (23) to block (25) .

Tack weld block (25) onto the body.

Bolt switch gp (22) to plate (19). Bolt the assembly to the frame.

Prior to welding the block onto the body, lower the body in order to verify the clearance of the plate assembly.

Weld (W1) 6.0 mm (0.25 inch) fillet weld on both sides of block (25) .

Adjustment Procedure for the Switch

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Illustration 9	g01185818
Typical Example

Lower the body all the way.

Loosen bolts (3) .

Align switch (1) with magnet (2) .
Note: When switch (1) is positioned higher in the bracket, the body will begin snub mode earlier when the body is being lowered. When switch (1) is positioned lower in the bracket, the body will begin snub mode later when the body is being lowered.