- Off-Highway Truck:
- 770 (S/N: BZZ1-UP)
- 772 (S/N: RLB1-UP)
- 773F (S/N: EED1-UP; EXD1-UP)
- 775F (S/N: DLS1-UP)
- 777F (S/N: JRP1-UP; JXP1-UP)
Description of Change: The body up switch and the lever has been replaced in order to improve service life. The body up switch and the lever has been replaced in order to reduce down time.
Adaptable To: The new 261-8652 Limit Switch As replaces the former 228-4808 Position Switch Gp. The 346-1149 Lever replaces the former 8D-4656 Lever .
The new 261-8652 Limit Switch As and 346-1149 Lever is adaptable to the machines BZZ1-509, RLB1-583, EED1-1082, EXD1-109, DLS1-1063, JRP1-2161 and JXP1-139.
The new 261-8652 Limit Switch As and the new 346-1149 Lever are effective in production with the machines BZZ510-UP, RLB584-UP, EED1083-UP, EXD110-UP, DLS1064-UP, JRP2162-UP and JXP140-UP.
Safety
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Do not attempt to assemble this machine until you read and you understand the assembly instructions. Improper assembly procedures could result in injury or death. |
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Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas. |
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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of LaborWashington, D.C. 20210 |
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When a hoist is used to lift any part or assembly, stand clear of the area under the part being raised. Always make sure that the hoist has adequate lifting capacity and the wire cable is not damaged. Failure to follow this instruction could lead to injury or death. Approximate weights of the components are shown in the table which follows. |
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Processes for Welding
Use the following electrodes: low hydrogen E7018 electrode, E70S-3 solid wire (dual shield) and E71T-1 flux cored wire.
All electrodes must be completely dry.
Do not weld in areas if there is a strong movement of air or in temperatures of less than 16° C (61° F).
The following welding processes are acceptable for this procedure:
- Gas metal arc welding (GMAW) Use 35 ± 5 cubic feet per hour of shielding gas (75% argon and 25% carbon dioxide). The AWS Class ER70S-3 is a welding process that can be used with any of the following welders: Lincoln L-50 and Hobart HB-25.
- Flux cored arc welding (FCAW) Use 35 ± 5 cubic feet per hour of shielding gas (75% argon and 25% carbon dioxide). The FCAW process is called the AWS Class E71T-1 process.
- Shielded metal arc welding (SMAW)
- Air arc gouging (DCEP) Use rods that have a diameter of 127 mm (5/16 inch) for carbon arc.
For additional guidelines for welding, refer to Special Instruction, REHS1841, "General Welding Procedures".
Required Parts
| Required parts for the 773F, 775F and the 777F Off-Highway Trucks | |||
| Item | Qty | Part Number | Description |
| 1a | 1 | 298-6122 (1) | Plate |
| 1b | 1 | 306-8942 (2) | Plate |
| 2 | 2 | 6V-8127 | Nuts |
| 3 | 2 | 120-3956 | Bolts |
| 4 | 2 | 161-6987 | Hard Washers |
| 5 | 1 | 346-1149 | Lever |
| 6 | 1 | 261-8652 | Limit switch |
| 7 | 1 | 130-5300 | Clip |
| 8 | 1 | 102-8804 | Receptacle Kit |
| 9 | 1 | 8T-8737 | Seal plug |
| 10 | 3 | 9X-3401 | Connector Pins |
| 11 | 1 | 294-9705 | Plate |
| ( 1 ) | Used with the 773F and 775F Off-Highway Trucks |
| ( 2 ) | Used with the 777F Off-Highway Trucks |
Rework Procedure
- Remove the existing 228-4808 Position Switch and 230-9204 Plate from the frame. Retain the two mounting bolts and the two washers that are used to mount the plate to the frame. Discard the remaining parts.
- Remove the existing 230-9206 Plate As from the dump body. Discard the plate and mounting hardware.
- For 773F and 775F Off-Highway Trucks, position plate (1a) and clip (7) to the frame with the two bolts and the two washers that were retained in Step 1.
For 777F Off-Highway Trucks, position plate (1b) and clip (7) to the frame with the two bolts and the two washers that were retained in Step 1.
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| Illustration 1 | g01959391 |
Typical installation of the frame for the 777F | |
- Install limit switch assembly (6) to plate (1) with two bolts (3), two washers (4) and two nuts (2) .
- Install lever (5) onto the shaft of limit switch assembly (6) .
- Remove the 2-pin receptacle from the 235-0095 Chassis Harness As .
- Install wire "750" (Purple) into location "1" of receptacle (8) with one pin (10). Install wire "765" (Blue) into location "2" of receptacle (8) with one pin (10). Install wire "126" (PINK) into location "3" of receptacle (8) with one pin (10). Install seal plug (9) into location "4" of receptacle (8). Install the wedge into receptacle (8) .
Note: The wedge is part of receptacle kit (8) .
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| Illustration 2 | g01964826 |
Receptacle assembly | |
- Position plate (11) to the dump body.
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| Illustration 3 | g01679938 |
Typical front view of the bodies for 773F and 775F Off-Highway Truck | |
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| Illustration 4 | g01679940 |
An inside view of the LH pivot for the dump body Section A-A (A) 105 ± 2 mm (4.1 ± 0.1 inch) (B) 293 ± 2 mm (11.5 ± 0.1 inch) (W1) 6 mm (0.24 inch) fillet weld with 1.5 mm (0.06 inch) deep weld penetration on both sides | |
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| Illustration 5 | g01679941 |
Typical front view of the bodies for the 777F Off-Highway Truck | |
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| Illustration 6 | g01692093 |
An inside view of the LH pivot for the dump body Section B-B (C) 401 ± 3 mm (15.8 ± 0.1 inch) (D) 62 ± 3 mm (2.4 ± 0.1 inch) (E) 145 ± 3 mm (5.7 ± 0.1 inch) (F) 10.5 degrees reference (W1) 6 mm (0.24 inch) fillet weld with 1.5 mm (0.06 inch) deep weld penetration on both sides | |
- Weld plate (11) to the dump body with weld (W1) .
- Clean the welds and paint the welds.
- Adjust the position switch.
For 773F and 775F Off-Highway Trucks, refer to Special Instruction, REHS2704, "Assembly Instructions for the 773F and 775F Off-Highway Trucks", "Adjust the Position Sensor for the Dump Body".
For the 777F Off-Highway Truck, refer to Special Instruction, REHS2594, "Assembly Instructions for the 777F Off-Highway Trucks", "Adjust the Position Sensor for the Dump Body".