Procedure to Install an Updated Body Position Switch on the 777F Off-Highway Trucks{1408, 7258} Caterpillar

Off-Highway Truck:

777F (S/N: WTK1-UP; JRP1-UP; JXP1-UP)

Introduction

ReferenceSpecial Instruction, REHS1841, "General Welding Procedures"

ReferenceOperation and Maintenance Manual, SEBU7790

The following procedure describes the process of installing an updated body position switch on the certain Off-Highway Trucks. The new magnet and orientation of the switch will help to provide more reliable operation of the position switch.

There are three separate installation instructions provided. Each section is for a different truck body style. Refer to the correct section for your truck body.

• ""Installation Procedure (Coal Bodies)" "

• ""Installation Procedure (Dual Slope Bodies)" "

• ""Installation Procedure (X Bodies)" "

Safety

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Cat dealer for replacement manuals. Proper care is your responsibility.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

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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.

Required Parts

Machine Preparation

1. Move the machine to a hard level surface.

2. Avoid sudden steering inputs when you are parking the machine.

3. Apply the service brakes in order to stop the machine.

4. Move the transmission control lever to the PARK position.

5. Raise the body and install the retaining pins. Refer to Operation and Maintenance Manual, SEBU7790 for instructions on securing the truck body. Place the hoist control lever in the FLOAT position for at least 10 seconds.

6. Turn the engine start switch to the OFF position in order to stop the engine.

7. Turn the battery disconnect switch to the OFF position.

8. Disconnect the battery. Refer to Operation and Maintenance Manual, "Battery or Battery Cable - Inspect/Replace" for additional information disconnecting the battery.

9. Chock the front wheels and the rear wheels. Refer to Disassembly and Assembly, "Wheel Chock (Front and Rear) - Remove and Install".

10. Release the pressure from the system. Refer to Operations and Maintenance Manual, "System Pressure Release".

Removal Procedure

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Illustration 1	g02730838
View of the rear of the frame (A) Limit switch assembly (B) Bracket (C) Harness assembly

1. Disconnect limit switch assembly (A) from harness assembly (C) .

2. Remove limit switch assembly (A) and bracket (B) from the frame. Discard all the hardware.

Fabrication Procedure

Coal Body

Illustration 2	g02729890
Typical view (1) Plate

Illustration 3	g02730003
Development view (1) Plate (A) 67 mm (2.638 inch) (B) 221 mm (8.701 inch) (C) 105 mm (4.134 inch)

Illustration 4	g02730007
(D) 60 mm (2.362 inch) (E) 119 mm (4.685 inch) (F) 162 mm (6.378 inch) (G) 48 mm (1.890 inch) (H) 60 mm (2.362 inch) (J) 150 mm (5.905 inch) (K) 25 mm (0.984 inch) (L) 50 mm (1.969 inch) (M) Radius (two places, two holes) (N) 10 mm (0.394 inch) by 26 mm (1.024 inch) Hole (two places) (P) 8 mm (0.315 inch) Radius (six places) (R) 75 mm (2.953 inch) (S) 6 mm (0.236 inch) (T) 20 ± 2 mm (0.787 ± 0.079 inch) Radius (U) 55 mm (2.165 inch) (V) 105 mm (4.134 inch) (W) 8 mm (0.315 inch) Radius (two places)

Dual Slope Body

Illustration 5	g02793180
Typical view (1) Plate

Illustration 6	g02791409
(A) 67 mm (2.638 inch) (B) 251 mm (9.882 inch) (C) 77 mm (3.031 inch)

Illustration 7	g02791411
(D) 89 mm (3.504 inch) (E) 150 mm (5.905 inch) (F) 192 mm (7.559 inch) (G) 78 mm (3.071 inch) (H) 90 mm (3.543 inch) (J) 180 mm (7.087 inch) (K) 25 mm (0.984 inch) (L) 50 mm (1.968 inch) (M) Radius (two places, two holes) (N) 10 mm (0.394 inch) by 26 mm (1.024 inch) Hole (two places) (P) 8 mm (0.315 inch) Radius (six places) (R) 75 mm (2.953 inch) (S) 6 mm (0.236 inch) (T) 20 ± 2 mm (0.787 ± 0.079 inch) Radius (U) 27 mm (1.063 inch) (V) 77 mm (3.031 inch) (W) 8 mm (0.315 inch) Radius (two places)

X Body

Illustration 8	g02793332
Typical view (1) Plate

Illustration 9	g02791412
(A) 77 mm (3.031 inch) (B) 238 mm (9.370 inch) (C) 145 mm (5.709 inch)

Illustration 10	g02791413
(D) 76 mm (2.992 inch) (E) 135 mm (5.315 inch) (F) 169 mm (6.653 inch) (G) 12 mm (0.472 inch) (H) 102 mm (4.016 inch) (J) 114 mm (4.488 inch) (K) 43.5 mm (1.713 inch) (L) 95 mm (3.740 inch) (M) 145 mm (5.709 inch) (N) 25 mm (0.984 inch) (P) 45 mm (1.772 inch) (R) 8 mm (0.315 inch) Radius (six places) (S) Radius (two places, two holes) (T) 10 mm (0.394 inch) by 26 mm (1.024 inch) Hole (two places) (U) 85 mm (3.346 inch) (V) 6 mm (0.236 inch) (W) 20 ± 2 mm (0.787 ± 0.079 inch) Radius (X) 8 mm (0.315 inch) Radius (two places)

Installation Procedure (Coal Bodies)

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Illustration 11	g02729890
Typical view (1) Plate

1. Fabricate one plate (1). Refer to ""Fabrication Procedure" ", ""Coal Body" ".

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Illustration 12	g02730840
(1) Plate

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Illustration 13	g02792674
(1) Plate (A) 240 ± 3 mm (9.449 ± 0.118 inch) (B) 52 ± 3 mm (2.047 ± 0.118 inch) (C) 325 ± 3 mm (12.795 ± 0.118 inch)

2. Position plate (1) on the plate assembly for the body.

   Note: Measurement (A) is from the front of the toe of the weld for the plate on the body.

   Note: Measurement (C) is to verify measurement (A) is correct by measuring from the center of the pivot bore to the back edge of plate (1) parallel to the body rails.

   Note: Measurement (B) is down from the body frame rails.

3. Tack weld plate (1) in place.

   Note: Refer to Special Instruction, REHS1841, "General Welding Procedures" before performing any welding on the machine.

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Illustration 14	g02792727
(1) Plate (2) 5G-7820 Magnet As (3) 8T-7547 Bolt (4) 8T-4224 Hard Washer (5) 6V-9189 Locknut

4. Secure magnet assembly (2) to plate (1) by using two bolts (3), four hard washers (4), and two locknuts (5) .

   Note: Leave magnet assembly (2) loose for adjustment.

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Illustration 15	g02792808
View of the rear of the frame (D) Block (6) 378-9063 Plate (7) 8T-4137 Bolt (8) 8T-4121 Hard Washer (9) 130-5300 Clip

5. Secure one plate (6) and two clips (9) to block (D) by using two bolts (7), and two hard washers (8) .

   Note: Tighten bolts (7) to a torque of 55 ± 10 N·m (40.5 ± 7.4 lb ft).

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Illustration 16	g02792823
View of the rear of the frame (4) 8T-4224 Hard Washer (6) 378-9063 Plate (9) 130-5300 Clip (10) 228-4808 Position Switch Gp (11) 4M-6425 Bolt

6. Secure one position switch group (10) and one clip (9) to plate (6) by using two bolts (11) and two hard washers (4) .

   Note: Tighten bolts (11) to a torque of 25 ± 6 N·m (220 ± 55 lb in).

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Illustration 17	g02792851
(E) Chassis harness assembly (9) 130-5300 Clip (10) 228-4808 Position Switch Gp (12) 383-2704 Switch Harness As

7. Connect switch harness assembly (12) to position switch group (10) and chassis harness assembly (E) .

8. Secure harness assembly (12) and chassis harness assembly (E) to three clips (9) .

9. Remove the body retaining pin and operate the hoist of the truck.

   Note: Refer to Operation and Maintenance Manual, SEBU7790 for instructions on removing the pins and operating the hoist.

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Illustration 18	g02792876
(F) 10 mm (0.394 inch) (2) 5G-7820 Magnet As (10) 228-4808 Position Switch Gp

10. With the body in the DOWN position, adjust magnet assembly (2) and position switch group (10) so that the gap is 10 mm (0.394 inch).

    Position magnet assembly (2) so that the body snubs at 203 to 254 mm (8 to 10 inch) between the front body pads and the frame rail.

11. Tighten the hardware that secures magnet assembly (2) to a torque of 28 ± 7 N·m (250 ± 62 lb in).

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Illustration 19	g02792894
(1) Plate (W1) 6 mm (0.236 inch) Fillet weld with 1.5 mm (0.059 inch) root penetration

Note: Refer to Special Instruction, REHS1841, "General Welding Procedures" before performing any welding on the machine.

12. Finish weld plate (1) on three sides.

13. Clean and paint plate (1) and the welds.

Installation Procedure (Dual Slope Bodies)

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Illustration 20	g02793180
Typical view (1) Plate

1. Fabricate one plate (1). Refer to ""Fabrication Procedure" ", ""Dual Slope Body" ".

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Illustration 21	g02793196
(1) Plate

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Illustration 22	g02793224
(1) Plate (A) 400 ± 1 mm (15.748 ± 0.0394 inch) (B) 43 ± 1 mm (1.6931 ± 0.0394 inch) (C) 17.5 ± 1 Degrees

2. Position plate (1) on the plate assembly for the body.

   Note: Measurement (A) is from the center of the pivot bore to the front of plate (1) .

   Note: Measurement (B) is from the center of the pivot bore to the bottom of plate (1) .

   Note: Measurement (C) is a 17.5 ± 1 Degree angle from parallel with the ground at the center of the pivot bore.

3. Tack weld plate (1) in place.

   Note: Refer to Special Instruction, REHS1841, "General Welding Procedures" before performing any welding on the machine.

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Illustration 23	g02793306
(1) Plate (2) 5G-7820 Magnet As (3) 8T-7547 Bolt (4) 8T-4224 Hard Washer (5) 6V-9189 Locknut

4. Secure magnet assembly (2) to plate (1) by using two bolts (3), four hard washers (4), and two locknuts (5) .

   Note: Leave magnet assembly (2) loose for adjustment.

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Illustration 24	g02792808
View of the rear of the frame (D) Block (6) 378-9063 Plate (7) 8T-4137 Bolt (8) 8T-4121 Hard Washer (9) 130-5300 Clip

5. Secure one plate (6) and two clips (9) to block (D) by using two bolts (7), and two hard washers (8) .

   Note: Tighten bolts (7) to a torque of 55 ± 10 N·m (40.5 ± 7.4 lb ft).

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Illustration 25	g02792823
View of the rear of the frame (4) 8T-4224 Hard Washer (6) 378-9063 Plate (9) 130-5300 Clip (10) 228-4808 Position Switch Gp (11) 4M-6425 Bolt

6. Secure one position switch group (10) and one clip (9) to plate (6) by using two bolts (11) and two hard washers (4) .

   Note: Tighten bolts (11) to a torque of 25 ± 6 N·m (220 ± 55 lb in).

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Illustration 26	g02792851
(E) Chassis harness assembly (9) 130-5300 Clip (10) 228-4808 Position Switch Gp (12) 383-2704 Switch Harness As

7. Connect switch harness assembly (12) to position switch group (10) and chassis harness assembly (E) .

8. Secure harness assembly (12) and chassis harness assembly (E) to three clips (9) .

9. Remove the body retaining pin and operate the hoist of the truck.

   Note: Refer to Operation and Maintenance Manual, SEBU7790 for instructions on removing the pins and operating the hoist.

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Illustration 27	g02792876
Typical view (F) 10 mm (0.394 inch) (2) 5G-7820 Magnet As (10) 228-4808 Position Switch Gp

10. With the body in the DOWN position, adjust magnet assembly (2) and position switch group (10) so that the gap is 10 mm (0.394 inch).

    Position magnet assembly (2) so that the body snubs at 203 to 254 mm (8 to 10 inch) between the front body pads and the frame rail.

11. Tighten the hardware that secures magnet assembly (2) to a torque of 28 ± 7 N·m (250 ± 62 lb in).

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Illustration 28	g02793316
(1) Plate (W1) 6 mm (0.236 inch) Fillet weld (W2) 5 mm (0.197 inch) Flare-bevel weld

Note: Refer to Special Instruction, REHS1841, "General Welding Procedures" before performing any welding on the machine.

12. Finish weld plate (1) on three sides with a 6 mm (0.236 inch) fillet weld. Finish weld the front side of plate (1) with a 5 mm (0.197 inch) flare-bevel weld.

13. Clean and paint plate (1) and the welds.

Installation Procedure (X Bodies)

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Illustration 29	g02793332
Typical view (1) Plate

1. Fabricate one plate (1). Refer to ""Fabrication Procedure" ", ""X Body" ".

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Illustration 30	g02793340
(1) Plate

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Illustration 31	g02793346
(1) Plate (A) 40 ± 3 mm (1.575 ± 0.118 inch) (B) 192 ± 3 mm (7.559 ± 0.118 inch) (C) 400 ± 3 mm (15.748 ± 0.118 inch)

2. Position plate (1) on the plate assembly for the body.

   Note: Measurement (A) is from the bottom of the body frame rail to the top of plate (1) .

   Note: Measurement (B) is from the bottom of the body frame rail to the bottom of plate (1) .

   Note: Measurement (C) is from the center of the pivot bore to the front edge of plate (1) .

3. Tack weld plate (1) in place.

   Note: Refer to Special Instruction, REHS1841, "General Welding Procedures" before performing any welding on the machine.

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Illustration 32	g02793367
(1) Plate (2) 5G-7820 Magnet As (3) 8T-7547 Bolt (4) 8T-4224 Hard Washer (5) 6V-9189 Locknut

4. Secure magnet assembly (2) to plate (1) by using two bolts (3), four hard washers (4), and two locknuts (5) .

   Note: Leave magnet assembly (2) loose for adjustment.

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Illustration 33	g02792808
View of the rear of the frame (D) Block (6) 378-9063 Plate (7) 8T-4137 Bolt (8) 8T-4121 Hard Washer (9) 130-5300 Clip

5. Secure one plate (6) and two clips (9) to block (D) by using two bolts (7), and two hard washers (8) .

   Note: Tighten bolts (7) to a torque of 55 ± 10 N·m (40.5 ± 7.4 lb ft).

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Illustration 34	g02792823
View of the rear of the frame (4) 8T-4224 Hard Washer (6) 378-9063 Plate (9) 130-5300 Clip (10) 228-4808 Position Switch Gp (11) 4M-6425 Bolt

6. Secure one position switch group (10) and one clip (9) to plate (6) by using two bolts (11) and two hard washers (4) .

   Note: Tighten bolts (11) to a torque of 25 ± 6 N·m (220 ± 55 lb in).

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Illustration 35	g02792851
(E) Chassis harness assembly (9) 130-5300 Clip (10) 228-4808 Position Switch Gp (12) 383-2704 Switch Harness As

7. Connect switch harness assembly (12) to position switch group (10) and chassis harness assembly (E) .

8. Secure harness assembly (12) and chassis harness assembly (E) to three clips (9) .

9. Remove the body retaining pin and operate the hoist of the truck.

   Note: Refer to Operation and Maintenance Manual, SEBU7790 for instructions on removing the pins and operating the hoist.

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Illustration 36	g02792876
Typical view (F) 10 mm (0.394 inch) (2) 5G-7820 Magnet As (10) 228-4808 Position Switch Gp

10. With the body in the DOWN position, adjust magnet assembly (2) and position switch group (10) so that the gap is 10 mm (0.394 inch).

    Position magnet assembly (2) so that the body snubs at 203 to 254 mm (8 to 10 inch) between the front body pads and the frame rail.

11. Tighten the hardware that secures magnet assembly (2) to a torque of 28 ± 7 N·m (250 ± 62 lb in).

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Illustration 37	g02793377
(1) Plate (W1) 5 mm (0.197 inch) Fillet weld (W2) 5 mm (0.197 inch) Flare-bevel weld

Note: Refer to Special Instruction, REHS1841, "General Welding Procedures" before performing any welding on the machine.

12. Finish weld plate (1) on three sides with a 5 mm (0.197 inch) fillet weld. Finish weld the front side of plate (1) with a 5 mm (0.197 inch) flare-bevel weld.

13. Clean and paint plate (1) and the welds.