Procedure to Install the Working at Heights Attachment on the 785C and 785D Off-Highway Trucks{0635, 7254, 7255, 7256} Caterpillar

Off-Highway Trucks:

785C (S/N: APX1-UP)

785D (S/N: MSY1-UP)

Introduction

The following procedure includes the instructions needed to install additional handrail groups for working at heights while the machine is being serviced. The 437-8751 Handhold Gp and the 437-8752 Handrail Gp are required to complete the following procedure.

The following groups are part of the 437-8751 Handhold Gp :

• 437-8754 Mounting Bracket Gp

• 437-8758 Handhold Gp

The following group is part of the 437-8752 Handrail Gp :

• 437-8773 Handrail Gp

Safety

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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine.

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When it is necessary to work under the machine with the body (bed) raised, attach the body (bed) retaining cable to the rear tow point. Install the rear tow point pin through the end of the retaining cable. Failure to properly secure the body (bed) may result in personal injury or death.

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Falling Hazard. May cause personal injury or death. Always attach safety lanyard to appropriate fixing point.

Required Parts

Prepare the Machine

Note: Permit only one operator on the machine. Either keep other personnel away from the machine, or keep other personnel in the sight of the operator.

1. Move the machine to a smooth horizontal location. Move away from any machines that are working and any personnel.

2. Move the transmission control to the NEUTRAL position and engage the parking brakes.

3. Fully raise the truck body and install the truck body retaining cable. Move the hoist control to the FLOAT position until the cable is tight, then move the hoist control to the HOLD position.

   Refer to Operation and Maintenance Manual, SEBU7792, "Cable (Truck Body Retaining)"

4. Stop the engine.

5. Place blocks in front of the wheels and behind the wheels.

Note: Customers/Installers should use a suitable lift or approved portable type access platform to assist in the installation.

Installation Procedure

Install the 437-8754 Mounting Bracket Gp

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Illustration 1	g03732357
View with a 2040 L (540 US gal) fuel tank (1) 8T-4956 Bolt (2) 8T-4223 Hard Washer (3) 421-1395 Bracket As (4) 423-1694 Bracket As (5) 391-0636 Bracket As (6) 8T-4195 Bolt (7) 8T-4121 Hard Washer (8) 420-7425 Plate (9) 421-1400 Bracket As (10) 8T-4186 Bolt (11) 7X-7729 Washer (12) 437-8774 Mount

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Illustration 2	g03732369
View with a 2725 L (720 US gal) fuel tank (1) 8T-4956 Bolt (2) 8T-4223 Hard Washer (3) 421-1395 Bracket As (4) 423-1694 Bracket As (5) 391-0636 Bracket As (6) 8T-4195 Bolt (7) 8T-4121 Hard Washer (8) 420-7425 Plate (9) 421-1400 Bracket As (10) 8T-4186 Bolt (11) 7X-7729 Washer (12) 437-8774 Mount

1. Secure bracket assemblies (3), bracket assemblies (4), bracket assemblies (5), plates (8), bracket assemblies (9), and mounts (12) by using bolts (1), hard washers (2), bolts (6), hard washers (7), bolts (10), and washers (11) .

   The following quantities are needed for a 2040 L (540 US gal) fuel tank:

   • 44 bolts (1)

   • 44 hard washers (2)

   • Eight bracket assemblies (3)

   • Two bracket assemblies (4)

   • Eight bracket assemblies (5)

   • Four bolts (6)

   • Four hard washers (7)

   • Two plates (8)

   • One bracket assembly (9)

   • Four bolts (10)

   • Four washers (11)

   • Two mounts (12)

   The following quantities are needed for a 2725 L (720 US gal) fuel tank:

   • 52 bolts (1)

   • 52 hard washers (2)

   • Eight bracket assemblies (3)

   • Two bracket assemblies (4)

   • 12 bracket assemblies (5)

   • Four bolts (6)

   • Four hard washers (7)

   • Two plates (8)

   • One bracket assembly (9)

   • Four bolts (10)

   • Four washers (11)

   • Two mounts (12)

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Illustration 3	g03732381
(2) 8T-4223 Hard Washer (13) 8T-4139 Bolt (14) 391-0614 Bracket As (15) 391-0621 Bracket As

2. Secure three bracket assemblies (14) and bracket assemblies (15) by using 16 bolts (13) and 16 hard washers (2) .

Install the 437-8758 Handhold Gp

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Illustration 4	g03729233
(1) 437-8759 Mounting Bracket Gp (2) 437-8769 Bracket Mounting Gp (3) 8T-4183 Bolt (4) 7X-3391 Hard Washer

1. Secure mounting bracket group (1) and bracket mounting group (2) to the rear of the beam assembly by using eight bolts (3) and eight hard washers (4) .

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Illustration 5	g03729284
(1) 437-8759 Mounting Bracket Gp (2) 437-8769 Bracket Mounting Gp (5) 391-1754 Handhold As

2. To store handhold assemblies (5), secure five handhold assemblies (5) to mounting bracket group (1) and bracket mounting group (2) .

Install the 437-8773 Handrail Gp and Position the 391-1754 Handhold As

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Illustration 6	g03729351
View with a 2040 L (540 US gal) fuel tank (1) 416-4489 Guardrail Gp (2) 391-0630 Guardrail Gp (3) 391-0628 Handrail Gp (4) 391-0639 Handrail As (5) 391-1754 Handhold As

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Illustration 7	g03729629
View with a 2725 L (720 US gal) fuel tank (1) 416-4489 Guardrail Gp (2) 391-0630 Guardrail Gp (3) 391-0628 Handrail Gp (4) 391-0639 Handrail As (5) 391-1754 Handhold As

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NOTICE
All handrail assemblies and guardrail assemblies must be removed from the brackets before the body is lowered.

1. Install handhold assemblies (5), guardrail groups (1), guardrail groups (2), handrail groups (3), and handrail assemblies (4) onto the available bracket assemblies.

   Refer to Illustration 6 and Illustration 7 for the locations based on the size of the fuel tank.

   When the handrail assemblies and guardrails assemblies are in use, insert the handrail assemblies and guardrail assemblies into the available brackets.

   Note: The bracket assemblies may require slight adjustments for easy installation and removal of the handrail assemblies.