785G IV Off-Highway Truck Field Assembly Caterpillar

Assembly Preparation

Usage:

785G RTL

Flow Chart

The process flow chart is provided as a reference and should be considered for planning or continuous improvement purposes only.

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Illustration 1	g06346617
Recommended Truck Assembly Process

Site Layout

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Illustration 2	g06132023
Recommended site layout for the 785G Off-Highway Truck (A) Chassis (B) Rear Axle Assembly (C) Cab Skid (D) Right-Hand Platform Skid (E) Left-Hand Walkway Skid (F) Front Suspension Cylinder Skid (G) Fuel Tank Skid (H) CEM Box (J) PETU box (K) CIODS and Exhaust Boxes

The work area for the truck chassis and the components should be level, flat, smooth, and drained. An area of approximately 25 m (80 ft) wide and 30 m (100 ft) is needed for the assembly of the truck.
The truck chassis should be located in the center of the assembly area. Keep the assembly area around the truck chassis clear. Also, the assembly area needs to be unobstructed in order for the crane to lift the components correctly.

Required Tools and Supplies

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Table 1
Required Tools and Supplies
Part Number	Part Description	Qty
-	208 L (55 US gal) barrels of TDTO / TO-4 for the hoist, torque converter, and brake oil systems. SAE viscosity grade 10 is recommended. Refer to the Operation and Maintenance Manual for more details	6
-	227 L (60 US gal) of TDTO for the transmission/drive train oil systems. Ambient temperatures that are extreme may require a different oil viscosity. Refer to Service Manual, SEBU6250, "Caterpillar Machine Lubricant Recommendations". Refer to the Operation and Maintenance Manual for more details	2
-	208 L (55 US gal) barrels of TDTO / TO-4 for the steering . Refer to the Operation and Maintenance Manual for more details	1
-	Steel rod that is 88.9 mm (3.50 inch) in diameter. The steel rod should be at least 4191 mm (165.0 inch) long	-
-	Crane or a suitable lifting device with a lifting capacity of 54430 kg (120000 lb).	1
-	Crane or a suitable lifting device with a lifting capacity of 36287 kg (80000 lb).	1
-	Lift truck with a lifting capacity of 6810 kg (15000 lb).	1
-	Several cables, lifting straps, and chains that have adequate lifting capacity	-
-	Shackles with a lifting capacity of 27240 kg (60050 lb).	4
-	Portable air compressor. The air compressor should have enough capacity to operate two 25.4 mm (1 inch) impact wrenches. The air compressor should have a minimum capacity of 3 CM (100 CFM).	1
	Use suitable cribbing that is 203 mm (8.0 inch) tall, 203 mm (8.0 inch)wide and 914.4 mm (36 inch) long. Stack the cribbing alternately, until the height of the cribbing is greater than the height of the trailer bed.
-	Suitable Cribbing 914 mm (36.0 inch) Length X 203 mm (8.0 inch) Width X 203 mm (8.0 inch) Height	40
-	Metal Stands The metal stands support the truck body before the truck body is installed to the truck frame.	4
-	Suitable Cribbing 203 mm (8 inch) Length X 102 mm (4 inch) Width X 102 mm (4 inch) Height	1
-	Stepladder that is 1.8 m (6 ft) tall.	1
-	Stepladder that is 3.6 m (12 ft) tall.	2
-	Suitable Rope 94 m (308 ft) of rope that is 19 mm (0.75 inch) in diameter.	1
-	Paint Spray Gun	1
8T-9293	Torque Wrench 54 to 342 N·m (40 to 252 lb ft)
-	T-size Nitrogen Bottles	20
175-5507	Nitrogen Charging Group	1
9U-5617	Oil Refill Pump
6V-4040	Inflation Gp
-	Loctite Graphite 50 Anti-Seize Lubricant	-
-	Loctite C5A Copper Antiseize	-
-	Loctite Low Breakloose PST	-
-	(Loctite 242)	-
-	Loctite 271	-
8T-3087	Hand Tap (M10X1.5)	1
8T-3091	Tap (M12X1.75)	1
4C-4968	Tap (M24X3.0)	1
4C-4969	Tap (M30X3.5)	1
4C-4970	Tap (M36X4)	1
138-7574	Link Bracket	3
138-7573	Link Bracket	3
138-7575	Link Brackets	3
138-7576	Link Bracket	1
386-6031	Lever Puller Hoist Gp	4
386-6033	Lever Puller Hoist Gp	1
176-6538	Spanner Wrench As	1
385-7874	Hydraulic Wrench	1
385-8479	Hydraulic Pump and Motor Gp (115V)	1
132-8231	Hydraulic Pump and Motor Gp (220V)	1
7X-1062	Ether Cylinder As	2
399-0774	Tool Gp (Reaction Arm)	1
5P-5265	Forcing Bolts	4
194-7586	Pneumatic Wrench Gp	1
147-6456	Wedge Removal Tool	1
376-4533	Pin	4
194-7586	Pneumatic Wrench Gp	1
194-7886	Drive Extension	1
4C-6723	Socket (1 7/16 inch)	1
4C-6724	Socket (46 mm)	1
208-8785	Plate	1
193-5474	Shackle	4
437-5528	Lift As.	2

Required tools and supplies to perform the field assembly.

The required tools and supplies should be present before assembly. If the required tools and supplies are not present, assembly will be more difficult and more time will be necessary to complete the assembly.

Reference: Service Magazine, SEPD0531, 3, July 2000, "Fabric Slings and Protective Sleeves Are Available for Lifting Truck Bodies"

Reference: Special Instruction, SMHS7867, "Use of 6V-4040 Inflation Group"

Reference: Operation and Maintenance Manual, SEBU5898, "Cold-Weather Recommendations for Caterpillar Machine"

Shipping Weights

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Personal injury or death can result from lifting a heavy assembly.
The heavy assembly can fall if using an incorrect hoist to lift the load.

Be sure the hoist has the correct capacity to lift a heavy assembly. Approximate weight of the assembly is given below.

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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.

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Table 2
Module	Weight
Truck frame module without rear axle housing	32000 kg (70000 lb)
Rear axle housing with final drives	16800 kg (37000 lb)
Front Suspension Group	4130 kg (9100 lb)
Tire	1910 kg (4200 lb)
2 Wheel Rims	2270 kg (5000 lb)
Body Pivot Pin	40 kg (88 lb)
Fuel Tank Assembly ⁽¹⁾	890 kg (1950 lb)
Fuel Tank Assembly ⁽²⁾	795 kg (1750 lb)
Right Side Platform Assembly and the Air Cleaner Group	2000 kg (4400 lb)
Shipping Crate 1 of 2	730 kg (1600 lb)
Shipping Crate 2 of 2	440 kg (970 lb)
Pallet for the Handrail	755 kg (1660 lb)
Cab Assembly	2160 kg (4750 lb)
Dual Slope Body with Tail Extension, Full Liners, and Side Boards	30900 kg (68000 lb)
Flat Floor Body with Interlocking grid and Impact Plate	27700 kg (61000 lb)

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⁽¹⁾	2500 L (660 US gal)
⁽²⁾	1900 L (500 US gal)

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Illustration 3	g06134070
Chassis

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Illustration 4	g06134417
Rear Axle

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Illustration 5	g06134043
Right-Hand Platform Skid

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Illustration 6	g06134053
Fuel Tank Skid

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Illustration 7	g06134064
Left-Hand Walkway Skid

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Illustration 8	g06134085
Cab Skid

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Illustration 9	g06134103
Exhaust and CIODS boxes

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Illustration 10	g06134119
CEM - Exhaust Module Box

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Illustration 11	g06134296
Front Strut Skid

Lifting and Cribbing

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Illustration 12	g06132181
Typical view of a Lifting and Tie-Down Diagram The lifting and tie-down diagram is located on the left frame rail near the front of the machine.

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Illustration 13	g06134623

Attach two 437-5528 Lift As., four 193-5474 Shackle and two suitable lifting devices at the four specified lifting locations on the chassis.
Note: Use spreader bars, if necessary.
Disconnect the tie-downs.
Use two suitable cranes in order to lift the 785G chassis from the trailer. The chassis weighs approximately 32000 kg (70000 lb).
Carefully lower the chassis onto support blocks or metal stands.
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Illustration 14 g06134630

View of proper lifting and cribbing of the rear axle and the transmission.
Use a crane and a suitable lifting device to unload the rear axle and the transmission. Position the rear axle and the transmission behind the machine. The approximate weight of the rear axle and transmission assembly is 16800 kg (37000 lb). Align the rear axle and transmission assembly with the chassis.

Before disconnecting the lifting device from the rear axle, place suitable cribbing under the transmission. Ensure that the transmission is level and secure.

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Illustration 15	g06132671
View of the fuel tank supported by cribbing.

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NOTICE

If the fuel tank is removed from the shipping pallet, use suitable cribbing to keep the fuel tank off of the ground. A plug and a drain on the bottom of the fuel tank can be damaged if the tank is placed directly on the ground.

Position the fuel tank onto suitable cribbing.

Cycle Times

Cycle time is calculated based on the Caterpillar Production System methodology consisting of value-added and non-value added elements. The cycle times provided in this document are intended to reflect the lowest and most repeatable time validated during the time studies of this value stream.

Cycle times are provided as a reference and should be considered for planning or continuous improvement purposes only.

The following table contains recommended value-added cycle times for the most common field assembly procedures.

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Table 3
Cycle Times
Assembly Procedure	Approximate Time (hours) Minus NVA⁽¹⁾	Recommended Number of People (average)
Power train	12	4
Front Suspension	12	4
Roll Over Protection (ROPS)	4	2
Cab	8	2
Left-Hand Walkway	4	2
Fuel Tank	4	2
Right-Hand Platform	16	4
Engine Aftertreatment	14	4
Air Cleaners	4	2
Handrails - Work-at-Height	2	2
Object Detect Arrangement front and rear	6	2
Mud Guards
Tires and Rims - Front	4	2
Tires and Rims - Rear	4	2
Body and Canopy	12
Commissioning