794 AC Off-Highway Truck Field Assembly Caterpillar

Parts and Specification Information

Illustration 1	g03864400

Note: Verify that all parts are shipped and undamaged for preparation of assembly. Missing or damaged parts can be ordered prior to assembly to avoid delays during assembly.

Installation Procedure

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Illustration 2	g03864428

1. Install four signal lamp groups (1) using three bolts (2), three washers (3), and three nuts (4) for each signal lamp group (1).

2. Connect wiring harness (5) to the four signal lamp groups (1).

3. Route and secure wiring harness (5) in 27 places using one clip (6), one bolt (7), and one hard washer (8) in each location.
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   Illustration 3	g03864458

4. Install two mud deflectors (9) with one plate (10), one plate (11), 25 bolts (12), 50 hard washers (13), and 25 nuts (14) on each side.
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   Illustration 4	g03864570

5. Install two chain assemblies (15) using two bolts (16) and two locknuts (17).
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   Illustration 5	g03864586
   View of the left-hand rear suspension and rear axle

6. Install cable (18) to the back of the frame.
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   Illustration 6	g03864929
   View of the underside of the body

7. Install ten plates (19) and ten plate assemblies (20) to the main rails of the body using 60 bolts (21), 120 hard washers (22), and 60 locknuts (23).

   Note: Shims may be required between plate (19) and plate assembly (20), so not all mounting hardware need be used.

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   Illustration 7	g03864619
   View of the truck body

8. Use a suitable lifting device to lift the body. The body weighs approximately 39915.92000 kg (88000 lb). Lift the body using the lift points indicated in Illustration 7.
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   Illustration 8	g03864628
   View of the rear suspension and body pivot

9. Position the body so that the body pivot lines up. Install two pins (24), two caps (25), and eight locking bolts (26).
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   Illustration 9	g03864966
   View of the right side hoist cylinder

10. Position the body to connect the hoist cylinders. Secure each hoist cylinder to the body using one pin (27), pin retainer (30), two bolts (31), and two hard washers (32). Remove the brackets retaining the hoist cylinders in place.
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    Illustration 10	g03865014
    View of the rear suspension

11. Weld two keeper pins (31) at the body pivot using a 20 mm (0.79 inch) fillet weld on the outside circumference. Insure there is a 3.18 to 4.77 mm (0.12520 to 0.18779 inch) gab between the keeper pin (33) and the pin.
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    Illustration 11	g03865043
    Side profile view of the right side of the machine

12. Temporarily install one block (32) on the left and right frame rails. Position the block (32) on the front edge of the body rail. Lower the body onto blocks (32). The body may only touch one or both of the two blocks (32). Whichever block (32) the body touches first, use the following steps to shim both sides of the body to that height.

13. Slide in shims (33) and shims (34) as needed to fill the gap between plate (19) and plate assembly (20) and the frame. Record the shims used for each pair.

14. Remove block (32) and raise and block the body.

15. Install the shims needed for each pair and then install and tighten the mounting hardware for plate (19) and plate assembly (20).
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    Illustration 12	g03865105
    View from the front looking through the center of the frame

16. Weld one guide (35) to bracket (36) and one guide (35) to bracket (37) using a 7 mm (0.275 inch) fillet weld on both sides.

17. Raise and lower the body to center the body on the frame. Position bracket (36) and (37) to be parallel with rub plate on the frame and with a 3.18 mm (0.125 inch) gap between guide (35) and the rub plate.

18. Weld bracket (36) and bracket (37) using 13 mm (0.5 inch) fillet welds on the top side and inside, and a 15.88 mm (0.625 inch) bevel weld on the bottom.
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    Illustration 13	g03865672
    View of the underside of the body

19. Route 442-3518 Hose As (A) up to the underside of the body and secure using one bolt (38), one hard washer (13), and one clip (39).

20. Connect hose assembly (40) to hose assembly (A) using one adapter assembly (41).

21. Secure hose assembly (40) to the body in four places using four bolts (38), four hard washers (13), and four clips (39).

22. Connect hose assembly (40) to the top of the hoist cylinder.

23. Repeat Steps 19 through 22 for 442-3518 Hose As (B).
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    Illustration 14	g03867244
    A view of the rear axle and body pivot

24. Install position sensor group (42) to the rear frame using five bolts (43) and five hard washers (44).

25. Install lever (45) to position sensor group (42) using bolt (46).

26. Install rod assembly (47) to lever (45) using one bolt (48), three hard washers (44), and one nut (49).

27. Install one bolt (50) and one hard washer (13) into rod assembly (47).

28. Position boss (51) 21.27 degrees up from level of the center axis of the body pivot and on the edge of the pivot. Weld boss (51) in place using a 4 mm (0.16 inch) fillet weld all the way around.

29. Connect rod assembly (47) to boss (51) using the hardware installed in step 27.