784C and 785C Off-Highway Trucks Machine Systems Caterpillar

Installation Procedure

1. Verify that all of the components of the truck body are clean and free of foreign material prior to installation.

2. Inspect all of the components for wear and replace the components, if necessary.
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   NOTICE
   Make sure the pin bores in the truck body and the truck frame are clean and free of abrasive contaminants before installing the truck body to the frame.

3. Remove all grease and all contaminants from the pin bores on the truck body and on the frame assembly.
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   Illustration 4	g00525996

   Note: Apply Tooling (B) to pin assembly (14) before installation.

4. Use two people to position pin (14) into the outside bore of the hinge mount of truck body (3). The weight of pin assembly (14) is approximately 39.3 kg (86.6 lb).

5. Repeat Step 4 for the remaining pin assembly.
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6. Install suitable clevises and suitable lifting devices to the front and rear lifting points (X) on truck body (3). The weight of truck body (3) is approximately 25855 kg (57000 lb).

7. Repeat Step 6 for the remaining side of truck body (3).
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8. Use the hoist in order to position truck body (3) and pin assemblies (14) for installation onto the frame assembly. The weight of truck body (3) is approximately 25855 kg (57000 lb).
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9. Install pin assembly (14) and washer (15) through truck body (3) and the frame assembly.

   Note: There are two thicknesses of washer (15). The two thicknesses of washer (15) are 10 mm (0.39 inch) and 6 mm (0.24 inch). Use two 6 mm (0.24 inch) thick washers if a 10 mm (0.39 inch) thick washer cannot be assembled in two places.

10. Use two bolts (13) and the washers in order to install plate (12).

11. Repeat Steps 9 and 10 for the remaining pin assembly.
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12. Use a suitable lifting sling and a hoist in order to support the weight of hoist cylinder (7). The weight of hoist cylinder (7) is approximately 834.61 kg (1840 lb).

13. Use the hydraulics of the truck in order to extend hoist cylinder (7). Align the cylinder pin bore of the mounting bracket of truck body (3) with the cylinder pin bore of hoist cylinder (7).

    Note: Apply Tooling (C) to pin assembly (10) before installation.

14. Align spacer (11) and install pin assembly (10) halfway through hoist cylinder (7).

15. Align the remaining spacer (11) and install pin assembly (10) through hoist cylinder (7).
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    Illustration 13	g00516555

16. Use two bolts (8) and the two washers in order to install bar (9). Tighten two bolts (8) to a torque of 105 ± 20 N·m (77.44 ± 14.75 lb ft).

17. Remove the lifting sling and the hoist from hoist cylinder (7).

18. Repeat Steps 12 through 17 for the remaining pin assembly.

19. Remove the suitable clevises and suitable lifting devices from truck body (3).
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20. Use a suitable lift truck to position ejector assembly (4) onto truck body (3) for installation. The weight of ejector assembly (4) is approximately 115.5 kg (254.6 lb).

21. Install pin (5) into truck body (3) and ejector assembly (4), as shown.

22. Install cotter pin (6) into pin (5), as shown.

23. Use the lift truck to slowly lower ejector assembly (4).

24. Repeat Steps 20 through 23 for the remaining ejector assembly.
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    Illustration 16	g00538937

25. Use bolt (1) and two hard washers in order to connect rod assembly (2) to truck body (3).

26. Adjust the length of rod assembly (2). Refer to Power Train Electronic Control System, Systems Operation/Testing and Adjusting, SENR1502, "Body Position Sensor Calibration" for the correct procedure.

27. Align the truck body with the frame assembly. Refer to Specifications, SENR1497, "Body Mounting" for the correct procedure.

End By:

1. Remove the wheel chocks. Refer to Disassembly and Assembly, "Wheel Chock (Front and Rear) - Remove and Install".