69D and 769D Off-Highway Trucks and 771D Quarry Truck Machine Systems Caterpillar

Installation Procedure

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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.

Note: Park the truck on a smooth, level surface before you perform any operations.

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Illustration 1	g00530631

Note: Inspect sleeve bearings in the frame assembly. If necessary, replace bearings that are worn or damaged.

1. Connect four shackles (2) to body assembly (1), as shown. Attach shackles (2) to a suitable lifting device. Secure the lifting device to a hoist. Position body assembly (1) on the frame assembly. The weight of the 771D body assembly is approximately 10350 kg (22817 lb). The weight of the 769D body assembly is approximately 11100 kg (24471 lb).
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   Illustration 2	g00530668

   Note: The thrust washer is located between the outside of the frame assembly and the body assembly. Use the three millimeter thrust washer only if the five millimeter thrust washer will not assemble in both places.

2. Insert pin assembly (3) through body assembly (1), thrust washer (not shown) and frame assembly (4).
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   Illustration 3	g00530730

3. Install plate (6) with two bolts (5) and the washers.

4. Repeat Step 2 and Step 3 for the remaining pin assembly.
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   Illustration 4	g00530744

5. Install magnet assembly (9) on body assembly (1) by installing two bolts (7) and the washers through bracket (8).

6. Align magnet assembly with electronic control. Refer to System Operation, "Body Position Sensor - Adjust".
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   Illustration 5	g00530786

7. Use Tooling (A) (not shown) in order to position hoist cylinder (12) for installation. Insert pin (13) through body assembly (1) and hoist cylinder (12).

   Note: Insert pin (13) with the notch upward.

8. Install bar (11) on body assembly (1) with two bolts (10) and the washers.

9. Repeat Step 7 and Step 8 for the remaining hoist cylinder.
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   Illustration 6	g00530840

10. Position hose assembly (14) by installing three bolts (15) and the washers through clip (16).

    Note: On machines with a central lube fitting block, connect hose assembly (14) to the block that is attached above the rear axle housing.

11. Repeat Step 10 for the remaining hose assembly.
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    Illustration 7	g00530897

12. Position rock ejector assembly (20), as shown. Install washers (17) by using the identification that was applied during the disassembly. Install pin (19) and cotter pin (18) into mounting bracket (21). The weight of the rock ejector assembly is 23 kg (51 lb).

13. Repeat Step 12 for the remaining rock ejector assembly.

End By:

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